Manual Del Man Lifh PDF

Technical
Publications
® S-40
Service
Manual
First Edition, First Printing

Part No. 32222
Introduction Service Manual - First Edition
Important
Read, understand and obey the safety rules and Genie North America
operating instructions in the Genie S-40 Operator's
Manual before attempting any maintenance or Telephone (206) 881-1800
repair procedure. Toll Free 800 536-1800
Fax (206) 883-3475
This service manual covers the Genie S-40
2WD and 4WD models introduced in 1994.
This manual provides detailed scheduled

Genie Europe
maintenance information for the machine owner Telephone (44) 0636-813943
and user. It also provides troubleshooting and Fax (44) 0636-815270
repair procedures for qualified service
professionals.
Basic mechanical, hydraulic and electrical skills
are required to perform most procedures.
However, several procedures require specialized
skills, tools, lifting equipment and a suitable
workshop. In these instances, we strongly
recommend that maintenance and repair be
performed at a Genie dealer service center.
Genie Industries has endeavored to deliver the

highest degree of accuracy possible. However,
continuous improvement of our products is a Genie
policy. Therefore product specifications are subject
to change without notice. ®
Copyright © 1994 by Genie Industries

Readers are encouraged to notify Genie of errors
and send in suggestions for improvement. All First Edition: First Printing, February 1994
communications will be carefully considered for Genie® is a registered trademark of
future printings of this and other manuals. Please Genie Industries. Registered 2009987
write to the technical publications team in care of These machines comply with
Genie Industries, PO Box 69, Redmond WA ANSI/SIA 92.5-1992.
98073-0069 U.S.A. Printed on recycled paper
If you have any questions, call Genie Industries. Patents Pending
Printed in U.S.A.
ii Genie S-40 Part No. 32222

Service Manual - First Edition Section 1 - Safety Rules
Safety Rules
Danger
Failure to obey the instructions and safety rules in
this manual, and the Genie S-40 Operator's
Manual will result in death or serious injury.
Many of the hazards identified in the operator's

manual are also safety hazards when maintenance
and repair procedures are performed.
Do Not Perform Maintenance

Unless:
You are trained and qualified to perform
maintenance on this machine.
You read, understand and obey:
- manufacturer’s instructions and safety rules
- employer’s safety rules and worksite
regulations
- applicable governmental regulations
You have the appropriate tools, lifting
equipment and a suitable workshop.
Part No. 32222 Genie S-40 iii

Section 1 - Safety Rules Service Manual - First Edition
SAFETY RULES
Personal Safety Workplace Safety

Any person working on or around a machine must Be sure to keep sparks, flames and
be aware of all known safety hazards. Personal lighted tobacco away from flammable and
safety and the continued safe operation of the combustible materials like battery gases
machine should be your top priority. and engine fuels. Always have an approved fire
extinguisher within easy reach.
Read each procedure thoroughly. This

manual and the decals, on the machine, Be sure that all tools and working areas
use signal words to identify the following: are properly maintained and ready for
use. Keep work surfaces clean and free of
Indicates the presence of
debris that could get into machine components and
a hazard that will cause
cause damage.
death or serious injury.
a hazard that may cause Be sure that your workshop or work area
death or serious injury. is properly ventilated and well lit.
a hazard that will or may
cause serious injury or Be sure any forklift, overhead crane or
damage to the machine. other lifting or supporting device is fully
capable of supporting and stabilizing the
Indicates special weight to be lifted. Use only chains or straps that
operation or maintenance are in good condition and of ample capacity.
information.
Be sure that fasteners intended for one

Be sure to wear protective eye wear and time use (i.e., cotter pins and self-locking
other protective clothing if the situation nuts) are not reused. These components
warrants it. may fail if they are used a second time.
Be aware of potential crushing hazards Be sure to properly dispose of old oil or

such as moving parts, free swinging or other fluids. Use an approved container.
unsecured components, and lifting or Please be environmentally safe.
placing loads. Always wear approved steel-toed
shoes.
iv Genie S-40 Part No. 32222

Service Manual - First Edition
Table of Contents
Introduction
Important Information ...................................................................................................... ii
Section One Safety Rules

General Safety Rules .................................................................................................... iii
Section Two Specifications

Machine Specifications ............................................................................................. 2 - 1
Performance Specifications ...................................................................................... 2 - 2
Hydraulic Specifications ............................................................................................ 2 - 3
Bolt Torque Specifications ........................................................................................ 2 - 4
Ford LSG 423 Engine Specifications ........................................................................ 2 - 5
Deutz F3L Engine Specifications .............................................................................. 2 - 7
Section Three Scheduled Maintenance Inspections

Introduction ............................................................................................................... 3 - 1
Table A ..................................................................................................................... 3 - 2
Table B ..................................................................................................................... 3 - 3
Table C ..................................................................................................................... 3 - 5
Table D ..................................................................................................................... 3 - 6
Maintenance Inspection Report ................................................................................ 3 - 7
Section Four Scheduled Maintenance Procedures

Introduction ............................................................................................................... 4 - 1
A-1 Inspect the Manuals ........................................................................................ 4 - 2
A-2 Inspect the Decals and Placards ..................................................................... 4 - 2
A-3 Inspect for Damage, Loose or Missing Parts .................................................. 4 - 2
A-4 Check the Engine Oil Level ............................................................................. 4 - 3
A-5 Check the Engine Coolant Level - Gasoline/LPG Models ............................... 4 - 3
A-6 Check for Fuel Leaks ...................................................................................... 4 - 3
A-7 Check the Hydraulic Oil Level ......................................................................... 4 - 4
A-8 Check for Hydraulic Leaks .............................................................................. 4 - 4
Part No. 32222 Genie S-40 v

TABLE OF CONTENTS
Section Four Scheduled Maintenance Procedures, continued

A-9 Check the Tire Pressure ................................................................................. 4 - 5
A-10 Test the Platform and Ground Controls ........................................................... 4 - 5
A-11 Test the Auxiliary Power Operation ................................................................. 4 - 6
A-12 Test the Tilt Sensor ......................................................................................... 4 - 7
A-13 Test the Limit Switches ................................................................................... 4 - 7
A-14 Test the Oscillate Axle .................................................................................... 4 - 9
A-15 Replace the Engine Oil and Filter - Gasoline/LPG Models ............................ 4 - 10
A-16 Replace the Engine Air Filter ........................................................................ 4 - 11
B-1 Check the Engine Belt(s) .............................................................................. 4 - 12
B-2 Check the Radiator - Gasoline/LPG Models .................................................. 4 - 12
B-3 Check the Oil Cooler and Cooling Fins - Deutz Diesel Models ...................... 4 - 12
B-4 Check the Exhaust System ........................................................................... 4 - 13
B-5 Check the Battery ......................................................................................... 4 - 14
B-6 Check the Hydraulic Tank Filter Condition Indicator ...................................... 4 - 14
B-7 Inspect the Electrical Wiring .......................................................................... 4 - 15
B-8 Inspect the Tires and Wheels ........................................................................ 4 - 15
B-9 Confirm the Proper Brake Configuration ....................................................... 4 - 16
B-10 Check the Oil Level in the Torque Hubs ........................................................ 4 - 16
B-11 Check and Adjust the Engine Idle Mixture - Gasoline/LPG Models ............... 4 - 17
B-12 Check and Adjust the Engine RPM ............................................................... 4 - 17
B-13 Test the Key Switch ...................................................................................... 4 - 19
B-14 Test the Emergency Stop Buttons ................................................................ 4 - 20
B-15 Test the Ground Control Override ................................................................. 4 - 20
B-16 Check the Directional Valve Linkage ............................................................. 4 - 21
B-17 Test the Platform Self-leveling ...................................................................... 4 - 21
B-18 Test the Service Horn ................................................................................... 4 - 21
B-19 Test the Foot Switch ..................................................................................... 4 - 22
B-20 Test the Engine Idle Select ........................................................................... 4 - 22
B-21 Test the Fuel Select Operation - Gasoline/LPG Models ................................ 4 - 23
vi Genie S-40 Part No. 32222

TABLE OF CONTENTS
Section Four Scheduled Maintenance Procedures, continued

B-22 Test the Drive Enable System ....................................................................... 4 - 23
B-23 Test the Drive Brakes ................................................................................... 4 - 24
B-24 Test the Drive Speed - Stowed Position ........................................................ 4 - 24
B-25 Test the Alarm Package - Optional Equipment ............................................. 4 - 25
B-26 Perform Hydraulic Oil Analysis ...................................................................... 4 - 25
B-27 Replace the Engine Oil and Filter - Deutz Diesel Models .............................. 4 - 26
C-1 Check the Boom Wear Pads ......................................................................... 4 - 27
C-2 Check the Turntable Rotation Bearing Bolts ................................................. 4 - 27
C-3 Check the Free-wheel Configuration ............................................................. 4 - 28
C-4 Grease the Turntable Rotation Bearing and Rotate Gear .............................. 4 - 29
C-5 Replace the Torque Hub Oil .......................................................................... 4 - 29
C-6 Replace the Hydraulic Tank Filter ................................................................. 4 - 31
C-7 Replace the Drive Loop Hydraulic Filter ........................................................ 4 - 31
C-8 Replace the Diesel Fuel Filter - Deutz Diesel Models ................................... 4 - 32
C-9 Replace the Gasoline Fuel Filter - Gasoline/LPG Models ............................. 4 - 32
C-10 Replace the PCV Valve - Gasoline/LPG Models ........................................... 4 - 34
C-11 Clean or Replace the Distributor Cap and Rotor - Gasoline/LPG Models ..... 4 - 34
C-12 Replace the Spark Plugs - Gasoline/LPG Models ......................................... 4 - 35
C-13 Check and Adjust the Air/LPG Mixture - Gasoline/LPG Models .................... 4 - 36
C-14 Check and Adjust the Ignition Timing - Gasoline/LPG Models ...................... 4 - 37
C-15 Check the Engine Valve Clearances - Deutz Diesel Models ......................... 4 - 37
D-1 Test or Replace the Hydraulic Oil .................................................................. 4 - 38
D-2 Change or Recondition the Engine Coolant - Gasoline/LPG Models ............. 4 - 39
D-3 Change the Fuel Lines .................................................................................. 4 - 41
D-4 Check the Engine Valve Clearance - Gasoline/LPG Models ......................... 4 - 42
D-5 Check the Engine Cylinder Compression - Gasoline/LPG Models ................ 4 - 42
D-6 Clean the PCV Hoses and Fittings - Gasoline/LPG Models .......................... 4 - 43
D-7 Check the Fuel Injection Pumps and Injectors - Deutz Diesel Models ........... 4 - 44
D-8 Check the Toothed Belt - Deutz Diesel Models ............................................. 4 - 44
D-9 Replace the Timing Belt - Gasoline/LPG Models .......................................... 4 - 44
Part No. 32222 Genie S-40 vii

TABLE OF CONTENTS
Section Five Troubleshooting Flow Charts

Introduction ............................................................................................................... 5 - 1
1 Engine Will Not Crank Over ............................................................................ 5 - 3
2 Engine Cranks Over But Will Not Start - Gasoline/LPG Models ...................... 5 - 5
3 Engine Cranks Over But Will Not Start - Deutz Diesel Models ...................... 5 - 12
4 Engine Will Not Start On LPG, But Will Start On Gasoline
- Gasoline/LPG Models ................................................................................. 5 - 15
5 Engine Will Not Start On Gasoline, But Will Start On LPG
- Gasoline/LPG Models ................................................................................. 5 - 17
6 Engine High Idle Inoperative - Gasoline/LPG Models ................................... 5 - 19
7 Engine Low Idle Inoperative - Gasoline/LPG Models .................................... 5 - 21
8 Engine High Idle Inoperative - Deutz Diesel Models ..................................... 5 - 22
9 Engine Low Idle Inoperative - Deutz Diesel Models ...................................... 5 - 24
10 All Functions Inoperative, Engine Starts and Runs ....................................... 5 - 25
11 All Lift and Steer Functions Inoperative, Drive Functions Operational ........... 5 - 26
12 Ground Controls Inoperative, Platform Controls Operate Normally ............... 5 - 27
13 Platform Controls Inoperative, Ground Controls Operate Normally ............... 5 - 28
14 Boom Up Function Inoperative ...................................................................... 5 - 29
15 Boom Down Function Inoperative ................................................................. 5 - 31
16 Boom Extend Function Inoperative ............................................................... 5 - 33
17 Boom Retract Function Inoperative ............................................................... 5 - 35
18 Turntable Rotate Function Inoperative .......................................................... 5 - 36
19 Turntable Rotate Left Function Inoperative ................................................... 5 - 38
20 Turntable Rotate Right Function Inoperative ................................................. 5 - 39
21 All Platform Leveling Functions Inoperative .................................................. 5 - 40
22 Platform Level Up Function Inoperative ........................................................ 5 - 41
23 Platform Level Down Function Inoperative .................................................... 5 - 42
viii Genie S-40 Part No. 32222

TABLE OF CONTENTS
Section Five Troubleshooting Flow Charts, continued

24 Platform Rotate Left Function Inoperative ..................................................... 5 - 43
25 Platform Rotate Right Function Inoperative ................................................... 5 - 44
26 Oscillate Function Inoperative ....................................................................... 5 - 45
27 Steer Left Function Inoperative ..................................................................... 5 - 46
28 Steer Right Function Inoperative ................................................................... 5 - 47
29 All Drive Functions Inoperative, All Other Functions Operate Normally ......... 5 - 48
30 Drive Forward Or Reverse Function Inoperative ........................................... 5 - 51
31 Traction Function Inoperative ........................................................................ 5 - 52
32 Machine Will Not Drive At Full Speed ........................................................... 5 - 53
33 Machine Drives At Full Speed With Platform Raised or Extended ................ 5 - 54
34 Drive Enable System Is Malfunctioning ......................................................... 5 - 55
35 Auxiliary Functions Inoperative ..................................................................... 5 - 56
Section Six Schematics

Introduction ................................................................................................................. 6-1
Electrical Symbols Legend ......................................................................................... 6-2
Electrical Schematic - Gasoline/LPG Models .............................................................. 6-3
Ground Control Box Legend - Gasoline/LPG Models ................................................. 6-5
Relay Panel Legend - Gasoline/LPG Models .............................................................. 6-6
Platform Control Box Legend - Gasoline/LPG Models ................................................ 6-7
Electrical Schematic - Diesel Models .......................................................................... 6-8
Ground Control Box Legend - Diesel Models ............................................................ 6-10
Platform Control Box Legend - Diesel Models .......................................................... 6-11
Hydraulic Symbols Legend ....................................................................................... 6-12
2WD Hydraulic Schematic - Non-Oscillating Axle ..................................................... 6-13
2WD Hydraulic Schematic - Oscillating Axle ............................................................ 6-14
4WD Hydraulic Schematic ........................................................................................ 6-15
Part No. 32222 Genie S-40 ix

TABLE OF CONTENTS
Section Seven Repair Procedures

Introduction ............................................................................................................... 7 - 1
Platform Controls
1-1 Joystick Controllers ......................................................................................... 7 - 2
1-2 Horsepower Limiter Board .............................................................................. 7 - 5
1-3 Foot Switch ..................................................................................................... 7 - 7
1-4 Resistors ......................................................................................................... 7 - 7
1-5 Toggle Switches .............................................................................................. 7 - 8
Platform Components
2-1 Platform .......................................................................................................... 7 - 9
2-2 Platform Leveling Slave Cylinder .................................................................... 7 - 9
2-3 Platform Rotator ............................................................................................ 7 - 10
Boom Components
3-1 Plastic Cable Track ....................................................................................... 7 - 12
3-2 Boom ............................................................................................................ 7 - 12
3-3 Boom Lift Cylinder ......................................................................................... 7 - 14
3-4 Extension Cylinder ........................................................................................ 7 - 15
3-5 Platform Leveling Master Cylinder ................................................................ 7 - 16
Turntable Covers
4-1 Turntable Covers .......................................................................................... 7 - 17
Deutz Engine F3L 1011
5-1 RPM Adjustment ........................................................................................... 7 - 18
5-2 Flex Plate ...................................................................................................... 7 - 18
5-3 Oil Temperature and Oil Pressure Gauges ................................................... 7 - 18
Ford LSG-423 Engine
6-1 Governor Actuator ........................................................................................ 7 - 19
6-2 Choke Adjustments ....................................................................................... 7 - 20
6-3 Timing Adjustment ........................................................................................ 7 - 21
6-4 Carburetor Adjustment .................................................................................. 7 - 21
6-5 RPM Adjustment ........................................................................................... 7 - 21
6-6 Flex Plate ...................................................................................................... 7 - 21
x Genie S-40 Part No. 32222

TABLE OF CONTENTS
Section Seven Repair Procedures, Ford LSG-423 Engine, continued

6-7 Water Temperature and Oil Pressure Gauges .............................................. 7 - 22
6-8 Vacuum Switch ............................................................................................. 7 - 22
Ground Controls
7-1 Control Relays .............................................................................................. 7 - 23
7-2 Toggle Switches, See 1-5, Toggle Switches ................................................... 7 - 8
7-3 Wago® Components ...................................................................................... 7 - 25
7-4 Resistor......................................................................................................... 7 - 26
7-5 Power Relay ................................................................................................. 7 - 26
Hydraulic Pumps
8-1 Lift/Steer Pump ............................................................................................. 7 - 27
8-2 Drive Hydraulic Pump ................................................................................... 7 - 28
Function Manifold
9-1 Function Manifold Components ..................................................................... 7 - 30
9-2 Valve Adjustments - Function Manifold ......................................................... 7 - 32
Fuel and Hydraulic Tanks
10-1 Hydraulic Tank .............................................................................................. 7 - 35
10-2 Fuel Tank ...................................................................................................... 7 - 36
Turntable Rotation Components
11-1 Rotation Hydraulic Motor ............................................................................... 7 - 37
11-2 Turntable Rotation Manifold Components ..................................................... 7 - 38
2WD Steering Axle Components
12-1 Yoke and Hub ............................................................................................... 7 - 39
12-2 Steering Cylinders ......................................................................................... 7 - 40
12-3 Tie Rod ......................................................................................................... 7 - 41
13-1 Yoke and Hub ............................................................................................... 7 - 42
13-2 Steering Cylinders ......................................................................................... 7 - 43
13-3 Tie Rod ......................................................................................................... 7 - 43
Part No. 32222 Genie S-40 xi

TABLE OF CONTENTS
Section Seven Repair Procedures, continued

Oscillating Axle Components
14-1 Oscillating Axle Cylinders .............................................................................. 7 - 44
Steer and Oscillate Manifolds
15-1 Oscillate Manifold Components ..................................................................... 7 - 45
15-2 Valve Adjustments ........................................................................................ 7 - 46
15-3 Directional Valve Manifold Components ........................................................ 7 - 47
15-4 Steer Manifold Components .......................................................................... 7 - 49
Non-steering Axle Components
16-1 Drive Motor ................................................................................................... 7 - 50
16-2 Torque Hub ................................................................................................... 7 - 50
2WD Drive Manifold
17-1 2WD Drive Manifold Components ................................................................. 7 - 52
4WD Drive Manifold
18-1 4WD Drive Manifold Components ................................................................. 7 - 56
xii Genie S-40 Part No. 32222

Service Manual - First Edition Section 2 - Specifications
Specifications
Machine Specifications
Stowed dimensions 2WD/RT 4WD/RT Tires and wheels 2WD Rear
2WD Front 4WD Front
Length 23 ft 11 in 23 ft 11 in Tires Only & Rear
7.28 m 7.28 m
Tire size 12.5L-16SL 12-16.5 NHS
Width 7 ft 6 in 7 ft 6 in
2.29 m 2.29 m Tire ply rating 12 8
Height 8 ft 2 in 8 ft 2 in Tire contact area 88 sq in 57 sq in

2.48 m 2.48 m 568 sq cm 368 sq cm
Weight 11,650 lbs 11,650 lbs Overall tire diameter 33.7 in 33.2 in
5,284 kg 5,284 kg 85.6 cm 84.3 cm
Ground clearance 12 1/2 in 12 1/2 in Tire pressure 45 psi 45 psi

31.8 cm 31.8 cm 3.10 bar 3.10 bar
Operational dimensions Wheel diameter 16 in 16 1/2 in

40.6 cm 41.9 cm
Maximum platform height 40 ft 40 ft
12.2 m 12.2 m Wheel width 10 in 9.75 in
25.4 cm 24.7 cm
Maximum horizontal reach 31 ft 8 in 31 ft 8 in
9.64 m 9.64 m Wheel lugs 8 @ 5/8 -18 9 @ 5/8 -18
Maximum turntable tailswing 34 in 34 in Lug nut torque 125 ft-lbs 125 ft-lbs
86.4 cm 86.4 cm 169.5 Nm 169.5 Nm
Wheelbase 7 ft 3 in 7 ft 3 in Fluid capacities

2.2 m 2.2 m
Fuel tank 30 gallons 114 liters
Minimum turning circle, 15 ft 8 in 15 ft 8 in
outside 4.77 m 4.77 m LPG tank 33.5 pounds 15.2 kg
Minimum turning circle, 6 ft 8 in 6 ft 8 in Hydraulic tank 45 gallons 170 liters

inside 2.02 m 2.02 m
Hydraulic system 50 gallons 189 liters
Turntable rotation continuous continuous (including tank)
Platform rotation 160° 160° Drive torque hub 17 fl oz 0.51 liters
Platform dimensions 6 ft 8 ft Turntable rotation 8 fl oz 0.24 liters

(Standard) (Optional) torque hub
Length 6 ft 8 ft Continuous improvement of our products is a Genie

1.83 m 2.44 m policy. Product specifications are subject to change
without notice.
Width 30 in 36 in
76.2 cm 91.4 cm
Maximum capacity 500 lbs 500 lbs

227 kg 227 kg
Part No. 32222 Genie S-40 2-1

Section 2 - Specifications Service Manual - First Edition
PERFORMANCE SPECIFICATIONS
Performance Specifications
Drive speeds, maximum 2WD 4WD Boom function speeds, maximum
from platform controls
Boom stowed 4.0 mph 3.5 mph
Gasoline/LPG models 6.4 km/h 5.6 km/h Boom up 40 to 60 seconds
40 ft/6.8 sec 40 ft/7.8 sec
12.2 m/6.8 sec12.2 m/7.8 sec Boom down 50 to 80 seconds
Boom stowed 3.5 mph 3 mph Boom extend 35 to 65 seconds

Deutz diesel models 5.6 km/h 4.8 km/h
Boom retract 40 to 70 seconds
40 ft/7.8 sec 40 ft/9.1 sec
12.2 m/7.8 sec12.2 m/9.1 sec Turntable rotate - 360° 70 to 110 seconds
Boom raised or extended 0.68 mph 0.68 mph Platform rotate - 160° 8 to 20 seconds
All models 1.1 km/h 1.1 km/h
40 ft/40 sec 40 ft/40 sec Platform level up 25 to 50 seconds
12.2 m/40 sec 12.2 m/40 sec
Platform level down 15 to 35 seconds
Gradeability (boom stowed) 2WD 4WD
Rough terrain 30% 40%
2-2 Genie S-40 Part No. 32222

HYDRAULIC SPECIFICATIONS
Hydraulic Specifications
Hydraulic fluid Dexron II equivalent Function pump
Drive pump Type: pressure balanced gear
Type: bi-directional variable displacement piston pump Displacement - static 0.98 cu in

16 cc
Displacement - 2500 rpm 0 to 31.6 gallons per minute
0 to 119.6 liters per minute Displacement - 2550 rpm 10.8 gallons per minute
0 to 40.8 liters per minute
Maximum drive pressure 3500 psi
241.3 bar Hydraulic tank circuit 10 micron with 25 psi
return line filter (1.7 bar) bypass
Charge pressure
neutral position 360 psi 25 bar Function manifold
drive position 250 psi 17 bar
Function relief 2600 psi
Medium pressure filter 3 micron valve pressure 179 bar
Medium pressure filter 50 psi Boom down 2200 psi

bypass pressure 3.4 bar relief valve pressure 152 bar
Drive manifold Boom extend 1950 psi

134 bar
Brake 250 psi
relief pressure 17.2 bar Steer/oscillate 3.5 gallons per minute
flow regulator 13.2 liters per minute
4WD front motor 2.5 to 8 gallons per minute
flow regulators 9.4 to 30.2 liters per minute Steer regulator 2 gallons per minute
7.6 liters per minute
4WD rear motor 5 to 15 gallons per minute
flow regulators 18.9 to 56.7 liters per minute Boom retract pressure 2600 psi
179 bar
2WD rear motor 8 to 22 gallons per minute
flow regulators 30.2 to 83.2 liters per minute Oscillate cylinder pressure 900 psi
62 bar
Front drive motors 4WD models
Auxiliary pump
Displacement 1.52 cu in
per revolution 25 cc Type: fixed displacement gear pump
Rear drive motors Displacement - static 0.152 cu in

2.5 cc
Displacement
per revolution 2.13 cu in 35 cc Displacement 1.4 gallons per minute
5.3 liters per minute
Auxiliary pump 2500 psi

relief pressure 176 bar

BOLT TORQUE SPECIFICATIONS
Bolt Torque Specifications

Size Threads SAE Grade 5 Bolts SAE Grade 8 Bolts
Torque - Dry Torque - Dry Torque - Dry Torque - Dry Torque - Dry Torque - Dry
inch-pounds foot-pounds Newton meters inch-pounds foot-pounds Newton meters
No. 10 24 43 5 60 7
32 49 6 68 8
1
/4 inch 20 96 11 144 16
28 120 14 168 19
5
/16 inch 18 17 23 25 34
24 19 28 25 34
3
/8 inch 16 30 41 45 61
24 35 48 50 68
7
/16 inch 14 50 68 70 95
20 55 75 80 109
1
/2 inch 13 75 102 110 149
20 90 122 120 163
9
/16 inch 12 110 149 150 204
18 120 163 170 231
5
/8 inch 11 150 204 220 298
18 170 231 240 326
3
/4 inch 10 260 353 380 515
16 300 407 420 570
7
/8 inch 9 430 583 600 814
14 470 637 660 895
1 inch 8 640 868 900 1221
12 700 949 1000 1356
Torque specification for lubricated bolts is 25% less than dry torque specification for bolt size.

FORD ENGINE LSG-423 SPECIFICATIONS
Ford Engine LSG-423

Displacement 140 cu in Starter motor
2.3 liters
Normal engine cranking speed 110 rpm
Number of cylinders 4
Current draw, normal load 150A
Bore & stroke 3.780 x 3.126 inches
96 x 79.4 mm Current draw, maximum load 460A
Horsepower 63 @ 4000 rpm Current draw, no load 70A
Firing order 1-3-4-2 Maximum circuit voltage drop 0.5V DC

while starting (normal temperature)
Low idle 1600 rpm
Brush length, new 0.50 in
High idle 2500 rpm 12.7 mm
Governor electronic Brush length wear limit 0.25 in

6.35 mm
Compression ratio 9.5:1
Brush spring tension 40 ounces
Compression pressure (approx.) 150 to 175 psi 11 Newtons
10 to 12 bar
Pressure ( psi) of lowest cylinder must be Bolt torque 55 to 75 inch-pounds
at least 75% of highest cylinder through brush 6 to 8.5 Nm
Valve clearances 0.040 to 0.050 inches Brush mounting 15 to 20 foot-pounds

1.0 to 1.3 mm bolt torque 20 to 27 Nm
Lubrication system Maximum commutator 0.005 inches

run-out 0.127 mm
Oil pressure 40 to 60 psi
(operating temp. @ 2600 rpm) 2.75 to 4.1 bar Battery
Oil capacity 5 quarts Type 12V, Group 31

(including filter) 4.7 liters
Quantity 1
Oil viscosity requirements
Cold cranking ampere 1000A
Temperature below 60°F / 15.5°C 5W-30
Reserve capacity @ 25A rate 200 minutes
-10°F to 90°F / -23°C to 32°C 10W-30
Fuel pump
Temperature above 10W-40 to 10W-50
-10°F / -23°C Static pressure 5 to 7 psi
0.34 to 0.48 bar
Temperature above 20W-40 or 20W-50
25°F / -4°C Minimum volume flow 1 pint
(in 25 seconds) 473 cc
Use oils meeting API classification SF (labeled SF/CC
or SF/CD) as they offer improved wear protection.

FORD ENGINE LSG-423 SPECIFICATIONS
Ignition System Bolt torque specifications

torque torque
Ignition spark advance 10° BTDC Bolt description (size) ft-lbs Nm
Ignition coil primary 1.13 to 1.25Ω Distributor clamp bolt (M-10) 14 to 21 19 to 28
resistance @ 75°F / 24°C
Distributor vacuum tube 5 to 8 7 to 11
Ignition coil secondary 7700 to 9300Ω to manifold adaptor
resistance @ 75°F / 24°C
Exhaust manifold to cylinder head bolt or nut (M-10):
Spark plug type Motorcraft AWSF-52 torque in sequence
first step 14 to 19 19 to 26
Spark plug gap 0.042 to 0.046 inches
second step 20 to 30 27 to 41
1.07 to 1.18 mm
Flywheel to crankshaft 56 to 64 76 to 87
Engine coolant
bolt (M-10)
Capacity 11.5 quarts
Fuel pump to cylinder 14 to 21 19 to 28
10.9 liters
block (M-8)
Alternator
Intake manifold to 14 to 21 19 to 28
Output 35A, 14.5V cylinder head bolt or nut (M-8)
Fan belt deflection 3 /8

to 1/2 inch Oil pressure sending unit to block 8 to 18 11 to 24
9 to 12 mm
Oil pan drain plug to pan (M-14) 15 to 25 20 to 34
Bolt torque specifications
Oil pan to block (M-6) 10 to 13.5 14 to 18
torque torque
Bolt description (size) ft-lbs Nm Oil filter insert to block 20 to 35 27 to 47
Auxiliary shaft gear bolt (M-10) 28 to 40 38 to 54 Rocker arm cover to 5 to 8 7 to 11
cylinder head (M-6)
Auxiliary shaft thrust 6 to 9 8 to 12
plate bolt (M-6) Spark plug to cylinder 5 to 10 7 to 14
head (M-14)
Timing belt tensioner 28 to 40 38 to 54
pivot bolt (M-10) Temperature sending 8 to 18 11 to 24
unit to block (M-14)
Timing belt tensioner 14 to 21 19 to 28
adjusting bolt (M-8) Water jacket drain plug to block 23 to 28 31 to 38
Camshaft gear bolt (M-12) 50 to 71 68 to 96 Water pump to block bolt (M-8) 14 to 21 19 to 28
Camshaft thrust plate bolt (M-6) 6 to 9 8 to 12 Auxiliary shaft cover bolt (M-6) 6 to 9 8 to 12
Carburetor to spacer stud (M-8) 7.5 to 15 10 to 20 Water outlet connection 14 to 21 19 to 28
bolt (M-8)
Carburetor spacer to 10 to 14 14 to 19
manifold bolt (M-8) Cylinder front cover bolt (M-6) 6 to 9 8 to 12
Crankshaft damper 103 to 133 140 to 180 Inner timing belt cover 14 to 21 19 to 28
bolt (M-14) stud (M-8)
Cylinder head bolt (M-12): torque in sequence Outer timing belt cover 6 to 9 8 to 12
first step 50 to 60 68 to 81 bolt (M-6)
second step 80 to 90 108 to 122

DEUTZ ENGINE F3L 1011 SPECIFICATIONS
Deutz Engine F3L 1011 Injection pump pressure 4351 psi

300 bar
Displacement 125.02 cu in
2.049 liters Injector opening pressure 3626 psi
250 bar
Number of cylinders 3
Fuel requirement diesel number 2-D
Bore and stroke 3.58 x 4.13 inches
91 x 105 mm Alternator output 55A, 14V
Horsepower 36 @ 2300 rpm Starter motor
Firing order 1-2-3 Current draw, no load 90A
Compression ratio 18.5:1 Brush length, new 0.7480 in

19 mm
Compression pressure 362 to 435 psi
25 to 30 bar Brush length, minimum 0.5 in
Pressure (psi) of lowest cylinder must be at least 85% of 12.7 mm
highest cylinder Battery
Low idle 1300 rpm Type 12V, Group 31
High idle 2300 rpm Quantity 1
Governor centrifugal mechanical Cold cranking ampere 1000A
Valve clearance, cold Reserve capacity @ 25A rate 200 minutes
Intake 0.012 in Fan belt deflection 3 /8
to 1/2 inch
0.3 mm 9 to 12 mm
Exhaust 0.020 in Bolt tightening specifications
0.5 mm torque torque
Lubrication system Bolt description (size, grade) ft-lbs Nm
Oil pressure 26 to 87 psi Camshaft/thrust bearing bolt 15 to 18 20 to 24

1.8 to 6.0 bar (M-8 x 35, 8.8)
Oil capacity 8.5 quarts Rocker arm bolts 15 to 18 20 to 24

(including filter) 8 liters (M-8 x 45, 8.8)
Oil viscosity requirements Rocker arm set screw nut 15 to 18 20 to 24
Temperature below 60°F / 15.5°C (synthetic) 5W-30 Cylinder head cover 6 to 7 8 to 10
-10°F to 90°F / -23°C to 32°C 10W-40 Blower rotor nut 33 to 41 45 to 55

(M-17 Valeo or M-18 Bosch)
Temperature above -4°F / -34°C 15W-40
Blower carrier bolts 15 to 18 20 to 24
Engine oil should have properties of API classification (M-8 x 50 Torx, 8.8)
CC/SE, CD/SE, CC/SF or CD/SF grades.
V-belt pulley bolts 28 to 34 38 to 46
Injection system (M-10 x 16, 8.8)
Injection pump make OMAP

DEUTZ ENGINE F3L 1011 SPECIFICATIONS
torque torque
Bolt tightening specifications, continued
ft-lbs Nm
torque torque
Bolt description (size, grade) ft-lbs Nm Oil thermostat housing screw 37 to 44 50 to 60
plug (M-38 x 1.5)
Idler pulley/V-belt pulley bolt 27 to 32 36 to 44
(M-10 x 25, 8.8) Oil thermostat housing bolts 5.5 to 7 7.5 to 9
(M-6 x 35 Torx, 8.8)
Idler pulley for toothed belt 30 to 36 41 to 49
(M-10 x 50, 8.8) Oil thermostat housing bolts 5.5 to 7 7.5 to 9
(M-6 x 80 Torx, 8.8)
Oil pump bolts 15 to 18 20 to 24
(M-8 x 35 Torx) Oil thermostat housing bolts 14 to 16 19 to 22
(M-6 x 105 Torx, 8.8)
Oil filter bracket bolts 7 to 8 9 to 11
(M-8 x 20 Torx, 8.8) Valve plunger housing bolts 14 to 16 19 to 22
(M-8 x 30 Torx, 8.8)
Oil intake housing bolts 15 to 18 20 to 24
(M-8 x 75 Torx) Alternator nuts (M-5) 3 4
Fuel pump bolts 15 to 18 20 to 24 Fuel bracket bolts (M-8 x 20, 8.8) 15 20
Injection pump bolts 15 to 18 20 to 24 Adapter housing bolts 70 to 77 95 to 105
(M-12 x 35, 10.9 or M-12 x 75, 10.9)
Injector cap nut 30 to 37 40 to 50
first step second step
Injector fastening bolt 15 to 18 20 to 24
tightening tightening
Injection line 10 to 12 13.5 to 16.5 torque angles
ft-lbs Nm 1st 2nd
Air intake manifold bolts 15 to 18 20 to 24
(M-8 x 30, 8.8) Main bearing bolts 37 50 60° 45°
Air intake manifold, 3-hole 15 to 18 20 to 24 Big end bolts 22 30 60° 60°
flange bolts (M-8 x 35 Torx, 8.8)
Flywheel bolts 22 30 60° 30°
Exhaust manifold bolts 27 to 32 36 to 44
(M-10 x 30 Torx, 10.9) Cylinder head step 1 22 30
studs step 2 59 80
Starter fastening bolts 28 to 34 38 to 46 step 3 118 160 120° NA
(M-10 x 28, 8.8)
Camshaft/central bolt 22 30 150° NA
Starter carrier bolts 50 to 60 68 to 82
(M-12 x 28, 8.8) Crankshaft/central bolt 96 130 210° NA
Oil pan bolts 15 to 18 20 to 24

(M-8 x 16 Torx, 8.8)
Oil drain bolts 37 to 44 50 to 60

Service Manual - First Edition Section 3 - Scheduled Maintenance Inspections
Scheduled Maintenance Inspections
About This Section

Warm Cold Dealer
Tools are New parts engine engine service
required required required required suggested
The Schedule
There are four types of maintenance inspections

that must be performed according to a schedule—
daily, quarterly, annual, two year. To account for
repeated procedures, the Maintenance Tables and
Observe and Obey: the Maintenance Inspection Report have been
divided into four subsections—A, B, C, D. Use the
Maintenance inspections shall be completed by following chart to determine which group(s) of
a person trained and qualified on the procedures are required to perform a scheduled
maintenance of this machine. inspection.
Scheduled maintenance inspections shall be
completed daily, quarterly, annually and every 2 Inspection Table or Checklist
years as specified on the Maintenance
Daily A
Inspection Report.
Failure to properly complete each Quarterly A+B
inspection when required may
Annual A+B+C
cause death, serious injury or
substantial damage.
Two year A+B+C+D
Immediately tag and remove from service a
damaged or malfunctioning machine.
Maintenance Tables
Repair any machine damage or malfunction
before operating machine. The maintenance tables contained in this section
provide summary information on the specific
Keep records on all inspections for three years. physical requirements for each inspection.
Machines that have been out of service for a Complete step-by-step instructions for each
period longer than 3 months must complete the scheduled maintenance procedure are provided in
quarterly inspection. section 4, Scheduled Maintenance Procedures.
Maintenance Inspection Report

The maintenance inspection report contains
checklists for each type of scheduled inspection.
Make copies of the Maintenance Inspection Report

to use for each inspection. Store completed forms
for three years.

Section 3 - Scheduled Maintenance Inspections Service Manual - First Edition
Maintenance Tables
Table A Tools are New parts

Warm
engine
Cold
engine
Dealer
service
A-1 Inspect the Manuals
A-2 Inspect the Decals and Placards
A-3 Inspect for Damage, Loose or Missing Parts
A-4 Check the Engine Oil Level
A-5 Check the Engine Coolant Level -

Gasoline/LPG Models
A-6 Check for Fuel Leaks
A-7 Check the Hydraulic Oil Level
A-8 Check for Hydraulic Leaks
A-9 Check the Tire Pressure
A-10 Test the Platform and Ground Controls
A-11 Test the Auxiliary Power Operation
A-12 Test the Tilt Sensor
A-13 Test the Limit Switches
A-14 Test the Oscillate Axle

(oscillating axle equipped models)

MAINTENANCE TABLES
Table A, continued Tools are New parts

Warm
engine
Cold
engine
Dealer
service
Every 100 hours, perform the following two engine

maintenance procedures.
A-15 Replace the Engine Oil and Filter -

Gasoline/LPG Models
A-16 Replace the Engine Air Filter
Table B
B-1 Check the Engine Belt(s)
B-2 Check the Radiator -

Gasoline/LPG Models
B-3 Check the Oil Cooler and Cooling Fins -

Deutz Diesel Models
B-4 Check the Exhaust System
B-5 Check the Battery
B-6 Check the Hydraulic Tank

Filter Condition Indicator
B-7 Inspect the Electrical Wiring
B-8 Inspect the Tires and Wheels

(including lug nut torque)
B-9 Confirm the Proper Brake Configuration
B-10 Check the Oil Level in the Torque Hubs
B-11 Check and Adjust the Engine Idle Mixture -

Gasoline/LPG Models
B-12 Check and Adjust the Engine RPM

MAINTENANCE TABLES
Table B, continued Tools are New parts

Warm
engine
Cold
engine
Dealer
service
B-13 Test the Key Switch
B-14 Test the Emergency Stop Buttons
B-15 Test the Ground Control Override
B-16 Check the Directional Valve Linkage
B-17 Test the Platform Self-leveling
B-18 Test the Service Horn
B-19 Test the Foot Switch
B-20 Test the Engine Idle Select
B-21 Test the Fuel Select Operation -

Gasoline/LPG Models
B-22 Test the Drive Enable System
B-23 Test the Drive Brakes
B-24 Test the Drive Speed -

Stowed Position
B-25 Test the Alarm Package -

Optional Equipment
B-26 Perform Hydraulic Oil Anaysis

See D-1 Test or Replace the Hydraulic Oil
Every 500 hours, perform the following engine

maintenance procedure.
B-27 Replace the Engine Oil and Filter -

Deutz Diesel Models

MAINTENANCE TABLES
Table C Tools are New parts

Warm
engine
Cold
engine
Dealer
service
C-1 Check the Boom Wear Pads
C-2 Check the Turntable Rotation Bearing Bolts
C-3 Check the Free-wheel Configuration
C-4 Grease the Turntable Rotation Bearing

and Rotate Gear
C-5 Replace the Torque Hub Oil
C-6 Replace the Hydraulic Tank Filter
C-7 Replace the Drive Loop Hydraulic Filter
C-8 Replace the Diesel Fuel Filter -

Deutz Diesel Models
C-9 Replace the Gasoline Fuel Filter -

Gasoline/LPG Models
C-10 Replace the PCV Valve -

Gasoline/LPG Models
C-11 Clean or Replace the Distributor Cap

and Rotor - Gasoline/LPG Models
C-12 Replace the Spark Plugs -

Gasoline/LPG Models
C-13 Check and Adjust the Air/LPG Mixture -

Gasoline/LPG Models
C-14 Check and Adjust the Ignition Timing -

Gasoline/LPG Models
C-15 Check the Engine Valve Clearances -

Deutz Diesel Models

MAINTENANCE TABLES
Table D Tools are New parts

Warm
engine
Cold
engine
Dealer
service
D-1 Test or Replace the Hydraulic Oil
D-2 Change or Recondition the Engine Coolant -

Gasoline/LPG Models
D-3 Change the Fuel Lines
D-4 Check the Engine Valve Clearance -

Gasoline/LPG Models
D-5 Check the Engine Cylinder Compression -

Gasoline/LPG Models
D-6 Clean the PCV Hoses and Fittings -

Gasoline/LPG Models
D-7 Check the Fuel Injection Pumps and Injectors -

Deutz Diesel Models
D-8 Check the Toothed Belt -

Deutz Diesel Models
D-9 Replace the Timing Belt -

Gasoline/LPG Models

Maintenance Inspection Report

Model Comments Warm Cold Dealer
Tools areY
Checklist A N New
R parts B-18 Service
engine horn engine service
Serial number required required required required suggested
Refer to Table A B-19 Foot switch
Date A-1 Manuals B-20 Engine idle select
A-2 Decals and placards B-21 Fuel select-gasoline
Hour meter
A-3 Damage, loose or B-22 Drive enable system
Machine owner missing parts B-23 Drive brakes
A-4 Engine oil level B-24 Drive speed-stowed
Inspected by (print) A-5 Engine coolant-gasoline B-25 Alarm package
A-6 Fuel leaks B-26 Hydraulic oil analysis
Inspector signature
A-7 Hydraulic oil level Perform every 500 hours:
Inspector title A-8 Hydraulic leaks B-27 Replace engine oil
A-9 Tire pressure and filter-Deutz
Inspector company
A-10 Platform and
Instructions ground controls Checklist C Y N R
· Make copies of this page to use for A-11 Auxiliary power Refer to Table C
each inspection. A-12 Tilt sensor C-1 Boom wear pads
· Select the appropriate checklist(s) for A-13 Limit switches
the type of inspection to be C-2 Turntable bearing bolts
performed. A-14 Oscillate Axle C-3 Free-wheel configuration
Perform every 100 hours: C-4 Grease rotation bearing
Daily Inspection: A
A-15 Replace engine oil
C-5 Torque hub oil
Quarterly Inspection: A+B and filter-gasoline
C-6 Hydraulic tank filter
Annual Inspection: A+B+C A-16 Replace air filter
C-7 Drive loop hydraulic filter
2 Year Inspection: A+B+C+D
C-8 Fuel filter-diesel
Checklist B Y N R
· Place a check in the appropriate box C-9 Fuel filter-gasoline
after each inspection procedure is Refer to Table B
completed. C-10 PCV valve-gasoline
B-1 Engine belt(s)
· Use the maintenance tables in this C-11 Distibutor cap-gasoline
B-2 Engine radiator
section and the step-by-step C-12 Spark plugs-gasoline
procedures in section 4 to learn how B-3 Oil cooler and fins-Deutz
C-13 Air/LPG mixture
to perform these inspections. B-4 Exhaust system
C-14 Ignition timing-gasoline
· If any inspection receives an “N”, tag B-5 Battery C-15 Valves-Deutz
and remove the machine from service,
B-6 Hydraulic tank filter
repair and re-inspect it. After repair,
place a check in the “R” box. B-7 Electrical wiring Checklist D Y N R
Legend B-8 Tires and wheels Refer to Table D
Y = yes, acceptable B-9 Brake configuration D-1 Hydraulic oil
N = no, remove from service B-10 Torque hub oil level D-2 Engine coolant-gasoline
R = repaired B-11 Idle mixture-gasoline D-3 Change fuel lines
B-12 Engine RPM D-4 Valves-gasoline
B-13 Key Switch D-5 Compression-gasoline
B-14 Emergency Stop D-6 PCV hoses-gasoline
B-15 Ground control override D-7 Fuel injection-Deutz
B-16 Valve linkage D-8 Toothed belt-Deutz
B-17 Platform leveling D-9 Timing belt-Ford

Warm Cold Dealer

Tools are New parts engine engine service
This page intentionally left blank.

Service Manual - First Edition Section 4 - Scheduled Maintenance Procedures
Scheduled Maintenance Procedures
About This Section

This section contains detailed procedures for each
scheduled maintenance inspection.
Each procedure includes a description, safety

information and step-by-step instructions.
Observe and Obey: Symbols Legend
Maintenance inspections shall be completed by Indicates the presence of a hazard

a person trained and qualified on the that will cause death or serious
maintenance of this machine. injury.
Scheduled maintenance inspections shall be Indicates the presence of a hazard

that may cause death or serious
completed daily, quarterly, annually and every 2
injury.
years as specified on the Maintenance
Inspection Report. Indicates the presence of a hazard
that will or may cause serious
Failure to perform each procedure
injury or damage to the machine.
as presented and scheduled may
cause death, serious injury or Indicates special operation or
substantial damage. maintenance information.
Immediately tag and remove from service a Indicates that a specific result is expected after
damaged or malfunctioning machine. performing a step.
Repair any machine damage or malfunction
before operating machine.
Keep records on all inspections for three years.
Unless otherwise specified, perform each
repair procedure with the machine in the
following configuration:
· machine parked on a flat, level surface
· boom in stowed position
· turntable rotated with the boom between
the non-steering wheels
· turntable secured with the turntable
rotation lock pin
· key switch in the OFF position with the
key removed
· wheels chocked

Section 4 - Scheduled Maintenance Procedures Service Manual - First Edition
Table A Procedures
A-1 2 Inspect all decals for legibility and damage.

Replace any damaged or illegible decal
Inspect the Manuals immediately.
Maintaining the operator’s and safety manuals in Contact your authorized Genie
good condition is essential to safe machine distributor or Genie Industries if
operation. Manuals are included with each replacement decals are needed.
machine and should be stored in the container
provided in the platform. An illegible or missing
manual will not provide safety and operational A-3
information necessary for a safe operating
condition.
Inspect for Damage, Loose or
Missing Parts
1 Check to be sure that the storage container is
present and in good condition. Daily machine condition inspections are essential
to safe machine operation and good machine
2 Check to make sure that the operator's, performance. Failure to locate and repair damage,
responsibilities and safety manual are present and discover loose or missing parts may result in
and complete in the storage container in the an unsafe operating condition.
platform.
1 Inspect the entire machine for damage and
3 Examine the pages of each manual to be sure
improperly installed or missing parts including:
that they are legible and in good condition.
· electrical components, wiring and electrical
4 Always return the manuals to the storage
cables
container after use.
· hydraulic hoses, fittings, cylinders and
Contact your authorized Genie
manifolds
distributor or Genie Industries if
replacement manuals are needed. · fuel and hydraulic tanks
· drive and turntable rotation motors and
A-2 torque hubs
Inspect the · boom components and wear pads
Decals and Placards · dents or damage to machine
Maintaining all of the safety and instructional · tires and wheels
decals and placards in good condition is
· engine and related components
mandatory for safe machine operation. Decals
alert operators and personnel to the many possible · limit switches, alarms, horn and beacon
hazards associated with using this machine. They
· nuts, bolts and other fasteners
also provide users with operation and maintenance
information. An illegible decal will fail to alert · platform entry mid-rail or gate
personnel of a procedure or hazard and could
result in unsafe operating conditions. · cracks in welds or structural components
· compartment covers and latches
1 Refer to the Decals section in the
Genie S-40 Operator's Manual and use the
decal list and illustrations to determine that all
decals and placards are in place.

TABLE A PROCEDURES
A-4 A-5
Check the Engine Oil Level Check the Engine Coolant Level
Maintaining the proper engine oil level is essential - Gasoline/LPG Models
to good engine performance and service life. Maintaining the engine coolant at the proper level
Operating the machine with an improper oil level is essential to engine service life. Improper coolant
can damage engine components. level will affect the engine's cooling capability and
Check the oil level with the damage engine components. Daily checks will
engine off. allow the inspector to identify changes in coolant
level that might indicate cooling system problems.
1 Check the oil level dipstick. Add oil as needed.
1 Check the fluid level in the coolant recovery
Result: The oil level should be in the "safe" tank. Add fluid as needed.
zone.
Result: The fluid level should be in the
NORMAL range.
Ford Engine LSG-423 5 quarts
Oil capacity (including filter) 4.7 liters
Ford Engine LSG-423 Oil viscosity requirements

A-6
Check for Fuel Leaks
below 60F / 15.5C 5W-30
Failure to detect and correct fuel leaks will result in
-10 to 90F / -23 to 32C 10W-30 an unsafe condition. An explosion or fuel fire may
cause death or serious injury.
above -10F / -23C 10W-40 or 10W-50
Engine fuels are combustible.
above 25F / -4C 20W-40 or 20W-50 Inspect the machine in an open,
well-ventilated area away from
Use oils meeting API classification SF (labeled SF/CC heaters, sparks, flames and
or SF/CD) as they offer improved wear protection. lighted tobacco. Always have an
approved fire extinguisher within
Deutz Engine F3L 1011 8.5 quarts easy reach.
Oil capacity (including filter) 8 liters
1 Open the shutoff valve on the liquid petroleum
Deutz Engine F3L 1011 Oil viscosity requirements gas (LPG) tank by turning it counterclockwise.
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


TABLE A PROCEDURES
2 Perform a visual inspection around the following Hydraulic oil specifications

areas. (An LPG detector may be necessary to
locate LPG leaks.) Hydraulic oil type Dexron II equivalent
Gasoline/LPG models:
Tank capacity 45 gallons
· LPG tank, hoses and fittings, solenoid shutoff 170 liters
valve, LPG regulator and carburetor
Hydraulic system 50 gallons
· gasoline tank, shutoff valve, solenoid shutoff (including tank) 189 liters
valve, hoses and fittings, fuel pump and
carburetor
Deutz Diesel models:
A-8
· fuel tank, shutoff valve, hoses and fittings,
fuel pump, fuel filter, fuel injection pumps and
Check for Hydraulic Leaks
fuel injectors Detecting hydraulic fluid leaks is essential to
If a fuel leak is discovered, keep operational safety and good machine performance.
any additional personnel from Undiscovered leaks can develop into hazardous
entering the area and do not situations, impair machine functions and damage
operate the machine. Repair the machine components.
leak immediately. 1 Inspect for hydraulic oil puddles, dripping or
residue on or around the following areas:
· hydraulic tank—filter, fittings, hoses, auxiliary
A-7 power unit and turntable surface
Check the Hydraulic Oil Level · engine compartment—fittings, hoses, main
Maintaining the hydraulic oil at the proper level is pump, filter and turntable surface
essential to machine operation. Improper hydraulic · all hydraulic cylinders
oil levels can damage hydraulic components. Daily
checks allow the inspector to identify changes in oil · all hydraulic manifolds
level that might indicate the presence of hydraulic · boom
system problems.
· the underside of the turntable
1 Be sure that the boom is in the stowed position,
then visually inspect the sight gauge located on · the underside of the drive chassis
the side of the hydraulic oil tank. · ground area under the machine
Result: The hydraulic oil level should be within
the top 2 inches (5 cm) of the sight gauge.

TABLE A PROCEDURES
A-9 A-10
Check the Tire Pressure Test the Platform and
This procedure does not need Ground Controls
to be performed on machines Testing the machine functions and the Emergency
equipped with the foam-filled Stop buttons for malfunctions is essential for safe
tire option. machine operation. An unsafe working condition
An over-inflated tire can explode exists if any function fails to operate properly or
and may cause death or serious either Emergency Stop button fails to stop all the
injury. machine functions and shut off the engine. Each
function should activate, operate smoothly and be
To safeguard maximum stability, achieve free of hesitation, jerking and unusual noise.
optimum machine handling and minimize tire
wear, it is essential to maintain proper pressure 1 Start the engine from the ground controls, and
in all air-filled tires. then operate each machine function through a
full cycle.
1 Check each tire with an air pressure gauge and
add air as needed. Result: All machine functions should operate
smoothly.
Tire specifications 2WD front 2WD rear 2 Push in the Emergency Stop button to the OFF
4WD front position.
& rear
Result: No function should operate, the engine
Tire size 12.5L-16SL 12-16.5NHS should stop.
Pressure 45 psi 45 psi Deutz Diesel models:

3.10 bar 3.10 bar All functions should stop
immediately. The engine will
shut off after 2 to 3 seconds.
3 Start the engine from the platform controls, and
then operate each machine function through a
full cycle.
Result: All machine functions should operate
smoothly.
4 Push in the Emergency Stop button to the OFF
position.
Result: No function should operate, the engine
should stop.
As a safety feature, selecting
and operating the ground
controls will override the
platform controls, including
the Emergency Stop button.

TABLE A PROCEDURES
A-11 4 At the platform controls, pull out the Emergency

Stop button to the ON position, then press down
Test the Auxiliary Power the foot switch.
Operation 5 Simultaneously hold the auxiliary power switch
Detection of auxiliary power system malfunctions is on while activating the following functions
essential for safe machine operation. An unsafe through a partial cycle:
working condition exists if the auxiliary powered · boom up/down
functions do not operate in the event of a main
power loss. When operating the machine on · extend and retract
engine power, selecting auxiliary power will stop · turntable rotate right/left
the engine immediately. Auxiliary power is
designed for short term emergency use only, · steer right/left
and excessive use will result in battery drain
and component damage.
1 Turn the key switch to ground control and pull

out the Emergency Stop button to the ON
position.
2 Simultaneously hold the auxiliary power switch
ON while activating the following functions
through a partial cycle:
· boom up/down
· extend and retract
· turntable rotate right/left
Result: Each function should operate smoothly.

3 Turn the key switch to platform control.

TABLE A PROCEDURES
A-12 A-13
Test the Tilt Sensor Test the Limit Switches
The tilt sensor sounds an alarm in the platform Drive Limit Switches
when the incline of the drive chassis exceeds
Detecting limit switch malfunctions is essential to
5 degrees.
safe machine operation. The drive limit switches
Select a level test area. The tilt are used to restrict drive speed when the boom is
alarm should not be sounding prior raised or extended. An improperly functioning drive
to test. limit switch will allow the machine to operate in an
unsafe position.
1 Start the engine from the platform controls.
1 Start the engine from the ground controls. Raise
2 Open the tank side cover and press down on
the boom 10 ft. (3 m) off the ground. Turn the
one side of the tilt sensor.
engine off.
Result: After a 1 second delay, the alarm in the
2 Visually inspect the drive limit switch located
platform should sound.
next to the boom lift cylinder for the following:
· broken or missing actuator arm
· missing fasteners
· loose wiring
a b c
a fuel tank
b tilt sensor
c ground control box
a b
a drive limit switch

b boom lift cylinder

TABLE A PROCEDURES
3 Remove the turntable end cover to access the 9 Lower the boom to the stowed position, then
limit switch mounted inside the boom. extend the boom 1 foot (30 cm).
4 Visually inspect the drive limit switch located in 10 Slowly move the drive control handle off center.
the pivot end of the boom. Inspect for the
Result: The machine should move at a reduced
following:
drive speed.
· broken or missing actuator arm
· missing fasteners Drive speed, maximum, raised or extended
· loose wiring All models 1 foot per second

0.3 meter per second
a
Drive Enable Limit Switch
1 With the engine off and the boom in the stowed

position, visually inspect the drive enable limit
switch for the following:
· broken or missing rollers or arms
· missing fasteners
· loose wiring
d c b
a drive limit switch

b boom
c extension boom tube
d extension cylinder
5 Lower the boom to the stowed position.

Then slowly move the drive control handle
off center. c b
Result: The machine should move at normal
drive speeds. a turntable
b drive enable limit switch
7 Raise the boom above the drive limit switch. c turntable rotation bearing
8 Slowly move the drive control handle off center.

Result: The machine should move at a reduced
drive speed.

TABLE A PROCEDURES
2 Manually activate the drive enable limit switch. A-14

Result: The drive enable limit switch roller Test the Oscillate Axle
should move freely and spring return to center.
A distinct click should be felt and heard.
(oscillating axle-equipped
models)
Proper axle oscillation is essential to safe machine
4 Rotate the turntable to the left until the boom is
operation. If the axle oscillation system is not
past the left non-steer wheel.
operating correctly, the stability of the machine is
Result: The drive enable indicator light should compromised and it may tip over.
be on. Drive function should not operate until
the drive enable switch is activated. 1 Start the engine from the platform controls.
5 Rotate the turntable to the right until the boom is 2 Drive the right steer tire up onto a 6 inch
past the right non-steer wheel. (15.2 cm) block or curb.
Result: The drive enable indicator light should Result: The three remaining tires should stay in
be on. Drive function should not operate until firm contact with the ground.
the drive enable switch is activated. 3 Drive the left steer tire up onto a 6 inch
(15.2 cm) block or curb.
Result: The three remaining tires should stay in
firm contact with the ground.
4 Drive both steer tires up onto a 6 inch
(15.2 cm) block or curb.
Result: The non-steer tires should stay in firm
contact with the ground.

TABLE A PROCEDURES
A-15 2 Pull the end of the oil drain hose out from
under the engine.
Replace the Engine Oil and
Filter - Gasoline/LPG Models
Ford engine specifications require
that this procedure be performed
every 100 hours. Perform this
procedure more often if dusty
conditions exist or the machine is
subjected to extended low idle
operation.
Periodic replacement of the engine oil and filter
is essential to good engine performance. Operating
the machine with an improper oil level or
neglecting periodic oil and filter changes can
damage engine components. A daily check of
elapsed machine hours against the hours noted
a b c a
on the oil filter will allow the inspector to anticipate
and perform oil and filter changes at the 100 hour a engine pivot plate
interval. b pivot plate retaining bolts
c oil drain hose
Perform this procedure after
warming the engine to normal 3 Remove the plug from the end of the drain hose
operating temperature. and allow all of the oil from the engine
to drain into a suitable container.
Beware of hot engine parts and
oil. Contact with hot engine oil 4 Install the plug into the drain hose.
and/or engine parts may cause
5 Remove the 2 bolts from the engine pivot plate.
severe burns.
Swing the engine pivot plate away from the
1 Remove the oil filler cap located on the machine to access the oil filter.
valve cover.
6 Use an oil filter wrench and remove the filter.
7 Apply a thin layer of oil to the new oil filter
gasket (filter part no. 28656). Then install the
filter and tighten it securely by hand.
4 - 10 Genie S-40 Part No. 32222

TABLE A PROCEDURES
8 Use a permanent ink marker to write the date A-16

and number of hours from the hour meter on
the oil filter. Replace the Engine Air Filter
9 Fill the engine with new oil per specifications Engine specifications require that
and install the filler cap. this procedure be performed every
100 hours. Perform this procedure
10 Start the engine from the ground controls. more often if dusty conditions
Allow the engine to run for 30 seconds, then exist.
turn the engine off.
Maintaining the engine air filter in good condition is
11 Check the oil filter and the oil drain hose essential to good engine performance and service
for leaks. life. Failure to perform this procedure can lead to
12 Swing the engine pivot plate back to its original poor engine performance and component damage.
position and replace the two retaining bolts. Perform this procedure with the
13 Check the engine oil level dipstick. Add oil engine off.
if needed. 1 Remove the end cap from the air cleaner
canister.
Ford Engine LSG-423 5 quarts
Oil capacity (including filter) 4.7 liters 2 Remove the mounting fastener from the air
filter, then remove the filter.
Ford Engine LSG-423 Oil viscosity requirements
3 Clean the inside of the canister and the gasket
with a dry cloth.
below 60F / 15.5C 5W-30
4 Insert the new filter and replace the mounting
-10 to 90F / -23 to 32C 10W-30 fastener.
above -10F / -23C 10W-40 or 10W-50 5 Replace the end cap on the canister.
above 25F / -4C 20W-40 or 20W-50 Air filters - Genie part numbers
Ford LSG-423 Engine 27916
Use oils meeting API classification SF (labeled SF/CC Deutz F3L 1011 29553
or SF/CD) as they offer improved wear protection.
Part No. 32222 Genie S-40 4 - 11

Table B Procedures
B-1 B-2
Check the Engine Belt(s) Check the Radiator
Maintaining the engine belt(s) is essential to good - Gasoline/LPG Models
engine performance and service life. The machine Maintaining the radiator in good condition is
will not operate properly with a loose or defective essential for good engine performance. Operating
belt and continued use may cause component a machine with a damaged or leaking radiator may
damage. result in engine damage. Also, restricting air flow
Do not inspect while the engine through the radiator (i.e., dirt or debris) will affect
is running. Remove the key to the performance of the cooling system. A frequent
secure from operation. check allows the inspector to identify changes in
the condition of the radiator that might indicate
Beware of hot engine cooling system problems.
components. Contact with hot
engine components may cause Do not inspect while the engine
severe burns. is running. Remove the key to
secure from operation.
1 Deutz Diesel models: Remove front engine
cover to access belt. Beware of hot engine
2 All models: Inspect the engine belt(s) for: engine components may cause
· cracking severe burns.
· glazing 1 Inspect the radiator for leaks and physical

damage.
· separation
2 Clean the radiator fins of debris and foreign
· breaks materials.
3 Check the engine belt(s) for proper tension.
B-3
Check the Oil Cooler and Cooling
Fins - Deutz Diesel Models
Maintaining the oil cooler in good condition is
essential for good engine performance. Operating
a machine with a damaged oil cooler may result in
engine damage. Also, restricting air flow through
the oil cooler will affect the performance of the
cooling system.
Ford engine Deutz Diesel engine Do not inspect while the engine
is running. Remove the key to
Belt deflection - all models 3/8inch to 1/2 inch secure from operation.
9 mm to 12 mm Beware of hot engine
engine components may cause
severe burns.
4 - 12 Genie S-40 Part No. 32222

TABLE B PROCEDURES
Oil Cooler B-4

1 Remove the cover from the side of the engine, Check the Exhaust System
then remove the oil cooler top cover.
Maintaining the exhaust system is essential to
2 Inspect the oil cooler for leaks and physical good engine performance and service life. Running
damage. the engine with a damaged or leaking exhaust
system can cause component damage and unsafe
a b c operating conditions.
Do not inspect while the engine

is running. Remove the key to
secure from operation.
Beware of hot engine
engine components may cause
severe burns.
1 Deutz Diesel models: Remove the 2 bolts from
the engine pivot plate. Swing the engine pivot
plate away from the machine to access the
a oil cooler exhaust system.
b cylinder head cooling fins
c blower fins
3 Clean the oil cooler of debris and foreign

material.
Cooling and Blower Fins
4 Inspect the blower fins for physical damage.
5 Clean the blower fins of debris and foreign
material.
6 Inspect the head cooling passages and fins for
physical damage or foreign material, using a
flashlight.
7 Clean the cylinder head cooling passages of
debris and foreign material.
a b b
a pivot plate retaining bolts

b engine pivot plate
Part No. 32222 Genie S-40 4 - 13

TABLE B PROCEDURES
2 Be sure that all nuts and bolts are tight. B-6

3 Inspect all welds for cracks. Check the Hydraulic Tank Filter
4 Inspect for exhaust leaks; i.e., carbon buildup Condition Indicator
around seams and joints.
Maintaining the hydraulic tank filter in good
condition is essential to good system performance
and safe machine operation. The filter condition
B-5 indicator will show when the hydraulic flow is
bypassing a clogged filter. If the filter is not
Check the Battery frequently checked and replaced, impurities
Proper battery condition is essential to good will remain in the hydraulic system and cause
engine performance and operational safety. component damage.
Improper fluid levels or damaged cables and 1 Start the engine from the platform controls.
connections can result in engine component
damage and hazardous conditions. 2 Move the engine speed control switch to high
idle (rabbit symbol).
Batteries contain acid. Avoid spilling or contacting
battery acid. Neutralize battery 3 Inspect the filter condition indicator.
acid spills with baking soda and
water. a
1 Put on protective clothing and eye wear.
2 Be sure that the battery cable connections are
free of corrosion.
b
3 Be sure that the battery hold downs and cable
c
connections are tight.
4 Remove the battery vent caps and check the
specific gravity with a hydrometer.
5 Check the battery acid level. If needed,
replenish with water to the bottom of the
battery fill tube. Do not overfill. a filter condition indicator
b filter
6 Install the vent caps.
c hydraulic tank
Result: The filter should be operating with the

plunger in the green area. If the display shows
the plunger in the red area, this indicates that
the hydraulic filter is being bypassed and the
filter should be replaced. See C-6, Replace the
Hydraulic Tank Filter.
4 - 14 Genie S-40 Part No. 32222

TABLE B PROCEDURES
B-7 B-8
Inspect the Electrical Wiring Inspect the Tires and Wheels
Maintaining electrical wiring in good condition is (including lug nut torque)
essential to safe operation and good machine Maintaining the tires and wheels in good
performance. Failure to find and replace burnt, condition is essential to safe operation and good
chafed, corroded or pinched wires could result in performance. Tire and/or wheel failure could result
unsafe operating conditions and may cause in a machine tip-over. Component damage may
component damage. also result if problems are not discovered and
Electrocution hazard. Contact with repaired in a timely fashion.
hot or live circuits may result in An over-inflated tire can
death or serious injury. Remove all explode and may cause death
rings, watches and other jewelry. or serious injury.
1 Inspect the following areas for burnt, chafed, 1 Check all tire treads and sidewalls for cuts,
corroded and loose wires: cracks, punctures and unusual wear.
· engine compartment electrical panel 2 Check each wheel for damage, bends and
· engine wiring harness cracked welds.
· inside of the ground control box 3 Check each lug nut for proper torque.
· turntable manifold wiring 4 Check the pressure in each air-filled tire.
2 Start the engine from the ground controls, then

Tires and 2WD front 2WD rear
raise the boom above the turntable covers. wheels 4WD front
3 Inspect the turntable area for burnt, chafed and & rear
pinched cables. Tire size 12.5L-16SL 12-16.5NHS
4 Lower the boom into the stowed position and
turn the engine off. Tire ply rating 12 8
5 Inspect the following areas for burnt, chafed,
corroded, pinched and loose wires: Overall tire diameter 33.7 in 33.2 in
85.6 cm 84.3 cm
· cable track on the boom
Tire pressure 45 psi 45 psi
· boom to platform cable harness 3.10 bar 3.10 bar
· inside of the platform control box Wheel diameter 16 in 16.5 in
40.6 cm 41.9 cm
Wheel width 10 in 9.75 in
25.4 cm 24.7 cm
Wheel lugs 8 @ 5/8-18 9 @ 5/8-18
Lug nut torque 125 ft-lbs 125 ft-lbs

169.5 Nm 169.5 Nm
Part No. 32222 Genie S-40 4 - 15

TABLE B PROCEDURES
B-9 B-10
Confirm the Proper Check the Oil Level
Brake Configuration in the Torque Hubs
Proper brake configuration is essential to safe Failure to maintain proper torque hub oil levels
operation and good machine performance. may cause the machine to perform poorly and
Hydrostatic brakes and hydraulically-released, continued use may cause component damage.
spring-applied individual wheel brakes can appear
to operate normally when they are actually not fully Drive Torque Hubs
operational. 1 Drive the machine to rotate the hub until the
1 Check each torque hub disconnect cap to be plugs are located one on top and the other at
sure it is in the engaged position. 90 degrees.
brake disengage position
brake engage position
2 Be sure the free-wheel valve on the drive pump

is closed (clockwise).
2 Remove the plug located at 90 degrees and

check the oil level.
Result: The oil level should be even with the
bottom of the plug hole.
3 If necessary, remove the top plug and add oil
until the oil level is even with the bottom of the
side plug hole.
4 Apply pipe thread sealant to the plug, and then
a b c d install it in the torque hub.
a drive pump 5 Repeat this procedure for each drive torque

b free-wheel valve hub.
c screwdriver
d lift pump Drive torque hub oil
The free-wheel valve should
Capacity 17 fluid ounces
always remain closed.
0.51 liters
Type: SAE 90 multipurpose hypoid gear oil - API service

classification GL5
4 - 16 Genie S-40 Part No. 32222

TABLE B PROCEDURES
Turntable Rotate Torque Hub B-11

1 Remove the plug located on the side of the hub Check and Adjust the Engine Idle
and check the oil level. Mixture - Gasoline/LPG Models
Result: The oil level should be even with the
Complete information to perform this procedure is
bottom of the plug hole.
available in the Ford LSG-423 2.3 Liter Industrial
Engine Service Manual (Ford number: 194-216).
Genie part number 29586.
B-12
Check and Adjust the
a Engine RPM
Maintaining the engine rpm at the proper setting for
b
both low and high idle is essential to good engine
performance and service life. The machine will not
operate properly if the rpm is incorrect and
b continued use may cause component damage.
a torque hub
Gasoline/LPG Models
b plug
Perform this procedure in gasoline
mode with the engine at normal
2 If necessary, add oil until the oil level is even operating temperature.
with the bottom of the side plug hole.
1 Disconnect the blue/black wire from the
3 Apply pipe thread sealant to the plug, and then governor actuator.
install it in the torque hub.
Turntable rotate torque hub oil

0.24 liters
TypeSAE 90 multipurpose hypoid gear oil - API service

classification GL5
Part No. 32222 Genie S-40 4 - 17

TABLE B PROCEDURES
2 Connect an rpm gauge to the engine, then start If low and high idle rpm’s are correct,
the engine from the ground controls. disregard adjustment steps 8 and 9.
Result: Carburetor low idle should be 900 rpm. 8 Remove the mounting fasteners from the
electronic governor located on the engine
Skip to step 4 if the low idle rpm is correct.
side bulkhead, then remove the back panel
3 Turn the idle adjustment screw on the from the governor.
carburetor clockwise to increase rpm or
9 Restart the engine, turn the low or high speed
counterclockwise to decrease rpm.
set screw clockwise to increase the rpm or
counterclockwise to decrease the rpm.
Do not adjust any trimpot other than specified in
this procedure.
a
b
Gasoline/LPG low idle adjustment b

a carburetor
b adjustment screw
Gasoline/LPG idle adjustment
4 Turn the engine off and reconnect the a low idle adjustment
b high idle adjustment
blue/black wire to the governor actuator.
5 Start the engine from the ground controls. 10 Re-assemble the governor and recheck low and
high idle.
Result: Electronic governor low idle should
be 1600 rpm. Gasoline/LPG models
6 Move the engine idle control switch to high idle
(rabbit symbol) from the ground controls. Low idle - carburetor 900 rpm
Result: High idle should be 2500 rpm. Low idle - electronic governor 1600 rpm
7 Turn the engine off. High idle 2500 rpm
Deutz Diesel models

1 Connect an rpm gauge to the engine, and then
start the engine from the ground controls.
Result: Low idle should be 1300 rpm.
Skip to step 3 if the low idle rpm is correct.
4 - 18 Genie S-40 Part No. 32222

TABLE B PROCEDURES
2 Loosen the lock nut, then turn the adjustment B-13

screw clockwise to increase the rpm or
counterclockwise to decrease the rpm. Tighten Test the Key Switch
the lock nut and recheck the rpm. Proper key switch action and response is essential
to safe machine operation. The machine can be
operated from the ground or platform controls and
the activation of one or the other is accomplished
with the key switch. Failure of the key switch to
activate the appropriate control panel could cause
f
a hazardous operating situation.
e
1 Pull out the Emergency Stop button to the ON
position at both the ground and platform
controls.
2 Turn the key switch to ground control, start the
engine and then turn the key switch to platform
a b c d control.
a solenoid boot 3 Check any machine function from the ground
b high idle adjustment nut controls.
c lock nut
d yoke Result: The machine functions should not
e low idle adjustment screw operate.
f lock nut
4 Turn the key switch to ground control.
3 Move the engine idle control switch to high idle
(rabbit symbol) from the ground controls. 5 Check any machine function from the platform
controls.
Result: High idle should be 2300 rpm.
Result: The machine functions should not
If high idle rpm is correct, disregard operate.
adjustment step 4.
6 Turn the key switch to the OFF position.
4 Loosen the yoke lock nut, then turn the
adjustment nut and solenoid boot Result: The engine should stop and no
counterclockwise to increase the rpm or functions should operate.
clockwise to decrease the rpm. Tighten the Deutz Diesel models: All functions
yoke lock nut and recheck the rpm. should stop immediately. The
engine will shut off after 2 to 3
Deutz Diesel models seconds.
Low idle 1300 rpm
High idle 2300 rpm
Part No. 32222 Genie S-40 4 - 19

TABLE B PROCEDURES
B-14 B-15
Test the Emergency Stop Buttons Test the Ground Control Override
Properly functioning Emergency Stop buttons A properly functioning ground control override is
are essential for safe machine operation. An essential to safe machine operation. The ground
improperly operating Emergency Stop button control override function is intended to allow
will fail to shut off power and stop all machine ground personnel to operate the machine from the
functions, resulting in a hazardous situation for ground controls whether or not the Emergency
ground and platform personnel. Stop button on the platform controls is in the ON or
OFF position. This function is particularly useful if
As a safety feature, selecting the operator at the platform controls cannot return
and operating the ground controls the boom to the stowed position.
will override the platform controls,
including the Emergency Stop 1 Push in the platform Emergency Stop button
button. to the OFF position.
1 Start the engine from the ground controls. 2 Start the engine from the ground controls.
2 Push down the Emergency Stop button to the 3 Operate each boom function through a
OFF position. partial cycle.
Result: The engine should shut off and no Result: All boom functions should operate.
machine functions should operate.
Deutz Diesel models: All functions
should stop immediately. The
engine will shut off after 2 to 3
seconds.
4 Push down the Emergency Stop button to the
OFF position.
Result: The engine should shut off and no

machine functions should operate.
The ground Emergency Stop
button will stop all machine
operation, even if the key switch
is switched to platform control.
4 - 20 Genie S-40 Part No. 32222

TABLE B PROCEDURES
B-16 B-17
Check the Directional Valve Test the Platform Self-leveling
Linkage Automatic platform self-leveling throughout
Proper axle oscillation is essential to safe machine the full cycle of boom raising and lowering is
operation. If the directional valve linkage is not essential for safe machine operation. The
operating correctly, the stability of the machine is platform is maintained at level by the platform
compromised and it may tip over. leveling slave cylinder which is controlled by the
master cylinder located at the base of the boom.
1 Remove the drive chassis cover from the A platform self-leveling failure creates an unsafe
non-steer end. working condition for platform and
ground personnel.
2 Inspect the linkage for the following:
· lock nuts are tight against yokes
lower the boom into the stowed position.
· yoke clevis pins are installed
2 Adjust the platform to a level position using the
· cotter pins are installed through clevis pins platform leveling switch.
· linkage is properly attached to 3 Raise and lower the boom through
directional valve a full cycle.
Result: The platform should remain level at
all times to within ±5 degrees.
a
B-18
Test the Service Horn
A functional service horn is essential to safe
machine operation. The service horn is activated at
the platform controls and sounds at the ground as
a warning to ground personnel. An improperly
functioning horn will prevent the operator from
b
alerting ground personnel of hazards or unsafe
c conditions.
d 1 Turn the key switch to platform control and
pull out the Emergency Stop button to the
ON position at both the ground and
a directional valve platform controls.
b lock nut
c yoke 2 Push down the service horn button at the
d clevis pin with cotter pin platform controls.
Result: The service horn should sound.
Part No. 32222 Genie S-40 4 - 21

TABLE B PROCEDURES
B-19 Foot switch activated high idle (rabbit and foot

switch symbols) should be used for normal
Test the Foot Switch machine operation. This selection activates high
A properly functioning foot switch is essential to idle only when the foot switch is pressed down.
safe machine operation. Machine functions should 1 Pull out the Emergency Stop button to the
activate and operate smoothly as long as the foot ON position at both the ground and platform
switch is pressed down, and promptly stop when controls.
the foot switch is released. The foot switch will also
shift the engine into high idle if the idle select is 2 Start the engine from the ground controls. Then
switched to the rabbit and foot switch symbol. An move the engine idle control switch to high idle
improperly functioning foot switch can cause an (rabbit symbol) and hold in the ON position.
unsafe working condition and endanger platform Result: The engine should change to high idle.
and ground personnel.
3 Release the engine idle control switch.
The engine should not start if the
foot switch is pressed down. Result: The engine should return to low idle.
1 Start the engine from the platform controls. 4 Turn the key switch to platform controls.
2 Without pressing down the foot switch, check 5 At the platform controls, move the engine idle
the machine functions. control switch to high idle (rabbit symbol).
Result: The machine functions should not Result: The engine should change to high idle.
operate. 6 Move the engine idle control switch to low idle
3 Press down the foot switch and operate the (turtle symbol).
machine functions. Result: The engine should change to low idle.
Result: The machine functions should operate. 7 Move the engine idle control switch to foot
switch activated high idle (rabbit and foot switch
symbol).
B-20 Result: The engine should not change to
Test the Engine Idle Select high idle.
8 Press down the foot switch.
A properly operating engine idle select switch
is essential to good engine performance and safe Result: The engine should change to high idle.
machine operation. There are three settings.
Gasoline/LPG models
Low idle (turtle symbol) allows the operator to
control individual boom functions only. Drive
Low idle 1600 rpm
functions do not operate at low idle.
High idle (rabbit symbol) allows the operator High idle 2500 rpm
to control multiple boom and/or drive functions
Deutz Diesel models
simultaneously. This setting maintains a
consistent high idle and is usually selected only
Low idle 1300 rpm
when the generator option is being used.
High idle 2300 rpm
4 - 22 Genie S-40 Part No. 32222

TABLE B PROCEDURES
B-21 B-22
Test the Fuel Select Operation Test the Drive Enable System
- Gasoline/LPG Models Proper drive enable system operation is
The ability to select and switch between essential to safe machine operation. When the
gasoline and LPG fuels as needed is essential to boom is past the non-steering wheels, drive
safe machine operation. A fuel selection can be movement is stopped and the indicator light turns
made when the engine is running or not. on. The drive enable switch must be used
Switching malfunctions and/or the failure of the to reactivate the drive function and should inform
engine to start and run properly in both fuel the operator that the machine will move in the
modes and through all idle speeds can indicate opposite direction that the drive and steer controls
fuel system problems that could develop into a are moved. An improperly functioning drive enable
hazardous situation. system may allow the machine to be moved into
an unsafe position.
Perform this test after checking
the gasoline and LPG fuel levels,
and warming the engine to normal 2 Rotate the turntable to the right until the boom is
operating temperature. past the right non-steering wheel.
1 Move the fuel select switch to gasoline and then Result: The drive enable indicator light should
move the engine idle control switch to foot turn on.
switch activated high idle (rabbit and foot switch 3 Slowly move the drive control handle off center.
symbol).
Result: The drive function should not operate.
2 Start the engine from the platform controls and
allow it to run at low idle. 4 Hold the drive enable toggle switch to either
side and slowly move the drive control handle
3 Press down the foot switch to allow the engine off center.
to run at high idle.
Result: The engine should start promptly and
operate smoothly in low and high idle.
4 Release the foot switch and stop the engine.
5 Move the fuel select switch to LPG.
6 Restart the engine and allow it to run at Always use the color-coded
low idle. direction arrows on the
7 Press down the foot switch to allow the engine platform control panel and the
to run at high idle. drive chassis to identify which
direction the machine will travel.
Result: The engine should start promptly and
operate smoothly in low and high idle. Result: The drive function should operate.
The engine may hesitate 5 Rotate the turntable to the left until the boom is
momentarily and then continue past the left non-steering wheel.
to run on the selected fuel if the Result: The drive enable indicator light should
fuel source is switched while come on.
the engine is running.
6 Repeat steps 3 and 4.
Part No. 32222 Genie S-40 4 - 23

TABLE B PROCEDURES
B-23 B-24
Test the Drive Brakes Test the Drive Speed
Proper brake action is essential to safe machine - Stowed Position
operation. The drive brake function should operate Proper drive function movement is essential to
smoothly, free of hesitation, jerking and unusual safe machine operation. The drive function should
noise. Hydrostatic brakes and hydraulically- respond quickly and smoothly to operator control.
released individual wheel brakes can appear to Drive performance should also be free of
operate normally when they are actually not fully hesitation, jerking and unusual noise over the
operational. entire proportionally controlled speed range.
Be sure that the machine is not in Select a test area that is firm, level
free-wheel or partial free-wheel and free of obstructions.
configuration. Refer to B-9 in this
section, Confirm the Proper Brake 1 Create start and finish lines by marking two
Configuration. lines on the ground 40 feet (12.2 m) apart.
Select a test area that is firm, level 2 Start the engine from the platform controls.
and free of obstructions.
3 Move the engine idle control switch to
1 Mark a test line on the ground for reference. foot switch activated high idle (rabbit and foot
switch), then lower the boom into the stowed
2 Start the engine from the platform controls. position.
3 Move the engine idle control switch to 4 Choose a point on the machine; i.e., contact
foot switch activated high idle (rabbit and patch of a tire, as a visual reference for use
foot switch), then lower the boom into the when crossing the start and finish lines.
stowed position.
5 Bring the machine to top drive speed before
4 Choose a point on the machine; i.e., contact reaching the start line. Begin timing when your
patch of a tire, as a visual reference for use reference point on the machine crosses the
when crossing the test line. start line.
5 Bring the machine to top drive speed before 6 Continue at full speed and note the time when
reaching the test line. Release the drive joystick the machine reference point crosses the finish
when your reference point on the machine line.
crosses the test line.
6 Measure the distance between the test line and Drive speed:
your machine reference point. stowed position 2WD 4WD
Braking: Gasoline/LPG models 40 ft/6.8 sec 40 ft/7.8 sec

paved surface 12.2 m/6.8 sec 12.2 m/7.8 sec
Stopping distance 2 to 4 ft Deutz Diesel models 40 ft/7.8 sec 40 ft/9.1 sec

0.60 to 1.21 m 12.2 m/7.8 sec 12.2 m/9.1 sec
The brakes must be able to hold

the machine on any slope it is able
to climb.
4 - 24 Genie S-40 Part No. 32222

TABLE B PROCEDURES
B-25 5 Press down the foot switch. Move the boom

control handle to the DOWN position, hold for a
Test the Alarm Package moment and then release it.
- Optional Equipment Result: The descent alarm should sound when
The alarm package includes: the control handle is held down.
· travel alarm 6 Press down the foot switch. Move the drive
control handle off center, hold for a moment
· descent alarm and then release it. Move the drive control
· flashing beacon handle off center in the opposite direction, hold
for a moment and then release it.
Alarms and a beacon are installed to alert
operators and ground personnel of machine Result: The travel alarm should sound when the
proximity and motion. The alarm package is drive control handle is moved off center in
installed on the turntable covers. either direction.
The alarms and beacon will

operate with the engine
running or not running. B-26
1 At the ground controls, pull out the Emergency Perform Hydraulic Oil Analysis
Stop button to the ON position and turn the key
switch to ground control. See D-1, Test or Replace the Hydraulic Oil.
Result: The flashing beacon should be on and

flashing.
2 Move the boom switch to the DOWN position,
hold for a moment and then release it.
Result: The descent alarm should sound when
the switch is held down.
3 Turn the key switch to platform control.
4 At the platform controls pull out the Emergency
Stop button to the ON position.
Result: The flashing beacon should be on
and flashing.
Part No. 32222 Genie S-40 4 - 25

TABLE B PROCEDURES
B-27
Replace the Engine Oil and
a
Filter - Deutz Diesel Models
Engine specifications require
that this procedure be performed
every 500 hours. Perform this b
c
procedure more often if dusty
conditions exist.
Periodic replacement of the engine oil and
filter is essential to good engine performance.
Operating the machine with an improper oil level or
neglecting periodic oil and filter changes can a engine oil level dipstick
damage engine components. A frequent check b oil filter
of elapsed machine hours against the hours c fuel filter
noted on the oil filter will allow the inspector to
anticipate and perform oil and filter changes at 6 Apply a thin layer of oil to the new filter gasket
the 500 hour interval. (filter part no. 29561). Then install the filter and
tighten it securely by hand.
Perform this procedure after
7 Use a permanent ink marker to write the date
warming the engine to normal
and number of hours from the hour meter on
operating temperature.
the oil filter.
8 Fill the engine with new oil per specifications
oil. Contact with hot engine oil
and replace the oil filler cap.
and/or engine parts may cause
severe burns. 9 Start the engine from the ground controls. Allow
the engine to run for 30 seconds then turn the
1 Remove the oil filler cap located on the
engine off.
valve cover.
10 Check the oil filter and oil pan for leaks.
2 Pull the end of the drain hose out from under
the engine. 11 Check the engine oil level dipstick. Add oil if
needed.
3 Remove the plug from the end of the drain hose
and allow all of the oil from the engine to drain
into a suitable container. Deutz Engine F3L 1011 8.5 quarts
Oil capacity (including filter) 8 liters
4 Install the plug into the drain hose.
Deutz Engine F3L 1011 Oil viscosity requirements
5 Use an oil wrench and remove the oil filter.
Temperature below 60°F / 15.5°C (synthetic) 5W-30
-10°F to 90°F / -23°C to 32°C 10W-40
Temperature above -4°F / -34°C 15W-40
Engine oil should have properties of API classification

4 - 26 Genie S-40 Part No. 32222

Table C Procedures
C-1 C-2
Check the Boom Check the Turntable Rotation
Wear Pads Bearing Bolts
Maintaining the boom wear pads in good condition Maintaining proper torque on the turntable bearing
is essential to safe machine operation. Wear pads bolts is essential to safe machine operation.
are placed on boom tube surfaces to provide a low Improper bolt torque could result in an unsafe
friction, replaceable wear pad between moving operating condition and component damage.
parts. Improperly shimmed wear pads or continued
use of worn out wear pads may result in 1 Raise the boom approximately 7 to 8 feet
component damage and unsafe operating (2.1 to 2.4 m).
conditions. 2 Be sure that each turntable mounting bolt is
torqued in sequence to 210 foot-pounds
1 Start the engine from the ground controls.
(285 Newton meters).
2 Raise the end of the boom to a comfortable
working height (chest high), then extend the 10
1
15
13
boom 1 foot (30 cm). 7
6 19
3 Measure each wear pad. Replace the wear pad
18
if it is less than 7/16 inch (11 mm) thick. If the 12
wear pad is more than 7/16 inch (11 mm) thick, 3 4

shim as necessary to obtain zero clearance and
zero drag. 11 17
4 Extend and retract the boom through the entire 20 5
range of motion to check for tight spots that 8 14

16 9
could cause binding or scraping. 2
Always maintain squareness Bolt torque sequence

between the boom outer and inner
tubes. 3 Lower the boom to the stowed position.
4 Check to ensure that each bearing mounting
bolt under the drive chassis is torqued in
sequence to 210 foot-pounds
(285 Newton meters).
1
10 15
13 7
6 19
18 12
3 4
11 17
20 5
8 14
16 9
2
Bolt torque sequence
Part No. 32222 Genie S-40 4 - 27

TABLE C PROCEDURES
C-3 Steer wheels: 4WD models
Check the Free-wheel 7 Chock the non-steering wheels to prevent the

machine from rolling.
Configuration
8 Position the lifting jack under the steering axle
Proper use of the free-wheel configuration is
and center it between the steering wheels.
essential to safe machine operation. The
free-wheel configuration is used primarily for 9 Lift the wheels off the ground and then place
towing. A machine configured to free-wheel without jack stands under the drive chassis for support.
operator knowledge may cause death or serious
10 Disengage the torque hubs by turning over the
injury and property damage.
torque hub disconnect caps on each
Collision hazard. Select a work steer wheel hub.
site that is firm and level.
disengage position
Non-steering wheels: All models
1 Chock the steer wheels to prevent the machine
from rolling.
2 Center a lifting jack of ample capacity engage position
(15,000 lbs/6,804 kg) under the drive chassis
between the non-steering wheels.
11 Manually rotate each steer wheel.
3 Lift the wheels off the ground and then place
Result: Each steer wheel should rotate with
jack stands under the drive chassis for support.
minimum effort.
4 Disengage the torque hubs by turning over the
torque hub disconnect caps on each 12 Re-engage the torque hubs by turning over
non-steering wheel hub. the hub disconnect caps. Carefully remove
the jack stands, lower the machine and
disengage position remove the jack.
Collision hazard. Failure to
re-engage the torque hubs may
cause death or serious injury and
engage position property damage.
5 Manually rotate each non-steering wheel.

Result: Each non-steering wheel should rotate
with minimum effort.
6 Re-engage the torque hubs by turning over
the hub disconnect caps. Carefully remove
the jack stands, lower the machine and
remove the jack.
Collision hazard. Failure to
re-engage the torque hubs may
cause death or serious injury and
property damage.
4 - 28 Genie S-40 Part No. 32222

TABLE C PROCEDURES
All models: C-4

13 Be sure the free-wheel valve on the drive pump Grease the Turntable Rotation
is closed (clockwise). Bearing and Rotate Gear
Yearly application of lubrication to the turntable
bearing and rotate gear is essential to good
machine performance and service life. Continued
use of an improperly greased bearing and gear will
result in component damage.
1 Locate the grease fitting on the platform end of

the tank side bulkhead.
2 Pump grease into the turntable rotation bearing.
a b c d Rotate the turntable in increments
of 4 to 5 inches (10 to 13 cm) at a time and
a drive pump repeat this step until the entire bearing has
b free-wheel valve been greased.
c screwdriver
d lift pump 3 Apply grease to each tooth of the drive gear,
located under the turntable.
The free-wheel valve should
always remain closed.
Oil type Multipurpose grease
C-5
Replace the Torque Hub Oil
Replacing the torque hub oil is essential for good
machine performance and service life. Failure to
replace the torque hub oil at yearly intervals may
cause the machine to perform poorly and
continued use may cause component damage.
Drive Torque Hubs:
1 Select the drive torque hub to be serviced. Then

drive the machine until one of the two plugs is
at the lowest point.
2 Remove both plugs and drain the oil.
Part No. 32222 Genie S-40 4 - 29

TABLE C PROCEDURES
3 Drive the machine until one plug is at the top a b

and the other is at 90 degrees.
f
c
d
e
4 Fill the hub with oil from the top hole until the oil
level is even with the bottom of the side hole. e
Apply pipe thread sealant to the plugs, and then
install the plugs.
a motor/brake mounting bolt
5 Repeat steps 1 through 4 for all the other drive b motor
torque hubs. c torque hub
d torque hub mounting bolt
e plug
Oil capacity per hub 17 fluid ounces f brake
0.51 liters
3 Remove the torque hub mounting bolts, and
Type: SAE 90 multipurpose hypoid gear oil - API service then remove the torque hub from the machine.
classification GL5 4 Remove the plug from the side of the torque
hub. Then drain the oil from the hub.
Turntable Rotate Torque Hub 5 Install the torque hub. Torque the hub mounting
bolts to 180 foot-pounds (244 Newton meters).
1 Secure the turntable from rotating with the
turntable rotation lock pin. 6 Install the brake and motor onto the torque hub.
7 Fill the hub with oil from the side hole until the
oil level is even with the bottom of the hole.
Apply pipe thread sealant to the plugs, and then
install the plugs.

0.24 liters
Type: SAE 90 multipurpose hypoid gear oil - API service

classification GL5
unlocked locked
2 Remove the motor/brake mounting bolts, and

then remove the motor and brake from the
torque hub and set them to the side.
4 - 30 Genie S-40 Part No. 32222

TABLE C PROCEDURES
C-6 C-7
Replace the Hydraulic Tank Filter Replace the Drive Loop
Replacement of the hydraulic tank filter is Hydraulic Filter
essential for good machine performance and
Replacing the drive loop hydraulic filter is essential
service life. A dirty or clogged filter may cause the
to good machine performance and service life. A
machine to perform poorly and continued use may
dirty or clogged filter may cause the machine to
cause component damage. Extremely dirty
perform poorly and continued use may cause
conditions may require that the filter be replaced
component damage. Extremely dirty conditions
more often.
may require that the filter be replaced more often.
Beware of hot oil. Contact with
Beware of hot oil. Contact with
hot oil may cause severe burns.
hot oil may cause severe burns.
Perform this procedure with the
engine off.
engine off.
1 Remove the filter with an oil filter wrench.
1 Open the engine side turntable cover and locate
2 Apply a thin layer of oil to the new oil filter the drive loop hydraulic filter mounted on the
gasket. engine near the main pump.
3 Install the new filter (part no. 20293) and tighten 2 Rotate the filter housing counterclockwise and
it securely by hand. Clean up any oil that may remove the housing.
have spilled during the installation procedure.
3 Remove the filter element from the housing.
4 Inspect the housing seal and replace it if
5 Inspect the filter and related components to necessary.
be sure that there are no leaks.
5 Install the new filter (part no. 20880) and hand
tighten the housing onto the filter head. Clean
up any oil that may have spilled during the
installation procedure.
7 Inspect the filter assembly to be sure that there
are no leaks.
Part No. 32222 Genie S-40 4 - 31

TABLE C PROCEDURES
C-8 3 Apply a thin layer of oil or diesel fuel to the new

fuel filter gasket.
Replace the Diesel Fuel
4 Install the new filter (part no. 29560) and tighten
Filter - Deutz Diesel Models it securely by hand. Clean up any
Replacing the diesel fuel filter is essential to good diesel fuel that might have spilled during the
engine performance and service life. A dirty or procedure.
clogged filter may cause the engine to perform 5 Turn the manual fuel shutoff valve, located at
poorly and continued use may cause component the fuel tank, to the OPEN position.
damage. Extremely dirty conditions may require
that the filter be replaced more often. 6 Start the engine from the ground controls, then
inspect the fuel filter for leaks.
Replace the fuel filter in an open, If a fuel leak is discovered, keep
well-ventilated area away from any additional personnel from
heaters, sparks, flames and entering the area and do not
lighted tobacco. Always have an operate the machine. Repair
approved fire extinguisher within the leak immediately.
easy reach.
engine off. C-9
1 Turn the manual fuel shutoff valve, located at Replace the Gasoline Fuel
the fuel tank, to the CLOSED position.
Filter - Gasoline/LPG Models
2 Remove the fuel filter with a filter wrench.
Replacing the gasoline fuel filter is essential to
good engine performance and service life. A dirty
or clogged filter may cause the engine to perform
poorly and continued use may cause component
damage. Extremely dirty conditions may require
that the filter be replaced more often.

Replace the fuel filter in an open,
a well-ventilated area away from
b
heaters, sparks, flames and
lighted tobacco. Always have an
easy reach.
a fuel filter Perform this procedure with the

b oil filter engine off.
4 - 32 Genie S-40 Part No. 32222

TABLE C PROCEDURES
1 Remove the 2 bolts from the engine pivot plate. a b

machine to access the fuel filter, located near
the carburetor.
a b a
Gasoline/LPG models
a fuel filter
b hose from the fuel filter to
a pivot plate retaining bolts the carburetor
b engine pivot plate c hose from the fuel pump to
the fuel filter
2 Loosen the filter bracket mounting bolt. d hose from the fuel shutoff
Disconnect the fuel hoses from the filter, then valve to the fuel pump
slide the filter out of the bracket.
3 Install the new fuel filter in the bracket with
the flow direction arrow on the filter, pointing
toward the carburetor. Tighten the bracket
mounting bolt, then connect the fuel hoses
to the filter.
4 Clean up any fuel that may have spilled during
the installation procedure.
5 Start the machine from the ground controls,
then inspect the fuel filter and hoses for leaks.
If a fuel leak is discovered, keep
any additional personnel from
entering the area and do not
operate the machine. Repair
the leak immediately.
6 Swing the engine pivot plate back to its original
position and replace the two retaining bolts.
Part No. 32222 Genie S-40 4 - 33

TABLE C PROCEDURES
C-10 2 Remove the hoses from the PCV valve, then

remove the valve.
Replace the PCV Valve
- Gasoline/LPG Models a b
Yearly replacement of the PCV valve is essential

to good engine performance. A malfunctioning
valve can impair crankcase ventilation and may
cause engine damage. c

engine off.
machine to access the PCV valve.
Shown with distributor cap removed

a PCV valve
b hose, PCV valve to carburetor
c hose, PCV valve to crankcase
3 Install the new PCV valve. Connect the hoses.

C-11
Clean or Replace the
a b a
Distributor Cap and Rotor
- Gasoline/LPG Models
a pivot plate retaining bolts A distributor cap and rotor that are clean and free
b engine pivot plate of damage, wear and corrosion are essential to
good engine performance and service life. A dirty
or worn cap and rotor may cause the engine to
component damage. Extremely dirty conditions
may require that the cap and rotor be replaced
more often.

engine off.
4 - 34 Genie S-40 Part No. 32222

TABLE C PROCEDURES
1 Remove the 2 bolts from the engine pivot plate. C-12

machine to access the distributor. Replace the Spark Plugs
Periodic replacement of the spark plugs is
essential to good engine performance and
service life. Worn, loose or corroded spark plugs
will cause the engine to perform poorly and may
result in component damage.

engine off.
1 Label, then disconnect the plug wires from the
spark plugs by grasping the molded boot. Do
not pull on the plug wire.
2 Blow out any debris around spark plugs.
3 Remove all the spark plugs from the engine.
4 Adjust the gap on each new spark plug.
a b a
5 Install the new spark plugs, then connect the
a pivot plate retaining bolts wires. Be sure that each spark plug wire is
b engine pivot plate attached to the correct spark plug.
2 Label and disconnect the coil and spark plug

Spark plug specifications
wires from the distributor cap.
3 Remove the cap and rotor from the distributor. Spark plug type Motorcraft AWSF-42
4 Clean the cap and rotor using electrical contact Spark plug gap 0.042 to 0.046 inches
cleaner or a damp cloth. 1.07 to 1.18 mm
5 Completely dry the cap and rotor.
Spark plug torque 5 to 10 foot-pounds
Moisture in the distributor cap will 7 to 14 Nm
cause the engine to run poorly.
6 Inspect the cap and rotor for corrosion, cracks
and abrasion. Replace the cap and rotor if they
are damaged.
7 Install the rotor and cap, then connect the coil
and spark plug wires.
9 Start the engine from the ground controls and
check the engine for proper operation.
Part No. 32222 Genie S-40 4 - 35

TABLE C PROCEDURES
C-13 2 Loosen the high idle mixture adjustment

lock nut.
Check and Adjust the Air/LPG
Mixture - Gasoline/LPG Models
Maintaining the proper air-to-fuel mixture during
LPG operation is essential to good engine
performance.

Perform this procedure in an open,
a
easy reach.
The engine rpm needs to be
preset for gasoline fuel operation
before adjusting the LPG idle
mixture. Refer to B-12, Check and a high idle mixture
adjustment screw
Adjust the Engine RPM.
The engine should be warmed to 3 Load the system by pressing the boom retract
normal operating temperature switch, then move the engine idle control switch
before performing this procedure. to high idle (rabbit symbol).
1 Move the fuel select switch to LPG fuel and 4 Adjust the high idle adjustment screw to obtain
start the engine from the ground controls. an air-to-fuel mixture ratio of 13.0:1 to 13.2:1,
using an exhaust gas analyzer.
If an exhaust gas analyzer is not
available, adjust to obtain peak or
optimum rpm.
4 - 36 Genie S-40 Part No. 32222

TABLE C PROCEDURES
5 Hold the adjustment screw and tighten the C-14

lock nut.
Check and Adjust the Ignition
6 Move the engine idle control switch to low idle
(turtle symbol) and adjust the low idle screw to
Timing - Gasoline/LPG Models
obtain an air-to-fuel mixture ratio Complete information to perform this procedure is
of 13.0:1 to 13.2:1. available in the Ford LSG-423 2.3 Liter Industrial
C-15
Check the Engine Valve
Clearances - Deutz Diesel Models
Complete information to perform this procedure
is available in the Deutz FL 1011 Workshop
Manual (Deutz Number 02611642). Genie part
number 29789.
a low idle mixture adjustment screw
Part No. 32222 Genie S-40 4 - 37

Table D Procedures
D-1 2 Remove the drain plug from the hydraulic tank.

Test or Replace the Hydraulic Oil 3 Completely drain the tank into a suitable
container. See capacity specifications listed
Replacement or testing of the hydraulic oil is below.
essential for good machine performance and
service life. Dirty oil and suction strainers may 4 Disconnect and cap the two suction hoses
cause the machine to perform poorly and that are attached to the hydraulic tank
continued use may cause component damage. shutoff valves.
Extremely dirty conditions may require oil changes 5 Remove the strainer assemblies from the tank.
to be performed more often.
6 Carefully clean any foreign material from
The machine uses Dexron II the strainers. Clean the strainers from the
equivalent hydraulic oil. Before inside out.
replacing the hydraulic oil, the oil
may be tested by an oil distributor 7 Apply pipe thread sealant to the strainer
for specific levels of contamination mounting threads, and then install them.
to verify that changing the oil is 8 Apply pipe thread sealant to the drain plug,
necessary. If the hydraulic oil and then install it in the tank.
is not replaced at the two year
inspection, quarterly testing 9 Install the two suction hoses.
(B-26) thereafter should be 10 Fill the tank with hydraulic oil until the level is
completed. within the top 2 inches (5 cm) of the sight
Perform this procedure with the gauge. Do not overfill.
boom in the stowed position. 11 Clean up any oil that may have spilled and open
1 Close the two hydraulic shutoff valves located the hydraulic tank valves.
at the hydraulic tank. 12 Prime the pump by doing the following:
Connect a 0 to 600 psi (0 to 41 bar) pressure
gauge to the test port on the drive pump.
Gasoline/LPG models:
Remove the high tension lead from the center
of the ignition coil.
open closed
Electrocution hazard. Contact with
Component damage hazard. The electrically charged circuits may
engine must not be started with cause death or serious injury.
the hydraulic tank shutoff valves in Remove all rings, watches and
the CLOSED position or component other jewelry.
damage will occur.
If the tank valves are closed,
remove the key from the key
switch and tag the machine to
inform personnel of the condition.
4 - 38 Genie S-40 Part No. 32222

TABLE D PROCEDURES
Deutz Diesel models: D-2

Hold the manual fuel shutoff valve Change or Recondition the
counterclockwise to the CLOSED position.
Engine Coolant
a - Gasoline/LPG Models
Replacing or reconditioning the engine coolant is
essential to good engine performance and service
life. Old or dirty coolant may cause the engine to
engine damage. Extremely dirty conditions may
require coolant to be changed more frequently.

coolant. Contact with hot engine
parts and/or coolant will cause
severe burns.
a manual fuel shutoff valve
engine off and cooled.
All models:
1 Put on protective clothing and eye wear.
Crank the engine with the starter motor for
2 Disconnect the coolant return hose at the
15 seconds, wait 15 seconds, then crank the
radiator and drain the coolant return tank.
engine an additional 15 seconds or until the
pressure reaches 320 psi (22 bar). 3 Remove the radiator cap from the radiator.
13 Connect the wiring and start the engine from
the ground controls. Check the hydraulic tank
for leaks.
Hydraulic system
Hydraulic tank capacity 45 gallons

170 liters
Hydraulic system 50 gallons

capacity (including tank) 189 liters
Hydraulic fluid Dexron ll equivalent
Part No. 32222 Genie S-40 4 - 39

TABLE D PROCEDURES
4 Remove the 2 bolts from the engine pivot plate. 10 Disconnect hose A from hard line B and hold
Swing the engine pivot plate away from the until coolant starts to pour out of the open hose.
machine to access the radiator petcock. Then immediately reconnect the hose.
a b
a hose A
b hard line B
a b a 11 Fill the radiator and then fill the coolant recovery

tank to the NORMAL range.
12 Clean up any coolant spilled during this
a pivot plate retaining bolts procedure.
13 Start the engine from the ground controls,
5 Open the petcock on the radiator and allow run it for 30 seconds, and then turn it off.
all the coolant to drain into a container.
14 Inspect for leaks and then check the fluid
6 After all the coolant has drained, close the level in the coolant recovery tank. Add
petcock. Connect the coolant return hose to water if needed.
the radiator.
15 Start the engine from the ground controls
7 Open the petcock on the engine block and allow and run it until reaching normal operating
the coolant to drain into a container. temperature.
After the fluid is drained, close the petcock.
16 Allow engine to cool and check the fluid level in
8 Replace all coolant hoses and clamps. the coolant recovery tank. Add water if needed.
9 Pour the proper coolant mixture (anti-freeze and
water) for your climate into the radiator until it is Ford Engine LSG-423 11.5 quarts
full. Coolant capacity 10.9 liters
4 - 40 Genie S-40 Part No. 32222

TABLE D PROCEDURES
D-3 a b b b b b b b
Change the Fuel Lines

Maintaining the fuel lines in good condition is
essential to safe operation and good engine
performance. Failure to detect a worn, cracked or
leaking fuel line may cause an unsafe operating
condition.

Replace the fuel lines in an open,
easy reach.
engine off.
1 Close the manual fuel shutoff valve, located
next to the fuel tank.
2 Remove and replace the fuel line hoses and
clamps according to the following illustrations:
Fuel may be expelled under f e d c
pressure. Wrap a cloth around fuel
hoses to absorb leaking fuel Deutz Diesel models
a hose from the injector to
before disconnecting them.
the fuel tank
b hoses connecting injectors
c hose from the fuel shutoff valve
to the fuel pump
d hose from the fuel pump to
the fuel filter
e hose from the fuel filter to the
injection pump
f hose from the injection pump
to the injectors
Part No. 32222 Genie S-40 4 - 41

TABLE D PROCEDURES
a b D-4
Check the Engine Valve
Clearance - Gasoline/LPG Models
D-5
c Check the Engine Cylinder
Compression
d Engine Service Manual (Ford number: 194-216).
Gasoline/LPG models
a fuel filter
b hose from the fuel filter to
the carburetor
c hose from the fuel pump
to the fuel filter
d hose from the fuel shutoff
valve to the fuel pump
3 Clean up any fuel that may have spilled during

this procedure.
inspect the fuel filter and hoses for leaks.
If a fuel leak is discovered, keep
any additional personnel from
entering the area and do not
operate the machine. Repair
the leak immediately.
4 - 42 Genie S-40 Part No. 32222

TABLE D PROCEDURES
D-6 2 Disconnect the hoses from the PCV valve, then

disconnect the hoses from the engine.
Clean the PCV Hoses and
Fittings - Gasoline/LPG Models a b
Maintaining PCV hoses is essential to good engine

performance. Improperly functioning PCV hoses
will fail to ventilate the crankcase and continued
use of neglected hoses could result in component
damage.
Perform this procedure with the c

engine off.
machine to access the PCV hoses.
Shown with distributor cap removed

a PCV valve
b hose, PCV valve to carburetor
c hose, PCV valve to crankcase
3 Clean the hoses with a mild cleaning solvent.

4 Dry both hoses and inspect them for cracks and
damage. Replace the hoses if they are
damaged.
a b a
a pivot plate retaining bolts

Part No. 32222 Genie S-40 4 - 43

TABLE D PROCEDURES
D-7
Check the Fuel Injection Pumps
and Injectors
- Deutz Diesel Models
available in the Deutz FL 1011 Workshop Manual
(Deutz number: 0291 1942). Genie part number
29789.
D-8
Check the Toothed Belt
- Deutz Diesel Models
available in the Deutz FL 1011 Operation Manual
(Deutz number: 0297 4706 EN). Genie part
number 29790.
D-9
Replace the Timing Belt
4 - 44 Genie S-40 Part No. 32222

Service Manual - First Edition Section 5 - Troubleshooting Flow Charts
Troubleshooting Flow Charts
Before Troubleshooting:
Read, understand and obey the safety rules
and operating instructions printed in the
Genie S-40 Operator’s Manual.
Be sure that all necessary tools and test
equipment are available and ready for use.
Observe and Obey:
Read each appropiate flow chart thoroughly.
Troubleshooting and repair procedures shall be Attempting shortcuts may produce hazardous
completed by a person trained and qualified on conditions.
the repair of this machine.
Be aware of the following hazards and follow
Immediately tag and remove from service a generally accepted safe workshop practices.
Crushing hazard. When testing
Repair any machine damage or malfunction or replacing any hydraulic
before operating the machine. component, always support
the structure and secure it
Unless otherwise specified, perform each from movement.
following configuration: Electrocution hazard. Contact
with electrically charged circuits
· machine parked on a flat level surface
may result in death or serious
· boom in stowed position injury. Remove all rings, watches
· turntable rotated with the boom between and other jewelry.
the non-steering wheels
Bodily injury hazard. Spraying
· turntable secured with the turntable hydraulic oil can penetrate and
rotation lock pin burn skin. Loosen hydraulic
· key switch in the OFF position with the connections very slowly to allow
key removed the oil pressure to dissipate
gradually. Do not allow oil to
· wheels chocked
squirt or spray.
Perform all troubleshooting on a
firm level surface.
Two persons will be required to
safely perform some
troubleshooting procedures.

Section 5 - Troubleshooting Flow Charts Service Manual - First Edition
TROUBLESHOOTING FLOW CHARTS
About This Section General Repair Process
When a malfunction is discovered, the flow charts

in this section will help a service professional Malfunction Identify Troubleshoot
pinpoint the cause of the problem. To use this discovered symptoms
section, basic hand tools and certain pieces of test
equipment are required—voltmeter, ohmmeter,
pressure gauges. problem
still exists
The location of terminals mentioned in this section
can be found on the appropriate electrical or Return to Inspect Perform
hydraulic schematics provided in Section 6, service problem and test repair
Schematics. solved
Since various degrees of a particular function

loss may occur, selecting the appropriate flow
chart may be troublesome. When a function will not
operate with the same speed or power as a
machine in good working condition, refer to the
flow chart which most closely describes the
problem.

Chart 1
Engine Will Not Check battery voltage. less than Check battery condition
12V OR check alternator
Crank Over OR check battery
12V or more cables OR replace the
Be sure the key switch battery.
is in the appropriate
position. Check voltage at center 0V Trace circuit back
terminal on start switch. through the key switch,
Be sure the emergency emergency stop button
and CB2, repair open.
stop buttons are pulled 12V
up into the on position.
Hold start switch and 0V Replace start toggle
Be sure the circuit check voltage at either switch.
side terminal on start
breaker(s) are not switch.
tripped.
12V
Hold start switch and 0V Repair blk wire circuit

check voltage at from start switch to
terminal TB33. TB33.
12V
Hold start switch and 0V Repair blk wire circuit

check voltage at from TB33 to start
terminal #3 on start lockout module terminal
lockout module. #3.
12V
Hold start switch and Check/repair open in

check voltage at 0V power supply wire to
terminal #6 and 7 at terminal #6 and 7 on
start lockout module. start lockout module.
12V
Hold start switch and Check ground wire to bad

0V Repair open in ground
check voltage at terminal #5 on start
terminal #1 on start lockout module. wire.
lockout module.
good
12V Consult Genie

Industries Service
Department.
Continued on the next

page.

CHART 1
Hold start switch and 0V Repair open in blk wire

Continued from the from terminal #1 on start
check voltage at
previous page. terminal #85 on CR1. lockout module to CR1.
12V
Check voltage at 0V Repair red wire circuit

terminal #30 on CR1. from battery to CB1 to
CR1 terminal #30.
12V
Hold start switch and Check ground to bad Repair open in ground
0V
check voltage at terminal #86 on CR1. to CR1.
terminal #87 on CR1.
good
12V Replace CR1 relay.
Check voltage at 0V Repair open in blk wire

initiate terminal starter circuit from CR1 to
solenoid. starter solenoid.
12V
Check, repair or
replace starter or starter
solenoid.

Chart 2
Engine Cranks Hold start switch and less Check battery condition
check battery voltage than OR check alternator OR
Over But Will while engine is 11V check for short circuits
cranking. OR check battery
Not Start - cables OR replace the
Gasoline/LPG more than 11V battery.
Models Check if engine coolant continuity Check if radiator and/or hot Check engine coolant
over-temperature engine block feels level OR check radiator
Be sure to check the sending signal post has excessively hot. fins for clogging OR
engine oil level and fill continuity to ground. check engine fan belts
as needed. OR see Ford service
manual for
not hot troubleshooting an
Be sure to check fuel
overheating engine.
levels and engine
coolant level. Remove wht wire from
temperature sending Replace temperature
Be sure the gasoline unit, check continuity to continuity switch sender.
shut-off valve is in the ground.
on position.
no continuity
Be sure that automatic
choke is not sticking no continuity Remove wht wire from Repair short in wht wire
closed. TB24. continuity circuit from TB24 to
temperature sender.
Perform following tests no continuity
in gasoline mode only.
Repair short in wht wire
circuit from terminal #10
start lock out module to
TB24 OR consult Genie
Industries Service
Department.
good
Remove #1 spark plug spark Go to Chart 2A,
and ground spark plug page 5 - 8.
body. Crank engine and
observe spark.
weak or no spark
Disable starter by See Ford service

removing blk wire at the 12V manual for
starter solenoid, hold troubleshooting ignition
start switch and check system.
voltage at positive
terminal on ignition coil.
less than 12V

page.

CHART 2
Hold start switch and Repair open in wht #21

Continued from the check voltage at wht 12V wire to ignition coil.
previous page. #21 on terminal #87 of
CR2.
0V
0V
Check voltage at red Repair open in red wire
wire on terminal #30 of circuit from battery to
CR2. CB1 to CR1 to CR2.
12V
Hold start switch and 0V Hold start switch and Repair open in blk wire
check voltage at check voltage at 12V from terminal #86 on
terminal #86 of CR2. terminal #9 on start CR2 to terminal #9 on
lockout module. start lockout module.
0V
Check voltage at 0V Repair open in power

terminal #6 and 7 on supply wires to terminal
start lockout module. #6 and 7 on start
lockout module.
12V
12V Check ground wire, bad Repair open in ground

terminal #5 on start circuit to start lockout
lockout module. module.
good
Replace the start

lockout module OR
consult Genie Industries
Service Department.
Check ground to no good Repair open in ground

terminal #85 on CR2. wire to CR2.
good

page.

CHART 2
Hold start switch and Repair open in brn #R8

Continued from the check voltage at wht on 12V wire to ignition coil.
previous page. terminal #87 of CR8.
0V
Check voltage at wht 0V Repair open in wht wire

wire on terminal #30 of circuit from terminal #87
CR8. on CR1 to terminal #30
on CR8.
12V
Hold start switch and 0V Repair open in blk wire

check voltage at from terminal #86 on
terminal #86 of CR8. CR1 to #86 on CR8.
12V

good
If weak spark still

exists, contact Genie
Industries Service
Department.

Chart 2A
Engine Cranks Crank engine and check Repair open in white

voltage at automatic #21 wire circuit from
Over But Will choke. 0V ignition module to
automatic choke.
Not Start -
12V
Gasoline/LPG
Models Check automatic choke
bad Adjust or replace
for proper adjustment or automatic choke OR
internal damage. consult Genie Industries
or Service Department.
good
Engine Runs
While Cranking With keyswitch on and
both mushroom
Repair open in red/wht
#36 wire circuit from
0V
Then Dies switches pulled out, TB36 to vacuum switch.
check voltage at red/wht
Continuation of “good #36 wire on vacuum
switch.
spark” fault path.
12V
Perform these tests in
gasoline mode only. 0V bad
Remove the blk wire Turn machine off. See Replace vacuum switch.
with diode from terminal Repair section for
#86 on CR6, crank the vacuum switch check.
engine over for 15
seconds and check
ok
voltage at red/blk wire
on vacuum switch bad
Replace vacuum line.
(reconnect blk wire after Check vacuum line for
test). restrictions.
ok
12V
See Ford service
manual to troubleshoot
low manifold vacuum.
With keyswitch on and
both mushroom
switches pulled out,
disconnect wires from 0V Repair open in red/blk
vacuum switch and wire circuit from vacuum
connect the wires switch to CR6.
together. Check the
voltage at terminal #86
on CR6.
12V

page.

CHART 2A
With keyswitch on and 0V Repair open in red

Continued from the both mushroom power wire circuit with
previous page. switches pulled out, diode.
check voltage at center
terminal on fuel select
switch in platform
control box.
12V
0V
With keyswitch on and Replace toggle switch.
both mushroom
check voltage on
gasoline side (blu/wht
wire) of fuel select
switch.
12V
With keyswitch on and Repair open in blu/wht

0V
both mushroom wire circuit from toggle
switches pulled out, switch to TP38 to TB38.
check voltage at
terminal TB38.
12V
With keyswitch on and 0V Repair open in blu/wht

both mushroom wire circuit from TB38 to
switches pulled out, terminal #30 on CR6.
check voltage at blu/wht
wire at terminal #30 on
CR6.
12V
With keyswitch on and 0V Check ground wire on no good Repair open in ground
both mushroom terminal #85 of CR6. wire.
switches pulled out.
Crank engine and check
good
voltage at terminal #87
on CR6.
Replace CR6.
12V

page.

CHART 2A
Hold start switch and 0V Repair open in blu/wht

Continued from the check voltage at blu/wht #38 wire circuit CR6 to
previous page. wire on anti-diesel valve anti-diesel valve.
(on engine carburetor).
12V
Hold start switch and 0V Repair open in blu/wht

check voltage at blu/wht #38 wire circuit from
#38 wire on gasoline anti-diesel valve to
solenoid (at gasoline gasoline solenoid.
tank).
12V
Hold start switch, does no Reconnect the two

engine fire? wires to vacuum switch
and check for fuel line
blockage OR replace
yes
anti-diesel valve OR see
Ford service manual for
Go to chart 2B, troubleshooting fuel
page 5 - 11. pump and/or carburetor
OR Consult Genie
Industries Service
Department.
5 - 10 Genie S-40 Part No. 32222

Chart 2B
Engine Runs Crank engine and check 0V Crank engine and check 0V Repair or replace
voltage at terminal #2 voltage at org/blk #41 alternator OR contact
While Cranking on start lockout module. wire on alternator. Genie Industries
Service Department.
Then Dies
6 to 7V
Repair open in org/blk

6 to 7V #41 wire circuit from
alternator to TB41 to
terminal #2 on start
lockout module.
While cranking engine yes Disconnect wht #24 wire Check oil level OR
for 15 seconds, check from oil pressure sender replace oil pressure
continuity to ground on and check continuity to yes sending unit OR refer to
terminal #10 start ground on signal post of Ford service manual for
lockout module. Is sender, while cranking troubleshooting low oil
continuity maintained? the engine. Is continuity pressure.
maintained?
no
no Repair short to ground

in wht #24 wire from
sender to TB24 to start
lockout module terminal
#10.
Check voltage at Disconnect red wire Replace start lockout

terminal #4 on start 12V from terminal #4 on start 12V module OR consult
lockout module. lockout module and Genie Industries
check voltage at Service Department.
terminal #4.
0V
0V
Repair short to power in
red wire circuit from
TB27.
Replace start lockout

module OR consult
Genie Industries
Service Department.
Part No. 32222 Genie S-40 5 - 11

Chart 3
Engine Cranks Hold start switch and less Check battery condition
check battery voltage than OR check alternator OR
Over But Will while engine is cranking. 11V check for short circuits
OR check battery cables
Not Start - OR replace the battery.
Deutz Diesel more than 11V
Models Check if engine coolant continuity Check if oil cooler hot Check engine oil level
over-temperature and/or engine block OR oil cooler fins for
Be sure to check the sending signal post has feels excessively hot. clogging OR check
engine oil level and fill continuity to ground. engine fan belts OR see
as needed. Deutz service manual
for troubleshooting an
not hot overheating engine.
Be sure to check
fuel level.
Be sure the diesel Remove wht wire from
temperature sending Replace temperature
shut-off valve is in unit, check continuity to continuity switch sender.
the on position. ground (on wire).
no continuity
no continuity Remove wht wire from Repair short in wht wire

TB24. continuity circuit from TB24 to
temperature sender.
no continuity
Repair short in wht wire

circuit from start lock out
module to TB24 OR
Service Department.
0 or
Disable starter by 12V Turn machine off and infinite Replace the fuel
removing blk wire at the isolate the fuel solenoid. ohms solenoid.
starter solenoid, hold Check the resistance of
start switch and check the solenoid.
voltage at positive
terminal on fuel
solenoid. 3.50 ohms
See Deutz service

0V manual for
troubleshooting fuel
Continued on the next system.
page.
5 - 12 Genie S-40 Part No. 32222

CHART 3
Hold start switch and Repair open in wht #21

Continued from the check voltage at wht 12V wire from CR2 to fuel
previous page. #21 wire on terminal #87 solenoid.
of CR2.
0V
0V
Check voltage at red Repair open in red wire
wire on terminal #30 of circuit from battery to
CR2. CB1 to CR1 to CR2.
12V
Hold start switch and Hold start switch and Repair open in blk wire
0V check voltage at 12V from terminal #86 on
check voltage at
terminal #86 of CR2. terminal #9 on start CR2 to terminal #9 on
0V
Check voltage at 0V Repair open in power

terminal #6 and 7 on supply wires to terminal
start lockout module. #6 and 7 on start lockout
module.
12V
12V Check ground wire, bad Repair open in ground

terminal #5 on start circuit to terminal #5 on
good
Replace the start

lockout module OR
Service Department.

good

page.
Part No. 32222 Genie S-40 5 - 13

CHART 3
Crank engine and check 0V Crank engine and check 0V Repair or replace
Continued from the voltage at org/blk #41 alternator OR contact
previous page. voltage at terminal #2 on
start lockout module. wire on alternator. Genie Industries Service
Department.
6 to 7V
Repair open in org/blk

6 to 7V #41 wire circuit from
alternator to TB41 to
terminal #2 on start
lockout module.
While cranking engine Disconnect wht #24 wire Check oil level OR
for 15 seconds, check yes from oil pressure sender replace oil pressure
continuity to ground on and check continuity to yes sending unit OR refer to
terminal #10 on start ground on signal post of Deutz service manual
lockout module. Is sender, while cranking for troubleshooting low
continuity maintained? the engine. Is continuity oil pressure.
maintained?
no
no Repair short to ground

wht #24 wire from
sender to TB24 to start
terminal #10 on lockout
module.
Check voltage at 12V Disconnect red wire Replace start lockout

terminal #4 on start from terminal #4 on start 12V module OR consult
lockout module. lockout module and Genie Industries Service
check voltage at Department.
terminal #4.
0V
0V
Repair positive short in
red wire circuit from
TB27.
Replace start lockout
module OR consult
Genie Industries Service
Department.
5 - 14 Genie S-40 Part No. 32222

Chart 4
Engine Will Not Disconnect LPG supply

line from LPG tank and
Start On LPG, bleed pressure from
line.
But Will Start
On Gasoline -
Gasoline/LPG With keyswitch on and 0V Replace fuel select
Models both mushroom switch.
Be sure fuel select check voltage at LPG
side (blu/red wire) of
switch is switched fuel select switch.
to LPG.
12V
Be sure to check
LPG fuel level. With keyswitch on and Repair open in blu/red
both mushroom 0V wire circuit from fuel
switches pulled out, select switch to TP39 to
check voltage at TB39. TB39.
12V
With keyswitch on and 0V Repair open in blu/red

check voltage at
12V
Crank engine for 15 0V Repair open in red/blk

seconds and check wire circuit from vacuum
voltage at terminal #86 switch to CR6 to CR7.
on CR7.
12V
Check ground wire to bad Repair open in ground

terminal #85 on CR7. to terminal #85 on CR7.
good

page.
Part No. 32222 Genie S-40 5 - 15

CHART 4
Hold start switch and 0V Replace CR7 relay.

Continued from the check voltage at
previous page. terminal #87 on CR7.
12V
Hold start switch and Repair open in blu/red

check voltage at blu/red 0V wire circuit from CR7
wire on LPG solenoid. terminal #87 to LPG
solenoid.
12V
0 or
infinite
Check resistance of ohms
LPG solenoid. Replace LPG solenoid.
9 to 10 ohms
Reconnect LPG tank

and starter then see
Maintenance section for
LPG adjustments OR
Service Department.
5 - 16 Genie S-40 Part No. 32222

Chart 5
Engine Will With keyswitch on and 0V Replace fuel select

both mushroom switch.
Not Start On switches pulled out,
Gasoline, check voltage at
gasoline side (blu/wht
But Will Start wire) of fuel select
switch.
On LPG -
12V
Gasoline/LPG
Models With keyswitch on and 0V Repair open in blu/wht
both mushroom wire circuit from fuel
Be sure fuel select switches pulled out, select switch to
check voltage at TB38. TP38 to TB38.
switch is switched
to gasoline.
12V
Be sure to check
gasoline fuel level. With keyswitch on and 0V Repair open in blu/wht
Be sure that engine check voltage at
choke is operating terminal #30 on CR6.
properly.
12V
Crank engine for 15 0V Repair open in red/blk

seconds and check wire circuit from vacuum
voltage at terminal #86 switch to CR6.
on CR6.
12V

terminal #85 on CR6. wire to terminal #85 on
CR6.
good
Hold start switch and Repair open in blu/wht

check voltage at blu/wht 0V wire circuit from CR6
wire on anti-diesel valve terminal #87
(on carburetor). to anti-diesel valve OR
replace CR6.
12V

page.
Part No. 32222 Genie S-40 5 - 17

CHART 5
Hold start switch and Repair open in blu/wht

Continued from the check voltage at blu/wht 0V wire circuit from CR6
previous page. wire on gasoline to fuel solenoid.
solenoid (at fuel tank).
12V
0 or
infinite
Check resistance of ohms Replace gasoline
gasoline solenoid. solenoid.
18 to 19 ohms
Check ground wire to bad

gas solenoid. Repair ground wire.
good
0 or
infinite
Check resistance of ohms Replace anti-diesel
anti-diesel valve. valve.
24 to 25 ohms
Reconnect starter,
check anti-diesel and
fuel valve for defects
OR see Ford service
manual for carburetor
troubleshooting.
5 - 18 Genie S-40 Part No. 32222

Chart 6
Engine Start engine and switch 0V Check voltage at center

0V
Repair open in circuit
rpm select to high idle terminal on rpm select supplying 12V to center
High Idle (rabbit symbol) for switch. terminal of switch.
Inoperative - following checks. Check
voltage at blk/red wire 12V
Gasoline/LPG on rpm switch.
Models Replace rpm select

toggle switch.
12V
If high idle operates
on LPG but not on 0V Repair open in blk/red
Check voltage at TB35. wire circuit from toggle
gasoline, see Ford switch to TP35 to TB35.
service manual for 12V
carburetor
troubleshooting. Check voltage at 0V Repair open in blk/red
terminal #30 on CR3. wire circuit from TB35 to
If high idle operates CR3.
on gasoline but not 12V
on LPG, see Repair
section for LPG Check voltage at 0V Repair open in wht #21
regulator adjustments. terminal #86 on CR3. wire circuit from TB21 to
Be sure throttle 12V
linkage from governor
to carburetor is not Check ground wire to bad Repair open in ground
binding, see Repair terminal #85 on CR3. wire to terminal #85 on
CR3.
section.
good
Be sure high idle can
be achieved by grasping Check voltage to 0V Replace CR3 relay.
the governor actuator
arm and momentarily 12V
pulling to throttle the
carburetor. Check voltage at Repair open in blk/red
0V
terminal #86 (blk/red) of wire circuit from
CR4. CR3 to CR4.
12V

CR4.
good

page.
Part No. 32222 Genie S-40 5 - 19

CHART 6
Check voltage at 12V Replace CR4 relay.

Continued from the terminal 5 on
previous page. electronic governor.
0V
Check voltage at 0V Repair open in red/wht

terminal 1 (red/wht wire) wire circuit from TB23 to
on electronic governor. electronic governor.
12V
Check voltage at 0V Repair open in red/wht

terminal 1 (red/wht wire) wire circuit from
on governor actuator. electronic governor to
governor actuator.
12V
Turn engine off, then Repair open in blu/blk

turn machine on but do 0V wire circuit from
not start engine. Check governor actuator to
voltage at terminal 4 electronic governor OR
on electronic governor. check and/or replace
governor actuator.
12V
Turn machine off, 0 or

remove both wires infinite
from governor actuator ohms Replace governor
and check resistance actuator.
across governor
actuator terminals.
2 to 3 ohms
Reconnect governor Repair open in brown

wires and restart engine 0V wire circuit from ignition
and check voltage at module to electronic
electronic governor governor.
terminal 3 (brown wire).
6 to 7V
See Maintenance
section for governor
adjustments OR replace
electronic governor.
5 - 20 Genie S-40 Part No. 32222

Chart 7
Engine Low Idle Start engine and switch Isolate the ground and
rpm select to low idle 12V platform rpm switches,
Inoperative - (turtle symbol). Check check individually and
voltage at terminal #30 replace defective switch.
Gasoline/LPG (blk wire) on CR3.
Models
0V
If low idle operates
on LPG but not on Check voltage at 0V Repair open in wht #21
gasoline, see Ford terminal #30 on CR4. wire circuit from TB21 to
CR3 to CR4.
service manual for
carburetor 12V
troubleshooting. 0V
Check voltage at Replace CR4 relay.
terminal #87A on CR4.
If low idle operates
on gasoline but not
12V
on LPG, see Repair
section for LPG Check voltage at Repair open in blk/red
regulator adjustments. 0V
terminal #5 on wire circuit from CR4
electronic governor. to electronic governor.
Be sure throttle
linkage from governor 12V
to carburetor is not
binding, see Repair Check voltage at 0V Repair open in brown
section. electronic governor wire circuit from ignition
terminal 3 (brown wire). module to electronic
governor.
6 to 7V
Turn machine off, Recheck throttle linkage

remove blu/blk wire from engine goes to high idle (see Repair section) OR
terminal #4 on electronic check and/or replace
governor and restart governor actuator OR
engine. see Ford service manual
for carburetor
troubleshooting.
engine goes to low idle
Recheck electronic
governor adjustments
OR replace electronic
governor.
Part No. 32222 Genie S-40 5 - 21

Chart 8
Engine Start engine, switch rpm Check high idle

solenoid adjustment (see
select switch to high idle
High Idle (rabbit symbol) and pulls in Maintenance section) or
check if 2-speed see Deutz workshop
Inoperative - solenoid pulls in. manual to troubleshoot
Deutz Diesel fuel injection system.
solenoid does
Models not pull in
Check voltage at blk/red 0V Check voltage on center 0V Repair open in circuit
Be sure mechanical wire on rpm select terminal of rpm select supplying 12V to center
linkage is not binding switch. switch. terminal of switch.
or defective.
12V
Be sure PR2 relay 12V
and 2-speed solenoid Replace toggle switch
grounding wires are
0V
free of corrosion and Check voltage at TB35. Repair open in blk/red
have full continuity wire circuit from toggle
switch to TP35 to TB35.
to ground. 12V
Check voltage at 0V Repair open in blk/red

12V
Check voltage to 0V Repair open in wht #21

12V

CR3.
good
Check voltage to 0V
Replace CR3 relay.
12V
Check voltage at initiate 0V Repair open in blk/red

terminal #86 on CR4. wire circuit from
CR3 to CR4.
12V

page.
5 - 22 Genie S-40 Part No. 32222

CHART 8
Check ground wire to bad Repair ground wire to

Continued from the terminal #85 on CR4.
previous page. terminal #85 on CR4.
good
Check voltage to 0V Repair open in wht #21

CR3 to CR4.
12V
Check voltage at the 0V Replace CR4 relay

blk/red wire on the OR repair open in
2-speed solenoid. blk/red wire circuit from
terminal #87 on CR4 to
12V 2-speed solenoid.
solenoid
Check if 2-speed binds Check linkage or
solenoid moves in and replace solenoid.
out freely.
moves freely
Replace 2-speed
solenoid. Note:
resistance across
solenoid terminals
should be approximately
0.3 ohms.
Part No. 32222 Genie S-40 5 - 23

Chart 9
Engine At platform controls, Isolate the platform and

start engine and switch 12V ground rpm switches,
Low Idle rpm select switch to check individually and
maintained low idle replace defective
Inoperative - (turtle symbol). Check switch.
Deutz Diesel volts at blk/red wire on
rpm select switch.
Models
0V
Check if
mechanical linkage 12V
Check voltage at the Replace CR4 relay.
from 2-speed red wire on the
2-speed solenoid.
solenoid to fuel
injection system is
0V
binding or defective.
solenoid
Check if 2-speed binds Check linkage or
solenoid moves in and replace solenoid.
out freely.
moves freely
Check adjustment of
linkage and fuel
injection system low
idle. See Maintenance
section.
ok
See Deutz workshop

manual to troubleshoot
fuel injection system OR
Service Department.
5 - 24 Genie S-40 Part No. 32222

Chart 10
All Functions Check hydraulic low Fill with Dexron II

fluid level. equivalent hydraulic
Inoperative, fluid.
Engine Starts ok
and Runs Check pump suction Open valves. If engine
line shutoff valves. closed has been run with
Valve handles should valves closed, it may
be parallel with hose. have damaged one
or both pumps.
open
Disconnect center coil spline Troubleshoot

wire from distributor cap turns inoperative boom
and isolate from functions and
grounding (Deutz inoperative drive
models, hold manual functions separately.
fuel shutoff lever
counterclockwise).
Remove function pump
from main pump but
leave all hoses
connected. Hold start
switch and crank engine
over while observing
spline drive at rear of
main pump.
spline does not turn
Engine to pump flex

plate coupling is
defective. See
Repair section.
Part No. 32222 Genie S-40 5 - 25

Chart 11
All Lift and Install a 0 to 3000 PSI 2400 Troubleshoot each

pressure gauge on psi function individually or
Steer Functions the function manifold. consult Genie Industries
Start engine, hold the Service Department.
Inoperative, boom retract function
Drive Functions and check the hydraulic
pressure.
Operational
less than 2400 psi
Be sure the hydraulic
suction line shutoff 2400
Adjust the function psi or Hold the boom retract
valve for the lift/steer manifold relief valve more switch and readjust
(item AB) all the way in the relief pressure to
pump is in the open (clockwise) counting 2400 psi.
position. the number of turns.
Hold the boom retract
Be sure all grounding switch and recheck
wires for the hydraulic the pressure.
manifold valves are free
less than 2400 psi
of corrosion and have
full continuity to ground.
Check the function ok Replace the relief valve
pump, see Repair OR manifold has
section. internal defects, consult
Genie Industries
bad Service Department.
Replace the pump.
5 - 26 Genie S-40 Part No. 32222

Chart 12
Ground Does the engine start yes Start the engine from
0V
Repair open in red wire
from the ground the ground controls and circuit from key switch
Controls controls? check the voltage on to function switches.
the center pole (red
Inoperative, wire) of the platform
Platform level switch.
Controls no 12V
Operate
Troubleshoot the
Normally functions individually.
Be sure all other Check voltage at red

functions operate wire on ground controls Repair open in red wire
normally, including contact of the key 0V circuit from emergency
switch (the red wire stop button to the
platform controls. checked should key switch.
originate at the
emergency stop button).
12V
Check voltage at red 0V Check if key switch yes Replace key switch
wire at ground controls internal cam is contact for ground
contact on the key activating ground controls.
switch. contact.
no
12V
Replace key switch.
Repair open in red wire

circuit from key switch
to function switches.
Part No. 32222 Genie S-40 5 - 27

Chart 13
Platform Does engine start from yes Start engine from the 0V Test and replace foot
the platform controls? platform, then press switch OR repair open
Controls down the foot switch in wht wire circuit from
and check voltage at foot switch to TP24.
Inoperative, TP24.
Ground
12V
Controls no
Operate Repair open in wht wire
circuit from TP24 to
Normally function controllers.
Be sure all 0V
Check voltage at TB22. Check for open in red
cables are in good wire circuit from key
condition with no switch to TB22 OR
12V Replace the key switch
kinks or abrasions. platform contacts.
0V
Check voltage at TP22. Repair open in blk-2
wire circuit from TB22
TP22.
12V
Check voltage at blk 0V Replace contact on

wire on platform emergency stop button.
emergency stop button.
12V
0V
Check voltage at TP23. Repair open in blk wire
circuit from emergency
stop button to TP23.
12V
Repair open in blk wire

circuit from TP23 to foot
switch OR replace foot
switch.
5 - 28 Genie S-40 Part No. 32222

Chart 14
Boom Up Hold ground control Repair open in red/wht

function switch up and 0V wire circuit (with diode)
Function check volts at red/wht from TB3 to proportional
wire on boom function valve.
Inoperative proportional valve.
Be sure all other
3 to 6V
functions operate
normally. 0 or infinite ohms
Remove both wires from Replace coil
valve coil and check
If boom up function resistance across the
operates normally from coil terminals.
the ground controls but
not from the platform 4.5 to 5.5 ohms
controls, troubleshoot
the platform controller. Hold toggle switch up function operates Replace defective
and manually override proportional valve.
See Repair section. proportional valve (push
in button on end of
If boom up function valve spool). Note:
operates normally from Overriding the valve will
require two people. If a
the platform controls but helper is not available,
not from the ground interchange the valve
controls, troubleshoot (item AA) with a like
valve (item Z).
the ground control
toggle switch. See
function inoperative
Repair section.
Hold ground control Repair open circuit in
function switch up. 0V red wire from TB1 to
Check volts at red wire boom function
on boom function directional valve.
directional valve.
12V
Remove both wires from

valve coil. Check
resistance across coil 0 or infinite ohms
Replace coil.
terminals.
4 to 5 ohms
Interchange flow
regulator valve (item Y) function operates Replace defective flow
with a like valve regulator valve.
(item X).

page.
Part No. 32222 Genie S-40 5 - 29

CHART 14
Hold toggle switch up function Check the resistance 0 or

Continued from the and manually override operates of the directional infinite Replace the defective
previous page. directional valve (push valve coils. ohms valve coil(s).
in button on end of
valve spool). Note: 4 to 5 ohms
Overriding the valve will
helper is not available, Replace the valve.
interchange the valve
(item R) with a like
valve (item S).
Interchange check valve function operates Replace defective

(item M) with a like shuttle valve.
valve (item K).
Install a 0 to 3000 PSI Check for mechanical

pressure gauge at the 2400 restrictions keeping
quick disconnect psi boom from moving
coupling on the function OR repair cylinder
manifold and hold the OR cylinder
function switch. counterbalance valve.
less than 2400 psi
Repair cylinder
OR replace cylinder
counterbalance valve
OR manifold has
internal defect, consult
Genie Industries
Service Department.
5 - 30 Genie S-40 Part No. 32222

Chart 15
Boom Down Hold ground control 0V Repair open in red/blk

function switch and wire circuit from TB2 to
Function check volts at red/blk directional valve.
Inoperative wire on boom function
directional valve.
Be sure all other
12V
functions operate
0 or
normally including Hold toggle switch down infinite
boom up function. function Check the resistance
and manually override operates of the down directional ohms Replace the coil.
the down directional valve coil.
If boom down function valve (push in button on
operates normally from end of valve spool).
Note: overriding the 4 to 5 ohms
the ground controls but valve will require two
not from the platform people. If a helper is not Replace the valve.
controls, troubleshoot available, interchange
the valve (item R) with a
the platform controller. like valve (item S).
See Repair section.
If boom down function
operates normally from Install a 0 to 3000 PSI Counting the turns, With boom fully lowered,
the platform controls but pressure gauge at the 1800 adjust the boom down function hold the function down
not from the ground quick disconnect psi relief valve (item F) in all operates switch. Adjust the relief
coupling on the function the way. Then operate valve to read 1800 PSI
controls, troubleshoot manifold and hold the the function down. and replace the cylinder
the ground control function switch. counterbalance valve.
toggle switch. See
Repair section. function inoperative
Check for mechanical

restrictions and/or a
less than 1800 psi condition exists in which
the cylinder
counterbalance valve is
not allowing the cylinder
to retract or the cylinder
has internal defects.
Disconnecting hydraulic
lines or adjusting the
Continued on the next cylinder counterbalance
page. valve in this situation
can be very dangerous
Please consult Genie
Industries Service
Department.
Part No. 32222 Genie S-40 5 - 31

CHART 15
1800 With boom fully lower,

Continued from the Adjust the boom down psi or
relief valve (item F) hold the function down
previous page. more switch. Adjust the relief
in one turn clockwise.
Then, with pressure valve to read 1800 psi.
gauge still attached,
operate the function
down.
less than 1800 psi
Remove the boom down Repair the boom lift

high pressure line from 1800 psi cylinder.
the manifold and cap the
port. Hold down function
and recheck pressure.
less than 1800 psi
Internal defect in
manifold OR one of the
previous tests involving
the pump or manifold
components was
possibly overlooked or
diagnosed incorrectly.
Recheck and/or consult
Department.
5 - 32 Genie S-40 Part No. 32222

Chart 16
Boom Extend Hold ground control 0V Repair open in wht/red

Function check volts at wht/red proportional valve.
Inoperative wire on proportional
valve.
Be sure all other
3 to 6V
functions operate
0 or
normally. Remove both wires from infinite
valve coil and check ohms
If boom extend function Replace coil.
resistance across the
operates normally from coil terminals.
the ground controls but
not from the platform 4.5 to 5.5 ohms
the platform controller. Hold toggle switch in function Replace the defective
extend position and operates proportional valve.
See Repair section. manually override
proportional valve (push
If boom extend function in button on end of
operates normally from valve spool). Note:
overriding the valve will
the platform controls but require two people. If a
not from the ground helper is not available,
controls, troubleshoot interchange the valve
(item Z) with a like valve
the ground control (item AA).
toggle switch. See
Repair section. function inoperative
Interchange flow function Replace defective flow

regulator valve (item X) operates regulator valve.
with a like valve
(item Y).
0 or
Hold toggle switch and Check the resistance of infinite Replace the defective
manually override function the directional valve
operates coil. ohms valve coil.
extend directional valve
(push in button on end
of valve spool). Note: 4 to 5 ohms
helper is not available, Replace the valve.
(item S) with a like valve
(item P).

page.
Part No. 32222 Genie S-40 5 - 33

CHART 16
Install a 0 to 3000 PSI 1200 Counting the turns, function With boom fully
Continued from the
pressure gauge at the psi adjust the boom extend operates extended, hold the
previous page. relief valve (item D) in extend function switch.
quick disconnect
coupling on the function all the way. Then Adjust the relief valve
manifold and hold the operate the extend to read 1200 PSI and
function switch. function. replace the cylinder
counterbalance valve.

restrictions and/or the
less than 1200 psi cylinder has internal
defects. Please consult
Department.
Adjust the boom extend

relief valve (item D) in 1200 With boom fully
one turn clockwise. psi extended, hold the
Then, with pressure extend function switch.
gauge still attached, Adjust the relief valve to
operate the function. read 1200 psi.
less than 1200 psi

1200
Remove the extend psi Repair the cylinder
function pressure line and/or replace cylinder
from the manifold and counterbalance valves.
cap the port. Then, with
pressure gauge still
attached, operate the
function.
less than 1200 psi
Internal defect in
manifold OR one of the
previous tests involving
the pump or manifold
components was
possibly overlooked or
Department.
5 - 34 Genie S-40 Part No. 32222

Chart 17
Boom Retract Hold ground control 0V Repair open in blk/wht

Function check volts at blk/wht directional valve.
Inoperative wire on extend/retract
function valve.
Be sure all other
12V
functions operate
function 0 or
normally including Hold toggle switch down infinite
boom extend function. operates Check the resistance ohms
and manually override of the retract directional Replace the coil.
the retract directional valve coil.
If boom retract function valve (push in button on
operates normally from end of valve spool). 4 to 5 ohms
Note: overriding the
the ground controls but valve will require two
not from the platform people. If a helper is not Replace the valve.
controls, troubleshoot available, interchange
the valve (item S) with a
the platform controller. like valve (item P).
See Repair section.
If boom retract function
operates normally from Install a 0 to 3000 psi 2400 Check for mechanical
the platform controls but pressure gauge at the psi restrictions keeping
not from the ground quick disconnect boom from retracting
coupling on the function OR repair cylinder
controls, troubleshoot manifold and hold the OR replace cylinder
the ground control function switch. counterbalance valve.
toggle switch. See
Repair section. less than 2400 psi
Repair cylinder
OR replace cylinder
counterbalance valve
OR manifold has
Genie Industries
Service Department.
Part No. 32222 Genie S-40 5 - 35

Chart 18
Turntable Hold ground control 0V Repair open in wht/red

Rotate Function check volts at wht/red proportional valve.
Inoperative wire on turntable rotate
function proportional
valve.
Be sure all other
functions operate 4 to 7V
normally. 0 or
Remove both wires infinite
If turntable rotate from valve coil and ohms
Replace the coil.
function operates check resistance across
normally from the the coil terminals.
ground controls but
4.5 to 5.5 ohms
not from the platform
controls, troubleshoot function Replace defective
Hold toggle switch and
the platform controller. manually override operates proportional valve.
See Repair section. proportional valve (push
in button on end of
If turntable rotate valve spool). Note:
function operates require two people. If a
normally from the helper is not available,
platform controls but interchange the valve
(item Z) with a like valve
not from the ground (item AA).
the ground control function inoperative
toggle switch. See
Repair section. Interchange rotation function
function flow regulator operates Replace defective flow
valve (item X) with a regulator valve.
like valve (item Y).
0 or
Hold toggle switch to function Check the resistance infinite Replace the defective
left and manually operates of the directional ohms valve coil(s).
override rotate left valve coils.
directional valve (push
in button on end of 4 to 5 ohms
valve spool). Note:
require two people. If a Replace the valve.
helper is not available,
(item P) with a like valve
(item S).

page.
5 - 36 Genie S-40 Part No. 32222

CHART 18
Interchange check valve function Replace defective

Continued from the operates check valve.
previous page. (item K) with a like valve
(item M).
Install a 0 to 3000 psi Check for mechanical

pressure gauge at the 2400 restrictions keeping
quick disconnect psi turntable from rotating
coupling on the function OR check rotation motor
manifold and hold the OR check rotation brake
function switch. OR check rotation
torque hub.
less than 2400 psi
Repair rotation motor

OR manifold has
Genie Industries
Service Department.
Part No. 32222 Genie S-40 5 - 37

Chart 19
Turntable Hold ground control 0V Repair open in wht/blk

Rotate Left check volts at wht/blk directional valve.
Function wire on rotate function
directional valve.
Inoperative
12V
Be sure all other
0 or
functions operate Remove both wires from infinite
normally including rotate left valve coil and ohms Replace the valve coil.
check resistance across
turntable rotate right the coil terminals.
function.
4 to 5 ohms
If turntable rotate left
function operates Hold toggle switch left
function
normally from the operates Replace the rotate
and manually override directional valve.
ground controls but not rotate left directional
valve (push in button on
from the platform end of valve spool).
controls, troubleshoot Note: overriding the
the platform controller. valve will require two
people. If a helper is not
See Repair section. available, interchange
the valve (item P) with a
If turntable rotate left like valve (item S).
function operates
normally from the function inoperative
platform controls but
2400 function
not from the ground Install a pressure gauge psi Interchange the operates
Replace defective
controls, troubleshoot at the quick-disconnect rotate left and right counterbalance valve.
coupling on the function counterbalance valves
the ground control manifold and hold the (item M and item N on
toggle switch. See function switch. turntable rotation
Repair section. motor).
less than 2400 psi
restrictions keeping
turntable from rotating
Remove the rotate left left OR replace
directional valve OR
function pressure line
from the manifold and repair rotation motor.
cap the port (S2).
Then, with pressure 2400
gauge still attached, psi
operate the function. Repair rotation motor.
less than 2400 psi
Replace the directional

valve OR the manifold
has internal defects OR
Consult Genie
Industries Service
Department.
5 - 38 Genie S-40 Part No. 32222

Chart 20
Turntable Hold ground control 0V Repair open in wht wire

function switch and circuit from TB4 to
Rotate Right check volts at wht wire directional valve.
Function on rotate function
directional valve.
Inoperative
12V
Be sure all other
0 or
functions operate Remove both wires from infinite
normally including rotate right valve coil ohms
and check resistance Replace the valve coil.
turntable rotate right across the coil
function. terminals.
If turntable rotate right 4 to 5 ohms

function operates
normally from the function
Hold toggle switch right operates Replace the rotate
ground controls but and manually override directional valve.
rotate right directional
not from the platform valve (push in button on
controls, troubleshoot end of valve spool).
the platform controller. Note: overriding the
valve will require two
See Repair section. people. If a helper is not
available, interchange
If turntable rotate right the valve (item P) with a
function operates like valve (item S).
normally from the
platform controls but function inoperative
not from the ground 2400 function Replace defective
controls, troubleshoot Install a pressure gauge psi Interchange the operates counterbalance valve.
at the quick-disconnect rotate right and left
the ground control coupling on the function counterbalance valves
toggle switch. See manifold and hold the (item M and item N on
Repair section. function switch. turntable rotation
motor).
less than 2400 psi
restrictions keeping
turntable from rotating
right OR replace
Remove the rotate right directional valve OR
function pressure line repair rotation motor.
from the manifold and
cap the port (S1). 2400
Then, with pressure psi
Repair rotation motor.
gauge still attached,
operate the function.
less than 2400 psi
Replace the directional OR Consult Genie

valve OR the manifold Industries Service
has internal defects. Department.
Part No. 32222 Genie S-40 5 - 39

Chart 21
All Platform Hold ground control 0V Repair org/red wire

function switch and circuit from TB16 to flow
Leveling check voltage at org/red control valve.
Functions wire on platform level
flow control valve.
Inoperative
12V
Be sure all other 0 or
functions operate infinite
Remove both wires from ohms
normally. valve coil and check Replace the coil.
resistance across coil
Be sure both automatic terminals.
and manual platform
4 to 8 ohms
leveling do not operate.
If automatic leveling Remove both hydraulic yes Replace the
hoses from the manifold counterbalance valves,
operates but manual (ports PL1 & PL2). Plug items B & C or valve
leveling does not, the hoses and cap the block A.
troubleshoot Platform manifold fittings.
Operate boom up
Leveling Up Function function and check if
Inoperative. platform levels.
no
Plumb a pressure gauge 2400 Check for mechanical

into the master cylinder psi restrictions OR replace
barrel-end hydraulic the slave cylinder
hose using a tee fitting. counterbalance valves.
Operate boom up
function and read
the pressure.
less than 2400 psi
Deadhead the pressure

gauge into the barrel-
end hydraulic hose from less
the master cylinder and than
raise the boom one inch 2400 psi Repair or replace the
at a time. Continually master cylinder.
monitor the pressure
gauge during boom up.
Do not allow the
pressure to exceed
2500 psi.
2400 psi or more
Repair or replace the

slave cylinder.
5 - 40 Genie S-40 Part No. 32222

Chart 22
Platform Level Hold ground control 0V Repair open in org wire

function switch and circuit from TB14 to
Up Function check voltage at org directional valve.
wire on platform level up
Inoperative function directional
valve.
Be sure all other
functions operate 12V
normally. 0 or
Remove both wires from infinite
If platform level up valve coil and check ohms
Replace the coil.
function operates resistance across the
normally from the coil terminals.
ground controls but
4 to 5 ohms
controls, troubleshoot function
Hold toggle switch and operates Replace the platform
the platform control manually override the leveling directional
toggle switch. See level up directional valve.
Repair section. valve (push in button
on end of valve spool).
If platform level up valve will require two
function operates people. If a helper is not
normally from the available, interchange
the valve (item O) with
platform controls but a like valve (item N).
not from the ground
controls, troubleshoot function inoperative
the ground control
function
toggle switch. See Interchange check valve operates Replace defective
Repair section. (item L) with like valve check valve.
(item K).
2400 2400
Install a pressure gauge psi or Interchange the Disconnecting hydraulic
at the quick disconnect level up and down psi or lines or adjusting the
more more
coupling on the function counterbalance valves cylinder counterbalance
manifold and hold the (items B & C). valves in this situation
function switch. can be very dangerous
function operates Please consult Genie
Industries Service
Department.
less than 2400 psi Replace defective

one of the previous
tests was possibly
overlooked or
Genie Industries
Service Department.
Part No. 32222 Genie S-40 5 - 41

Chart 23
Platform Level Hold ground control 0V Repair open in org/blk

function switch and wire circuit from TB15
Down Function check voltage at org/blk to directional valve.
wire on platform level
Inoperative down function
directional valve.
Be sure all other
normally. 0 or
If platform level down valve coil and check ohms
Replace the coil.
function operates resistance across the
normally from the coil terminals.
ground controls but
4 to 5 ohms
controls, troubleshoot function
Hold toggle switch and operates Replace the platform
the platform control manually override the leveling directional
toggle switch. See level down directional valve.
Repair section. valve (push in button
on end of valve spool).
If platform level down valve will require two
function operates people. If a helper is not
the valve (item O) with
platform controls but a like valve (item N).
not from the ground
the ground control
function
toggle switch. See Interchange check valve operates Replace defective
Repair section. (item L) with like valve check valve.
(item K).
2400 2400
Install a pressure gauge psi or Interchange the level up Disconnecting hydraulic
at the quick disconnect and down psi or lines or adjusting the
more more
coupling on the function counterbalance valves cylinder counterbalance
manifold and hold the (items B & C). valves in this situation
function switch. can be very dangerous
function operates Please consult Genie
Industries Service
Department.
less than 2400 psi Replace defective

one of the previous
tests was possibly
overlooked or
Genie Industries
Service Department.
5 - 42 Genie S-40 Part No. 32222

Chart 24
Platform Rotate Hold ground control Repair open in grn/blk

function switch and 0V wire circuit from TB18 to
Left Function check voltage at grn/blk directional valve.
Inoperative wire on platform rotate
left function directinal
valve.
Be sure all other
normally.
0 or infinite ohms
Remove both wires from Replace the coil.
If platform rotate left valve coil and check
function operates reisitance across coil
normally from the terminals.
ground controls but
4 to 5 ohms
controls, troubleshoot function operates
Hold toggle switch left Replace platform rotate
the platform control and manually override directional valve.
toggle switch. See rotate left directional
Repair section. valve (push in button on
end of valve spool).
Note: overriding valve
If platform rotate left will require two people.
function operates If a helper is not
the valve (item N) with a
platform controls but like valve (item O).
not from the ground
the ground control
toggle switch. See Install a pressure gauge Check for mechanical
Repair section. at quick disconnect 2400 psi or more restrictions OR
coupling on rotate hydraulic rotator or
function manifold and function manifold has
hold function switch. internal defect. Consult
Genie Industries
2400 psi Service Department.

(item H) with like valve check valve.
(item L).
Replace directional
valve OR manifold has
internal defects OR
Service Department.
Part No. 32222 Genie S-40 5 - 43

Chart 25
Platform Rotate Hold ground control Repair open in grn wire

function switch and 0V circuit from TB17 to
Right Function check voltage at grn directional valve.
Inoperative wire on platform rotate
right function directional
valve.
Be sure all other
normally.
0 or infinite ohms
Remove both wires from Replace the coil.
If platform rotate right valve coil and check
function operates reisitance across coil
normally from the terminals.
ground controls but
4 to 5 ohms
controls, troubleshoot function operates
Hold toggle switch right Replace platform rotate
the platform control and manually override directional valve.
toggle switch. See rotate left directional
Repair section. valve (push in button on
end of valve spool).
Note: overriding valve
If platform rotate right will require two people.
function operates If a helper is not
the valve (item N) with a
platform controls but like valve (item O).
not from the ground
the ground control
toggle switch. See Install a pressure gauge 2400 psi or more Check for mechanical
Repair section. at quick disconnect restrictions OR
coupling on rotate hydraulic rotator or
function manifold and function manifold has
hold function switch. internal defect. Consult
Genie Industries
2400 psi Service Department.

(item I) with like valve check valve.
(item L).
Replace directional
valve OR manifold has
internal defects OR
Service Department.
5 - 44 Genie S-40 Part No. 32222

Chart 26
Oscillate Check for linkage bad Re-adjust or replace

Function damage or improper linkage.
linkage set-up. See
Inoperative Repair section, 15-2
How to Set Up the
Be sure all other Directional Valve
Linkage.
function operate
normally. good
Install a pressure gauge Adjust the sequence

at the quick disconnect valve. See Repair
coupling on the oscillate less procedure 15-2, How to
manifold. Disconnect than Adjust the Oscillate
linkage from drive 900 psi Sequence Valve
chassis and manually Pressure OR consult
activate directional Genie Industries
valve while engine is Service Department.
running. Check the
pressure.
900 psi
Consult Genie
Industries Service
Department.
Part No. 32222 Genie S-40 5 - 45

Chart 27
Steer Left Start the engine from 0V Repair or replace the

the platform, press steer microswitch in
Function down foot switch, hold controller handle.
Inoperative the steer switch left and
check voltage at
terminal 8 on the drive
Be sure all other controller (blu wire).
functions operate
normally. 12V
Hold the steer switch 0V Repair open in blu wire

left and check voltage circuit from steer switch
at TB36. to TP36 to TB36.
12V
Hold the steer switch 0V Repair open in blu wire

left and check voltage at circuit from TB36 to
blu wire on steer valve. steer valve.
12V
0 or
steer left coil and check ohms Replace steer left
resistance across coil valve coil.
terminals.
4 to 8 ohms
Replace steer valve OR

Service Department.
5 - 46 Genie S-40 Part No. 32222

Chart 28
Steer Right Start the engine from 0V Repair or replace the

the platform, press steer microswitch in
Function down foot switch, hold controller handle.
Inoperative the steer switch right
and check voltage at
terminal 7 on the drive
Be sure all other controller (blu/blk wire).
functions operate
normally. 12V
Hold the steer switch 0V Repair open in blu/blk

right and check voltage wire circuit from steer
at TB37. switch to TP37 to TB37.
12V
Hold the steer switch Repair open in blu/blk

right and check voltage 0V
at blu/blk wire on wire circuit from TB37
steer valve. to steer valve.
12V
0 or
steer right coil and ohms Replace steer right
check resistance across valve coil.
coil terminals.
4 to 8 ohms
Replace steer valve OR

Service Department.
Part No. 32222 Genie S-40 5 - 47

Chart 29
All Drive Start engine from machine does not move Repair or replace the
ground controls and drive pump.
Functions standing clear of the
Inoperative, tires, momentarily move
pump control override
All Other lever in each direction.
Functions machine moves

Operate
Move to platform, machine Place a jumper wire
Normally press down foot switch, drives between TB30 and no drive Repair open in
hold drive enable TB12 and test drive wht wire circuit from
Be sure the hydraulic switch to either side without holding drive TP30 to TB30.
and try to drive. enable switch.
suction line valve is in
the open position.
machine drives
Be sure machine is
not in the free wheel Replace drive enable
limit switch OR repair
configuration. no drive open in wire circuits
from terminal TB30 to
limit switch and from
limit switch to TB12.
Disconnect drive pump 0 or

electronic displacement infinite
controller (EDC) wires. ohms
Check resistance Replace EDC.
across both wires on
EDC side of quick
disconnect.
20 to 24 ohms
Press down foot switch Correct insufficient

and check voltage at less than 12V voltage supply
horsepower limiter (alternator or battery)
board terminal 1. OR repair open in wht
wire circuit supplying
12V or more 12V to terminal 1.

page.
5 - 48 Genie S-40 Part No. 32222

CHART 29
Switch rpm select 0V Check voltage at TB41. 6 to 7V Repair open in org/blk

Continued from the wire circuit from TB41 to
switch to rabbit with foot
previous page. switch, press down foot horsepower limiter
switch and check 0V terminal 3.
voltage at terminal 3 on
horsepower limiter. Check voltage at Repair open in org/blk
6 to 7V
org/blk wire on engine wire circuit from
alternator. alternator to TB41.
0V
6 to 7V
Repair or replace
alternator.
Press down foot switch

and check voltage at 0V Replace horsepower
terminal 10 on limiter board.
horsepower limiter.
9 to 12V
Press down foot switch Repair open in red wire

and check voltage at 0V circuit from horse power
terminal 6 on drive limiter board to drive
controller. control terminal 6.
9 to 12V

page.
Part No. 32222 Genie S-40 5 - 49

CHART 29
Disconnect drive pump 0V Repair or replace drive

Continued from the controller.
previous page. EDC wires, press down
foot switch, hold drive
controller in full forward
position and check
voltage across
terminals 4 and 5
on drive controller.
4 to 7V
Press down foot switch, Repair open in either

hold drive controller in 0V wht or wht/blk wire
full forward position circuit from drive
and check voltage controller to TP30 and
across terminals TP31 respectively.
TP30 and TP31.
4 to 7V
Press down foot switch,

hold drive controller in Repair open in either
full forward position 0V
wht or wht/blk wire
and check voltage circuit from TB30 and
across terminals TB31 respectively.
TB30 and TB31.
4 to 7V
Press down foot switch, Repair open in wht/blk

hold drive controller in wire circuit from TB31 to
full forward position and 0V EDC quick disconnect
check voltage across OR repair open in wht
the two wires at EDC wire circuit from TB30 to
quick disconnect. EDC quick disconnect.
4 to 7V
Replace drive pump

EDC OR consult Genie
Industries Service
Department.
5 - 50 Genie S-40 Part No. 32222

Chart 30
Drive Forward Disconnect the EDC voltage readings different Repair or replace the
wire connector from the drive controller.
Or Reverse drive pump, start
Function engine, move the drive
controller to full forward
Inoperative position and note the
voltage across terminals
TB30 and TB31.
Be sure all other Reverse the volt meter
functions operate leads and move the
normally including drive controller to full
reverse position and
drive in opposite note the voltage.
direction of
malfunction. voltage readings the same
Adjust the drive pump Defective Sundstrand

null (neutral). See no improvement drive pump, contact
Sundstrand Series 40 Sundstrand authorized
Service Manual. repair facility.
symptoms improve
Check all drive speeds

and monitor for recurring
symptoms. Possible
contamination in
hydraulic system.
Part No. 32222 Genie S-40 5 - 51

Chart 31
Traction Any type of traction

problem, consult Genie
Function Industries Service
Department.
Inoperative
Be sure all other
functions operate
normally.
5 - 52 Genie S-40 Part No. 32222

Chart 32
Machine Will With boom fully stowed, full Repair or replace boom
check TB40 for continuity lift drive limit switch or
Not Drive At continuity to ground. boom extend limit
switch.
Full Speed
no continuity
Be sure all other
With boom fully stowed, full Orange wire shorted
functions operate
check horsepower continuity to ground, repair
normally. limiter board terminal 6 orange wire circuit from
for continuity to ground. TB40 to horsepower
Be sure the free-wheel limiter board.
valve is closed on the no continuity
drive pump.
Re-adjust or replace
horsepower limiter
board. See Repair
section OR consult
Genie Industries
Service Department.
Part No. 32222 Genie S-40 5 - 53

Chart 33
Machine Drives Raise boom off drive full Disconnect electronic Defective Sundstrand
limit switch, turn continuity displacement controller 0 to 3V drive pump. Replace or
At Full Speed machine off and check (EDC) wires on drive repair at authorized
continuity between pump, move drive Sundstrand repair
With Platform ground and terminal 6 controller to full forward facility.
Raised or on horsepower limiter position and check
board. voltage between
Extended terminals 4 and 5
on drive controller.
Remove machine from
service immediately. 4 to 7V
no continuity
Be sure boom lift drive Replace horsepower
limit switch or boom limiter board.
extend drive limit switch
full
is not being held down Check continuity continuity Repair open in org wire
or up. between ground circuit from TB40 to
and TB40. horsepower limiter
board terminal 6.
Be sure wiring to limit
switches is intact and no continuity
shows no sign of
Repair limit switch
tampering. wiring OR replace boom
lift drive limit switch OR
Be sure orange wire replace boom extend
(cable 1) is properly drive limit switch.
attached to horsepower
limiter.
5 - 54 Genie S-40 Part No. 32222

Chart 34
Drive Enable Do not hold the drive Will holding the drive Troubleshoot
enable switch and no enable switch allow no horsepower limit board,
System Is check if machine will boom to drive in drive controller or
drive in the stowed stowed position over drive pump. See chart
Malfunctioning position with boom over non-steer wheels? 30.
non-steer wheels?
yes
yes Repair or replace drive

enable limit switch.
Do not hold the drive

enable switch and
check if machine will yes Repair or replace drive
drive in the stowed enable limit switch.
position with boom over
the steer wheels?
no
Will holding the drive

enable switch allow
boom to drive in
stowed position over
steer wheels?
no
Repair or replace drive

enable toggle switch.
Part No. 32222 Genie S-40 5 - 55

Chart 35
Auxiliary With engine not running pump Deadhead a pressure less than Hold auxiliary switch
lift switch cover, hold runs gauge into the pressure 2000 psi and adjust pump relief
Functions auxiliary switch and line of the auxiliary valve or replace pump.
listen for sound of pump and hold the
Inoperative auxiliary pump running. auxiliary power switch.
Be sure all other
2000 psi
functions operate
normally. Reconnect pressure
line and check battery
Be sure key switch condition. There is
pump does not run
is in the appropriate possibly not enough
position and the battery capacity to
operate both aux. pump
emergency stop and function valves.
buttons are pulled
up into the on
Hold the auxiliary power Replace defective
position. switch and check the 0V
voltage at terminal auxiliary power
Be sure engine is TB27. toggle switch.
not running when
using auxiliary 12V
power.
Hold the auxiliary power
Note: Operating switch and check the Repair open in red wire
voltage at initiate 0V
auxiliary power with circuit from
terminal (red wire) on TB27 to PR1.
the engine running PR1 motor start
should immediately solenoid.
kill the engine.
12V
Hold the auxiliary power

switch and check the 0V
voltage at positive Replace PR1 relay.
power cable on auxiliary
power unit.
12V
Check auxiliary power

unit grounding cable
OR repair or replace
electric motor.
5 - 56 Genie S-40 Part No. 32222

Service Manual - First Edition Section 6 - Schematics
Schematics
About This Section

There are two groups of schematics in this
section. An illustration legend precedes each
group of drawings.
Electrical Schematics
Observe and Obey: Electrocution hazard. Contact

with electrically charged circuits
Troubleshooting and repair procedures shall be may result in death or serious
completed by a person trained and qualified on injury. Remove all rings, watches
the repair of this machine. and other jewelry.
Immediately tag and remove from service a Hydraulic Schematics
Repair any machine damage or malfunction hydraulic oil can penetrate and
before operating the machine. burn skin. Loosen hydraulic
connections very slowly to allow
Before Troubleshooting: the oil pressure to dissipate
Read, understand and obey the safety rules
squirt or spray.
and operating instructions printed in the Genie
S-40 Operator's Manual. General Repair Process
Be sure that all necessary tools and test
equipment are available and ready for use. Malfunction Identify Troubleshoot
discovered symptoms
problem
still exists
Return to Inspect Perform

service problem and test repair
solved

Section 6 - Schematics Service Manual - First Edition
Electrical Symbols Legend
TB17
15AMP.
PR5
WTS1 N.O.
ORG/BLK-1
BLK
Circuit breaker
GRN/BLK
Water temperature Starter motor
Wire color switch relay
with cable normally closed
number
WHT #51
TB20
Solenoid or Ground FS1 TR2
RED
relay coil supression BLK 1 T 6
circuit 3
2
Terminal Foot switch
Time delay relay
TILT
ALARM
TP29 LS4
NC 3 6
NO
1 T
PLAT
Quick disconnect Horn
Limit switch KS1
2 TR1
terminal
GRND
Time delay relay
BLK #21 TB21 Key switch
LS1
T-circuits connect L4 OP NO
at terminal TS3
Light Limit switch

normally open
START
ENGINE
HORN P4
held closed
T-circuits Toggle switch SPDI
connect Horn button
normally open
10
TS6
Resistor LS2
NC
LEFT
RIGHT
Connection Limit switch P1
no terminal normally closed Toggle switch DPDT
held open Emergency Stop
button BP2
normally closed
PWM
A
+
-
X
Circuits crossing Tilt sensor R
no connection VAC
Single axis
CR4
Vacuum switch proportional

controller
Relay contact
Diode Spark plug normally open
BP1
PWM PWM
OPS1 N.C.
+ A A
+ +
- -
PR4 X X
R R
-
Oil pressure
switch Relay panel Dual axis
Glow plug normally closed contactor proportional
Battery controller

Service Manual Section 6 - Schematics
Electrical Schematic -
Gasoline/LPG Models
HIGH RPM
TP35
ENGINE SPEED
TS4
BLK/RED-1
TS12
ENGINE SPEED
CR3
CR4
NO
HIGH RPM BLK/RED

HIGH IDLE RELAY
TB35
CR3
HIGH IDLE CUTOUT

RELAY
GOVERNOR
ACTUATOR
RED/WHT-E.H.
CR4
1
NC
BLU/BLK-E.H.
2
BLK/RED#R4-E.H.
TP39
ELECTRONIC
GOVERNOR
BLU/RED-1 RED/WHT#23-E.H.
TS3
5
2
3
4
6
1
LP FUEL
GAS BLU/WHT-1
TP38
TS11
BLU/RED#R7-E.H.
LPG SOLENOID
TB39
CR7
LP FUEL
NO
GAS BLU/WHT#R6-E.H.
ANTI-DIESEL VALVE
TB38
CR6
NO
BLU/WHT#R6-E.H.
GASOLINE SOLENOID
FB
FLASHING BEACONS
CR6 CR7
RED/WHT#23-E.H. RED/BLK#R6-E.H.
FUEL RELAY
VAC
IGN./START
MODULE
TP33
WHT
HM
BLK-1 HOUR METER

TS2
3 START INPUT
1 START RELAY
9 IGN./FUEL ON
2 TACHOMETER
8 KEY BYPASS
10 ENG. FAULT
KEY PWR.
BATTERY
GROUND
AUX. ON
ENGINE
TS10
START OIL PRESSURE

TB24
OPS1
NC
SENDER
TB33
5
4
6
7
ENGINE WHT#24-E.H.
WATER TEMP.
WTS1
START BLK SENDER

NO
CR2
TB21
CR2
NO
AUTOMATIC
blk CHOKE
IGNITION
org
MODULE
pur
RED
WHT
GRN
DISTRIBUTOR
WHT#21-E.H. RED
RESISTOR
G
IGNITION
WIRE
-
SYSTEM
COIL
CR8
CR8
NO
+
CR1
BLK#R1-E.H.
CR1
NO
STARTER
STARTER MOTOR
TS9
GRN
WHT
TB27
TS1
PR1
TP25
RED RED#27-E.H.
TP27
AUXILIARY POWER
TB24
RELAY
RED-1
GRN
AUX PUMP
AUXILIARY PUMP
GRN
PR1
NO
TP19
TB19
FS1
WHT GRN/WHT-3 GRN/WHT#19-E.H.

BLK
TP23
TB23
WHT WHT-2 RED/WHT#23-E.H.

LEVEL SENSOR
BLK
TP26
BLK
HORN
TP9
CR5
P3
P2
BLK BLK/RED-3 BLK/RED

SERVICE HORN
TP22
RELAY
TB9
TB22
CR5
NO
BLK-2 BLK-6
SERVICE HORN
PLAT
GRND
KS1
RED
P1
Service Manual
Part No. 32222

BRN/BLK-E.H.
TB41
ORG/BLK-1 ORG/BLK#41-E.H.
RED
STA.
FLD.
RED
ALTERNATOR
S F
WHT#21-E.H.
REGULATOR
15AMP.
15AMP.
RED-E.H.
VOLTAGE
BAT.
I A
GRD.
CB1
CB2
Gasoline/LPG Models
Genie S-40
TB20
-
RED RED#20-E.H.
Section 6 - Schematics
6-3
Gasoline/LPG Models
6-4
Genie S-40
Service Manual
Part No. 32222
GRN-2
GROUND
TP13
TB13
LS3
BLU/RED-3 WHT-5
D.E.
GRN-5
L1
TB30
DRIVE ENABLE
LIMIT SWITCH
WHT-1 RED-5 BLK-5
TB12
WHT#12-E.H.
TS8
TP30
TP12
DRIVE ENABLE BLU/WHT-3

TP31
TB31
WHT/BLK-1 WHT/BLK#31-E.H. DRIVE EDC

TP32
TB32
WHT/RED-1 WHT/RED#32-E.H.
BRAKE
TP37
TB37
BLU/BLK-1 BLU/BLK#37-E.H.
STEER RIGHT
TB36
BLU-1 BLU#36-E.H.
STEER LEFT
TP36
1
3
5
7
8
2
4
6
DP1
RED
TB40
LS2
NC
ORG-1 WHT-6 GRN-6

TP41
BOOM UP
LIMITER
TP40
LIMIT SWITCH
LS1
HORSE
POWER
BOARD
NC
10
7
3
5
8
9
1
2
4
6
WHT-7 BLK-7
BOOM EXTEND
LIMIT SWITCH
TP6
WHT/RED-3
TP5
WHT/BLK-3
WHT-3 WHT
TP4
WHT-4
TURNTABLE ROTATE R
RIGHT
TB4
WHT/BLK
TURNTABLE ROTATE
LEFT WHT/BLK-4
TS17
TURNTABLE ROTATE L
TB5
PWM
R
+
A
X
BP1
TURNTABLE ROTATE
WHT/RED-4
& EXTEND RETRACT
TB6
FLOW CONTROL
RED
TB1
RED-4
PRIMARY BOOM UP
UP RED/BLK
PRIMARY BOOM
TB2
DOWN
PWM
RED/BLK-4
-
R
+
A
TS16
PRIMARY BOOM DOWN

TB3
RED/WHT-4
PRIMARY BOOM
TP1
FLOW CONTROL
RED-3
RED/BLK-3
TP2
TP3
RED/WHT-3
TP7
BLK-3
EXTEND
BOOM
RETRACT BLK/WHT-3
TS7
R1
TP8
BLK-4
BOOM EXTEND
10 EXTEND TB7 BLK/WHT
BOOM
RETRACT BLK/WHT-4
TS15
BOOM RETRACT
TB8
R2
15
BLK/RED-4
TP14
ORG-3
UP
PLATFORM LEVEL
DOWN ORG/BLK-3 ORG
TS6
TP15
TS14
ORG-4
PLAT LEVEL UP
TB14
UP PLATFORM LEVEL ORG/BLK
DOWN ORG/BLK-4
PLAT LEVEL DN
TB15
TB16
TP16
ORG/RED-4
PLAT LEVEL F.C.
ORG/RED-3
TP17
GRN-3
LEFT
PLATFORM ROTATE
RIGHT GRN/BLK-3 GRN
TS5
TS13
TP18
GRN-4
PLATFORM ROTATE LEFT
TB17
LEFT GRN/BLK
PLATFORM ROTATE
RIGHT GRN/BLK-4
PLATFORM ROTATE RIGHT
TB18
Ground Control Box Legend -

Gasoline/LPG Models
GRN/WHT-1 45 SPARE
GRN/BLK-1 44 SPARE
GRN-1 43 SPARE
ORG/RED-1 42 SPARE
G1 G2 G3
CABLE OG/BK E.H.ORG/BLK-1 41 PULSE PICKUP
ORG-1 40 WHT-7 WHT-6 LIMIT SWITCH
#7
BLU/RED-1 39 BU/RD CR7 BU/RD S.P. L.P.
BLU/WHT-1 38 BU/WT CR6 BU/WT S.P. GAS
BU/BK E.H. BLU/BLK-1 37 STEER LEFT
BLU E.H. BLU-1 36 STEER PIGHT
BLK/RED-1 35 BK/RD S.P. RPM
CABLE BLK/WHT-1 34 GLOW PLUG
BLK CR1 BLK-1 33 BLK S.P.
P1 KS1 #6
WT/RD E.H.WHT/RED-1 32 WT/RD D.B.
START
TS9 31
BRAKE
WT/BK E.H. WHT/BLK-1 E.D.C.
NC
WHT-1 30 RED-5 E.D.C.
NO NO 29
R/W-1 2WD/4WD
NC RED/BLK-1 28 SPARE
CABLE RED E.H. RED-1 27 RED D.B. RED S.P. AUX. PWR.
#5 WT/RD E.H. 26 WT/RD S.P. TEMP. SENDER
WT/BK E.H. 25 WT/BK S.P. OIL PRESSURE SENDER
WHT E.H. 24 WHT S.P. WARNING SENDER
WHT E.H. WHT-2 23 WHT S.P. KEYSWITCH PWR.
BLK-2 22 BLK CR5 BLK S.P. PWR. TO PLAT.
WHT E.H. WHT CR2 21 WHT S.P. IGNITION PWR.
RED E.H. 20 RED S.P. 12V BATT. SUPPLY
GRN/WHT-4 GRN/WHT-3 19 TILT ALARM
GRN/BLK-4 GRN/BLK-3 18 GR/BK D.B. GR/BK S.P. PLAT. ROT. R.
HM TS15 TS16 GRN-4 GRN-3 17 GRN D.B. GRN S.P. PLAT. ROT. L.
CABLE ORG/RED-4 ORG/RED-3 16 OG/RD D.B. OG/RD S.P. PLAT. LEVEL F.C.
#1 ORG/BLK-4 ORG/BLK-3 15 OG/BK D.B. OG/BK S.P. PLAT. LEVEL DN.
ORG-4 ORG-3 14 ORG D.B. ORG S.P. PLAT. LEVEL. UP
BLU/RED-3 13 WHT-5 DRV. ENA. LT.
WHT-E.H. BLU/WHT-3 12 BLK-5 DRV. ENA.
BLU/BLK-4 BLU/BLK-3 11 BU/BK D.B. BU/BK S.P.
TS11 TS17 BLU-4 BLU-3 10 BLU D.B. BLU S.P.
TS10 BLK/RED-3 9 BK/RD CR4 HORN
BLK/WHT-4 BLK/WHT-3 8 BK/WT D.B. BK/WT S.P. BOOM RETRACT
BLK-4 BLK-3 7 BLK D.B. BLK S.P. BOOM EXTEND
W/R-4 WHT/RED-3 6 WT/RD S.P. TURN. ROT. F.C.
CABLE WHT/BLK-4 WHT/BLK-3 5 WT/BK D.B. WT/BK S.P. TURN. ROT. L
#2 4 WHT D.B.
TS14 WHT-4 WHT-3
3
WHT S.P. TURN. ROT. R
R/W-4 RED/WHT-3 RD/WT S.P. BOOM F.C.
TS12 CB1 CB2 TS13 RED/BLK-4 RED/BLK-3 2 RD/BK D.B. RD/BK S.P. BOOM DOWN
RED-4 RED-3 1 RED D.B. RED S.P. BOOM UP
D C B A
R2
DIODE
BLOCKS
CABLE
#3
LABEL DESCRIPTION 1 START RELAY

P1 EMERGENCY STOP BUTTON 2 TACHOMETER IGN./START
KS1 KEY SWITCH MODULE
3 START INPUT
TS9 AUXILIARY SWITCH
TS10 ENGINE START SWITCH 4 AUX. ON
TS11 ENGINE FUEL SELECT SWITCH 5 GROUND

TS12 ENGINE RPM SWITCH
6 BATTERY
TS13 PLATFORM ROTATE SWITCH
TS14 PLATFORM LEVEL SWITCH 7 KEY PWR.
CABLE
TS15 BOOM EXTEND/RETRACT SWITCH 8 KEY BYPASS
#4
TS16 BOOM UP/DOWN SWITCH
9 IGN./FUEL ON
TS17 TURNTABLE ROTATE SWITCH
10 ENG. FAULT
CB1 CIRCUIT BREAKER, CONTROLS, 15A
CB2 CIRCUIT BREAKER, ENGINE, 15A
CR1 CR2 CR3 CR4
HM HOUR METER
START IGNITION RPM RPM
R2 RESISTOR, 10 OHM, BOOM FUNCTIONS
RELAY RELAY CUTOUT RELAY
RELAY
G1 VOLT METER GAGE
G2 OIL PRESSURE GAGE
G3 WATER TEMP. GAGE
CR5 CR6 CR7 CR8

HORN FUEL FUEL BALLAST
RELAY CUTOUT CUTOUT BYPASS
RELAY RELAY RELAY
ENGINE
HARNESS

Section 6 - Schematics Service Manual
Relay Panel Legend -

Gasoline/LPG Models
IGNITION COIL VOLTAGE REG.
I A S F
PUR
IGNITION MODULE
ORG
BLK
GRN
RED
WHT
6 5 4 3 2 1
GOVERNOR

Platform Control Box Legend -

Gasoline/LPG Models
NC NC
STOP
P2
SELECT
TS3
FUEL
DP1
8 7 6 5 4 3 2 1
R.P.M.
TS4
HIGH
SPARE 45 GRN/WHT-1
SPARE 44 GRN/BLK-1
START
SPARE 43 GRN-1
TS2
SPARE 42 ORG/RED-1
PULSE PICKUP 41 ORG/BLK-1
LED
L1
LIMIT SWITCH 40 ORG-1
L.P. 39 BLU/RED-1
GAS 38 BLU/WHT-1
STEER LEFT 37 BLU/BLK-1
STEER RIGHT 36 BLU-1
RPM 35 BLK/RED-1
DRIVE ENABLE
GLOW PLUG 34 BLK/WHT-1
START 33 BLK-1
TS8
BRAKE 32 WHT/RED-1
E.D.C. 31 WHT/BLK-1
E.D.C. 30 WHT-1
2WD/4WD 29 RED/WHT-1
SPARE 28 RED/BLK-1
AUX. PWR. 27 RED-1
PWR. TO F.S. 26 BLK (F.S.)
PWR. (START) 25 GREEN (F.S.)
PWR. (CONT.) 24 WHT (H.P.L.)
PWR. FRM PLAT. 23 WHT-2
PWR. TO PLAT. 22
AUX.
TS1
BLK-2
21
RETRACT
20
EXTEND
F.S.
TS7
TILT ALARM 19 GRN/WHT-3
PLAT. ROT. R. 18 GRN/BLK-3
PLAT. ROT. L. 17 GRN-3
PLAT. LVL. F.C. 16 ORG/RED-3
PLAT. LVL. DN. 15 ORG/BLK-3
PLAT. LVL. UP 14 ORG-3
DRV. ENA. LT. 13 BLU/RED-3
110
DRV. ENA. 12 BLU/WHT-3
SEC. BOOM DN. 11 BLU/BLK-3
SEC.BOOM UP 10 BLU-3
PLATFORM
ROTATE
HORN 9 BLK/RED-3
TS5
RETRACT 8 BLK/WHT-3
CABLE
EXTEND 7 BLK-3
#1
ROTATE F.C. 6 WHT/RED-3
ROTATE RIGHT 5 WHT/BLK-3 A - X R
+
ROTATE LEFT 4 WHT-3
BOOM F.C. 3 RED/WHT-3
PLATFORM
BOOM DN. 2 RED/BLK-3
LEVEL
BP1
TS6
BOOM UP 1 RED-3
CABLE
HORSE POWER LIMITER
#2
X -
R A
+
CABLE
GRN-2
1 2 3 4 5 6 7 8 9 10
#3
NO
HORN
P3
ALARM
STUD
GRD.
TILT
Diesel Models
Diesel Models
P2 FS1 TP25
TP22 TP26 GRN GRN GRN
BLK BLK BLK
WHT
TB24
WHT
TS1 TS2 TS4
START
HIGH RPM
BLK-2
WHT
ENGINE
ENGINE SPEED
P3
TP23
HORN
BLK
CB2 TB22
KS1 TP9 TP19 TP27 TP33 TP35
15AMP. P1
RED RED PLAT
GRND
WHT-2
GRN/WHT-3
BLK/RED-3
BLK/RED-1
RED-1
BLK-1
TS9 TS10 TS12
HIGH RPM
START
ENGINE
ENGINE SPEED
ORG/BLK-1
BLK
RED
TB19 TB27
TB23 TB33
TB9 TB35
TB41 1 START RELAY
BLK/RED
2 TACHOMETER IGN./START
RED
CB1 3 START INPUT MODULE

4 AUX. ON
15AMP.
5 GROUND
TB20 RED
6 BATTERY
7 KEY PWR.
RED#20-E.H.
8 KEY BYPASS
9 IGN./FUEL ON
CR1 10 ENG. FAULT
CR1 CR2 CR2
NO NO
BLK#R1-E.H.
TB21
CR3 CR3
NO
RED/WHT#23-E.H.
GRN/WHT#19-E.H.
RED#27-E.H.
ORG/BLK#41-E.H.
BLK/RED
CR4 CR4
NO
WHT#21-E.H.
BLK/RED#R4-E.H.
TB24
WHT#24-E.H.
PR1 PR1
NO
WHT
ALTERNATOR
EXCT.
CR5 CR5
NO
BAT. BAT.
+ + -
BLK-6
STA.
STARTER WTS1
AUX PUMP HM
NO
REGULATOR
IND. OPS1
-
NC
SERVICE HORN
RELAY
SERVICE HORN
LEVEL SENSOR
RELAY
AUXILIARY POWER
FUEL SOLENOID
SENDER
WATER TEMP.
SENDER
OIL PRESSURE
HOUR METER
RPM SOLENOID
RELAY
HIGH IDLE CUTOUT
HIGH IDLE RELAY

AUXILIARY PUMP
STARTER MOTOR

Diesel Models
6-9
Genie S-40
Service Manual
Part No. 32222
GRN-2
GROUND
TP13
TB13
LS3
BLU/RED-3 WHT-5
D.E.
GRN-5
L1
TB30
DRIVE ENABLE
LIMIT SWITCH
WHT-1 RED-5 BLK-5
TB12
WHT#12-E.H.
TS8
TP30
TP12
DRIVE ENABLE BLU/WHT-3

TP31
TB31
WHT/BLK-1 WHT/BLK#31-E.H. DRIVE EDC

TP32
TB32
WHT/RED-1 WHT/RED#32-E.H.
BRAKE
TP37
TB37
BLU/BLK-1 BLU/BLK#37-E.H.
STEER RIGHT
TB36
BLU-1 BLU#36-E.H.
STEER LEFT
TP36
1
3
5
7
8
2
4
6
DP1
RED
TB40
LS2
NC
ORG-1 WHT-6 GRN-6

TP41
BOOM UP
LIMITER
TP40
LIMIT SWITCH
LS1
HORSE
POWER
BOARD
NC
10
7
3
5
8
9
1
2
4
6
WHT-7 BLK-7
BOOM EXTEND
LIMIT SWITCH
TP6
WHT/RED-3
TP5
WHT/BLK-3
WHT-3 WHT
TP4
WHT-4
TURNTABLE ROTATE R
RIGHT
TB4
WHT/BLK
TURNTABLE ROTATE
LEFT WHT/BLK-4
TS17
TURNTABLE ROTATE L
TB5
PWM
R
+
A
X
BP1
TURNTABLE ROTATE
WHT/RED-4
& EXTEND RETRACT
TB6
FLOW CONTROL
RED
TB1
RED-4
PRIMARY BOOM UP
UP RED/BLK
PRIMARY BOOM
TB2
DOWN
PWM
RED/BLK-4
-
R
+
A
TS16
PRIMARY BOOM DOWN

TB3
RED/WHT-4
PRIMARY BOOM
TP1
FLOW CONTROL
RED-3
RED/BLK-3
TP2
TP3
RED/WHT-3
TP7
BLK-3
EXTEND
BOOM
RETRACT BLK/WHT-3
TS7
R1
TP8
BLK-4
TB7 BOOM EXTEND
10 EXTEND BLK/WHT
BOOM
RETRACT BLK/WHT-4
TS15
BOOM RETRACT
TB8
R2
15
BLK/RED-4
TP14
ORG-3
UP
PLATFORM LEVEL
DOWN ORG/BLK-3 ORG
TS6
TP15
TS14
ORG-4
PLAT LEVEL UP
TB14
UP PLATFORM LEVEL ORG/BLK
DOWN ORG/BLK-4
PLAT LEVEL DN
TB15
TB16
TP16
ORG/RED-4
PLAT LEVEL F.C.
ORG/RED-3
TP17
GRN-3
LEFT
PLATFORM ROTATE
RIGHT GRN/BLK-3 GRN
TS5
TS13
TP18
GRN-4
PLATFORM ROTATE LEFT
TB17
LEFT GRN/BLK
PLATFORM ROTATE
RIGHT GRN/BLK-4
PLATFORM ROTATE RIGHT
TB18
Ground Control Box Legend -

Diesel Models
GRN/WHT-1 45 SPARE
GRN/BLK-1 44 SPARE
GRN-1 43 SPARE
ORG/RED-1 42 SPARE
G1 G2 G3
CABLE OG/BK E.H.ORG/BLK-1 41 PULSE PICKUP
ORG-1 40 WHT-7 WHT-6 LIMIT SWITCH
#7
BLU/RED-1 39 BU/RD CR7 BU/RD S.P. L.P.
BLU/WHT-1 38 BU/WT CR6 BU/WT S.P. GAS
BU/BK E.H. BLU/BLK-1 37 STEER LEFT
BLU E.H. BLU-1 36 STEER PIGHT
BLK/RED-1 35 BK/RD S.P. RPM
CABLE BLK/WHT-1 34 GLOW PLUG
BLK CR1 BLK-1 33 BLK S.P.
P1 KS1 #6
WT/RD E.H.WHT/RED-1 32 WT/RD D.B.
START
TS9 31
BRAKE
WT/BK E.H. WHT/BLK-1 E.D.C.
NC
WHT-1 30 RED-5 E.D.C.
NO NO 29
R/W-1 2WD/4WD
NC RED/BLK-1 28 SPARE
CABLE RED E.H. RED-1 27 RED D.B. RED S.P. AUX. PWR.
#5 WT/RD E.H. 26 WT/RD S.P. TEMP. SENDER
WT/BK E.H. 25 WT/BK S.P. OIL PRESSURE SENDER
WHT E.H. 24 WHT S.P. WARNING SENDER
WHT E.H. WHT-2 23 WHT S.P. KEYSWITCH PWR.
BLK-2 22 BLK CR5 BLK S.P. PWR. TO PLAT.
WHT E.H. WHT CR2 21 WHT S.P. IGNITION PWR.
RED E.H. 20 RED S.P. 12V BATT. SUPPLY
GRN/WHT-4 GRN/WHT-3 19 TILT ALARM
GRN/BLK-4 GRN/BLK-3 18 GR/BK D.B. GR/BK S.P. PLAT. ROT. R.
HM TS15 TS16 GRN-4 GRN-3 17 GRN D.B. GRN S.P. PLAT. ROT. L.
CABLE ORG/RED-4 ORG/RED-3 16 OG/RD D.B. OG/RD S.P. PLAT. LEVEL F.C.
#1 ORG/BLK-4 ORG/BLK-3 15 OG/BK D.B. OG/BK S.P. PLAT. LEVEL DN.
ORG-4 ORG-3 14 ORG D.B. ORG S.P. PLAT. LEVEL. UP
BLU/RED-3 13 WHT-5 DRV. ENA. LT.
WHT-E.H. BLU/WHT-3 12 BLK-5 DRV. ENA.
BLU/BLK-4 BLU/BLK-3 11 BU/BK D.B. BU/BK S.P.
TS17 BLU-4 BLU-3 10 BLU D.B. BLU S.P.
TS10 BLK/RED-3 9 BK/RD CR4 HORN
BLK/WHT-4 BLK/WHT-3 8 BK/WT D.B. BK/WT S.P. BOOM RETRACT
BLK-4 BLK-3 7 BLK D.B. BLK S.P. BOOM EXTEND
W/R-4 WHT/RED-3 6 WT/RD S.P. TURN. ROT. F.C.
CABLE WHT/BLK-4 WHT/BLK-3 5 WT/BK D.B. WT/BK S.P. TURN. ROT. L
#2 4 WHT D.B.
TS14 WHT-4 WHT-3
3
WHT S.P. TURN. ROT. R
R/W-4 RED/WHT-3 RD/WT S.P. BOOM F.C.
TS12 CB1 CB2 TS13 RED/BLK-4 RED/BLK-3 2 RD/BK D.B. RD/BK S.P. BOOM DOWN
RED-4 RED-3 1 RED D.B. RED S.P. BOOM UP
D C B A
R2
DIODE
BLOCKS
CABLE
#3
LABEL DESCRIPTION 1 START RELAY

P1 EMERGENCY STOP BUTTON 2 TACHOMETER IGN./START
KS1 KEY SWITCH MODULE
3 START INPUT
TS9 AUXILIARY SWITCH
TS10 ENGINE START SWITCH 4 AUX. ON
5 GROUND
TS12 ENGINE RPM SWITCH
6 BATTERY
TS13 PLATFORM ROTATE SWITCH
TS14 PLATFORM LEVEL SWITCH 7 KEY PWR.
CABLE
TS15 BOOM EXTEND/RETRACT SWITCH 8 KEY BYPASS
#4
TS16 BOOM UP/DOWN SWITCH
9 IGN./FUEL ON
TS17 TURNTABLE ROTATE SWITCH
10 ENG. FAULT
CB1 CIRCUIT BREAKER, CONTROLS, 15A
CB2 CIRCUIT BREAKER, ENGINE, 15A
CR1 CR2 CR3 CR4
HM HOUR METER
START FUEL RPM RPM
R2 RESISTOR, 10 OHM, BOOM FUNCTIONS
RELAY RELAY CUTOUT RELAY
RELAY
G1 VOLT METER GAGE
G2 OIL PRESSURE GAGE
G3 WATER TEMP. GAGE
CR5
HORN
RELAY
ENGINE
HARNESS
Part No. 32222 Genie S-40 6 - 10

Platform Control Box Legend -

Diesel Models
NC NC
STOP
P2
DP1
8 7 6 5 4 3 2 1
R.P.M.
TS4
HIGH
SPARE 45 GRN/WHT-1
SPARE 44 GRN/BLK-1
START
SPARE 43 GRN-1
TS2
SPARE 42 ORG/RED-1
PULSE PICKUP 41 ORG/BLK-1
LED
L1
LIMIT SWITCH 40 ORG-1
L.P. 39 BLU/RED-1
GAS 38 BLU/WHT-1
STEER LEFT 37 BLU/BLK-1
STEER RIGHT 36 BLU-1
RPM 35 BLK/RED-1
DRIVE ENABLE
GLOW PLUG 34 BLK/WHT-1
START 33 BLK-1
TS8
BRAKE 32 WHT/RED-1
E.D.C. 31 WHT/BLK-1
E.D.C. 30 WHT-1
2WD/4WD 29 RED/WHT-1
SPARE 28 RED/BLK-1
AUX. PWR. 27 RED-1
PWR. TO F.S. 26 BLK (F.S.)
PWR. (START) 25 GREEN (F.S.)
PWR. (CONT.) 24 WHT (H.P.L.)
PWR. FRM PLAT. 23 WHT-2
PWR. TO PLAT. 22
AUX.
TS1
BLK-2
21
RETRACT
20
EXTEND
F.S.
TS7
TILT ALARM 19 GRN/WHT-3
PLAT. ROT. R. 18 GRN/BLK-3
PLAT. ROT. L. 17 GRN-3
PLAT. LVL. F.C. 16 ORG/RED-3
PLAT. LVL. DN. 15 ORG/BLK-3
PLAT. LVL. UP 14 ORG-3
DRV. ENA. LT.
110
13 BLU/RED-3
DRV. ENA. 12 BLU/WHT-3
SEC. BOOM DN. 11 BLU/BLK-3
SEC.BOOM UP 10 BLU-3
PLATFORM
ROTATE
HORN 9 BLK/RED-3
TS5
RETRACT 8 BLK/WHT-3
CABLE
EXTEND 7 BLK-3
#1
ROTATE F.C. 6 WHT/RED-3
ROTATE RIGHT 5 WHT/BLK-3 A - X R
+
ROTATE LEFT 4 WHT-3
BOOM F.C. 3 RED/WHT-3
PLATFORM
BOOM DN. 2 RED/BLK-3
LEVEL
BP1
TS6
BOOM UP 1 RED-3
CABLE
HORSE POWER LIMITER
#2
X -
R A
+
CABLE
GRN-2
1 2 3 4 5 6 7 8 9 10
#3
NO
HORN
P3
ALARM
STUD
GRD.
TILT
6 - 11 Genie S-40 Part No. 32222
2WD Hydraulic Schematic

- Non-Oscilating Axle
Service Manual - First Edition Section 6 - Schematics
Hydraulic Symbols Legend
Cylinder
Pressure gauge Solenoid operated 2 pos.,
4 way, directional valve
Differential
sensing valve
Accumulator
Filter
Solenoid operated 3 pos.,
4 way, directional valve (DO1)
0.035
Orifice with size Solenoid operated

proportional valve
2 pos., 3 way, shuttle valve

Fixed displacement
pump
Variable orifice
or shut-off valve
Flow regulator valve

Bi-directional, Check valve 3 pos., 4 way, directional valve
variable
displacement pump
Solenoid operated 2 pos.,

Relief valve 3 way, directional valve
Sequencing valve
Bi-directional motor
Priority
flow divider
Counterbalance valve
2-speed, Unloader valve
bi-directional motor
Pump prime mover

(engine or motor) Solenoid operated
dump valve Pilot operated flow
control valve Pressure compensating valve
Part No. 32222 Genie S-40 6 - 12


- Non-Oscilating Axle
SLAVE
X
TURNTABLE
BOOM BOOM
X
EXTENSION UP/DOWN
PLATFORM
ROTATE
A B
MASTER
.025
PLATFORM
LEVEL TURNTABLE
PR1 PR2 PL1 PL2 S1 S2 EXTEND RETRACT R1 R2 P1 P2 BOOM
X X
OPTIONAL B
2500
PSI
FUNCTION C
MOTOR/GEN. MANIFOLD 2200
50 D
PSI HIGH 1950
PSI
F
360 PSI
PSI PRESS. A
H I
FILTER TEST
N S R
O P
3.5 Q
GPM
3500 J
PSI PRESS.
T
U X Y
V
FUNCTION L K
E AB M
PUMP 2600
PSI Z AA
6.4 GPM. X
PRESS.
AC W
DRIVE PUMP 0.1
T1 GPM
TANK
2500
PSI
25 SEC REG
PSI
3 3
PSI PSI
RESERVOIR AUX. PUMP
A
TANK B
L K STEER MANIFOLD
M4
REAR
RIGHT H G
M2
I J
M3
REAR
LEFT E F
M1
STEERING
B
DRIVE A
250 PSI
MANIFOLD
Part No. 32222 Genie S-40 6 - 13


- Oscilating Axle

Oscilating Axle
SLAVE
X
TURNTABLE
BOOM BOOM
X
EXTENSION UP/DOWN
PLATFORM
ROTATE
A B
MASTER
.025
PLATFORM
LEVEL TURNTABLE BOOM
PR1 PR2 PL1 PL2 S1 S2 EXTEND RETRACT R1 R2 P1 P2
X X
OPTIONAL FUNCTION 2500

MANIFOLD B PSI C
MOTOR/GEN. 2200
50 D
PSI HIGH 1950
PSI
360 PSI F
PSI PRESS. A
H I
FILTER TEST
R
N O P S
3.5 Q
GPM
3500 J
PRESS.
PSI
T
U V X Y
FUNCTION L K
AB M
E PUMP 2600
PSI Z AA
6.4 GPM. X
PRESS.
AC
DRIVE PUMP W 0.1
T1 GPM
TANK
2500
PSI
25 SEC REG
3 3 PSI
PSI PSI
RESERVOIR AUX. PUMP OSCILLATE
1.5
A
TANK
A B
L K STEER MANIFOLD
M4
REAR
RIGHT H G OSCILLATE DIRECTIONAL VALVE
OSCILLATE MANIFOLD
M2
P P8
X
I J
M3 900
PSI
X
REAR
LEFT D B
E F A VALVE A CYL
M1
F G
B VALVE
C B CYL
STEERING E
B
DRIVE
MANIFOLD A 250 PSI
Part No. 32222 Genie S-40 6 - 14


SLAVE
X
TURNTABLE
BOOM BOOM
X
EXTENSION UP/DOWN
PLATFORM
ROTATE
A B
MASTER
.025
PLATFORM
LEVEL TURNTABLE BOOM
PR1 PR2 PL1 PL2 S1 S2 EXTEND RETRACT R1 R2 P1 P2
X X
OPTIONAL 2500
FUNCTION B PSI C
MOTOR/GEN. MANIFOLD 2200
50 D PSI
PSI HIGH 1950
360 F
PRESS. A PSI
PSI
H I
FILTER TEST
R
N O P S
3.5 Q
GPM
3500 J
PSI PRESS.
T
U X Y
V
FUNCTION L K
AB M
E PUMP 2600
PSI Z AA
6.4 GPM. X
PRESS.
AC
DRIVE PUMP W 0.1
T1 GPM
TANK
2500
PSI
25 SEC REG
3 3 PSI
PSI PSI
RESERVOIR AUX. PUMP OSCILLATE
1.5
A
A
TANK B
Q R T
S STEER MANIFOLD
M7 M8
REAR FRONT
RIGHT M N P RIGHT
O OSCILLATE DIRECTIONAL VALVE
M5 M6
OSCILLATE MANIFOLD
P P8
I J L
X
M3 K M4 900
PSI
REAR FRONT X
B
LEFT E F H LEFT A VALVE
D A CYL
M1 G M2
G
F C
B VALVE B CYL
STEERING E
DRIVE B
MANIFOLD
A 250 PSI
Part No. 32222 Genie S-40 6 - 15

Service Manual - First Edition Section 7 - Repair Procedures
Repair Procedures
About This Section

Most of the procedures in this section should only
be performed by a trained service professional
in a suitably equipped workshop. Select the
appropriate repair procedure after troubleshooting
the problem.
Observe and Obey: Perform disassembly procedures to the point
where repairs can be completed. Then to
Repair procedures shall be completed by a
re-assemble, perform the disassembly steps in
person trained and qualified on the repair of
reverse order.
this machine.
Immediately tag and remove from service a General Repair Process
Repair any machine damage or malfunction Malfunction Identify Troubleshoot
before operating the machine. discovered symptoms
Before Repairs Start:

problem
Read, understand and obey the safety rules still exists
and operating instructions in the
Genie S-40 Operator’s Manual. Return to Inspect Perform
service problem and test repair
Be sure that all necessary tools and parts are solved
available and ready for use.
Read each procedure completely and adhere Symbols Legend
to the instructions. Attempting shortcuts may
Indicates the presence of a hazard that will cause
produce hazardous conditions.
death
Unless otherwise specified, perform each or serious injury.
Indicates the presence of a hazard that may
following configuration:
cause death
· machine parked on a flat, level surface or serious injury.
· boom in stowed position
Indicates the presence of a hazard that will or
· turntable rotated with the boom between may cause serious personal injury
the non-steering wheels or
· turntable secured with the turntable damage to the machine.
rotation lock pin
Indicates special operation or maintenance
· key switch in the OFF position with the information.
key removed
Indicates that a specific result is expected
· wheels chocked
after performing a series of steps.

Section 7 - Repair Procedures Service Manual - First Edition
Platform Controls
1-1 1 Check the battery condition with a volt meter.

The reading should be 12V DC or more to
Joystick Controllers accurately adjust the controller.
Maintaining joystick controllers at the proper 2 Turn the key switch to platform control and
settings is essential to safe machine operation. pull out the Emergency Stop button to the
Every joystick controller should operate smoothly ON position at both the ground and platform
and provide proportional speed control over its controls. Do not start the engine.
entire range of motion. 3 Open the platform control box lid and locate
the boom up/down controller.
a b
a b c d e f g h i j
a ramp rate adjustable trimpot

e d c b dual (lo) range adjustable trimpot
c terminal "R", activates max-out range
Platform control box d terminal unused
a horsepower limiter board e terminal "X", auxiliary
b quick disconnect terminal strip f terminal "-", ground
c drive proportional controller g terminal "+", battery, positive
d boom proportional controller h terminal "A", proportional output
e turntable rotate proportional controller i threshold adjustable trimpot
j max-out adjustable trimpot
4 Set the preliminary ramp rate: Turn the trimpot

Boom Up/Down Controller adjustment screw clockwise 15 turns or until
you hear a repeated click.
Adjustments
5 Connect the red(+) lead from a volt meter to
Do not adjust the joystick the “A” terminal on the controller printed circuit
controllers unless the static board. Connect the black(-) lead to ground.
battery voltage is above
12V DC and the alternator 6 Set the threshold: Press down the foot switch,
is operating properly with then slowly move the control handle off center
12.5 to 14.5V DC output. until the moment a voltage reading appears.
Adjust the voltage to 2.5V DC. Turn the
Electrocution hazard. Contact threshold trimpot adjustment screw clockwise
with electrically charged circuits to increase the voltage or counterclockwise to
may result in death or serious decrease the voltage.
injury. Remove all rings, watches
and other jewelry.

PLATFORM CONTROLS
7 Set the max-out: Press down the foot switch, 16 Start a timer and simultaneously move the
then move the control handle all the way to control handle all the way to the UP position.
the UP position. Adjust the voltage to 5.9V DC. Note how long it takes to reach the maximum
Turn the max-out trimpot adjustment screw voltage recorded in step 14. This is the
clockwise to increase the voltage or ramp speed.
counterclockwise to decrease the voltage.
17 Set the ramp rate: turn the trimpot to obtain
8 Set the dual (lo) range: Press down the foot a 3 to 4 second ramp speed. Turn the
switch, then move the control handle all the trimpot clockwise to increase the time or
way to the DOWN position. Adjust the voltage counterclockwise to decrease the time.
to 5.9V DC. Turn the dual range trimpot
adjustment screw clockwise to increase the Boom up/down specifications
voltage or counterclockwise to decrease
Threshold 2.58V DC
the voltage.
Boom up - Max-out 5.9V DC
9 Start the engine and move the engine idle
Cycle time 40 to 60 seconds
control switch to foot switch activated high
idle (rabbit and foot switch symbol). Lower Boom down - Dual (lo) range 5.9V DC
the boom to the stowed position. Cycle time 50 to 80 seconds
Engine should be at normal Ramp rate 3 to 4 seconds

operating temperature.
10 Start a timer and record how long it takes for
the boom to fully raise. Adjust the Turntable Rotation Controller
max-out trimpot to achieve a 40 to 60 second
cycle time.
Adjustments
11 Start a timer and record how long it takes for Do not adjust the joystick
the boom to fully lower. Adjust the dual range controllers unless the static
trimpot to achieve an 50 to 80 second cycle battery voltage is above
time. 12V DC and the alternator is
operating properly with
If the function cycle time is not 12.5 to 14.5V DC output.
achievable, check the relief valve
pressure. See 9-2, Valve Electrocution hazard. Contact
Adjustments - Function Manifold. with electrically charged circuits
12 Turn the engine off and re-connect the injury. Remove all rings, watches
volt meter. and other jewelry.
13 Pull out the Emergency Stop button to 1 Check the battery condition with a volt meter.
the ON position. The reading should be 12V DC or more to
accurately adjust the controller.
14 Press down the foot switch and then move the
control handle all the way to the UP position. 2 Turn the key switch to platform control and
Record the maximum voltage reading. pull out the Emergency Stop button to
15 Start the engine. the ON position at both the ground and
platform controls. Do not start the engine.

PLATFORM CONTROLS
3 Open the platform control box lid and locate 8 Set the max-out: Press down the foot switch,
the turntable rotation controller. Refer to the then move the control handle all the way to the
platform control box illustration, page 7-2. left or right. Adjust the voltage to 5.5V DC.
Turn the max-out trimpot adjustment screw
clockwise to increase the voltage or
a b c d e f g h i j counterclockwise to decrease the voltage.
9 Start the engine and move the engine idle
control switch to foot switch activated high idle
(rabbit and foot switch symbol).
Engine should be at normal operating
temperature.
10 Start a timer and record how long it takes the
turntable to rotate through a complete circle.
Adjust the max-out trimpot to achieve a
70 to 110 second cycle time.
11 Turn the engine off and re-connect the
a ramp rate adjustable trimpot
b dual (lo) range adjustable trimpot volt meter.
c terminal "R", activates max-out range
d terminal unused 12 Pull out the Emergency Stop button to
e terminal "X", auxiliary the ON position.
f terminal "-", ground
g terminal "+", battery, positive 13 Press down the foot switch and then move the
h terminal "A", proportional output control handle all the way to the left or right.
i threshold adjustable trimpot Record the maximum voltage reading.
j max-out adjustable trimpot
14 Start the engine.
4 Set the preliminary ramp rate: Turn the trimpot
adjustment screw clockwise 15 turns or until 15 Start a timer and simultaneously move the
you hear a repeated click. control handle all the way to the left or right.
Note how long it takes to reach the maximum
5 Connect the red(+) lead from a volt meter to
voltage recorded in step 13. This is the
the “A” terminal on the controller printed circuit
ramp rate.
board. Connect the black(-) lead to ground.
16 Set the ramp rate: Turn the trimpot to obtain
6 Set the threshold: Press down the foot switch,
a 3 to 4 second ramp speed. Turn the trimpot
then slowly move the control handle off center
clockwise to increase the time or
until the moment a voltage reading appears.
counterclockwise to decrease the time.
Adjust the voltage to 2.5V DC. Turn the
threshold trimpot adjustment screw clockwise Turntable rotation specifications
to increase the voltage or counterclockwise
to decrease the voltage. Threshold 2.5V DC
7 Set the dual (lo) range: Turn the trimpot Turntable rotation - Max-out 5.5V DC
adjustment screw clockwise 15 turns or until Cycle time 70 to 110 seconds
you hear a click. This is the only dual range
Ramp rate 3 to 4 seconds
adjustment for this controller.

PLATFORM CONTROLS
1-2 a
Horsepower Limiter Board
The horsepower limiter board is responsible for
governing drive pump output. It senses engine
rpm from the alternator. The horsepower limiter
board senses drops in rpm normally due to
increased drive resistance (rough terrain or
incline), and decreases voltage to the drive
controller which in turn decreases voltage to the
drive pump, thereby reducing pump output to
maintain optimum engine rpm and horsepower.
Three adjustments are required for optimum
Platform control box
performance. a horsepower limiter board
How to Adjust the Horsepower

3 Connect the black(-) lead from a DC volt meter
Limiter Board to the no. 2 terminal, and the red(+) lead to the
The engine rpm must be no. 10 terminal.
correct before performing this
procedure. See Maintenance a
Procedure B-12, Check and 12V DC or greater
ground b
Adjust the Engine RPM. engine rpm sensor
not used
Do not adjust the horsepower not used
low drive speed limit switch
limiter board unless the static not used
battery voltage is above 12V DC not used
not used
and the alternator is operating output to drive controller
c
properly with 12.5 to 14.5V DC
output.
Gasoline/LPG models: Perform Horsepower limiter board
this procedure in gasoline mode. a "A" potentiometer-maximum voltage
output to the controller in the stowed
1 Remove the fasteners from the platform position
b "B" potentiometer-maximum voltage
control box lid. output to the drive controller in the
boom raised position
2 Open the control box lid and locate the
c "C" potentiometer-reaction rate or
horsepower limiter board. how fast the voltage output reacts to
the change in engine rpm
Electrocution hazard. Contact
with electrically charged circuits 4 Start the engine from the platform controls.
injury. Remove all rings, watches 5 Move the engine idle control switch to foot
and other jewelry. switch activated high idle (rabbit and foot
switch symbol).

PLATFORM CONTROLS
6 Press down the foot switch and adjust the 13 Raise the boom above the drive limit switch.
"A" potentiometer counterclockwise to increase
voltage or clockwise to decrease voltage.
"A" potentiometer specifications - all models
Voltage setting 9.5V DC
7 Move the engine idle control switch to low idle

(turtle symbol).
8 Press down the foot switch and then adjust
the "C" potentiometer to obtain a
0.01V DC to 0.03V DC voltage reading.
9 Move the engine idle control switch to foot a b
switch activated high idle (rabbit and foot
switch symbol). a drive limit switch
b boom lift cylinder
10 Press down the foot switch and re-adjust the
"A" potentiometer to the previous voltage
setting in step 6. 14 Drive the machine for 40 feet (12 m) and
record the elapsed time. Repeat this step in
11 Be sure that the boom is in the stowed position,
the opposite drive direction.
then drive the machine and observe how the
engine rpm reacts to drive control handle 15 Adjust the "B" potentiometer to obtain the
movement. If the engine surges or hunts, correct raised drive speed of 1 foot per second
adjust the "C" potentiometer counterclockwise (30.5 cm per second). Turn the "B"
until surging is minimized. potentiometer counterclockwise to increase
voltage or clockwise to decrease voltage.
Under an extreme load, an
excessive counterclockwise 16 Close the platform control box lid and install
adjustment to the "C" the fasteners.
potentiometer will cause
the engine to stall. The "C" Drive speed specifications
potentiometer adjustment is a
Stowed position distance: 40 ft / 12 m
compromise between engine
2WD 4WD
stability (surging) and engine
Gasoline/LPG models 40 ft/6.8 sec 40 ft/7.8 sec
rpm droop.
12.2 m/6.8 sec 12.2 m/7.8 sec
12 Disconnect the volt meter. Deutz Diesel models 40 ft/7.8 sec 40 ft/9.1 sec
12.2 m/7.8 sec 12.2 m/9.1 sec
Boom raised or distance: 40 ft / 12 m

extended 1 foot per second
All models 30.5 cm per second

PLATFORM CONTROLS
1-3 1-4
Foot Switch Resistors
How to Test the Foot Switch The resistor is used to maintain proper control of
boom extend/retract. The resistor is located in the
1 Turn the key switch to the OFF position and platform control box.
separate the wiring quick disconnect plug from
the platform toe board. Refer to the schematic legends
for resistor locations and values.
2 Do not press down the foot switch. Connect the
leads from an ohmmeter or continuity tester to How to Test the Resistors
each wire combination listed below and check
for continuity. 1 Turn the key switch to the OFF position.
2 Connect the leads from an ohmmeter to each
Test Desired result end of the resistor being tested.
green to black continuity 3 Compare the ohmmeter reading with the
(zero Ω) resistance rating printed on the resistor.
green to white no continuity
(infinite Ω)
black to white no continuity
Do not use the color of the

connector as a guide for these
tests. Use the actual wire color
to identify which connector to
use for testing.
3 Press down the foot switch. Connect the leads
from an ohmmeter or continuity tester to each
wire combination listed below and check for
continuity.
Test Desired result
green to black no continuity

(infinite Ω)
green to white no continuity
black to white continuity

(zero Ω)

PLATFORM CONTROLS
1-5 Test Desired result

Toggle Switches Left position
Toggle switches used for single function switching terminal 1 to 2, 3, 4, 5 & 6 no continuity
are single pole double throw (SPDT) switches. (infinite Ω)
Dual function switching requires a double pole terminal 2 to 3 continuity
double throw (DPDT) switch. (zero Ω)
How to Test a Toggle Switch terminal 2 to 4, 5 & 6 no continuity
Continuity is the equivalent of 0 to terminal 3 to 4, 5 & 6 no continuity

3 ohms. A simple continuity tester terminal 4 to 5 & 6 no continuity
may not accurately test the
switch. terminal 5 to 6 continuity
This procedure covers fundamental switch testing Center position There are no terminal
and does not specifically apply to all varieties of combinations that will
toggle switches. produce continuity
(infinite Ω)
1 Turn the key switch to the OFF position. Tag
and disconnect all wiring from the toggle switch Right position
to be tested. terminal 1 to 2 continuity
(zero Ω)
2 Connect the leads of an ohmmeter to the
switch terminals in the following combinations terminal 1 to 3, 4, 5 & 6 no continuity
listed below to check for continuity. (infinite Ω)
Left Center Right
terminal 2 to 3, 4, 5 & 6 no continuity
terminal 3 to 4, 5 & 6 no continuity
terminal 4 to 5 continuity
terminal 4 to 6 no continuity
1 3 1 3 1 3
2 2 2
Single pole
double throw
(SPDT) 1 2 3 1 2 3 1 2 3
4 5 6 4 5 6 4 5 6
Double pole
double throw
(DPDT)
1 2 3 1 2 3 1 2 3

Platform Components
2-1 any lifting pressure.

Platform 4 Remove the pin retainer fastener from both
the barrel and rod-end pins.
How to Remove the Platform 5 Drive the rod-end pin out using a soft
metal drift.
1 Remove the cable harness from the cable
clamp located on the platform mounting 6 Manually pivot the rotator up and secure it
bracket and separate the foot switch quick to the boom.
disconnect plug.
7 Use a soft metal drift and drive the barrel-end
2 Remove the platform control box mounting pin out.
bolts, then lower the control box and
8 Carefully pull the cylinder out of the boom.
set it aside.
9 Disconnect the hydraulic hoses from the
3 Remove the platform mounting bolts and lift the
slave cylinder and connect them together
platform off the mount.
with a connector. Cap the fittings on the
cylinder.
2-2 hydraulic oil can penetrate and
burn skin. Loosen hydraulic
Platform Leveling Slave Cylinder connections very slowly to allow
the oil pressure to dissipate
The slave cylinder and the rotator pivot are the gradually. Do not allow oil to squirt
two primary supports for the platform. The slave or spray.
cylinder keeps the platform level through the
entire range of boom motion. It operates in a
closed-circuit hydraulic loop with the master
cylinder. The slave cylinder is equipped with
counterbalance valves to prevent movement in
the event of a hydraulic line failure.
How to Remove the Slave

Cylinder
Before cylinder removal is
considered, bleed the slave
cylinder to be sure there is no
air in the closed loop.
1 Remove the platform. See 2-1, How to Remove
the Platform.
2 Extend the boom until the slave cylinder
barrel-end pivot pin is accessible.
3 Support the platform rotator, but do not apply

PLATFORM COMPONENTS
How to Bleed the Slave Cylinder 2-3

Do not start the engine. Use Platform Rotator
auxiliary power for all machine
functions in this procedure. The platform rotator is a hydraulically activated
helical gear assembly used to rotate the platform
1 Raise the boom to a horizontal position. 160 degrees.
2 Move the platform level switch up and down
through two platform leveling cycles to remove How to Remove the
any air that might be in the system. Platform Rotator
Component damage hazard. Mark
the platform mounting weldment
and the rotator flange before
removing the platform mounting
weldment. The platform mounting
weldment must be replaced in the
exact same position on the rotator
flange as it was before removal. If
a new rotator is installed or the
rotator is disassembled, proper
alignment can be achieved by
rotating the rotator all the way to
the left and then installing the
platform mounting weldment all
the way in the left position.
1 Remove the platform. See 2-1,
How to Remove the Platform.
2 Disconnect and plug the hydraulic hoses from
the platform rotator.
hydraulic oil can penetrate and
gradually. Do not allow oil to squirt
or spray.
3 Support the platform mounting weldment, but
do not apply any lifting pressure.
4 Remove the six mounting bolts from the
platform mounting weldment, then remove the
center bolt and slide the platform mounting
weldment off of the platform rotator.
5 Support the platform rotator. Do not apply
any lifting pressure.
7 - 10 Genie S-40 Part No. 32222

PLATFORM COMPONENTS
6 Support the platform leveling slave cylinder. 3 Open the top bleed valve on the rotator, but do
not remove it.
7 Remove the pin retainer from the slave cylinder
barrel-end pivot pin.
a
8 Use a soft metal drift to remove the
barrel-end pin.
9 Disconnect and plug the hydraulic hoses from
the slave cylinder. Pull the hoses up through
the platform rotator.
squirt or spray. d c b
10 Remove the pin retainer from the slave cylinder a top bleed valve
rod-end pivot pin and the rotator pivot pin. b bottom bleed valve
c clear hose
11 Use a soft metal drift to drive both pins out, d container
then remove the platform rotator from the
machine. 4 Hold the platform rotate switch to the LEFT
position until the platform is fully rotated.
How to Bleed the Platform Rotator Continue holding the switch until air stops
coming out of the bleed valve. Then close
Do not start the engine. Use the bleed valve.
auxiliary power for all machine
functions in this procedure. Crushing hazard. Keep clear of
the platform during rotation.
1 Move the platform rotate switch to the right
then the left through two platform rotation 5 Connect the clear hose to the bottom bleed
cycles, then hold the switch to the RIGHT valve and open the valve. Do not remove the
position until the platform is fully rotated to the bleed valve.
right. 6 Hold the platform rotate switch to the RIGHT
2 Connect a clear hose to the top bleed valve. position until the platform is fully rotated.
Place the other end of the hose in a container Continue holding the switch until air stops
to collect any drainage. Secure the container to coming out of the bleed valve. Then close
the boom. the bleed valve.
Crushing hazard. Keep clear of
the platform during rotation.
7 Remove the hose from the bleed valve and
clean up any hydraulic oil that may have
spilled.
8 Rotate the platform full right then left and
inspect the bleed valves for leaks.
Part No. 32222 Genie S-40 7 - 11

Boom Components
3-1 3-2
Plastic Cable Track Boom
The boom cable track guides cables and hoses How to Shim the Boom
running up the boom. It can be repaired link by link
without removing the cables and hoses that run Measure each wear pad. Replace
through it. Removing the entire boom cable track the pad if it is less than 7/16 inch
is only necessary when performing major repairs (11 mm) thick. If the pad is more
that involve removing the boom. than 7/16 inch (11 mm) thick,
perform the following procedure.
How to Repair the Plastic 1 Extend the boom 10 inches (25 cm).
Cable Track
2 Remove the wear pad mounting fasteners.
Component damage hazard.
3 Install the new shims under the wear pad to
The boom cable track can be
obtain zero clearance and zero drag.
damaged if it is twisted.
4 Use a round punch to align the shim to the
wear pad. Install the mounting fasteners.
5 Extend and retract the boom through an entire
cycle. Check for tight spots that could cause
scraping or binding.
a Always maintain squareness
between the outer and inner boom
b tubes.
How to Remove
a link separation point the Boom
b lower clip
This procedure requires specific
1 Use a screwdriver to pry down on the repair skills, lifting equipment and
lower clip. a suitable workshop. Attempting
this procedure without these skills
2 Repeat step 1 for each link.
and tools may cause death or
3 To remove a single link, open the lower clip serious injury and significant
and then use a screwdriver to pry the link component damage. Dealer
to the side. service is strongly recommended.
boom in the stowed position.
1 Remove the platform. See 2-1,
How to Remove the Platform.
2 Remove the platform rotator and leveling slave
cylinder. See 2-3, How to Remove the Platform
Rotator.
7 - 12 Genie S-40 Part No. 32222

BOOM COMPONENTS
3 Remove the mounting fasteners from the 15 Attach a similar lifting device to the lift cylinder.
counterbalance valve manifold on the end of
16 Place support blocks under the cylinder, across
the boom. Then remove the manifold and set it
the turntable.
aside.
17 Remove the pin retaining fastener from the
4 Support the cable track with an overhead
boom lift cylinder rod-end pin. Use a soft metal
crane.
drift to remove the pin.
5 Remove the hose/cable cover from the pivot
Crushing hazard. The boom lift
end of the boom.
cylinder will fall unless it is
6 Remove the cable track mounting bolts at the properly supported.
platform end of the boom.
18 Lower the rod end of the lift cylinder onto
7 Remove the side panel from the cable track to support blocks. Protect the cylinder rod from
access the cable track mounting bolts. damage.
8 Remove the cable track mounting fasteners, 19 Use the crane to lift the boom to a horizontal
then remove the cable track from the position.
boom and lay it off to the side.
20 Remove the pin retaining fastener from the
Component damage hazard. boom pivot pin.
The boom cable track
21 Remove the boom pivot pin with a soft metal
can be damaged if it is twisted.
drift, then carefully remove the boom from the
9 Carefully raise the boom enough to access the machine.
master cylinder rod-end pivot pin.
Crushing hazard. If the overhead
10 Remove the turntable end cover. crane is not properly attached,
the boom may become
11 Remove the retaining bolt from the master
unbalanced and fall when it is
cylinder rod-end pivot pin. Use a soft metal drift
removed from the machine.
to remove the pin. Pull the cylinder back and
secure it from moving. How to Disassemble
12 Remove the drive speed limit switch the Boom
mounted on the inside of the pivot end of
the boom. Do not disconnect the wiring. Complete disassembly of the
boom is only necessary
13 Disconnect and plug the extension cylinder if the outer or inner boom tubes
hydraulic hoses. Cap the fittings on the must be replaced. The extension
cylinder. cylinder can be removed without
Bodily injury hazard. Spraying completely disassembling of the
hydraulic oil can penetrate and boom. See 3-4, How to Remove
burn skin. Loosen hydraulic the Extension Cylinder.
connections very slowly to allow 1 Remove the boom. See 3-2,
the oil pressure to dissipate How to Remove the Boom.
squirt or spray. 2 Place blocks under the extension cylinder for
support.
14 Attach an overhead crane to the center point
of the boom.
Part No. 32222 Genie S-40 7 - 13

BOOM COMPONENTS
3 Remove the retaining fastener from the 3-3

extension cylinder barrel-end pivot pin. Use a
soft metal drift to remove the pin. Boom Lift Cylinder
4 Remove and label the wear pads from the
How to Remove the Boom
Lift Cylinder
Pay careful attention to the
location and amount of shims used This procedure requires specific
with each wear pad. repair skills, lifting equipment and
a suitable workshop. Attempting
5 Support and slide the extension tube out of the
this procedure without these skills
and tools may result in death or
Crushing hazard. The extension serious injury and significant
tube will fall when it is removed component damage. Dealer
from the boom if is not properly service is strongly recommended.
supported.
1 Raise the boom until the boom lift cylinder
6 Remove the snap rings from the extension rod-end pin is above the turntable covers.
cylinder rod-end pins. Use a soft metal drift to
2 Place blocks under the cylinder for support.
remove the pins.
3 Support the boom with an overhead crane.
7 Support and slide the extension cylinder out
Do not lift the boom.
of the platform end of the extension boom.
4 Support the balance point of the boom lift
8 Remove and label the wear pads from the
cylinder with an overhead crane or similar lifting
extension boom.
device.
Pay careful attention to the
Crushing hazard. If the overhead
location and amount of shims used
crane is not properly attached,
with each wear pad.
the lift cylinder may become
unbalanced and fall when it is
disconnected from the machine.
5 Remove the pin retaining fastener from the lift
cylinder rod-end pivot pin. Use a soft metal drift
to remove the pin, then allow the lift cylinder to
rest on the blocks. Protect the cylinder rod
from damage.
Crushing hazard. The lift
cylinder will fall unless it is
properly supported.
6 Use the crane to lift the boom to a horizontal
position.
7 Remove the turntable end cover to access the
lift cylinder mounting bracket (label and
disconnect the alarm wiring, if equipped).
7 - 14 Genie S-40 Part No. 32222

BOOM COMPONENTS
8 Disconnect and plug the boom lift cylinder 3 Remove the snap rings from the extension
hydraulic hoses. Cap the fittings on the cylinder rod-end pins. Use a soft metal drift to
cylinder. remove the pins.
Bodily injury hazard. Spraying 4 Remove the turntable end cover (label and
hydraulic oil can penetrate and disconnect the alarm wiring, if equipped).
5 Disconnect and plug the master cylinder
hydraulic hoses. Cap the fittings on the
cylinder.
squirt or spray. Bodily injury hazard. Spraying
9 Remove the mounting fasteners from the lift
cylinder mounting bracket.
10 With the lift cylinder being supported by the the oil pressure to dissipate
overhead crane, pull the cylinder toward the gradually. Do not allow oil to
platform until it is out. squirt or spray.
Component damage hazard. The 6 Remove the pin retaining fasteners from both
cables and hydraulic hoses can master cylinder pins.
be damaged if the lift cylinder is
7 Use a soft metal drift to remove the pins. Then
pulled across them.
remove the master cylinder from the machine.
3-4 8 Disconnect and plug the extension cylinder
Extension Cylinder hydraulic hoses. Cap the fittings on the
cylinder.
The extension cylinder extends and retracts the Bodily injury hazard. Spraying
boom extension tube. The extension cylinder is hydraulic oil can penetrate and
equipped with counterbalance valves to prevent burn skin. Loosen hydraulic
movement in the event of a hydraulic line failure. connections very slowly to allow
How to Remove the gradually. Do not allow oil to
Extension Cylinder squirt or spray.
This procedure requires specific 9 Place a small block under the cylinder for
repair skills, lifting equipment and support.
a suitable workshop. Attempting 10 Remove the pin retaining fastener from the
this procedure without these skills extension cylinder barrel-end pivot pin. Use a
and tools may cause death or soft metal drift to remove the pin.
serious injury and significant
component damage. Dealer 11 Support and slide the extension cylinder out of
service is strongly recommended. the extension boom.
1 Raise the boom to a horizontal position. Crushing hazard. The extension
cylinder will fall when it is removed
2 Extend the boom until the extension cylinder from the extension boom if it is
rod-end mounting pins are accessible. not properly supported.
Part No. 32222 Genie S-40 7 - 15

BOOM COMPONENTS
3-5
Platform Leveling
Master Cylinder
The master cylinder acts as a pump for the slave
cylinder. It’s part of the closed circuit hydraulic
loop that keeps the platform level through the
entire range of boom motion. The master cylinder
is attached to the lift cylinder and is located at the
base of the boom.
How to Remove the Platform

Leveling Master Cylinder
1 Raise the boom to a horizontal position.
2 Remove the turntable end cover to access the
master cylinder.
3 Disconnect and plug the master cylinder
hydraulic hoses. Cap the fittings on the
cylinder.
squirt or spray.
4 Remove the pin retaining fasteners from both
master cylinder pins.
5 Use a soft metal drift to remove the pins.
7 - 16 Genie S-40 Part No. 32222

Turntable Covers
4-1
Turntable Covers
How to Remove a
Turntable Cover
1 Raise the turntable cover. Support the open
cover with an overhead crane or forklift.
Do not lift it.
Crushing hazard. Due to its heavy
weight, do not attempt to support
the cover by hand.
2 Remove the upper and lower retaining clips
from the gas strut.
3 Gently pry the strut pivot sockets off of the ball
studs and remove the strut. Protect the strut
cylinder rod from damage.
4 Remove the cover hinge bolts, that fasten the
hinge support bracket to the bulkhead.
5 Carefully lift and remove the cover from
the machine.
If a turntable cover must be
replaced, be sure that all
appropriate safety and
instructional decals are
applied to the new cover.
Alignment adjustments may be
necessary when a new cover
is installed.
Part No. 32222 Genie S-40 7 - 17

Deutz Engine F3L 1011
5-1 3 Apply Loctite® removable thread sealant to the

coupler set screw. Torque the set screw to
RPM Adjustment 45 ft-lbs (61 Nm).
Refer to Maintenance Procedures, B-12, Component damage hazard. Do
Check and Adjust the Engine RPM. not force the drive pump during
installation or the flex plate teeth
may become damaged.
5-2 4 Assemble the engine and torque the pump
Flex Plate mountint plate to 34 ft-lbs (46 Nm).
The flex plate acts as a coupler between the

engine and the pump. It is bolted to the engine 5-3
flywheel and has a splined center to drive Oil Temperature and Pressure
the pump.
Gauges
How to Remove the Flex Plate
The oil temperature gauge is an electrical gauge.
1 Disconnect the wiring plug at the electronic The sending unit has limit contacts that are factory
displacement controller (EDC), located on set. The contacts will close at 300o F (147o C).
the drive pump. When the contacts close, the engine will shut off
2 Support the drive pump with an appropriate to prevent damage and will not start until the
lifting device. Then remove all of the pump temperature drops below the contact point.
mounting plate to engine bell housing bolts. Temperature will be indicated when the key is on
and the Emergency Stop Button is pulled out to
3 Carefully pull the pump away from the engine the ON position.
and secure it from moving.
4 Remove the flex plate mounting fasteners, Do not crank the engine with
then remove the flex plate from the engine. the over-temperature light on.
How to Install the Flex Plate The oil pressure gauge is an electrical gauge. The
sending unit has limit contacts that are factory set.
1 Install the flex plate onto the flywheel with the The contacts will close at 7 psi (0.48 bar). When
flat side of the spline against the flywheel. the contacts close, the engine will shut off to
Torque the flex plate mounting bolts to prevent damage. Oil pressure will be indicated
34 ft-lbs (46 Nm). when the engine is running.
2 Install the coupler onto the pump shaft with the
set screw toward the pump. Leave a 3/16 inch
Do not continue to run the engine
(4.7 mm) gap between the coupler and pump
with the low oil pressure light on.
end plate.
7 - 18 Genie S-40 Part No. 32222

Ford LSG-423 Engine
a b c d
g
110°
Governor actuator and linkage

6-1 a clevis yoke
Governor Actuator b linkage rod
c carburetor
d throttle plate shaft
How to Set Up the Governor e governor actuator
f actuator shaft
Actuator and Linkage g actuator arm
Adjustment of the governor

actuator is only necessary when
the governor actuator or the 4 Position the linkage rod so that the throttle is in
linkage has been replaced. the idle position. Then adjust the clevis yoke on
1 Connect the linkage rod to the throttle plate the linkage rod to obtain the proper length.
shaft, then tighten the lock nut. Install the yoke onto the actuator arm and
tighten the lock nut.
2 Fasten the lock nut and clevis yoke to the
linkage rod. Do not tighten the lock nut 5 With the throttle in the idle position and the
against the clevis yoke. actuator arm at a 110 degree angle to the
linkage, rotate the actuator shaft slightly
3 Loosen the fastener on the actuator arm. counterclockwise to pre-load the spring.
Rotate the actuator arm until it is at a Tighten the fastener on the actuator arm
110 degree angle to the linkage rod. without releasing the shaft.
Part No. 32222 Genie S-40 7 - 19

FORD LSG-423 ENGINE
6 Manually pull the actuator arm through a full 6-2

cycle to be sure that the linkage moves freely.
Be sure that the linkage activates the throttle Choke Adjustments
shaft to approximately half throttle.
This engine is equipped with an electrically heated
The linkage must be free of automatic choke. The choke has a poppet valve to
friction and obstruction. Do not enhance cold starting ability on LPG fuel.
let it rub against the engine,
brackets or hoses. Choke adjustments are affected
by climate. Richer adjustment
Component damage hazard. will be necessary in colder
If the throttle linkage is improperly climates, leaner adjustment
adjusted and allowed to reach full in warmer climates.
throttle, the engine will over-rev
and cause component damage. Automatic Choke with
Poppet Valve
The choke functions in both gasoline and LPG
mode. The choke butterfly may be adjusted to a
fully closed (rich) position for colder climates and
the poppet valve will provide a flow path during
LPG fueled operation.
rich lean
7 - 20 Genie S-40 Part No. 32222

FORD LSG-423 ENGINE
6-3 Flex Plate Removal

Timing Adjustment 1 Disconnect and remove the hose between
the carburetor venturi and the air cleaner.
available in the Ford LSG-423 2.3 Liter Industrial 2 Disconnect the linkage from the governor,
Engine Service Manual (Ford number: 194-216). then remove the governor linkage from
Genie part number 29586. the carburetor. Do not alter the length of
the linkage.
3 Disconnect the wiring plug at the electronic
displacement controller (EDC), located on
6-4 the drive pump.
Carburetor Adjustment 4 Remove the mounting fasteners from the
regulator mounting bracket, then pull the
Complete information to perform this procedure is bracket up past the bell housing. Secure
available in the Ford LSG-423 2.3 Liter Industrial the bracket before continuing.
Genie part number 29586. 5 Support the drive pump with an appropriate
lifting device. Then remove all of the pump
mounting plate to engine bell housing bolts.
6 Carefully pull the pump away from the
6-5 engine and secure it from moving.
RPM Adjustment 7 Remove the flex plate mounting fasteners,
then remove the flex plate from the engine.
Refer to Maintenance Procedures, B-12, Check
and Adjust the Engine RPM. How to Install the Flex Plate
1 Install the flex plate onto the flywheel with the
raised spline against the flywheel. Torque the
flex plate mounting bolts to 34 ft-lbs (46 Nm).
6-6
2 Install the coupler onto the pump shaft with the
Flex Plate set screw towards the pump. Leave a 3/16 inch
(4.7 mm) gap between the coupler and pump
The flex plate acts as a coupler between the end plate.
engine and the pump. It is bolted to the engine
flywheel and has a splined center to drive 3 Apply Loctite® removable thread sealant to the
the pump. coupler set screw. Torque the set screw to
45 ft-lbs (61 Nm).
Component damage hazard. Do
not force the drive pump during
installation or the flex plate teeth
may become damaged.
4 Assemble the engine and torque the
pumpmountint plate to 34 ft-lbs (46 Nm).
Part No. 32222 Genie S-40 7 - 21

FORD LSG-423 ENGINE
6-7 6-8
Water Temperature and Oil Vacuum Switch
Pressure Gauges
How to Test the Vacuum Switch
The water temperature gauge is an electrical
gauge. The sending unit has limit contacts that are a b
factory set. The contacts will close at 230o F
(109o C). When the contacts close, the engine will
shut off to prevent damage and will not start until
the temperature drops below the contact point.
Temperature will be indicated when the key is on
and the Emergency Stop Button is pulled out to
the ON position.

Do not crank the engine with
the over-temperature light on.
The oil pressure gauge is an electrical gauge. The
sending unit has limit contacts that are factory set.
The contacts will close at 8 psi (0.55 bar). When d c
the contacts close, the engine will shut off to
prevent damage. Oil pressure will be indicated a ohmmeter
b common terminal (SOL.)
when the engine is running. c vacuum switch
d normally open terminal (ING.)
Do not continue to run the engine 1 Connect the leads from an ohmmeter or
with the low oil pressure light on. continuity tester to the common and normally
open terminals.
Result: There should be no continuity
(infinite Ω).
2 Apply mild suction to the vacuum port.
Result: The switch should close and show full
continuity (zero Ω).
Do not short the vacuum switch
terminals to ground.
7 - 22 Genie S-40 Part No. 32222

Ground Controls
7-1 Test Desired result

Control Relays terminal 13 to 14 160 to 170Ω
Relays used for single function switching are terminal 8 to 5, 4, 1,12 & 9 no continuity
single pole double throw (SPDT) relays. (There (infinite Ω)
are two types of single pole double throw relays terminal 5 to 4, 1, 12 & 9 no continuity
used for ground controls.) Dual function switching
requires a double pole double throw (DPDT) relay. terminal 4 to 1 & 9 no continuity
How to Test a Double Pole Double
Throw Relay terminal 4 to 12 continuity
(zero Ω)
Electrocution hazard.
Contact with electrically charged
circuits may cause death or
serious injury. Remove all rings,
4 Connect 12V DC to terminal 14 and a ground
watches and other jewelry.
wire to terminal 13, then test the following
This procedure covers fundamental relay testing terminal combinations.
and does not specifically apply to all varieties
of relays. Test Desired result
1 Turn the key switch to the OFF position and terminal 8 to 1, 5, 9 & 4 no continuity
remove the key. (infinite Ω)
2 Label and then disconnect all the wiring from terminal 5 to 1, 4 & 12 no continuity
the relay to be tested. terminal 4 to 1, 9 & 12 no continuity
3 Connect the leads from an ohmmeter to each terminal 1 to 9 & 12 no continuity
terminal combination and check for continuity.
Terminals 13 and 14 represent the coil and terminal 8 to 12 continuity
should not be tested in any other combination. (zero Ω)
i a (zero Ω)
h b
g d
f e
a terminal no. 5
b terminal no. 1
c relay
d terminal no. 13
e terminal no. 9
f terminal no. 12
g terminal no. 14
h terminal no. 4
i terminal no. 8
Part No. 32222 Genie S-40 7 - 23

GROUND CONTROLS
How to Test a Single Pole Test Desired result

Double Throw Relay terminal 13 to 14 190 to 200Ω
This procedure covers fundamental relay terminal 5 to 1 & 9 no continuity
testing and does not specifically apply to all (infinite Ω)
varieties of relays.
Socket Connection Relay (zero Ω)
1 Turn the key switch to the OFF position and

remove the key. 4 Connect 12V DC to terminal 14 and a ground
2 Label and then disconnect all the wiring from wire to terminal 13, then test the following
the relay to be tested. terminal combinations.
3 Connect the leads from an ohmmeter or Test Desired result

continuity tester to each terminal combination
terminal 1 to 5 & 9 no continuity
and check for continuity. Terminals 13 and 14
(infinite Ω)
represent the coil and should not be tested in
any other combination. terminal 5 to 9 continuity
(zero Ω)
a
f d
a terminal no. 5
b terminal no. 1
c relay
d terminal no. 13
e terminal no. 9
f terminal no. 14
7 - 24 Genie S-40 Part No. 32222

GROUND CONTROLS
Direct Connection Relay 7-2

1 Label and then disconnect all the wiring from Toggle Switches
the relay to be tested.
See 1-5, Toggle Switches.
2 Connect the leads from an ohmmeter or
continuity tester to each terminal combination
and check for continuity. Terminals 85 and 86
represent the coil and should not be tested in
any other combination.
7-3
Wago® Components
e a How to Remove a Wago®

d b
Component
c Electrocution hazard.
a terminal no. 87a
b terminal no. 85 A small screwdriver is provided
c terminal no. 30
d terminal no. 86
and should be used when
e terminal no. 87 removing a Wago® component.
This screwdriver is located in the
Test Desired result operator’s manual storage box in
the platform.
terminal 85 to 86 85 to 95Ω
1 Label the wiring from the component to be
terminal 87 to 87a & 30 no continuity removed.
(infinite Ω)
2 Use the provided screwdriver to push in and
terminal 87a to 30 continuity release the wire from the component.
(zero Ω)
3 Locate the removal tab on the bottom or top
side of the component.
3 Connect 12V DC to terminal 85 and a ground
4 Use the provided screwdriver to gently pry up
wire to terminal 86, then test the following
on the tab of the component and remove it.
terminal combinations.
Test Desired result
terminal 87 to 87a & 30 no continuity

(infinite Ω)
(zero Ω)
Part No. 32222 Genie S-40 7 - 25

GROUND CONTROLS
7-4 2 Connect 12V DC to one of the small posts and

a ground wire to the other small post, then test
Resistors the following terminal combination.
How to Test the Resistor Test Desired result
The resistor is used to maintain proper control of 2 large posts continuity (zero Ω)
boom function speeds. A 10 ohm resistor reduces
voltage to all the boom function switches.
Turn the key switch to the OFF a b b a

position and remove the key.
1 Disconnect either end of one of the wires
connected to the resistor to be tested.
end or wiring of the resistor being tested.
3 Compare the ohmmeter reading with the
resistance rating printed on the resistor.
7-5
Power Relay
a high amp power contact terminal
Electrocution hazard. Contact with (large post)
b solenoid activate coil terminal
electrically charged circuits may (small post)
result in death or serious injury.
Remove all rings, watches and
other jewelry.
How to Test the Power Relay

Electrocution hazard. Disconnect
the ground cable from the battery
before performing this procedure.
terminal combination and check for continuity.
Test Desired result
2 small posts 13 to 17Ω
2 large posts no continuity

(infinite Ω)
Any small post to no continuity

any large post (infinite Ω)
7 - 26 Genie S-40 Part No. 32222

Hydraulic Pumps
8-1 5 Deutz Diesel models: Hold the manual

fuel shutoff valve counterclockwise to the
Lift/Steer Pump CLOSED position.
All models: Observe the pressure gauge

How to Test the Lift/Steer Pump while cranking the engine. Immediately stop
cranking if the pressure reaches or exceeds
1 Disconnect and plug the high pressure
3000 psi (206 bar).
hydraulic hose from the lift/steer pump.
Hydraulic pressure in excess of
3000 psi (206 bar) will cause
damage to the machine.
the oil pressure to dissipate Result: If the pressure gauge reads
gradually. Do not allow oil to 3000 psi (206 bar), immediately stop
squirt or spray. cranking the engine. The pump is good.
2 Connect a 0 to 5000 psi (0 to 350 bar) pressure Result: If the pressure fails to reach 3000 psi
gauge to the high pressure port. (206 bar), the pump is bad and will need to be
serviced or replaced.
3 Gasoline/LPG models: Remove the high
tension lead from the center of the ignition coil. 6 Gasoline/LPG models: Reconnect the high
tension lead to the ignition coil.
Electrocution hazard. Contact with
electrically charged circuits may
cause death or serious injury.
Remove all rings, watches and
other jewelry.
4 Turn the key switch to ground control and
pull out the Emergency Stop button to the
ON position.
Part No. 32222 Genie S-40 7 - 27

HYDRAULIC PUMPS
How to Remove the 8-2

Lift/Steer Pump Drive Hydraulic Pump
1 Close the two hydraulic tank valves located at
The drive hydraulic pump is a bi-directional
the hydraulic tank.
variable displacement piston pump. The pump
output is controlled by the electronic displacement
controller (EDC), located on the pump. The only
adjustment that can be made to the pump is the
neutral or null adjustment. Any internal service to
the pump should only be performed at an
authorized Sundstrand-Sauer service center.
open closed How to Remove the Drive

Component damage hazard. The Hydraulic Pump
engine must not be started with Component damage hazard. The
the hydraulic tank shutoff valves work area and surfaces where this
in the CLOSED position or procedure will be performed must
component damage will occur. be clean and free of debris that
If the tank valves are closed, could get into the hydraulic
remove the key from the key system and cause severe
switch and tag the machine to component damage. Dealer
inform personnel of the condition. service is recommended.
2 Disconnect and plug the lift/steer pump 1 Disconnect the electrical connection at the
hydraulic hoses. Cap the fittings. electronic displacement controller (EDC)
Bodily injury hazard. Spraying located on the drive pump.
hydraulic oil can penetrate and 2 Close the two hydraulic tank valves located at
burn skin. Loosen hydraulic the hydraulic tank.
squirt or spray.
3 Remove the pump mounting bolts. Carefully
remove the pump.
Be sure to open the two hydraulic open closed
tank valves and prime the pump Component damage hazard. The
after installing the pump. engine must not be started with
the hydraulic tank shutoff valves
in the CLOSED position or
component damage will occur. If
the tank valves are closed,
remove the key from the key
switch and tag the machine to
inform personnel of the condition.
7 - 28 Genie S-40 Part No. 32222

HYDRAULIC PUMPS
3 Disconnect the hydraulic hoses from the pumps

and cap them.
squirt or spray.
4 Support the pump and remove the two
drive pump mounting bolts. Carefully
remove the pump.
Be sure to open the two hydraulic
tank valves and prime the pump
after installing the pump.
How to Prime the Pump

1 Connect a 0 to 600 psi (0 to 41 bar) pressure
gauge to the test port on the drive pump.
tension lead from the center of the ignition coil.
Deutz Diesel models: Hold the manual fuel
shutoff valve counterclockwise to the CLOSED
position.
3 Crank the engine with the starter motor for
15 seconds, wait 15 seconds, then crank the
pressure reaches 320 psi (22 bar).
Part No. 32222 Genie S-40 7 - 29

Function Manifold
9-1
Function Manifold Components
Index Schematic
No. Description Item Function Torque
1 3 position 4 way D03 valve ............... N ........... Platform rotate .................................. 30-35 in-lbs / 3-4 Nm
2 Counterbalance valve ........................ B ........... Platform level up ............................... 35-40 ft-lbs / 47-54 Nm
3 Sandwich valve manifold ................... A ........... Platform level
4 3 position 4 way D03 valve ............... O ........... Platform level .................................... 30-35 in-lbs / 3-4 Nm
5 3 position 4 way D03 valve ............... P ........... Turntable rotate ................................ 30-35 in-lbs / 3-4 Nm
6 Cover plate ........................................ Q ....................................................................... 30-35 in-lbs / 3-4 Nm
7 3 position 4 way D03 valve ............... R ........... Boom up/down .................................. 30-35 in-lbs / 3-4 Nm
8 3 position 4 way D03 valve ............... S ........... Boom extend/retract ......................... 30-35 in-lbs / 3-4 Nm
9 Counterbalance valve ........................ C ........... Platform level down .......................... 35-40 ft-lbs / 47-54 Nm
10 Check valve ....................................... K ........... Turntable rotate
differential sensing .......................................... 11-13 ft-lbs / 15-18 Nm
11 Check valve ....................................... M .......... Boom up/down
12 Flow regulator valve .......................... Y ........... Boom up/down .................................. 10-12 ft-lbs / 14-16 Nm
13 Relief valve, 1950 psi (134 bar) ........ D ........... Boom extend ..................................... 25-30 ft-lbs / 34-41 Nm
14 Relief valve, 2200 psi (152 bar) ........ F ........... Boom down ....................................... 25-30 ft-lbs / 34-41 Nm
15 Proportional solenoid valve ............... AA ......... Boom ................................................. 10-12 ft-lbs / 14-16 Nm
16 Flow regulator valve .......................... X ........... Turntable rotate/
boom extend/retract ....................................... 10-12 ft-lbs / 14-16 Nm
17 Normally closed poppet valve ........... J ............ Platform level .................................... 25-30 ft-lbs / 34-41 Nm
18 Proportional solenoid valve ............... Z ........... Turntable rotate/
boom extend/retract ....................................... 10-12 ft-lbs / 14-16 Nm
19 Flow regulator valve .......................... V ........... Platform level .................................... 10-12 ft-lbs / 14-16 Nm
20 Differential sensing valve .................. AC ........ All functions ....................................... 10-12 ft-lbs / 14-16 Nm
21 Flow regulator valve .......................... U ........... Platform rotate .................................. 10-12 ft-lbs / 14-16 Nm
22 Flow regulator valve .......................... W .......... Differential sensing circuit ................. 10-12 ft-lbs / 14-16 Nm
23 Diagnostic fitting ............................................... Testing
24 Relief valve, 2600 psi (179 bar) ........ AB ......... System relief ..................................... 35-40 ft-lbs / 47-54 Nm
25 Priority flow regulator valve ............... T ........... Steering ............................................. 10-12 ft-lbs / 14-16 Nm
26 Check valve ....................................... I ............ Platform rotate right -
27 Check valve ....................................... H ........... Platform rotate left -
28 Check valve ....................................... L ........... Platform level -
7 - 30 Genie S-40 Part No. 32222

FUNCTION MANIFOLD
1 2 3 4 5 6 7 8
10
11
28 12
27
26
25 13
14
24
15
16
23 22 21 20 19 18 17
Part No. 32222 Genie S-40 7 - 31

FUNCTION MANIFOLD
9-2 How to Adjust the Boom Down

Valve Adjustments - Relief Valve
Function Manifold Perform this procedure with the boom in the
stowed position.
How to Adjust the Main 1 Connect a 0 to 3000 psi (0 to 206 bar) pressure
Relief Valve gauge to the test port on the function manifold.
Perform this procedure with the boom in the 2 Start the engine from the ground controls.
stowed position.
3 Hold the boom down switch with the boom fully
1 Connect a 0 to 3000 psi (0 to 206 bar) pressure lowered, and observe the pressure reading on
gauge to the test port on the function manifold. the pressure gauge.
2 Start the engine from the ground controls. 4 Turn the engine off. Hold the relief valve and
remove the cap (item 14, function manifold).
3 Hold the retract switch with the boom fully
retracted, and observe the pressure reading on 5 Adjust the internal hex socket. Turn it clockwise
the pressure gauge. to increase the pressure or counterclockwise to
decrease the pressure. Then install the relief
4 Turn the engine off. Hold the relief valve and valve cap.
Tip-over hazard. Do not adjust
5 Adjust the internal hex socket. Turn it clockwise the relief valves higher than
to increase the pressure or counterclockwise to recommended.
valve cap. 6 Restart the engine. Hold the boom down switch
with the boom fully lowered and recheck the
Tip-over hazard. Do not adjust valve pressure.
the relief valves higher than
recommended. Boom down relief valve specifications
6 Restart the engine. Hold the retract switch with Pressure 2200 psi
the boom fully retracted, and recheck the valve 152 bar
pressure.
Main relief valve specifications
Pressure 2600 psi

179 bar
7 - 32 Genie S-40 Part No. 32222

FUNCTION MANIFOLD
How to Adjust the Boom Extend How to Override a Valve

Relief Valve A hydraulic valve may need to be manually
Perform this procedure with the boom in the overridden to troubleshoot a malfunction. The
stowed position. proportional boom functions (boom up/down and
turntable rotate) use a variable position
1 Connect a 0 to 3000 psi (0 to 206 bar) pressure proportional valve and a three position directional
gauge to the test port on the function manifold. valve. Example: one position for boom up, one
position for neutral and one position for boom
down. The platform rotate function uses a three
3 Hold the extend switch with the boom fully position valve. The platform level uses a three
extended, and observe the pressure reading on position and a two position valve. The three
the pressure gauge. position valves and the proportional valves can be
manually overridden. To identify the manifold
4 Turn the engine off. Hold the relief valve and
valves see 9-1, Function Manifold, in this section.
1 Push the button on the end of the valve in
5 Adjust the internal hex socket. Turn it clockwise
¼ inch (6 mm).
to increase the pressure or counterclockwise to
valve cap.
Tip-over hazard. Do not adjust
the relief valves higher than
recommended.
6 Restart the engine. Hold the extend switch with
the boom fully extended, and recheck the valve
pressure.
Boom extend relief valve specifications
Pressure 1950 psi

2 Move the ground control function switch for the
134 bar
function being overridden to operate function.
Collision hazard. Impact with
moving boom components may
cause death or serious injury. Use
extreme caution when overriding a
machine function. Identify the
direction of machine movement
before overriding a valve.
Part No. 32222 Genie S-40 7 - 33

FUNCTION MANIFOLD
How to Check the Resistance

of a Valve Coil
1 Turn the key switch to the OFF position and
disconnect the wires from the valve coil to be
tested.
2 Connect the leads from an ohmmeter to the
valve coil terminals.
Valve coil specifications
Proportional solenoid valve 5Ω
3 position 4 way directional valve 4.5Ω
Normally closed poppet valve 7Ω
7 - 34 Genie S-40 Part No. 32222

Fuel and Hydraulic Tanks
10-1 4 Disconnect the hydraulic hoses from the tank.

Hydraulic Tank 5 Remove the mounting fasteners from the
bottom of the tank.
The primary functions of the hydraulic tank are to 6 Use an appropriate lifting device to remove the
cool, clean and deaerate the hydraulic fluid during tank from the machine.
operation. This tank has a 45 gallon (170 liter)
capacity and an oil level gauge with a temperature Always use pipe thread sealant
indicator. It utilizes internal suction strainers for when installing the drain plug.
the pump supply suction lines and has an external Use only Dexron II equivalent
return line filter with a condition indicator. hydraulic fluid.
How to Remove the Component damage hazard.
Hydraulic Tank Be sure to open the two hydraulic
tank valves and prime the pump
Component damage hazard. after installing the hydraulic tank.
The work area and surfaces
where this procedure will be How to Prime the Pump
performed must be clean and 1 Connect a 0 to 600 psi (0 to 41 bar) pressure
free of debris that could get gauge to the test port on the drive pump.
into the hydraulic system.
1 Remove the fuel tank. See 10-2, How to tension lead from the center of the ignition coil.
Remove the Fuel Tank.
2 Close the two hydraulic tank valves located at Contact with electrically charged
the hydraulic tank. circuits may cause death or
Deutz Diesel models: Hold the manual fuel
shutoff valve counterclockwise to the CLOSED
position.
3 Crank the engine with the starter motor for
open closed 15 seconds, wait 15 seconds, then crank the
3 Completely drain the oil from the tank by pressure reaches 320 psi (22 bar).
removing the drain plug located in the
bottom of the tank.
Burn hazard. Contact with hot oil
may cause severe burns.
Part No. 32222 Genie S-40 7 - 35

FUEL AND HYDRAULIC TANKS
10-2
Fuel Tank
How to Remove the Fuel Tank

Explosion hazard. Engine fuels
are combustible. Remove the fuel
tank in an open, well-ventilated
area away from heaters, sparks,
flames and lighted tobacco.
Always have an approved fire
extinguisher within easy reach.
Explosion hazard. When
transferring fuel, connect a
grounding wire between the
machine and pump or container.
1 Turn the manual fuel shutoff valve to the
CLOSED position.
2 Gasoline/LPG models: Disconnect, drain and

plug the fuel hose.
Deutz Diesel models: Disconnect, drain and
plug the supply and return fuel lines. Cap the
fuel return fitting on the fuel tank.
3 Remove the mounting fasteners from the
bottom of the tank.
4 Use an appropriate lifting device to remove the
tank from the machine.
Clean the fuel tank and inspect
for rust and corrosion before
installing.
7 - 36 Genie S-40 Part No. 32222

Turntable Rotation Components
11-1 2 Disconnect the hydraulic hoses from the motor

and manifold, and cap them.
Rotation Hydraulic Motor
Bodily injury hazard.
Spraying hydraulic oil can
How to Remove the Rotation penetrate and burn skin. Loosen
Hydraulic Motor hydraulic connections very slowly
to allow the oil pressure to
1 Secure the turntable from rotating with the
dissipate gradually. Do not
turntable rotation lock pin.
allow oil to squirt or spray.
3 Remove the motor mounting bolts, then
remove the motor from the brake.
a b
d
Unlocked position
e
f e
a motor/brake mounting bolts

b motor
c brake
d torque hub mounting bolts
e plug
f torque hub
How to Remove the Turntable

Rotation Brake or Torque Hub
Locked position
Refer to Maintenance Procedures, C-5, How to
Replace the Torque Hub Oil.
Part No. 32222 Genie S-40 7 - 37

TURNTABLE ROTATION COMPONENTS
11-2
Turntable Rotation Manifold Components
Index Schematic
1 Shuttle valve 2 position 3 way ........... C ........... Turntable rotation brake release ...... 10-13 ft-lbs / 14-18 Nm
2 Counterbalance valve ........................ A ........... Turntable rotate - right ...................... 35-40 ft-lbs / 47-54 Nm
3 Counterbalance valve ........................ B ........... Turntable rotate - left ........................ 35-40 ft-lbs / 47-54 Nm
1 2 3
Plug Torque Specifications

Description Hex size Torque
1
SAE No. 2 /8 50 in-lbs / 6 Nm
3
SAE No. 4 /16 13 ft-lbs / 18 Nm
1
SAE No. 6 /4 18 ft-lbs / 24 Nm
5
SAE No. 8 /16 50 ft-lbs / 68 Nm
9
SAE No. 10 /16 55 ft-lbs / 75 Nm
5
SAE No. 12 /8 75 ft-lbs / 102 Nm
7 - 38 Genie S-40 Part No. 32222

12-1 5 Remove the lug nuts, then the tire and

wheel assembly.
Yoke and Hub
6 Remove the retaining bolt from the king pin.
How to Remove the Yoke 7 Attach a strap from a lifting device to the
and Hub yoke/hub assembly for support.
8 Use a slide hammer to remove the upper king
1 Remove the retaining bolt, then the pivot pin
pin, then use a soft metal drift to drive the
from both the steering cylinder and the tie rod.
lower king pin down and out.
Crushing hazard. The yoke/hub
a b c d assembly will fall when the king
pins are removed if it is not
properly supported.
Torque specifications
Lug nut 125 ft-lbs

169.5 Nm
h f f e
a tie rod
b axle
c king pin/retaining bolt
d yoke
e hub
f pivot pin/retaining bolt
g steering cylinder
2 Loosen the wheel lug nuts. Do not

remove them.
3 Block the non-steering wheels, and then
center a lifting jack under the steering axle.
4 Raise the machine 6 inches (15 cm) and place
blocks under the chassis for support.
Part No. 32222 Genie S-40 7 - 39

2WD STEERING AXLE COMPONENTS
How to Remove the 6 Install the washer and slotted nut.

Hub and Bearings 7 Tighten the slotted nut to 35 foot-pounds
(47 Nm).
1 Loosen the wheel lug nuts. Do not remove
them. 8 Loosen the slotted nut, then re-tighten to
8 foot-pounds (11 Nm).
2 Block the non-steering wheels and place a
lifting jack under the steering axle. 9 Install a new cotter pin. Bend the cotter pin
to lock it in.
3 Raise the machine and place blocks under
the chassis for support. 10 Install the dust cap, then the tire and wheel
assembly. Torque the wheel lug nuts to
4 Remove the lug nuts. Then remove the tire 125 foot-pounds (169.5 Nm).
and wheel assembly.
5 Remove the dust cap, cotter pin and
slotted nut.
12-2
6 Pull the hub off the spindle. The washer and Steering Cylinders
outer bearing should fall loose from the hub.
7 Place the hub on a flat surface and gently pry How to Remove a
the bearing seal out of the hub. Remove the
rear bearing.
Steering Cylinder
There are two identical steering cylinders that
How to Install the work in parallel. They are part of the same
Hub and Bearings hydraulic circuit, but move in opposite directions.
The tie rod maintains equal movement of the tires.
When replacing a wheel bearing, Bushings are used at both ends of each steering
both the inner and outer bearings cylinder clevis.
including the pressed-in races
must be replaced. 1 Disconnect and plug the hydraulic hoses from
the steering cylinder. Cap the fittings.
1 Be sure that both bearings are packed
with grease. Bodily injury hazard. Spraying
2 Place the large inner bearing into the rear
of the hub.
3 Press the bearing seal evenly into the hub the oil pressure to dissipate
until it is flush. gradually. Do not allow oil to
squirt or spray.
4 Slide the hub onto the yoke spindle.
2 Remove the pin retaining fasteners. Then
Component damage. Do not remove the pivot pin from each end of the
apply excessive force or damage steering cylinder.
to the lip of the seal may occur.
3 Remove the steering cylinder.
5 Place the outer bearing into the hub.
7 - 40 Genie S-40 Part No. 32222

12-3 3 Center a lifting jack under the steering axle,

then raise the machine.
Tie Rod
4 Loosen the jam nut on the adjustable end
of the tie rod.
How to Remove the Tie Rod
5 Remove the pin retaining fasteners, then
1 Remove the pin retaining fasteners, then remove the pivot pin from the adjustable end of
remove the pivot pin from each end of the tie the tie rod.
rod.
6 Slide the tie rod off the yoke and adjust it by
2 Remove the tie rod. turning the end.
How to Perform the Toe-in One turn on the adjustable end
Adjustment equals approximately 1/8 inch
(3.2 mm) change in the front
Perform this procedure on a and rear measurements.
firm, level surface. Block the
7 Slide the tie rod onto the yoke. Install the
non-steering tires and be sure
pivot pin, then install the retaining bolt.
that the machine is in the
stowed position. 8 Tighten the jam nut against the tie rod.
1 Straighten the steer wheels. 9 Lower the machine and recheck the
front and back measurements (step 2).
2 Measure the steer tires, front to front and back
If further adjustment is needed, repeat
to back, using a measuring fixture.
steps 3 through 8.
Toe-in specification 0 ± 1/8 inch (6.35 mm)
Part No. 32222 Genie S-40 7 - 41

13-1 from the wheel motor. Cap the wheel motor

hydraulic fittings.
Yoke and Hub
How to Remove the Yoke burn skin. Loosen hydraulic
and Hub connections very slowly to allow
The yoke installation utilizes bushings and a thrust
washer that may require periodic replacement.
squirt or spray.
The yoke must be removed before the torque hub
can be removed. 4 Loosen the wheel lug nuts. Do not
remove them.
Rotate the turntable until the platform is 5 Block the non-steering wheels, and then
between the steer tires. center a lifting jack under the steering axle.
2 Remove the pin retaining fasteners, then 6 Raise the machine 15 inches (38 cm) and place
remove the pivot pin from both the steering blocks under the chassis for support.
cylinder and the tie rod. 7 Remove the lug nuts, then remove the tire and
wheel assembly.
a 8 Remove the hydraulic hose mounting bracket

from the top of the yoke.
9 Remove the roll pin from the upper king pin.
10 Remove the retaining bolts from the upper and
b lower king pins.
11 Remove the drive motor mounting fasteners.
12 Slide the drive motor shaft out of the brake and
then remove it.
13 Attach a strap from a lifting device to the
c
yoke/torque hub assembly for support.
g f e d
a oscillate cylinder
b king pin
c torque hub
d yoke
e pivot pin
f steer cylinder
g tie rod
3 Disconnect and plug the hydraulic hoses
7 - 42 Genie S-40 Part No. 32222

14 Use a slide hammer to remove the upper king 13-3

pin, then use a soft metal drift to drive the
lower king pin down and out. Tie Rod
Crushing hazard. The yoke/torque
hub assembly will fall when the
How to Remove the Tie Rod
lower king pin is removed if it is This procedure is the same as the 2WD
not properly supported. procedure. See Repair Procedure 12-3,
15 Place the yoke/torque hub assembly on a flat How to Remove the Tie Rod.
surface with the torque hub down. Remove the
bolts that secure the yoke to the torque hub.
How to Perform the Toe-in
Adjustment
Torque specifications
This procedure is the same as the 2WD
Lug nut 125 ft-lbs procedure. See Repair Procedure 12-3,
169.5 Nm How to Perform the Toe-in Adjustment.
Torque hub mounting bolts 120 ft-lbs
163 Nm
Drive motor mounting bolts 75 ft-lbs

102 Nm
13-2
Steering Cylinders
How to Remove a
Steering Cylinder
This procedure is the same as the 2WD
procedure. See repair procedure 12-2,
How to Remove a Steering Cylinder.
Part No. 32222 Genie S-40 7 - 43

Oscillating Axle Components
14-1 4 Remove the pin retaining fasteners from both

pivot pins.
Oscillating Axle
5 Attach a strap from a lifting device to the
Lock-out Cylinders cylinder for support.
The oscillating axle cylinders extend and retract 6 Use a soft metal drift to remove the pins.
between the drive chassis and the oscillating axle.
The cylinders are equipped with counterbalance
valves to prevent movement in the event of a
hydraulic line failure. The valves are not
adjustable.
How to Remove an Oscillating

Axle Cylinder
This procedure requires specific
repair skills and a suitable
workshop. Attempting this
procedure without these skills
and tools may result in death or
serious injury and significant
component damage. Dealer
service is strongly recommended.
Perform this procedure on a firm,
level surface with the boom in
the stowed position.
1 Block the non-steering wheels, then center a
lifting jack between the steering wheels under
the axle pivot pin.
2 Raise the machine 6 inches (15 cm) and place
blocks under the drive chassis.
3 Disconnect and plug the oscillating axle
cylinder hydraulic hoses, and cap the cylinder
fittings.
gradually. Do not allow oil to squirt
or spray.
7 - 44 Genie S-40 Part No. 32222

Steer and Oscillate Manifolds
15-1
Oscillate Manifold Components
Index Schematic
1 Diagnostic fitting ............................................... Testing
2 Differential sensing valve .................. A ........... Differential sensing ........................... 10-12 ft-lbs / 14-16 Nm
3 Check valve ....................................... D ........... Oscillate check - left ......................... 35-40 ft-lbs / 47-54 Nm
4 Pilot operated unloader valve
1200 psi (82.7 bar) ............................ B ........... Sequencing ....................................... 10-12 ft-lbs / 14-16 Nm
5 Shuttle valve 2 position 3 way ........... C ........... Pilot ................................................... 10-12 ft-lbs / 14-16 Nm
6 Piston ................................................. G ........... Check valve circuit
7 Check valve ....................................... E ........... Oscillate check - right ....................... 35-40 ft-lbs / 47-54 Nm
8 Shuttle valve 2 position 3 way ........... F ........... Unloading .......................................... 35-40 ft-lbs / 47-54 Nm
1 2
6 5

Description Hex size Torque Description Hex size Torque
1 5
SAE No. 2 /8 50 in-lbs / 6 Nm SAE No. 8 /16 50 ft-lbs / 68 Nm
3 9
SAE No. 4 /16 13 ft-lbs / 18 Nm SAE No. 10 /16 55 ft-lbs / 75 Nm
1 5
SAE No. 6 /4 18 ft-lbs / 24 Nm SAE No. 12 /8 75 ft-lbs / 102 Nm
Part No. 32222 Genie S-40 7 - 45

STEER AND OSCILLATE MANIFOLDS
15-2
Valve Adjustments
How to Adjust the Sequencing

Valve Pressure
gauge to the test port located on the oscillate
manifold.
squirt or spray.
2 Disconnect the directional valve linkage, by
removing the clevis yoke from the drive
chassis.
4 With the engine running, manually activate the
valve and observe the pressure reading on the
pressure gauge.
5 Turn the engine off. Hold the valve and remove
the cap (index 4).
to increase the pressure or counterclockwise
to decrease the pressure. Then install the
valve cap.
7 Restart the engine. manually activate the valve
and recheck the valve pressure.
8 Turn the engine off, then remove the
pressure gauge and assemble the directional
valve linkage.
Unloader valve specifications
Pressure 1200 psi

82.7 bar
7 - 46 Genie S-40 Part No. 32222

15-3
Directional Valve Manifold Components
Index Schematic
1 Cap ................................................................... Breather ............................................ 20-25 ft-lbs / 27-33
Nm
2 Spool valve ....................................................... Directional control
Part No. 32222 Genie S-40 7 - 47

How to Set Up the Directional

Valve Linkage
Adjustment of the directional valve
linkage is only necessary when
the linkage or valve has been
replaced.
1 Lower the boom to the stowed position.
2 Use a "bubble type" level to be sure the floor is
completely level.
Failure to perform this procedure
on a level floor will compromise
the stability of the machine and
may result in the machine tipping
over.
3 Remove the drive chassis cover from the
non-steer end.
4 Disconnect the linkage clevis yoke from the
drive chassis (if not already disconnected).
5 Place a "bubble type" level across the drive
chassis non-steer end. Check to be sure the
drive chassis is completely level.
6 To level the drive chassis, start the engine and
push up or pull down on the linkage adjustment
rod until the machine is completely level.
7 Verify that the ground and drive chassis are
completely level.
8 Adjust the length of the rod by turning the clevis
yoke until the clevis yoke can be pinned to the
drive chassis.
9 Install the clevis yoke pin then the cotter pin.
Be sure to bend the cotter pin.
10 Measure the distance between the drive
chassis and the non-steer axle on both sides
(from the inside of the drive chassis).
If the distance is not equal and the
adjustment to the linkage was
completed with the ground and
drive chassis level, consult Genie
Industries Service Department.
7 - 48 Genie S-40 Part No. 32222

15-4
Steer Manifold Components
Index Schematic
1 3 position 4 way D03 valve .............................. Steering ............................................. 30-35 in-lbs / 3-4 Nm
2 Priority flow regulator valve ............... A ........... Oscillate ............................................ 10-12 ft-lbs / 14-16 Nm

5
SAE No. 2 1
/8 50 in-lbs / 6 Nm SAE No. 8 /16 50 ft-lbs / 68 Nm
9
SAE No. 4 3
/16 13 ft-lbs / 18 Nm SAE No. 10 /16 55 ft-lbs / 75 Nm
5
SAE No. 6 1
/4 18 ft-lbs / 24 Nm SAE No. 12 /8 75 ft-lbs / 102 Nm
Part No. 32222 Genie S-40 7 - 49

Non-steering Axle Components
16-1 16-2
Drive Motor Torque Hub
Component damage hazard. How to Remove a Drive
Repairs to the motor should only
be performed by an authorized Torque Hub
Sundstrand-Sauer dealer. 1 Remove the drive motor. See 16-1, How to
Remove a Drive Motor.
How to Remove a Drive Motor
2 Disconnect the hydraulic hose from the brake
A drive motor can only be removed from the inside and plug it. Then remove the hydraulic fitting
of the chassis. and the bleed valve.
Component damage hazard. The 3 Loosen the wheel lug nuts. Do not
work area and surfaces where this remove them.
procedure will be performed must
be clean and free of debris that 4 Center a lifting jack under the non-steering
could get into the hydraulic axle. Raise the machine and place blocks
system and cause severe under the drive chassis to support it.
component damage. Dealer 5 Remove the wheel lug nuts, then the tire and
service is recommended. wheel assembly.
1 Disconnect the hydraulic hoses from the drive 6 Place a second lifting jack under the torque hub
motor and plug them. for support.
Bodily injury hazard. Spraying 7 Remove the bolts that attach the torque hub to
hydraulic oil can penetrate and the chassis, then remove the torque hub.
connections very slowly to allow Crushing hazard. The torque
the oil pressure to dissipate hub will fall if it is not properly
gradually. Do not allow oil to squirt supported when the mounting
or spray. bolts are removed.
2 Remove the drive motor mounting bolts. Torque specifications
3 Slide the drive motor shaft out of the brake and Lug nut 125 ft-lbs
then remove it. 169.5 Nm
Torque specifications Drive torque hub mounting bolts 120 ft-lbs

163 Nm
Drive motor mounting bolts 75 ft-lbs
102 Nm Drive motor mounting bolts 75 ft-lbs
102 Nm
7 - 50 Genie S-40 Part No. 32222

Part No. 32222 Genie S-40 7 - 51

2WD Drive Manifold
17-1
2WD Drive Manifold Components
Index Schematic
1 Relief valve, 250 psi (17 bar) ............ A ........... Charge pressure ........................... 15-18 ft-lbs / 20-24 Nm
2 Flow regulator valve .......................... G ........... RR flow control in reverse ............ 15-18 ft-lbs / 20-24 Nm
3 Flow regulator valve .......................... K ........... RR flow control in forward ............ 15-18 ft-lbs / 20-24 Nm
4 Flow regulator valve .......................... F ........... LR flow contol in reverse .............. 15-18 ft-lbs / 20-24 Nm
5 Flow regulator valve .......................... J ............ LR flow control in forward ............. 15-18 ft-lbs / 20-24 Nm
6 Flow control valve .............................. H ........... RR flow regulator in reverse ......... 15-18 ft-lbs / 20-24 Nm
7 Flow control valve .............................. E ........... LR flow regulator in reverse ........ 15-18 ft-lbs / 20-24 Nm
8 Flow control valve .............................. L ........... RR flow regulator in forward ......... 15-18 ft-lbs / 20-24 Nm
9 Flow control valve .............................. I ............ LR flow regulator in forward ......... 15-18 ft-lbs / 20-24 Nm
10 Shuttle valve ...................................... B ........... Charge pressure circuit ................ 15-18 ft-lbs / 20-24 Nm

1
SAE No. 2 /8 50 in-lbs / 6 Nm SAE No. 8 5
/16 50 ft-lbs / 68 Nm
3
SAE No. 4 /16 13 ft-lbs / 18 Nm SAE No. 10 9
/16 55 ft-lbs / 75 Nm
1
SAE No. 6 /4 18 ft-lbs / 24 Nm SAE No. 12 5
/8 75 ft-lbs / 102 Nm
7 - 52 Genie S-40 Part No. 32222

2WD DRIVE MANIFOLD
1 2 3 4 5 6 7 8 9
10
Part No. 32222 Genie S-40 7 - 53

2WD DRIVE MANIFOLD
17-2
Valve Adjustments
How to Adjust the Charge

Pressure Relief Valve
gauge to the test port located on the drive
manifold.
squirt or spray.
3 Drive the machine slowly in either direction and
observe the pressure reading on the pressure
gauge.
remove the cap (index 1).
valve cap.
6 Restart the engine. Drive the machine in either
direction and recheck the valve pressure.
7 Turn the engine off, then remove the
pressure gauge.
Relief valve specifications
Pressure 250 psi

17 bar
7 - 54 Genie S-40 Part No. 32222

Part No. 32222 Genie S-40 7 - 55

4WD Drive Manifold
18-1
4WD Drive Manifold Components
Index Schematic
1 Flow regulator valve .......................... S ........... RF flow control in forward ............. 15-18 ft-lbs / 20-24 Nm
2 Flow regulator valve .......................... R ........... RR flow control in forward ............ 15-18 ft-lbs / 20-24 Nm
3 Flow regulator valve .......................... O ........... RF flow control in reverse ............. 15-18 ft-lbs / 20-24 Nm
4 Flow regulator valve .......................... N ........... RR flow control in reverse ............ 15-18 ft-lbs / 20-24 Nm
5 Flow regulator valve .......................... K ........... LF flow control in forward ............. 15-18 ft-lbs / 20-24 Nm
6 Flow regulator valve .......................... J ............ LR flow control in forward ............. 15-18 ft-lbs / 20-24 Nm
7 Flow regulator valve .......................... G ........... LF flow control in reverse ............. 15-18 ft-lbs / 20-24 Nm
8 Flow regulator valve .......................... F ........... LR flow contol in reverse .............. 15-18 ft-lbs / 20-24 Nm
9 Flow control valve .............................. Q ........... RR flow regulator in forward ......... 15-18 ft-lbs / 20-24 Nm
10 Flow control valve .............................. M .......... RR flow regulator in reverse ......... 15-18 ft-lbs / 20-24 Nm
11 Flow control valve .............................. I ............ LR flow regulator in forward ......... 15-18 ft-lbs / 20-24 Nm
12 Flow control valve .............................. E ........... LR flow regulator in reverse ......... 15-18 ft-lbs / 20-24 Nm
13 Relief valve, 250 psi (17 bar) ............ A ........... Charge pressure ........................... 15-18 ft-lbs / 20-24 Nm
14 Shuttle valve 3 position 3 way ........... B ........... Charge pressure circuit ................ 15-18 ft-lbs / 20-24 Nm
15 Flow control valve .............................. H ........... LF flow regulator in reverse .......... 15-18 ft-lbs / 20-24 Nm
16 Flow control valve .............................. L ........... LF flow regulator in forward .......... 15-18 ft-lbs / 20-24 Nm
17 Flow control valve .............................. P ........... RF flow regulator in reverse ......... 15-18 ft-lbs / 20-24 Nm
18 Flow control valve .............................. T ........... RF flow regulator in forward ......... 15-18 ft-lbs / 20-24 Nm
7 - 56 Genie S-40 Part No. 32222

4WD DRIVE MANIFOLD
1 2 3 4 5 6 7 8 9 10 11 12 13 14
18
17
16
15
Part No. 32222 Genie S-40 7 - 57

4WD DRIVE MANIFOLD
Plug Torque Specifications 6 Restart the engine. Drive the machine in either
direction and recheck the valve pressure.
Description Hex size Torque 7 Turn the engine off, then remove the
SAE No. 2 1
/8 50 in-lbs / 6 Nm pressure gauge.
SAE No. 4 3
/16 13 ft-lbs / 18 Nm Relief valve specifications
SAE No. 6 1
/4 18 ft-lbs / 24 Nm Pressure 250 psi
17 bar
5
SAE No. 8 /16 50 ft-lbs / 68 Nm
9
SAE No. 10 /16 55 ft-lbs / 75 Nm
5
SAE No. 12 /8 75 ft-lbs / 102 Nm
18-2
Valve Adjustments
How to Adjust the Charge

Pressure Relief Valve
gauge to the test port located on the drive
manifold.
squirt or spray.
3 Drive the machine slowly in either direction
and observe the pressure reading on the
pressure gauge.
remove the cap (index 13).
valve cap.
7 - 58 Genie S-40 Part No. 32222

Genie North America
18340 NE 76th Street
P.O. Box 97030
Redmond, Washington
98073-9730
Distributed By:
Genie Europe
Brunel Drive
Newark
Nottinghamshire
NG24 2EG England

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Technical

First Edition, First Printing

This manual provides detailed scheduled

Genie Industries has endeavored to deliver the

Copyright © 1994 by Genie Industries

ii Genie S-40 Part No. 32222

Many of the hazards identified in the operator's

Do Not Perform Maintenance

Part No. 32222 Genie S-40 iii

Personal Safety Workplace Safety

Read each procedure thoroughly. This

Be sure that fasteners intended for one

Be aware of potential crushing hazards Be sure to properly dispose of old oil or

iv Genie S-40 Part No. 32222

Section One Safety Rules

Section Two Specifications

Section Three Scheduled Maintenance Inspections

Section Four Scheduled Maintenance Procedures

Part No. 32222 Genie S-40 v

Section Four Scheduled Maintenance Procedures, continued

vi Genie S-40 Part No. 32222

Section Four Scheduled Maintenance Procedures, continued

Part No. 32222 Genie S-40 vii

Section Five Troubleshooting Flow Charts

viii Genie S-40 Part No. 32222

Section Five Troubleshooting Flow Charts, continued

Section Six Schematics

Part No. 32222 Genie S-40 ix

Section Seven Repair Procedures

x Genie S-40 Part No. 32222

Section Seven Repair Procedures, Ford LSG-423 Engine, continued

Part No. 32222 Genie S-40 xi

Section Seven Repair Procedures, continued

xii Genie S-40 Part No. 32222

Height 8 ft 2 in 8 ft 2 in Tire contact area 88 sq in 57 sq in

Ground clearance 12 1/2 in 12 1/2 in Tire pressure 45 psi 45 psi

Operational dimensions Wheel diameter 16 in 16 1/2 in

Wheelbase 7 ft 3 in 7 ft 3 in Fluid capacities

Minimum turning circle, 6 ft 8 in 6 ft 8 in Hydraulic tank 45 gallons 170 liters

Platform rotation 160° 160° Drive torque hub 17 fl oz 0.51 liters

Platform dimensions 6 ft 8 ft Turntable rotation 8 fl oz 0.24 liters

Length 6 ft 8 ft Continuous improvement of our products is a Genie

Maximum capacity 500 lbs 500 lbs

Part No. 32222 Genie S-40 2-1

Boom stowed 3.5 mph 3 mph Boom extend 35 to 65 seconds

Gradeability (boom stowed) 2WD 4WD

Rough terrain 30% 40%

2-2 Genie S-40 Part No. 32222

Drive pump Type: pressure balanced gear

Type: bi-directional variable displacement piston pump Displacement - static 0.98 cu in

Medium pressure filter 50 psi Boom down 2200 psi

Drive manifold Boom extend 1950 psi

Rear drive motors Displacement - static 0.152 cu in

Auxiliary pump 2500 psi

Part No. 32222 Genie S-40 2-3

BOLT TORQUE SPECIFICATIONS

Bolt Torque Specifications

2-4 Genie S-40 Part No. 32222

FORD ENGINE LSG-423 SPECIFICATIONS

Ford Engine LSG-423

Horsepower 63 @ 4000 rpm Current draw, no load 70A

Firing order 1-3-4-2 Maximum circuit voltage drop 0.5V DC

Governor electronic Brush length wear limit 0.25 in