Genie S-40 TRAX User manual

Operator’s Manual
with Maintenance Information
Second Edition
Ninth Printing
Part No. 43645
from 832 to 7189

Genie S-40 & Genie S-45 Part No. 43645
Operator's Manual Second Edition • Ninth Printing
Copyright © 1994 by Genie Industries
First Edition: First Printing February, 1994
Second Edition: Ninth Printing, February 2011
"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
Printed on recycled paper
Printed in U.S.A.
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
Safety Rules .............................................................. 1
Controls ..................................................................... 7
Pre-operation Inspection........................................... 10
Maintenance ............................................................. 12
Function Tests .......................................................... 16
Workplace Inspection ................................................ 22
Operating Instructions ............................................... 23
Transport and Lifting Instructions .............................. 27
Decals ...................................................................... 30
Specifications ........................................................... 32
Contact us:
Internet: http://www.genielift.com
E-mail: [email protected]

Part No.43645 Genie S-40 & Genie S-45 1
Operator's ManualSecond Edition • NInth Printing
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:
You learn and practice the principles of safe
machine operation contained in this operator's
manual.
1 Avoid hazardous situations.
Know and understand the safety rules before
going on to the next section.
2 Always perform a pre-operation inspection.
3 Always perform function tests prior to use.
4 Inspect the workplace.
5 Only use the machine as it was intended.
You read, understand and obey:
Manufacturer's instructions and safety
rules—safety and operator's manuals
and machine decals
employer's safety rules and worksite
regulations
applicable governmental regulations
You are properly trained to safely operate the
machine.

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Operator's Manual Second Edition • Ninth Printing
SAFETY RULES
Electrocution Hazards
This machine is not electrically insulated and will
not provide protection from contact with or
proximity to electrical current.
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 to 200KV 15 4.60
200KV to 350KV 20 6.10
350KV to 500KV 25 7.62
500KV 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.
Tip-over Hazards
Occupant, equipment and materials shall not
exceed the maximum platform capacity.
Maximum platform capacity 500 lbs 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
personnel must be removed from the platform
before attempting to free the platform using the
ground controls.

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Operator's ManualSecond Edition • NInth Printing
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 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 & CSA
150 lbs / 667 N
Maximum allowable
side force - CE
90 lbs / 400 N
Do not alter or disable machine components that in
any way affect safety and stability.
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.
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.

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Operator's Manual Second Edition • Ninth Printing
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.
Do not climb down from the platform when raised.
Keep the platform floor clear of debris.
Lower the platform entry mid-rail or close the entry
gate before operating.
SAFETY RULES
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 controls and drive chassis for drive
and steer functions.

Part No.43645 Genie S-40 & Genie S-45 5
Operator's ManualSecond Edition • NInth Printing
SAFETY RULES
Do not lower the boom unless the area below is
clear of personnel and obstructions.
Limit travel speed according to the condition of the
ground surface, congestion, slope, location of
personnel and any other factors which may cause
collision.
Do not operate a boom in the path of any crane
unless the controls of the crane have been locked
out and/or precautions have been taken to prevent
any potential collision.
No stunt driving or horseplay while operating a
machine.
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.
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.
Damaged Machine Hazards
Do not use a damaged or malfunctioning machine.
Conduct a thorough pre-operation inspection of the
machine and test all functions before each work
shift. Immediately tag and remove from service a
damaged or malfunctioning machine.
Be sure all maintenance has been performed as
specified in this manual and the appropriate
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.

6 Genie S-40 & Genie S-45 Part No.43645
Operator's Manual Second Edition • Ninth 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:
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.43645 Genie S-40 & Genie S-45 7
Operator's ManualSecond Edition • NInth Printing
Ground Control Panel
1 Platform rotate switch
2 Turntable rotate switch
3 Boom up/down switch
4 Boom extend/retract switch
5 Diesel models: Glow plug switch (if equipped)
Gasoline/LPG models: Gasoline/LPG select
switch
6 Key switch for platform/off/ground selection
7 Auxiliary power switch
8 Gasoline/LPG models: Water temperature
gauge
Diesel models: Oil temperature gauge
9 Oil pressure gauge
10 Voltage gauge
11 Red Emergency Stop button
12 Hour meter
13 Gasoline/LPG models: Check engine light
14 Function enable switch
15 Engine start switch
16 15A breaker for engine electrical circuits
17 20A breaker for oil cooler and options
18 15A breaker for control electrical circuits
19 S-45 models: Jib boom up/down switch
20 Platform level switch
Controls

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Operator's Manual Second Edition • Ninth Printing
CONTROLS
13 54
15
7 Diesel models: Glow plug switch (if equipped)
8 Engine start switch
9 Engine idle (rpm) select switch
Rabbit & Foot Switch: foot switch activated
high idle
Turtle: low idle
Rabbit: high idle
Platform Control Panel
1 Horn button
2 Platform level switch
3 Platform rotate switch
4 S-45 models: Jib boom up/down switch
5 Auxiliary power switch
6 Optional equipment
2
616

Part No.43645 Genie S-40 & Genie S-45 9
Operator's ManualSecond Edition • NInth Printing
CONTROLS
10 Gasoline/LPG models: Gasoline/LPG select
switch
11 Red Emergency Stop button
12 Proportional control handle for drive function and
thumb rocker for steer function OR dual axis
proportional control handle for drive and steer
functions
117 8
12
14
6 9 10
6 613
13 Drive enable indicator light
14 Drive enable switch
15 Boom extend/retract switch
16 Dual axis proportional control handle for boom
up/down and turntable rotate left/right functions

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Pre-operation Inspection
Do Not Operate Unless:
You learn and practice the principles of safe
machine operation contained in this operator's
manual.
1 Avoid hazardous situations.
2 Always perform a pre-operation
inspection.
Know and understand the pre-operation
inspection before going on to the next
section.
3 Always perform function tests prior to use.
4 Inspect the workplace.
5 Only use the machine as it was intended.
Fundamentals
It is the responsibility of the operator to perform a
pre-operation inspection and routine maintenance.
The pre-operation inspection is a visual inspection
performed by the operator prior to each work shift.
The inspection is designed to discover if anything
is apparently wrong with a machine before the
operator performs the function tests.
The pre-operation inspection also serves to
determine if routine maintenance procedures are
required. Only routine maintenance items specified
in this manual may be performed by the operator.
Refer to the list on the next page and check each
of the items.
If damage or any unauthorized variation from
factory delivered condition is discovered, the
machine must be tagged and removed from
service.
Repairs to the machine may only be made by a
qualified service technician, according to the
manufacturer's specifications. After repairs are
completed, the operator must perform a
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.43645 Genie S-40 & Genie S-45 11
Operator's ManualSecond Edition • NInth Printing
PRE-OPERATION INSPECTION
Pre-operation Inspection
RBe sure that the operator’s, safety and
responsibilities manuals are complete, legible
and in the storage container located in the
platform.
RBe sure that all decals are legible and in place.
See Decals section.
RCheck for engine oil leaks and proper oil level.
Add oil if needed. See Maintenance section.
RCheck for hydraulic oil leaks and proper oil level.
Add oil if needed. See Maintenance section.
RCheck for engine coolant leaks and proper level
of coolant. Add coolant if needed. See
Maintenance section.
RCheck for battery fluid leaks and proper fluid
level. Add distilled water if needed. See
Maintenance section.
RCheck 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:
RElectrical components, wiring and
electrical cables
RHydraulic hoses, fittings, cylinders and
manifolds
RFuel and hydraulic tanks
RDrive and turntable motors and drive hubs
RBoom wear pads
RTires and wheels
REngine and related components
RLimit switches and horn
RAlarms and beacons (if equipped)
RNuts, bolts and other fasteners
RPlatform entry mid-rail or gate
Check entire machine for:
RCrack in welds or structural components
RDents or damage to machine
RBe sure that all structural and other critical
components are present and all associated
fasteners and pins are in place and properly
tightened.
RAfter you complete your inspection, be sure that
all compartment covers are in place and
latched.

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Maintenance
Observe and Obey:
Only routine maintenance items specified in this
manual shall be performed by the operator.
Scheduled maintenance inspections shall be
completed by qualified service technicians,
according to the manufacturer's specifications
and the requirements specified in the
responsibilities manual.
Maintenance Symbols Legend
The following symbols have been
used in this manual to help
communicate the intent of the
instructions. When one or more of
the symbols appear at the
beginning of a maintenance
procedure, it conveys the meaning
below.
Indicates that tools will be required to
perform this procedure.
Indicates that new parts will be
required to perform this procedure.
Indicates that a cold engine is required
before performing this procedure.
Check the Engine Oil Level
Maintaining the proper engine oil level is essential
to good engine performance and service life.
Operating the machine with an improper oil level
can damage engine components.
Check the oil level with the
engine off.
1 Check the oil dipstick.
Ford models:
Result: The oil level should be between the ADD
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 5W-30
-10° to 90°F / -23° to 32°C 5W-30
above -10°F / -23°C 5W-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.43645 Genie S-40 & Genie S-45 13
Operator's ManualSecond Edition • NInth Printing
MAINTENANCE
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.
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

14 Genie S-40 & Genie S-45 Part No.43645
Operator's Manual Second Edition • Ninth Printing
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
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.
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
hot or live circuits may result in
death or serious injury. Remove all
rings, watches and other jewelry.
Bodily injury hazard. Batteries
contain acid. Avoid spilling or
contacting battery acid. Neutralize
battery acid spills with baking soda
and water.
1 Put on protective clothing and eye wear.
2 Be sure that the battery cable connections are
tight and free of corrosion.
3 Be sure that the battery hold-down 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 and a
corrosion preventative sealant will
help eliminate corrosion on the
battery terminals and cables.
MAINTENANCE

Part No.43645 Genie S-40 & Genie S-45 15
Operator's ManualSecond Edition • NInth Printing
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-
inflated tire can explode and could
cause death or serious injury.
Tip-over hazard. Do not use
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
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.
MAINTENANCE

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Operator's Manual Second Edition • Ninth Printing
FunctionTests
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.
Do Not Operate Unless:
You learn and practice the principles of safe
machine operation contained in this operator's
manual.
1 Avoid hazardous situations.
2 Always perform a pre-operation
inspection.
3 Always perform function tests prior to
use.
Know and understand the function tests
before going on to the next section.
4 Inspect the workplace.
5 Only use the machine as it was intended.
1 Select a test area that is firm, level and free of
obstruction.
At the Ground Controls
2 Turn the key switch to ground control.
3 Pull out the red Emergency Stop button to
the on position.
Result: The beacon (if equipped) should flash.
4 Start the engine. See Operating Instructions
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.
6 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.
8 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.

Part No.43645 Genie S-40 & Genie S-45 17
Operator's ManualSecond Edition • NInth Printing
FUNCTION TESTS
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.
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.
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.

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Operator's Manual Second Edition • Ninth Printing
FUNCTION TESTS
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/steer 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.
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
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.