Terex Genie S-40 Operator's Manual
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Terex Genie S-40 Operator's Manual

Terex Genie S-40 Operator's Manual

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  • Page 2: Table Of Contents

    Copyright © 1994 by Genie Industries Contact us: Seventh Edition: Second Printing, March 2011 Internet: http://www.genielift.com "Genie" and "S" are registered trademarks of E-mail: awp.techpub@terex.com Genie Industries in the U.S.A. and many other countries. These machines comply with AS1418.10 Printed on recycled paper Printed in U.S.A.

  • Page 3: Introduction

    Internet: www.genielift.com 2 Always perform a pre-operation inspection. E-mail: awp.techpub@terex.com 3 Always perform function tests prior to use. 4 Inspect the workplace. 5 Only use the machine as it was intended. You read, understand and obey the manufacturer's instructions and safety rules—...
  • Page 4 Operator's Manual Seventh Edition • Second Printing Introduction Hazard Classification Intended Use Genie uses symbols, color coding and signal words This machine is intended to be used only to lift to identify the following: personnel, along with their tools and materials to an aerial work site.

  • Page 5: Symbol And Hazard Pictorials Definitions

    Operator's Manual Seventh Edition • Second Printing Symbol and Hazard Pictorials Definitions Crush Hazard Explosion Hazard Fire Hazard Explosion Hazard Electrocution Hazard Fall Hazard Crush Hazard Tip-over Hazard Tip-over Hazard Tip-over Hazard Read service Rated platform Tip-over Hazard Tip-over Hazard Electrocution manual capacity...
  • Page 6 Operator's Manual Seventh Edition • Second Printing Symbol and Hazard Pictorials Definitions Lanyard Wheel load Voltage rating for Pressure rating for Fire extinguisher power to platform air line to platform attachment point Avoid contact. Tie-down Tie-down Weight of welder Wind speed instructions instructions reduces capacity...

  • Page 7: General Safety

    Operator's Manual Seventh Edition • Second Printing General Safety Safety signs and locations Part No. 226478 S-40 • S-45...
  • Page 8 Operator's Manual Seventh Edition • Second Printing General Safety Safety signs and locations S-40 • S-45 Part No. 226478...
  • Page 9 Operator's Manual Seventh Edition • Second Printing General Safety Safety signs and locations Part No. 226478 S-40 • S-45...

  • Page 10: Personal Safety

    Operator's Manual Seventh Edition • Second Printing Personal Safety 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.

  • Page 11: Work Area Safety

    Operator's Manual Seventh Edition • Second Printing Work Area Safety Allow for platform movement, electrical line sway or Electrocution Hazards sag and beware of strong or gusty winds. Keep away from the machine if it contacts This machine is not energized power lines.
  • Page 12 Operator's Manual Seventh Edition • Second Printing Work Area Safety Do not raise or extend Do not raise the boom the boom unless the when wind speeds may machine is on a firm, exceed 12.5 m/s. If level surface. wind speeds exceed 12.5 m/s when the Do not depend on the boom is raised, lower...
  • Page 13 Operator's Manual Seventh Edition • Second Printing Work Area Safety Do not push the machine or other objects with the Do not place or attach boom. overhanging loads to any part of this Do not contact adjacent structures with the boom. machine.
  • Page 14 Operator's Manual Seventh Edition • Second Printing Work Area Safety Operation on Slopes Hazards Fall Hazards Do not drive the machine on a slope that exceeds Occupants must wear a the maximum uphill, downhill or side slope rating of safety belt or harness the machine.
  • Page 15 Operator's Manual Seventh Edition • Second Printing Work Area Safety Limit travel speed Collision Hazards according to the condition of the ground Be aware of limited surface, congestion, sight distance and blind slope, location of spots when driving or personnel, and any operating.
  • Page 16 Operator's Manual Seventh Edition • Second Printing Work Area Safety Explosion and Fire Hazards Battery Safety Do not start the engine if you smell or detect liquid Burn Hazards petroleum gas (LPG), gasoline, diesel fuel or other explosive substances. Batteries contain acid. Always wear protective Do not refuel the machine with the engine running.
  • Page 17 Operator's Manual Seventh Edition • Second Printing 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...
  • Page 18 Operator's Manual Seventh Edition • Second Printing Work Area Safety Lockout After Each Use Pipe Cradle Safety 1 Select a safe parking location—firm level Read, understand and obey all warnings and surface, clear of obstruction and traffic. instructions provided with the pipe cradles. 2 Retract and lower the boom to the stowed Do not exceed the rated platform capacity.

  • Page 19: Legend

    Operator's Manual Seventh Edition • Second Printing Legend 1 Foot switch 8 Boom 2 Manual storage container 9 Platform controls 3 Sliding mid-rail 10 Platform 4 Lanyard anchorage point 11 Jib boom (S-45) 5 Non- steer tire 6 Steer tire 7 Ground controls Part No.

  • Page 20: Controls

    Operator's Manual Seventh Edition • Second Printing Controls Platform Control Panel 7 Deutz Diesel models: Glow plug switch 1 Horn button (if equipped) Perkins models: Glow plug indicator light 2 Platform level switch 8 Engine start switch 3 Platform rotate switch 9 Engine idle (rpm) select switch 4 S-45 models: Jib boom up/down switch ·...
  • Page 21 Seventh Edition • Second Printing Operator's Manual Controls 14 Machine not level indicator light (if equipped) 10 Gasoline/LPG models: Gasoline/LPG select switch 15 Drive enable indicator light 11 Red Emergency Stop button 16 Drive enable switch 12 Proportional control handle for drive function and 17 Boom extend/retract switch thumb rocker for steer function OR dual axis proportional control handle for drive and steer...
  • Page 22 Operator's Manual Seventh Edition • Second Printing Controls Platform Control Panel 6 Drive speed select switch Machine on incline symbol: Low range operation 1 Horn button for inclines. Push the horn button and the horn will sound. Machine on level surface symbol: High range Release the horn button and the horn will stop.
  • Page 23 Operator's Manual Seventh Edition • Second Printing Controls 12 Dual axis proportional control handle for drive 16 Drive enable switch and steer functions To drive when the drive enable light is on, hold OR Proportional control handle for drive function the drive enable switch to either side and slowly and thumb rocker for steer function move the drive control handle off center.
  • Page 24 Operator's Manual Seventh Edition • Second Printing Controls Ground Control Panel 1 Turntable rotate switch 13 Hour meter 2 Boom up/down switch 14 Gasoline/LPG models: Gasoline/LPG select switch 3 Boom extend/retract switch 15 Deutz Diesel models: Glow plug switch 4 Platform overload indicator light (if equipped) 5 Not used Perkins models: Glow plug indicator light...
  • Page 25 Operator's Manual Seventh Edition • Second Printing Controls Ground Control Panel 7 Gasoline/LPG models: Water temperature gauge Diesel models: Oil temperature gauge 1 Turntable rotate switch 8 Key switch for platform/off/ground selection Move the turntable rotate switch to the right and the Turn the key switch to the platform position and turntable will rotate to the right.
  • Page 26 Operator's Manual Seventh Edition • Second Printing Controls 15 Deutz Diesel models: Glow plug switch 22 Platform level switch (if equipped) Move the platform level Move the glow plug switch to either side and switch up and the level of hold for 3 to 5 seconds.

  • Page 27: Inspections

    Operator's Manual Seventh Edition • Second Printing 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 Do Not Operate Unless: performed by the operator prior to each work shift. The inspection is designed to discover if anything You learn and practice the principles of safe is apparently wrong with a machine before the...
  • Page 28 Operator's Manual Seventh Edition • Second Printing Inspections Pre-operation Inspection Nuts, bolts and other fasteners Be sure that the operator’s, safety and responsibilities manuals are complete, legible Platform entry mid-rail or gate and in the storage container located in the Check entire machine for: platform.
  • Page 29 Operator's Manual Seventh Edition • Second Printing 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 Do Not Operate Unless: malfunctions are discovered, the machine must be tagged and removed from service.
  • Page 30 Operator's Manual Seventh Edition • Second Printing Inspections 1 Select a test area that is firm, level and free of Test the Tilt Sensor obstruction. 9 Pull out the platform red Emergency Stop button At the Ground Controls to the on position. Turn the key switch to platform control.
  • Page 31 Operator's Manual Seventh Edition • Second Printing Inspections At the Platform Controls Test the Foot Switch 22 Push in the platform Emergency Stop button to Test Emergency Stop the off position. 15 Turn the key switch to platform control and 23 Pull out the red Emergency Stop button to restart the engine.
  • Page 32 Operator's Manual Seventh Edition • Second Printing Inspections Test the Steering Test the Oscillate Axle (if equipped) 29 Press down the foot switch. 35 Start the engine from the platform controls. 30 Press the thumb rocker switch on top of the 36 Drive the right steer tire up onto a 15 cm block drive control handle in the direction indicated by or curb.
  • Page 33 Operator's Manual Seventh Edition • Second Printing Inspections Test the Drive Enable System Test Limited Drive Speed 39 Press down the foot switch and lower the boom 43 Press down the foot switch. to the stowed position. 44 Raise the boom to just above horizontal. 40 Rotate the turntable until the boom moves past one of the non-steer wheels.
  • Page 34 Operator's Manual Seventh Edition • Second Printing Inspections Test Auxiliary Controls 49 Shut off the engine. 50 Pull out the red Emergency Stop button to the on position. 51 Press down the foot switch. 52 Simultaneously hold the auxiliary power switch on and activate each function control handle or toggle switch.

  • Page 35: Workplace Inspection

    Operator's Manual Seventh Edition • Second Printing Inspections Workplace Inspection Be aware of and avoid the following hazardous situations: · drop-offs or holes · bumps, floor obstructions or debris Do Not Operate Unless: · sloped surfaces You learn and practice the principles of safe ·...
  • Page 36 Label - Wheel Load, S-40 52865 Warning - Annual Inspection 226501 Label - Wheel Load, S-45 52966 Cosmetic - 4 x 2 226515 Instructions - Operating Instructions 52967 Cosmetic - 4 x 4 62072 Cosmetic - Genie S-40 S-40 • S-45 Part No. 226478...
  • Page 37 Operator's Manual Seventh Edition • Second Printing Inspections Ground Controls Side Platform Chassis Shading indicates decal is hidden from view, i.e. under covers Engine Side Part No. 226478 S-40 • S-45...

  • Page 38: Operating Instructions

    Operator's Manual Seventh Edition • Second Printing Operating Instructions 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. Do Not Operate Unless: Using the machine for anything other than lifting personnel, along with their tools and materials, to...

  • Page 39: Emergency Stop

    Operator's Manual Seventh Edition • Second Printing Operating Instructions Starting the Engine In extreme cold conditions, -18°C and below, machines should be equipped with optional cold start kits. Attempting to start the engine when 1 At the ground controls, turn the key switch to temperatures are below -18°C may require the use the desired position.
  • Page 40 Operator's Manual Seventh Edition • Second Printing Operating Instructions Operation from Ground To Position Platform 1 Press down the foot switch. 1 Turn the key switch to ground control. 2 Slowly move the appropriate function control 2 Pull out the red Emergency Stop button to handle or toggle switch according to the the on position.
  • Page 41 Operator's Manual Seventh Edition • Second Printing Operating Instructions 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.
  • Page 42 Operator's Manual Seventh Edition • Second Printing Operating Instructions Drive Enable Engine Idle Select (rpm) Light on indicates that the Select engine idle (rpm) using the symbols on the boom has moved just past control panel. either non-steer wheel and the When the foot switch is not pressed, the engine will drive function has been idle at its lowest rpm.
  • Page 43 Operator's Manual Seventh Edition • Second Printing Operating Instructions Observe and Obey: Pipe Cradle Instructions 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 and the platform.
  • Page 44 Operator's Manual Seventh Edition • Second Printing Operating Instructions Pipe Cradle Operation Platform Overload Indicator Light 1 Be sure the pipe cradle assembly and installation instructions have been followed Light flashing indicates the properly and that the pipe cradles are secured to platform is overloaded.
  • Page 45 Operator's Manual Seventh Edition • Second Printing Operating Instructions Check Engine Light After Each Use (if equipped) 1 Select a safe parking location—firm level surface, clear of obstruction and traffic. Light on and engine stopped: Tag the machine and remove from 2 Retract and lower the boom to the stowed service.

  • Page 46: Transport And Lifting Instructions

    Operator's Manual Seventh Edition • Second Printing 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 uphill or downhill maximum slope rating, the Observe and Obey: machine must be loaded and unloaded using a...
  • Page 47 Operator's Manual Seventh Edition • Second Printing Transport and Lifting Instructions Securing the Platform - S-40 Securing to Truck or Trailer for 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.
  • Page 48 Operator's Manual Seventh Edition • Second Printing 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.

  • Page 49: Maintenance

    Operator's Manual Seventh Edition • Second Printing 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 this Note: Check the oil level with the engine off.
  • Page 50 Operator's Manual Seventh Edition • Second Printing 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 is oil levels can damage hydraulic components.
  • Page 51 Operator's Manual Seventh Edition • Second Printing Maintenance 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.
  • Page 52 Operator's Manual Seventh Edition • Second Printing 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.

  • Page 53: Specifications

    Operator's Manual Seventh Edition • Second Printing Specifications S-40 Fuel tank capacity 76 liters Height, working maximum 14.2 m Hydraulic pressure, maximum 179 bar (boom functions) Height, platform maximum 12.2 m System voltage Height, stowed maximum 2.49 m Vibration does not exceed 2.5 m/s Horizontal reach maximum 9.7 m Weight...
  • Page 54 Operator's Manual Seventh Edition • Second Printing Specifications S-45 Hydraulic pressure, maximum 179 bar (boom functions) Height, working maximum 15.7 m Fuel tank capacity 76 liters Height, platform maximum 13.7 m System voltage Height, stowed maximum 2.49 m Vibration does not exceed 2.5 m/s Horizontal reach maximum 11.2 m Weight...
  • Page 55 Operator's Manual Seventh Edition • Second Printing Specifications S-40 Range of Motion Chart S-45 Range of Motion Chart Part No. 226478 S-40 • S-45...

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