Terex Genie Lift Guard S-40 User manual

Operator's Manual Seventh Edition • Second Printing
S-40 • S-45 PartNo.226478
Copyright © 1994 by Genie Industries
Seventh Edition: Second Printing, March 2011
"Genie" and "S" are registered trademarks of
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.
Important
Read,understandandobeythesesafetyrulesand
operatinginstructionsbeforeoperatingthismachine.
Onlytrainedandauthorizedpersonnelshallbe
permitted to operate this machine. This manual should
beconsidered apermanentpart of yourmachineand
should remain with the machine at all times. If you
have any questions, call Genie Industries.
Contents
Page
Introduction ................................................................ 1
Symboland Hazard Pictorials Definitions................... 3
GeneralSafety........................................................... 5
PersonalSafety ......................................................... 8
Work Area Safety....................................................... 9
Legend ......................................................................17
Controls ....................................................................18
Inspections ...............................................................25
OperatingInstructions...............................................36
Transportand LiftingInstructions ..............................44
Maintenance .............................................................47
Specifications ...........................................................51
Contact us:
Internet:http://www.genielift.com
E-mail:[email protected]

Operator's Manual
Seventh Edition • Second Printing
PartNo.226478 S-40 • S-45 1
Introduction
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
machineoperationcontainedinthisoperator's
manual.
1 Avoidhazardoussituations.
Knowandunderstandthesafetyrulesbefore
going on to the next section.
2 Alwaysperformapre-operationinspection.
3 Always perform function tests prior to use.
4 Inspect the workplace.
5 Only use the machine as it was intended.
Youread,understandandobeythe
manufacturer'sinstructions and safety rules—
safetyandoperator'smanualsandmachine
decals.
Youread,understandandobeyemployer's
safety rules and worksite regulations.
Youread,understandandobeyallapplicable
governmentalregulations.
Youareproperlytrainedtosafelyoperate the
machine.
Owners, Users and Operators:
Genieappreciates your choice of our machinefor
yourapplication.Ournumberonepriorityis user
safety, which is best achieved by our joint efforts.
We feel that you make a major contribution to
safety if you, as the equipment users and
operators:
1 Comply with employer, job site and
governmentalrules.
2 Read, understand and follow the instructions
in this and other manuals supplied with this
machine.
3 Use goodsafe work practices ina
commonsenseway.
4 Onlyhavetrained/certifiedoperators,directed
byinformedandknowledgeablesupervision,
runningthemachine.
If there is anything in this manual that is not clear
orwhichyoubelieveshould be added, please
contact us.
Internet:www.genielift.com
E-mail:[email protected]

Operator's Manual Seventh Edition • Second Printing
2 S-40 • S-45 PartNo.226478
Intended Use
This machine is intended to be used only to lift
personnel, along with their tools and materials to an
aerial work site.
Introduction
Safety Sign Maintenance
Replace any missing or damaged safety signs.
Keep operator safety in mind at all times. Use mild
soap and water to clean safety signs. Do not use
solvent-basedcleanersbecausetheymaydamage
the safety sign material.
Hazard Classification
Genie uses symbols, color coding and signal words
to identify the following:
Safety alert symbol—used to alert
youtopotentialpersonalinjury
hazards. Obey all safety
messages that follow this symbol
to avoid possible injury or death.
Indicatesa hazardous situation
which, if not avoided, will result in
deathorseriousinjury.
Indicatesa hazardous situation
which, if not avoided, could result
in death or serious injury.
Indicatesa hazardous situation
which, if not avoided, could result
inminor ormoderateinjury.
Indicatesa hazardous situation
which, if not avoided, could result
inpropertydamage.
Red
Orange
Yellow
Blue

Operator's Manual
Seventh Edition • Second Printing
PartNo.226478 S-40 • S-45 3
CrushHazard ExplosionHazard FireHazard ExplosionHazard Electrocution
Hazard
FallHazard CrushHazard Tip-overHazard
Symbol and Hazard Pictorials Definitions
Tip-overHazard Tip-overHazard
Tip-overHazard Tip-overHazard Electrocution
Hazard
Maintainrequired
clearance.
Readthe
operator’s
manual.
Keep off this
surface. Keepawayfrom movingparts. Keepawayfrom path of moving
platform.
Onlytrained
maintenance
personnelshould
access
compartments.
Nosmoking.
Noflame.
Stopengine.
Platformuphill:
1 Lowerboom.
2 Retract boom.
Platformdownhill:
1 Retract boom.
2 Lowerboom.
Do not use ether
orotherhigh
energystarting
aids on machines
equippedwith
glowplugs.
Readservice
manual Ratedplatform capacity

Operator's Manual Seventh Edition • Second Printing
4 S-40 • S-45 PartNo.226478
Lanyard
attachmentpoint
Symbol and Hazard Pictorials Definitions
Wheelload Voltageratingfor
powertoplatform Pressureratingfor air line to platform
Avoid contact. Tie-down
instructions Tie-down instructions
Fireextinguisher
Weightofwelder
reducescapacity Windspeed
+
+
=
X1

Operator's Manual
Seventh Edition • Second Printing
PartNo.226478 S-40 • S-45 5
Safety signs and locations
General Safety

Operator's Manual Seventh Edition • Second Printing
6 S-40 • S-45 PartNo.226478
General Safety
Safety signs and locations

Operator's Manual
Seventh Edition • Second Printing
PartNo.226478 S-40 • S-45 7
Safety signs and locations
General Safety

Operator's Manual Seventh Edition • Second Printing
8 S-40 • S-45 PartNo.226478
Personal Safety
Fall Protection
Personal fall protection equipment (PFPE) is
requiredwhenoperatingthismachine.
Occupants must wear a safety belt or harness in
accordancewithgovernmentalregulations.Attach
the lanyard to the anchor provided in the platform.
Operators must comply with employer, job site and
governmentalrulesregardingtheuseofpersonal
protectiveequipment.
All PFPE must comply with applicable
governmentalregulations,andmustbeinspected
and used in accordance with the PFPE
manufacturer’sinstructions.

Operator's Manual
Seventh Edition • Second Printing
PartNo.226478 S-40 • S-45 9
Electrocution Hazards Allow for platform movement, electrical line sway or
sag and beware of strong or gusty winds.
Keep away from the machine if it contacts
energizedpowerlines.Personnelonthegroundor
in the platform must not touch or operate the
machine until energized power lines are shut off.
Donotoperatethemachine duringlightning or
storms.
Do not use the machine as a ground for welding.
Tip-over Hazards
Occupants,equipment and materials shall not
exceed the maximum platform capacity for the
restrictedorunrestricted range of motion.
Maximum platform capacity 227 kg
Maximum occupants 2
The weight of options and accessories, such as
pipecradlesand welders, will reducetherated
platform capacity and must be factored into the
total platform load. See the decals with the options
andaccessories.
If using accessories, read, understand and obey
the decals and instructions with the accessory.
Work Area Safety
This machine is not
electricallyinsulated
andwillnot provide
protection from contact
with or proximity to
electricalcurrent.
Maintain safe distances
fromelectricalpower
linesandapparatusin
accordancewith
applicable
governmental
regulationsandthe
followingchart.
LineVoltage Required Clearance
0 to 50KV 3.0 m
50 to 200KV 4.6 m
200 to 350KV 6.1 m
350 to 500KV 7.6 m
500 to 750KV 10.6 m
750 to 1000KV 13.7 m

Operator's Manual Seventh Edition • Second Printing
10 S-40 • S-45 PartNo.226478
Do not raise or extend
the boom unless the
machine is on a firm,
level surface.
Donot depend onthe
tilt alarm as a level
indicator. The tilt alarm
sounds in the platform
onlywhen themachine
is on a severe slope.
If the tilt alarm sounds
when the platform is
raised:Useextreme
caution. Identify the
condition of the boom
on the slope as shown
below. Follow the steps
tolowerthe boom
before moving to a firm,
level surface. Do not
rotatetheboomwhile
lowering.
If the tilt alarm sounds
with the platform uphill:
First lower the boom,
then retract the boom.
If the tilt alarm sounds
withtheplatform
downhill:
First retract the boom,
thenlowertheboom.
Do not raise the boom
whenwindspeedsmay
exceed 12.5 m/s. If
windspeedsexceed
12.5 m/s when the
boomisraised,lower
the boom and do not
continuetooperatethe
machine.
Donotoperatethe
machineinstrongor
gusty winds. Do not
increasethe surface
area of the platform or
the load. Increasing the
areaexposedtothe
windwilldecrease
machine stability.
Useextreme careand
slowspeedswhile
driving the machine in
thestowed position
acrossuneventerrain,
debris,unstableor
slipperysurfacesand
nearholesanddrop-
offs.
Do not drive the
machineonornear
uneventerrain,
unstablesurfaces or
otherhazardous
conditions with the
boomraisedor
extended.
Do not use the machine
as a crane.
Work Area Safety

Operator's Manual
Seventh Edition • Second Printing
PartNo.226478 S-40 • S-45 11
Work Area Safety
Do not place or attach
overhangingloadsto
any part of this
machine.
Donotplaceladdersor
scaffolds in the
platformor against any
part of this machine.
Do not transport tools
andmaterials unless
they are evenly
distributedand can be
safely handled by
person(s)inthe
platform.
Do not use the machine
on a moving or mobile
surface or vehicle.
Do not push the machine or other objects with the
boom.
Do not contact adjacent structures with the boom.
Do not tie the boom or platform to adjacent
structures.
Do not place loads outside the platform perimeter.
Do not push off or pull
towardanyobject
outside
of the platform.
Maximum allowable
side force
400 N
Do not alter or disable machine components that in
any way affect safety and stability.
Do not replace items critical to machine stability
with items of different weight or specification.
Do not use air-filled tires. These machines are
equippedwithfoam-filledtires.Wheelweightand
propercounterweightconfigurationarecriticalto
stability.
Do not replace factory-installed tires with tires of
different specification or ply rating.
Do not modify or alter an aerial work platform
withoutprior writtenpermissionfrom the
manufacturer.Mountingattachmentsforholding
toolsor 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.
Be sure all tires are in good condition and lug nuts
areproperlytightened.
Do not use the platform controls to free a platform
thatis caught, snagged orotherwiseprevented
from normal motion by an adjacent structure. All
personnelmustbe removed from the platform
before attempting to free the platform using the
groundcontrols.

Operator's Manual Seventh Edition • Second Printing
12 S-40 • S-45 PartNo.226478
Fall HazardsOperation on Slopes Hazards
Do not drive the machine on a slope that exceeds
the maximum uphill, downhill or side slope rating of
the machine. Slope rating applies only to machines
in the stowed position.
Maximum slope rating, stowed position, 2WD
Platform downhill 30% (17°)
Platform uphill 15% (9°)
Side slope 25% (14°)
Maximum slope rating, stowed position, 4WD
Platform downhill 40% (22°)
Platform uphill 40% (22°)
Side slope 25% (14°)
Note: Slope rating is subject to ground conditions
andadequatetraction.
Work Area Safety
Occupants must wear a
safety belt or harness
inaccordancewith
governmental
regulations. Attach the
lanyardto theanchor
providedinthe
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
theplatformwhen
raised.
Keeptheplatformfloor
clear of debris.
Lowertheplatform
entry mid-rail or close
theentry gate before
operating.
Do not enter or exit the
platform unless the
machine is in the
stowedpositionand the
platform is at ground
level.

Operator's Manual
Seventh Edition • Second Printing
PartNo.226478 S-40 • S-45 13
Collision Hazards Limit travel speed
accordingtothe
conditionoftheground
surface,congestion,
slope, location of
personnel,andany
otherfactorswhich
may cause collision.
Donot operateaboom
in the path of any crane
unless the controls of
thecranehave been
lockedoutand/or
precautionshavebeen
taken to prevent any
potentialcollision.
No stunt driving or
horseplaywhile
operatingamachine.
Work Area Safety
Be aware of limited
sight distance and blind
spotswhendrivingor
operating.
Be aware of the boom
positionandtailswing
whenrotatingthe
turntable.
Checkthe work area for
overheadobstructions
orotherpossible
hazards.
Beaware ofcrushing
hazardswhengrasping
theplatformguardrail.
Operatorsmustcomply
with employer, job site
andgovernmentalrules
regardingtheuseof
personalprotective
equipment.
Observeandusethe
color-codeddirection
arrowsontheplatform
controlsand drive
chassis for drive and
steer functions.
Donot lower theboom
unlesstheareabelow
is clear of personnel
andobstructions.
Bodily Injury Hazard
Do not operate the machine with a hydraulic oil or
air leak. An air leak or hydraulic leak can penetrate
and/orburnskin.
Alwaysoperatethemachineinawell-ventilated
areatoavoidcarbonmonoxidepoisoning.
Impropercontact with components underanycover
will cause serious injury. Only trained maintenance
personnel should access compartments. Access
by the operator is only advised when performing a
pre-operationinspection.Allcompartmentsmust
remainclosedandsecuredduringoperation.

Operator's Manual Seventh Edition • Second Printing
14 S-40 • S-45 PartNo.226478
Battery Safety
Burn Hazards
Work Area Safety
Explosion and Fire Hazards
Do not start the engine if you smell or detect liquid
petroleumgas(LPG), gasoline, diesel fuel or other
explosive substances.
Donotrefuel the machine with the engine running.
Refuel the machine and charge the battery only in
anopen, well-ventilated areaawayfrom sparks,
flames and lighted tobacco.
Donotoperatethe machine in hazardous locations
orlocationswherepotentially flammableor
explosive gases or particles may be present.
Donot spray ether intoenginesequipped with glow
plugs.
Damaged Machine Hazards
Donotusea damaged or malfunctioning machine.
Conductathoroughpre-operationinspectionofthe
machine and test all functions before each work
shift. Immediately tag and remove from service a
damagedormalfunctioningmachine.
Besureallmaintenance has been performed as
specifiedin this manual and theappropriateGenie
servicemanual.
Be sure all decals are in place and legible.
Be sure the operator’s, safety and responsibilities
manualsarecomplete, legible and in the storage
containerlocatedon the platform.
Component Damage Hazards
Do not use any battery or charger greater than 12V
tojump-starttheengine.
Do not use the machine as a ground for welding.
Batteries contain acid.
Alwayswearprotective
clothingandeyewear
whenworkingwith
batteries.
Avoid spilling or
contacting battery acid.
Neutralizebatteryacid
spills with baking soda
andwater.
Explosion Hazard
Keep sparks, flames
andlightedtobacco
awayfrom batteries.
Batteries emit
explosive gas.
Electrocution Hazard
Avoid contact with electrical terminals.

Operator's Manual
Seventh Edition • Second Printing
PartNo.226478 S-40 • S-45 15
Welder Safety
Read,understandandobeyallwarningsand
instructionsprovided withtheweldingpowerunit.
Do not connect weld leads or cables unless the
welding power unit is turned off at the platform
controls.
Donotoperateunless the weld cables are properly
connectedandthewelderisproperlygrounded.
Theweight of the welder will reduce therated
platform capacity and must be factored into the
totalplatform load.Thewelderpowersupply weighs
34 kg.
Donotoperatethewelderunlessafire extinguisher
is immediately available for instant use.
Work Area Safety
Weld Line to Platform Safety
Read,understandandobeyallwarningsand
instructionsprovided withtheweldingpowerunit.
Do not connect weld leads or cables unless the
welding power unit is turned off at the platform
controls.
Donotoperateunless the weld cables are properly
connected.
Connect the positive lead to the twist-lock
connectorattheturntableand platform.
Clamp the negative lead to the ground post at the
turntableandplatform.

Operator's Manual Seventh Edition • Second Printing
16 S-40 • S-45 PartNo.226478
Lockout After Each Use
1 Select a safe parking location—firm level
surface, clear of obstruction and traffic.
2 Retract and lower the boom to the stowed
position.
3 Rotate the turntable so that the boom is between
thenon-steerwheels.
4 Turn the key switch to the off position and
remove the key to secure from unauthorized
use.
5 Chockthewheels.
Pipe Cradle Safety
Read,understandandobeyallwarningsand
instructions provided with the pipe cradles.
Do not exceed the rated platform capacity. The
pipe cradle assembly and the weight in the pipe
cradles will reduce rated platform capacity and
must be factored into total platform load.
The pipe cradle assembly weighs 9.5 kg.
The maximum capacity of the pipe cradle assembly
is 91 kg.
The weight of the pipe cradle assembly and the
load in the pipe cradles may limit the maximum
number of occupants in platform.
Center the load within the perimeter of the platform.
Secure the load to the platform.
Do not obstruct the entrance or the exit of the
platform.
Do not obstruct the ability to operate the platform
controls or the red Emergency Stop button.
Donot operateunlessyou areadequately
instructed and are aware of all of the hazards
associated with movement of the platform with an
overhangingload.
Do not cause a horizontal force or side load to the
machine by raising or lowering a fixed or
overhangingload.
ElectrocutionHazard: Keeppipesaway from all
energizedelectricalconductors.
Work Area Safety

Operator's Manual
Seventh Edition • Second Printing
PartNo.226478 S-40 • S-45 17
Legend
1 Foot switch
2 Manualstoragecontainer
3 Slidingmid-rail
4 Lanyardanchoragepoint
5 Non-steertire
6 Steertire
7 Groundcontrols
8 Boom
9 Platformcontrols
10 Platform
11 Jibboom(S-45)

Operator's Manual Seventh Edition • Second Printing
18 S-40 • S-45 PartNo.226478
Controls
13 54
17
7 Deutz Diesel models: Glow plug switch
(ifequipped)
Perkins models: Glow plug indicator light
8 Engine start switch
9 Engine idle (rpm) select switch
· Turtle: foot switch activated low idle
· Rabbit: foot switch activated high idle
PlatformControlPanel
1 Hornbutton
2 Platform level switch
3 Platform rotate switch
4 S-45 models: Jib boom up/down switch
5 Auxiliarypowerswitch
6 Drive speed select switch
2
1819