Operator`s Manual
Contents
1. Part No 438645 Second Edition Eighth Printing Operator s Manual Observe and Obey M Only qualified riggers should rig and lift the machine M Be sure the crane capacity loading surfaces and straps or lines are sufficient to withstand the machine weight See the serial plate for the machine weight TRANSPORT AND LIFTING INSTRUCTIONS Lifting Instructions Fully lower and retract the boom Move the jib boom parallel with the ground Remove all loose items on the machine Use the turntable rotation lock to secure the turntable 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 There are two lifting points on the chassis and one on the turntable Adjust the rigging to prevent damage to the machine and to keep the machine level X Axis Y Axis S 40 4 41 ft 3 23 ft 1 34 m 98 cm S 45 3 86 ft 3 12 ft 1 18 m 95 cm Turntable Lifting Point 1 II Chassis Lifting Y Axis Points 2 X Axis Part No 43645 Genie S 40 amp Genie S 45 29 Operator s Manual Second Edition Eighth Printing Decals Decal Inspection Use the pictures on the next page to verify that all decals are legible and in place Below is a numerical list with quantities and descriptions Part No Decal Description 25994 Caution Component Damage Hazard 27204 Arrow2. Do not place or attach overhanging loads to any part of this machine Do not place ladders or scaffolds in the platform or against any part of this machine Do not use the machine on a moving or mobile surface or vehicle Be sure all tires are in good condition air filled tires are properly inflated and lug nuts are properly tightened Operator s Manual Second Edition Eighth Printing SAFETY RULES 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 a S gt A Do not climb down from the platform when raised P Keep the platform floor clear of debris Lower the platform entry mid rail or close the entry gate before operating 4 Genie S 40 amp Genie S 45 Collision Hazards Be aware of limited sight distance and blind spots when driving or operating Be aware of boom position and tailswing when rotating turntable Operators must comply with employer job site and governmental rules regarding the use of personal protective equipment Check the work area for overhead obstructions or other possible hazards Be aware of crushing hazards when grasping the platform guard rail Observe and use color coded direction arrows on the platform contr
3. 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 pre operation inspection function tests and a workplace inspection before using the machine Part No 43645 Genie S 40 amp Genie S 45 23 Operator s Manual Second Edition Eighth Printing OPERATING INSTRUCTIONS Starting the Engine 1 At the ground controls turn the key switch to the desired position 2 Be sure both ground and platform control red Emergency Stop buttons are pulled out to the on position 3 Gasoline LPG models Choose fuel by moving the fuel select switch to the desired
4. R Operator s Manual with Maintenance Information S 40 S 45 Second Edition Eighth Printing Part No 43645 Operator s Manual Second Edition Eighth Printing Ed Important Read understand and obey these safety rules and operating instructions before operating this machine Only trained and authorized personnel shall be permitted to operate this machine This manual should be considered a permanent part of your machine and should remain with the machine at all times If you have any questions call Genie Industries Contents Page Salety Rules Re a ER Ee EE 1 CONTO ARE EE EE OE EE 7 Pre operation InspectION ese Re ee ee 10 Maintenance ees ee Ee Ee Ee Ee Ee ee Ee ee Ee ee Ee ee ee ed 12 FUNGUO TOS IS eindes EE oe Re N GE OE EE ES 16 Workplace Inspection ee ee ee ek ER RE RE ee 22 Operating Instructions ees ee ee EE Ee ee RE EE ee 23 Transport and Lifting Instructions esse ee ee 27 GAS EE EN N 30 SDEGCIICATIONS ossaile 32 Copyright 1994 by Genie Industries Contact us os d First Edition First Printing February 1994 Internet http www genielift com n Second Edition Eighth Printing February 2003 E mail techpub genieind com 9 9 y Genie and S are registered trademarks of Genie Industries in the U S A and many other countries These machines comply with ANSI SIA 92 5 1992 g Printed on recycled paper Printed in U S A Genie S 40 amp Genie S 45
5. Note The pump free wheel valve should always remain closed Genie S 40 amp Genie S 45 27 Operator s Manual Second Edition Eighth Printing TRANSPORT AND LIFTING INSTRUCTIONS Securing to Truck or Trailer for Transit Always use the turntable rotation lock pin each time the machine is transported Turn the key switch to the off position and remove the key before transporting Inspect the entire machine for loose or unsecured items Securing the Chassis Use chains of ample load capacity Use a minimum of 5 chains Adjust the rigging to prevent damage to the chains Truck bed a EE EE E se 3 pl 4 28 Genie S 40 amp Genie S 45 Securing the Platform S 40 Place a block under the platform rotator Do not allow the block to contact the platform cylinder Secure the platform with a nylon strap placed through the lower platform support Do not use excessive downward force when securing the boom section Securing the Platform S 45 Place a block under the jib knuckle Do not allow the block to contact the platform cylinder Secure the platform with a nylon strap placed over the jib knuckle Do not use excessive downward force when securing the boom section Fully raise the jib for transport
6. above 10 F 23 C SW 30 above 25 F 4 C 10W 30 Use oils meeting API classification SH or SG grade Units ship with 10 40 CC SG Part No 438645 Second Edition Eighth Printing Operator s Manual Deutz F3L 1011F Engine Oil viscosity requirements below 60 F 15 5 C synthetic 5W 30 10 F to 90 F 23 C to 32 C 10W 40 above 4 F 34 C 15W 40 Engine oil should have properties of API classification CC SE or CC SF grades Units ship with 10 40 CC SG Perkins 704 30 Engine Oil viscosity requirements below 60 F 15 5 C 15W 40 10 F to 90 F 23 C to 32 C 10W 30 above 4 F 34 C 15W 40 Engine oil should have properties of API classification CF4 grade Units ship with 10 40 CC SG Part No 43645 MAINTENANCE Check the Hydraulic Oil Level Maintaining the hydraulic oil at the proper level is essential to machine operation Improper hydraulic oil levels can damage hydraulic components Daily checks allow the inspector to identify changes in oil level that might indicate the presence of hydraulic system problems 1 Be sure the boom is in the stowed position 2 Visually inspect the sight gauge located on the side of the hydraulic oil tank Add oil as needed Result The hydraulic oil level should be within the top 2 inches 5 cm of the sight gauge Hydraulic oil specifications Hydraulic oil type Refer to machine decal Genie S 40 amp Genie S 45 13 Operator s Ma
7. personnel must be removed from the platform before attempting to free the platform using the ground controls Part No 438645 Second Edition Eighth Printing Operator s Manual 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 Ss N NS Use extreme care and slow speeds while driving the machine in 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 push off or pull toward any object outside of the platform Maximum allowable side force ANSI amp CSA 150 Ibs 667 N Maximum allowable side force CE 90 Ibs 400 N Do not alter or disable machine components that in any way affect safety and stability Part No 43645 Genie S 40 amp Genie S 45 SAFETY RULES Do not replace items critical to machine stability with items of different weight or specification Do not modify or alter an aerial 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 N
8. the engine by moving the start toggle switch to either side Result The engine should not start 25 Do not press down the foot switch and restart the engine 26 Move the lift drive select switch to the lift position if equipped 27 Do not press down the foot switch Test each machine function Result The machine functions should not operate Test Machine Functions 28 Move the lift drive select switch to the lift position if equipped 29 Press down the foot switch 30 Activate each machine function control handle or toggle switch Result All boom platform functions should operate through a full cycle Machines equipped with Platform Level Control Disable Function The platform level toggle switch will not operate when the boom is raised past the drive speed limit switch 18 Genie S 40 amp Genie S 45 Test the Steering 31 Move the lift drive select switch to the drive position if equipped 32 Press down the foot switch 33 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 drive steer 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 34 Press the thumb rocker switch in the direction indicated by the yellow triangle on the control panel OR slowly move the drive stee
9. 13 Pull out the red Emergency Stop button to the on position 14 Simultaneously hold the auxiliary power switch on and activate each boom function toggle switch Note To conserve battery power test each function through a partial cycle Result All boom functions should operate Part No 43645 FUNCTION TESTS At the Platform Controls Test Emergency Stop 15 Turn the key switch to platform control and restart the engine 16 Push in the platform red Emergency Stop button to the off position Result The engine should turn off and all functions should not operate 17 Pull out the red Emergency Stop button and restart the engine Test the Hydraulic Oil Return Filter 18 Move the engine idle select switch to high idle rabbit symbol 19 Locate and check the hydraulic filter condition indicator Result The filter should be operating with the plunger or the needle in the green area 20 Move the engine idle select switch to foot switch activated high idle rabbit and foot switch symbol Test the Horn 21 Push the horn button Result The horn should sound Genie S 40 amp Genie S 45 17 Operator s Manual Second Edition Eighth Printing FUNCTIONTESTS Test the Foot Switch 22 Push in the platform Emergency Stop button to the off position 23 Pull out the red Emergency Stop button to the on position but do not start the engine 24 Press down the foot switch and attempt to start
10. Blue 27205 Arrow Yellow 27206 Triangle Blue 27207 Triangle Yellow 27564 Danger Electrocution Hazard 28157 Label Dexron 28158 Label Unleaded 28159 Label Diesel 28160 Label Liquid Petroleum Gas 28161 Danger Crushing Hazard 28163 Notice Max Side Force 150 Ibs 667 N 28164 Notice Hazardous Materials 28165 Notice Foot Switch 28171 Label No Smoking 28174 Label Power to Platform 230V 28175 Caution Compartment Access 28176 Notice Missing Manuals 28177 Warning Platform Rotate 28181 Warning No Step or Ride 28235 Label Power to Platform 115V 28236 Warning Failure To Read 30080 Notice Maximum Load 31060 Danger Tip over Hazard Interlock 32657 Platform Control Panel 32700 Danger Safety Rules 32703 Notice Ford Engine Specs LRG 423 32719 Notice Tire Specifications 32721 Notice Deutz Diesel Engine Specs 32726 Label Glow Plug option 30 Genie S 40 amp Genie S 45 Quantity i 1 i 2 2 2 1 1 1 2 3 1 1 1 1 2 1 1 2 1 2 1 1 3 1 2 1 4 1 1 Part No 32728 33952 35599 38149 40434 43646 43647 43663 49741 44769 44981 44986 49925 49926 52155 52966 52967 53037 62072 62073 62074 62075 62959 62960 63461 72160 72164 72847 82195 82336 82469 82317 Shading indicates decal is hidden from view i e Decal Description Label Generator option Danger Tilt Alarm Notice Align Air Hoses Label Patents Label Lanya
11. Genie S 40 amp Genie S 45 Tire size 2WD front tires only 12 5L 16SL rear tires only 12 16 5 NHS Tire size 2WDRT amp 4WD front amp rear 12 16 5 NHS Fuel tank capacity 30 gallons 114 liters Hydraulic pressure maximum 2600 psi 179 bar boom functions System voltage 12V Weight See Serial Plate Machine weights vary with option configurations Airborne noise emissions 80 dB Maximum sound level at normal operating workstations A weighted Drive Speeds 2WD AWD Drive speed stowed 4 0 mph 3 5 mph Gasoline LPG models 6 4 km h 5 6 km h 40 ft 6 8 sec 40 ft 7 8 sec 12 2 m 6 8 sec 12 2 m 7 8 sec Drive speed stowed 3 5 mph 3 mph Diesel models 5 6 km h 4 8 km h 40 ft 7 8 sec 40 ft 9 1 sec 12 2 m 7 8 sec 12 2 m 9 1 sec Drive speed 0 68 mph 0 68 mph raised or extended 1 1 km h 1 1 km h all models 4O ft 40 sec 4O ft 40 sec 12 2 m 40 sec 12 2 m 40 sec Floor Loading Information GVW Rated Load 12 364 Ibs 5608 kg Axle load maximum 9000 Ibs 4081 kg Wheel load maximum 4500 Ibs 2041 kg Localized pressure per tire 65 psi 4 6 kg cm 448 kPa Occupied pressure 172 psf 8 23 kPa Note Floor loading information is approximate and does not incorporate different option configurations It should be used only with adequate safety factors Part No 438645 Second Edition Eighth Printing Operator s Manual Model S 45 Height working maximum 51 ft 15 5m Height platform maximum 45 ft 13 7 m Height stowed maximum 8 f
12. Part No 43645 Second Edition Eighth Printing Operator s Manual Safety Rules Danger Failure to obey the instructions and safety rules in this manual will result in death or serious injury Do Not Operate Unless M You learn and practice the principles of safe machine operation contained in this operator s manual 1 Avoid hazardous situations Know and understand the safety rules before going on to the next section 2 Always perform a pre operation inspection 3 Always perform function tests prior to use 4 Inspect the workplace 5 Only use the machine as it was intended M You read understand and obey Manufacturer s instructions and safety rules safety and operator s manuals and machine decals employer s safety rules and worksite regulations applicable governmental regulations M You are properly trained to safely operate the machine Part No 43645 Genie S 40 amp Genie S 45 1 Operator s Manual Second Edition Eighth Printing SAFETY RULES Electrocution Hazards This machine is not electrically insulated and will not provide protection from contact with or proximity to electrical current l SW N T b Maintain safe distances from electrical power lines and apparatus in accordance with applicable governmental regulations and the following chart Voltage Minimum Safe Phase to Phase Approach Distance Feet Meters 0 to 300V Avoid Contact 300V to 50KV 10 3 05 50KV
13. boom has moved pasta non steer tire and drive function is turned off Use color coded direction arrows on this panel and drive chassis to identif the direction machine will travel 04 3 10 Gasoline LPG models Gasoline LPG select 13 Drive enable indicator light switch 14 Drive enable switch 11 Red Emergency Stop button 15 Boom extend retract switch 12 Proportional control handle for drive function and thumb rocker for steer function OR dual axis proportional control handle for drive and steer functions 16 Dual axis proportional control handle for boom up down and turntable rotate left right functions Part No 43645 Genie S 40 amp Genie S 45 9 Operator s Manual Second Edition Eighth Printing Pre operation Inspection Do Not Operate Unless MI You learn and practice the principles of safe machine operation contained in this operator s manual 1 Avoid hazardous situations 2 Always perform a pre operation inspection 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 10 Genie S 40 amp Genie S 45 Fundamentals lt 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
14. down bracket is secure 4 Remove the battery vent caps 5 Check the battery acid level If needed replenish with distilled water to the bottom of the battery fill tube Do not overfill 6 Install the vent caps Adding terminal protectors anda corrosion preventative sealant will help eliminate corrosion on the battery terminals and cables Part No 438645 Second Edition Eighth Printing Operator s Manual Check the Tire Pressure This procedure does not need to be performed on machines equipped with the foam filled tire option Bodily injury hazard An over AWARNING inflated tire can explode and could cause death or serious injury Tip over hazard Do not use AWARNING P O S naz d temporary flat tire repair products To safeguard maximum stability achieve optimum machine handling and minimize tire wear it is essential to maintain proper pressure in all air filled tires 1 Check each tire with an air pressure gauge Add air as needed Tire pressure 45 psi 3 1 bar High Flotation Tire Pressure 38 psi 2 6 bar MAINTENANCE Scheduled Maintenance Maintenance performed quarterly annually and every two years must be completed by a person trained and qualified to perform maintenance on this machine according to the procedures found in the service manual for this machine Machines that have been out of service for more than three months must receive the quarterly inspection before they are pu
15. the left steer tire up onto a 6 inch 15cm block or curb Result The three remaining tires should stay in firm contact with the ground 43 Drive both steer tires up onto a 6 inch 15 cm block or curb Result The non steer tires should stay in firm contact with the ground Part No 43645 FUNCTION TESTS Test the Drive Enable System 44 Move the lift drive select switch to the lift position if equipped 45 Press down the foot switch and lower the boom to the stowed position 46 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 47 Move the lift drive select switch to the drive position if equipped 48 Move the drive control handle off center Result The drive function should not operate 49 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 Blue f lt platform controls and the drive chassis to identify the direction of travel Yellow Genie S 40 amp Genie S 45 19 Operator s Manual Second Edition Eighth Printing FUNCTION TESTS Tes
16. to 200KV 15 4 60 200KV to 350KV 20 6 10 350KV to 500KV 25 7 62 SOOKV to 750KV 35 10 67 750KV to 1000KV 45 13 72 Allow for platform movement electrical line sway or sag and beware of strong or gusty winds Keep away from the machine if it contacts energized power lines Personnel on the ground or in the platform must not touch or operate the machine until energized power lines are shut off Do not operate the machine during storms or lightning Do not use the machine as a ground for welding 2 Genie S 40 amp Genie S 45 Tip over Hazards Occupant equipment and materials shall not exceed the maximum platform capacity Maximum platform capacity 500 Ibs 227 kg Maximum occupants 2 Do not raise or extend the boom unless the machine is on a firm level surface Do not depend on the tilt alarm as a level indicator The tilt alarm sounds in the platform only when the machine is on a severe slope If the tilt alarm sounds Do not extend rotate or raise the boom above horizontal Move the machine to a firm level surface before raising the platform If the tilt alarm sounds when the platform is raised use extreme caution to retract the boom and lower the platform Do not rotate the boom while lowering Move the machine to a firm level surface before raising the platform Do not use the platform controls to free a platform that is caught snagged or otherwise prevented from normal motion by an adjacent structure All
17. City Phone 52 55 5666 5242 Fax 52 55 5666 3241 California Proposition 65 WARNING The exhaust from this product contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm Genie North America Phone 425 881 1800 Toll Free USA and Canada 800 536 1800 Fax 425 883 3475 Genie Australia Pty Ltd Phone 61 7 3375 1660 Fax 61 7 3375 1002 Genie China Phone 86 21 53852570 Fax 86 21 53852569 Genie Malaysia Phone 60 4 228 1235 Fax 60 4 226 6872 Genie Japan Phone 81 3 3453 6082 Fax 81 3 3453 6083 Genie Korea Phone 82 2 558 7267 Fax 82 2 558 3910 Genie Africa Phone 27 11 455 0373 Fax 27 11 455 0355 Genie Latin America Phone 55 11 4055 2499 Fax 55 11 4043 1661
18. TION 6 Genie S 40 amp Genie S 45 Safety alert symbol used to alert personnel to potential personal injury hazards Obey all safety messages that follow this symbol to avoid possible injury or death Red used to indicate the presence of an imminently hazardous situation which if not avoided will result in death or serious injury Orange used to indicate the presence of a potentially hazardous situation which if not avoided could result in death or serious injury Yellow with safety alert symbol used to indicate the presence of a potentially hazardous situation which if not avoided may cause minor or moderate injury Yellow without safety alert symbol used to indicate the presence of a potentially hazardous situation which if not avoided may result in property damage Green used to indicate operation or maintenance information Part No 438645 Second Edition Eighth Printing Operator s Manual Controls S G Or AUXILIARY POWER A O 2 STOP 00009 9 Q 0O Q 7 OIL COOLER OPTION e H N M 4 O OOG X N O BO wl N ras m 4 5 AM 15 AMP FUNCTION ENABLE 20 Gs Gs 7 9 5 Ground Control Panel 1 Platform rotate switch 9 Oilpressure gauge 2 Turntable rotate switch 10 Voltage gauge 3 Boom up down switch 11 Red Emergency Stop button 4 Boom extend retract switch 12 Hourmeter 5 Diesel models Glow plug switch
19. aged 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 service manual Be sure all decals are in place and legible Be sure that the operator s safety and responsibilities manuals are complete legible and in the storage container located in the platform Genie S 40 amp Genie S 45 5 Operator s Manual Second Edition Eighth Printing SAFETY RULES Bodily Injury Hazard Do not operate the machine with a hydraulic oil or air leak An air leak or hydraulic leak can penetrate and or burn skin Always operate the machine in a well ventilated area to avoid carbon monoxide poisoning Battery Safety Burn Hazards Batteries contain acid Always wear protective clothing and eyewear when working with batteries Avoid spilling or contacting battery acid Neutralize battery acid spills with baking soda and water Explosion Hazard Keep sparks flames and lighted tobacco away from batteries Batteries emit explosive gas Electrocution Hazard Avoid contact with electrical terminals Decal Legend Genie product decals use symbols color coding and signal words to identify the following A ADANGER AWARNING ACAUTION CAU
20. chine 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 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 22 Genie S 40 amp Genie S 45 Workplace Inspection 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 Part No 43645 Second Edition Eighth Printing Operator s Manual Operating Instructions Do Not Operate Unless MI You learn and practice the principles of safe machine operation contained in this operator s manual 1 Avoid hazardous situations
21. d 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 Genie S 40 amp Genie S 45 25 Operator s Manual Second Edition Eighth Printing OPERATING INSTRUCTIONS Generator To operate the generator move the generator toggle switch to the generator position The engine will continue to run but no drive or platform functions will operate Plug power tools into the power to platform GFCI outlet To resume machine functions move the generator toggle switch to the machine functions position All functions will operate Engine Idle Select rpm Select engine idle rom using the symbols on the control panel o Rabbit and foot switch symbol foot switch activated high idle Turtle symbol low idle Rabbit symbol high idle Check Engine Light if equipped Light on and engine stopped Tag the machine and remove from service Light on and engine still running Contact service personnel within 24 hours 26 Genie S 40 amp Genie S 45 Stopping the Engine Push in the red Emergency Stop button and turn the key switch to the off position Fall Protection Personal fall protection equipment PFPE is required when operating this machine All PFPE must comply with applicable governmental regulations and must be inspected and used in accordance with the PFPE manufacturer s instructions A
22. 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 lf 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 bya qualified service technician according to the manufacturer s specifications After repairs are completed the operator must perform a pre operation inspection again before going on to the function tests Scheduled maintenance inspections shall be performed by qualified service technicians according to the manufacturer s specifications and the requirements listed in the responsibilities manual Part No 438645 Second Edition Eighth Printing ee ee Pre operation Inspection E m Be sure that the operator s safety and responsibilities manuals are complete legible and in the storage container located in the platform Be sure that all decals are legible and in place See Decals section Check for engine oil leaks and proper oil level Add oil if needed See Maintenance section Check for hydraulic oil leaks and proper oil lev
23. el Add oil if needed See Maintenance section Check for engine coolant leaks and proper level of coolant Add coolant if needed See Maintenance section Check for battery fluid leaks and proper fluid level Add distilled water if needed See Maintenance section Check for proper tire pressure Add air if needed See Maintenance section Check the following components or areas for damage improperly installed or missing parts and unauthorized modifications Part No 43645 H Electrical components wiring and electrical cables _I Hydraulic hoses fittings cylinders and manifolds Fuel and hydraulic tanks Drive and turntable motors and drive hubs Boom wear pads Tires and wheels Engine and related components Limit switches and horn Alarms and beacons if equipped Nuts bolts and other fasteners L LL LL LL ove D Platform entry mid rail or gate Operators Manual PRE OPERATION INSPECTION Check entire machine for H Crack in welds or structural components L Dents or damage to machine _I Be sure that all structural and other critical components are present and all associated fasteners and pins are in place and properly tightened _I After you complete your inspection be sure that all compartment covers are in place and latched Genie S 40 amp Genie S 45 11 Operator s Manual Second Edition Eighth Printing Maintenance Observe and Obey MI Only routine maintenance items
24. fter 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 5 Chock the wheels Part No 43645 Second Edition Eighth Printing Operator s Manual Transport and Lifting Instructions Observe and Obey M The transport vehicle must be parked on a level surface MI The transport vehicle must be secured to prevent rolling while the machine is being loaded M Be sure the vehicle capacity loading surfaces and straps or lines are sufficient to withstand the machine weight See the serial plate for the machine weight M Be sure the turntable is secured with the turntable rotation lock before transporting Be sure to unlock the turntable for operation Part No 43645 Free wheel Configuration for Winching Chock the wheels to prevent the machine from rolling 2WD models Release the non steer wheel brakes by turning over Disengage the drive hub disconnect caps 4WD models Release the wheel brakes by Engage 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 Reverse the procedures described to re engage the brakes
25. if equipped 13 Gasoline LPG models Check engine light Gasoline LPG models Gasoline LPG select 14 Function enable switch switch 15 Engine start switch 6 Key switch for platform off ground selection 16 15A breaker for engine electrical circuits 17 20A breaker for oil cooler and options 8 Gasoline LPG models Watertemperature ad gauge 18 15A breaker for control electrical circuits Diesel models Oil temperature gauge 19 S 45 models Jib boom up down switch 20 Platform level switch 7 Auxiliary power switch Part No 43645 Genie S 40 amp Genie S 45 7 Operator s Manual Second Edition Eighth Printing CONTROLS HORN PLATFORM LEVEL PLATFORM ROTATE JIB BOOM AUXILIARY POWER d Ka a or BOOM RETRACT O A el A BOOM EXTEND TURNTABLE TURNTABLE ROTATE ROTATE Platform Control Panel 7 Diesel models Glow plug switch if equipped 1 Horn button 8 Engine start switch Platform level switch 9 Engine idle rom select switch Rabbit amp Foot Switch foot switch activated Platform rotate switch high idle S 45 models Jib boom up down switch Turtle low idle Rabbit high idle Auxiliary power switch O OO fF W N Optional equipment 8 Genie S 40 amp Genie S 45 Part No 43645 Second Edition Eighth Printing Operator s Manual CONTROLS GLOW PLUG ENGINE START ENGINE RPM FUEL SELECT STOP D m 4 SIW iaae DOWN TO STOP EER DRIVE ENABLE OPERATION Light on indicates that
26. nual Second Edition Eighth Printing MAINTENANCE Check the Engine Coolant Level Liquid Cooled Models Maintaining the engine coolant at the proper level is essential to engine service life Improper coolant level will affect the engine s cooling capability and damage engine components Daily checks will allow the inspector to identify changes in coolant level that might indicate cooling system problems Burn hazard Beware of hot engine ACAUTION parts and coolant Contact with hot engine parts and or coolant may Cause severe burns 1 Check the fluid level in the coolant recovery tank Add fluid as needed Result The fluid level should be at the FULL mark Do not remove the radiator cap 14 Genie S 40 amp Genie S 45 Check the Batteries Proper battery condition is essential to good engine performance and operational safety Improper fluid levels or damaged cables and connections can result in engine component damage and hazardous conditions Electrocution hazard Contact with AWARNING hot or live circuits may result in death or serious injury Remove all rings watches and other jewelry Bodily injury hazard Batteries AWARNING contain acid Avoid spilling or contacting battery acid Neutralize battery acid spills with baking soda and water 1 Puton protective clothing and eye wear 2 Be sure that the battery cable connections are tight and free of corrosion 3 Be sure that the battery hold
27. ols and drive chassis for drive and steer functions Part No 43645 Second Edition Eighth Printing Operator s Manual Do not lower the boom unless the area below Is clear of personnel and obstructions mad mt 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 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 Machines with hydraulic shutoff valves Be sure the hydraulic shutoff valves located by the pump under the engine side cover are open before starting the engine Part No 43645 SAFETY RULES Explosion and Fire Hazards Do not start the engine if you smell or detect liquid petroleum gas LPG gasoline diesel fuel or other explosive substances Do not refuel the machine with the engine running Refuel the machine and charge the battery only in an open well ventilated area away from sparks flames and lighted tobacco Do not operate the machine in hazardous locations or locations where potentially flammable or explosive gases or particles may be present Dam
28. on and activate desired function The drive function will not operate with auxiliary power Operation from Ground 1 Turn the key switch to ground control 2 Pull out the red Emergency Stop button to the on position 3 Gasoline LPG models Choose fuel by moving the fuel select switch to the desired position 4 Start the engine To Position Platform 1 Hold the function enable switch to either side 2 Move the appropriate toggle switch according to the markings on the control panel Drive and steer functions are not available from the ground controls Machines equipped with Platform Level Control Disable Function The platform level toggle switch will not operate when the boom is raised past the drive speed limit switch Part No 43645 Second Edition Eighth Printing Operator s Manual Operation from Platform 1 Turn the key switch to platform control 2 Pull out both ground and platform red Emergency Stop buttons to the on position 3 Gasoline LPG models Choose fuel by moving the fuel select switch to the desired position 4 Start the engine Do not press down the foot switch when starting the engine To Position Platform 1 Move the lift drive select switch to the lift position if equipped 2 Press down the foot switch 3 Slowly move the appropriate function control handle or toggle switch according to the markings on the control panel Machines equipped with Platform Level Control Disable Func
29. oom and steer functions should operate Drive functions should not operate with auxiliary power Part No 43645 Second Edition Eighth Printing Operator s Manual EE EE EE EE FUNCTION TESTS Test the Lift Drive Select Function CE models Machines with lift drive select switch 65 Move the lift drive select switch to the lift position 66 Press down the foot switch 67 Move the drive control handle off center Result No drive functions should operate 68 Activate each boom function toggle switch Result All boom functions should operate 69 Move the lift drive select switch to the drive position 70 Press down the foot switch 71 Activate each boom function toggle switch Result No boom functions should operate 72 Move the drive control handle off center Result The drive functions should operate 73 Repair any malfunctions before operating the machine Machines without lift drive select switch 74 Press down the foot switch 75 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 76 Repair any malfunctions before operating the machine Part No 43645 Genie S 40 amp Genie S 45 21 Operator s Manual Second Edition Eighth Printing Workplace Inspection Do Not Operate Unless M You learn and practice the principles of safe ma
30. or 32721 RE eee Gad Or 5 T did mm oa EN or 63461 l 33559 2 31060 28174 or 32719 or 32719 or a 28181 28235 72847 72847 28175 Engine 28177 28160 27564 28164 28161 Side Part No 43645 Genie S 40 amp Genie S 45 31 Operator s Manual Second Edition Eighth Printing Specifications Model S 40 Height working maximum 46 ft 14m Height platform maximum AO ft 12 2 m Height stowed maximum 8 ft 2 in 2 49 m Horizontal reach maximum 31 ft 8 in 9 65 m Width 7 ft 6 in 2 29 m Length stowed 23 ft 11 in 7 29 m Maximum load capacity 500 ID 227 kg 6 foot platform Maximum load capacity 500 ID 227 kg 8 foot platform Wheelbase 7 ft 3 in 2 2 m Turning radius outside 15 ft 8 in 4 78 m Turning radius inside 6 ft 8 in 2 03 m Turntable rotation degrees continuous Turntable tailswing 34 in 86 4 cm Power source Ford 63 Hp Gasoline LPG LRG 423 or choice LRG 425 EFI or Deutz 36 Hp Diesel F3L 1011 or Perkins 704 30 Diesel Controls 12V DC proportional 72 in x 30 in 1 8 m x 76 cm Platform dimensions 6 foot length x width 96 in x 36 In 2 4mx 91cm Platform dimensions 8 foot length x width Platform leveling self leveling Platform rotation 160 AC outlet in platform standard Gradeability stowed 2WD 30 Gradeability stowed 4WD 40 Ground clearance 121 2 in 31 8 cm Continuous improvement of our products is a Genie policy Product specifications are subject to change without notice or obligation 32
31. position 4 Move the engine start toggle switch to either side If the engine fails to start or dies the restart delay will disable the start switch for 3 seconds If the engine fails to start after 15 seconds of cranking determine the cause and repair any malfunction Wait 60 seconds before trying to start again All models In extreme cold conditions 20 F 6 C and below warm the engine for 5 minutes to prevent hydraulic system damage Gasoline LPG models In extreme cold conditions 20 F 6 C and below the machine should be started on gasoline then switched to LPG Emergency Stop Push in the red Emergency Stop button to the off position at the ground or platform controls to stop all machine functions and turn the engine off Repair any function that operates when the red Emergency Stop button is pushed in Selecting and operating the ground controls will override the platform red Emergency Stop button 24 Genie S 40 amp Genie S 45 Auxiliary Controls Use auxiliary power if the primary power source engine fails 1 Turn the key switch to ground or platform control 2 Pull out the red Emergency Stop button to the on position 3 Move the lift drive select switch to the lift position if equipped when operating the auxiliary controls from the platform 4 Press down the foot switch when operating the auxiliary controls from the platform 5 Simultaneously hold the auxiliary power switch
32. r 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 Test Drive and Braking 35 Move the lift drive select switch to the drive position if equipped 36 Press down the foot switch 37 Slowly move the drive control handle in the direction indicated by the blue arrow on the control panel until the machine begins to move then return the handle to the center position Result The machine should move in the direction that the blue arrow points on the drive chassis then come to an abrupt stop Part No 438645 Second Edition Eighth Printing Operator s Manual 38 Slowly move the drive control handle in the direction indicated by the yellow arrow on the control panel until the machine begins to move then return the handle to the center position Result The machine should move in the direction that the yellow arrow points on the drive chassis then come to an abrupt stop Note The brakes must be able to hold the machine on any slope it is able to climb Test the Oscillate Axle oscillating axle equipped models 39 Move the lift drive select switch to the drive position if equipped 40 Start the engine from the platform controls 41 Drive the right steer tire up onto a 6 inch 15cm block or curb Result The three remaining tires should stay in firm contact with the ground 42 Drive
33. rd Anchorage Ground Control Panel Notice Operating Instructions Notice Function Enable Notice Ford Engine Specs LRG 425 EFI Label Lift Drive Select option Label Airline to Platform Notice Max Manual Force 90 Ibs 400 N Ground Control Panel Ground Control Panel Platform Control Panel Cosmetic 4 x 2 Cosmetic 4 x 4 Notice Deutz Diesel Engine Specs Cosmetic Genie S 40 Cosmetic S 40 Cosmetic Genie S 45 Cosmetic S 45 Cosmetic S 40 Cosmetic S 45 Notice Perkins Diesel Engine Specs Ground Control Panel Platform Control Panel Notice Tire Specifications Hi Flotation Ground Control Panel Label Chevron Rykon Platform Control Panel Notice Operating Instructions under covers Quantity 1 ak ad ND AA AA ND AI OT AI mk Part No 43645 Second Edition Eighth Printing Operator s Manual Laan EE EE EE DECALS 43646 or 43647 27564 Serial 28161 28174 44981 49925 or 25994 Plate 38149 or 28235 32719 28159 72160 or 28157 or 82195 Ground 82336 Controls Side 28171 i 40434 32700 28177 43663 28161 33952 32719 32728 43647 32726 52966 or Chassis 44769 52967 32657 A or 52155 27204 Bam or 82469 27206 7 g i 32700 27207 Ll 28236 ma D 28176 27907 __ 30080 Ch 27206 SS qe 28165 ET 27205 44981 28163 62073 or Platform or 44986 62075 62072 or 62959 ganra oA or 62960 28174 or 28235 P 32703 E
34. rmal operating workstations A weighted Drive Speeds 2WD AWD Drive speed stowed 4 0 mph 3 5 mph Gasoline LPG models 6 4 km h 5 6 km h 40 ft 6 8 sec 40 ft 7 8 sec 12 2 m 6 8 sec 12 2 m 7 8 sec Drive speed stowed 3 5 mph 3 mph Diesel models 5 6 km h 4 8 km h 40 ft 7 8 sec 40 ft 9 1 sec 12 2 m 7 8 sec 12 2 m 9 1 sec Drive speed 0 68 mph 0 68 mph raised or extended 1 1 km h 1 1 km h all models 40 ft 40 sec 4O ft 40 sec 12 2 m 40 sec 12 2 m 40 sec Floor Loading Information GVW Rated Load 16 266 lbs 7378 kg Axle load maximum 13 900 Ibs 6303 kg Wheel load maximum 6970 lbs 3160 kg Localized pressure per tire 65 psi 4 6 kg cm 448 kPa Occupied pressure 219 psf 10 50 kPa Note Floor loading information is approximate and does not incorporate different option configurations It should be used only with adequate safety factors Genie S 40 amp Genie S 45 33 Operator s Manual Second Edition Eighth Printing SPECIFICATIONS S 40 Range of Motion Chart S 45 Range of Motion Chart 34 Genie S 40 amp Genie S 45 Part No 43645 Genie Holland Phone 31 70 51 78836 Fax 31 70 51 13993 Genie Scandinavia Phone 46 31 3409612 Fax 46 31 3409613 Genie France Phone 33 0 2 37 26 09 99 Fax 33 0 2 37 26 09 98 Genie Ib rica Phone 34 93 579 5042 Fax 34 93 579 5059 Genie Germany Phone 49 0 4202 88520 Fax 49 0 4202 8852 20 Genie U K Phone 44 0 1476 584333 Fax 44 0 1476 584334 Genie Mexico
35. section Test Emergency Stop 5 Push in the red Emergency Stop button to the off position Result The engine should turn off and all functions should not operate Pull out the red Emergency Stop button to the on position and restart the engine Test the Machine Functions 7 Do not hold the function enable switch to either side Attempt to activate each boom and platform function toggle switch Result All boom and platform functions should not operate Hold the function enable switch to either side and activate each boom and platform function toggle switch Result All boom and platform functions should operate through a full cycle The descent alarm if equipped should sound while the boom is lowering Machines equipped with Platform Level Control Disable Function The platform level toggle switch will not operate when the boom is raised past the drive speed limit switch 16 Genie S 40 amp Genie S 45 Part No 43645 Second Edition Eighth Printing Operator s Manual Test the Tilt Sensor 9 Pull out the platform red Emergency Stop button to the on position Turn the key switch to platform control 10 Open the tank side turntable cover and locate the tilt sensor next to the control box 11 Press down one side of the tilt sensor Result The alarm located in the platform should sound Test Auxiliary Controls 12 Turn the key switch to ground control and shut the engine off
36. specified in this manual shall be performed by the operator M Scheduled maintenance inspections shall be completed by qualified service technicians according to the manufacturer s specifications and the requirements specified in the responsibilities manual Maintenance Symbols Legend The following symbols have been used in this manual to help communicate the intent of the instructions When one or more of the symbols appear at the beginning of amaintenance procedure it conveys the meaning below Indicates that tools will be required to perform this procedure Indicates that new parts will be required to perform this procedure Indicates that a cold engine is required before performing this procedure 12 Genie S 40 amp Genie S 45 Check the Engine Oil Level Maintaining the proper engine oil level is essential to good engine performance and service life Operating the machine with an improper oil level can damage engine components Check the oil level with the engine off 1 Check the oil dipstick Ford models Result The oil level should be between the app and SAFE marks Add oil as needed Deutz Models Result The oil level should be within the two marks on the dipstick Perkins Models Result The oil level should be within the two notches on the dipstick Ford LRG 425 EFI Engine Oil viscosity requirements below 60 F 15 5 C SW 30 10 to 90 F 23 to 32 C 5W a0
37. t 2 in 2 49 m Horizontal reach maximum 36 it 8 in 11 2 m Width 7 ft 6 in 2 29 m Length stowed 27 ft 10 in 8 5m Maximum load capacity 500 ID 227 kg 6 foot platform Maximum load capacity 500 ID 227 kg 8 foot platform Wheelbase 7 ft 3 in 2 2 m Turning radius outside 15 ft 8 in 4 78 m Turning radius inside 6 ft 8 in 2 03 m Turntable rotation degrees continuous Turntable tailswing 34 in 86 4 cm Power source Ford 63 Hp Gasoline LPG LRG 423 or choice LRG 425 EFI or Deutz 36 Hp Diesel F3L 1011 or Perkins 704 30 Diesel Controls 12V DC proportional 72 in x 30 in 1 8m x 76 cm Platform dimensions 6 foot length x width 96 in x 36 in 2 4mx 91cm Platform dimensions 8 foot length x width Platform leveling self leveling Platform rotation 160 AC outlet in platform standard Gradeability stowed 2WD 30 Gradeability stowed 4WD 40 Ground clearance 121 2 in 31 8 cm Continuous improvement of our products is a Genie policy Product specifications are subject to change without notice or obligation Part No 43645 SPECIFICATIONS Tire size 2WD front tires only 12 5L 16SL rear tires only 12 16 5 NHS Tire size 2WDRT amp 4WD front amp rear 12 16 5 NHS Hydraulic pressure maximum 2600 psi 179 bar boom functions Fuel tank capacity 30 gallons 114 liters System voltage 12V Weight See Serial Plate Machine weights vary with option configurations Airborne noise emissions 80 dB Maximum sound level at no
38. t Limited Drive Speed 50 Move the lift drive select switch to the lift position if equipped 51 Press down the foot switch 52 Raise the boom to just above horizontal 53 Move the lift drive select switch to the drive position if equipped 54 Slowly move the drive control handle to the full drive position Result The maximum achievable drive speed with the boom raised should not exceed 1 foot 30 cm per second 55 Move the lift drive select switch to the lift position if equipped 56 Lower the boom to the stowed position 57 Extend the boom 1 foot 30 cm 58 Move the lift drive select switch to the drive position if equipped 59 Slowly move the drive control handle to the full drive position Result The maximum achievable drive speed with the boom extended should not exceed 1 foot 30 cm per second If the drive speed with the boom raised or extended exceeds 1 foot 30 cm per second immediately tag and remove the machine from service 20 Genie S 40 amp Genie S 45 Test Auxiliary Controls 60 Shut off the engine 61 Pull out the red Emergency Stop button to the on position 62 Move the lift drive select switch to the lift position if equipped 63 Press down the foot switch 64 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 b
39. t back into service Part No 43645 Genie S 40 amp Genie S 45 15 Operator s Manual Second Edition Eighth Printing Function Tests Do Not Operate Unless MI You learn and practice the principles of safe machine operation contained in this operator s manual 1 Avoid hazardous situations 2 Always perform a pre operation inspection 3 Always perform function tests prior to use Know and understand the function tests before going on to the next section 4 Inspect the workplace 5 Only use the machine as it was intended Fundamentals The function tests are designed to discover any malfunctions before the machine is put into service The operator must follow the step by step instructions to test all machine functions A malfunctioning machine must never be used If malfunctions are discovered the machine must be tagged and removed from service Repairs to the machine may only be made by a qualified service technician according to the manufacturer s specifications After repairs are completed the operator must perform a pre operation inspection and function tests again before putting the machine into service Select a test area that is firm level and free of obstruction At the Ground Controls 2 Turn the key switch to ground control Pull out the red Emergency Stop button to the on position Result The beacon if equipped should flash Start the engine See Operating Instructions
40. tion The platform level toggle switch will not operate when the boom is raised past the drive speed limit switch To Steer 1 Move the lift drive select switch to the drive position if equipped 2 Press down the foot switch 3 Slowly move the drive steer control handle in the direction indicated by the 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 Part No 43645 OPERATING INSTRUCTIONS To Drive 1 Move the lift drive select switch to the drive position if equipped Press down the foot switch Increase speed Slowly move the drive control handle off center Decrease speed Slowly move the drive control handle toward center Stop Return the drive control handle to center or release the foot switch Use the color coded direction arrows on the platform controls and the drive chassis to identify the direction the machine will travel Machine travel speed is restricted when the boom is raised or extended Drive Enable Light on indicates that the boom has moved just past either non 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 an
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