Genie Industries S-40 User Manual

208 pages

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Service

Manual

Technical

Publications

First Edition, First Printing

Part No. 32222

S-40

Table of Contents5
Specifications13
Machine Specifications13
Performance Specifications14
Hydraulic Specifications15
Bolt Torque Specifications16
Ford LSG 423 Engine Specifications17
Deutz F3L Engine Specifications20
Scheduled Maintenance Inspections21
Maintenance Inspection Report27
Scheduled Maintenance Procedures29
Inspect the Manuals30
Inspect the Decals and Placards30
Inspect for Damage, Loose or Missing Parts30
Check the Engine Oil Level31
Check the Engine Coolant Level - Gasoline/Lpg Models31
Check for Fuel Leaks31
Check the Hydraulic Oil Level32
Check for Hydraulic Leaks32
Check the Tire Pressure33
Test the Platform and Ground Controls33
Test the Auxiliary Power Operation34
Test the Tilt Sensor35
Test the Limit Switches35
Test the Oscillate Axle37
Replace the Engine Oil and Filter - Gasoline/Lpg Models38
Replace the Engine Air Filter39
Check the Engine Belt(S)40
Check the Radiator - Gasoline/Lpg Models40
Check the Oil Cooler and Cooling Fins - Deutz Diesel Models40
Check the Exhaust System41
Check the Battery42
Check the Hydraulic Tank Filter Condition Indicator42
Inspect the Electrical Wiring43
Inspect the Tires and Wheels43
Confirm the Proper Brake Configuration44
Check the Oil Level in the Torque Hubs44
Check and Adjust the Engine Idle Mixture - Gasoline/Lpg Models45
Check and Adjust the Engine RPM45
Test the Key Switch47
Test the Emergency Stop Buttons48
Test the Ground Control Override48
Check the Directional Valve Linkage49
Test the Platform Self-Leveling49
Test the Service Horn49
Test the Foot Switch50
Test the Engine Idle Select50
Test the Fuel Select Operation - Gasoline/Lpg Models51
Test the Drive Enable System51
Test the Drive Brakes52
Test the Drive Speed - Stowed Position52
Test the Alarm Package - Optional Equipment53
Perform Hydraulic Oil Analysis53
Replace the Engine Oil and Filter - Deutz Diesel Models54
Check the Boom Wear Pads55
Check the Turntable Rotation Bearing Bolts55
Check the Free-Wheel Configuration56
Grease the Turntable Rotation Bearing and Rotate Gear57
Replace the Torque Hub Oil57
Replace the Hydraulic Tank Filter59
Replace the Drive Loop Hydraulic Filter59
Replace the Diesel Fuel Filter - Deutz Diesel Models60
Replace the Gasoline Fuel Filter - Gasoline/Lpg Models60
Replace the PCV Valve - Gasoline/Lpg Models62
Clean or Replace the Distributor Cap and Rotor - Gasoline/Lpg Models62
Replace the Spark Plugs - Gasoline/Lpg Models63
Check and Adjust the Air/Lpg Mixture - Gasoline/Lpg Models64
Check and Adjust the Ignition Timing - Gasoline/Lpg Models65
Check the Engine Valve Clearances - Deutz Diesel Models65
Test or Replace the Hydraulic Oil66
Change or Recondition the Engine Coolant - Gasoline/Lpg Models67
Change the Fuel Lines69
Check the Engine Valve Clearance - Gasoline/Lpg Models70
Check the Engine Cylinder Compression - Gasoline/Lpg Models70
Clean the PCV Hoses and Fittings - Gasoline/Lpg Models71
Check the Fuel Injection Pumps and Injectors - Deutz Diesel Models72
Check the Toothed Belt - Deutz Diesel Models72
Replace the Timing Belt - Gasoline/Lpg Models72
Troubleshooting Flow Charts73
Engine will Not Crank over75
Engine Cranks over but will Not Start - Gasoline/Lpg Models80
Engine Cranks over but will Not Start - Deutz Diesel Models84
Engine will Not Start on LPG, but will Start on Gasoline - Gasoline/Lpg Models87
Engine will Not Start on Gasoline, but will Start on LPG89
Engine High Idle Inoperative - Gasoline/Lpg Models91
Engine Low Idle Inoperative - Gasoline/Lpg Models93
Engine High Idle Inoperative - Deutz Diesel Models94
Engine Low Idle Inoperative - Deutz Diesel Models96
All Functions Inoperative, Engine Starts and Runs97
All Lift and Steer Functions Inoperative, Drive Functions Operational98
Ground Controls Inoperative, Platform Controls Operate Normally99
Platform Controls Inoperative, Ground Controls Operate Normally100
Boom up Function Inoperative101
Boom down Function Inoperative103
Boom Extend Function Inoperative105
Boom Retract Function Inoperative107
Turntable Rotate Function Inoperative108
Turntable Rotate Left Function Inoperative110
Turntable Rotate Right Function Inoperative111
All Platform Leveling Functions Inoperative112
Platform Level up Function Inoperative113
Platform Level down Function Inoperative114
Platform Rotate Left Function Inoperative115
Platform Rotate Right Function Inoperative116
Oscillate Function Inoperative117
Steer Left Function Inoperative118
Steer Right Function Inoperative119
All Drive Functions Inoperative, All Other Functions Operate Normally120
Drive Forward or Reverse Function Inoperative123
Traction Function Inoperative124
Machine will Not Drive at Full Speed125
Machine Drives at Full Speed with Platform Raised or Extended126
Drive Enable System Is Malfunctioning127
Auxiliary Functions Inoperative128
Schematics129
Electrical Symbols Legend130
Electrical Schematic - Gasoline/Lpg Models131
Ground Control Box Legend - Gasoline/Lpg Models134
Relay Panel Legend - Gasoline/Lpg Models135
Platform Control Box Legend - Gasoline/Lpg Models136
Electrical Schematic - Diesel Models137
Ground Control Box Legend - Diesel Models140
Platform Control Box Legend - Diesel Models141
Hydraulic Symbols Legend143
2WD Hydraulic Schematic - Non-Oscillating Axle144
2WD Hydraulic Schematic - Oscillating Axle145
4WD Hydraulic Schematic147
Platform Controls151
Joystick Controllers151
Horsepower Limiter Board154
Foot Switch156
Resistors156
Toggle Switches157
Platform Components158
Platform158
Platform Leveling Slave Cylinder158
Platform Rotator159
Boom Components161
Plastic Cable Track161
Boom161
Boom Lift Cylinder163
Extension Cylinder164
Platform Leveling Master Cylinder165
Turntable Covers166
Deutz Engine F3L 1011167
RPM Adjustment167
Flex Plate167
Oil Temperature and Oil Pressure Gauges167
Ford LSG-423 Engine168
Governor Actuator168
Choke Adjustments169
Timing Adjustment170
Carburetor Adjustment170
RPM Adjustment170
Flex Plate170
Water Temperature and Oil Pressure Gauges171
Vacuum Switch171
Ground Controls172
Control Relays172
Wago Components174
Resistor175
Power Relay175
Hydraulic Pumps176
Lift/Steer Pump176
Drive Hydraulic Pump177
Function Manifold179
Function Manifold Components179
Valve Adjustments - Function Manifold181
Fuel and Hydraulic Tanks184
Hydraulic Tank184
Fuel Tank185
Turntable Rotation Components186
Rotation Hydraulic Motor186
Turntable Rotation Manifold Components187
2WD Steering Axle Components188
Yoke and Hub188
Steering Cylinders189
Tie Rod190
4WD Steering Axle Components191
Yoke and Hub191
Steering Cylinders192
Tie Rod192
Steer and Oscillate Manifolds194
Oscillate Manifold Components194
Valve Adjustments195
Directional Valve Manifold Components196
Steer Manifold Components198
Non-Steering Axle Components199
Drive Motor199
Torque Hub199
2WD Drive Manifold201
2WD Drive Manifold Components201
Valve Adjustments203
4WD Drive Manifold205
4WD Drive Manifold Components205
Valve Adjustments207

Questions and Answers:

J
Jose WaltersAug 1, 2025
What to do if the battery voltage is less than 12V on Genie Industries S-40?
- D
  Donald WellsAug 1, 2025
  If the battery voltage of your Genie Industries Boom Lift is less than 12V, you should check the battery condition, alternator, and battery cables. If necessary, replace the battery.

Genie Industries S-40 Specifications

General

Horizontal Reach	31 ft 3 in (9.53 m)
Lift Capacity	500 lbs
Weight	12, 700 lb (5, 761 kg)
Power Source	Diesel
Drive Speed	3.0 mph (4.8 km/h)
Machine Width	7 ft 6 in
Fuel Type	Diesel
Platform Height	40 ft
Maximum Working Height	46 ft (14 m)

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