Terex Genie S-40/45 User manual

Operator's Manual Supplement
Lift Tools Access Deck
Original Instructions
First Edition
Fourth Printing
Part No. 1292178GT
ANSI/CSA
North America
South America
Asia

Operator's Manual Supplement First Edition • Fourth Printing
Introduction
2 Part No. 1292178GT
Introduction
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, contact us.
Contact Us:
Internet: www.genielift.com
E-mail: [e-mail]
Copyright © 2018 by Terex Corporation
First Edition: Fourth Printing, October 2020
Genie is a registered trademark of Terex South Dakota, Inc. in
the U.S.A. and many other countries. "S", “Z” and "XC" are
trademarks of Terex South Dakota, Inc.
This accessory complies with
ANSI/SAIA A92.20
CAN/CSA B.354.6

First Edition • Fourth Printing Operator's Manual Supplement
Introduction
Part No. 1292178GT 3
Approved Models (6 ft)
Model
Serial Number
S®-40/45
from S4016H-22550
S®-40/45 XC
from S40XCH-101
S®-40/45 TRAX
from S4016H-22550
S®-60/65
from S60H-36659
S®-60/65 XC
from S60XCH-45001
S®-60 X
from S60H-36659
S®-60 HC
from S60H-36659
S®-60/65 TX
from S60H-36659
S®-80/85
from S85H-13582
S®-80 X
from S85H-13582
S®-80/85 XC
from S80XCH-101
S®-100
from S100D-1672
S®-105
from S105D-1665
S®-120
from S120D-1705
S®-125
from S125D-1660
S®-100 HD
from S100D-1672
Model
Serial Number
S®-120 HD
from S120D-1705
SX™-105 XC
from SX105D-174
SX™-135 XC
from SX135H-127
SX™-125 XC
from SX125D-101
SX™-150
from SX150H-201
SX™-180
from SX180H-365
Z®-45 XC
from Z4525XCM-101
Z®-45/25
from Z4525N-57509
Z®-45/25J
from Z4525N-57509
Z®-45/25J RT
from Z4525N-57509
Z®-45/25 RT
from Z4525N-57509
Z®-60/34
from Z60H-746
Z®-60/37
from Z60H-746
Z®-62
from Z62H-3077
Z®-80
from Z80H-6076
Z®-135
from ZX135H-2889
ZX®-135
from ZX135H-2889
Do not install the Access Deck
system on any Genie product
other than the designated
models.
The Access Deck can only be
mounted on the mid rails of the
platform. The Access Deck can
never be mounted on the top
rail.
Do not operate the boom while
using the Access Deck.

Operator's Manual Supplement First Edition • Fourth Printing
Introduction
4 Part No. 1292178GT
Approved Models (8 ft)
Model
Serial Number
S®-40/45
from S40-001
S®-40/45 XC
from S40XCH-101
S®-40/45 TRAX
from S40-001
S®-60/65
from S60-653
S®-60/65 XC
from S65XCM-101
S®-60 X
from S60-653
S®-60 HC
from S60-653
S®-60/65 TX
from S60-653
S®-80/85
from S80-001
S®-80 X
from S80-001
S®-80/85 XC
from S80XCH-101
S®-100
from S100-101
S®-105
from S105-101
S®-120
from S120-101
S®-125
from S125-101
S®-100 HD
from S100HD14D-200
Model
Serial Number
S®-120 HD
from S120HD14D-201
SX™-105 XC
from SX105D-174
SX™-135 XC
from SX135H-101
SX™-125 XC
from SX125D-101
SX™-150
from SX15015H-100
SX™-180
from SX18013-005
Z®-60/34
from Z60-001
Z®-60/37
from Z60M-101
Z®-62
from Z6215A-101
Z®-80
from Z8003-101
Z®-135
from Z135-100
ZX®-135
from ZX13513-2001
Do not install the Access Deck
system on any Genie product
other than the designated
models.
The Access Deck can only be
mounted on the mid rails of the
platform. The Access Deck can
never be mounted on the top
rail.
Do not operate the boom while
using the Access Deck.

First Edition • Fourth Printing Operator's Manual Supplement
Introduction
Part No. 1292178GT 5
Genie Self-propelled Boom
Products and Lift Tools Access
Deck Guidance
Boom-supported Elevating Work Platforms are
designed to carry personnel, along with their tools,
and materials to an aerial work site. When platform
access is limited and the personnel need to reach
a work area that is beyond their working height,
the Access Deck provides an elevated deck,
above the main floor, to allow an occupant to
extend their working height.
This document provides guidance for the
use of the Access Deck on Genie self-
propelled boom products.
Definitions
Qualified person
A "qualified person" one who, by possession of a
recognized degree, certificate, or professional
standing, or by extensive knowledge, training and
experience, has demonstrated his/her ability to
solve or resolve problems related to the subject
matter, the work, or the project.
Genie Self-propelled Booms may be used
to lift under the following guidelines:
1The owner/employer/user/operator of the
boom is responsible for providing fall
protection for boom operator.
2A "qualified person" with knowledge of fall
protection regulations and systems must
design the work space and the Access Deck
system to ensure worker safety.
3Genie Booms have been stability tested on
level ground with the rated load in the
platform. The combined weight on the Access
Deck must not exceed 300 lbs/136 kg.
Note: The weight of the Access Deck
assembly must be subtracted from the
platform capacity that it is mounted on.
Access Deck for 8 ft Platform
36 lbs/16 kg
Access Deck for 6 ft Platform
29 lbs/13 kg
4Attachment and use of an Access Deck must
be approved and authorized by the equipment
owner.
5It is the responsibility of the equipment owner
and/or the contractor to perform a hazard
analysis when using the Access Deck, and
ensure that the equipment complies with the
essential health and safety requirements
applicable to the jobsite, as well as local, state,
provincial, and federal rules and regulations,
and standards related to the use of the
equipment.
6The boom must be on a firm level surface to
use the Access Deck.
7A person trained in the operation of the Genie
boom shall remain on the ground near the
machine base controls to prevent
unauthorized use and to prevent the machine
from being operated while using the Access
Deck.

Operator's Manual Supplement First Edition • Fourth Printing
Introduction
6 Part No. 1292178GT
Owner/Employer/User/Operator
Requirements:
Owner/Employer/User/Operator
Requirements:
1Operators must be trained and qualified on
safe operation of the equipment, and be
familiar with the specific model of Genie
equipment as follows:
Be familiar and comply with the equipment
operating and safety manuals, decals and
warnings.
Understand all control functions.
Be aware of and understand all safety
devices specific to the equipment being
used.
Be instructed how to avoid the hazards.
2Comply with all applicable jobsite, local, state,
provincial, and federal rules and regulations,
and standards related to the use of the
equipment.
3The equipment must be in proper working
condition and configuration.
In consideration for Genie's guidance herein, the
equipment owner, employer, user and operator
hereby agree to indemnify and hold harmless
Terex USA and its parent and affiliated companies
against any and all liabilities, claims, suits, losses,
costs and legal fees caused by, arising out of, or
resulting from any negligent act or omission in the
operation of the equipment; the failure to comply
with the criteria set forth in this manual related to
the use of a boom with an Access Deck the safety
rules and operating instructions in the Operator's
Manual. By proceeding with the use of a boom
with an Access Deck, you agree to adhere to
the requirements set forth herein, including
said indemnification. If you do not agree, do
not proceed with the proposed use.

First Edition • Fourth Printing Operator's Manual Supplement
Introduction
Part No. 1292178GT 7
Danger
Failure to obey the instructions and
safety rules in this manual will result
in death or serious injury.
Note
The Lift Tools™ Access Deck complies with the
requirements of ANSI/CSA markets. All other
markets are prohibited from use.
The Access Deck can only be used on Genie
Boom-Supported Elevating Work Platforms
equipped with the following 6 ft and 8 ft platforms:
Side entry swing gate platforms with 2 sliding
mid-rails.
TRI entry platforms
Note: 8ft TRI entry platforms with three sliding
mid-rails. 6ft TRI entry platforms prohibited.
Front entry platforms with single sliding mid-
rail (8 ft only)
Use on all other platforms is prohibited.

Operator's Manual Supplement First Edition • Fourth Printing
Introduction
8 Part No. 1292178GT
Using the Access Deck with the
options below will result in
death or serious injury.
The Access Deck cannot be properly installed on
platforms equipped with the following:
Panel cradle (option)
Center mounted swing gate (option)
Genie Fall Arrest Bar
Half mesh (option)
Full mesh (option)
Aircraft Protection (option)
Using the Access Deck with the
options below will result in death
or serious injury.
The Access Deck cannot be used on platforms
equipped with the following:
Front entry platforms with single sliding mid-
rail (6 ft only)
Lift Tools™ Access Deck
Safety
Read, understand and obey all warnings and
instructions provided with the Access Deck.
Do not exceed the rated platform capacity. The
weight of the Access Deck assembly will reduce
the rated platform capacity and must be subtracted
from the total platform load.
Access Deck for 8 ft
Platform
36 lbs/16 kg
Access Deck for 6 ft
Platform
29 lbs/13 kg
The Access Deck assembly and handle must be
mounted for use together.
Be sure the Access Deck is securely installed.
Only use the folding handle for stability.
When the Access Deck structure is attached, this
manual should be with the machine at all times.
The Access Deck can be transported on the mid-
rail when all locking mechanisms are engaged and
securely fastened to the platform. The platform is
required to be parallel to the ground at all times
during transportation.
Do not use Access Deck with
ice, grease or debris on the
mid-rail surfaces.
Do not operate the boom once
the operator has tied off and
standing on the Access Deck.

First Edition • Fourth Printing Operator's Manual Supplement
Introduction
Part No. 1292178GT 9
Symbol and Hazard Pictorials
Definitions
The Access Deck
weighs:
8 ft: 36 lbs/16 kg
6 ft: 29 lbs/13 kg
Read the supplement,
part number 1292178.
Tip-over hazard
Maximum capacity
300 lbs/136 kg.
Pre-operation Inspection
Be sure that the operator’s manual, safety
manual, responsibilities manual and any
necessary supplements are complete, legible
and in the storage container located in the
platform.
Be sure that all decals are legible and in place.
Check the Access Deck for damage or wear,
improperly installed, loose or missing parts and
unauthorized modifications.
Nuts, bolts and other fasteners
Cracks in welds or structural components
Dents or damage to Access Deck
Check platform mounting location. The
mounting location must be undamaged
and clear of debris, ice, oily and slippery
surfaces.

Operator's Manual Supplement First Edition • Fourth Printing
Introduction
10 Part No. 1292178GT
Decal Inspection
Use the inspection to verify that all decals are
legible and in place. Decals may vary depending
on machine configuration.
8 foot Access Deck
Part No. Decal Description
Qty
1281174GTDecal, Lanyard , fall arrest/fall restraint
8
1292288GTDecal, Max Capacity, Word, Access Deck
(8ft)
1
1292288FRGT Decal, Max Capacity, Word,
Access Deck (8ft)
1
6 foot Access Deck
Part No. Decal Description
Qty
1281174GTDecal, Lanyard , fall arrest/fall restraint
8
1293709GTDecal, Max Capacity, Word, Access Deck
(6ft)
1
1293709FRGT Decal, Max Capacity, Word,
Access Deck (6ft)
1

First Edition • Fourth Printing Operator's Manual Supplement
Operating Instructions
Part No. 1292178GT 11
Operating Instr uctions
Lift Tools™ Access Deck Operation
1Verify the Access Deck installation instructions
have been followed properly and that the
Access Deck and handle are secured with
locking pins to the platform railings.
Tip-over hazard The weight of
the Access Deck will reduce
the rated platform capacity of
the machine and must be
factored into the platform
load.
Occupants must wear a
safety belt or harness in
accordance with
governmental
regulations. Attach the
lanyard to the anchor
provided in the platform.
Lanyard to be 6 ft
retractable.
Do not sit, stand, or
climb on the platform
guard rails and Access
Deck toeboard. Maintain
a firm footing on the
platform or Access Deck
floor at all times.
2Pull the lock pin on the right side of the step to
lower and swing Access Deck step down.
3Rotate the handle up to the vertical position.
Secure the handle with the 3/8" lock pin on the
handle assembly.
Annual Inspection
Inspect for missing or loose components.
Check all fasteners are properly tightened.
Inspect all components for damage or wear.
Check for cracks, bends and corrosion.
Inspect all welds for cracks.
Verify the Access Deck rotates freely about the
right wear-pad slot on the mid-rail.
Verify the locking cam engages the mid-rail with
audible click and locks fully with the pop pin on the
deck.
Verify the pop pin on the step engages in both the
open and closed position with audible click.
Verify the handle can freely rotate around the
shoulder bolt.
Verify the detent pin and lock the handle both up
and down.
Inspection After a Fall
Note: In the event of an operator fall, the Access
Deck and the Genie boom must be immediately
removed from service and inspected by a
"qualified person". If the Access Deck and the
Genie boom pass the inspections listed below, the
Access Deck and the Genie boom may be
returned to service.
Inspect all structural components of the Access
Deck and the Genie boom. Replace any bent or
damaged components. Replace any components
with cracked welds. Replace all mounting
fasteners for the Access Deck.
Perform an Annual Inspection on the Access Deck
Perform a Pre-Operation Inspection on both the
Access Deck and the Genie boom.

Operator's Manual Supplement First Edition • Fourth Printing
Installation Instructions
12 Part No. 1292178GT
Installation Instructions
Observe and Obey:
This procedure shall be completed by a
person authorized to install the Access Deck.
Immediately tag and remove from service a
damaged or malfunctioning machine.
Repair any machine damage or malfunction
before operating the machine.
Before Starting Installation
Read, understand and obey the safety rules
and operating instructions in the appropriate
Genie Operator’s Manual and Supplements.
Be sure that all necessary tools and parts are
available and ready for use.
Read this procedure completely and adhere to
the instructions.
Note: Refer to the illustration page for
installation instructions.
Contents of Kit 1293700GT
(6 ft/1.8 m Platform)
Description
Genie part number
Qty.
(1) Manual, Supplement
1292178GT
1
(2) Decal, Maximum Capacity,
Word
1293709GT
2
(3) Decal, Maximum Capacity,
Word (FR)
1293709FRGT
2
(4) Decal, Cosmetic, Lift Tool
Access Deck
1292296GT
1
(5) Assembly, Deck
-
1
(6) Assembly, Handle
-
1
(7) U-bolt, 1.5 x 3/8
-
2
(8) Nylock flange nut, 3/8-16
-
4
(9) Bumper, Rubber, 5/16-18
-
1
(10) Nut, 5/16-18
-
1
(11) Nylock flange nut, 5/16-18
-
1

First Edition • Fourth Printing Operator's Manual Supplement
Installation Instructions
Part No. 1292178GT 13
Contents of Kit 1291798GT
(8 ft/2.4 m Platform)
Description
Genie part number
Qty.
(1) Manual, Supplement
1292178GT
1
(2) Decal, Maximum Capacity,
Word
1292288GT
2
(3) Decal, Maximum Capacity,
Word (FR)
1292288FRGT
2
(4) Decal, Cosmetic, Lift Tool
Access Deck
1292296GT
1
(5) Assembly, Deck
-
1
(6) Assembly, Handle
-
1
(7) U-bolt, 1.5 x 3/8
-
2
(8) Nylock flange nut, 3/8-16
-
4
(9) Bumper, Rubber, 5/16-18
-
1
(10) Nut, 5/16-18
-
1
(11) Nylock flange nut, 5/16-18
-
1
(12) Screw, HHF, 10-24X0.625
-
1
(13) Nylock flange nut, 10-24
-
1
(14) Steel Lanyard,, 8"
-
1
(15) Quick release pin, 3/8X 5"
-
1
(16) Vertical rail lock forming
-
1
(17) Screw, HHF, 1/4-20X0.75
-
2
(18) Nylock flange nut, 1/4-20
-
2
Deck Installation
Note: The deck assembly can only be installed on
the mid-rails of the platform.
1Slide the right side of the deck assembly so it
is fully seated against the mid-rail of the
platform (see illustration).
2Pull the locking pin on the left side of the deck
assembly to release the locking cam.
3Lower the deck assembly onto the left side
mid-rail until it is fully seated into the locking
cam.
Note: The locking pin will make an audible click
when fully seated.
4For side entry swing gate platform with sliding
midrail and tri entry platform- Install the vertical
rail lock forming to the left side of preexisted
vertical rail lock forming on access deck toe
board using 1/4-20 X0.75 screw and 1/4-
20 flange nut.
5For front entry platform with single sliding
midrail (only 8 ft platforms)- Install the vertical
rail lock forming to the right side of preexisted
forming lock on access deck toe board using
1/4-20 X0.75 screw and 1/4-20 flange nut.
6Position and secure the quick release pin onto
the toe board near the vertical rail lock forming
using 10-24X0.625 screw and 10-24 flange nut
with the help of 8 inch steel lanyard
7Position the deck assembly to the vertical rail
and pull the locking pin and rotate the step
down all the way.
Note: The locking pin will make an audible click
when fully seated.

Operator's Manual Supplement First Edition • Fourth Printing
Installation Instructions
14 Part No. 1292178GT
Handle Installation
Note: Handle assembly must be mounted and
accessible near the Access Deck anytime the
Access Deck is mounted.
1Mount the handle assembly to the platform
railing using both the U-bolts and 3/8-
16 nylock flange nuts. Do not over tighten.
2Install the 5/16-18 nut onto the rubber bumper.
Install the bumper assembly into the handle
forming and secure with the 5/16-18 nylock
flange nut. Do not tighten at this time.
3Rotate the handle up to the vertical position.
Secure the handle with the 3/8" lock pin on the
handle assembly.
4Adjust the inside nut on the rubber bumper
until the bumper sits firmly against the handle.
Tighten the 5/16-18 nylock nut.
5Insert the supplement Operator's Manual into
the manual storage box located in the
platform.

First Edition • Fourth Printing Operator's Manual Supplement
Installation Instructions
Part No. 1292178GT 15
Side entry swing gate platforms with 2 sliding mid-rails
1
Lock pin
2
Assembly, handle
3
Bumper
4
Nut, 5/16-18
5
Nylock flange nut, 3/8-16
6
Nylock flange nut, 5/16-18
7
U-bolt,
8
Quick release pin (8 ft platforms)
9
Flange nut, 1/4-20
10
Vertical rail lock forming
11
Nylock flange nut, 10-24
12
Screw, HHF, 10-24X.625
13
Screw, HHF, 1/4-20X 0.75
14
Assembly, access deck

Operator's Manual Supplement First Edition • Fourth Printing
Installation Instructions
16 Part No. 1292178GT
Front entry platforms with single sliding midrail (8 ft only)
1
Lock pin
2
Assembly, handle
3
Bumper
4
Nut, 5/16-18
5
Nylock flange nut, 3/8-16
6
Nylock flange nut, 5/16-18
7
U-bolt,
8
Quick release pin (8 ft platforms)
9
Flange nut, 1/4-20
10
Vertical rail lock forming
11
Nylock flange nut, 10-24
12
Screw, HHF, 10-24X.625
13
Screw, HHF, 1/4-20X 0.75
14
Assembly, access deck
Lift Tools Acc essD eck
Part No. 1292178GT
Operator's M anual Suppl ement
First Edition • Fo urth Printing