Service Manual: Technical Publications

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

Part No. 52271
Introduction Service Manual - Second Edition
Important Genie North America

Read, understand and obey the safety rules and Telephone (425) 881-1800
operating instructions in the appropriate Toll Free 800 536-1800 in U.S.A.
Genie S-40 Operator's Manual before attempting Toll Free 800 426-8089 in Canada
any maintenance or repair procedure. Fax (425) 556-8649
This service manual covers the Genie S-40 2WD

and 4WD models. Genie Europe
This manual provides detailed scheduled Office Telephone (44) 01636-605030
maintenance information for the machine owner Office FaxFax (44) 01636-611090
and user. It also provides troubleshooting and Parts Telephone (44) 01636-605002
repair procedures for qualified service Parts Fax (44) 01636-611091
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 Copyright © 1998 by Genie Industries
highest degree of accuracy possible. However,
Second Edition: First Printing, August 1998
continuous improvement of our products is a Genie
policy. Therefore product specifications are subject "Genie" and "S" are Registered Trademarks
to change without notice. of Genie Industries in the USA and many other
countries.
Readers are encouraged to notify Genie of errors These machines comply with
and send in suggestions for improvement. All ANSI/SIA 92.5-1992.
communications will be carefully considered for Printed on recycled paper
future printings of this and other manuals. Please
Printed in U.S.A.
write to the technical publications team in care of
Genie Industries, PO Box 97030, Redmond WA
98073-97030 U.S.A.
If you have any questions, please call Genie

Industries.
ii Genie S-40 Part No. 52271

Service Manual - Second Edition Section 1 - Safety Rules
Safety Rules
Danger
Failure to obey the instructions and safety rules in
this manual, and the appropriate 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. 52271 Genie S-40 iii

Section 1 - Safety Rules Service Manual - Second 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. 52271

Service Manual - Second 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
Ford LRG 423 Engine Specifications ........................................................................ 2 - 4
Deutz F3L 1011F Engine Specifications ................................................................... 2 - 6
Hydraulic Hose and Fitting Torque Specifications ..................................................... 2 - 8
Bolt Torque Specifications ........................................................................................ 2 - 9
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. 52271 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 Oscillate Axle (if equipped) ................................................................ 4 - 5
A-11 Test the Platform and Ground Controls ........................................................... 4 - 6
A-12 Test the Auxiliary Power Operation ................................................................. 4 - 6
A-13 Test the Tilt Sensor ......................................................................................... 4 - 7
A-14 Test the Limit Switches ................................................................................... 4 - 8
A-15 Replace the Engine Oil and Filter - Gasoline/LPG Models ............................ 4 - 10
A-16 Drain the Fuel Filter/Water Separator - Deutz Diesel Models ........................ 4 - 11
A-17 Replace the Engine Air Filter ......................................................................... 4 - 12
B-1 Check the Engine Belt ................................................................................... 4 - 13
B-2 Check the Radiator - Gasoline/LPG Models .................................................. 4 - 14
B-3 Check the Oil Cooler and Cooling Fins - Deutz Diesel Models ...................... 4 - 14
B-4 Check the Exhaust System ........................................................................... 4 - 15
B-5 Check the Battery ......................................................................................... 4 - 16
B-6 Check the Hydraulic Tank Filter Condition Indicator ...................................... 4 - 16
B-7 Inspect the Electrical Wiring .......................................................................... 4 - 17
B-8 Inspect the Tires and Wheels (including lug nut torque) ................................ 4 - 17
B-9 Confirm the Proper Brake Configuration ....................................................... 4 - 18
B-10 Check the Oil Level in the Torque Hubs ........................................................ 4 - 18
B-11 Check and Adjust the Engine Idle Mixture - Gasoline/LPG Models ............... 4 - 19
B-12 Check and Adjust the Engine RPM ............................................................... 4 - 19
B-13 Test the Key Switch ...................................................................................... 4 - 21
B-14 Test the Emergency Stop Switches .............................................................. 4 - 21
B-15 Test the Ground Control Override ................................................................. 4 - 22
B-16 Check the Directional Valve Linkage ............................................................. 4 - 22
B-17 Test the Platform Self-leveling ...................................................................... 4 - 23
B-18 Test the Horn ................................................................................................ 4 - 23
B-19 Test the Foot Switch ..................................................................................... 4 - 23
B-20 Test the Engine Idle Select ........................................................................... 4 - 24
B-21 Test the Fuel Select Operation - Gasoline/LPG Models ................................ 4 - 24
B-22 Test the Drive Enable System ....................................................................... 4 - 25
vi Genie S-40 Part No. 52271

TABLE OF CONTENTS
Section Four Scheduled Maintenance Procedures, continued

B-23 Test the Drive Brakes ................................................................................... 4 - 25
B-24 Test the Drive Speed - Stowed Position ........................................................ 4 - 26
B-25 Test the Alarm Package - Optional Equipment .............................................. 4 - 27
B-26 Perform Hydraulic Oil Analysis ...................................................................... 4 - 27
B-27 Replace the Engine Oil and Filter - Deutz Diesel Models .............................. 4 - 27
C-1 Check the Boom Wear Pads ......................................................................... 4 - 29
C-2 Check the Turntable Rotation Bearing Bolts ................................................. 4 - 29
C-3 Check the Free-wheel Configuration ............................................................. 4 - 30
C-4 Grease the Turntable Rotation Bearing and Rotate Gear .............................. 4 - 31
C-5 Replace the Torque Hub Oil .......................................................................... 4 - 31
C-6 Replace the Hydraulic Tank Filter ................................................................. 4 - 33
C-7 Replace the Drive Loop Hydraulic Filter ........................................................ 4 - 33
C-8 Replace the Diesel Fuel Filter/Water Separator - Deutz Diesel Models......... 4 - 34
C-9 Replace the Gasoline Fuel Filter - Gasoline/LPG Models ............................. 4 - 34
C-10 Replace the PCV Valve - Gasoline/LPG Models ........................................... 4 - 36
C-11 Replace the Spark Plugs - Gasoline/LPG Models ......................................... 4 - 37
C-12 Check and Adjust the Air/LPG Mixture - Gasoline/LPG Models .................... 4 - 37
C-13 Check and Adjust the Ignition Timing - Gasoline/LPG Models ...................... 4 - 38
C-14 Check the Engine Valve Clearances - Deutz Diesel Models ......................... 4 - 38
D-1 Test or Replace the Hydraulic Oil .................................................................. 4 - 39
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 - 42
D-7 Check the Fuel Injection Pumps and Injectors - Deutz Diesel Models ........... 4 - 43
D-8 Check the Toothed Belt - Deutz Diesel Models ............................................. 4 - 43
D-9 Replace the Timing Belt - Gasoline/LPG Models .......................................... 4 - 43
D-10 Grease the Steer Axle Wheel Bearings, 2WD Models .................................. 4 - 44
Part No. 52271 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
2A Engine Cranks Over But Will Not Start OR Engine Runs
While Cranking the Dies- Gasoline/LPG Models ............................................. 5 - 8
2B Engine Runs While Cranking Then Dies ....................................................... 5 - 11
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 - 22
8 Engine High Idle Inoperative - Deutz Diesel Models ..................................... 5 - 23
9 Engine Low Idle Inoperative - Deutz Diesel Models ...................................... 5 - 25
10 All Functions Inoperative, Engine Starts and Runs ....................................... 5 - 26
11 All Lift and Steer Functions Inoperative, Drive Functions Operational ........... 5 - 27
12 Ground Controls Inoperative, Platform Controls Operate Normally ............... 5 - 28
13 Platform Controls Inoperative, Ground Controls Operate Normally ............... 5 - 29
14 Boom Up Function Inoperative ...................................................................... 5 - 30
15 Boom Down Function Inoperative ................................................................. 5 - 33
16 Boom Extend Function Inoperative ............................................................... 5 - 36
17 Boom Retract Function Inoperative ............................................................... 5 - 38
18 Turntable Rotate Left Function Inoperative ................................................... 5 - 40
19 Turntable Rotate Right Function Inoperative ................................................. 5 - 44
20 All Platform Leveling Functions Inoperative .................................................. 5 - 48
21 Platform Level Up Function Inoperative ........................................................ 5 - 49
22 Platform Level Down Function Inoperative .................................................... 5 - 51
23 Platform Rotate Left Function Inoperative ..................................................... 5 - 53
24 Platform Rotate Right Function Inoperative ................................................... 5 - 55
25 Oscillate Function Inoperative ....................................................................... 5 - 57
26 Steer Left Function Inoperative ..................................................................... 5 - 58
viii Genie S-40 Part No. 52271

TABLE OF CONTENTS
Section Five Troubleshooting Flow Charts, continued

27 Steer Right Function Inoperative ................................................................... 5 - 60
28 All Drive Functions Inoperative, All Other Functions Operate Normally ......... 5 - 62
29 Drive Forward Or Reverse Function Inoperative ........................................... 5 - 65
30 Traction Function Inoperative ........................................................................ 5 - 66
31 Machine Will Not Drive At Full Speed ............................................................ 5 - 67
32 Machine Drives At Full Speed With Platform Raised or Extended ................. 5 - 68
33 Drive Enable System Is Malfunctioning ......................................................... 5 - 69
34 Auxiliary Functions Inoperative ..................................................................... 5 - 70
Section Six Schematics

Introduction ............................................................................................................... 6 - 1
Electrical Components .............................................................................................. 6 - 2
Electrical Symbols Legend ....................................................................................... 6 - 4
Abbreviation Legend ................................................................................................. 6 - 5
Electrical Schematic - Gasoline/LPG Models ............................................................ 6 - 7
Ground Control Box Legend - Gasoline/LPG Models ............................................... 6 - 9
Ground Control Box Wiring Diagram - Gasoline/LPG Models ................................. 6 - 10
Platform Control Box Legend - Gasoline/LPG Models ............................................ 6 - 11
Platform Control Box Wiring Diagram - Gasoline/LPG Models ................................ 6 - 12
Electrical Schematic - Deutz Diesel Models ............................................................ 6 - 13
Ground Control Box Legend - Deutz Diesel Models ............................................... 6 - 15
Ground Control Box Wiring Diagram - Deutz Diesel Models ................................... 6 - 16
Platform Control Box Legend - Deutz Diesel Models .............................................. 6 - 17
Platform Control Box Wiring Diagram - Deutz Diesel Models ................................. 6 - 18
Hydraulic Symbols Legend ..................................................................................... 6 - 20
2WD Hydraulic Schematic - Non-oscillating axle .................................................... 6 - 21
2WD Hydraulic Schematic - Oscillating axle ........................................................... 6 - 22
4WD Hydraulic Schematic - Oscillating axle ........................................................... 6 - 23
Part No. 52271 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 - 8
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 Boom Cable Track ........................................................................................ 7 - 12
3-2 Boom ............................................................................................................ 7 - 14
3-3 Boom Lift Cylinder ......................................................................................... 7 - 16
3-4 Extension Cylinder ........................................................................................ 7 - 17
3-5 Platform Leveling Master Cylinder ................................................................ 7 - 18
Turntable Covers
4-1 Turntable Covers .......................................................................................... 7 - 19
Deutz Engine F3L 1011F
5-1 RPM Adjustment ........................................................................................... 7 - 20
5-2 Flex Plate ...................................................................................................... 7 - 20
5-3 Oil Temperature and Oil Pressure Gauges ................................................... 7 - 20
Ford LRG-423 Engine
6-1 Governor Actuator ......................................................................................... 7 - 21
6-2 Choke Adjustments ....................................................................................... 7 - 22
6-3 Timing Adjustment ........................................................................................ 7 - 23
6-4 Carburetor Adjustment .................................................................................. 7 - 23
6-5 RPM Adjustment ........................................................................................... 7 - 23
6-6 Flex Plate ...................................................................................................... 7 - 23
x Genie S-40 Part No. 52271

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

6-7 Water Temperature and Oil Pressure Gauges .............................................. 7 - 24
6-8 Vacuum Switch ............................................................................................. 7 - 25
Ground Controls
7-1 Control Relays .............................................................................................. 7 - 26
7-2 Toggle Switches, See 1-5, Toggle Switches ................................................... 7 - 8
7-3 Wago® Components ...................................................................................... 7 - 27
7-4 Resistors ....................................................................................................... 7 - 27
7-5 Power Relay ................................................................................................. 7 - 28
Hydraulic Pumps
8-1 Lift/Steer Pump ............................................................................................. 7 - 29
8-2 Drive Pump ................................................................................................... 7 - 29
Manifolds
9-1 Function Manifold Components ..................................................................... 7 - 32
9-2 Valve Adjustments - Function Manifold ......................................................... 7 - 36
9-3 Turntable Rotation Manifold Components ..................................................... 7 - 39
9-4 Oscillate Manifold Components ..................................................................... 7 - 40
9-5 Valve Adjustments - Oscillate Manifold ......................................................... 7 - 41
9-6 Directional Valve Manifold Components ........................................................ 7 - 42
9-7 Steer Manifold Components, Oscillating Models ........................................... 7 - 44
9-8 Steer Manifold Components, Non-oscillating Models .................................... 7 - 45
9-9 2WD Drive Manifold Components ................................................................. 7 - 46
9-10 Valve Adjustments, 2WD Drive Manifold ....................................................... 7 - 48
9-11 4WD Drive Manifold Components ................................................................. 7 - 50
9-12 Valve Adjustments, 4WD Drive Manifold ....................................................... 7 - 52
. Fuel and Hydraulic Tanks
10-1 Fuel Tank ...................................................................................................... 7 - 53
10-2 Hydraulic Tank .............................................................................................. 7 - 53
Turntable Rotation Components
11-1 Rotation Hydraulic Motor ............................................................................... 7 - 56
Part No. 52271 Genie S-40 xi

TABLE OF CONTENTS
Section Seven Repair Procedures, continued

2WD Steering Axle Components
12-1 Yoke and Hub ............................................................................................... 7 - 58
12-2 Steering Cylinders ......................................................................................... 7 - 59
12-3 Tie Rod ......................................................................................................... 7 - 60
13-1 Yoke and Hub ............................................................................................... 7 - 61
13-2 Steering Cylinders, See 12-2, Steering Cylinders ......................................... 7 - 59
13-3 Tie Rod, See 12-3, Tie Rod .......................................................................... 7 - 60
Oscillating Axle Components
14-1 Oscillating Axle Lock-out Cylinders ............................................................... 7 - 63
Non-steering Axle Components
15-1 Drive Motor ................................................................................................... 7 - 64
15-2 Torque Hub ................................................................................................... 7 - 64
xii Genie S-40 Part No. 52271

Service Manual - Second Edition Section 2 - Specifications
Specifications
Machine Specifications Maximum capacity 500 lbs 500 lbs
227 kg 227 kg
Stowed dimensions 2WD/RT 4WD/RT
Maximum allowable
Length 23 ft 11 in 23 ft 11 in side force (ANSI and CSA) 150 lbs 150 lbs
7.01 m 7.01 m 68 kg 68 kg
Width 7 ft 6 in 7 ft 6 in Tires and wheels 2WD

2.3 m 2.3 m 2WD Front 4WD Front
Tires Only and Rear
Height 8 ft 2 in 8 ft 2 in
2.5 m 2.5 m Tire size 12.5L-16SL 12-16.5 NHS
Tire ply rating 12 8
Weight 11,650 lbs 11,650 lbs
5284 kg 5284 kg Tire contact area 88 sq in 57 sq in
568 sq cm 368 sq cm
Ground clearance 12 1/2 in 12 1/2 in
31.8 cm 31.8 cm Overall tire diameter 33.7 in 33.2 in
85.6 cm 84.3 cm
Operational dimensions
Tire pressure 45 psi 45 psi
Maximum platform height 40 ft 40 ft 3.1 bar 3.1 bar
12.2 m 12.2 m
Wheel diameter 16 in 161/2 in
Maximum horizontal reach 31 ft 8 in 31 ft 8 in 40.6 cm 41.9 cm
9.65 m 9.65 m Wheel width 10 in 9 3/4 in
25.4 cm 24.8 cm
Maximum turntable tailswing 34 in 34 in
86.4 cm 86.4 cm Wheel lugs 8@ 5/8 -18 9@ 5/8 -18
Wheelbase 7 ft 3 in 7 ft 3 in Lug nut torque

2.21 m 2.21 m Dry 125 ft-lbs 169.5 Nm
Lubricated 94 ft-lbs 127.4 Nm
Minimum turning radius, 7 ft 10 in 7 ft 10 in
outside 2.4 m 2.4 m Fluid capacities
Fuel tank 30 gallons
Minimum turning radius, 3 ft 4 in 3 ft 4 in
114 liters
inside 1m 1m
LPG tank 33.5 pounds
Turntable rotation continuous continuous 15.2 kg
Platform rotation 160° 160° Hydraulic tank 45 gallons
170 liters
Platform dimensions 6 ft 8 ft
(Standard) (Optional) Hydraulic system 50 gallons
(including tank) 189 liters
Length 6 ft 8 ft
1.83 m 2.44 m Drive torque hubs 17 fl oz
0.5 liters
Width 30 in 36 in
76.2 cm 91.4 cm Turntable rotation 8 fl oz
torque hub 0.24 liters
Continuous improvement of our products is a
Genie policy. Product specifications are subject to
change without notice.
Part No. 52271 Genie S-40 2-1

Section 2 - Specifications Service Manual - Second Edition
SPECIFICATIONS
Performance Specifications Boom function speeds, maximum

from platform controls
Drive speeds, maximum 2WD 4WD
Boom up 40 to 60 seconds
Drive speed, stowed 4 mph 3.5 mph
Gasoline/LPG models 6.4 km/h 5.6 km/h Boom down 50 to 80 seconds
40 ft/6.8 sec 40 ft/7.8 sec Boom extend 35 to 65 seconds
12.2 m/6.8 sec 12.2 m/7.8 sec
Boom retract 40 to 70 seconds
Drive speed, stowed 3.5 mph 3 mph
Deutz Diesel models 5.6 km/h 4.8 km/h Turntable rotate, 360°
40 ft/7.8 sec 40 ft/9.1 sec boom fully stowed 70 to 110 seconds
12.2 m/7.8 sec12.2 m/9.1 sec
Platform rotate, 160° 8 to 20 seconds
Drive speed, 0.6 mph 0.6 mph
raised or extended 1 km/h 1 km/h Platform level up 25 to 50 seconds
- all models 40 ft/40 sec 40 ft/40 sec
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. 52271

SPECIFICATIONS
Hydraulic Specifications Function pump
Hydraulic fluid Dexron equivalent Type: pressure balanced gear
Drive pump Displacement - static 1.14 cu in

19 cc
Type: bi-directional variable displacement piston pump
Displacement - 2500 rpm 0 to 12.3 gallons per minute
Displacement - 2500 rpm 0 to 31.6 gallons per minute 0 to 46.6 liters per minute
0 to 119.6 liters per minute
Hydraulic tank circuit 10 micron with 25 psi
Maximum drive pressure 3500 psi return line filter (1.7 bar) bypass
241.3 bar
Charge pressure
neutral position 290 psi 20 bar Function manifold
drive position 250 psi 17 bar Function relief valve pressure
Medium pressure filter 3 micron S-60 2600 psi 179 bar
S-65 2900 psi 200 bar
Medium pressure filter 50 psi
bypass pressure 3.4 bar Boom down 2100 psi
relief valve pressure 145 bar
Drive manifold
Boom extend 2500 psi
Brake 250 psi 172 bar
relief pressure 17.2 bar
Oscillate axle 950 psi
Steer end drive motors 4WD models 65 bar
4WD front motor 2.5 to 8 gallons per minute Steer regulator 3.5 gallons per minute
flow regulators 9.4 to 30.2 liters per minute 13.2 liters per minute
4WD rear motor 5 to 15 gallons per minute Auxiliary pump

flow regulators 18.9 to 56.7 liters per minute
Type: fixed displacement gear pump
2WD rear motor 8 to 22 gallons per minute
flow regulators 30.2 to 83.2 liters per minute Displacement - static 0.152 cu in
2.5 cc
Front drive motors 4WD models
Displacement 1.4 gallons per minute
Displacement 5.3 liters per minute
per revolution 1.52 cu in 25 cc
Auxiliary pump 2500 psi
Non-steer end drive motors relief pressure 172 bar
Displacement
per revolution 2.13 cu in 35 cc

SPECIFICATIONS
Ford Engine LRG-423 Starter motor
Displacement 140 cu in Normal engine cranking speed 200 to 250 rpm

2.3 liters Current draw, normal load 170A
Number of cylinders 4 Current draw, maximum load 200A
Bore & stroke 3.781 x 3.126 inches Current draw, minimum 140A
96.04 x 79.4 mm
Maximum circuit voltage drop 0.5V DC
Horsepower 63 @ 4000 rpm while starting (normal temperature)
Firing order 1-3-4-2 Brush length, new 0.66 in
Low idle - carburetor 900 rpm 16.8 mm
Low idle - electronic governor 1600 rpm Brush length wear limit 0.25 in
6.35 mm
High idle 2500 rpm
Brush spring tension 64 ounces
Governor electronic 18 Newtons
Compression ratio 9.4:1 Bolt torque 45 to 84 inch-pounds

through brush 5.08 to 9.5 Nm
Compression pressure (approx.)
Pressure (psi) of lowest cylinder must be Brush mounting 15 to 20 foot-pounds
at least 75% of highest cylinder bolt torque 20 to 27 Nm
Valve clearances - 0.035 to 0.055 inches Maximum commutator 0.005 inches

collapsed tappet 0.889 to 1.397 mm run-out 0.127 mm
Lubrication system Battery
Oil pressure 40 to 60 psi Type 12V, Group 31

(operating temp. @ 2000 rpm) 2.75 to 4.1 bar
Quantity 1
Oil capacity 5 quarts
(including filter) 4.7 liters Cold cranking ampere 1000A
Oil viscosity requirements Reserve capacity @ 25A rate 200 minutes
Temperature below 60°F / 15.5°C 5W-30 Fuel pump
-10°F to 90°F / -23°C to 32°C 10W-30 Electronic solenoid 7 psi

0.48 bar
Temperature above 10W-40 to 10W-50
-10°F / -23°C Ignition System
Temperature above 20W-40 or 20W-50 Spark plug type Motorcraft AWSF-52C

20°F / -6.6°C Spark plug gap 0.042 to 0.046 inches
Use oils meeting API classification SG (labeled SG/CC 1.07 to 1.18 mm
or SG/CD) as they offer improved wear protection.
Units ship with 10W-40 SG/CC.

SPECIFICATIONS
Engine coolant Oil pan to block (M-6) 10 to 13.5 14 to 18
Capacity 111/2 quarts Oil filter insert to block 21 to 26 28 to 35

10.9 liters
Rocker arm cover to 7 to 10 9 to 13
Alternator cylinder head (M-6)
Output 95A, 14.5V Spark plug to cylinder 7 to 15 9 to 20

head (M-14)
Bolt torque specifications
torque torque Temperature sending 8 to 18 11 to 24
Bolt description (size) ft-lbs Nm unit to block (M-14)
Timing belt tensioner 29 to 40 40 to 55 Water jacket drain plug to block 12 to 18 16 to 24

pivot bolt (M-10)
Water pump to block bolt (M-8) 15 to 22 20 to 30
Timing belt tensioner 25 to 29 35 to 40
adjusting bolt (M-8) Water outlet connection 15 to 22 20 to 30
bolt (M-8)
Camshaft gear bolt (M-12) 52 to 66 70 to 90
Cylinder front cover bolt (M-6) 10 to 12 13 to 16
Camshaft thrust plate bolt (M-6) 6 to 9 8 to 12
Inner timing belt cover 15 to 22 20 to 30
Carburetor to spacer stud (M-8)7.5 to 15 10 to 20 stud (M-8)
Carburetor spacer to 10 to 14 14 to 19 Outer timing belt cover 6 to 9 8 to 12

manifold bolt (M-8) bolt (M-6)
Crankshaft damper 92 to 122 125 to 165

bolt (M-14)
Cylinder head bolt (M-12): torque in sequence

first step 50 to 60 68 to 81
second step 80 to 90 108 to 122
Bolt torque specifications

torque torque
Bolt description (size) ft-lbs Nm
Exhaust manifold to cylinder head bolt or nut (M-10):

torque in sequence
first step 14 to 19 19 to 26
second step 35 to 50 47 to 68
Flywheel to crankshaft 54 to 64 73 to 87
bolt (M-10)
Intake manifold to 15 to 22 20 to 30
cylinder head bolt or nut (M-8)
Oil pressure sending unit to block 8 to 18 11 to 24
Oil pan drain plug to pan (M-14) 15 to 25 20 to 34

SPECIFICATIONS
Deutz Engine F3L 1011F Injection pump pressure 4351 psi

300 bar
Displacement 125 cu in
2.05 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 @ 3000 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
12.7 mm
Low idle 1300 rpm
Battery
High idle 2300 rpm
Type 12V, Group 31
Governor centrifugal mechanical
Quantity 1
Valve clearance, cold
Cold cranking ampere 1000A
Intake 0.012 in
0.3 mm Reserve capacity @ 25A rate 200 minutes
Fan belt deflection 3 /8

to 1/2 inch
Exhaust 0.020 in
0.5 mm 9 to 12 mm
Lubrication system Bolt tightening specifications

torque torque
Oil pressure 26 to 87 psi Bolt description (size, grade) ft-lbs Nm
1.8 to 6.0 bar
Camshaft/thrust bearing bolt 15 to 18 20 to 24
Oil capacity 8.5 quarts (M-8 x 35, 8.8)
(including filter) 8 liters
Rocker arm bolts 15 to 18 20 to 24
Oil viscosity requirements (M-8 x 45, 8.8)
Temperature below 60°F / 15.5°C (synthetic) 5W-30 Rocker arm set screw nut 15 to 18 20 to 24
-10°F to 90°F / -23°C to 32°C 10W-40 Cylinder head cover 6 to 7 8 to 10
Temperature above -4°F / -34°C 15W-40 Blower rotor nut 33 to 41 45 to 55

(M-17 Valeo or M-18 Bosch)
Engine oil should have properties of API classification
CC/SG or CD/SG grades. Blower carrier bolts 15 to 18 20 to 24
Units ship with 10W-40 SG/CC. (M-8 x 50 Torx, 8.8)
Injection system V-belt pulley bolts 28 to 34 38 to 46

(M-10 x 16, 8.8)
Injection pump make OMAP

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

SPECIFICATIONS
Hydraulic Hose and Fitting Torque Specifications

Your machine is equipped with Parker Seal-Lok® O-ring face seal fittings and hose ends. Machines that
utilize Parker Seal-Lok® O-ring face seal hoses and fittings require that the fittings and hose ends be
torqued to specification when they are removed and installed or when new hoses or fittings are installed.
Hydraulic Hose and Fitting Torque Specifications

SAE O-ring Boss Port - tube fitting Seal-Lok® - hose end
SAE Dash Installing SAE Dash
Size into... ft. lbs. Nm Size ft. lbs. Nm
-4 Aluminum 11 14.9 -4 18 24.4
Steel 16 21.7 -6 27 36.6
-6 Aluminum 23 31.2 -8 40 54.2
Steel 35 47.5 -10 63 85.4
-8 Aluminum 40 54.2 -12 90 122
Steel 60 81.3 -16 120 162.7
-10 Aluminum 69 93.6 -20 140 190
Steel 105 142.4 -24 165 223.7
-12 Aluminum 93 126.1
Steel 140 190
-16 Aluminum 139 188.5
Steel 210 284.7
-20 Aluminum 172 233.2
Steel 260 352.5
-24 Aluminum 208 282
Steel 315 427.1
Torque Procedure
1 Replace the O-ring. The O-ring must be 3 Be sure that the face seal O-ring is seated and
replaced anytime the seal has been broken. retained properly.
The O-ring cannot be re-used if the fitting or
4 Position the tube and nut squarely on the face
hose end has been tightened beyond finger
seal end of the fitting and tighten the nut finger
tight.
tight.
The O-rings used in the Parker
Seal Lok® fittings and hose ends 5 Tighten the nut or fitting to the appropriate
are a custom-size O-ring. They torque per given size as shown in the table
are not a standard SAE size above.
O-ring. They are available in the 6 Operate all machine functions and inspect the
O-ring field service kit hoses and fittings and related components to
(Genie part no. 49612). be sure that there are no leaks.
2 Lubricate the O-ring before installation.
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 50 70
14 68 95
20 55 75 80 109
1/2 inch 75 110
13 102 149
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 specifications for lubricated bolts are 25% less than dry torque specifications for each bolt size.
These bolt torque specifications are for general use only. Specification may vary depending on application of bolt.

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2 - 10 Genie S-40 Part No. 52271

Service Manual - Second 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 - Second 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 Oscillate Axle (if equipped)
A-11 Test the Platform and Ground Controls
A-12 Test the Auxiliary Power Operation
A-13 Test the Tilt Sensor
A-14 Test the Limit Switches

MAINTENANCE TABLES
Table A, continued Tools are New parts

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

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

Gasoline/LPG Models
A-16 Drain the Fuel Filter/Water Separator-

Deutz Diesel Models
A-17 Replace the Engine Air Filter
Table B
B-1 Check the Engine Belt
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

MAINTENANCE TABLES
Table B, continued Tools are New parts

Warm
engine
Cold
engine
Dealer
service
B-12 Check and Adjust the Engine RPM
B-13 Test the Key Switch
B-14 Test the Emergency Stop Switches
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 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
Warm Cold Dealer

Table C Tools are New parts engine engine 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/Water Separator

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

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

Gasoline/LPG Models
C-11 Replace the Spark Plugs -

Gasoline/LPG Models
C-12 Check and Adjust the Air/LPG Mixture -

Gasoline/LPG Models
C-13 Check and Adjust the Ignition Timing -

Gasoline/LPG Models
C-14 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
D-10 Grease the Steer Axle Wheel Bearings-

2WD Models

Maintenance Inspection Report

Model Comments B-17 Platform
Warm leveling
Cold Dealer
Tools areY New
Checklist A N R parts engine
B-18 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-Gas/LPG
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-Gas/LPG 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 Diesel
Inspector company
A-10 Oscillate axle
Instructions A-11 Platform and Checklist C Y N R
· Make copies of this page to use for ground controls Refer to Table C
each inspection. A-12 Auxiliary power C-1 Boom wear pads
· Select the appropriate checklist(s) for A-13 Tilt sensor
the type of inspection to be C-2 Turntable bearing bolts
performed. A-14 Limit switches 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-Gas/LPG Models
C-6 Hydraulic tank filter
Annual Inspection: A+B+C A-16 Drain filter/separator
Deutz Diesel C-7 Drive loop hydraulic filter
2 Year Inspection: A+B+C+D
A-17 Replace air filter C-8 Fuel filter-Deutz Diesel
· Place a check in the appropriate box C-9 Fuel filter-Gas/LPG
after each inspection procedure is
completed. Checklist B Y N R C-10 PCV valve-Gas/LPG
· Use the maintenance tables in this Refer to Table B C-11 Spark plugs-Gas/LPG
section and the step-by-step C-12 Air/LPG mixture
B-1 Engine belt
procedures in section 4 to learn how C-13 Ignition timing-Gas/LPG
to perform these inspections. B-2 Engine radiator-Gas/LPG
C-14 Valves-Deutz Diesel
· If any inspection receives an “N”, tag B-3 Oil cooler and fins-Diesel
and remove the machine from B-4 Exhaust system
service, repair and re-inspect it. After Checklist D Y N R
B-5 Battery
repair, place a check in the “R” box. Refer to Table D
B-6 Hydraulic tank filter
Legend D-1 Hydraulic oil
B-7 Electrical wiring
Y = yes, acceptable D-2 Engine coolant-Gas/LPG
N = no, remove from service B-8 Tires and wheels
D-3 Change fuel lines
R = repaired B-9 Brake configuration
D-4 Valves-Gas/LPG
B-10 Torque hub oil level
D-5 Compression-Gas/LPG
B-11 Idle mixture-Gas/LPG
D-6 PCV hoses-Gas/LPG
B-12 Engine RPM
D-7 Fuel injection-Diesel
B-13 Key switch
D-8 Toothed belt-Diesel
B-14 Emergency Stop
D-9 Timing belt-Gas/LPG
B-15 Ground control override
D-10 Wheel bearings
B-16 Directional valve

Warm Cold Dealer

Tools are New parts engine engine service

Service Manual - Second 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
maintenance 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 - Second 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
information necessary for a safe operating A-3
condition.
Inspect for Damage, Loose or
1 Check to be sure that the storage container is Missing Parts
present and in good condition.
Daily machine condition inspections are essential
2 Check to make sure that the operator's, to safe machine operation and good machine
responsibilities and safety manual are present performance. Failure to locate and repair damage,
and complete in the storage container in the and discover loose or missing parts may result in
platform. an unsafe operating condition.
3 Examine the pages of each manual to be sure
1 Inspect the entire machine for damage and
that they are legible and in good condition.
improperly installed or missing parts including:
4 Always return the manuals to the storage
· Electrical components, wiring and electrical
container after use.
cables
Contact your authorized Genie
· Hydraulic hoses, fittings, cylinders and
distributor or Genie Industries if
manifolds
replacement manuals are needed.
· Fuel and hydraulic tanks
· Drive and turntable rotation motors and
A-2 torque hubs
Inspect the · Axle components
Decals and Placards · Boom components and wear pads
Maintaining all of the safety and instructional
· Dents or damage to machine
decals and placards in good condition is
mandatory for safe machine operation. Decals · Tires and wheels
alert operators and personnel to the many possible
· Engine and related components
hazards associated with using this machine. They
also provide users with operation and maintenance · Limit switches
information. An illegible decal will fail to alert
personnel of a procedure or hazard and could · Alarms, horn and beacon (if equipped)
result in unsafe operating conditions. · Nuts, bolts and other fasteners
1 Refer to the Decals section in the appropriate · Platform entry mid-rail or gate
Genie S-40 Operator's Manual and use the
· Cracks in welds or structural components
decal list and illustrations to determine that all
decals and placards are in place. · Compartment covers and latches

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 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 LRG-423 Engine 5 quarts
Oil capacity (including filter) 4.7 liters Fluids in the radiator are under
pressure and extremely hot. Use
Ford LRG-423 Engine
caution when removing cap and
Oil viscosity requirements
adding fluids.
below 60°F / 15.5°C 5W-30
-10° to 90°F / -23° to 32°C 10W-30

A-6
above -10°F / -23°C 10W-40 or 10W-50 Check for Fuel Leaks
above 25°F / -4°C 20W-40 or 20W-50 Failure to detect and correct fuel leaks will result in
an unsafe condition. An explosion or fuel fire may
Use oils meeting API classification SF (labeled SF/CC cause death or serious injury.
or SF/CD) as they offer improved wear protection.
Engine fuels are combustible.
Deutz Engine F3L 1011F 8.5 quarts Inspect the machine in an open,
Oil capacity (including filter) 8 liters well-ventilated area away from
heaters, sparks, flames and
Deutz Engine F3L 1011F Oil viscosity requirements lighted tobacco. Always have an
approved fire extinguisher within
below 60°F / 15.5°C (synthetic) 5W-30 easy reach.
-10°F to 90°F / -23°C to 32°C 10W-40 1 Open the shutoff valve on the liquid petroleum
gas (LPG) tank by turning it counterclockwise.
above -4°F / -34°C 15W-40 2 Perform a visual inspection around the following
areas. (An LPG detector may be necessary to
locate LPG leaks.)
CC/SE, CD/SE, SF/CC or SF/CD grades.

TABLE A PROCEDURES
Gasoline/LPG models: A-8

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

170 liters
Hydraulic system 50 gallons

(including tank) 189 liters

TABLE A PROCEDURES
A-9 A-10
Check the Tire Pressure Test the Oscillate Axle
This procedure does not need (if equipped)
to be performed on machines Proper axle oscillation is essential to safe machine
equipped with the foam-filled operation. If the axle oscillation system is not
tire option. operating correctly, the stability of the machine is
An over-inflated tire can explode compromised and it may tip over.
and may cause death or serious
1 Start the engine from the platform controls.
injury.
2 Drive the right steer tire up onto a 6 inch
To safeguard maximum stability, achieve
(15.2 cm) block or curb.
optimum machine handling and minimize tire
wear, it is essential to maintain proper pressure Result: The three remaining tires should stay in
in all air-filled tires. firm contact with the ground and the chassis
should remain level at all times.
1 Check each tire with an air pressure gauge and
add air as needed. 3 Drive the left steer tire up onto a 6 inch
Tire specifications Result: The three remaining tires should stay in
firm contact with the ground and the chassis
Tire size
should remain level at all times.
2WD (front tires only) 12.5-16 SL
2WD and 4WD (front and rear tires) 12-16.5 NHS 4 Drive both steer tires up onto a 6 inch
Pressure 45 psi
3.1 bar Result: The non-steer tires should stay in firm
contact with the ground.
If the chassis does not remain
level during test, see Repair
Procedure 9-6, How to Set Up the
Directional Valve Linkage OR see
Repair Procedure 9-5, How to
Adjust the Oscillate Sequencing
Valve Pressure.

TABLE A PROCEDURES
A-11 6 Start the engine from the platform controls.

Test the Platform and 7 Do not press down on the footswitch.
Ground Controls 8 Attempt to operate all machine functions.
Testing the machine functions and the Emergency Result: All machine functions should not
Stop buttons for malfunctions is essential for safe operate.
machine operation. An unsafe working condition
9 Press down on the footswitch and activate each
exists if any function fails to operate properly or
machine function.
either Emergency Stop button fails to stop all the
machine functions and shut off the engine. Each Result: All machine functions should operate
function should activate, operate smoothly and be through a full cycle.
free of hesitation, jerking and unusual noise.
10 Push in the Emergency Stop button to the OFF
1 Pull out the Emergency Stop button at the position at the platform controls.
ground controls to the ON position. Result: No function should operate, the engine
2 Start the engine from the ground controls. should stop.
3 Do not hold the function enable switch to either As a safety feature, selecting
side. Attempt to activate each boom and and operating the ground
platform function toggle switch. controls will override the
platform controls, including
Result: All boom and platform functions should the Emergency Stop switch.
not operate.
Deutz Diesel models:
4 Hold the function enable switch to either side All functions should stop
and activate each boom and platform function immediately. The engine will
toggle switch. shut off after 2 to 3 seconds.
Result: All boom and platform functions should
operate through a full cycle. Descent alarm (if
equipped) should sound while the boom is
lowering. A-12
5 Push in the Emergency Stop button to the OFF
Test the Auxiliary Power
position. Operation
Result: No function should operate, the engine Detection of auxiliary power system malfunctions is
should stop. essential for safe machine operation. An unsafe
working condition exists if the auxiliary powered
Machines equipped with Platform
functions do not operate in the event of a main
Level Control Disable Function:
power loss. When operating the machine on
The platform level function will not
engine power, selecting auxiliary power will stop
operate when the boom is raised
the engine immediately. Auxiliary power is
or extended past the drive speed
designed for short term use only,
limit switches.
and excessive use will result in battery drain
Deutz Diesel models: and component damage.
All functions should stop
immediately. The engine will 1 Turn the key switch to ground control and pull
shut off after 2 to 3 seconds. out the Emergency Stop button to the ON
position at the ground controls.

TABLE A PROCEDURES
2 Lift the red auxiliary power switch cover. A-13

3 Simultaneously hold the auxiliary power switch Test the Tilt Sensor
ON and activate each boom function toggle
switch. The tilt sensor sounds an alarm located in the
platform when the incline of the turntable exceeds
the rating on the serial plate.
Select a level test area. The tilt

alarm should not be sounding prior
to the test.
2 Open the tank side turntable cover and press
down on one side of the tilt sensor.
To conserve battery power, test Result: After a 1.5 second delay, the alarm in
each function through a partial the platform should sound.
cycle.
Tip-over hazard. The alarm should
Result: All boom functions should operate. be audible at the ground controls.
4 Turn the key switch to platform control. If the alarm is not audible at the
ground controls, replace the
5 Pull out the Emergency Stop button to the ON alarm.
position at the platform controls, then press
down the foot switch.
6 Lift the red auxiliary power switch cover.
7 Simultaneously hold the auxiliary power switch
ON and activate each function control handle or
toggle switch
a b c
a fuel tank
b tilt sensor
To conserve battery power, test
c ground control box
each function through a partial
cycle.
Result: All boom and steer functions should
operate. Drive functions should not operate with
auxiliary power.

TABLE A PROCEDURES
A-14 3 Visually inspect the boom extend drive limit

switch located on the end of the cable track on
Test the Limit Switches the boom. Inspect for the following:
Drive Limit Switches · Broken or missing roller or arm
Detecting limit switch malfunctions is essential to · Missing fasteners
safe machine operation. The drive limit switches · Loose wiring
are used to restrict drive speed when the boom is
raised or extended. An improperly functioning drive
limit switch will allow the machine to operate at an
unsafe drive speed.
1 Remove the cover from the rear of the turntable
to access the drive limit switch.
2 Visually inspect the drive limit switch mounted
to the turntable side plate at the pivot end of the
boom. Inspect for the following:
· Broken or missing roller or roller head
a b
· Missing fasteners
· Loose wiring a boom extend drive limit switch (LS1)
b cable track
a b 4 Start the engine from the ground controls.

5 Extend the boom approximately 3 feet (0.9 m).
6 Manually activate the boom extend drive limit
switch.
Result: The boom extend drive limit switch arm
should move freely and spring return to center.
A distinct click should be felt and heard.
7 Turn the keyswitch to platform control.
8 Fully retract the boom.
9 Slowly move the drive control handle
off center.
Result: The machine should move at normal
drive speeds.
10 Raise the boom to just above horizontal.
c
11 Slowly move the drive control handle off center.
a turntable riser Result: The machine should move at a reduced
b boom drive speed.
c boom drive limit switch (LS2)
12 Lower the boom to the stowed position, then
extend the boom 3 feet (91 cm).

TABLE A PROCEDURES
13 Slowly move the drive control handle off center. 3 Manually activate the drive enable limit switch.
Result: The machine should move at a reduced Result: The drive enable limit switch roller
drive speed. should move freely and spring return to center.
A distinct click should be felt and heard.
Drive speed, maximum,
raised or extended
Result: The drive enable indicator light should
All models 1 foot per second
be on.
0.31 meter per second
5 Rotate the turntable so the boom is between the
non-steer tires.
Drive Enable Limit Switch 6 Rotate the turntable to the left until the boom is
A properly functioning drive enable limit switch is past the left non-steer wheel.
essential for safe machine operation and Result: The drive enable indicator light should
workplace safety. The drive enable limit switch
be on. Drive function should not operate until
stops the drive function when the boom is rotated
the drive enable toggle switch is activated.
past a non-steer tire and alerts the operator that
the machine may drive in the opposite direction 7 Rotate the turntable to the right until the boom is
that the drive and steer control handle is moved. past the right non-steer wheel.
1 At the ground controls, start the engine and Result: The drive enable indicator light should
rotate the boom between the steer and be on. Drive function should not operate until
non-steer tires. Turn the engine off. the drive enable toggle switch is activated.
2 Visually inspect the drive enable limit switch for
the following:
· Broken or missing roller or arm
· Missing fasteners
· Loose wiring
a
c b
a turntable
b drive enable limit switch (LS3)
c turntable rotation bearing

TABLE A PROCEDURES
A-15 2 Place a suitable container under the engine

pivot plate directly below the oil pan drain plug.
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 b
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 oil pan and allow all
operating temperature. of the oil from the engine to drain into a suitable
Beware of hot engine parts and oil. container. See capacity specifications below.
Contact with hot engine oil and/or 4 Install the plug into the oil pan.
engine parts may cause severe
burns. 5 Remove the 2 engine pivot plate retaining bolts
from under the engine pivot plate. Swing the
1 Remove the oil filler cap located on the engine pivot plate away from the machine to
valve cover. access the oil filter.
6 Use an oil filter wrench and remove the filter.
7 Apply a thin layer of oil to the new oil filter
gasket (Genie part no. 28656). Then install the
filter and tighten it securely by hand.
8 Use a permanent ink marker to write the date
and number of hours from the hour meter on
the oil filter.
9 Fill the engine with new oil per specifications
and install the filler cap. See capacity
specifications below.
10 Start the engine from the ground controls.
Allow the engine to run for 30 seconds, then
turn the engine off.
4 - 10 Genie S-40 Part No. 52271

TABLE A PROCEDURES
11 Check the oil filter and the oil pan drain plug for A-16
leaks.
Drain the Fuel Filter/ Water
12 Swing the engine pivot plate back to its original
position and replace the two pivot plate
Separator - Deutz Diesel Models
retaining bolts. Engine specifications require that
13 Check the engine oil level dipstick. Add oil this procedure be performed every
if needed. 500 hours. Poor fuel quality or
very wet conditions may
necessitate performing this
Ford LRG-423 Engine 5 quarts
procedure more often.
Oil capacity (including filter) 4.7 liters
Proper maintenance of the fuel filter/water
Ford LRG-423 Engine separator is essential for good engine
Oil viscosity requirements performance. Failure to perform this procedure can
lead to poor engine performance and component
below 60°F / 15.5°C 5W-30
damage.
-10° to 90°F / -23° to 32°C 10W-30 Engine fuels are combustible.
Perform this procedure in an open,
above -10°F / -23°C 10W-40 or 10W-50 well-ventilated area away from
above 25°F / -4°C 20W-40 or 20W-50 lighted tobacco. Always have an
Use oils meeting API classification SF (labeled SF/CC
easy reach.
or SF/CD) as they offer improved wear protection.
Perform this procedure with the
engine off.
1 Loosen the drain plug located at the bottom of
the filter. Allow the water to drain into a suitable
container until fuel starts to come out.
Immediately tighten the drain plug.
a fuel filter
b drain plug
Part No. 52271 Genie S-40 4 - 11

TABLE A PROCEDURES
2 Clean up any fuel that may have spilled. A-17

If the fuel filter is completely Replace the Engine Air Filter
drained, you must prime the fuel
filter/water separator before Engine specifications require that
starting the engine. Refer to C-8 in this procedure be performed every
this section, Replace The Diesel 100 hours. Perform this procedure
Fuel Filter/Water Separator, for more often if dusty conditions
instructions on how to prime the exist.
fuel filter/water separator. Maintaining the engine air filter in good condition is
3 Start the engine from the ground controls and essential to good engine performance and service
check the fuel filter/water separator for leaks. life. Failure to perform this procedure can lead to
poor engine performance and component damage.
engine off.
1 Remove the retaining ring from the end cap of
the air filter canister.
2 Remove the end cap from the air cleaner
canister.
3 Remove the air filter retaining fastener, then
remove the filter.
4 Clean the inside of the canister and the gasket
with a damp cloth.
5 Insert the new filter and replace the mounting
fastener.
6 Replace the end cap on the canister, then
replace the retaining ring.
Air filters - Genie part numbers

Ford LRG-423 Engine 27916
Deutz F3L 1011F Engine 27916
4 - 12 Genie S-40 Part No. 52271

Table B Procedures
B-1 5 Check the engine belt for proper tension.
Check the Engine Belt
Maintaining the engine belt(s) is essential to good
engine performance and service life. The machine
will not operate properly with a loose or defective
belt and continued use may cause component
damage.
Do not inspect while the engine

is running. Remove the key to
secure from operation. Deutz Diesel engine
Beware of hot engine
components. Contact with hot
engine components may cause Ford LRG-423 engines are
severe burns. equipped with a serpentine belt
and incorporate a self adjusting
1 Deutz Diesel models: Remove the 2 bolts from pulley tensioner. No adjustment is
under the engine pivot plate. Swing the engine required.
pivot plate away from the machine to access
the front engine access cover mounting 3 /8
Belt deflection - inch to 1/2 inch
fasteners.
Deutz Diesel models 9 mm to 12 mm
2 Remove the front engine access cover
mounting fasteners.
3 All models: Inspect the engine belt for:
· Cracking
· Glazing
· Separation
· Breaks
4 Replace belt if any damage is found.
Part No. 52271 Genie S-40 4 - 13

TABLE B PROCEDURES
B-2 B-3
Check the Radiator Check the Oil Cooler and Cooling
- Gasoline/LPG Models Fins - Deutz Diesel Models
Maintaining the radiator in good condition is Maintaining the oil cooler in good condition is
essential for good engine performance. Operating essential for good engine performance. Operating
a machine with a damaged or leaking radiator may a machine with a damaged oil cooler may result in
result in engine damage. Also, restricting air flow engine damage. Also, restricting air flow through
through the radiator (i.e., dirt or debris) will affect the oil cooler will affect the performance of the
the performance of the cooling system. A frequent cooling system.
check allows the inspector to identify changes in
the condition of the radiator that might indicate Do not inspect while the engine
cooling system problems. is running. Remove the key to
secure from operation.
Do not inspect while the engine
Beware of hot engine
components. Contact with hot
secure from operation.
engine components may cause
Beware of hot engine parts and severe burns.
coolant. Contact with hot engine
Oil Cooler
parts and/or coolant may cause
severe burns. 1 Remove the fasteners from the engine side
1 Remove the 2 engine pivot plate retaining bolts cover, then remove the cover.
from under the engine pivot plate. Swing the 2 Inspect the oil cooler for leaks and physical
engine pivot plate away from the machine to damage.
access the radiator.
a b c
2 Inspect the radiator for leaks and physical
damage.
3 Clean the radiator fins of debris and foreign
materials.
a oil cooler
b cylinder head cooling fins
c fan blower fins
3 Clean the oil cooler of debris and foreign

material.
4 - 14 Genie S-40 Part No. 52271

TABLE B PROCEDURES
Cooling and Fan Blower Fins 1 Deutz Diesel models: Remove the 2 bolts from
under the engine pivot plate. Swing the engine
4 Inspect the fan blower fins for physical damage. pivot plate away from the machine to access
5 Clean the fan blower fins of debris and foreign the exhaust system.
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.
B-4
Check the Exhaust System
Maintaining the exhaust system is essential to
good engine performance and service life. Running
the engine with a damaged or leaking exhaust
system can cause component damage and unsafe a b b
operating conditions.
Do not inspect while the engine a engine pivot plate

b pivot plate retaining bolts
secure from operation. 2 All models: Be sure that all nuts and bolts are
Beware of hot engine tight.
components. Contact with hot 3 Inspect all welds for cracks.
engine components may cause
4 Inspect for exhaust leaks; i.e., carbon buildup
severe burns.
around seams and joints.
Part No. 52271 Genie S-40 4 - 15

TABLE B PROCEDURES
B-5 B-6
Check the Battery Check the Hydraulic Tank Filter
Proper battery condition is essential to good Condition Indicator
engine performance and operational safety. Maintaining the hydraulic tank filter in good
Improper fluid levels or damaged cables and condition is essential to good system performance
connections can result in engine component and safe machine operation. The filter condition
damage and hazardous conditions. indicator will show when the hydraulic flow is
Electrocution hazard. Contact with bypassing a clogged filter. If the filter is not
hot or live circuits may result in frequently checked and replaced, impurities
death or serious injury. Remove all will remain in the hydraulic system and cause
rings, watches and other jewelry. component damage.
Batteries contain acid. Avoid 1 Start the engine from the platform controls.
spilling or contacting battery acid. 2 Move the engine speed control switch to high
Neutralize battery acid spills with idle (rabbit symbol).
baking soda and water.
3 Inspect the filter condition indicator.
1 Put on protective clothing and eye wear.
2 Be sure that the battery cable connections are
free of corrosion. a
3 Be sure that the battery hold downs and cable

connections are tight.
4 Remove the battery vent caps and check the
b
specific gravity with a hydrometer.
c
5 Check the battery acid level. If needed,
replenish with distilled water to the bottom of
the battery fill tube. Do not overfill.
6 Install the vent caps.
Adding terminal protectors and a
a filter condition indicator
corrosion preventative sealant will b filter
help eliminate corrosion on the c hydraulic tank
battery terminals and cables.
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 - 16 Genie S-40 Part No. 52271

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, Tip-over hazard. Do not use
corroded and loose wires: temporary flat tire repair products.
· Engine compartment electrical panel 1 Check all tire treads and sidewalls for cuts,
(Gasoline/LPG models) cracks, punctures and unusual wear.
· Engine wiring harness
2 Check each wheel for damage, bends and
· Inside of the ground control box cracked welds.
· Turntable manifold wiring 3 Check each lug nut for proper torque.
2 Start the engine from the ground controls and
raise the boom above the turntable covers. 4 Check the pressure in each air-filled tire.
3 Inspect the turntable area for burnt, chafed and Tires and wheels 2WD Front 2WD Rear
pinched cables. 4WD Front
and Rear
4 Lower the boom into the stowed position and
turn the engine off. Tire size 12.5-16 SL 12-16.5 NHS
5 Inspect the following areas for burnt, chafed,
Pressure 45 psi 45 psi
corroded, pinched and loose wires: 3.1 bar 3.1 bar
· Cable track on the boom
Tire ply rating 12 8
· Boom to platform cable harness
Wheel lugs 8 @ 5/8 -18 9 @ 5/8 -18
· Inside of the platform control box
Lug nut torque, dry 125 ft-lbs 125 ft-lbs
· Boom cable cover 169.5 Nm 169.5 Nm
Lug nut torque, lubricated 94 ft-lbs 94 ft-lbs
127.4 Nm 127.4 Nm
Part No. 52271 Genie S-40 4 - 17

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).
The free-wheel valve is located on 2 Remove the plug located at 90 degrees and
the bottom of the drive pump. check the oil level.
Result: The oil level should be even with the
bottom of the plug hole.
d 3 If necessary, remove the top plug and add oil

until the oil level is even with the bottom of the
a c side plug hole.
b 4 Apply pipe thread sealant to the plug, and then
install it in the torque hub.
5 Repeat this procedure for each drive torque
hub.
a drive pump
b free-wheel valve
c lift pump Drive torque hub oil
d screwdriver
Capacity 17 fl oz
The free-wheel valve should
0.5 liters
always remain closed.
Type: SAE 90 multipurpose hypoid gear oil - API service
classification GL5
4 - 18 Genie S-40 Part No. 52271

TABLE B PROCEDURES
Turntable Rotate Torque Hub B-12

1 Remove the plug located on the side of the hub Check and Adjust the
and check the oil level. Engine RPM
Result: The oil level should be even with the
Maintaining the engine rpm at the proper setting for
bottom of the plug hole.
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
continued use may cause component damage.
Gasoline/LPG Models:
Perform this procedure in gasoline
mode with the engine at normal
a
operating temperature.
b
1 Disconnect the blue/black wire from the
governor actuator.
2 Connect an rpm gauge to the engine, then start
the engine from the ground controls.
a torque hub
b plug Result: Carburetor low idle should be 900 rpm.
Skip to step 4 if the low idle rpm is correct.
2 If necessary, add oil until the oil level is even
with the bottom of the side plug hole. 3 Turn the idle adjustment screw on the
carburetor clockwise to increase rpm or
3 Apply pipe thread sealant to the plug, and then
counterclockwise to decrease rpm.
install it in the torque hub.
Turntable rotate torque hub oil
Capacity 8 fluid ounces

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

classification GL5
a carburetor
b adjustment screw
B-11 4 Turn the engine off and reconnect the

Check and Adjust the Engine Idle blue/black wire to the governor actuator.
Mixture - Gasoline/LPG Models 5 Start the engine from the ground controls.
Complete information to perform this procedure is Result: Electronic governor low idle should
available in the Ford LRG-423 2.3 Liter Industrial be 1600 rpm.
Engine Service Manual (Ford number: PPD-194-
287). Genie part number 33907.
Part No. 52271 Genie S-40 4 - 19

TABLE B PROCEDURES
6 Move the function enable toggle switch to the Deutz Diesel models:
high idle (rabbit symbol) position at the ground
controls. 1 Connect an rpm gauge to the engine, and then
start the engine from the ground controls.
Result: High idle should be 2500 rpm.
Result: Low idle should be 1300 rpm.
7 Turn the engine off.
Skip to step 3 if the low idle rpm is correct.
If low and high idle rpm’s are correct,
disregard adjustment steps 8 and 9. 2 Loosen the low idle lock nut, then turn the low
idle adjustment screw clockwise to increase the
8 Remove the mounting fasteners from the rpm or counterclockwise to decrease the rpm.
electronic governor located on the engine Tighten the low idle lock nut and recheck the
side bulkhead, then remove the back panel rpm.
from the governor.
9 Restart the engine, turn the low or high speed
trimpot screw clockwise to increase the rpm or
counterclockwise to decrease the rpm.
Do not adjust any trimpot other f
than specified in this procedure. e
a b c d
b a solenoid boot
b high idle adjustment nut
c yoke lock nut
a low idle adjustment d yoke
b high idle adjustment e low idle adjustment screw
f low idle lock nut
10 Apply a drop of silicone to the top of the trimpot
screw. Apply a bead of silicone to the surface of 3 Move the function enable toggle switch to the
the back panel prior to re-assembly. high idle (rabbit symbol) position at the ground
controls.
11 Re-assemble the governor and recheck low and
high idle. Result: High idle should be 2300 rpm.
If high idle rpm is correct, disregard
Gasoline/LPG models adjustment step 4.
Low idle - carburetor 900 rpm
Low idle - electronic governor 1600 rpm
High idle 2500 rpm
4 - 20 Genie S-40 Part No. 52271

TABLE B PROCEDURES
4 Loosen the yoke lock nut, then turn the high idle 6 Turn the key switch to the OFF position.
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
yoke lock nut and recheck the rpm. Deutz Diesel models: All functions
should stop immediately. The
Be sure the solenoid fully retracts
engine will shut off after 2 to 3
when activating high idle.
seconds.
Deutz Diesel models
Low idle 1300 rpm B-14

High idle 2300 rpm Test the Emergency
Stop Buttons
Properly functioning Emergency Stop buttons
B-13 are essential for safe machine operation. An
Test the Key Switch improperly operating Emergency Stop button
will fail to shut off power and stop all machine
Proper key switch action and response is essential functions, resulting in a hazardous situation for
to safe machine operation. The machine can be ground and platform personnel.
operated from the ground or platform controls and
the activation of one or the other is accomplished As a safety feature, selecting
with the key switch. Failure of the key switch to and operating the ground controls
activate the appropriate control panel could cause will override the platform controls,
a hazardous operating situation. including the Emergency Stop
button.
1 Pull out the Emergency Stop button to the ON
position at both the ground and platform 1 Start the engine from the ground controls.
controls. 2 Push down the Emergency Stop button to the
2 Turn the key switch to ground control, start the OFF position.
engine and then turn the key switch to platform Result: The engine should shut off and no
control. machine functions should operate.
3 Check any machine function from the ground Deutz Diesel models: All
controls. functions should stop immediately.
The engine will shut off after 2 to 3
Result: The machine functions should not
seconds.
operate.
4 Turn the key switch to ground control.
4 Push down the Emergency Stop button to the
5 Check any machine function from the platform OFF position.
controls.
Result: The engine should shut off and no
Result: The machine functions should not machine functions should operate.
operate.
The ground Emergency Stop
button will stop all machine
operation, even if the key switch
is switched to platform control.
Part No. 52271 Genie S-40 4 - 21
TABLE B PROCEDURES
B-15 B-16
Test the Ground Control Override Check the Directional Valve
A properly functioning ground control override is Linkage
essential to safe machine operation. The ground Perform this test only on models
control override function is intended to allow equipped with a oscillating axle.
ground personnel to operate the machine from the
ground controls whether or not the Emergency Proper axle oscillation is essential to safe machine
Stop button on the platform controls is in the ON or operation. If the directional valve linkage is not
OFF position. This function is particularly useful if operating correctly, the stability of the machine is
the operator at the platform controls cannot return compromised and it may tip over.
the boom to the stowed position.
1 Remove the drive chassis cover from the
1 Push in the platform Emergency Stop button non-steer end.
to the OFF position.
2 Inspect the linkage for the following:
· Lock nut is tight against yoke
3 Operate each boom function through a · Yoke clevis pins are installed
partial cycle.
· Cotter pins are installed through clevis pins
Result: All boom functions should operate.
· Linkage is properly attached to
directional valve
a directional valve
b clevis pin with cotter pin (hidden)
c yoke
d lock nut
4 - 22 Genie S-40 Part No. 52271

TABLE B PROCEDURES
B-17 2 Push down the horn button at the platform

controls.
Test the Platform Self-leveling
Result: The horn should sound.
Automatic platform self-leveling throughout
the full cycle of boom raising and lowering is If necessary, the horn can be
essential for safe machine operation. The adjusted to obtain the loudest
platform is maintained at level by the platform volume by turning the adjustment
leveling slave cylinder which is operates in a screw near the wire terminals on
closed loop hydraulic circuit with the master the horn.
cylinder located at the base of the boom.
A platform self-leveling failure creates an unsafe
working condition for platform and
ground personnel. B-19
Test the Foot Switch
1 Start the engine from the ground controls and
lower the boom into the stowed position. A properly functioning foot switch is essential to
safe machine operation. Machine functions should
2 Hold the function enable toggle switch to either
activate and operate smoothly as long as the foot
side and adjust the platform to a level position
switch is pressed down, and promptly stop when
using the platform level toggle switch.
the foot switch is released. The foot switch will also
3 Raise and lower the boom through shift the engine into high idle if the idle select is
a full cycle. switched to the rabbit and foot switch symbol. An
improperly functioning foot switch can cause an
Result: The platform should remain level at
unsafe working condition and endanger platform
all times to within ±5 degrees.
and ground personnel.
The engine should not start if the

foot switch is pressed down.
B-18
1 Turn the keyswitch to platform controls and pull
Test the Horn out the Emergency Stop button to the ON
A functional horn is essential to safe machine position at both the ground and platform
operation. The horn is activated at the platform controls.
controls and sounds at the ground as a warning to 2 Press down the footswitch and attempt to start
ground personnel. An improperly functioning horn the engine by moving the start toggle switch to
will prevent the operator from alerting ground either side.
personnel of hazards or unsafe conditions.
Result: The engine should not start.
1 Turn the key switch to platform control and 3 Do not press down the footswitch and start the
pull out the Emergency Stop button to the engine.
ON position at both the ground and
platform controls. 4 Do not press down the footswitch. Check the
machine functions.
Result: The machine functions should not
operate.
5 Press down the foot switch and operate the
machine functions.
Result: The machine functions should operate.
Part No. 52271 Genie S-40 4 - 23

TABLE B PROCEDURES
B-20 7 Move the engine idle control switch to foot

switch activated high idle (rabbit and foot switch
Test the Engine Idle Select symbol).
A properly operating engine idle select switch Result: The engine should not change to
is essential to good engine performance and safe high idle.
machine operation. There are three settings.
8 Press down the foot switch.
Low idle (turtle symbol) allows the operator to
control individual boom functions only. Drive Result: The engine should change to high idle.
functions do not operate at low idle.
High idle (rabbit symbol) allows the operator
to control multiple boom and/or drive functions B-21
simultaneously. This setting maintains a Test the Fuel Select Operation
consistent high idle and is usually selected only
when the generator option is being used. - Gasoline/LPG Models
Foot switch activated high idle (rabbit and foot The ability to select and switch between
switch symbols) should be used for normal gasoline and LPG fuels as needed is essential to
machine operation. This selection activates high safe machine operation. A fuel selection can be
idle only when the foot switch is pressed down. made when the engine is running or not.
Switching malfunctions and/or the failure of the
1 Pull out the Emergency Stop button to the engine to start and run properly in both fuel
ON position at both the ground and platform modes and through all idle speeds can indicate
controls. fuel system problems that could develop into a
hazardous situation.
2 Start the engine from the ground controls. Then
move the function enable toggle switch to the Perform this test after checking
high idle (rabbit symbol) position and hold in the the gasoline and LPG fuel levels,
ON position. and warming the engine to normal
Result: The engine should change to high idle. operating temperature.
3 Release the function enable toggle switch. 1 Move the fuel select switch to gasoline and then
move the engine idle control switch to foot
Result: The engine should return to low idle. switch activated high idle (rabbit and foot switch
symbol).
4 Turn the key switch to platform controls.
2 Start the engine from the platform controls and
5 At the platform controls, move the engine idle
allow it to run at low idle.
control switch to high idle (rabbit symbol).
3 Press down the foot switch to allow the engine
Result: The engine should change to high idle.
to run at high idle.
6 Move the engine idle control switch to low idle
Result: The engine should start promptly and
(turtle symbol).
operate smoothly in low and high idle.
Result: The engine should change to low idle.
4 Release the foot switch and shut the engine off
by pushing the Emergency Stop button in to the
OFF position.
5 Move the fuel select switch to LPG.
4 - 24 Genie S-40 Part No. 52271

TABLE B PROCEDURES
6 Restart the engine and allow it to run at 4 Hold the drive enable toggle switch to either
low idle. side and slowly move the drive control handle
off center.
7 Press down the foot switch to allow the engine
to run at high idle.
Result: The engine should start promptly and
operate smoothly in low and high idle.
The engine may hesitate
momentarily and then continue
to run on the selected fuel if the Always use the color-coded
fuel source is switched while direction arrows on the
the engine is running. platform control panel and the
drive chassis to identify which
direction the machine will travel.
B-22 Result: The drive function should operate.
Test the Drive Enable System 5 Rotate the turntable to the left until the boom is
past the left non-steering wheel.
Proper drive enable system operation is
essential to safe machine operation. When the Result: The drive enable indicator light should
boom is past the non-steering wheels, drive come on.
movement is stopped and the indicator light turns 6 Repeat steps 3 and 4.
on. The drive enable switch must be to either side
to reactivate the drive function and should inform
the operator that the machine will move in the
opposite direction that the drive and steer controls B-23
are moved. An improperly functioning drive enable
system may allow the machine to be moved into Test the Drive Brakes
an unsafe position. Proper brake action is essential to safe machine
1 Start the engine from the platform controls. operation. The drive brake function should operate
smoothly, free of hesitation, jerking and unusual
2 Rotate the turntable to the right until the boom is noise. Hydrostatic brakes and hydraulically-
past the right non-steering wheel. released individual wheel brakes can appear to
operate normally when they are actually not fully
Result: The drive enable indicator light should
operational.
turn on.
3 Slowly move the drive control handle off center. Be sure that the machine is not in
free-wheel or partial free-wheel
Result: The drive function should not operate. configuration. Refer to B-9 in this
section, Confirm the Proper Brake
Configuration.
Select a test area that is firm, level
and free of obstructions.
1 Mark a test line on the ground for reference.
Part No. 52271 Genie S-40 4 - 25

TABLE B PROCEDURES
3 Move the engine idle control switch to B-24

foot switch activated high idle (rabbit and
foot switch), then lower the boom into the Test the Drive Speed
stowed position. - Stowed Position
4 Choose a point on the machine; i.e., contact Proper drive function movement is essential to
patch of a tire, as a visual reference for use safe machine operation. The drive function should
when crossing the test line. respond quickly and smoothly to operator control.
5 Bring the machine to top drive speed before Drive performance should also be free of
reaching the test line. Release the drive joystick hesitation, jerking and unusual noise over the
when your reference point on the machine entire proportionally controlled speed range.
crosses the test line. Select a test area that is firm, level
6 Measure the distance between the test line and and free of obstructions.
your machine reference point. 1 Create start and finish lines by marking two
lines on the ground 40 feet (12.2 m) apart.
Braking:
paved surface 2WD 4WD 2 Start the engine from the platform controls.
3 Move the engine idle control switch to
Stopping distance 2 to 4 ft 2 to 4 ft
foot switch activated high idle (rabbit and foot
0.6 to 1.2 m 0.6 to 1.2 m
switch), then lower the boom into the stowed
position.
The brakes must be able to hold 4 Choose a point on the machine; i.e., contact
the machine on any slope it is able patch of a tire, as a visual reference for use
to climb. when crossing the start and finish lines.
5 Bring the machine to top drive speed before
reaching the start line. Begin timing when your
reference point on the machine crosses the
start line.
6 Continue at full speed and note the time when
the machine reference point crosses the finish
line.
Drive speed:
stowed position 2WD 4WD
Gasoline/LPG models 40 ft/6.8 sec 40 ft/7.8 sec

12.2 m/6.8 sec 12.2 m/7.8 sec
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
4 - 26 Genie S-40 Part No. 52271

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

control handle off center, hold for a moment
Test the Alarm Package and then release it. Move the drive control
- Optional Equipment handle off center in the opposite direction, hold
for a moment and then release it.
The alarm package includes:
Result: The travel alarm should sound when the
· Travel alarm drive control handle is moved off center in
· Descent alarm either direction.
· Flashing beacon
Alarms and a beacon are installed to alert
operators and ground personnel of machine
B-26
proximity and motion. The alarm package is Perform Hydraulic Oil Analysis
installed on the turntable covers.
See D-1, Test or Replace the Hydraulic Oil.
The alarms and beacon will
operate with the engine
running or not running.
B-27
1 Turn the key switch to ground control and pull
out the Emergency Stop button to the ON
Replace the Engine Oil and
position at both the ground and platform Filter - Deutz Diesel Models
controls.
Engine specifications require
Result: The flashing beacon should be on and that this procedure be performed
flashing. every 500 hours. Perform this
procedure more often if dusty
2 Move the function enable switch to either side
conditions exist.
and activate the boom toggle switch in the DOWN
position, hold for a moment and then release it. Periodic replacement of the engine oil and
filter is essential to good engine performance.
Result: The descent alarm should sound when Operating the machine with an improper oil level or
the switch is held down. neglecting periodic oil and filter changes can
3 Turn the key switch to platform control. damage engine components. A frequent check
of elapsed machine hours against the hours
Result: The flashing beacon should be on noted on the oil filter will allow the inspector to
and flashing. anticipate and perform oil and filter changes at
4 Press down the foot switch. Move the boom the 500 hour interval.
control handle to the DOWN position, hold for a
Perform this procedure after
moment and then release it.
warming the engine to normal
Result: The descent alarm should sound when operating temperature.
the control handle is held down.
Beware of hot engine parts and oil.
Contact with hot engine oil and/or
engine parts may cause severe
burns.
1 Remove the oil filler cap located above the
dipstick.
Part No. 52271 Genie S-40 4 - 27

TABLE B PROCEDURES
2 Pull the end of the drain hose out from under 10 Check the oil filter and oil drain hose for leaks.
the engine.
11 Check the engine oil level dipstick. Add oil if
3 Remove the plug from the end of the drain hose needed.
and allow all of the oil from the engine to drain
into a suitable container. See capacity Deutz Engine F3L 1011F 8.5 quarts
specifications to the right. Oil capacity (including filter) 8 liters
4 Install the plug into the drain hose. Deutz Engine F3L 1011F 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

a
Temperature above -4°F / -34°C 15W-40

CC/SE, CD/SE, CC/SF or CD/SF grades.
c b
a engine oil level dipstick

b fuel filter
c oil filter
6 Apply a thin layer of oil to the new filter gasket

(genie part no. 49924). Then install the filter
and tighten it securely by hand.
the oil filter.
8 Fill the engine with new oil per specifications
and install the oil filler cap.
9 Start the engine from the ground controls. Allow
the engine to run for 30 seconds then turn the
engine off.
4 - 28 Genie S-40 Part No. 52271

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 and place a safety chock on
component damage and unsafe operating the lift cylinder rod. Carefully lower the boom
conditions. onto the lift cylinder safety chock.
Crushing hazard. Keep hands
If the wear pads are not worn
away from cylinder and all moving
below specification but are still
parts when lowering the boom.
within specification, see Repair
Procedure 3-2, How to Shim the The lift cylinder safety chock is
Boom. available through Genie
(part no. 33484).
2 Be sure that each turntable mounting bolt is
2 Raise the end of the boom to a comfortable
torqued in sequence to 210 foot-pounds
working height (chest high), then extend the
(285 Newton meters).
boom 1 foot (30 cm).
1
10 15
3 Measure each wear pad. Replace the wear pad 13 7
if it is less than specification. If the wear pad is 6 19
not less than specification, shim as necessary
to obtain zero clearance and zero drag. 18 12
4 Extend and retract the boom through the entire 3 4
range of motion to check for tight spots that

11
may cause binding or scraping of the boom. 17
20 5
Always maintain squareness
between the outer and inner 8 14
16 9
boom tubes. 2
Bolt torque sequence

Wear pad specifications
Upper and side wear pads 9/16 inch 14.3 mm

Bottom wear pads 11/16 inch 17.5 mm
Part No. 52271 Genie S-40 4 - 29

TABLE C PROCEDURES
3 Lower the boom to the stowed position. 4 Disengage the torque hubs by turning over the
torque hub disconnect caps on each
4 Check to ensure that each bearing mounting
non-steering wheel hub.
bolt under the drive chassis is torqued in
sequence to 210 foot-pounds disengage position
(285 Newton meters).
1
10 15
13 7
6 19
engage position
18 12
5 Manually rotate each non-steering wheel.
3 4
Result: Each non-steering wheel should rotate
11 17 with minimum effort.
20 5 6 Re-engage the torque hubs by turning over
8 14 the hub disconnect caps. Rotate each wheel to
16
2
9
check for engagement. Lift the machine and
remove the jack stands.
Bolt torque sequence Collision hazard. Failure to
re-engage the torque hubs may
cause death or serious injury and
property damage.
C-3
Steer wheels: 4WD models
Check the Free-wheel
7 Chock the non-steering wheels to prevent the
Configuration machine from rolling.
Proper use of the free-wheel configuration is 8 Center a lifting jack of ample capacity
essential to safe machine operation. The (20,000 lbs/9072 kg) under the drive chassis
free-wheel configuration is used primarily for between the non-steer tires.
towing. A machine configured to free-wheel without
operator knowledge may cause death or serious 9 Lift the wheels off the ground and then place
injury and property damage. jack stands under the drive chassis for support.
Collision hazard. Select a work 10 Disengage the torque hubs by turning over the
site that is firm and level. torque hub disconnect caps on each
steer wheel hub.
Non-steering wheels: All models
1 Chock the steer wheels to prevent the machine disengage position

from rolling.
2 Center a lifting jack of ample capacity
(20,000 lbs/9072 kg) under the drive chassis
between the non-steer tires. engage position
3 Lift the wheels off the ground and then place

jack stands under the drive chassis for support. 11 Manually rotate each steer wheel.
Result: Each steer wheel should rotate with
minimum effort.
4 - 30 Genie S-40 Part No. 52271

TABLE C PROCEDURES
12 Re-engage the torque hubs by turning over C-4

the hub disconnect caps. Rotate each wheel to
check for engagement. Lift the machine and Grease the Turntable Rotation
remove the jack stands. Bearing and Rotate Gear
Collision hazard. Failure to Yearly application of lubrication to the turntable
re-engage the torque hubs may bearing and rotate gear is essential to good
cause death or serious injury and machine performance and service life. Continued
property damage. use of an improperly greased bearing and gear will
All models: result in component damage.
13 Be sure the free-wheel valve on the drive pump 1 Locate the grease fitting on the platform end of
is closed (clockwise). the tank side bulkhead.
The free-wheel valve is located on 2 Pump grease into the turntable rotation bearing.
the bottom of the drive pump. Rotate the turntable in increments
of 4 to 5 inches (10 to 13 cm) at a time and
repeat this step until the entire bearing has
been greased.
3 Apply grease to each tooth of the drive gear,
d located under the turntable.
a c
Grease type Multipurpose grease
b
a drive pump
b free-wheel valve C-5
c lift pump
d screwdriver Replace the Torque Hub Oil
The free-wheel valve should Replacing the torque hub oil is essential for good
always remain closed. 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 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. 52271 Genie S-40 4 - 31

TABLE C PROCEDURES
3 Drive the machine until one plug is at the top Turntable Rotate Torque Hub:
and the other is at 90 degrees.
1 Secure the turntable from rotating with the
turntable rotation lock pin.
4 Fill the hub with oil from the top hole until the oil
level is even with the bottom of the side hole. unlocked locked
Apply pipe thread sealant to the plugs, and then 2 Remove the motor/brake mounting bolts, and
install the plugs. then remove the motor and brake from the
5 Repeat steps 1 through 4 for all the other drive torque hub and set them to the side.
torque hubs. Component damage hazard.
Hoses can be damaged if they are
Oil capacity per hub 17 fl oz kinked or pinched.
0.5 liters
a b
Type: SAE 90 multipurpose hypoid gear oil - API
service classification GL5
f
c
a motor/brake mounting bolt

b motor
c torque hub
d torque hub mounting bolt
e plug
f brake
3 Remove the torque hub mounting bolts, and

then use a lifting device to remove the torque
hub from the machine.
4 Remove the plug from the side of the torque
hub. Then drain the oil from the hub.
4 - 32 Genie S-40 Part No. 52271
TABLE C PROCEDURES
5 Install the torque hub. Torque the hub mounting 5 Start the engine from the ground controls.
bolts to 180 foot-pounds (244 Newton meters).
6 Inspect the filter and related components to
6 Install the brake and motor onto the torque hub. be sure that there are no leaks.
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 C-7
install the plugs.
Replace the Drive Loop
Turntable rotate torque hub Hydraulic Filter
Oil capacity 8 fluid ounces Replacing the drive loop hydraulic filter is essential
0.24 liters to good machine performance and service life. A
dirty or clogged filter may cause the machine to
Type: SAE 90 multipurpose hypoid gear oil - API perform poorly and continued use may cause
service classification GL5 component damage. Extremely dirty conditions
may require that the filter be replaced more often.
Beware of hot oil. Contact with

hot oil may cause severe burns.
C-6 Perform this procedure with the

engine off.
Replace the Hydraulic Tank Filter
1 Open the engine side turntable cover and locate
Replacement of the hydraulic tank filter is the drive loop hydraulic filter mounted on the
essential for good machine performance and engine near the main pump.
service life. A dirty or clogged filter may cause the
2 Remove the filter housing by using a wrench on
machine to perform poorly and continued use may
the nut provided on the bottom of the housing.
cause component damage. Extremely dirty
conditions may require that the filter be replaced 3 Remove the filter element from the housing.
more often.
4 Inspect the housing seal and replace it if
Beware of hot oil. Contact with necessary.
hot oil may cause severe burns. 5 Install the new filter (Genie part no. 20880) and
Perform this procedure with the hand tighten the housing onto the filter head.
engine off. Clean up any oil that may have spilled during
the installation procedure.
1 Remove the filter with an oil filter wrench.
2 Apply a thin layer of oil to the new oil filter
gasket. 7 Inspect the filter assembly to be sure that there
are no leaks.
3 Install the new filter (genie part no. 46014) and
tighten it securely by hand. Clean up any oil 8 Clean up any oil that may have spilled.
that may have spilled during the installation
procedure.
the oil filter.
Part No. 52271 Genie S-40 4 - 33

TABLE C PROCEDURES
C-8 Prime the fuel pump:

Replace the Diesel Fuel 3 Fill the new filter (Genie part no. 29560) with
Filter/Water Separator - Deutz fresh diesel fuel and apply a thin layer of oil or
diesel fuel to the new fuel filter gasket.
Diesel Models
4 Install the new filter and tighten it securely by
Replacing the diesel fuel filter is essential to good hand. Clean up any diesel fuel that might have
engine performance and service life. A dirty or spilled during the procedure.
clogged filter may cause the engine to perform
poorly and continued use may cause component 5 Turn the manual fuel shutoff valve, located at
damage. Extremely dirty conditions may require the fuel tank, to the OPEN position.
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.

a Replace the fuel filter in an open,
b well-ventilated area away from
lighted tobacco. Always have an
easy reach.
a oil filter Perform this procedure with the
b fuel filter/water separator engine off.
4 - 34 Genie S-40 Part No. 52271

TABLE C PROCEDURES
1 Remove the 2 bolts from under the engine pivot 3 Install the new fuel filter (Genie part no. 33971)
plate. Swing the engine pivot plate away from into the fitting on the carburetor.
the machine to access the fuel filter, located
4 Connect the fuel hose to the filter.
near the carburetor.
5 Clean up any fuel that may have spilled during
the installation procedure.
6 Start the machine from the ground controls,
then inspect the fuel filter and hose for leaks.
If a fuel leak is discovered, keep
any additional personnel from
operate the machine. Repair
the leak immediately.
position and replace the two retaining bolts.
a b a
a pivot plate retaining bolts

b engine pivot plate
2 Disconnect the fuel hose from the filter, then

remove the filter from the fitting.
a b
a fuel filter
b hose from the fuel pump to
the fuel filter
Part No. 52271 Genie S-40 4 - 35

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

remove the valve.
Replace the PCV Valve
- Gasoline/LPG Models
Yearly replacement of the PCV valve is essential to
good engine performance. A malfunctioning PCV
valve can impair crankcase ventilation and may
cause engine damage.

engine off.
1 Remove the 2 engine pivot plate retaining bolts
from under the engine pivot plate. Swing the
engine pivot plate away from the machine to
access the PCV valve.
a PCV valve
3 Install the new PCV valve. Connect the hoses.

position and replace the two retaining bolts.
a b a

4 - 36 Genie S-40 Part No. 52271

TABLE C PROCEDURES
C-11 C-12
Replace the Spark Plugs Check and Adjust the Air/LPG
- Gasoline/LPG Models Mixture - Gasoline/LPG Models
Periodic replacement of the spark plugs is Maintaining the proper air-to-fuel mixture during
essential to good engine performance and LPG operation is essential to good engine
service life. Worn, loose or corroded spark plugs performance.
will cause the engine to perform poorly and may
result in component damage. Engine fuels are combustible.
Perform this procedure in an open,
Perform this procedure with the well-ventilated area away from
engine off. heaters, sparks, flames and
1 Label, then disconnect the plug wires from the
spark plugs by grasping the molded boot. Do
easy reach.
not pull on the plug wire.
The engine rpm needs to be
2 Blow out any debris around spark plugs.
preset for gasoline fuel operation
3 Remove all the spark plugs from the engine. before adjusting the LPG idle
mixture. Refer to B-12, Check and
4 Adjust the gap on each new spark plug. Adjust the Engine RPM.
5 Install the new spark plugs, then connect the The engine should be warmed to
wires. Be sure that each spark plug wire is normal operating temperature
attached to the correct spark plug. before performing this procedure.
Spark plug specifications 1 Move the fuel select switch to LPG fuel and
start the engine from the ground controls.
Spark plug type Motorcraft AWSF-52C
2 Loosen the high idle mixture adjustment
lock nut.
Spark plug gap 0.042 to 0.046 inches
1.07 to 1.18 mm a
Spark plug torque 5 to 10 foot-pounds

7 to 14 Nm
a high idle mixture

adjustment screw
Part No. 52271 Genie S-40 4 - 37

TABLE C PROCEDURES
3 Load the system by activating the boom retract C-13

function, then move the function enable toggle
switch to the high idle (rabbit symbol) position. Check and Adjust the Ignition
4 Adjust the high idle adjustment screw to obtain
Timing - Gasoline/LPG Models
an air-to-fuel mixture ratio of 13.0:1 to 13.2:1, Complete information to perform this procedure is
using an exhaust gas analyzer. available in the Ford LRG-423 2.3 Liter Industrial
Preliminary setting is 1/4 inch of Engine Service Manual (Ford number: PPD-194-
threads showing. Measure from 287). Genie part number 33907.
top of lock nut to top of adjustment
screw.
If an exhaust gas analyzer is not C-14
available, adjust to obtain peak or
optimum rpm.
Check the Engine Valve
Clearances - Deutz Diesel Models
5 Hold the adjustment screw and tighten the
lock nut. Complete information to perform this procedure
is available in the Deutz FL 1011F Workshop
6 Return the function enable toggle switch to the
Manual (Deutz Number 0297 7195).
center position and adjust the low idle screw to
Genie part number 52229.
obtain an air-to-fuel mixture ratio
of 13.0:1 to 13.2:1.
a low idle mixture adjustment screw
Preliminary setting: turn low idle

adjustment screw clockwise all the
way in. Turn low idle adjustment
screw counterclockwise 2 3/4
turns.
4 - 38 Genie S-40 Part No. 52271

Table D Procedures
D-1 D-2
Test or Replace the Hydraulic Oil Change or Recondition the
Replacement or testing of the hydraulic oil is Engine Coolant
essential for good machine performance and - Gasoline/LPG Models
service life. Dirty oil and suction strainers may
cause the machine to perform poorly and Replacing or reconditioning the engine coolant is
continued use may cause component damage. essential to good engine performance and service
Extremely dirty conditions may require oil changes life. Old or dirty coolant may cause the engine to
to be performed more often. perform poorly and continued use may cause
engine damage. Extremely dirty conditions may
The machine uses Dexron require coolant to be changed more frequently.
equivalent hydraulic oil. Before
replacing the hydraulic oil, the oil Beware of hot engine parts and
may be tested by an oil distributor coolant. Contact with hot engine
for specific levels of contamination parts and/or coolant will cause
to verify that changing the oil is severe burns.
necessary. If the hydraulic oil is Perform this procedure with the
not replaced at the two year engine off and cooled.
inspection, test the oil quarterly.
Replace the oil when it fails the 1 Put on protective clothing and eye wear.
test.
2 Disconnect the coolant return hose at the
Perform this procedure with the radiator and drain the coolant return tank into a
boom in the stowed position. suitable container.
1 Remove the hydraulic tank. See Repair 3 Slowly remove the radiator cap from the
Procedure 10-2, How to Remove the Hydraulic radiator.
Tank.
Bodily injury hazard. Allow any
The pump needs to primed before pressure to dissipate gradually
starting the engine. See Repair before removing the radiator cap.
Procedure 10-2, How to Remove
the Hydraulic Tank.
Component damage hazard. Be
sure that the hydraulic tank shutoff
valves are in the OPEN position
before priming the pump. The
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.
Part No. 52271 Genie S-40 4 - 39

TABLE D PROCEDURES
4 Remove the 2 engine pivot plate retaining bolts 10 Disconnect the hose coupler at the fan end from
from under the engine pivot plate. Swing the the tube that is connected to the water pump
engine pivot plate away from the machine to and hold it until coolant starts to come out of the
access the radiator drain valve. open hose. Then immediately reconnect the
hose.
b a
a b a
a tube connected to water pump
b hose coupler
11 Fill the radiator and then fill the coolant recovery
5 Open the drain valve on the radiator and allow tank to the NORMAL range.
all the coolant to drain into a suitable container. 12 Clean up any coolant spilled during this
6 After all the coolant has drained, close the drain procedure.
valve. Connect the coolant return hose to 13 Start the engine from the ground controls,
the radiator. run it for 30 seconds, and then turn it off.
7 Open the drain valve on the engine block and 14 Inspect for leaks and then check the fluid
allow the coolant to drain into a container. level in the coolant recovery tank. Add
After the fluid is drained, close the drain valve. water if needed.
8 Replace all coolant hoses and clamps. 15 Start the engine from the ground controls
9 Pour the proper coolant mixture (anti-freeze and and run it until reaching normal operating
water) for your climate into the radiator until it is temperature.
full. 16 Allow engine to cool and check the fluid level in
the coolant recovery tank. Add water if needed.
Ford Engine 11.5 quarts

Coolant capacity 10.9 liters
4 - 40 Genie S-40 Part No. 52271

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,
well-ventilated area away from
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. 52271 Genie S-40 4 - 41

TABLE D PROCEDURES
a b c D-4
Check the Engine Valve
Clearance - Gasoline/LPG Models
Complete information to perform this procedure is
available in the Ford LRG-423 2.3 Liter Industrial
D-5
Check the Engine Cylinder
Compression
d
Gasoline/LPG 287). Genie part number 33907.
a carburetor
b fuel filter
c hose from the fuel filter to
the fuel pump
d hose from the fuel pump D-6
to the fuel tank (not shown)
Clean the PCV Hoses and
3 Clean up any fuel that may have spilled during
this procedure.
Fittings - Gasoline/LPG Models
Maintaining PCV hoses is essential to good engine
4 Start the engine from the ground controls, then
performance. Improperly functioning PCV hoses
inspect the fuel filter and hoses for leaks.
will fail to ventilate the crankcase and continued
If a fuel leak is discovered, keep use of neglected hoses could result in component
any additional personnel from damage.
operate the machine. Repair Perform this procedure with the
the leak immediately. engine off.
4 - 42 Genie S-40 Part No. 52271

TABLE D PROCEDURES
1 Remove the 2 engine pivot plate retaining bolts 5 Dry both hoses and inspect them for cracks and
from under the engine pivot plate. Swing the damage. Replace the hoses if they are
engine pivot plate away from the machine to damaged.
access the PCV hoses.
D-7
Check the Fuel Injection Pump
and Injectors - Deutz Diesel
Models
available in the Deutz FL 1011F Workshop Manual
(Deutz number: 0297 7195).
a b a
D-8
Check the Toothed Belt
b engine pivot plate - Deutz Diesel Models
2 Disconnect the hose from the PCV valve, then Complete information to perform this procedure is
disconnect the hose from the engine. available in the Deutz FL 1011F Operation Manual
(Deutz number: 0297 4706 EN).
a
D-9
Replace the Timing Belt
c
b
a carburetor to valve cover hose

b PCV valve
c PCV valve to carburetor hose
3 Disconnect the hose from the carburetor, then

disconnect the hose from the valve cover.
4 Clean the hoses with a mild cleaning solvent.
Part No. 52271 Genie S-40 4 - 43

TABLE D PROCEDURES
D-10 9 Check for wheel bearing wear by attempting to

move the wheel hub side to side, then up and
Grease the Steer Axle down.
Wheel Bearings - 2WD Models Result: If there is side to side or up and down
Maintaining the steer axle wheel bearings is movement, proceed to step 10 to replace the
essential for safe machine operation and service wheel bearings with new ones.
life. Operating the machine with loose or worn When replacing a wheel bearing,
wheel bearings may cause an unsafe operating both the inner and outer bearings,
condition and continued use may result in including the pressed-in races,
component damage. Extremely wet or dirty must be replaced.
conditions or regular steam cleaning and pressure
washing of the machine may require that this Result: If there is no side to side or up and
procedure be performed more often. down movement, grease the wheel bearings.
10 Remove the castle nut.
1 Loosen the wheel lug nuts. Do not remove
them. 11 Pull the hub off of the spindle. The washer and
outer bearing should fall loose from the hub.
2 Block the non-steering wheels, then center a
lifting jack under the steer axle. 12 Place the hub on a flat surface and gently pry
the bearing seal out of the hub. Remove the
3 Raise the machine 6 inches (15 cm) and place rear bearing.
blocks under the drive chassis for support.
13 Pack both bearings with clean, fresh grease.
4 Remove the lug nuts, then remove the tire and
wheel assembly. 14 Place the large inner bearing into the rear of the
hub.
5 Check for wheel bearing wear by attempting to
move the wheel hub side to side, then up and 15 Install a new bearing grease seal into the hub
down. by pressing it evenly into the hub until it is flush.
Result: There should be no side to side or up Always replace the bearing grease
and down movement. seal when removing the hub.
Skip to step 10 if there is no movement. 16 Slide the hub onto the yoke spindle.
Component damage. Do not
6 Remove the dust cap from the hub, then
apply excessive force or damage
remove the cotter pin from the castle nut.
to the lip of the seal may occur.
7 Tighten the castle nut to 35 foot-pounds
17 Place the outer bearing into the hub.
(47 Nm) to seat the bearings.
18 Install the washer and slotted nut.
8 Loosen the castle nut, then re-tighten to
8 foot-pounds (11 Nm). 19 Tighten the slotted nut to 35 foot-pounds
(47 Nm) to seat the bearings.
20 Loosen the slotted nut, then re-tighten to
8 foot-pounds (11 Nm).
21 Install a new cotter pin. Bend the cotter pin
to lock it in.
22 Install the dust cap, then the tire and wheel
assembly. Torque the wheel lug nuts to
125 foot-pounds (169.5 Nm).
4 - 44 Genie S-40 Part No. 52271
Service Manual - Second Edition Section 5 - Troubleshooting Flow Charts
Troubleshooting Flow Charts

Before Troubleshooting:
Read, understand and obey the safety rules
and operating instructions printed in the
appropriate 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.
repair procedure with the machine in the
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 - Second 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 RKYYZNGT
)NKIQHGZZKX_IUTJOZOUT
<
Crank Over )NKIQHGZZKX_\URZGMK 58INKIQGRZKXTGZUX
58INKIQHGZZKX_IGHRKY
58XKVRGIKZNKHGZZKX_
Be sure the key switch
<UXSUXK
is in the appropriate
position.
=OZNZNKQK_Y]OZIN :XGIKIOXI[OZHGIQ
Be sure that both Z[XTKJZUMXU[TJ < ZNXU[MNZNKQK_Y]OZIN
Emergency Stop IUTZXURYGTJHUZN KSKXMKTI_YZUVH[ZZUT
+SKXMKTI_9ZUVH[ZZUTY GTJ)(XKVGOXUVKT
buttons are pulled out to GXKV[RRKJU[ZZUZNK 54
the ON position. VUYOZOUTINKIQZNK
\URZGMKGZZNKIKTZKX
Be sure the circuit ZKXSOTGRUTZNKYZGXZ
ZUMMRKY]OZIN:9
breakers are not
tripped. <
Be sure the battery is

.URJZNKYZGXZZUMMRK 8KVGOXUVKTOTP[SVKX
fully charged. Y]OZINZUKOZNKXYOJKGTJ ]OXKLXUSUTKYOJKULZNK
<
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KOZNKXYOJKZKXSOTGRUT XKVRGIKYZGXZZUMMRK
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<
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<
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\URZGMKGZZKXSOTGR ZU:(
:(
<
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<
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UTOMTOZOUTYZGXZSUJ[RK
<
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VGMK

CHART 1
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)UTZOT[KJLXUSZNK < HGJ 8KVGOXUVKTOTMXU[TJ
KOZNKXYOJKGTJINKIQ ZKXSOTGR UTOMTOZOUT
VXK\OU[YVGMK ]OXK
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OMTOZOUTYZGXZSUJ[RK
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)UTY[RZ-KTOK/TJ[YZXOKY
< 9KX\OIK*KVGXZSKTZ
.URJZNKYZGXZY]OZINZU 8KVGOXUVKTOTHRQ]OXK
KOZNKXYOJKGTJINKIQ < LXUSZKXSOTGR UT
\URZGMKGZZKXSOTGR OMTOZOUTYZGXZSUJ[RKZU
UT)8 )8
<
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ZKXSOTGR UT)8 IOXI[OZLXUSHGZZKX_ZU
)(ZU)8ZKXSOTGR

<
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< HGJ
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\URZGMKGZZKXSOTGR )8 )8
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<
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<
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UTZNKYZGXZKXYURKTUOJ
<
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IGHRK IGHRKZUYZGXZKX
<
8KVGOXUXXKVRGIKYZGXZKX
UXYZGXZKXYURKTUOJ

Chart 2
Engine Cranks =OZNZNKQK_Y]OZIN
RKYY
ZNGT
Over But Will Z[XTKJZUMXU[TJ
IUTZXURYGTJHUZN
<
58INKIQGRZKXTGZUX58
INKIQLUXYNUXZIOXI[OZY
Not Start - +SKXMKTI_9ZUVH[ZZUTY
V[RRKJU[ZZUZNKUT
58INKIQHGZZKX_IGHRKY
58XKVRGIKZNKHGZZKX_
Gasoline/LPG VUYOZOUTNURJYZGXZ
Y]OZINZUKOZNKXYOJKGTJ
Models INKIQHGZZKX_\URZGMK
]NORKKTMOTKOYIXGTQOTM
Be sure to check the

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engine oil level and fill
as needed.
)NKIQOLKTMOTKIUURGTZ )NKIQOLXGJOGZUXGTJUX )NKIQKTMOTKIUURGTZ
IUTZOT[OZ_ NUZ
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Be sure to check fuel [TOZYOMTGRVUYZNGY KÎKYYO\KR_NUZ LOTYLUXIRUMMOTM58
levels and engine IUTZOT[OZ_ZUMXU[TJ INKIQKTMOTKLGTHKRZY
coolant level. 58YKK,UXJYKX\OIK
SGT[GRLUX
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Be sure the gasoline TUZNUZ U\KXNKGZOTMKTMOTK
shut-off valve is in the
ON or OPEN position.
Be sure that automatic IUTZOT[OZ_

8KSU\K]NZ]OXKLXUS 8KVRGIKZKSVKXGZ[XK
choke is not sticking ZKSVKXGZ[XKYKTJOTM Y]OZINYKTJKX
closed. [TOZINKIQIUTZOT[OZ_ZU
MXU[TJUTZKSVKXGZ[XK
YKTJOTM[TOZ
Perform following tests
in gasoline mode only.
TUIUTZOT[OZ_
Be sure that the water TUIUTZOT[OZ_
temperature gauge 8KSU\K]NZ]OXKLXUS

IUTZOT[OZ_
8KVGOXYNUXZOT]NZ]OXK
:(GTJINKIQ IOXI[OZLXUS:(ZU
does not show an IUTZOT[OZ_ZUMXU[TJ ZKSVKXGZ[XKYKTJKX
overheated condition.
TUIUTZOT[OZ_
IOXI[OZLXUSZKXSOTGR
UTOMTOZOUTYZGXZSUJ[RK
ZU:(58IUTY[RZ
-KTOK/TJ[YZXOKY9KX\OIK
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HUJ_)XGTQKTMOTKGTJ
UHYKX\KYVGXQ
]KGQUXTUYVGXQ
)UTZOT[KJUTZNKTK^Z
VGMK

CHART 2
*OYGHRKYZGXZKXH_ 9KK,UXJYKX\OIK
)UTZOT[KJLXUSZNK
XKSU\OTMHRQ]OXKGZZNK < SGT[GRLUX
VXK\OU[YVGMK
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YZGXZY]OZINZUKOZNKX Y_YZKS
YOJKGTJINKIQ\URZGMK
GZZNK]NOZK]OXKUTZNK
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RKYYZNGT<
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<
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\URZGMKGZ]NZ UT IUOR
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<
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<
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)8 :(ZU)(ZU)8ZU
)8
<
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KOZNKXYOJKGTJINKIQ < INKIQ\URZGMKGZ < LXUSZKXSOTGR UT
\URZGMKGZZKXSOTGR ZKXSOTGR UTOMTOZOUT )8ZUZKXSOTGR UT
UL)8 YZGXZSUJ[RK OMTOZOUTYZGXZSUJ[RK
<
)NKIQ\URZGMKGZ 8KVGOXUVKTOTVU]KX
<
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YZGXZSUJ[RK ZU)8ZU)8ZU
ZKXSOTGR UTOMTOZOUT
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<
TU
)NKIQIUTZOT[OZ_LXUS 8KVGOXUVKTOTHXU]T
< IUTZOT[OZ_
MXU[TJ]OXKGZZKXSOTGR MXU[TJ]OXKZUOMTOZOUT
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VGMK

CHART 2
TU
)NKIQIUTZOT[OZ_LXUS IUTZOT[OZ_ 8KVGOXUVKTOTHXU]T
)UTZOT[KJLXUSZNK
MXU[TJZUZKXSOTGR MXU[TJ]OXKIOXI[OZZU
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UT)8 )8
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]OZN]KGQYVGXQ58
IUTY[RZ-KTOK/TJ[YZXOKY
9KX\OIK

Chart 2A
Engine Cranks .URJZNKYZGXZY]OZINZU 8KVGOXUVKTOT]NOZK
Over But Will KOZNKXYOJKGTJINKIQ
ZNK\URZGMKGZZNK]NOZK
<
]OXKIOXI[OZLXUSZNK
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Not Start - ]OXKUTZNKINUQK]NORK
IXGTQOTMZNKKTMOTK
G[ZUSGZOIINUQK
Gasoline/LPG
<
Models
)NKIQG[ZUSGZOIINUQK 'JP[YZUXXKVRGIK
or LUXVXUVKXGJP[YZSKTZUX
HGJ
G[ZUSGZOIINUQK58
OTZKXTGRJGSGMK IUTY[RZ-KTOK/TJ[YZXOKY
Engine Runs 9KX\OIK*KVGXZSKTZ
MUUJ
While Cranking
Then Dies =OZNQK_Y]OZINUTGTJ
HUZN+SKXMKTI_9ZUV
<
8KVGOXUVKTOTXKJ]NZ
]OXKIOXI[OZLXUS
H[ZZUTYV[RRKJU[ZZUZNK :(ZU\GI[[SY]OZIN
Perform these tests in 54VUYOZOUTINKIQ
gasoline mode only. \URZGMKGZXKJ]NZ
]OXKUT\GI[[SY]OZIN
<
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<
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<
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54VUYOZOUTJOYIUTTKIZ <
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UT)8
<
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VGMK

CHART 2A
=OZNQK_Y]OZINZ[XTKJZU 8KVGOXUVKTOTXKJ
)UTZOT[KJLXUSZNK
MXU[TJIUTZXURYGTJ < VU]KX]OXKIOXI[OZ]OZN
VXK\OU[YVGMK
HUZN+SKXMKTI_9ZUV JOUJKZUL[KRYKRKIZ
H[ZZUTYV[RRKJU[ZZUZNK ZUMMRKY]OZIN:9
54VUYOZOUTIXGTQZNK
KTMOTKGTJINKIQ
\URZGMKGZIKTZKX
ZKXSOTGRUTL[KRYKRKIZ
Y]OZIN:9OTMXU[TJ
IUTZXURHU^
<
<
=OZNQK_Y]OZINUTGTJ 8KVRGIKZUMMRKY]OZIN
HUZN+SKXMKTI_9ZUV
54VUYOZOUTIXGTQ
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\URZGMKUTMGYUROTKYOJK
HR[]NZ]OXKULL[KR
YKRKIZY]OZIN
<
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HUZN+SKXMKTI_9ZUV < ]OXKIOXI[OZLXUSZUMMRK
H[ZZUTYV[RRKJU[ZZUZNK :9ZUMMRKY]OZINZU
UTVUYOZOUTIXGTQ :(
KTMOTKGTJINKIQ
\URZGMKGZZKXSOTGR
:(
<
=OZNQK_Y]OZINUTGTJ 8KVGOXUVKTOTHR[]NZ
<
HUZN+SKXMKTI_9ZUV ]OXKIOXI[OZLXUS:(ZU
H[ZZUTYV[RRKJU[ZZUZNK ZKXSOTGR UT)8
54VUYOZOUTIXGTQ
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<
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< TUMUUJ
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54VUYOZOUTIXGTQZNK
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UT)8
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<
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CHART 2A
.URJZNKYZGXZY]OZINZU 8KVGOXUVKTOTHR[]NZ
)UTZOT[KJLXUSZNK <
KOZNKXYOJKGTJINKIQ ]OXKIOXI[OZLXUS
VXK\OU[YVGMK
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UTGTZOJOKYKR\GR\KUT
KTMOTKIGXH[XKZUX
<
TU
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< IUTZOT[OZ_
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\URZGMKGZHR[]NZ L[KRV[SVZUMXU[TJ L[KRV[SV
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< GTZOJOKYKR\GR\KZUL[KR
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TU
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58)UTY[RZ-KTOK
/TJ[YZXOKY9KX\OIK
*KVGXZSKTZ
5 - 10 Genie S-40 Part No. 52271

Chart 2B
Engine Runs .URJYZGXZY]OZINZU
<
)XGTQKTMOTKGTJINKIQ
<
)NKIQGRZKXTGZUX]OXOTM
While Cranking KOZNKXYOJKGTJINKIQ
\URZGMKGZZKXSOTGR UT
\URZGMKGZUXMHRQ
]OXKUTGRZKXTGZUX
58XKVGOXUXXKVRGIK
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Then Dies OMTOZOUTYZGXZSUJ[RK -KTOK/TJ[YZXOKY9KX\OIK
*KVGXZSKTZ
ZU<
8KVGOXUVKTOTUXMHRQ
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ZKXSOTGR OMTOZOUT MXU[TJUTYOMTGRVUYZUL ,UXJYKX\OIKSGT[GRLUX
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IUTZOT[OZ_SGOTZGOTKJ% ZNKKTMOTK/YIUTZOT[OZ_ VXKYY[XK
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TU
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TU
TU
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OT]NZ ]OXKLXUS
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<
ZKXSOTGR UTOMTOZOUT LXUSZKXSOTGR UT < SUJ[RK58IUTY[RZ
YZGXZSUJ[RK OMTOZOUTYZGXZSUJ[RKGTJ -KTOK/TJ[YZXOKY9KX\OIK
INKIQ\URZGMKGZ *KVGXZSKTZ
ZKXSOTGR
< <
:KYZG[ÔROGX_VU]KX
ZUMMRKY]OZINKY:9GTJ
8KVRGIKOMTOZOUTYZGXZ :99KK8KVGOX
SUJ[RK58IUTY[RZ 9KIZOUT
*KVGXZSKTZ
Part No. 52271 Genie S-40 5 - 11

Chart 3
Engine Cranks .URJZNKYZGXZY]OZINZU
RKYY
ZNGT
Over But Will KOZNKXYOJKGTJINKIQ
HGZZKX_\URZGMK]NORK
<
58INKIQGRZKXTGZUX58
INKIQLUXYNUXZIOXI[OZY
Not Start - KTMOTKOYIXGTQOTM 58INKIQHGZZKX_IGHRKY
58XKVRGIKZNKHGZZKX_
Deutz Diesel <UXSUXK
Models
)NKIQOLKTMOTKU\KX )NKIQOLUORIUURKX )NKIQKTMOTKUORRK\KR
Be sure to check the ZKSVKXGZ[XKYKTJOTM
IUTZOT[OZ_
GTJUXKTMOTKHRUIQ
NUZ
58UORIUURKXLOTYLUX
engine oil level and fill YOMTGRVUYZNGY LKKRYKÎKYYO\KR_NUZ IRUMMOTM58INKIQ
as needed. IUTZOT[OZ_ZUMXU[TJ KTMOTKLGTHKRZY58YKK
*K[Z`YKX\OIKSGT[GR
LUXZXU[HRKYNUUZOTMGT
Be sure to check U\KXNKGZOTMKTMOTK
fuel level. TUZNUZ
Be sure the diesel fuel

shut-off valve is in 8KSU\K]NZ]OXKLXUS IUTZOT[OZ_ 8KVRGIKZKSVKXGZ[XK
the on position. ZKSVKXGZ[XKYKTJOTM Y]OZINYKTJOTM[TOZ
[TOZINKIQIUTZOT[OZ_ZU
Be sure that the battery MXU[TJUTYKTJOTM
[TOZ
is fully charged.
TUIUTZOT[OZ_
TUIUTZOT[OZ_
8KSU\K]NZ]OXKLXUS IUTZOT[OZ_ 8KVGOXYNUXZOT]NZ]OXK
:( IOXI[OZLXUS:(ZU
ZKSVKXGZ[XKYKTJKX
TUIUTZOT[OZ_
IOXI[OZLXUSOMTOZOUTYZGXZ
SUJ[RKZU:(58
9KX\OIK*KVGXZSKTZ
UX
*OYGHRKZNKYZGXZKXH_ :[XTZNKSGINOTKULL OTLOTOZK 8KVRGIKZNKL[KR
XKSU\OTMZNKHRQ]OXKGZ GTJOYURGZKZNKL[KR UNSY YURKTUOJ

<
ZNKYZGXZKXYURKTUOJ YURKTUOJ)NKIQZNK
.URJZNKYZGXZY]OZINZU XKYOYZGTIKULZNK
KOZNKXYOJKGTJINKIQ YURKTUOJ
ZNK\URZGMKGZVUYOZO\K
ZKXSOTGRUTL[KR
UNSY
YURKTUOJ
9KK*K[Z`YKX\OIK
SGT[GRLUX
<
ZXU[HRKYNUUZOTML[KR
Y_YZKS
)UTZOT[KJUTZNKTK^Z
VGMK
5 - 12 Genie S-40 Part No. 52271

CHART 3
.URJYZGXZY]OZINGTJ 8KVGOXUVKTOT]NZ
)UTZOT[KJLXUSZNK
INKIQ\URZGMKGZ]NZ < ]OXKLXUS)8ZUL[KR
VXK\OU[YVGMK
]OXKUTZKXSOTGR YURKTUOJ
UL)8
<
)NKIQ\URZGMKGZXKJ 8KVGOXUVKTOTXKJ]OXK
<
]OXKUTZKXSOTGR UL IOXI[OZLXUSHGZZKX_ZU
)8 )(ZU)8ZU)8
<
.URJZNKYZGXZY]OZINZU .URJZNKYZGXZY]OZINZU 8KVGOXUVKTOTHRQ]OXK

<
KOZNKXYOJKGTJINKIQ < LXUSZKXSOTGR UT
KOZNKXYOJKGTJINKIQ
\URZGMKGZZKXSOTGR \URZGMKGZZKXSOTGR UT )8ZUZKXSOTGR UT
UL)8 ZNKOMTOZOUTYZGXZSUJ[RK ZNKOMTOZOUTYZGXZSUJ[RK
<
)NKIQ\URZGMKGZ 8KVGOXUVKTOTVU]KX
<
ZKXSOTGR GTJUT Y[VVR_]OXKYZUZKXSOTGR
OMTOZOUTYZGXZSUJ[RK GTJUTOMTOZOUTYZGXZ
SUJ[RK
<
)NKIQIUTZOT[OZ_LXUS TU 8KVGOXUVKTOTHXU]T
MXU[TJZUHXU]T]OXKGZ IUTZOT[OZ_ MXU[TJ]OXKIOXI[OZZU

<
ZKXSOTGR UTOMTOZOUT ZKXSOTGR UTOMTOZOUT
YZGXZSUJ[RK YZGXZSUJ[RK
IUTZOT[OZ_
8KVRGIKZNKOMTOZOUT
YZGXZSUJ[RK58IUTY[RZ
*KVGXZSKTZ
TU
IUTZOT[OZ_
MXU[TJZUZKXSOTGR MXU[TJ]OXKIOXI[OZZU
UT)8 )8
MUUJ
)UTZOT[KJUTZNKTK^Z
VGMK
Part No. 52271 Genie S-40 5 - 13

CHART 3
)XGTQKTMOTKGTJINKIQ )XGTQKTMOTKGTJINKIQ 8KVGOXUXXKVRGIK

)UTZOT[KJLXUSZNK < <
\URZGMKGZZKXSOTGR UT \URZGMKGZUXMHRQ GRZKXTGZUX58IUTZGIZ
VXK\OU[YVGMK
OMTOZOUTYZGXZSUJ[RK ]OXKUTGRZKXTGZUX -KTOK/TJ[YZXOKY9KX\OIK
*KVGXZSKTZ
ZU<
8KVGOXUVKTOTUXMHRQ
]OXKIOXI[OZLXUS
ZU< GRZKXTGZUXZU:(ZU
ZKXSOTGR UTOMTOZOUT
YZGXZSUJ[RK
=NORKIXGTQOTMKTMOTK *OYIUTTKIZ]NZ ]OXK )NKIQUORRK\KR58
LUXYKIUTJYINKIQ LXUSUORVXKYY[XKYKTJKX XKVRGIKUORVXKYY[XK
IUTZOT[OZ_ZUMXU[TJUT _KY GTJINKIQIUTZOT[OZ_ZU _KY YKTJOTM[TOZ58XKLKXZU
ZKXSOTGR UTOMTOZOUT MXU[TJUTYOMTGRVUYZUL *K[Z`YKX\OIKSGT[GR
YZGXZSUJ[RK/Y YKTJKX]NORKIXGTQOTM LUXZXU[HRKYNUUZOTMRU]
IUTZOT[OZ_SGOTZGOTKJ% ZNKKTMOTK/YIUTZOT[OZ_ UORVXKYY[XK
SGOTZGOTKJ%
TU
*OYIUTTKIZ]NZ ]OXK )NKIQUORRK\KR58
LXUSKTMOTKZKSVKXGZ[XK XKVRGIKKTMOTK
YKTJKXGTJINKIQ ZKSVKXGZ[XKYKTJOTM
_KY
IUTZOT[OZ_ZUMXU[TJUT [TOZ58XKLKXZU*K[Z`
YOMTGRVUYZULYKTJKX YKX\OIKSGT[GRLUX
]NORKIXGTQOTMZNK ZXU[HRKYNUUZOTMG
KTMOTK/YIUTZOT[OZ_ U\KXNKGZKJKTMOTK
SGOTZGOTKJ%
TU
TU
8KVGOXYNUXZZUMXU[TJ
OT]NZ ]OXKLXUS
YKTJOTM[TOZYZU:(ZU
ZKXSOTGR UTOMTOZOUT
YZGXZSUJ[RK
)NKIQ\URZGMKGZ *OYIUTTKIZXKJ]OXK 8KVRGIKOMTOZOUTYZGXZ

<
ZKXSOTGR UTOMTOZOUT LXUSZKXSOTGR UT < SUJ[RK58IUTY[RZ
YZGXZSUJ[RK OMTOZOUTYZGXZSUJ[RKGTJ -KTOK/TJ[YZXOKY9KX\OIK
INKIQ\URZGMKGZ *KVGXZSKTZ
ZKXSOTGR
< <
:KYZG[ÔROGX_VU]KX
ZUMMRKY]OZINKY:9GTJ
8KVRGIKOMTOZOUTYZGXZ :99KK8KVGOX
SUJ[RK58IUTY[RZ 9KIZOUT
*KVGXZSKTZ
5 - 14 Genie S-40 Part No. 52271

Chart 4
Engine Will Not *OYIUTTKIZ26-Y[VVR_
Start On LPG, ROTKLXUS26-ZGTQGTJ
HRKKJVXKYY[XKLXUS
But Will Start ROTK
On Gasoline -
Gasoline/LPG =OZNQK_Y]OZINZ[XTKJZU < 8KVRGIKL[KRYKRKIZ
Models MXU[TJIUTZXURYGTJ
HUZN+SKXMKTI_9ZUV
Y]OZIN
Be sure fuel select 54VUYOZOUTIXGTQ
switch is switched KTMOTKGTJINKIQ
to LPG. \URZGMKGZ26-YOJK
HR[XKJ]OXKULL[KR
YKRKIZY]OZIN:9
Be sure to check
LPG fuel level. <
=OZNQK_Y]OZINZ[XTKJZU 8KVGOXUVKTOTHR[XKJ
<
MXU[TJIUTZXURYGTJ ]OXKIOXI[OZLXUSL[KR
HUZN+SKXMKTI_9ZUV YKRKIZY]OZINZU:(
54VUYOZOUTIXGTQ
KTMOTKGTJINKIQ
\URZGMKGZ:(
<
=OZNQK_Y]OZINZ[XTKJZU 8KVGOXUVKTOTHR[XKJ
<
MXU[TJIUTZXURYGTJ ]OXKIOXI[OZLXUS:(ZU
HUZN+SKXMKTI_9ZUV ZKXSOTGR UT)8
UTVUYOZOUTIXGTQ
KTMOTKGTJINKIQ
\URZGMKGZZKXSOTGR
UT)8
<
)XGTQKTMOTKLUX 8KVGOXUVKTOTXKJHRQ
<
YKIUTJYGTJINKIQ ]OXKIOXI[OZLXUS\GI[[S
\URZGMKGZZKXSOTGR Y]OZINZU)8ZU)8
UT)8
<
HGJ
MXU[TJZUHXU]T]OXKUT MXU[TJ]OXKIOXI[OZZU
ZKXSOTGR UT)8 ZKXSOTGR UT)8
MUUJ
)UTZOT[KJUTZNKTK^Z
VGMK
Part No. 52271 Genie S-40 5 - 15

CHART 4
.URJZNKYZGXZY]OZINZU <
)UTZOT[KJLXUSZNK 8KVRGIK)8XKRG_
KOZNKXYOJKGTJINKIQ
VXK\OU[YVGMK
\URZGMKGZZKXSOTGR
UT)8
<
.URJZNKYZGXZY]OZINZU 8KVGOXUVKTOTHR[XKJ
KOZNKXYOJKGTJINKIQ < ]OXKIOXI[OZLXUS)8
\URZGMKGZHR[XKJ]OXK ZKXSOTGR ZU26-
UT26-YURKTUOJ YURKTUOJ
<
UX
OTLOTOZK
)NKIQXKYOYZGTIKUL UNSY
8KVRGIK26-YURKTUOJ
26-YURKTUOJ
ZUUNSY
8KIUTTKIZ26-ZGTQ
GTJYZGXZKXZNKTYKK
3GOTZKTGTIKYKIZOUTLUX
26-GJP[YZSKTZY58
9KX\OIK*KVGXZSKTZ
5 - 16 Genie S-40 Part No. 52271

Chart 5
Engine Will =OZNQK_Y]OZINZ[XTKJZU < 8KVRGIKL[KRYKRKIZ
Not Start On MXU[TJIUTZXURYGTJ
HUZN+SKXMKTI_9ZUV
Y]OZIN
Gasoline, H[ZZUTYV[RRKJU[ZZUZNK
54VUYOZOUTIXGTQ
But Will Start KTMOTKGTJINKIQ
\URZGMKGZMGYUROTKYOJK
On LPG - HR[]NZ]OXKULL[KR
YKRKIZY]OZIN:9
Gasoline/LPG
Models <
=OZNQK_Y]OZINZ[XTKJZU 8KVGOXUVKTOTHR[]NZ
Be sure fuel select MXU[TJIUTZXURYGTJ
<
]OXKIOXI[OZLXUSL[KR
switch is switched HUZN+SKXMKTI_9ZUV YKRKIZY]OZINZU:(
to gasoline. H[ZZUTYV[RRKJU[ZZUZNK
54VUYOZOUTIXGTQ
KTMOTKGTJINKIQ
Be sure to check \URZGMKGZ:(
gasoline fuel level.
<
Be sure that engine
choke is operating =OZNQK_Y]OZINZ[XTKJZU 8KVGOXUVKTOTHR[XKJ
<
properly. MXU[TJIUTZXURYGTJ ]OXKIOXI[OZLXUS:(ZU
HUZN+SKXMKTI_9ZUV ZKXSOTGR UT)8
UTVUYOZOUTIXGTQ
KTMOTKGTJINKIQ
\URZGMKGZZKXSOTGR
UT)8
<
)XGTQKTMOTKLUX 8KVGOXUVKTOTXKJHRQ
<
YKIUTJYGTJINKIQ ]OXKIOXI[OZLXUS\GI[[S
\URZGMKGZZKXSOTGR Y]OZINZU)8
UT)8
<
TU
IUTZOT[OZ_
MXU[TJZUHXU]T]OXKUT MXU[TJ]OXKIOXI[OZZU
IUTZOT[OZ_
.URJZNKYZGXZY]OZINZU 8KVGOXUVKTOTHR[]NZ
KOZNKXYOJKGTJINKIQ ]OXKIOXI[OZLXUS)8
<
\URZGMKGZHR[]NZ]OXK ZKXSOTGR
UTGTZOJOKYKR\GR\KUT ZUGTZOJOKYKR\GR\K58
IGXH[XKZUX XKVRGIK)8
<
)UTZOT[KJUTZNKTK^Z
VGMK
Part No. 52271 Genie S-40 5 - 17

CHART 5
TU
)UTZOT[KJLXUSZNK < IUTZOT[OZ_
KOZNKXYOJKGTJINKIQ MXU[TJZUHXU]T]OXKGZ MXU[TJ]OXKIOXI[OZZUZNK
VXK\OU[YVGMK
\URZGMKGZHR[]NZ]OXK L[KRV[SV L[KRV[SV
UTZNKL[KRV[SV
IUTZOT[OZ_
8KVGOXUVKTOTHR[]NZ
]OXKLXUSGTZOJOKYKR
< YURKTUOJZUL[KRV[SV
58XKVRGIKL[KRV[SV
TU
< IUTZOT[OZ_
KOZNKXYOJKGTJINKIQ MXU[TJZUHXU]T]OXKGZ MXU[TJ]OXKIOXI[OZZUZNK
\URZGMKGZHR[]NZ]OXK MGYUROTKYURKTUOJ MGYUROTKYURKTUOJ
UTMGYUROTKYURKTUOJGZ
L[KRZGTQ
IUTZOT[OZ_
8KVGOXUVKTOTHR[]NZ
]OXKLXUSL[KRV[SVZU
MGYUROTKYURKTUOJ58
< XKVRGIKMGYUROTK
YURKTUOJ
UX
OTLOTOZK
)NKIQXKYOYZGTIKUL UNSY 8KVRGIKMGYUROTK
MGYUROTKYURKTUOJ YURKTUOJ
ZUUNSY
UX
OTLOTOZK
)NKIQXKYOYZGTIKUL UNSY 8KVRGIKGTZOJOKYKR
GTZOJOKYKR\GR\K \GR\K
ZUUNSY
RKYYZNGT
/TYZGRRGVXKYY[XKMG[MK 8KVRGIKL[KRV[SV58
VYO
ZUZNKL[KRV[SV.URJ INKIQGTZOJOKYKRGTJ
YZGXZY]OZINZUKOZNKX L[KR\GR\KLUXJKLKIZY
YOJKGTJUHYKX\KZNK
VXKYY[XKUTZNKMG[MK
SUXKZNGTVYO
8KIUTTKIZYZGXZKXGTJ
YKK,UXJYKX\OIKSGT[GR
LUXIGXH[XKZUX
ZXU[HRKYNUUZOTM58
9KX\OIK*KVGXZSKTZ
5 - 18 Genie S-40 Part No. 52271

Chart 6
Engine 9ZGXZKTMOTKGTJSU\K )NKIQ\URZGMKGZIKTZKX 8KVGOXUVKTOTVU]KX
< <
High Idle ZNKXVSYKRKIZZUNOMN
OJRKXGHHOZY_SHURLUX
ZKXSOTGRUTXVSYKRKIZ
Y]OZIN:9GTJ:9
Y[VVR_IOXI[OZZUIKTZKX
ZKXSOTGRULY]OZIN
Inoperative - ZNKLURRU]OTMINKIQY
)NKIQ\URZGMKGZHRQXKJ
<
Gasoline/LPG ]OXKUTXVSYKRKIZ
Y]OZIN:9GTJ:9
Models 8KVRGIKXVSYKRKIZ
ZUMMRKY]OZIN
If high idle operates <
on LPG but not on

gasoline, see Ford <
)NKIQ\URZGMKGZ:( 8KVGOXUVKTOTHRQXKJ
service manual for ]OXKIOXI[OZLXUSZUMMRK
carburetor Y]OZINZU:6ZU:(
troubleshooting. <
If high idle operates

on gasoline but not )NKIQ\URZGMKGZ 8KVGOXUVKTOTHRQXKJ
<
on LPG, see Repair ZKXSOTGR HRQXKJUT ]OXKIOXI[OZLXUS
)8 :(ZU)8
section for LPG
regulator adjustments.
<
Be sure throttle TU
linkage from governor MXU[TJZUZNKHXU]T
IUTZOT[OZ_
MXU[TJ]OXKIOXI[OZZU
to carburetor is not ]OXKUTZKXSOTGR UL ZKXSOTGR UT)8
binding. )8
Be sure high idle can IUTZOT[OZ_
be achieved by grasping
the governor actuator )NKIQ\URZGMKGZ < 8KVGOXUVKTOT]NOZK
ZKXSOTGR UT)8 VU]KX]OXKLXUS

arm and momentarily ZKXSOTGRUT)8ZU
pulling to throttle the )8ZU)8
carburetor. <
)NKIQ\URZGMKGZ < 8KVRGIK)8XKRG_
ZKXSOTGR'UT)8
<
)NKIQ\URZGMKGZ 8KVGOXYNUXZOTHRQXKJ
<
ZKXSOTGRUTKRKIZXUTOI 8]OXKZUZKXSOTGR
MU\KXTUX UTVXKIOYOUTMU\KXTUX
<
)UTZOT[KJUTZNKTK^Z
VGMK
Part No. 52271 Genie S-40 5 - 19

CHART 6
)NKIQ\URZGMKGZ < 8KVGOXUVKTOT]NZ]OXK

)UTZOT[KJLXUSZNK
ZKXSOTGR UT)8 IOXI[OZLXUS)8
VXK\OU[YVGMK
ZKXSOTGR ZU)8

<
)NKIQ\URZGMKGZ < 8KVGOXUVKTOTXJHRQ
ZKXSOTGR UT)8 8]OXKIOXI[OZLXUS
\GI[[SY]OZINZU)8
ZU)8ZUZKXSOTGR
UT)8
<
TU
)NKIQIUTZOT[OZ_LXUS 8KVGOXUVKTOTMXU[TJ
IUTZOT[OZ_
MXU[TJZUHXU]T]OXKUT ]OXKZUZKXSOTGR UT
ZKXSOTGR UL)8 )8
IUTZOT[OZ_
<
)NKIQ\URZGMKZU
8KVRGIK)8XKRG_
ZKXSOTGR UT)8
<
)NKIQ\URZGMKGZ 8KVGOXUVKTOTXKJ]NZ
<
ZKXSOTGRXKJ]NZ]OXK ]OXKIOXI[OZLXUSZKXSOTGR
UTKRKIZXUTOIMU\KXTUX UT)8ZUZKXSOTGR
UTKRKIZXUTOI
MU\KXTUX
<
)NKIQ\URZGMKGZ 8KVGOXUVKTOTXKJ]NZ
<
ZKXSOTGRXKJ]NZ]OXK ]OXKIOXI[OZLXUS
UTMU\KXTUXGIZ[GZUX KRKIZXUTOIMU\KXTUX
ZKXSOTGR ZUMU\KXTUX
GIZ[GZUXZKXSOTGR
<
)NKIQIUTZOT[OZ_LXUS TU 8KVGOXUVKTOTHR[HRQ
ZKXSOTGR UTVXKIOYOUT IUTZOT[OZ_ ]OXKIOXI[OZLXUS
MU\KXTUXZUHR[HRQ MU\KXTUXGIZ[GZUXZU
ZKXSOTGR UTMU\KXTUX KRKIZXUTOIMU\KXTUX
GIZ[GZUX
L[RRIUTZOT[OZ_
)UTZOT[KJUTZNKTK^Z
VGMK
5 - 20 Genie S-40 Part No. 52271

CHART 6
)NKIQ\URZGMKUTXKJ 8KVGOXUVKTOTXKJ]NZ
)UTZOT[KJLXUSZNK <
]NZ]OXKUTMU\KXTUX ]OXKLXUSMU\KXTUX
VXK\OU[YVGMK
GIZ[GZUX IUTZXURRKXZUMU\KXTUX
GIZ[GZUX
<
:[XTSGINOTKULL UX
XKSU\KHUZN]OXKY OTLOTOZK
LXUSMU\KXTUXGIZ[GZUX UNSY 8KVRGIKMU\KXTUX
GTJINKIQXKYOYZGTIK GIZ[GZUX
GIXUYYMU\KXTUX
GIZ[GZUXZKXSOTGRY
ZUUNSY
8KIUTTKIZMU\KXTUX 8KVGOXUVKTOTHXU]T
]OXKYGTJXKYZGXZKTMOTK < ]OXKIOXI[OZLXUSOMTOZOUT
GTJINKIQ\URZGMKGZ IUORVR[MZUKRKIZXUTOI
KRKIZXUTOIMU\KXTUX MU\KXTUX
ZKXSOTGRGTJHXU]T
]OXKY
<
9KK3GOTZKTGTIK
YKIZOUTLUXMU\KXTUX
GJP[YZSKTZY58XKVRGIK
KRKIZXUTOIMU\KXTUX
Part No. 52271 Genie S-40 5 - 21

Chart 7
Engine Low Idle 9ZGXZKTMOTKGTJY]OZIN /YURGZKZNKMXU[TJGTJ
Inoperative - XVSYKRKIZZURU]OJRK
Z[XZRKY_SHUR)NKIQ
<
VRGZLUXSXVSZUMMRK
Y]OZINKY:9GTJ:9
Gasoline/LPG \URZGMKGZZKXSOTGR
HRQXJ]OXKUT)8
INKIQOTJO\OJ[GRR_GTJ
XKVRGIKJKLKIZO\KY]OZIN
Models
<
If low idle operates

on LPG but not on )NKIQ\URZGMKGZ < 8KVGOXUVKTOT]NZ]OXK
ZKXSOTGR UT)8 IOXI[OZLXUSZKXSOTGR

gasoline, see Ford
UT)8ZU)8ZKXSOTGR
service manual for
carburetor <
troubleshooting.
If low idle operates )NKIQ\URZGMKGZ

<
8KVRGIK)8XKRG_
on gasoline but not ZKXSOTGR 'UT)8
on LPG, see Repair

section for LPG <
regulator adjustments.
)NKIQ\URZGMKGZ 8KVGOXUVKTOTHRQXKJ
<
ZKXSOTGR UT ]OXKIOXI[OZLXUS)8
Be sure throttle
KRKIZXUTOIMU\KXTUX ZKXSOTGR 'ZU
linkage from governor KRKIZXUTOIMU\KXTUX
to carburetor is not ZKXSOTGR
binding, see Repair <
section.
)NKIQ\URZGMKGZ 8KVGOXUVKTOTHXU]T
KRKIZXUTOIMU\KXTUX < ]OXKIOXI[OZLXUSOMTOZOUT
ZKXSOTGRGTJHXU]T SUJ[RKZUKRKIZXUTOI
]OXKY MU\KXTUX
<
:[XTSGINOTKULL 8KINKIQZNXUZZRKROTQGMK
XKSU\KHR[HRQ]OXKLXUS YKK8KVGOXYKIZOUT58
KTMOTKMUKYZUNOMNOJRK
ZKXSOTGR UTKRKIZXUTOI INKIQGTJUXXKVRGIK
MU\KXTUXGTJXKYZGXZ MU\KXTUXGIZ[GZUX58
KTMOTK YKK,UXJYKX\OIKSGT[GR
LUXIGXH[XKZUX
ZXU[HRKYNUUZOTM
KTMOTKMUKYZURU]OJRK
8KINKIQKRKIZXUTOI
MU\KXTUXGJP[YZSKTZY
58XKVRGIKKRKIZXUTOI
MU\KXTUX
5 - 22 Genie S-40 Part No. 52271

Chart 8
Engine 9ZGXZKTMOTKY]OZINXVS )NKIQNOMNOJRK
YURKTUOJ
High Idle YKRKIZY]OZINZUNOMNOJRK
XGHHOZY_SHURGTJ
V[RRYOT
GJP[YZSKTZYKK
3GOTZKTGTIKYKIZOUT
Inoperative - INKIQOLYVKKJ
YURKTUOJV[RRYOT
58YKK*K[Z`]UXQYNUV
Deutz Diesel L[KROTPKIZOUTY_YZKS
YURKTUOJJUKY
Models TUZV[RROT
Be sure mechanical )NKIQ\URZGMKGZHRQXKJ )NKIQ\URZGMKUTXKJ 8KVGOXUVKTOTIOXI[OZ

< <
linkage is not binding ]OXKUTXVSYKRKIZ ]OXKGZIKTZKXZKXSOTGRUL Y[VVR_OTM<ZUIKTZKX
or defective. Y]OZIN:9GTJ:9 XVSYKRKIZY]OZIN ZKXSOTGRULY]OZIN
Be sure 2-speed <
solenoid grounding
wires are free of < 8KVRGIKZUMMRKY]OZIN
corrosion and have full

continuity to ground.
<
)NKIQ\URZGMKGZ:( 8KVGOXUVKTOTHRQXKJ
]OXKIOXI[OZLXUSZUMMRK
Y]OZINZU:(
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8KVRGIK)8XKRG_
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Part No. 52271 Genie S-40 5 - 23

CHART 8
)UTZOT[KJLXUSZNK )NKIQ\URZGMKGZ < 8KVGOXUVKTOTHRQXKJ
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UNSY
5 - 24 Genie S-40 Part No. 52271

Chart 9
Engine 'ZZNKVRGZLUXSIUTZXURY /YURGZKZNKVRGZLUXSGTJ
Low Idle YZGXZZNKKTMOTKGTJ
SU\KZNKXVSYKRKIZ
<
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Deutz Diesel Z[XZRKY_SHUR)NKIQ
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Models UTXVSYKRKIZY]OZIN
Check if <
mechanical linkage <

)NKIQ\URZGMKGZZNK 8KVRGIK)8XKRG_
from 2-speed
HRQXKJ]OXKUTZNK
solenoid to fuel YVKKJYURKTUOJ
injection system is
binding or defective. <
YURKTUOJ
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YURKTUOJSU\KYOTGTJ XKVRGIKYURKTUOJ
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9KK*K[Z`]UXQYNUV
L[KROTPKIZOUTY_YZKS58
9KX\OIK*KVGXZSKTZ
Part No. 52271 Genie S-40 5 - 25

Chart 10
All Functions )NKIQN_JXG[ROI RU] ,ORR]OZN*K^XUT
Inoperative, LR[OJRK\KR KW[O\GRKTZN_JXG[ROI
LR[OJ
Engine Starts UQ
and Runs
)NKIQV[SVY[IZOUTROTK IRUYKJ *UZNKV[SVYLKKR _KY /LKTMOTKNGYHKKTX[T
YN[ZULL\GR\KY/TZNK KÎKYYO\KR_NUZ% ]OZN\GR\KYIRUYKJOZ
UVKTVUYOZOUTZNK\GR\K SG_NG\KJGSGMKJUTK
NGTJRKYYNU[RJHK UXHUZNV[SVY6RKGYK
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/TJ[YZXOKY9KX\OIK
TU *KVGXZSKTZ
5VKT\GR\KYGTJYZGXZ
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*OYIUTTKIZOMTOZOUTIUOR :XU[HRKYNUUZ
YVROTK
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SGT[GRL[KRYN[ZULLRK\KX L[TIZOUTYYKVGXGZKR_
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YVROTKJUKYTUZZ[XT
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JKLKIZO\K58SGOT
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9KX\OIK*KVGXZSKTZ
5 - 26 Genie S-40 Part No. 52271

Chart 11
All Lift and /TYZGRRGZU69/

:XU[HRKYNUUZKGIN
VYOUX
Steer Functions HGXVXKYY[XK
MG[MKUTZNKL[TIZOUT
SUXK
L[TIZOUTOTJO\OJ[GRR_UX
Inoperative, SGTOLURJ9ZGXZKTMOTK
SU\KZNKL[TIZOUT
9KX\OIK*KVGXZSKTZ
Drive Functions KTGHRKZUMMRKY]OZINZU
KOZNKXYOJKGTJNURJZNK
Operational HUUSXKZXGIZL[TIZOUT
ZUMMRKY]OZINGTJINKIQ
ZNKN_JXG[ROIVXKYY[XK
Be sure the hydraulic
suction line shutoff RKYYZNGT
VYO
valve for the lift/steer
pump is in the open 'JP[YZZNKL[TIZOUT 3U\KZNKL[TIZOUT
position. SGTOLURJY_YZKSXKROKL KTGHRKY]OZINZUKOZNKX
\GR\KOZKS>GRRZNK VYOUX YOJKGTJNURJZNKHUUS
]G_OTIRUIQ]OYK SUXK XKZXGIZY]OZINGTJ

Be sure all grounding
IU[TZOTMZNKT[SHKXUL XKGJP[YZZNKXKROKL
wires for the hydraulic Z[XTY3U\KZNKL[TIZOUT VXKYY[XKZUVYOLUX
manifold valves are free KTGHRKY]OZINZUKOZNKX 9UXVYOLUX
YOJKGTJNURJZNKHUUS 9
of corrosion and have XKZXGIZZUMMRKY]OZINGTJ
full continuity to ground. XKINKIQZNKVXKYY[XK
RKYYZNGT
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)NKIQYZKKXL[TIZOUTY 8KVGOXUXXKVRGIK
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OZKS=58XKVGOXUX
XKVRGIKLRU]XKM[RGZUX
\GR\KOZKS((58
SGTOLURJNGYGTOTZKXTGR
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YZKKXOTMOTUVKXGZO\K
/TJ[YZXOKY9KX\OIK
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HGJ
8KVRGIKZNKL[TIZOUT
V[SV
Part No. 52271 Genie S-40 5 - 27

Chart 12
Ground *UKYZNKKTMOTKYZGXZ
_KY
9ZGXZZNKKTMOTKLXUS 8KVGOXUVKTOTXKJ]OXK
Controls LXUSZNKMXU[TJ
IUTZXURY%
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3U\KZNKL[TIZOUT
<
IOXI[OZLXUSQK_Y]OZINZU
L[TIZOUTKTGHRKZUMMRK
Inoperative, KTGHRKZUMMRKY]OZINZU
KOZNKXYOJKGTJINKIQ
Y]OZINZUKGINL[TIZOUT
ZUMMRKY]OZIN
Platform ZNK\URZGMKUTZNK
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Controls VRGZLUXSXUZGZKZUMMRK
Y]OZIN:9
Operate
Normally TU <
Be sure all other :XU[HRKYNUUZKGIN
L[TIZOUTOTJO\OJ[GRR_
functions operate
normally, including
the platform
controls. =OZNHUZN+SKXMKTI_ 8KVGOXUVKTOTXKJ]OXK
9ZUVH[ZZUTYV[RRKJU[Z < IOXI[OZLXUSKSKXMKTI_
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< _KY
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IUTZXURYGTJHUZN MXU[TJIUTZGIZ IUTZXURY
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TU
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IUTZXURYIUTZGIZUTZNK 19
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8KVGOXUVKTOTXKJ]OXK
IOXI[OZLXUSQK_Y]OZINZU
L[TIZOUTKTGHRKZUMMRK
Y]OZINZUKGINL[TIZOUT
ZUMMRKY]OZIN
5 - 28 Genie S-40 Part No. 52271

Chart 13
Platform *UKYKTMOTKYZGXZLXUS _KY 9ZGXZKTMOTKLXUSZNK :KYZUXXKVRGIKLUUZ
Controls ZNKVRGZLUXSIUTZXURY% VRGZLUXSIUTZXURYZNKT
VXKYYJU]TZNKLUUZ
<
Y]OZINYKK8KVGOX
9KIZOUT58XKVGOXUVKT
Inoperative, Y]OZINGTJINKIQ
\URZGMKGZ:6
OT]NZ]OXKIOXI[OZLXUS
LUUZY]OZINZU:6
Ground
<
Controls
TU
Operate 8KVGOXUVKTOT]NZ]OXK
IOXI[OZLXUS:6ZU
Normally L[TIZOUTZUMMRKY]OZINKY
GTJL[TIZOUTIUTZXURRKXY
Be sure all
cables from chassis <
)NKIQ\URZGMKGZ:( 8KVGOXUVKTOTXKJ]OXK
through the cable IOXI[OZLXUSQK_Y]OZINZU
track are in good :(588KVRGIKZNK
condition with no <

VRGZLUXSIUTZXURYIUTZGIZ
GZZNKQK_Y]OZIN
kinks or abrasions.
<
)NKIQ\URZGMKGZ:6 8KVGOXUVKTOTHRQ
]OXKIOXI[OZLXUS:(
:6
<
)NKIQ\URZGMKGZHRQ 8KVGOXUVKTOTHRQ]OXK
]OXKUTOTV[ZYOJKUL < LXUS:6ZU
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9ZUVH[ZZUTIUTZGIZ6 6
<
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< _KY
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+SKXMKTI_9ZUVH[ZZUTY
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IUTZGIZ
<
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+SKXMKTI_9ZUVH[ZZUT
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8KVGOXUVKTOTHRQ]OXK
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+SKXMKTI_9ZUVH[ZZUT
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58XKVRGIKLUUZY]OZIN
58IUTY[RZ-KTOK
/TJ[YZXOKY9KX\OIK
*KVGXZSKTZ
Part No. 52271 Genie S-40 5 - 29

Chart 14
Boom Up =OZNQK_Y]OZINOT 3U\KZNKL[TIZOUT 8KVGOXUVKTOTXKJ]NZ
Function MXU[TJVUYOZOUTGTJ
HUZN+SKXMKTI_9ZUV
KTGHRKY]OZINZUKOZNKX
YOJKGTJNURJZNKHUUS
]OXKIOXI[OZLXUS:(ZU
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< ZU<
Inoperative H[ZZUTYV[RRKJU[ZZUZNK
54VUYOZOUTSU\KZNK
[VZUMMRKY]OZIN:9
UTMXU[TJVGTKROTZNK
VXUVUXZOUTGR\GR\KIUOR
OZKS658XKVGOXUVKT
L[TIZOUTKTGHRKY]OZINZU [VJOXKIZOUTGTJINKIQ OTHXU]TMXU[TJ]OXK

Be sure all other KOZNKXYOJKGTJNURJZNK \URZGMKGZ:( IOXI[OZZU\GR\KIUOR
functions operate HUUS[VZUMMRKY]OZIN
:9UTMXU[TJVGTKR
normally. OT[VJOXKIZOUTGTJ
<
INKIQ\URZGMKUTXKJ
]NZ]OXKUTHUUS[V =OZNZNKQK_Y]OZINOT ZU< 8KVGOXUVKTOTXKJ]NZ
JU]TVXUVUXZOUTGR\GR\K VRGZLUXSVUYOZOUTGTJ ]OXKLXUS:6ZU:(
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INKIQ\URZGMKGZ:6
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OTHXU]TMXU[TJ]OXK
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<UXSUXK
/TJ[YZXOKY9KX\OIK
*KVGXZSKTZ
)UTZOT[KJUTZNKTK^Z
VGMK
5 - 30 Genie S-40 Part No. 52271

CHART 14
=OZNQK_Y]OZINOT 3U\KZNKL[TIZOUT 8KVGOXUVKTOTXKJ

)UTZOT[KJLXUSZNK
MXU[TJVUYOZOUTGTJ KTGHRKY]OZINZUKOZNKX ]OXKIOXI[OZLXUS:(ZU
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HUZN+SKXMKTI_9ZUV YOJKGTJNURJZNKHUUS HUUS[VL[TIZOUT
< SUXK
H[ZZUTYV[RRKJU[ZZUZNK [VZUMMRKY]OZIN:9 JOXKIZOUTGR\GR\KIUOR
54VUYOZOUTSU\KZNK UTMXU[TJVGTKROT[V OZKS(58XKVGOXUVKT
L[TIZOUTKTGHRKY]OZINZU JOXKIZOUTGTJINKIQ OTHXU]TMXU[TJ]OXK
KOZNKXYOJKGTJNURJZNK \URZGMKGZ:( IOXI[OZZU\GR\KIUOR
HUUS[VZUMMRKY]OZIN
:9UTMXU[TJVGTKR
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OT[VJOXKIZOUTGTJ
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]OXKUTHUUS[VJU]T =OZNQK_Y]OZINOT :XU[HRKYNUUZHUUS[V
JOXKIZOUTGR\GR\KIUOR VRGZLUXSVUYOZOUTGTJ L[TIZOUTZUMMRKY]OZIN
OZKS( HUZN+SKXMKTI_9ZUV :9UTMXU[TJ

<UX
H[ZZUTYV[RRKJU[ZZUZNK IUTZXURVGTKR58XKVGOX
SUXK
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VGTKROT[VJOXKIZOUTGTJ *KVGXZSKTZ
INKIQ\URZGMK:(
<
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'IZO\GZKLUUZY]OZINGTJ SUXK 8KVGOXUVKTOTXKJ]OXK
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58IUTY[RZ-KTOK
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)UTZOT[KJUTZNKTK^Z
VGMK
Part No. 52271 Genie S-40 5 - 31

CHART 14
*OYIUTTKIZ]OXKYZU UX
)UTZOT[KJLXUSZNK
HUUS[VJOXKIZOUTGR OTLOTOZK
VXK\OU[YVGMK 8KVRGIKHUUS[V
\GR\KIUOROZKS(GTJ UNSY
JOXKIZOUTGR\GR\KIUOR
ZKYZZNKXKYOYZGTIKULZNK
OZKS(
\GR\KIUOR9KK8KVGOX
9KIZOUT
ZUUNSY
L[TIZOUT
3U\KL[TIZOUTKTGHRK UVKXGZKY 8KVRGIKJKLKIZO\K
Y]OZINZUKOZNKXYOJKGTJ JOXKIZOUTGR\GR\K
NURJZNKHUUS[VZUMMRK
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IUTZXURYOTZNK[V
JOXKIZOUT3GT[GRR_
U\KXXOJKZNKJOXKIZOUTGR
\GR\KH_V[YNOTMOTUT
ZNKKTJULZNK\GR\K
YVUUR
L[TIZOUTOTUVKXGZO\K
/TYZGRRGZU69/ )NKIQLUXSKINGTOIGR
HGXVXKYY[XK XKYZXOIZOUTYQKKVOTM
MG[MKGZZNKW[OIQ 69/UX HUUSLXUSSU\OTM58
JOYIUTTKIZIU[VROTMUT SUXK XKVGOXI_ROTJKXUX
ZNKHUUSL[TIZOUT I_ROTJKXIU[TZKXHGRGTIK
SGTOLURJGTJYZGXZZNK \GR\K58IUTY[RZ-KTOK
KTMOTK3U\KZNK /TJ[YZXOKY9KX\OIK
L[TIZOUTKTGHRKY]OZINZU *KVGXZSKTZ
HUUS[VZUMMRKY]OZIN
GZZNKMXU[TJIUTZXURYOT
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INKIQZNKVXKYY[XK
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+ÎNGTMKLRU]XKM[RGZUX L[TIZOUT
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\GR\KOZKS-)NKIQ XKM[RGZUX\GR\K
HUUS[VL[TIZOUT
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SGTOLURJIU[RJNG\KGT
OTZKXTGRJKLKIZ)UTY[RZ
*KVGXZSKTZ
5 - 32 Genie S-40 Part No. 52271

Chart 15
Boom Down =OZNQK_Y]OZINOT 3U\KZNKL[TIZOUT 8KVGOXUVKTOTXKJ]NZ
HUZN+SKXMKTI_9ZUV
YOJKGTJNURJZNKHUUS
]OXKIOXI[OZLXUS:(ZU
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< ZU<
54VUYOZOUTSU\KZNK
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OZKS658XKVGOXUVKT
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Be sure all other KOZNKXYOJKGTJNURJZNK GTJINKIQ\URZGMKGZ IOXI[OZZU\GR\KIUOR
functions operate HUUSJU]TZUMMRK :(
Y]OZIN:9UTMXU[TJ
normally. VGTKROTJU]TJOXKIZOUT
<
GTJINKIQ\URZGMKUT
XKJ]NZ]OXKUTHUUS
[VJU]TVXUVUXZOUTGR =OZNZNKQK_Y]OZINOT ZU< 8KVGOXUVKTOTXKJ]NZ
\GR\KIUOROZKS6 ZNKVRGZLUXSVUYOZOUTGTJ ]OXKLXUS:6ZU:(
HUZN+SKXMKTI_9ZUV
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:6
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OTHXU]TMXU[TJ]OXK
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VGMK
Part No. 52271 Genie S-40 5 - 33

CHART 15
=OZNQK_Y]OZINOT 3U\KZNKL[TIZOUT 8KVGOXUVKTOTXKJHRQ

)UTZOT[KJLXUSZNK
MXU[TJVUYOZOUTGTJ KTGHRKY]OZINZUKOZNKX ]OXKIOXI[OZLXUS:(
VXK\OU[YVGMK <UX
HUZN+SKXMKTI_9ZUV YOJKGTJNURJZNKHUUS ZUHUUSJU]TL[TIZOUT
< SUXK
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5 - 34 Genie S-40 Part No. 52271

CHART 15
)UTZOT[KJLXUSZNK
HUUSJU]TJOXKIZOUTGR OTLOTOZK
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\GR\KIUOROZKS(GTJ UNSY
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8KYKZHUUSJU]TXKROKL
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YKK8KVGOX9KIZOUT58
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/TJ[YZXOKY9KX\OIK
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Part No. 52271 Genie S-40 5 - 35

Chart 16
Boom Extend =OZNQK_Y]OZINOT 3U\KZNKL[TIZOUT 8KVGOXUVKTOTHRQXKJ
HUZN+SKXMKTI_9ZUV
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OZKS-58XKVGOXUVKT
L[TIZOUTKTGHRKY]OZINZU OTZNKK^ZKTJJOXKIZOUT OTHXU]TMXU[TJ]OXK

functions operate HUUSK^ZKTJZUMMRK :(
Y]OZIN:9UTMXU[TJ
normally. VGTKROTK^ZKTJJOXKIZOUT
<
GTJINKIQ\URZGMKUT
HRQXKJ]OXKUTHUUS
K^ZKTJXKZXGIZ =OZNQK_Y]OZINOT ZU< 8KVGOXUVKTOTHRQXKJ
VXUVUXZOUTGR\GR\KIUOR VRGZLUXSVUYOZOUTGTJ ]OXKLXUS:6ZU:(
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IUTZXURVGTKROTK^ZKTJ
JOXKIZOUTGTJINKIQ
\URZGMKGZ:6
<
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INKIQ\URZGMKGZIKTZKX Y[VVR_IOXI[OZLXUS:6
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8KVGOX9KIZOUT ZUMMRKY]OZIN:9
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:6
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VGMK
5 - 36 Genie S-40 Part No. 52271

CHART 16
)UTZOT[KJLXUSZNK
HUUSK^ZKTJJOXKIZOUTGR OTLOTOZK
VXK\OU[YVGMK 8KVRGIKHUUSK^ZKTJ
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K^ZKTJJOXKIZOUT
3GT[GRR_U\KXXOJKZNK
JOXKIZOUTGR\GR\KH_
V[YNOTMOTUTZNKKTJUL
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MG[MKGZZNKW[OIQ 69/UX HUUSLXUSK^ZKTJOTM
JOYIUTTKIZIU[VROTMUT SUXK 58XKVGOXI_ROTJKXUX
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HUUSK^ZKTJZUMMRK
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\GR\KOZKS-]OZNGROQK XKM[RGZUX\GR\K
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\GR\K58L[TIZOUT
SGTOLURJIU[RJNG\KGT
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Part No. 52271 Genie S-40 5 - 37

Chart 17
Boom Retract =OZNQK_Y]OZINOT 3U\KZNKL[TIZOUT 8KVGOXUVKTOTHRQXKJ
HUZN+SKXMKTI_9ZUV
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OZKS-58XKVGOXUVKT
L[TIZOUTKTGHRKY]OZINZU OTZNKK^ZKTJJOXKIZOUT OTHXU]TMXU[TJ]OXK

functions operate HUUSXKZXGIZZUMMRK :(
Y]OZIN:9UTMXU[TJ
normally. VGTKROTZNKXKZXGIZ
<
JOXKIZOUTGTJINKIQ
\URZGMKUTHRQXKJ]OXK
UTHUUSK^ZKTJXKZXGIZ =OZNQK_Y]OZINOT ZU< 8KVGOXUVKTOTHRQXKJ
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5 - 38 Genie S-40 Part No. 52271

CHART 17
)UTZOT[KJLXUSZNK
HUUSK^ZKTJJOXKIZOUTGR OTLOTOZK
VXK\OU[YVGMK 8KVRGIKHUUSK^ZKTJ
\GR\KIUOROZKS)GTJ UNSY
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\GR\KIUOR9KK8KVGOX
9KIZOUT
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MXU[TJIUTZXURYOTZNK
K^ZKTJJOXKIZOUT
3GT[GRR_U\KXXOJKZNK
JOXKIZOUTGR\GR\KH_
V[YNOTMOTUTZNKKTJUL
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MG[MKGZZNKW[OIQ 69/UX HUUSLXUSXKZXGIZOTM
JOYIUTTKIZIU[VROTMUT SUXK 58XKVGOXI_ROTJKXUX
SGTOLURJGTJYZGXZZNK \GR\KY58IUTY[RZ
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HUUSXKZXGIZZUMMRK
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\GR\KOZKS-]OZNGROQK XKM[RGZUX\GR\K
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HUUSXKZXGIZL[TIZOUT
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\GR\K58L[TIZOUT
SGTOLURJIU[RJNG\KGT
*KVGXZSKTZ
Part No. 52271 Genie S-40 5 - 39

Chart 18
Turntable =OZNQK_Y]OZINOT 3U\KZNKL[TIZOUT 8KVGOXUVKTOT]NZXKJ
Rotate Left MXU[TJVUYOZOUTGTJ
HUZN+SKXMKTI_9ZUV
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Function H[ZZUTYV[RRKJU[ZZUZNK
54VUYOZOUTSU\KZNK
< Z[XTZGHRKXUZGZKZUMMRK
Y]OZIN:9UTMXU[TJ
OZKS958XKVGOXUVKT
Inoperative L[TIZOUTKTGHRKY]OZINZU
VGTKROTZNKRKLZJOXKIZOUT
GTJINKIQ\URZGMKGZ
OTHXU]TMXU[TJ]OXK
IOXI[OZZU\GR\KIUOR
Z[XTZGHRKXUZGZKZUMMRK :(
Be sure all other Y]OZIN:9UTMXU[TJ
functions operate VGTKROTZNKRKLZJOXKIZOUT
GTJINKIQ\URZGMKUT
normally.
]NZXKJ]OXKUTZ[XTZGHRK
XUZGZKRKLZXOMNZ
VXUVUXZOUTGR\GR\KIUOR <
OZKS9
=OZNQK_Y]OZINOT ZU< 8KVGOXUVKTOT]NZXKJ
VRGZLUXSVUYOZOUTGTJ ]OXKLXUS:6ZU:(
HUZN+SKXMKTI_9ZUV
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XUZGZKRKLZXOMNZ
VXUVUXZOUTGRIUTZXURRKX
(6UTVRGZLUXS
IUTZXURVGTKROTZNKRKLZ
JOXKIZOUTGTJINKIQ
\URZGMKGZ:6
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58IUTY[RZ-KTOK
/TJ[YZXOKY9KX\OIK
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)UTZOT[KJUTZNKTK^Z
VGMK
5 - 40 Genie S-40 Part No. 52271

CHART 18
=OZNQK_Y]OZINOT 3U\KZNKL[TIZOUT 8KVGOXUVKTOT]NZHRQ

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Part No. 52271 Genie S-40 5 - 41

CHART 18
)UTZOT[KJLXUSZNK
Z[XTZGHRKXUZGZKRKLZ OTLOTOZK
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JOXKIZOUTGR\GR\KIUOR UNSY
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MG[MKGZZNKW[OIQ +ÎNGTMKLRU]XKM[RGZUX L[TIZOUT
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RKLZJOXKIZOUTGTJINKIQ SUZUX58L[TIZOUT
ZNKVXKYY[XK SGTOLURJSG_NG\KGT
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)UTZOT[KJUTZNKTK^Z
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5 - 42 Genie S-40 Part No. 52271

CHART 18
6R[SHGZUVYO RKYYZNGT ,[TIZOUTSGTOLURJIU[RJ

)UTZOT[KJLXUSZNK
ZUHGXVXKYY[XK VYO NG\KGTOTZKXTGRJKLKIZ
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SGTOLURJZUZNKZ[XTZGHRK
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L[TIZOUTLXUSUVKXGZOTM
58XKVRGIKYN[ZZRK\GR\K
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Part No. 52271 Genie S-40 5 - 43

Chart 19
Turntable =OZNQK_Y]OZINOT 3U\KZNKL[TIZOUT 8KVGOXUVKTOT]NZXKJ
Rotate Right MXU[TJVUYOZOUTGTJ
HUZN+SKXMKTI_9ZUV
YOJKGTJNURJZNK
]OXKIOXI[OZLXUS:(ZU
Z[XTZGHRKXUZGZKRKLZXOMNZ
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Function H[ZZUTYV[RRKJU[ZZUZNK
54VUYOZOUTSU\KZNK
< Z[XTZGHRKXUZGZKZUMMRK
Y]OZIN:9UTMXU[TJ
OZKS958XKVGOXUVKT
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VGTKROTZNKXOMNZ
JOXKIZOUTGTJINKIQ
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IOXI[OZZU\GR\KIUOR
Z[XTZGHRKXUZGZKZUMMRK \URZGMKGZ:(
Be sure all other Y]OZIN:9UTMXU[TJ
functions operate VGTKROTZNKXOMNZ
JOXKIZOUTGTJINKIQ
normally.
\URZGMKUT]NZXKJ]OXK
UTZ[XTZGHRKXUZGZKRKLZ
XOMNZVXUVUXZOUTGR\GR\K <
IUOROZKS9
=OZNQK_Y]OZINOT ZU< 8KVGOXUVKTOT]NZXKJ
VRGZLUXSVUYOZOUTGTJ ]OXKLXUS:6ZU:(
HUZN+SKXMKTI_9ZUV
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XUZGZKRKLZXOMNZ
(6UTVRGZLUXS
IUTZXURVGTKROTZNKXOMNZ
JOXKIZOUTGTJINKIQ
\URZGMKGZ:6
<
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58IUTY[RZ-KTOK
/TJ[YZXOKY9KX\OIK
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)UTZOT[KJUTZNKTK^Z
VGMK
5 - 44 Genie S-40 Part No. 52271

CHART 19
=OZNQK_Y]OZINOT 3U\KZNKL[TIZOUT 8KVGOXUVKTOT]NZ]OXK

)UTZOT[KJLXUSZNK
MXU[TJVUYOZOUTGTJ KTGHRKY]OZINZUKOZNKX IOXI[OZLXUS:(ZU
VXK\OU[YVGMK <UX
HUZN+SKXMKTI_9ZUV YOJKGTJNURJZNK Z[XTZGHRKXUZGZKXOMNZ
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H[ZZUTYV[RRKJU[ZZUZNK < Z[XTZGHRKXUZGZKRKLZXOMNZ L[TIZOUTJOXKIZOUTGR\GR\K
54VUYOZOUTSU\KZNK ZUMMRKY]OZIN:9UT IUOROZKS'58XKVGOX
L[TIZOUTKTGHRKY]OZINZU MXU[TJVGTKROTZNKXOMNZ UVKTOTHXU]TMXU[TJ
KOZNKXYOJKGTJNURJZNK JOXKIZOUTGTJINKIQ ]OXKIOXI[OZZU\GR\KIUOR
Z[XTZGHRKXUZGZKRKLZXOMNZ \URZGMKGZ:(
ZUMMRKY]OZIN:9UT
MXU[TJVGTKROTZNKXOMNZ
<
JOXKIZOUTGTJINKIQ
\URZGMKUT]NZ]OXKUT
HUUSL[TIZOUT =OZNQK_Y]OZINOT :XU[HRKYNUUZZ[XTZGHRK
JOXKIZOUTGR\GR\KIUOR VRGZLUXSVUYOZOUTGTJ XUZGZKRKLZXOMNZL[TIZOUT
OZKS' HUZN+SKXMKTI_9ZUV ZUMMRKY]OZIN:9UT

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H[ZZUTYV[RRKJU[ZZUZNK MXU[TJIUTZXURVGTKR58
SUXK
54VUYOZOUTGIZO\GZK XKVGOXUVKTOT]NZ]OXK
LUUZY]OZINGTJZ[XTZGHRK IOXI[OZLXUS:9ZU:(
XUZGZKRKLZXOMNZ 58IUTY[RZ-KTOK
VXUVUXZOUTGRIUTZXURRKX /TJ[YZXOKY9KX\OIK
(6UTVRGZLUXS *KVGXZSKTZ
JOXKIZOUTGTJINKIQ
\URZGMK:(
<
<UX
'IZO\GZKLUUZY]OZINGTJ SUXK 8KVGOXUVKTOT]NZHRQ
Z[XTZGHRKXUZGZKRKLZXOMNZ ]OXKLXUS:6ZU:(
(6UTVRGZLUXS
JOXKIZOUTGTJINKIQ
\URZGMK:6
<UXSUXK
<
<
OTHXU]TMXU[TJ]OXK
IOXI[OZLXUSMXU[TJZU
<UXSUXK
(6
8KVGOX9KIZOUT58
XKVRGIKIUTZXURRKX(6
58IUTY[RZ-KTOK
/TJ[YZXOKY9KX\OIK
*KVGXZSKTZ
)UTZOT[KJUTZNKTK^Z
VGMK
Part No. 52271 Genie S-40 5 - 45

CHART 19
)UTZOT[KJLXUSZNK
Z[XTZGHRKXUZGZKXOMNZ OTLOTOZK
VXK\OU[YVGMK 8KVRGIKZ[XTZGHRKXUZGZK
JOXKIZOUTGR\GR\KIUOR UNSY
XOMNZJOXKIZOUTGR\GR\K
OZKS'GTJZKYZZNK
IUOROZKS'
IUOR9KK8KVGOX9KIZOUT
ZUUNSY
L[TIZOUT
NURJZNKZ[XTZGHRKXUZGZK
RKLZXOMNZZUMMRKY]OZINGZ
ZNKMXU[TJIUTZXURYOT
ZNKXOMNZJOXKIZOUT
3GT[GRR_U\KXXOJKZNK
JOXKIZOUTGR\GR\KH_
V[YNOTMOTUTZNKKTJUL
ZNK\GR\KYVUUR
L[TIZOUTOTUVKXGZO\K
/TYZGRRGZU69/
HGXVXKYY[XK

MG[MKGZZNKW[OIQ +ÎNGTMKLRU]XKM[RGZUX L[TIZOUT
69/UX
JOYIUTTKIZIU[VROTMUT \GR\KOZKS/]OZNGROQK UVKXGZKY 8KVRGIKJKLKIZO\KLRU]
SUXK
ZNKHUUSL[TIZOUT \GR\KOZKS.)NKIQ XKM[RGZUX\GR\K
SGTOLURJGTJYZGXZZNK Z[XTZGHRKXUZGZKXOMNZ
KTMOTK3U\KZNK L[TIZOUT
L[TIZOUTOTUVKXGZO\K
Z[XTZGHRKXUZGZKXOMNZ
ZUMMRKY]OZINGZZNK
MXU[TJIUTZXURYOTZNK 8KVGOXZ[XTZGHRKXUZGZOUT
XOMNZJOXKIZOUTGTJINKIQ SUZUX58L[TIZOUT
ZNKVXKYY[XK SGTOLURJSG_NG\KGT
*KVGXZSKTZ
RKYYZNGT69/
)UTZOT[KJUTZNKTK^Z
VGMK
5 - 46 Genie S-40 Part No. 52271

CHART 19
6R[SHGZUVYO RKYYZNGT ,[TIZOUTSGTOLURJIU[RJ

)UTZOT[KJLXUSZNK
ZUHGXVXKYY[XK VYO NG\KGTOTZKXTGRJKLKIZ
VXK\OU[YVGMK
MG[MKOTZUZNKNUYK )UTY[RZ-KTOK/TJ[YZXOKY
LXUSZNKL[TIZOUT 9KX\OIK*KVGXZSKTZ
SGTOLURJZUZNKZ[XTZGHRK
XUZGZOUTHXGQK3U\KZNK
KOZNKXYOJKGTJGIZO\GZK
ZNKZ[XTZGHRKXUZGZKXOMNZ
L[TIZOUT
VYOUXSUXK
+ÎNGTMKZ[XTZGHRK
XUZGZKXOMNZGTJRKLZ L[TIZOUT
IU[TZKXHGRGTIK\GR\KY UVKXGZKY 8KVRGIKJKLKIZO\K
OZKSY00GTJ11 IU[TZKXHGRGTIK\GR\K
'IZO\GZKZ[XTZGHRKXUZGZK
RKLZL[TIZOUT
L[TIZOUTOTUVKXGZO\K
)NKIQLUXSKINGTOIGR
XKYZXOIZOUTYQKKVOTM
Z[XTZGHRKXUZGZKXOMNZ
L[TIZOUTLXUSUVKXGZOTM
58XKVRGIKYN[ZZRK\GR\K
OZKS//58IUTY[RZ
*KVGXZSKTZ
Part No. 52271 Genie S-40 5 - 47

Chart 20
All Platform 8KSU\KHUZNN_JXG[ROI 8KVRGIKZNK
Leveling NUYKYLXUSZNKSGTOLURJ
VUXZY62626R[M
_KY IU[TZKXHGRGTIK\GR\KY
UTL[TIZOUTSGTOLURJ
Functions ZNKNUYKYGTJIGVZNK
SGTOLURJLOZZOTMY3U\K
OZKSY,,--
Inoperative ZNKL[TIZOUTKTGHRK
Y]OZINZUKOZNKXYOJKGTJ
GIZO\GZKZNKHUUS[V
Be sure all other L[TIZOUTGTJINKIQZU
functions operate YKKOLVRGZLUXSRK\KRY
normally.
TU
6R[SHGZUVYO )NKIQLUXSKINGTOIGR
ZUHGXVXKYY[XK 69/ XKYZXOIZOUTY58XKVRGIK
MG[MKOTZUSGYZKX ZNKYRG\KI_ROTJKX
I_ROTJKXXUJKTJ IU[TZKXHGRGTIK\GR\KY
N_JXG[ROINUYKNUYK
IUTTKIZKJZUVUXZ62
[YOTMGZKKLOZZOTM
'IZO\GZKHUUS[V
L[TIZOUTGTJINKIQZNK
VXKYY[XK
RKYYZNGT69/
/TYZGRRGZUVYO RKYYZNGT
ZUHGXVXKYY[XK 69/ 8KVGOXUXXKVRGIKZNK
MG[MKOTZUZNKHGXXKR SGYZKXI_ROTJKX
KTJN_JXG[ROINUYKLXUS
ZNKSGYZKXI_ROTJKXGTJ
XGOYKZNKVXOSGX_HUUS
UTKOTINGZGZOSK
)UTZOT[GRR_SUTOZUXZNK
VXKYY[XKMG[MKJ[XOTM
HUUS[V*UTUZGRRU]
ZNKVXKYY[XKZUKÎKKJ
69/
69/UXSUXK
8KVGOXUXXKVRGIKZNK
YRG\KI_ROTJKX
5 - 48 Genie S-40 Part No. 52271

Chart 21
Platform Level =OZNZNKQK_Y]OZIN =OZNZNKQK_Y]OZIN 8KVGOXUVKTOTUXM]OXK
Up Function Z[XTKJZUMXU[TJIUTZXUR
GTJHUZN+SKXMKTI_
Z[XTKJZUMXU[TJIUTZXUR
GTJHUZN+SKXMKTI_
<UX
SUXK
LXUS:(ZUVRGZLUXS
RK\KR[VJOXKIZOUTGR\GR\K
Inoperative 9ZUVH[ZZUTYV[RRKJU[Z
54VUYOZOUTSU\K
ZUZNK
9ZUVH[ZZUTYV[RRKJU[Z
ZUZNKUTVUYOZOUTSU\K
IUOROZKS:58XKVGOX
UVKTOTHXU]TMXU[TJ
ZNKL[TIZOUTKTGHRK < ZNKL[TIZOUTKTGHRK ]OXKIOXI[OZZU\GR\KIUOR

Be sure all other Y]OZINZUKOZNKXYOJKGTJ Y]OZINZUKOZNKXYOJKGTJ
functions operate GIZO\GZKZNKVRGZLUXS GIZO\GZKZNKVRGZLUXS
RK\KRZUMMRKY]OZIN:9 RK\KRZUMMRKY]OZIN:9
normally. OTZNK[VJOXKIZOUTGTJ OTZNK[VJOXKIZOUTGTJ
INKIQZNK\URZGMKGZUXM INKIQZNK\URZGMKGZ
]OXKUTVRGZLUXSRK\KR[V :(
L[TIZOUTJOXKIZOUTGR\GR\K
OZKS:
<
=OZNZNKQK_Y]OZIN :XU[HRKYNUUZVRGZLUXS
Z[XTKJZUVRGZLUXS RK\KRZUMMRKY]OZINKY
IUTZXURGTJHUZN :9GTJ:9UT
+SKXMKTI_9ZUVH[ZZUTY MXU[TJGTJVRGZLUXS
V[RRKJU[ZZUZNKUT IUTZXURVGTKRY58XKVGOX
<
VUYOZOUTGIZO\GZKZNK UVKTOTXKJVU]KX]OXK
LUUZY]OZINGTJZNK IOXI[OZZU:9GTJ:9
VRGZLUXSRK\KRZUMMRK 58XKVGOXUVKTOTUXM
Y]OZIN:9OTZNK[V ]OXKIOXI[OZLXUS:9
JOXKIZOUTGTJINKIQZNK GTJ:9ZU:(58
\URZGMKGZ:( IUTY[RZ-KTOK/TJ[YZXOKY
9KX\OIK*KVGXZSKTZ
<UXSUXK
:XU[HRKYNUUZVRGZLUXS
RK\KRZUMMRKY]OZIN:9
UTMXU[TJIUTZXURVGTKR
58XKVGOXUVKTOTXKJ
<UXSUXK
VU]KX]OXKIOXI[OZZU
:958XKVGOXUVKTOT
UXM]OXKIOXI[OZLXUS
:9ZU:(58
9KX\OIK*KVGXZSKTZ
)UTZOT[KJUTZNKTK^Z
VGMK
Part No. 52271 Genie S-40 5 - 49

CHART 21
*OYIUTTKIZZNK]OXKY UX
)UTZOT[KJLXUSZNK
LXUSZNKVRGZLUXSRK\KR OTLOTOZK
VXK\OU[YVGMK 8KVRGIKZNKVRGZLUXS
[VJOXKIZOUTGR\GR\KIUOR UNSY
RK\KR[VJOXKIZOUTGR\GR\K
OZKS:GTJZKYZZNK
IUOROZKS:
IUOR
ZUUNSY
+ÎNGTMKVRGZLUXSRK\KR L[TIZOUT
[VGTJJU]TJOXKIZOUTGR UVKXGZKY 8KVRGIKZNKJKLKIZO\K
\GR\KYOZKSY:GTJ< JOXKIZOUTGR\GR\K
GTJGIZO\GZKZNKVRGZLUXS
RK\KR[VL[TIZOUT
L[TIZOUTOTUVKXGZO\K
[VGTJJU]T UVKXGZKY 8KVRGIKZNKJKLKIZO\K
IU[TZKXHGRGTIK\GR\KY IU[TZKXHGRGTIK\GR\K
OZKSY,,GTJ--GTJ
GIZO\GZKZNKVRGZLUXS
RK\KR[VL[TIZOUT
L[TIZOUTOTUVKXGZO\K
/TYZGRRGZU )NKIQLUXSKINGTOIGR
ZUHGXVXKYY[XK XKYZXOIZOUTYQKKVOTM
VYO
MG[MKGZZNKW[OIQ VRGZLUXSRK\KR[V
UXSUXK
JOYIUTTKIZIU[VROTMUT L[TIZOUTLXUSUVKXGZOTM
ZNKL[TIZOUTSGTOLURJ 58XKVRGIKYRG\K
GTJGIZO\GZKZNKVRGZLUXS I_ROTJKX58XKVRGIK
RK\KR[VL[TIZOUT YRG\KI_ROTJKX
IU[TZKXHGRGTIK\GR\KY
58IUTY[RZ-KTOK
/TJ[YZXOKY9KX\OIK
RKYYZNGTVYO *KVGXZSKTZ
L[TIZOUT
+ÎNGTMKVRGZLUXSRK\KR
UVKXGZKY
LRU]XKM[RGZUX\GR\K 8KVRGIKJKLKIZO\KLRU]
OZKS;]OZNGROQK\GR\K XKM[RGZUX\GR\K
OZKS++GTJGIZO\GZK
ZNKVRGZLUXSRK\KR[V
L[TIZOUT
L[TIZOUTOTUVKXGZO\K
:KYZSGYZKXI_ROTJKX
YKK)NGXZ58
XKVGOXUXXKVRGIKYRG\K
I_ROTJKXUXYRG\K
\GR\KY58L[TIZOUT
SGTOLURJSG_NG\KGT
*KVGXZSKTZ
5 - 50 Genie S-40 Part No. 52271

Chart 22
Platform Level =OZNZNKQK_Y]OZIN =OZNZNKQK_Y]OZIN 8KVGOXUVKTOTUXMHRQ
Down Function Z[XTKJZUMXU[TJIUTZXUR
GTJHUZN+SKXMKTI_
GTJHUZN+SKXMKTI_
<UX
]OXKLXUS:(ZU
VRGZLUXSRK\KRJU]T
SUXK
54VUYOZOUTSU\K
ZUZNK
ZUZNKUTVUYOZOUTSU\K
OZKS<58XKVGOXUVKT
ZNKL[TIZOUTKTGHRK < ZNKL[TIZOUTKTGHRK OTHXU]TMXU[TJ]OXK

Be sure all other Y]OZINZUKOZNKXYOJKGTJ Y]OZINZUKOZNKXYOJKGTJ IOXI[OZZU\GR\KIUOR
RK\KRZUMMRKY]OZIN:9 RK\KRZUMMRKY]OZIN:9
normally. OTZNKJU]TJOXKIZOUT OTZNKJU]TJOXKIZOUT
GTJINKIQZNK\URZGMKGZ GTJINKIQZNK\URZGMKGZ
UXMHRQ]OXKUTVRGZLUXS :(
RK\KRJU]TL[TIZOUT
JOXKIZOUTGR\GR\K
<
OZKS<
Z[XTKJZUVRGZLUXS RK\KRZUMMRKY]OZINKY
<
VRGZLUXSRK\KRZUMMRK 58XKVGOXUVKTOTUXM
Y]OZIN:9OTZNKJU]T HRQ]OXKIOXI[OZLXUS
JOXKIZOUTGTJINKIQZNK :9GTJ:9ZU:(
\URZGMKGZ:( 58IUTY[RZ-KTOK
/TJ[YZXOKY9KX\OIK
*KVGXZSKTZ
<UXSUXK
RK\KRZUMMRKY]OZIN:9
UTMXU[TJIUTZXURVGTKR
<UXSUXK 58XKVGOXUVKTOTXKJ
VU]KX]OXKIOXI[OZZU
:958XKVGOXUVKTOT
UXMHRQ]OXKIOXI[OZLXUS
:9ZU:(58
9KX\OIK*KVGXZSKTZ
)UTZOT[KJUTZNKTK^Z
VGMK
Part No. 52271 Genie S-40 5 - 51

CHART 22
)UTZOT[KJLXUSZNK
LXUSZNKVRGZLUXSRK\KR OTLOTOZK
JU]TJOXKIZOUTGR\GR\K UNSY
RK\KRJU]TJOXKIZOUTGR
IUOROZKS<GTJZKYZZNK
\GR\KIUOROZKS<
IUOR
ZUUNSY
JU]TGTJ[VJOXKIZOUTGR UVKXGZKY 8KVRGIKZNKJKLKIZO\K
\GR\KYOZKSY<GTJ: JOXKIZOUTGR\GR\K
GTJGIZO\GZKZNKVRGZLUXS
RK\KRJU]TL[TIZOUT
L[TIZOUTOTUVKXGZO\K
JU]TGTJ[V UVKXGZKY 8KVRGIKZNKJKLKIZO\K
OZKSY--GTJ,,GTJ
GIZO\GZKZNKVRGZLUXS
RK\KRJU]TL[TIZOUT
L[TIZOUTOTUVKXGZO\K
VYO
MG[MKGZZNKW[OIQ VRGZLUXSRK\KRJU]T
UXSUXK
ZNKL[TIZOUTSGTOLURJ 58XKVRGIKYRG\K
GTJGIZO\GZKZNKVRGZLUXS I_ROTJKX58XKVRGIK
RK\KRJU]TL[TIZOUT YRG\KI_ROTJKX
IU[TZKXHGRGTIK\GR\KY
58IUTY[RZ-KTOK
/TJ[YZXOKY9KX\OIK
L[TIZOUT
+ÎNGTMKVRGZLUXSRK\KR
UVKXGZKY
LRU]XKM[RGZUX\GR\K 8KVRGIKJKLKIZO\KLRU]
OZKS;]OZNGROQK\GR\K XKM[RGZUX\GR\K
OZKS++GTJGIZO\GZK
ZNKVRGZLUXSRK\KRJU]T
L[TIZOUT
L[TIZOUTOTUVKXGZO\K
:KYZSGYZKXI_ROTJKX
YKK)NGXZ58
XKVGOXUXXKVRGIKYRG\K
I_ROTJKXUXYRG\K
\GR\KY58L[TIZOUT
SGTOLURJSG_NG\KGT
*KVGXZSKTZ
5 - 52 Genie S-40 Part No. 52271

Chart 23
Platform Rotate =OZNZNKQK_Y]OZIN =OZNZNKQK_Y]OZIN 8KVGOXUVKTOTMXT]OXK
Left Function Z[XTKJZUMXU[TJIUTZXUR
GTJHUZN+SKXMKTI_
GTJHUZN+SKXMKTI_
<UX
LXUS:(ZUVRGZLUXS
XUZGZKRKLZJOXKIZOUTGR
SUXK
54VUYOZOUTSU\K
ZUZNK
ZUZNKUTVUYOZOUTSU\K
\GR\KIUOROZKS))58
XKVGOXUVKTOTHXU]T
ZNKL[TIZOUTKTGHRK < ZNKL[TIZOUTKTGHRK MXU[TJ]OXKIOXI[OZZU

Be sure all other Y]OZINZUKOZNKXYOJKGTJ Y]OZINZUKOZNKXYOJKGTJ \GR\KIUOR
XUZGZKZUMMRKY]OZIN XUZGZKZUMMRKY]OZIN
normally. :9OTZNKRKLZJOXKIZOUT :9OTZNKRKLZJOXKIZOUT
GTJINKIQZNK\URZGMKGZ GTJINKIQZNK\URZGMKGZ
MXT]OXKUTVRGZLUXS :(
XUZGZKRKLZL[TIZOUT
JOXKIZOUTGR\GR\K
<
OZKS))
Z[XTKJZUVRGZLUXS XUZGZKZUMMRKY]OZINKY
<
VRGZLUXSXUZGZKZUMMRK 58XKVGOXUVKTOTMXT
Y]OZIN:9OTZNKRKLZ ]OXKIOXI[OZLXUS:9
JOXKIZOUTGTJINKIQZNK GTJ:9ZU:(58
\URZGMKGZ:( IUTY[RZ-KTOK/TJ[YZXOKY
9KX\OIK*KVGXZSKTZ
<UXSUXK
XUZGZKZUMMRKY]OZIN
:9UTMXU[TJIUTZXUR
VGTKR58XKVGOXUVKTOT
<UXSUXK XKJVU]KX]OXKIOXI[OZZU
:958XKVGOXUVKTOT
MXT]OXKIOXI[OZLXUS
:9ZU:(58
9KX\OIK*KVGXZSKTZ
)UTZOT[KJUTZNKTK^Z
VGMK
Part No. 52271 Genie S-40 5 - 53

CHART 23
)UTZOT[KJLXUSZNK
LXUSZNKVRGZLUXSXUZGZK OTLOTOZK
RKLZJOXKIZOUTGR\GR\KIUOR UNSY
XUZGZKRKLZJOXKIZOUTGR
OZKS))GTJZKYZZNK
\GR\KIUOROZKS))
IUOR
ZUUNSY
+ÎNGTMKVRGZLUXS L[TIZOUT
XUZGZKRKLZGTJXOMNZ UVKXGZKY 8KVRGIKZNKJKLKIZO\K
JOXKIZOUTGR\GR\KYOZKSY JOXKIZOUTGR\GR\K
))GTJ**GTJ
GIZO\GZKZNKVRGZLUXS
XUZGZKRKLZL[TIZOUT
L[TIZOUTOTUVKXGZO\K
XUZGZKRKLZGTJXOMNZ UVKXGZKY 8KVRGIKZNKJKLKIZO\K
GZZNKIU[TZKXHGRGTIK
\GR\KSGTOLURJGTJ
GIZO\GZKZNKVRGZLUXS
XUZGZKRKLZL[TIZOUT
L[TIZOUTOTUVKXGZO\K
VYO
MG[MKGZZNKW[OIQ VRGZLUXSXUZGZKRKLZ
UXSUXK
ZNKL[TIZOUTSGTOLURJ 58XKVGOXUXXKVRGIK
GTJGIZO\GZKZNKVRGZLUXS VRGZLUXSXUZGZUX58
XUZGZKRKLZL[TIZOUT XKVRGIKVRGZLUXSXUZGZUX
IU[TZKXHGRGTIK\GR\K
SGTOLURJ58IUTY[RZ
XUZGZKXKM[RGZUX\GR\K UVKXGZKY 8KVRGIKJKLKIZO\KLRU]
OZKS++]OZNGROQK XKM[RGZUX\GR\K
\GR\KOZKS;GTJ
GIZO\GZKZNKVRGZLUXS
XUZGZKRKLZL[TIZOUT
L[TIZOUTOTUVKXGZO\K
9KX\OIK*KVGXZSKTZ
5 - 54 Genie S-40 Part No. 52271

Chart 24
Platform Rotate =OZNZNKQK_Y]OZIN =OZNZNKQK_Y]OZIN 8KVGOXUVKTOTMXTHRQ
Right Function Z[XTKJZUMXU[TJIUTZXUR
GTJHUZN+SKXMKTI_
GTJHUZN+SKXMKTI_
<UX
]OXKLXUS:(ZU
VRGZLUXSXUZGZKXOMNZ
SUXK
54VUYOZOUTSU\K
ZUZNK
ZUZNKUTVUYOZOUTSU\K
OZKS**58XKVGOX
ZNKL[TIZOUTKTGHRK < ZNKL[TIZOUTKTGHRK UVKTOTHXU]TMXU[TJ

Be sure all other Y]OZINZUKOZNKXYOJKGTJ Y]OZINZUKOZNKXYOJKGTJ ]OXKIOXI[OZZU\GR\KIUOR
XUZGZKZUMMRKY]OZIN XUZGZKZUMMRKY]OZIN
normally. :9OTZNKXOMNZ :9OTZNKXOMNZ
JOXKIZOUTGTJINKIQZNK JOXKIZOUTGTJINKIQZNK
\URZGMKGZMXTHRQ]OXK \URZGMKGZ:(
UTVRGZLUXSXUZGZKXOMNZ
L[TIZOUTJOXKIZOUTGR\GR\K
<
OZKS**
Z[XTKJZUVRGZLUXS XUZGZKZUMMRKY]OZINKY
<
VRGZLUXSXUZGZKZUMMRK 58XKVGOXUVKTOTMXT
Y]OZIN:9OTZNKXOMNZ HRQ]OXKIOXI[OZLXUS
JOXKIZOUTGTJINKIQZNK :9GTJ:9ZU:(
\URZGMKGZ:( 58IUTY[RZ-KTOK
/TJ[YZXOKY9KX\OIK
*KVGXZSKTZ
<UXSUXK
XUZGZKZUMMRKY]OZIN
:9UTMXU[TJIUTZXUR
VGTKR58XKVGOXUVKTOT
<UXSUXK XKJVU]KX]OXKIOXI[OZZU
:958XKVGOXUVKTOT
MXTHRQ]OXKIOXI[OZLXUS
:9ZU:(58
9KX\OIK*KVGXZSKTZ
)UTZOT[KJUTZNKTK^Z
VGMK
Part No. 52271 Genie S-40 5 - 55

CHART 24
)UTZOT[KJLXUSZNK
LXUSZNKVRGZLUXSXUZGZK OTLOTOZK
XOMNZJOXKIZOUTGR\GR\K UNSY
XUZGZKXOMNZJOXKIZOUTGR
IUOROZKS**GTJZKYZ
\GR\KIUOROZKS**
ZNKXKYOYZGTIKULZNK
\GR\KIUOR
ZUUNSY
XUZGZKXOMNZGTJRKLZ UVKXGZKY 8KVRGIKZNKJKLKIZO\K
JOXKIZOUTGR\GR\KYOZKSY JOXKIZOUTGR\GR\K
**GTJ))GTJ
GIZO\GZKZNKVRGZLUXS
XUZGZKXOMNZL[TIZOUT
L[TIZOUTOTUVKXGZO\K
XUZGZKXOMNZGTJRKLZ UVKXGZKY 8KVRGIKZNKJKLKIZO\K
GZZNKIU[TZKXHGRGTIK
\GR\KSGTOLURJGTJ
GIZO\GZKZNKVRGZLUXS
XUZGZKXOMNZL[TIZOUT
L[TIZOUTOTUVKXGZO\K
VYO
MG[MKGZZNKW[OIQ VRGZLUXSXUZGZKXOMNZ
UXSUXK
ZNKL[TIZOUTSGTOLURJ 58XKVGOXUXXKVRGIK
GTJGIZO\GZKZNKVRGZLUXS VRGZLUXSXUZGZUX58
XUZGZKXOMNZL[TIZOUT XKVRGIKVRGZLUXSXUZGZUX
IU[TZKXHGRGTIK\GR\K
SGTOLURJ58IUTY[RZ
XUZGZKXKM[RGZUX\GR\K UVKXGZKY 8KVRGIKJKLKIZO\KLRU]
OZKS++]OZNGROQK XKM[RGZUX\GR\K
\GR\KOZKS;GTJ
GIZO\GZKZNKVRGZLUXS
XUZGZKXOMNZL[TIZOUT
L[TIZOUTOTUVKXGZO\K
9KX\OIK*KVGXZSKTZ
5 - 56 Genie S-40 Part No. 52271

Chart 25
Oscillate 8KSU\KZNKINGYYOY HGJ 8KGJP[YZUXXKVRGIK
Function IU\KXGZZNKTUTYZKKX
KTJ)NKIQZNKROTQGMK
ROTQGMK
Inoperative LUXJGSGMKUXOSVXUVKX
ROTQGMKGJP[YZSKTZ9KK
8KVGOXYKIZOUT
Be sure all other .U]ZU9KZ;VZNK
function operate *OXKIZOUTGR<GR\K
2OTQGMK
normally.
MUUJ
/TYZGRRGZUVYO 'JP[YZZNKYKW[KTIK
ZUHGXVXKYY[XK \GR\K9KK8KVGOX
MG[MKGZZNKW[OIQ RKYYZNGT VXUIKJ[XK.U]ZU
JOYIUTTKIZIU[VROTMUT VYO 'JP[YZZNK5YIORRGZK
ZNKUYIORRGZKSGTOLURJ 9KW[KTIOTM<GR\K
*OYIUTTKIZZNKUYIORRGZK 6XKYY[XK58IUTY[RZ
ROTQGMKLXUSTUTYZKKX -KTOK/TJ[YZXOKY9KX\OIK
G^RK9ZGXZZNKKTMOTK *KVGXZSKTZ
GTJSGT[GRR_GIZO\GZK
ZNKJOXKIZOUTGR\GR\K
)NKIQZNKVXKYY[XK
VYO
9KX\OIK*KVGXZSKTZ
Part No. 52271 Genie S-40 5 - 57

Chart 26
Steer Left =OZNQK_Y]OZINOT =OZNQK_Y]OZINOT <UX 8KVGOXUVKTOTHR[
Function VRGZLUXSVUYOZOUTGTJ
HUZN+SKXMKTI_9ZUV
VRGZLUXSVUYOZOUTGTJ
HUZN+SKXMKTI_9ZUV
SUXK ]OXKIOXI[OZLXUSJXO\K
IUTZXURRKX*6ZU:6
54VUYOZOUTGIZO\GZK <
54VUYOZOUTGIZO\GZK
ZNKTZU:(
LUUZY]OZINGTJYZKKX LUUZY]OZINGTJYZKKX
Be sure all other XUIQKXY]OZINUTJXO\K XUIQKXY]OZINUTJXO\K
functions operate IUTZXURRKX*6OTRKLZ IUTZXURRKX*6OTRKLZ
JOXKIZOUTGTJINKIQ JOXKIZOUTGTJINKIQ
normally. \URZGMKUT:( \URZGMKGZZNKIUTZXURRKX
ZKXSOTGR]OZNZNKHR[
]OXKGZZGINKJ
<
8KVGOXUXXKVRGIKYZKKX
<UXSUXK
SOIXUY]OZINUTJXO\K
IUTZXURRKX)UTY[RZ
*KVGXZSKTZ
=OZNQK_Y]OZINOT 8KVGOXUVKTOTHR[
VRGZLUXSVUYOZOUTGTJ ]OXKIOXI[OZZNGZX[TY
HUZN+SKXMKTI_9ZUV LXUS:(ZUYZKKXRKLZ
H[ZZUTYV[RRKJU[ZZUZNK < JOXKIZOUTGR\GR\KIUORUT
54VUYOZOUTGIZO\GZK YZKKXSGTOLURJ58
LUUZY]OZINGTJYZKKX XKVGOXUVKTOTHXU]T
XUIQKXY]OZINUTJXO\K MXU[TJ]OXKIOXI[OZZU
IUTZXURRKX*6OTRKLZ YZKKXRKLZ\GR\KIUOR
JOXKIZOUTGTJINKIQ
\URZGMKUTHR[ ]OXK
UTYZKKXRKLZJOXKIZOUTGR
\GR\KIUOROZKS::UT
YZKKXSGTOLURJ
<UXSUXK
*OYIUTTKIZ]OXKYZU UX 8KVRGIKYZKKXRKLZ
YZKKXRKLZJOXKIZOUTGR OTLOTOZK JOXKIZOUTGR\GR\KIUOR
\GR\KIUOROZKS::UT UNSY OZKS::58XKVGOX
YZKKXSGTOLURJGTJZKYZ UVKTOTHXU]TMXU[TJ
ZNKXKYOYZGTIKULZNK ]OXKIOXI[OZZUYZKKXRKLZ
\GR\KIUOR \GR\KIUOR
ZUUNSY
)UTZOT[KJUTZNKTK^Z
VGMK
5 - 58 Genie S-40 Part No. 52271

CHART 26
)UTZOT[KJLXUSZNK
VXK\OU[YVGMK 69/UX
MG[MKGZZNKW[OIQ YZKKXRKLZL[TIZOUTLXUS
SUXK
JOYIUTTKIZIU[VROTMUT UVKXGZOTM58XKVGOXUX
ZNKHUUSL[TIZOUT XKVRGIKYZKKXI_ROTJKX
SGTOLURJGTJGIZO\GZK 58XKVRGIKLRU]
ZNKYZKKXRKLZL[TIZOUT XKM[RGZUX\GR\KOZKS
==58IUTY[RZ-KTOK
/TJ[YZXOKY9KX\OIK
RKYYZNGT69/
*KVGXZSKTZ
I_ROTJKX58YZKKX
SGTOLURJIU[RJNG\KGT
*KVGXZSKTZ
Part No. 52271 Genie S-40 5 - 59

Chart 27
Steer Right =OZNQK_Y]OZINOT =OZNQK_Y]OZINOT <UX 8KVGOXUVKTOTHR[HRQ
Function VRGZLUXSVUYOZOUTGTJ
HUZN+SKXMKTI_9ZUV
VRGZLUXSVUYOZOUTGTJ
HUZN+SKXMKTI_9ZUV
SUXK ]OXKIOXI[OZLXUS
JXO\KIUTZXURRKX*6ZU
54VUYOZOUTGIZO\GZK <
54VUYOZOUTGIZO\GZK
:6ZNKTZU:(
LUUZY]OZINGTJYZKKX LUUZY]OZINGTJYZKKX
Be sure all other XUIQKXY]OZINUTJXO\K XUIQKXY]OZINUTJXO\K
functions operate IUTZXURRKX*6OTXOMNZ IUTZXURRKX*6OTZNK
JOXKIZOUTGTJINKIQ XOMNZJOXKIZOUTGTJINKIQ
normally. \URZGMKUT:( \URZGMKGZZNKIUTZXURRKX
ZKXSOTGR]OZNZNKHR[HRQ
]OXKGZZGINKJ
<
<UXSUXK
SOIXUY]OZINUTJXO\K
IUTZXURRKX)UTY[RZ
*KVGXZSKTZ
=OZNQK_Y]OZINOT 8KVGOXUVKTOTHR[HRQ
VRGZLUXSVUYOZOUTGTJ ]OXKIOXI[OZZNGZX[TY
HUZN+SKXMKTI_9ZUV LXUS:(ZUYZKKXXOMNZ
H[ZZUTYV[RRKJU[ZZUZNK < JOXKIZOUTGR\GR\KIUORUT
54VUYOZOUTGIZO\GZK YZKKXSGTOLURJ58
LUUZY]OZINGTJYZKKX XKVGOXUVKTOTHXU]T
XUIQKXY]OZINUTJXO\K MXU[TJ]OXKIOXI[OZZU
IUTZXURRKX*6OTZNK YZKKXXOMNZ\GR\KIUOR
XOMNZJOXKIZOUTGTJINKIQ
\URZGMKUTHR[HRQ
]OXKUTYZKKXXOMNZ
OZKS::UTYZKKX
SGTOLURJ
<UXSUXK
*OYIUTTKIZ]OXKYZU UX 8KVRGIKYZKKXXOMNZ
YZKKXXOMNZJOXKIZOUTGR OTLOTOZK JOXKIZOUTGR\GR\KIUOR
\GR\KIUOROZKS::UT UNSY OZKS::58XKVGOX
YZKKXSGTOLURJGTJZKYZ UVKTOTHXU]TMXU[TJ
ZNKXKYOYZGTIKULZNK ]OXKIOXI[OZZUYZKKXXOMNZ
\GR\KIUOR \GR\KIUOR
ZUUNSY
)UTZOT[KJUTZNKTK^Z
VGMK
5 - 60 Genie S-40 Part No. 52271

CHART 27
)UTZOT[KJLXUSZNK
VXK\OU[YVGMK 69/UX
MG[MKGZZNKW[OIQ YZKKXXOMNZL[TIZOUTLXUS
SUXK
JOYIUTTKIZIU[VROTMUT UVKXGZOTM58XKVGOXUX
ZNKHUUSL[TIZOUT XKVRGIKYZKKXI_ROTJKX
SGTOLURJGTJGIZO\GZK 58XKVRGIKLRU]
ZNKYZKKXXOMNZL[TIZOUT XKM[RGZUX\GR\KOZKS
==58IUTY[RZ-KTOK
/TJ[YZXOKY9KX\OIK
RKYYZNGT69/
*KVGXZSKTZ
I_ROTJKX58YZKKX
SGTOLURJIU[RJNG\KGT
*KVGXZSKTZ
Part No. 52271 Genie S-40 5 - 61

Chart 28
All Drive =OZNZNKQK_Y]OZIN RKYY
Functions Z[XTKJZUVRGZLUXS
IUTZXURGTJHUZN
ZNGT
<
)NKIQIUTZOT[OZ_UL
HXU]TMXU[TJ]OXKLXUS IUTZOT[OZ_
8KVGOXUVKTOTVU]KX
Y[VVR_IOXI[OZLXUS:6
Inoperative, +SKXMKTI_9ZUVH[ZZUTY
V[RRKJU[ZZUZNK 54
ZKXSOTGR UT*6ZU
MXU[TJ
ZUZKXSOTGR UTJXO\K
PU_YZOIQ*6
All Other VUYOZOUTGIZO\GZKZNK
LUUZY]OZINGTJINKIQZNK
TUIUTZOT[OZ_
Functions \URZGMKGZZKXSOTGR UT
ZNKJXO\KPU_YZOIQ*6
Operate 8KVGOXUVKTOTHXU]T
MXU[TJ]OXKIOXI[OZLXUS
Normally MXU[TJZU*6
<UXSUXK
Be sure the rpm toggle

switch is in the
RKYY
footswitch activated =OZNZNKQK_Y]OZIN
ZNGT
)NKIQIUTZOT[OZ_UL 8KVGOXUVKTOTVU]KX
Z[XTKJZUVRGZLUXS HXU]TMXU[TJ]OXKLXUS Y[VVR_IOXI[OZLXUS:6

high idle position. < IUTZOT[OZ_
IUTZXURGTJHUZN ZKXSOTGR UTZNK ZUZKXSOTGR UTZNK
+SKXMKTI_9ZUVH[ZZUTY NUXYKVU]KXROSOZKX NUXYKVU]KXROSOZKX

Be sure the hydraulic V[RRKJU[ZZUZNK 54 IOXI[OZHUGXJZUMXU[TJ IOXI[OZHUGXJ
tank shut off valves are VUYOZOUTGIZO\GZKZNK
LUUZY]OZINGTJINKIQZNK
in the OPEN position. TUIUTZOT[OZ_
\URZGMKGZZKXSOTGR UT
ZNKNUXYKVU]KXROSOZKX
Be sure machine is IOXI[OZHUGXJ 8KVGOXUVKTOTHXU]T
not in the free wheel MXU[TJ]OXKIOXI[OZLXUS
configuration. MXU[TJZUZKXSOTGR UT
IOXI[OZHUGXJ
<UXSUXK
'IZO\GZKZNKLUUZY]OZIN 'IZO\GZKZNKLUUZY]OZIN ZU< 8KVRGIKNUXYKVU]KX
GTJNURJZNKJXO\K GTJINKIQZNK\URZGMKGZ ROSOZKXHUGXJ

<
PU_YZOIQOTZNKL[RR ZKXSOTGR UTZNK
LUX]GXJVUYOZOUTGTJ NUXYKVU]KXROSOZKX
INKIQZNK\URZGMKGZ HUGXJ
ZKXSOTGR UTZNK
NUXYKVU]KXROSOZKX
<
HUGXJ
'IZO\GZKZNKLUUZY]OZIN 8KVGOXUVKTOTUXMHRQ
GTJINKIQZNK\URZGMK ZU< ]OXKLXUSGRZKXTGZUX
UTZNKUXMHRQ ]OXK ZU:(ZU:6ZU
UTZNKGRZKXGZUX ZKXSOTGR UT
NUXYKVU]KXROSOZKX
HUGXJ
<
ZU<
8KVGOXUXXKVRGIK
GRZKXTGZUX
)UTZOT[KJUTZNKTK^Z
VGMK
5 - 62 Genie S-40 Part No. 52271

CHART 28
'IZO\GZKZNKLUUZY]OZIN 8KVGOXUVKTOT]OXKLXUS
)UTZOT[KJLXUSZNK
GTJNURJZNKJXO\K ZKXSOTGR UT
VXK\OU[YVGMK <
PU_YZOIQOTZNKL[RR NUXYKVU]KXROSOZKX
LUX]GXJVUYOZOUTGTJ HUGXJZUZKXSOTGR UT
INKIQZNK\URZGMKGZ ZNKJXO\KPU_YZOIQ
ZKXSOTGR UTZNKJXO\K
PU_YZOIQIUTZXURRKX
ZU<
TU
)UTTKIZZNKVUYOZ\K )NKIQIUTZOT[OZ_LXUS 8KVGOXUVKTOTHXU]T
< IUTZOT[OZ_
RKGJLXUSG\URZSKZKXZU ZKXSOTGR UTJXO\K MXU[TJ]OXKIOXI[OZLXUS
ZKXSOTGR UTZNK PU_YZOIQZUMXU[TJ ZKXSOTGR UTJXO\K
PU_YZOIQGTJZNKTKMGZO\K PU_YZOIQZUMXU[TJ
RKGJZUZKXSOTGR UT
IUTZOT[OZ_
ZNKPU_YZOIQ'IZO\GZKZNK
LUUZY]OZINGTJNURJZNK
JXO\KPU_YZOIQOTZNKL[RR 8KVRGIKJXO\KPU_YZOIQ
LUX]GXJVUYOZOUTGTJ IUTZXURRKX58IUTY[RZ
INKIQZNK\URZGMK -KTOK/TJ[YZXOKY9KX\OIK
GIXUYYZNK GTJ *KVGXZSKTZ
ZKXSOTGRYUTZNKJXO\K
PU_YZOIQIUTZXURRKX
<
TU
)UTTKIZZNKVUYOZ\K )NKIQIUTZOT[OZ_LXUS 8KVGOXUVKTOTHXU]T
< IUTZOT[OZ_
RKGJLXUSG\URZSKZKXZU ZKXSOTGR UTJXO\K MXU[TJ]OXKIOXI[OZLXUS
ZKXSOTGR UTZNK PU_YZOIQZUMXU[TJ ZKXSOTGR UTJXO\K
PU_YZOIQGTJZNKTKMGZO\K PU_YZOIQZUMXU[TJ
RKGJZUZKXSOTGR UT
IUTZOT[OZ_
ZNKPU_YZOIQ'IZO\GZKZNK
LUUZY]OZINGTJNURJZNK
JXO\KPU_YZOIQOTZNKL[RR 8KVRGIKJXO\KPU_YZOIQ
XK\KXYKVUYOZOUTGTJ IUTZXURRKX58IUTY[RZ
INKIQZNK\URZGMK -KTOK/TJ[YZXOKY9KX\OIK
GIXUYYZNK GTJ *KVGXZSKTZ
ZKXSOTGRYUTZNKJXO\K
PU_YZOIQIUTZXURRKX
<
)UTZOT[KJUTZNKTK^Z
VGMK
Part No. 52271 Genie S-40 5 - 63

CHART 28
'IZO\GZKZNKLUUZY]OZIN =OZNZNKLUUZY]OZIN 8KVGOXUVKTOT]NZ]OXK

)UTZOT[KJLXUSZNK
GTJNURJZNKJXO\K GIZO\GZKJGTJZNKJXO\K LXUSZKXSOTGR UT
VXK\OU[YVGMK
PU_YZOIQOTZNKL[RR PU_YZOIQOTZNKL[RR JXO\KPU_YZOIQZU:9ZU
LUX]GXJVUYOZOUTGTJ < LUX]GXJVUYOZOUTSU\K < :6ZU:(ZNXU[MN
INKIQZNK\URZGMK ZNKJXO\KKTGHRKZUMMRK JXO\KKTGHRKROSOZY]OZIN
GIXUYYZNK]NZ ]OXK Y]OZIN:9ZUKOZNKX 29ZU:(ZU]NZ
GTJZNK]NZHRQ ]OXK YOJKGTJINKIQZNK ]OXKUT+*)W[OIQ
UT+*) \URZGMKGIXUYYZNK]NZ JOYIUTTKIZVR[M
]OXKGTJZNK]NZHRQ
UT+*)
<
)UTTKIZZNKVUYOZ\K 8KVGOXUVKTOTHR[]NZ
<
RKGJLXUSG\URZSKZKXZU ]OXKLXUS:9ZU:6
ZKXSOTGR UTZNK ZU:(
PU_YZOIQGTJ]OZNZNK
LUUZY]OZINGIZO\GZKJGTJ
ZNKJXO\KPU_YZOIQOTZNK
L[RRLUX]GXJVUYOZOUT
SU\KZNKJXO\KKTGHRK
ZUMMRKY]OZIN:9ZU
TKMGZO\KRKGJLXUSZNK
\URZSKZKXUTZUZNK
HR[]NZ]OXKUT:9GTJ
INKIQZNK\URZGMK
<
<
)UTTKIZZNKVUYOZ\K 8KVGOXUVKTOT]OXKLXUS
RKGJLXUSG\URZSKZKXZU ZKXSOTGR LXUSJXO\K
ZKXSOTGR UTZNK PU_YZOIQ*6ZUJXO\K
PU_YZOIQGTJ]OZNZNK < KTGHRKZUMMRKY]OZIN
LUUZY]OZINGIZO\GZKJGTJ :958XKVRGIKJXO\K
ZNKJXO\KPU_YZOIQOTZNK PU_YZOIQIUTZXURRKX58
L[RRLUX]GXJVUYOZOUT IUTY[RZ-KTOK/TJ[YZXOKY
NURJZNKTKMGZO\KRKGJUL 9KX\OIK*KVGXZSKTZ
ZNK\URZSKZKXUTZUZNK
IKTZKXZKXSOTGRULZNK
JXO\KKTGHRKZUMMRK
Y]OZIN:9GTJINKIQ
ZNK\URZGMK
<
8KVRGIKJXO\KKTGHRK
ZUMMRKY]OZIN:9
:XU[HRKYNUUZJXO\K
LUX]GXJGTJJXO\K
XK\KXYKL[TIZOUTY
YKVGXGZKR_58XKVRGIK
V[SV58IUTY[RZ-KTOK
/TJ[YZXOKY9KX\OIK
*KVGXZSKTZ
5 - 64 Genie S-40 Part No. 52271

Chart 29
Drive Forward *OYIUTTKIZZNK+*) \URZGMKXKGJOTMYJOLLKXKTZ 8KVGOXUXXKVRGIKZNK
Or Reverse ]OXKIUTTKIZUXLXUSZNK
JXO\KV[SVYZGXZ
JXO\KIUTZXURRKX*6
Function KTMOTKSU\KZNKJXO\K
IUTZXURRKXZUL[RRLUX]GXJ
Inoperative VUYOZOUTGTJTUZKZNK
\URZGMKGIXUYYZNK]NZ
GTJZNK]NZHRQ
Be sure all other ]OXKZKXSOTGRYUTZNK
functions operate +*)8K\KXYKZNK\URZ
normally including SKZKXRKGJYGTJSU\K
ZNKJXO\KIUTZXURRKXZUL[RR
drive in opposite XK\KXYKVUYOZOUTGTJ
direction of TUZKZNK\URZGMK
malfunction.
\URZGMKXKGJOTMY
ZNKYGSK
UX
OTLOTOZK
UNSY
)NKIQZNKXKYOYZGTIKUL 8KVRGIKZNK+*)
ZNK+*)
ZUUNSY
'JP[YZZNKJXO\KV[SV *KLKIZO\K9[TJYZXGTJ
T[RRTK[ZXGR)UTY[RZ TUOSVXU\KSKTZ JXO\KV[SVIUTZGIZ
-KTOK/TJ[YZXOKY9KX\OIK 9[TJYZXGTJG[ZNUXO`KJ
*KVGXZSKTZ XKVGOXLGIOROZ_
Y_SVZUSYOSVXU\K
8KGJP[YZJXO\KPU_YZOIQ
IUTZXURRKX58OLVXUHRKS
YZORRVKXYOYZYIUTY[RZ
*KVGXZSKTZ
Part No. 52271 Genie S-40 5 - 65

Chart 30
Traction 'T_Z_VKULZXGIZOUT
VXUHRKSIUTY[RZ-KTOK
Function /TJ[YZXOKY9KX\OIK
Inoperative *KVGXZSKTZ
Be sure all other

functions operate
normally.
5 - 66 Genie S-40 Part No. 52271

Chart 31
Machine Will =OZNZNKHUUSOTZNK 8KVGOXYNUXZZUMXU[TJ
IUTZOT[OZ_
Not Drive At YZU]KJVUYOZOUTINKIQ
IUTZOT[OZ_LXUS:(ZU
OT]NZ]OXKYZUROSOZ
Y]OZINKY29GTJ29
Full Speed MXU[TJ 58XKVGOXUXXKVRGIK
HUUSROLZJXO\KROSOZ
Y]OZINUXHUUSK^ZKTJ
Be sure all other ROSOZY]OZIN
functions operate TUIUTZOT[OZ_
normally.
Be sure the machine is =OZNZNKHUUSOTZNK 8KVGOXYNUXZZUMXU[TJ
not raised above or YZU]KJVUYOZOUTINKIQ OTUXGTMK]OXKLXUS
ZKXSOTGR UT IUTZOT[OZ_ :(ZU:6ZU

extended beyond the NUXYKVU]KXROSOZKX ZKXSOTGR UT
drive limit switches. HUGXJLUXIUTZOT[OZ_ZU NUXYKVU]KXROSOZKX
MXU[TJ IOXI[OZHUGXJ
Be sure the boom drive

limit switch is clear of TUIUTZOT[OZ_
any debris and is not

activated when the 8KGJP[YZUXXKVRGIK
NUXYKVU]KXROSOZKX
boom is in the stowed HUGXJ58INKIQLUX
position. SOYGROMTSKTZULROSOZ
Y]OZINKY29GTJ29
Be sure that the boom 58IUTY[RZ-KTOK
/TJ[YZXOKY9KX\OIK
extend drive limit switch *KVGXZSKTZ
arm is being activated

when the boom is fully
retracted.
Be sure the wiring to
limit switches is intact
and show no sign of
damage or corrosion.
Be sure the free-wheel

valve is closed on the
drive pump.
Part No. 52271 Genie S-40 5 - 67

Chart 32
Machine Drives +^ZKTJZNKHUUSVGYZ 8KVRGIKNUXYKVU]KX
At Full Speed ZNKJXO\KROSOZY]OZINGTJ
INKIQIUTZOT[OZ_LXUS IUTZOT[OZ_
ROSOZKXHUGXJ58XK
GJP[YZNUXYKVU]KX
With Platform MXU[TJZUZKXSOTGR UT
ROSOZKXHUGXJ58IUTY[RZ
Raised or HUGXJ *KVGXZSKTZ
Extended TUIUTZOT[OZ_
Be sure boom drive limit )NKIQIUTZOT[OZ_LXUS IUTZOT[OZ_ 8KVGOXUVKTOTUXM]OXK
switch is being activated MXU[TJZU:( IOXI[OZLXUS:(ZU
:6ZUZKXSOTGR UT
by the cam on the boom
NUXYKVU]KXROSOZKX
when the boom is IOXI[OZHUGXJ
raised. TUIUTZOT[OZ_
Be sure that the boom

extend drive limit switch :KYZROSOZY]OZINKY9KK 8KVRGIKJKLKIZO\KROSOZ
HGJ
is not being held down VXUIKJ[XK'OTZNK Y]OZINIUTZGIZ58
3GOTZKTGTIK9KIZOUT XKVRGIKROSOZY]OZIN
or being activated when
the boom is extended.
MUUJ
Be sure the wiring to

8KVGOXUVKTLXUS]NZ
limit switches is intact ]OXKYGZ:(ZUJXO\K
and show no sign of ROSOZY]OZINKY29GTJ
damage or corrosion. 29ZNKTLXUSHXU]T
MXU[TJ]OXKYZUMXU[TJ
5 - 68 Genie S-40 Part No. 52271

Chart 33
Drive Enable =OZNQK_Y]OZINOT =OZNQK_Y]OZINOT
<
8KVGOXUVKTOTVU]KX
System Is VRGZLUXSVUYOZOUTGTJ
HUZN+SKXMKTI_9ZUV
VRGZLUXSVUYOZOUTGTJ
HUZN+SKXMKTI_9ZUV
Y[VVR_IOXI[OZLXUS
:6
Malfunctioning H[ZZUTYV[RRKJU[ZZUZNK
54VUYOZOUTGTJZNK
TU H[ZZUTYV[RRKJU[ZZUZNK
54VUYOZOUTGIZO\GZK
HUUSXUZGZKJHKZ]KKT LUUZY]OZINGTJJXO\K
Be sure the boom is in ZNKTUTYZKKXZOXKY IUTZXURRKXOTLUX]GXJ
the stowed position. GIZO\GZKLUUZY]OZINGTJ JOXKIZOUTGTJINKIQ
JXO\KIUTZXURRKXOT \URZGMKGZZKXSOTGR UT
LUX]GXJJOXKIZOUT=ORR JXO\KIUTZXURRKX*6
[TOZJXO\K%
<UXSUXK
8KVGOXUVKTLXUS
ZKXSOTGR UT*6ZU
IKTZKXZKXSOTGRUT:9
_KY 58XKLKXZU)NGXZ58
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HUZN+SKXMKTI_9ZUV TU YOJKGTJGIZO\GZKZNK _KY SGINOTKJUKYTUZ
H[ZZUTYV[RRKJU[ZZUZNK LUUZY]OZINGTJJXO\K UVKXGZKVXUVKXR_
54VUYOZOUTGTJZNK LUX]GXJL[TIZOUT=ORR IUTY[RZ-KTOK/TJ[YZXOKY
HUUSXUZGZKJHKZ]KKT [TOZJXO\K% 9KX\OIK*KVGXZSKTZ
ZNKYZKKXKTJZOXKY
GIZO\GZKLUUZY]OZINGTJ
TU
JXO\KIUTZXURRKXOT
LUX]GXJJOXKIZOUT=ORR
[TOZJXO\K% 8KVGOXUVKTOTHR[]NZ
]OXKLXUSJXO\KKTGHRK
ZUMMRKY]OZIN:9ZU
:6ZU:(58
XKVRGIKJXO\KKTGHRK
_KY ZUMMRKY]OZIN:9
)NKIQLUXIUTZOT[OZ_ IUTZOT[OZ_ 'IZO\GZKROSOZY]OZINH_ 8KVRGIKJXO\KKTGHRK
LXUS:(ZU:( NGTJGTJINKIQ IUTZOT[OZ_ ROSOZY]OZINIUTZGIZ58
IUTZOT[OZ_LXUS:(ZU XKVRGIKJXO\KKTGHRK
:( ROSOZY]OZIN29
TUIUTZOT[OZ_
TUIUTZOT[OZ_
8KVGOXUVKTLXUS:(
6RKGYKHKMOT
ZNXU[MNXKJ]OXKZU29
ZXU[HRKYNUUZOTMLXUS
ZNKTLXUS29ZNXU[MN HKMOTTOTMULINGXZ58
HRQ]OXKZU:( IUTY[RZ-KTOK/TJ[YZXOKY
9KX\OIK*KVGXZSKTZ
Part No. 52271 Genie S-40 5 - 69

Chart 34
Auxiliary 2OLZZNKXKJG[ÔROGX_ SUZUX /TYZGRRGZUVYO 8KIUTTKIZVXKYY[XK
Functions V[SVY]OZINIU\KXNURJ
G[ÔROGX_Y]OZINGTJ
UVKXGZKY ZUHGXVXKYY[XK
MG[MKOTZUZNKVXKYY[XK
VYO ROTKGTJINKIQHGZZKX_
IUTJOZOUT:NKXKOY
Inoperative ROYZKTLUXYU[TJUL
G[ÔROGX_V[SVSUZUX
VUXZULZNKG[ÔROGX_
V[SVGTJNURJZNK
VUYYOHR_TUZKTU[MN
HGZZKX_IGVGIOZ_ZU
UVKXGZOTM G[ÔROGX_VU]KXZUMMRK UVKXGZKHUZNG[^V[SV

Be sure all other Y]OZINGTJTUZKZNK GTJL[TIZOUT\GR\KY
functions operate VXKYY[XK
normally. RKYYZNGT
VYO
Be sure key switch
is in the appropriate )NKIQLUXGVUYOZO\K 8KVGOXUXXKVRGIKV[SV
IUTTKIZOUTHKZ]KKT MUUJ 58XKVRGIKXKROKL\GR\K

position and both KRKIZXOISUZUXGTJZNK )UTY[RZ-KTOK/TJ[YZXOKY
Emergency Stop V[SVH_XKSU\OTMZNK 9KX\OIK*KVGXZSKTZ
buttons are pulled V[SVLXUSZNKSUZUX
H[ZRKG\KGRRZNKNUYKY
out to the ON SUZUXJUKY
IUTTKIZKJ<OY[GRR_
position. TUZUVKXGZK
INKIQIU[VROTM
IUTTKIZOUT
Be sure engine is
not running when HGJ
using auxiliary
power. 8KVRGIKZNKG[ÔROGX_
VU]KX[TOZ
Note: Operating
auxiliary power with
the engine running HGJ
=OZNZNKQK_Y]OZIN < :KYZ689KK8KVGOX 8KVRGIK68
should immediately Z[XTKJZUMXU[TJIUTZXUR 6XUIKJ[XK
kill the engine. GTJHUZN+SKXMKTI_
MUUJ
54VUYOZOUT
ZUZNK
GIZO\GZKZNKG[ÔROGX_
V[SVZUMMRKY]OZINGTJ 'IZO\GZKZNKG[ÔROGX_ <UX 8KVGOXUVKTLXUS:(
INKIQZNK\URZGMKUTZNK V[SVZUMMRKY]OZINGTJ SUXK ZU6858XKVGOXUVKT
XKJIGHRKUTZNK INKIQZNK\URZGMKGZ OTHXU]TMXU[TJ]OXK
G[ÔROGX_VU]KX[TOZ :( IOXI[OZZU6858
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<
'IZO\GZKZNKG[ÔROGX_ 8KVGOXUVKTOTXKJ
V[SVZUMMRKY]OZINGTJ < VU]KXY[VVR_]OXKLXUS
INKIQZNK\URZGMKGZZNK QK_Y]OZIN19ZU
IKTZKXZKXSOTGRUL:9 G[ÔROGX_ZUMMRKY]OZIN
< :9
<UXSUXK
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]OXKLXUS:9ZU:(
58XKVRGIK:9
)UTZOT[KJUTZNKTK^Z
VGMK
5 - 70 Genie S-40 Part No. 52271

CHART 34
)NKIQIUTZOT[OZ_LXUS 8KVRGIKTKMGZO\KIGHRK
)UTZOT[KJLXUSZNK HGJ
TKMGZO\KZKXSOTGRUT LXUSG[ÔROGX_V[SVZU
VXK\OU[YVGMK
G[ÔROGX_VU]KX[TOZZU MXU[TJ
MXU[TJ
MUUJ
8KVRGIKG[ÔROGX_V[SV
SUZUX
Part No. 52271 Genie S-40 5 - 71

5 - 72 Genie S-40 Part No. 52271

Service Manual - Second 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 may
Troubleshooting and repair procedures shall be result in death or serious injury.
completed by a person trained and qualified on Remove all rings, watches and
the repair of this machine. 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 gradually. Do not allow oil to squirt
and operating instructions printed in the or spray.
appropriate 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 - Second Edition
Electrical Components
Item Description Genie Part Manufacturer Manufacturer Qty

Part Number Part Number
BAT ................ Battery, 1000 CCA, 12V DC .. 30143 ........... Trojan ................................... C31XH-2 ........................ 1
BP1 ................ Joystick controller, Dual axis . 24493 ........... OEM Controls ...................... EJS5M6881 ................... 1
CB1, CB2 ....... Circuit breaker ....................... 24018 ........... ETA ...................................... 45-700-IG1-P10 ............. 2
CR1through
CR7, 17, 18,
19 ................... Relay, SPDT, 12V DC ........... 34052 ........... Potter-Brumfield .................. VF4-15F11-CO5 .......... 10
Diode .............. Diode, 6 amp, 200 PIV .......... 45782 ........... Motorola ............................... MOTMR752 ................. 36
DP1 ................ Joystick controller-Drive ........ 20424 ........... OEM Controls ...................... MCH1159AD1386 .......... 1
FB .................. Flashing beacon .................... 20189 ........... ECCO Electronic Controls ... 6400X ............................. 2
FS1 ................ Footswitch .............................. 13482 ........... Linemaster Switch Corp. ..... 632-S ............................. 1
G1 .................. Gauge - Voltage .................... 30789 ........... VDO ..................................... 332-502 .......................... 1
G2 .................. Gauge - Oil Pressure ............. 30786 ........... VDO ..................................... 350-516 .......................... 1
G3 .................. Gauge - Water Temp. ........... 30787 ........... VDO ..................................... 310-502 .......................... 1
H1 .................. Alarm, Warble tone ................ 19270 ........... Floyd Bell Inc. ...................... MW-09-616-Q ................ 1
H2 .................. Horn, 12V DC, 130 dB ........... 19145 ........... Sparton Engineered Prod. ... 7431A-24823-5 .............. 1
H3 .................. Alarm, intermittent ................. 18963 ........... Floyd Bell Inc. ...................... XB-09-630-Q .................. 1
H4 .................. Alarm, chime tone ................. 45462 ........... Floyd Bell Inc. ...................... CH-09-525-Q ................. 1
HM ................. Hourmeter .............................. 19506 ........... ENM Corporation ................. T40A4508 ...................... 1
KS1 ................ Contact - Keyswitch, N.O. ..... 45081 ........... Telemecanique .................... ZB2-BE101 .................... 2
L1 ................... LED - Red, 12V DC ............... 32335 ........... Arctolectric Corp. ................. LE177C39007 ................ 1
LS1, 2, 3 ........ Contact - Limit switch,

N.C.H.O. ................................ 19491 ........... Telemecanique .................... XESP2051 ..................... 3
Level sensor .. Level sensor, 4.5° .................. 44586 ........... Power Comp. of Midwest .... LS36 ............................... 1
P1, P2 ............ Contact, N.C. ......................... 29732 ........... Telemecanique .................... ZB2-BE102 .................... 4
P3 ................... Contact, N.O. ......................... 45081 ........... Telemecanique .................... ZB2-BE101 .................... 1
PR1 ................ Relay, 12V DC continuous .... 27155 ........... Stancor ................................ 70-902 ............................ 1
This list continues on the next page.

ELECTRICAL COMPONENTS
Item Description Genie Part Manufacturer Manufacturer Qty

Part Number Part Number
R1 .................. Resistor, 100W 25 watt .......... 27116 ........... Dale ..................................... RH25-100R-1% ............. 1
R2 .................. Resistor, 10W 25 watt ............ 27287 ........... Dale ..................................... RH25-10R-1% ............... 1
TS1, TS9 ........ Toggle switch, DPST

2 position momentary ............ 13480 ........... Microswitch Control Inc. ...... 2NT1-8 ........................... 2
TS2, 5, 8, 10,
12, 13 ............. Toggle switch, SPDT
TS20 .............. Toggle switch, DPST

2 position maintained ............ 27378 ........... Microswitch Control Inc. ...... 2NT1-3 ........................... 1
TS4 ................ Toggle switch, DPDT

TS6,7,14,15,
16,17 .............. Toggle switch, DPDT
TS3, TS11
(Gas/LPG) ...... Toggle switch, DPST
TS3, TS11
(Diesel) ........... Toggle switch, SPDT
VAC ................ Vacuum switch ...................... 22278 ........... Peterson Industrial .............. 1501-L ............................ 1

Electrical Symbols Legend
TB17
15AMP. DP1
WTS1 N.O.
BLK
1
2
Circuit breaker 3
GRN/BLK
ORG/BLK-1
4
5
Water temperature 6
7
switch 8
normally open
Wire color
with cable Single axis
number FS1
RED drive controller
BLK
Solenoid or Ground
WHT #51
relay coil supression Foot switch
TB20 circuit TR2 2
1 T
6
PLAT
3
KS1
RED-5
WHT-5
TILT
Terminal ALARM
TB=Terminal base GRND Time delay relay

TP=Terminal platform
Horn Key switch
NC NO
TS3
TP29 LS3
START
ENGINE
BLK-5
GRN-5
Quick disconnect L4 OP HORN P4 Toggle switch SPDT

terminal
Limit switch
Light
BLK #21 TB21
Horn button
normally open TS6
LS2
T-circuits connect NC
LEFT
RIGHT
at terminal
10
P1
Limit switch
normally closed Toggle switch DPDT
Resistor held open Emergency Stop
button BP2
T-circuits normally closed PWM

A
connect +
-
VAC X
R
Vacuum switch Single axis

CR4
Tilt sensor proportional

Connection
no terminal controller
Relay contact
OPS1 N.C.
normally open
1 START RELAY
2 TACHOMETER
3 START INPUT
Spark plug 4 AUX. ON
5 GROUND
PR4 BATTERY
6
Circuits crossing Oil pressure 7 KEY PWR.
no connection switch 8
9
KEY BYPASS
IGN./FUEL ON
normally closed 10 ENG. FAULT
Relay panel
contactor Ignition start
module
Glow plug BP1
Diode AUX.
1
PUMP D2 D1
2 A R
3
4 - +
5 + -
LS1 6 R A
NO 7 D1 D2
+
Auxiliary pump 8
9
10
Limit switch
normally open Horsepower Dual axis
-
held closed limiter board Ramp up and down
proportional controller
Battery

Abbreviation Legend
LABEL DESCRIPTION
BAT ............. Battery
BP ............... Proportional controller
CB ............... Circuit breaker
CR ............... Control relay
DP ............... Drive proportional controller
FB ................ Flashing beacon
FS ................ Foot switch
G ................. Gauge
H .................. Horn or Alarm
HM ............... Hour meter
KS ............... Keyswitch
L .................. LED
LS ................ Limit switch
P .................. Power switch
PR ............... Power relay
R .................. Resistor
TB ................ Terminal base location
TP ................ Terminal platform location
TS ................ Toggle switch
VAC ............. Vacuum switch


Section 6 - Schematics Service Manual
Electrical Schematic-
Gasoline/LPG Models
A B C D E F G H I J K L M N

Service Manual Section 6 - Schematics
Gasoline/LPG Models
N M L K J I H G F E D C B A

Ground Control Box Legend-

Gasoline/LPG Models

Ground Control Box Wiring Diagram-

Gasoline/LPG Models
6 - 10 Genie S-40 Part No. 52271

Platform Control Box Legend-

Gasoline/LPG Models
Part No. 52271 Genie S-40 6 - 11

Platform Control Box Wiring Diagram-

Gasoline/LPG Models
6 - 12 Genie S-40 Part No. 52271

Section 6 - Schematics Service Manual
Diesel Models
A B C D E F G H I J K L M N
6 - 13 Genie S-40 Part No. 52271

Diesel Models
Part No. 52271 Genie S-40 6 - 14

Ground Control Box Legend-

Diesel Models
Part No. 52271 Genie S-40 6 - 15

Ground Control Box Wiring Diagram-

Diesel Models
6 - 16 Genie S-40 Part No. 52271

Platform Control Box Legend-

Diesel Models
Part No. 52271 Genie S-40 6 - 17

Platform Control Box Wiring Diagram-

Diesel Models
6 - 18 Genie S-40 Part No. 52271

Part No. 52271 Genie S-40 6 - 19

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
6 - 20 Genie S-40 Part No. 52271

2WD Hydraulic Schematic

Non-Oscillating Axle
Part No. 52271 Genie S-40 6 - 21


Oscillating Axle
Part No. 52271 Genie S-40 6 - 22


Oscillating Axle
Part No. 52271 Genie S-40 6 - 23

Service Manual - Second 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 this reverse order.
machine.
General Repair Process
Immediately tag and remove from service a
Repair any machine damage or malfunction Malfunction Identify Troubleshoot
discovered symptoms
before operating the machine.
Before Repairs Start: problem

still exists
Read, understand and obey the safety rules
and operating instructions in the appropriate
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.
Symbols Legend
Read each procedure completely and adhere
to the instructions. Attempting shortcuts may Indicates the presence of a hazard
produce hazardous conditions. that will cause death
or serious injury.
Unless otherwise specified, perform each
repair procedure with the machine in the Indicates the presence of a hazard
following configuration: that may cause death
or serious injury.
· Machine parked on a flat, level surface
· Boom in stowed position Indicates the presence of a hazard
that will or may cause serious
· Turntable rotated with the boom between personal injury or
the non-steering wheels damage to the machine.
· Turntable secured with the turntable
Indicates special operation or
rotation lock pin
maintenance information.
· Key switch in the OFF position with the
key removed Indicates that a specific result is expected
after performing a series of steps.
· Wheels chocked

Section 7 - Repair Procedures Service Manual - Second 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 terminal "D2" directional output

b terminal "A" proportional output
f e d c
c terminal "-" ground
d terminal "+" positive
Platform control box e terminal "R" activates max-out range
a horsepower limiter board f terminal "D1" directional output
b terminals g ramp rate adjustable trimpot
c drive proportional controller h lo range adjustable trimpot
d extend/retract proportional controller i threshold adjustable trimpot
e boom proportional controller j hi range adjustable trimpot
f turntable rotate proportional controller
4 Set the preliminary ramp rate: Turn the trimpot
adjustment screw counterclockwise 15 turns or
until you hear a repeated click.
Boom Up/Down Controller
5 Connect the red(+) lead from a volt meter to
Adjustments the “A” terminal on the controller printed circuit
Do not adjust the joystick board. Connect the black(-) lead to ground.
controllers unless the static battery
6 Set the threshold: Press down the foot switch,
voltage is above
then slowly move the control handle off center
12V DC and the alternator
until the moment a voltage reading appears.
is operating properly with
Adjust the voltage to 3.5V DC. Turn the
13.6 to 14.5V DC output.
threshold trimpot adjustment screw clockwise to
Electrocution hazard. Contact increase the voltage or counterclockwise to
with electrically charged circuits decrease the voltage.
injury. Remove all rings, watches
and other jewelry.

PLATFORM CONTROLS
7 Set the hi range: 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 8.5V 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 rate.
counterclockwise to decrease the voltage.
17 Set the ramp rate: turn the trimpot to obtain
8 Set the lo range: Press down the foot switch, a 3 to 4 second ramp speed. Turn the
then move the control handle all the way to the trimpot clockwise to increase the time or
DOWN position. Adjust the voltage counterclockwise to decrease the time.
to 6.2V DC. Turn the dual range trimpot
adjustment screw clockwise to increase the Boom up/down specifications
voltage or counterclockwise to decrease
the voltage. Threshold 3.5V DC
9 Start the engine and move the engine idle
Boom up - hi range 8.5V DC
control switch to foot switch activated high Cycle time 55 to 85 seconds
idle (rabbit and foot switch symbol). Lower
the boom to the stowed position. Boom down - lo range 6.2V DC
Engine should be at normal Cycle time 90 to 120 seconds
operating temperature.
Ramp rate 3 to 4 seconds
10 Start a timer and record how long it takes for
the boom to fully raise. Adjust the
max-out trimpot to achieve a 55 to 85 second
cycle time.
Turntable Rotation Controller
Adjustments
11 Start a timer and record how long it takes for
the boom to fully lower. Adjust the dual range Do not adjust the joystick
trimpot to achieve an 90 to 120 second cycle controllers unless the static battery
time. voltage is above
12V DC and the alternator is
If the function cycle time is not
operating properly with
achievable, check the relief valve
13.6 to 14.5V DC output.
pressure. See 10-2, Valve
Adjustments - Function Manifold. Electrocution hazard. Contact
with electrically charged circuits
12 Turn the engine off and re-connect the
volt meter.
injury. Remove all rings, watches
13 Pull out the Emergency Stop button to and other jewelry.
the ON position.
1 Check the battery condition with a volt meter.
14 Press down the foot switch and then move the The reading should be 12V DC or more to
control handle all the way to the UP position. accurately adjust the controller.
Record the maximum voltage reading.
2 Turn the key switch to platform control and
15 Start the engine. pull out the Emergency Stop button to
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 7 Set the hi range: Press down the foot switch,
the turntable rotation controller. Refer to the fully retract the boom, then move the control
platform control box illustration, page 7-2. handle all the way to the left or right. Adjust the
voltage to 5.5V DC. Turn the max-out trimpot
adjustment screw clockwise to increase the
a b c d e f g h i j voltage or counterclockwise to decrease the
voltage.
8 Set the lo range: Press down the foot switch,
extend the boom 3 feet, then move the control
handle all the way to the left or right. Adjust the
voltage to 4.5V DC. Turn the lo range trimpot
adjustment screw clockwise to increase the
voltage or 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).
a terminal "D2" directional output Engine should be at normal

b terminal "A" proportional output operating temperature.
c terminal "-" ground
d terminal "+" positive 10 Fully retract the boom, then start a timer and
e terminal "R" activates max-out range record how long it takes the turntable to rotate
f terminal "D1" directional output
through a complete circle. Adjust the max-out
g ramp rate adjustable trimpot
h lo range adjustable trimpot trimpot to achieve a 80 to 100 second cycle
i threshold adjustable trimpot time.
j hi range adjustable trimpot
11 Extend the boom, then start a timer and record
4 Set the preliminary ramp rate: Turn the trimpot how long it takes the turntable to rotate through
adjustment screw counterclockwise 15 turns or a complete circle. Adjust the lo range trimpot to
until you hear a repeated click. achieve a 130 to 160 second cycle time.
5 Connect the red(+) lead from a volt meter to the 12 Turn the engine off and re-connect the
“A” terminal on the controller printed circuit volt meter.
board. Connect the black(-) lead to ground.
13 Pull out the Emergency Stop button to
6 Set the threshold: Press down the foot switch, the ON position.
then slowly move the control handle off center
until the moment a voltage reading appears. 14 Press down the foot switch and then move the
Adjust the voltage to 3.5V DC. Turn the control handle all the way to the left or right.
threshold trimpot adjustment screw clockwise to Record the maximum voltage reading.
increase the voltage or counterclockwise 15 Start the engine.
to decrease the voltage.
16 Start a timer and simultaneously move the
control handle all the way to the left or right.
Note how long it takes to reach the maximum
voltage recorded in step 14. This is the
ramp rate.

PLATFORM CONTROLS
17 Set the ramp rate: Turn the trimpot to obtain 1-2

a 5 second ramp speed. Turn the trimpot
clockwise to increase the time or Horsepower Limiter Board
counterclockwise to decrease the time.
The horsepower limiter board is responsible for
Turntable rotation specifications
governing drive pump output. It senses engine rpm
from the alternator. The horsepower limiter board
Threshold 3.5V DC senses drops in rpm normally due to increased
drive resistance (rough terrain or incline), and
Turntable rotation - decreases voltage to the drive controller which in
hi range (boom retracted) 5.5V DC turn decreases voltage to the drive pump, thereby
Cycle time 80 to 100 seconds reducing pump output to maintain optimum engine
lo range (boom extended) 4.5V DC rpm and horsepower. Three adjustments are
Cycle time 130 to 160 seconds required for optimum performance.
Ramp rate 5 seconds How to Adjust the Horsepower

Limiter Board
The engine rpm must be
correct before performing this
procedure. See Maintenance
Procedure B-12, Check and
Adjust the Engine RPM.
Do not adjust the horsepower
limiter board unless the static
battery voltage is above 12V DC
and the alternator is operating
properly with 12.5 to 14.5V DC
output.
Gasoline/LPG models: Perform
this procedure in gasoline mode.
1 Remove the fasteners from the platform
control box lid.

PLATFORM CONTROLS
2 Open the control box lid and locate the 5 Move the engine idle control switch to foot
horsepower limiter board. switch activated high idle (rabbit and foot switch
symbol).
Electrocution hazard. Contact
with electrically charged circuits 6 Press down the foot switch and adjust the
may result in death or serious "A" potentiometer counterclockwise to increase
injury. Remove all rings, watches voltage or clockwise to decrease voltage.
and other jewelry.
"A" potentiometer specifications - all models
a
Voltage setting 10.5 to 11.5V 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
Platform control box 0.01V DC to 0.03V DC voltage reading.
a horsepower limiter board
9 Move the engine idle control switch to foot
switch activated high idle (rabbit and foot switch
3 Connect the black(-) lead from a DC volt meter symbol).
to the no. 2 terminal, and the red(+) lead to the
no. 10 terminal. 10 Press down the foot switch and re-adjust the
"A" potentiometer to the previous voltage
setting in step 6.
a
12V DC or greater
ground
11 Be sure that the boom is in the stowed position,
b
engine rpm sensor then drive the machine and observe how the
not used
not used engine rpm reacts to drive control handle
low drive speed limit switch movement. If the engine surges or hunts, adjust
not used
not used the "C" potentiometer counterclockwise until
not used surging is minimized.
output to drive controller
c
Under an extreme load, an
excessive counterclockwise
Horsepower limiter board adjustment to the "C"
a "A" potentiometer maximum voltage
potentiometer will cause
output to the controller in the stowed the engine to stall. The "C"
position potentiometer adjustment is a
compromise between engine
b "B" potentiometer maximum voltage
output to the drive controller in the stability (surging) and engine
boom raised position rpm droop.
c "C" potentiometer reaction rate or 12 Disconnect the volt meter.
how fast the voltage output reacts to
the change in engine rpm 13 Raise the boom above horizontal.
4 Start the engine from the platform controls. 14 Drive the machine for 40 feet (12 m) and
record the elapsed time. Repeat this step in
the opposite drive direction.

PLATFORM CONTROLS
15 Adjust the "B" potentiometer to obtain the 2 Do not press down the foot switch. Connect the
correct raised drive speed of 1 foot per second leads from an ohmmeter or continuity tester to
(0.31 m per second). Turn the "B" each wire combination listed below and check
potentiometer counterclockwise to increase for continuity.
voltage or clockwise to decrease voltage.
Do not use the color of the
16 Close the platform control box lid and install connector as a guide for these
the fasteners. tests. Use the actual wire color
to identify which wire to use for
Drive speed specifications testing.
Stowed position distance: 40 ft / 12 m Test Desired result

2WD 4WD
Gasoline/LPG models 40 ft/6.8 sec 40 ft/7.8 sec red to black continuity
12.2 m/6.8 sec 12.2 m/7.8 sec (zero W)
Deutz Diesel models 40 ft/7.8 sec 40 ft/9.1 sec red to white no continuity
12.2 m/7.8 sec 12.2 m/9.1 sec (infinite W)
Boom raised or distance: 40 ft / 12 m black to white no continuity

extended 1 foot per second
All models 30.5 cm per second
Do not use the color of the

connector as a guide for these
tests. Use the actual wire color
to identify which wire to use for
1-3 testing.
Foot Switch 3 Press down the foot switch. Connect the leads
from an ohmmeter or continuity tester to each
How to Test the Foot Switch wire combination listed below and check for
continuity.
1 Turn the key switch to the OFF position and
separate the wiring quick disconnect plug from Test Desired result
the platform toe board.
red to black no continuity
(infinite W)
red to white no continuity
black to white continuity

(zero W)

PLATFORM CONTROLS
Left Center Right

1-4
Resistors
The resistors are used on 4WD machines to
maintain low range drive speed. The resistors are
located in the platform control box.
Refer to the schematic legends

1 3 1 3 1 3
for resistor locations and values. 2 2 2
Single pole
How to Test the Resistors double throw
(SPDT) 1 2 3 1 2 3 1 2 3
1 Turn the key switch to the OFF position. 6 6 6
4 5 4 5 4 5
2 Disconnect either end of one of the wires Double pole

double throw
connected to the resistor to be tested. (DPDT)
3 Connect the leads from an ohmmeter to each 1 2 3 1 2 3 1 2 3
end or wiring of the resistor being tested.

Test Desired result
4 Compare the ohmmeter reading with the
resistance rating printed on the resistor. Left position
terminal 1 to 2, 3, 4, 5 & 6 no continuity

(infinite W)
1-5 terminal 2 to 3 continuity

(zero W)
Toggle Switches
terminal 2 to 4, 5 & 6 no continuity
Toggle switches used for single function switching terminal 3 to 4, 5 & 6 no continuity
are single pole double throw (SPDT) switches.
Dual function switching requires a double pole terminal 4 to 5 & 6 no continuity
double throw (DPDT) switch. terminal 5 to 6 continuity
Center position There are no terminal combinations
How to Test a Toggle Switch that will produce continuity
Continuity is the equivalent of 0 to (infinite W)
3 ohms. A simple continuity tester Right position
may not accurately test the switch.
terminal 1 to 2 continuity
This procedure covers fundamental switch testing (zero W)
and does not specifically apply to all varieties of
terminal 1 to 3, 4, 5 & 6 no continuity
toggle switches.
(infinite W)
1 Turn the key switch to the OFF position. Tag terminal 2 to 3, 4, 5 & 6 no continuity
and disconnect all wiring from the toggle switch
to be tested. terminal 3 to 4, 5 & 6 no continuity
2 Connect the leads of an ohmmeter to the switch terminal 4 to 5 continuity

terminals in the following combinations listed terminal 4 to 6 no continuity
below to check for continuity.
terminal 5 to 6 no continuity

Platform Components
2-1 2-2
Platform Platform Leveling Slave Cylinder
How to Remove the Platform The slave cylinder and the rotator pivot are the
two primary supports for the platform. The slave
1 Separate the foot switch quick disconnect plug. cylinder keeps the platform level through the
entire range of boom motion. It operates in a
2 Support the platform support weldment with a
closed-circuit hydraulic loop with the master
appropriate lifting device.
cylinder. The slave cylinder is equipped with
3 Open the platform control box and remove the counterbalance valves to prevent movement in
platform control box mounting fasteners. Then the event of a hydraulic line failure.
lower the control box and set it aside.
How to Remove the Platform
If your machine is equipped with
an airline to platform option, the Leveling Slave Cylinder
airline must be disconnected from
Before cylinder removal is
the platform before removal.
considered, bleed the slave
4 Remove the platform mounting fasteners and cylinder to be sure there is no
remove the platform from the machine. air in the closed loop.
Crushing hazard. The platform When removing a hose assembly
may become unstable and fall if it or fitting, the O-ring on the fitting
is not properly supported. and/or hose end must be replaced
and then torqued to specification
during installation.
Refer to Section Two, Hydraulic
Hose and Fitting Torque
Specifications.
1 Extend the boom until the slave cylinder
barrel-end pivot pin is accessible.
2 Raise the boom slightly and place blocks under
the platform.
3 Lower the boom until the platform is resting on
the blocks just enough to support the platform.
Do not rest the entire weight of the
boom on the blocks.

PLATFORM COMPONENTS
4 Tag, disconnect and plug the hydraulic hoses 2-3

from the slave cylinder at the union located
near the platform rotate counterbalance valve Platform Rotator
manifold and connect them together using a
connector. Cap the fittings on the cylinder. The platform rotator is a hydraulically activated
helical gear assembly used to rotate the platform
Bodily injury hazard. Spraying 160 degrees.
hydraulic oil can penetrate and
burn skin. Loosen hydraulic How to Remove the
the oil pressure to dissipate
Platform Rotator
gradually. Do not allow oil to Component damage hazard. Mark
squirt or spray. the platform mounting weldment
5 Pull the slave cylinder hoses through the and the rotator flange before
platform rotator. removing the platform mounting
weldment. The platform mounting
6 Remove the pin retaining fastener from weldment must be replaced in the
the slave cylinder rod-end pivot pin. Do not exact same position on the rotator
remove the pin. flange as it was before removal. If
7 Remove the external retaining ring from the a new rotator is installed or the
barrel-end pivot pin. rotator is disassembled, proper
alignment can be achieved by
8 Use a soft metal drift to drive the rod-end pivot rotating the rotator all the way to
pin out. the left and then installing the
platform mounting weldment all
9 Use a soft metal drift and drive the barrel-end
the way in the left position.
pin out.
When removing a hose assembly
10 Carefully pull the cylinder out of the boom.
or fitting, the O-ring on the fitting
Component damage hazard. and/or hose end must be replaced
Hoses can be damaged if they are and then torqued to specification
kinked or pinched. during installation.
Specifications.
How to Bleed the Slave Cylinder
1 Remove the platform. See 2-1,
Do not start the engine. Use How to Remove the Platform.
auxiliary power for all machine
functions in this procedure. 2 Tag, disconnect and plug the hydraulic hoses
from the platform rotator. Cap the fittings on the
1 Raise the boom to a horizontal position. rotator.
2 Move the platform level switch up and down Bodily injury hazard. Spraying
through two platform leveling cycles to remove hydraulic oil can penetrate and
any air that might be in the system. burn skin. Loosen hydraulic
gradually. Do not allow oil to squirt
or spray.
7 - 10 Genie S-40 Part No. 52271

PLATFORM COMPONENTS
3 Support the platform mounting weldment, but do 3 Open the top bleed valve on the rotator, but do
not apply any lifting pressure. not remove it.
4 Remove the six mounting bolts from the a
platform mounting weldment, then remove the
center bolt and slide the platform mounting
weldment off of the platform rotator.
Crushing hazard. The platform
mounting weldment may become
unbalanced and fall if it is not
properly supported.
5 Support the platform rotator. Do not apply
any lifting pressure.
6 Support the rod end of the platform leveling
slave cylinder. d c b
a top bleed valve
7 Remove the pin retainer from the slave cylinder
b bottom bleed valve
rod-end pivot pin and the rotator pivot pin. c container
d clear hose
8 Use a soft metal drift to drive both pins out, then
remove the platform rotator from the machine. 4 Move the function enable toggle switch to either
side and activate and hold the platform rotate
Crushing hazard. The platform
switch to the LEFT position until the platform is
rotator may become unbalanced
fully rotated. Continue holding the switch until
and fall if it is not properly
air stops coming out of the bleed valve. Then
supported.
close the bleed valve.
Crushing hazard. Keep clear of
How to Bleed the Platform the platform during rotation.
Rotator 5 Connect the clear hose to the bottom bleed
valve and open the valve. Do not remove the
Do not start the engine. Use bleed valve.
auxiliary power for all machine
functions in this procedure. 6 Move the function enable toggle switch to either
side and activate and hold the platform rotate
1 Move the function enable toggle switch to either switch to the RIGHT position until the platform is
side and activate the platform rotate switch to fully rotated. Continue holding the switch until
the right then the left through two platform air stops coming out of the bleed valve. Then
rotation cycles, then hold the switch to the RIGHT closethe bleed valve.
position until the platform is fully rotated to the
right. Crushing hazard. Keep clear of
the platform during rotation.
2 Connect a clear hose to the top bleed valve.
Place the other end of the hose in a container 7 Remove the hose from the bleed valve and
to collect any drainage. Secure the container to clean up any hydraulic oil that may have spilled.
the boom. 8 Rotate the platform full right then left and
inspect the bleed valves for leaks.
Part No. 52271 Genie S-40 7 - 11

Boom Components
3-1 4 Tag, disconnect and plug the hydraulic hoses
from the platform leveling cylinder at the union
Boom Cable Track and connect the hoses from the cylinder
together using a connector.
The boom cable track guides cables and hoses
running up the boom. It can be repaired link by link Bodily injury hazard. Spraying
without removing the cables and hoses that run hydraulic oil can penetrate and
through it. Removing the entire boom cable track is burn skin. Loosen hydraulic
necessary when performing major repairs that connections very slowly to allow
involve removing the boom. the oil pressure to dissipate
How to Remove the Boom squirt or spray.
Cable Track 5 Raise the boom to a horizontal position.
When removing a hose assembly 6 Remove the fasteners from the drive speed limit
or fitting, the O-ring on the fitting switch mounted on the side of the cable track at
and/or hose end must be replaced the pivot end of the boom. Do not disconnect
and then torqued to specification the wiring.
during installation. 7 Remove the fasteners from the side panel on
Refer to Section Two, Hydraulic the lower cable track, then remove the panel.
Hose and Fitting Torque Pull all of the cables out of the channel.
Specifications.
8 Remove the cable cover on the side of the
1 Open the platform control box and remove the
boom.
platform control box mounting fasteners.
9 Place blocks in between the upper and lower
2 Separate the footswitch quick disconnect then
cable tracks and secure the upper and lower
lower the platform control box and lay it off to
tracks together.
the side.
Crushing hazard. If the upper and
3 Tag, disconnect and plug the hydraulic hoses
lower cable tracks are not properly
from the "V1" and "V2" ports on the
secured together, the cable track
counterbalance valve manifold located near the
may become unbalanced and fall
platform rotator. Cap the fittings on the
when it is removed from the
manifold.
machine.
10 Remove the hose and cable clamp at the
platform end of the cable track.
burn skin. Loosen hydraulic
connections very slowly to allow 11 Attach a lifting strap from an overhead crane to
the oil pressure to dissipate the cable track.
12 Remove the mounting fasteners from the upper
squirt or spray.
cable track at the platform end of the extension
boom.
13 Remove the cable track mounting fasteners that
attach the lower cable track to the boom.
7 - 12 Genie S-40 Part No. 52271

BOOM COMPONENTS
14 Remove the cable track from the machine and 5 Lift up the hoses and cables and carefully
place it on a structure capable of supporting it. remove the damaged 4 link section of cable
track.
Crushing hazard. The cable track
may become unbalanced and fall Component damage hazard.
if it is not properly attached to the Hoses and cables can be
overhead crane. damaged if they are kinked or
pinched.
Component damage hazard.
Cables and hoses can be 6 Remove the upper rollers from the replacement
damaged if they are kinked or section of cable track.
pinched.
7 Lift up the hoses and cables and carefully insert
How to Repair the Boom the new 4 link section of cable track.
Cable Track Component damage hazard.

Hoses and cables can be
Component damage hazard. damaged if they are kinked or
The boom cable track can be pinched.
damaged if it is twisted.
8 Connect the ends of the replacement cable
A cable track repair kit is available track section to the existing cable track using
through the Genie Industries the fasteners provided in the kit. Do not
Service Parts Department, overtighten the fasteners.
part no. 46677. The kit includes a
4 link section of cable track, Component damage hazard.
fasteners, other miscellaneous Over tightening the fasteners will
parts and detailed instructions. result in the cable track not
rotating and may bind during
1 Remove the boom cable track. See 4-1, How to operation.
Remove the Boom Cable Track.
Be sure that the fasteners are
2 Visually inspect the cable track and determine installed from the inside out so the
which 4 link section needs to be replaced. nuts are on the outside of the
3 Drill out the 4 spot welds on each side of the cable track.
cable track using a 17/64" drill bit. Repeat this 9 Install the black rollers onto the new section of
step for the other end of the 4 link section of cable track.
cable track.
10 Install cable track onto the machine and operate
Component damage hazard. the boom extend/retract function throught a full
Cables and hoses can be cycle to ensure smooth operation of the new
damaged if the drill bit comes in section of cable track.
contact with them. Protect the
hoses and cables with a block of
wood to prevent drilling into the
hoses and cables.
4 Remove the retaining fasteners from upper
black rollers from the 4 link section of cable
track to be replaced. Remove the rollers.
Part No. 52271 Genie S-40 7 - 13

BOOM COMPONENTS
3-2 How to Remove the Boom

Boom This procedure requires specific
repair skills, lifting equipment and
How to Shim the Boom a suitable workshop. Attempting
this procedure without these skills
1 Measure each upper and side wear pad. and tools may cause death or
Replace the pad if it is less than serious injury and significant
9/16 inch (14.3 mm) thick. If the component damage. Dealer
pad is more than 9/16 inch service is strongly recommended.
(14.3 mm) thick, perform the Perform this procedure with the
following procedure. boom in the stowed position.
2 Measure the bottom wear pad. When removing a hose assembly
Replace the pad if it is less than or fitting, the O-ring on the fitting
11/16 inch (17.5 mm) thick. If the and/or hose end must be replaced
pad is more than 11/16 inch and then torqued to specification
(17.5 mm) thick, perform the during installation.
following procedure. Refer to Section Two, Hydraulic
3 Extend the boom until the wear pads are Specifications.
accessible.
1 Remove the platform. See 2-1,
4 Loosen the wear pad mounting fasteners. How to Remove the Platform.
5 Install the new shims under the wear pad to 2 Remove the platform rotator and leveling slave
obtain zero clearance and zero drag. cylinder. See 2-3, How to Remove the Platform
6 Tighten the mounting fasteners. Rotator.
7 Extend and retract the boom through an entire 3 Remove the cable track. See 3-1, How to
cycle. Check for tight spots that may cause Remove the Boom Cable Track.
binding or scraping of the boom. 4 Raise the boom to a horizontal position.
Always maintain squareness 5 Remove the turntable end cover.
between the outer and inner boom
tubes. 6 Remove the retaining fastener from the master
cylinder rod-end pivot pin. Use a soft metal drift
to remove the pin. Pull the cylinder back and
secure it out of the way.
When pulling the master cylinder
back, be sure not to damage the
master cylinder hoses or fittings.
7 Remove the fasteners from the drive speed limit
switch mounted to the turntable riser at the
pivot end of the boom. Do not disconnect the
wiring.
7 - 14 Genie S-40 Part No. 52271

BOOM COMPONENTS
8 Tag, disconnect and plug the extension cylinder How to Disassemble the Boom
hydraulic hoses. Cap the fittings on the
cylinder. Complete disassembly of the
boom is only necessary
Bodily injury hazard. Spraying if the outer or inner boom tubes
hydraulic oil can penetrate and must be replaced. The extension
burn skin. Loosen hydraulic cylinder can be removed without
connections very slowly to allow completely disassembling the
the oil pressure to dissipate boom. See 3-4, How to Remove
gradually. Do not allow oil to the Extension Cylinder.
squirt or spray.
1 Remove the boom. See 3-2,
9 Attach an overhead 5 ton (4536 kg) crane to the How to Remove the Boom.
center point of the boom.
2 Place blocks under the extension cylinder for
10 Attach a similar lifting device to the lift cylinder. support.
11 Place support blocks under the lift cylinder, 3 Remove the pin retaining fastener from the
across the turntable. extension cylinder barrel-end pivot pin at the
12 Remove the pin retaining fastener from the pivot end of the boom. Use a soft metal drift to
boom lift cylinder rod-end pin. Use a soft metal remove the pin.
drift to remove the pin. 4 Remove and label the wear pads from the
Crushing hazard. The boom lift platform end of the boom.
cylinder will fall unless it is Pay careful attention to the
properly supported. location and amount of shims
13 Lower the rod end of the lift cylinder onto used with each wear pad.
support blocks. Protect the cylinder rod from 5 Support and slide the extension tube out of the
damage. boom tube.
14 Remove the pin retaining fastener from the Crushing hazard. The extension
boom pivot pin. tube may become unbalanced and
15 Remove the boom pivot pin with a soft metal fall when it is removed from the
drift, then carefully remove the boom from the boom tube if it is not properly
machine. supported.
Crushing hazard. If the overhead During removal, the overhead

crane is not properly attached, crane strap will need to be
the boom may become carefully adjusted for proper
unbalanced and fall when it is balancing.
removed from the machine. 6 Remove the external snap rings from the
extension cylinder rod-end pivot pin at the
platform end of the extension tube. Use a soft
metal drift to remove the pin.
Part No. 52271 Genie S-40 7 - 15

BOOM COMPONENTS
7 Support and slide the extension cylinder out of 2 Place support blocks under the cylinder across
the base end of the extension tube. Place the the turntable.
extension cylinder on blocks for support.
3 Attach an overhead 5 ton (4536 kg) crane to the
Crushing hazard. The extension boom. Do not lift the boom.
cylinder may become unbalanced 4 Support the rod end of the boom lift cylinder
and fall when it is removed from with an overhead crane or similar lifting device.
the number 3 boom tube if it is not
properly supported. Crushing hazard. If the overhead
crane is not properly attached,
During removal, the overhead the lift cylinder may become
crane strap will need to be unbalanced and fall when it is
carefully adjusted for proper disconnected from the machine.
balancing.
5 Tag, disconnect and plug the boom lift cylinder
8 Remove and label the wear pads from the hydraulic hoses. Cap the fittings on the
extension cylinder. cylinder.
Pay careful attention to the Bodily injury hazard. Spraying
location and amount of shims hydraulic oil can penetrate and
used with each wear pad. burn skin. Loosen hydraulic
3-3 squirt or spray.
Boom Lift Cylinder 6 Remove the pin retaining fastener from the lift
cylinder rod-end pivot pin. Use a soft metal drift
How to Remove the Boom to remove the pin, then lower the lift cylinder
onto the blocks. Protect the cylinder rod from
Lift Cylinder damage.
This procedure requires specific Crushing hazard. The lift cylinder
repair skills, lifting equipment and may become unbalanced and fall
a suitable workshop. Attempting if it is not properly supported.
this procedure without these skills
and tools may result in death or 7 Remove the four mounting fasteners from the
serious injury and significant barrel-end cylinder pin mounting plate.
component damage. Dealer
8 With the lift cylinder being supported by the
service is strongly recommended.
overhead crane, pull the cylinder toward the
When removing a hose assembly platform until it is out.
Crushing hazard. The lift cylinder
and/or hose end must be replaced
if it is not properly supported.
Refer to Section Two, Hydraulic Component damage hazard. The
Hose and Fitting Torque cables and hydraulic hoses can be
Specifications. damaged if the lift cylinder is
1 Raise the boom until the boom is horizontal. pulled across them.
7 - 16 Genie S-40 Part No. 52271

BOOM COMPONENTS
3-4 7 Tag, disconnect and plug the extension cylinder

Extension Cylinder 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
squirt or spray.
Extension Cylinder
8 Remove the barrel-end pivot pin retaining
This procedure requires specific fasteners.
repair skills, lifting equipment and
a suitable workshop. Attempting 9 Place a rod through the barrel-end pivot pin and
this procedure without these skills twist to remove the pin.
and tools may cause death or
serious injury and significant
Refer to Section Two, Hydraulic 10 Support and slide the extension cylinder out of
Hose and Fitting Torque the pivot end of the boom.
Specifications.
Crushing hazard. The extension
1 Extend the boom until the extension cylinder cylinder will fall when it is removed
rod-end pivot pin is accessible in the extension from the extension boom if it is not
tube. properly supported.
2 Remove the platform. See 2-1, How to Remove Note the length of the cylinder
the Platform. after removal. The cylinder must
be at the same length for
3 Remove the master cylinder. See 3-5, How to
installation.
Remove the Master Cylinder.
4 Raise the boom to a horizontal position.
5 Remove the external snap rings from the
extension cylinder rod-end pin (at the platform
end). Use a soft metal drift to remove the pin.
6 Remove the turntable end cover.
Part No. 52271 Genie S-40 7 - 17

BOOM COMPONENTS
3-5 6 Place a rod through the barrel-end pivot pin and

twist to remove the pin.
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
located at the base of the boom.
How to Remove the Platform

7 Remove the pin retaining fastener from the rod-
Leveling Master Cylinder end pivot pin.
When removing a hose assembly 8 Use a soft metal drift to remove the pin.
and/or hose end must be replaced 9 Remove the master cylinder from the machine.
and then torqued to specification Crushing hazard. The master
during installation. cylinder may become unbalanced
Refer to Section Two, Hydraulic and fall if it is not properly attached
Hose and Fitting Torque to the overhead crane.
Specifications.
1 Raise the boom until the master cylinder
rod-end pivot pin is accessible.
2 Remove the turntable end cover to access the
master cylinder.
3 Tag, disconnect and plug the master cylinder
cylinder.
squirt or spray.
4 Attach a lifting strap from an overhead crane to
the lug on the rod end of the cylinder.
5 Remove the pin retaining fasteners from the
master cylinder barrel-end pivot pin.
7 - 18 Genie S-40 Part No. 52271

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.
Protect the cover from damage
byusing carpet or padding on the
crane or fork lift forks.
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.
Mark the locationof the hinge
support bracket on the bulkhead to
ensure proper cover alignment
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.
Crushing hazard. The turntable
cover may become unbalanced
and fall if it is not properly
supported and secured to a
appropriate lifting device.
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. 52271 Genie S-40 7 - 19

Deutz Engine F3L 1011F

5-1 How to Install the Flex Plate
RPM Adjustment 1 Install the flex plate onto the flywheel with the
raised spline towards the pump. Torque the flex
Refer to Maintenance Procedures, B-12, plate mounting bolts to 34 ft-lbs (46 Nm).
Check and Adjust the Engine RPM.
2 Install the coupler onto the pump shaft with the
set screw toward the pump. Leave a 1/2 inch
(12.7 mm) gap between the coupler and pump
end plate.
5-2
3 Apply Loctite® removable thread sealant to the
Flex Plate coupler set screw. Torque the set screw to
45 ft-lbs (61 Nm).
The flex plate acts as a coupler between the
engine and the pump. It is bolted to the engine Component damage hazard. Do
flywheel and has a splined center to drive not force the drive pump during
the pump. installation or the flex plate teeth
may become damaged.
a b c d e
4 Install the pump and torque the pump mounting
plate fasteners to 34 ft-lbs (46 Nm).
5-3
Oil Temperature and Pressure
f Gauges
a pump
The oil temperature gauge is an electrical gauge.
b pump shaft
c coupler The sending unit has limit contacts that are factory
d flex plate with raised spline set. The contacts will close at 300o F (147o C).
e flywheel When the contacts close, the engine will shut off to
f 1/2 inch gap
prevent damage and will not start until the
temperature drops below the contact point.
How to Remove the Flex Plate Temperature will be indicated when the key is on
1 Disconnect the wiring plug at the electronic and the Emergency Stop Button is pulled out to the
displacement controller (EDC), located on ON position.
the drive pump. Component damage hazard.

2 Support the drive pump with an appropriate Do not crank the engine with
lifting device. Then remove all of the pump the over-temperature light on.
mounting plate to engine bell housing bolts. The oil pressure gauge is an electrical gauge. The
3 Carefully pull the pump away from the engine sending unit has limit contacts that are factory set.
and secure it from moving. The contacts will close at 7 psi (0.48 bar). When
the contacts close, the engine will shut off to
4 Remove the flex plate mounting fasteners, prevent damage. Oil pressure will be indicated
then remove the flex plate from the flywheel. when the engine is running.
Do not crank the engine with the
low oil pressure light on.
7 - 20 Genie S-40 Part No. 52271
Ford LRG-423 Engine
a b c d
g
110°
6-1 Governor actuator and linkage

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 4 Position the linkage rod so that the throttle is in
actuator is only necessary when the idle position. Then adjust the clevis yoke on
the governor actuator or the the linkage rod to obtain the proper length.
linkage has been replaced. Install the yoke onto the actuator arm.
1 Connect the linkage rod to the throttle plate 5 With the throttle in the idle position and the
shaft, then tighten the lock nut. actuator arm at a 110 degree angle to the
linkage, rotate the clevis yoke on the linkage
2 Fasten the lock nut and clevis yoke to the
rod two turns counterclockwise to pre-load the
linkage rod. Do not tighten the lock nut
spring. Tighten the lock nut on the linkage rod.
against the clevis yoke.
3 Loosen the fastener on the actuator arm. Rotate
the actuator arm until it is at a 110 degree angle
to the linkage rod. Then tighten the actuator
arm fastener.
Part No. 52271 Genie S-40 7 - 21

FORD LRG-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
Component damage hazard. automatic choke. The choke has a poppet valve to
If the throttle linkage is improperly enhance cold starting ability on LPG fuel.
adjusted and allowed to reach full
throttle, the engine will over-rev Choke adjustments are affected
and cause component damage. by climate. Richer adjustment
will be necessary in colder
The linkage must be free of friction climates, leaner adjustment
and obstruction. Do not in warmer climates.
let it rub against the engine,
brackets or hoses. 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 - 22 Genie S-40 Part No. 52271

FORD LRG-423 ENGINE
6-3 6-6
Timing Adjustment Flex Plate
Complete information to perform this procedure is The flex plate acts as a coupler between the
available in the Ford LRG-423 2.3 Liter Industrial engine and the pump. It is bolted to the engine
Engine Service Manual (Ford number: PPD-194- flywheel and has a splined center to drive
287). Genie part number 33907. the pump.
a b c d e
6-4
Carburetor Adjustment
available in the Ford LRG-423 2.3 Liter Industrial f
Engine Service Manual (Ford number: PPD-194- a pump
287). Genie part number 33907. b pump shaft
c coupler
d flex plate with raised spline
e flywheel
f 1/4 inch gap
6-5
RPM Adjustment Flex Plate Removal
1 Disconnect and remove the hose between
Refer to Maintenance Procedures, B-12, Check the carburetor venturi and the air cleaner.
and Adjust the Engine RPM.
2 Disconnect the linkage from the governor,
then remove the governor linkage from
the carburetor. Do not alter the length of
the linkage.
3 Disconnect the wiring plug at the electronic
displacement controller (EDC), located on
the drive pump.
4 Remove the mounting fasteners from the
regulator mounting bracket, then pull the
bracket up past the bell housing. Secure
the bracket before continuing.
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
engine and secure it from moving.
7 Remove the flex plate mounting fasteners,
then remove the flex plate from the fly wheel.
Part No. 52271 Genie S-40 7 - 23

FORD LRG-423 ENGINE
How to Install the Flex Plate 6-7

1 Install the flex plate onto the flywheel with the Water Temperature and Oil
raised spline towards the pump. Torque the flex Pressure Gauges
plate mounting bolts to 34 ft-lbs (46 Nm).
2 Install the coupler onto the pump shaft with the The water temperature gauge is an electrical
set screw towards the pump. Leave a 1/4 inch gauge. The sending unit has limit contacts that are
(6.35 mm) gap between the coupler and pump factory set. The contacts will close at 230°F
end plate. (109° C). When the contacts close, the engine will
shut off to prevent damage and will not start until
3 Apply Loctite® removable thread sealant to the the temperature drops below the contact point.
coupler set screw. Torque the set screw to Temperature will be indicated when the key is on
45 ft-lbs (61 Nm). and the Emergency Stop Button is pulled out to the
ON position.
Component damage hazard. Do
not force the drive pump during Component damage hazard.
installation or the flex plate teeth Do not crank the engine with
may become damaged. the over-temperature light on.
4 Install the pump and torque the pump mounting The oil pressure gauge is an electrical gauge. The
plate fasteners to 34 ft-lbs (46 Nm). sending unit has limit contacts that are factory set.
The contacts will close at 8 psi (0.55 bar). When
the contacts close, the engine will shut off to
prevent damage. Oil pressure will be indicated
when the engine is running.

Do not crank the engine with the
low oil pressure light on.
7 - 24 Genie S-40 Part No. 52271

FORD LRG-423 ENGINE
6-8
Vacuum Switch
How to Test the Vacuum Switch

a b
d c
a ohmmeter
b common terminal (SOL.)
c vacuum switch
d normally open terminal (ING.)
1 Connect the leads from an ohmmeter or

continuity tester to the common and normally
open terminals.
Result: There should be no continuity
(infinite W).
2 Apply mild suction to the vacuum port.
Result: The switch should close and show full
continuity (zero W).
Do not short the vacuum switch
terminals to ground.
Part No. 52271 Genie S-40 7 - 25

Ground Controls
7-1
Control Relays
Relays used for single function switching are single
pole double throw (SPDT) relays.
How to Test a Single Pole Double

a terminal no. 87a - N.C.
Throw Relay b terminal no. 85 - ground
c terminal no. 30 - common
Electrocution hazard. d terminal no. 86 - coil
Contact with electrically charged e terminal no. 87 - N.O.
circuits may cause death or
serious injury. Remove all rings,
watches and other jewelry. Control Relay Schematic - without resistor
Direct Connection Relay
1 Label and then disconnect all the wiring from

the relay to be tested.
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.
Test Desired result
terminal 85 to 86 without resistor 85 to 95W
terminal 85 to 86 with resistor 75 to 85W
terminal 87 to 87a & 30 no continuity Control Relay Schematic - with resistor

(infinite W)
terminal 87a to 30 continuity

(zero W)
3 Connect 12V DC to terminal 85 and a ground

wire to terminal 86, then test the following
terminal combinations.
Test Desired result
terminal 87 to 87a & 30 no continuity

(infinite W)
terminal 87 to 30 continuity
(zero W)
7 - 26 Genie S-40 Part No. 52271

GROUND CONTROLS
7-2 7-4
Toggle Switches Resistors
See 1-5, Toggle Switches. How to Test the Resistor
The resistor is used to maintain proper control of
boom function speeds. A 10 ohm resistor reduces
7-3 voltage to all the boom function switches at the
ground controls.
Wago® Components
Refer to the schematic legends for
How to Remove a Wago® resistor locations and values.
Component 1 Turn the key switch to the OFF position.
Electrocution hazard. 2 Disconnect either end of one of the wires

Contact with electrically charged connected to the resistor to be tested.
circuits may cause death or 3 Connect the leads from an ohmmeter to each
serious injury. Remove all rings, end or wiring of the resistor being tested.
watches and other jewelry.
4 Compare the ohmmeter reading with the
A small screwdriver is provided resistance rating printed on the resistor.
and should be used when
removing a Wago® component.
This screwdriver is located in the
operator’s manual storage box in
the platform.
1 Label the wiring from the component to be
removed.
2 Locate the removal tab on the bottom or top
side of the component.
3 Use a small narrow flat blade screwdriver to
push in and release the wire from the
component.
4 Use the small narrow flat blade screwdriver to
gently pry up on the tab of the component and
remove it.
Part No. 52271 Genie S-40 7 - 27

GROUND CONTROLS
7-5 2 Connect 12V DC to one of the small posts and

a ground wire to the other small post, then test
Power Relay the following terminal combination.
Electrocution hazard. Contact with Test Desired result

electrically charged circuits may
result in death or serious injury. 2 large posts continuity (zero W)
Remove all rings, watches and
other jewelry.
a b b a
The power relay is mounted on the
backside of the ground control
box.
How to Test the Power Relay

Electrocution hazard. Disconnect
the ground cable from the battery
before performing this procedure.
1 Connect the leads from an ohmmeter to each
terminal combination and check for continuity.
Test Desired result

a high amp power contact terminal
(large post)
2 small posts 12 to 16W
b solenoid activate coil terminal
2 large posts no continuity (small post)
(infinite W)
Any small post to no continuity

any large post (infinite W)
7 - 28 Genie S-40 Part No. 52271

Hydraulic Pumps
8-1 3 Remove the pump mounting bolts. Carefully
remove the pump.
Lift/Steer Pump
Be sure to open the two hydraulic
How to Remove the tank valves and prime the pump
Lift/Steer Pump after installing the pump.
and/or hose end must be replaced 8-2
during installation. Drive Pump
Hose and Fitting Torque The drive pump is a bi-directional variable
Specifications. displacement piston pump. The pump output is
controlled by the electronic displacement controller
1 Close the two hydraulic tank valves located at (EDC), located on the pump. The only adjustment
the hydraulic tank. 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. Call Genie
Industries Service Department to locate your local
authorized service center.
How to Remove the Drive Pump

open closed Component damage hazard. The
work area and surfaces where this
Component damage hazard. The procedure will be performed must
engine must not be started with be clean and free of debris that
the hydraulic tank shutoff valves in could get into the hydraulic system
the CLOSED position or component and cause severe component
damage will occur. damage. Dealer service is
If the tank valves are closed, recommended.
remove the key from the key
switch and tag the machine to When removing a hose assembly
inform personnel of the condition. or fitting, the O-ring on the fitting
2 Tag, disconnect and plug the lift/steer pump and then torqued to specification
hydraulic hoses. Cap the fittings on the pump. during installation.
Specifications.
connections very slowly to allow 1 Disconnect the electrical connection at the
the oil pressure to dissipate electronic displacement controller (EDC)
gradually. Do not allow oil to located on the drive pump.
squirt or spray.
Part No. 52271 Genie S-40 7 - 29

HYDRAULIC PUMPS
2 Close the two hydraulic tank valves located at How to Prime the Pump
the hydraulic tank.
1 Connect a 0 to 600 psi (0 to 41 bar) pressure
gauge to the test port on the drive pump.
2 Gasoline/LPG models: Disconnect the
electrical connector at the ignition coils. The
ignition coils are located above the alternator.
Electrocution hazard.
Contact with electrically charged
open closed
circuits may cause death or
Component damage hazard. The serious injury. Remove all rings,
engine must not be started with watches and other jewelry.
the hydraulic tank shutoff valves in Deutz Diesel models: Hold the manual fuel
the CLOSED position or component shutoff valve clockwise to the CLOSED position.
valves are closed, remove the key a
condition.
3 Tag and disconnect and plug the hydraulic
hoses from the drive and lift/steer pumps. Cap
the fittings on the pumps.
a manual fuel shutoff valve
squirt or spray.
4 Support the pump with a lifting device and 3 Crank the engine with the starter motor for
remove the two drive pump mounting fasteners. 15 seconds, wait 15 seconds, then crank the
engine an additional 15 seconds or until the
5 Carefully pull the drive pump out until the pump pressure reaches 320 psi (22 bar).
coupler separates from the flex plate.
4 Gasoline/LPG models: Connect the ignition
6 Remove the drive pump from the machine. coil wiring and start the engine from the ground
controls. Check for hydraulic leaks.
Be sure to open the two hydraulic
tank valves and prime the pump
after installing the pump.
7 - 30 Genie S-40 Part No. 52271

Part No. 52271 Genie S-40 7 - 31

Manifolds
9-1
Function Manifold Components
The function manifold is located on the tank side tray, behind the ground control box.
Index Schematic
No. Description Item Function Torque
1 3 position 4 way D03 valve ................ A ........... Turntable rotate left/right ....................... 30-35 in-lbs / 3-4 Nm
2 3 position 4 way D03 valve ................ B ........... Boom up/down ...................................... 30-35 in-lbs / 3-4 Nm
3 3 position 4 way D03 valve ................ C ........... Boom extend/retract .............................. 30-35 in-lbs / 3-4 Nm
4 Check valve, pilot operated ............... D ........... Boom extend/retract circuit ................ 11-13 ft-lbs / 15-18 Nm
5 Relief valve, 1950 psi (134 bar) ........ E ........... Boom extend ...................................... 25-30 ft-lbs / 34-41 Nm
6 Relief valve, 2200 psi (152 bar) ........ F ........... Boom down ........................................ 25-30 ft-lbs / 34-41 Nm
7 Flow regulator valve,
1.5 gpm (5.7 l/min) ............................. G ........... Boom extend/retract circuit
(prevents overflowing
the proportional valve) ...................... 10-12 ft-lbs / 14-16 Nm
1.5 gpm (5.7 l/min) ............................. H ........... Boom up/down circuit
the proportional valve) ...................... 10-12 ft-lbs / 14-16 Nm
1.5 gpm (5.7 l/min) ............................. I ............ Turntable rotate left/right
the proportional valve) ........................ 10-12 ft-lbs / 14-6 Nm
0.1 gpm (0.38 l/min) ........................... J ............ Bleeds off differential
sensing valves to tank ...................... 10-12 ft-lbs / 14-16 Nm
11 Check valve ....................................... K ........... Differential sensing circuit,
boom extend/retract .......................... 11-13 ft-lbs / 15-18 Nm
12 Orifice - Plug, 0.140 inch (3.56 mm) .. L ........... Boom extend/retract circuit
13 Proportional solenoid valve ............... M .......... Boom extend/retract .......................... 10-12 ft-lbs / 14-16 Nm
14 Check valve ....................................... N ........... Differential sensing circuit,
boom up/down .................................. 11-13 ft-lbs / 15-18 Nm
15 Check valve ....................................... O ........... Differential sensing circuit,
turntable rotate left/right .................... 11-13 ft-lbs / 15-18 Nm
16 Proportional solenoid valve ............... P ........... Boom up/down .................................. 10-12 ft-lbs / 14-16 Nm
17 Check valve ....................................... Q ........... Differential sensing circuit,
platform level up ............................... 11-13 ft-lbs / 15-18 Nm
18 Check valve ....................................... R ........... Differential sensing circuit,
platform level down ........................... 11-13 ft-lbs / 15-18 Nm
This list continues. Please turn the page
7 - 32 Genie S-40 Part No. 52271

MANIFOLDS
Part No. 52271 Genie S-40 7 - 33

MANIFOLDS
Function Manifold Components, continued

Index Schematic
19 Proportional solenoid valve ............... S ........... Turntable rotate left/right ................... 10-12 ft-lbs / 14-16 Nm
20 Solenoid valve - N.O. Poppet ............ T ........... Platform level up ............................... 25-30 ft-lbs / 34-41 Nm
0.6 gpm (2.27 l/min) ........................... U ........... Platform level circuit .......................... 10-12 ft-lbs / 14-16 Nm
22 Solenoid valve - N.O. Poppet ............ V ........... Platform level down .......................... 25-30 ft-lbs / 34-41 Nm
23 Differential sensing valve .................. W .......... Meters flow to functions .................... 10-12 ft-lbs / 14-16 Nm
24 Relief valve, 2900 psi (200 bar) ........ X ........... System relief ..................................... 35-40 ft-lbs / 47-54 Nm
25 Diagnostic nipple ............................... Y ........... Testing
26 Check valve ....................................... Z ........... Differential sensing circuit
Platform rotate left ............................. 11-13 ft-lbs / 15-18 Nm
27 Check valve ....................................... AA ......... Differential sensing circuit
Platform rotate right .......................... 11-13 ft-lbs / 15-18 Nm
28 Priority flow regulator valve, .............. BB ......... Steering ............................................. 10-12 ft-lbs / 14-16 Nm
2 gpm (7.57 l/min), without oscillate axle
3 gpm (11.4 l/min), with oscillate axle
29 Solenoid valve - N.O. Poppet ........... CC ........ Platform rotate left ............................. 25-30 ft-lbs / 34-41 Nm
30 Solenoid valve - N.O. Poppet ........... DD ........ Platform rotate right .......................... 25-30 ft-lbs / 34-41 Nm
0.6 gpm (2.27 l/min) ........................... EE ......... Platform rotate .................................. 10-12 ft-lbs / 14-16 Nm
32 Counterbalance valve ........................ FF ......... Platform level up ............................... 35-40 ft-lbs / 47-54 Nm
33 Counterbalance valve ........................ GG ........ Platform level down .......................... 35-40 ft-lbs / 47-54 Nm
34 Check valve ....................................... HH ........ Boom extend/retract circuit ............... 11-13 ft-lbs / 15-18 Nm
Plug Torque Specifications

Description Hex size Torque SAE No. 6 1/4 18 ft-lbs / 24 Nm
SAE No. 2 1/8 50 in-lbs / 6 Nm SAE No. 8 5/16 50 ft-lbs / 68 Nm
SAE No. 4 3/16 13 ft-lbs / 18 Nm SAE No. 10 9/16 55 ft-lbs / 75 Nm
7 - 34 Genie S-40 Part No. 52271

MANIFOLDS
Part No. 52271 Genie S-40 7 - 35

MANIFOLDS
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 System 1 Connect a 0 to 5000 psi (0 to 345 bar) pressure
Relief Valve gauge to the test port (item 23) on the function
manifold.
boom in the stowed position. 2 Start the engine from the ground controls.
1 Connect a 0 to 5000 psi (0 to 345 bar) pressure 3 Hold the function enable switch to either side
gauge to the test port (item 23) on the function and activate and hold the boom down switch
manifold. with the boom fully lowered. Observe the
pressure reading on the pressure gauge.
4 Turn the engine off. Use a wrench to hold the
3 Hold the function enable switch to either side relief valve and remove the cap
and activate and hold the retract switch with the (item 6, function manifold).
boom fully retracted. Observe the pressure
reading on the pressure gauge. 5 Adjust the internal hex socket. Turn it clockwise
to increase the pressure or counterclockwise to
4 Turn the engine off. Use a wrench to hold the decrease the pressure. Then install the relief
relief valve and remove the cap valve cap.
(item 23, function manifold).
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 specified.
decrease the pressure. Then install the relief
valve cap. 6 Repeat steps 2 through 5 and recheck relief
valve pressure.
the relief valves higher than
Boom down relief valve specifications
specified.
6 Repeat steps 2 through 5 and recheck relief Pressure 2200 psi
valve pressure. 152 bar
System relief valve specifications
Pressure 2900 psi 200 bar
7 - 36 Genie S-40 Part No. 52271

MANIFOLDS
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 overridden to troubleshoot a malfunction. The
boom in the stowed position. proportional boom functions (boom up/down,
extend/retract and turntable rotate) use a variable
1 Connect a 0 to 3000 psi (0 to 207 bar) pressure position proportional valve and a three position
gauge to the test port (item 23) on the function directional valve. Example: one position for boom
manifold. up, one position for neutral and one position for
boom down. The platform rotate function uses a
three position valve. The platform level uses a
3 Hold the function enable switch to either side three position and a two position valve. The three
and activate and hold the extend switch with the position valves and the proportional valves can be
boom fully extended. Observe the pressure manually overridden. To identify the manifold
reading on the pressure gauge. valves see 10-1, Function Manifold, in this section.
4 Turn the engine off. Use a wrench to hold the 1 Push the button on the end of the valve in
relief valve and remove the cap ¼ inch (6 mm).
(item 5, function manifold).
5 Adjust the internal hex socket. Turn it clockwise
to increase the pressure or counterclockwise to
decrease the pressure. Then install the relief
valve cap.
the relief valves higher than
specified.
6 Repeat steps 2 through 5 and recheck relief
valve pressure.
2 Hold the function enable switch to either side
Boom extend relief valve specifications and move the ground control function switch for
the function being overridden to operate
Pressure 1950 psi function.
134 bar 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. 52271 Genie S-40 7 - 37

MANIFOLDS
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, 12V 8.6W

(schematic items M, P and S)
3 position 4 way directional valve, 10V 3.2W

(schematic items A, B and C)
Normally open poppet valve 6.4W

(schematic item T, V, CC and DD)
7 - 38 Genie S-40 Part No. 52271

MANIFOLDS
9-3
Turntable Rotation Manifold Components
The turntable rotation manifold is mounted to the turntable rotation motor on the tank side of the turntable.
Index Schematic
1 Shuttle valve 2 position 3 way ........... II ........... Turntable rotation brake release ....... 10-13 ft-lbs / 14-18 Nm
2 Counterbalance valve ........................ JJ .......... Turntable rotate right ........................ 35-40 ft-lbs / 47-54 Nm
3 Counterbalance valve ........................ KK ......... Turntable rotate left ........................... 35-40 ft-lbs / 47-54 Nm
1 2 3
JJ
KK
II

Description Hex size Torque
SAE No. 2 1/ 8 50 in-lbs / 6 Nm
SAE No. 4 3/16 13 ft-lbs / 18 Nm
SAE No. 6 1/ 4 18 ft-lbs / 24 Nm
Part No. 52271 Genie S-40 7 - 39

MANIFOLDS
9-4
Oscillate Manifold Components
The oscillate manifold is mounted inside the drive chassis at the non-steer end.
Index Schematic
1 Orifice plug, 0.052 inch (1.32 mm) .... LL ......... Differential sensing circuit
2 Differential sensing valve .................. MM ....... Differential sensing ........................... 10-12 ft-lbs / 14-16 Nm
3 Check valve ....................................... NN ........ Oscillate check - left .......................... 35-40 ft-lbs / 47-54 Nm
4 Pilot operated unloader valve,
950 psi (65 bar) ................................. OO ........ Sequencing ....................................... 10-12 ft-lbs / 14-16 Nm
5 Shuttle valve, 2 position 3 way ......... PP ......... Pilot ................................................... 10-12 ft-lbs / 14-16 Nm
6 Piston ................................................................ Check valve circuit
(the piston is located between
index numbers 3 and 7)
7 Check valve ....................................... QQ ........ Oscillate check - right ....................... 35-40 ft-lbs / 47-54 Nm
8 Shuttle valve, 2 position 3 way .......... RR ........ Unloading .......................................... 35-40 ft-lbs / 47-54 Nm
9 Diagnostic fitting ............................................... Testing
1 2
LL
MM
NN
3
RR OO
8 4
7
PP
QQ
6 5
Description Hex size Torque
SAE No. 2 1/8 50 in-lbs / 6 Nm
SAE No. 4 3/16 13 ft-lbs / 18 Nm
SAE No. 6 1/4 18 ft-lbs / 24 Nm
7 - 40 Genie S-40 Part No. 52271

MANIFOLDS
9-5 7 Repeat steps 3 through 6 and manually activate

the valve and recheck the valve pressure.
Valve Adjustments -
8 Turn the engine off, then remove the
Oscillate Manifold pressure gauge and assemble the directional
valve linkage.
How to Adjust the Oscillate
Sequencing Valve Pressure Sequencing valve specifications
When removing a hose assembly Pressure 950 psi

or fitting, the O-ring on the fitting 65 bar
Specifications.
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 unloader valve
and remove the cap (item 4).
to increase the pressure or counterclockwise
to decrease the pressure. Then install the
valve cap.
Tip-over hazard. Do not adjust the
relief valve higher than specified.
Part No. 52271 Genie S-40 7 - 41

MANIFOLDS
9-6
Directional Valve Manifold Components
The directional valve manifold is mounted inside the drive chassis at the non-steer end.
Index
No. Description Function Torque
1 Cap ................................................................... Breather ............................................. 20-25 ft-lbs / 27-33Nm
2 Spool valve ....................................................... Directional control
7 - 42 Genie S-40 Part No. 52271

MANIFOLDS
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 Check the tire pressure in all four tires and add
air if needed to meet specification.
4 Remove the drive chassis cover from the
non-steer end.
5 Disconnect the linkage clevis yoke from the
drive chassis (if not already disconnected).
6 Place a "bubble type" level across the drive
chassis non-steer end. Check to be sure the
drive chassis is completely level.
7 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.
8 Verify that the ground and drive chassis are
completely level.
9 Adjust the length of the rod by turning the clevis
yoke until the clevis yoke can be pinned to the
drive chassis.
10 Install the clevis yoke pin then the cotter pin. Be
sure to bend the cotter pin.
11 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.
Part No. 52271 Genie S-40 7 - 43

MANIFOLDS
9-7
Steer Manifold Components, Oscillating Models
The steer manifold is mounted underneath the function manifold.
Index Schematic
1 3 position 4 way solenoid valve ......... SS ......... Steer left/right ....................................... 30-35 in-lbs / 3-4 Nm
2 Check valve ....................................... TT ......... Priority flow regulator circuit .............. 10-12 ft-lbs / 14-16 Nm
3 Orifice plug, 0.025 inch (0.635 mm) .. UU ........ Priority flow regulator circuit
4 Priority flow
regulator valve, 2 gpm (7.57 l/min) .... VV ......... Regulates flow to
oscillate manifold .............................. 10-12 ft-lbs / 14-16 Nm
SS
TT
UU
4 2
VV
3
7 - 44 Genie S-40 Part No. 52271

MANIFOLDS
9-8
Steer Manifold Components, Non-oscillating Models
The steer manifold is underneath the function manifold.
Index Schematic
No. Description Item Function
1 3 position 4 way D03 valve ................ SS ......... Steer left/right
SS
Part No. 52271 Genie S-40 7 - 45

MANIFOLDS
9-9
2WD Drive Manifold Components
The drive manifold is mounted inside the drive chassis at the non-steer end.
Index Schematic
1 Relief valve, 250 psi (17.2 bar) ......... WW ....... Charge pressure circuit ..................... 10-12 ft-lbs / 14-16 Nm
4 Flow divider/combiner valve .............. XX ......... Controls flow to drive motors
in forward and reverse ...................... 25-30 ft-lbs / 34-41 Nm
3 Orifice, 0.070 in (1.78 mm) ................ YY ......... Drive circuit
2 Shuttle valve, 3 position 3 way .......... ZZ ......... Charge pressure circuit that
gets hot oil out of low pressure
side of drive pump and allows
low pressure flow path for
brake release and 2-speed
motor shift ......................................... 15-18 ft-lbs / 20-24 Nm

SAE No. 6 1/4 18 ft-lbs / 24 Nm
7 - 46 Genie S-40 Part No. 52271

MANIFOLDS
Part No. 52271 Genie S-40 7 - 47

MANIFOLDS
9-10
Valve Adjustments, 2WD
Drive Manifold
How to Adjust the Charge

Pressure Relief Valve
gauge to the test port located on the drive
manifold.
3 Drive the machine slowly in either direction and
observe the pressure reading on the pressure
gauge.
4 Turn the engine off. Hold the charge pressure
relief valve and remove the cap (item 1).
valve cap.
6 Restart the engine. Drive the machine in either
direction and recheck the valve pressure.
pressure gauge.
Charge Pressure Relief valve specifications
Pressure 250 psi

17.2 bar
7 - 48 Genie S-40 Part No. 52271

MANIFOLDS
Part No. 52271 Genie S-40 7 - 49

MANIFOLDS
9-11
4WD Drive Manifold Components
The drive manifold is mounted inside the drive chassis at the non-steer end.
Index Schematic
1 Flow divider/combiner valve .............. AB ......... Controls flow to flow
divider/combiner valves 4 and 5 ....... 25-30 ft-lbs / 34-41 Nm
2 Relief valve, 250 psi (17.2 bar) ......... AC ........ Charge pressure circuit ..................... 10-12 ft-lbs / 14-16 Nm
3 Orifice - plug, 0.052 inch (1.32 mm) .. AD ........ Front drive motor circuit
4 Flow divider/combiner valve .............. AE ......... Controls flow to steer end
drive motors in forward
and reverse ....................................... 25-30 ft-lbs / 34-41 Nm
5 Flow divider/combiner valve .............. AF ......... Controls flow to non-steer end
drive motors in forward
and reverse ....................................... 25-30 ft-lbs / 34-41 Nm
6 Orifice, 0.070 in (1.78 mm) ................ AG ........ Rear drive motor circuit
7 Orifice, 0.070 in (1.78 mm) ................ AH ........ Equalizes pressure on both sides
of flow divider combiner valve
Index no. 1
8 Shuttle valve, 3 position 3 way .......... AI .......... Charge pressure circuit
that gets hot oil out of low pressure
side of drive pump and allows low
pressure flow path for brake
release and 2-speed motor shift ....... 15-18 ft-lbs / 20-24 Nm

SAE No. 6 1/4 18 ft-lbs / 24 Nm
7 - 50 Genie S-40 Part No. 52271

MANIFOLDS
Part No. 52271 Genie S-40 7 - 51

MANIFOLDS
9-12
Valve Adjustments, 4WD
Drive Manifold
How to Adjust the Charge

Pressure Relief Valve
gauge to the test port located on the drive
manifold.
3 Drive the machine slowly in either direction and
observe the pressure reading on the pressure
gauge.
4 Turn the engine off. Hold the charge pressure
relief valve and remove the cap (index 3).
valve cap.
6 Restart the engine. Drive the machine in either
direction and recheck the valve pressure.
pressure gauge.
Charge Pressure Relief valve specifications
Pressure 250 psi

17.2 bar
7 - 52 Genie S-40 Part No. 52271

Fuel and Hydraulic Tanks

10-1 10-2
Fuel Tank Hydraulic Tank
How to Remove the Fuel Tank The primary functions of the hydraulic tank are to
cool, clean and deaerate the hydraulic fluid during
Explosion hazard. Engine fuels operation. It utilizes internal suction strainers for
are combustible. Remove the fuel the pump supply lines and has an external return
tank in an open, well-ventilated line filter with a filter condition indicator.
area away from heaters, sparks,
flames and lighted tobacco. How to Remove the
Always have an approved fire Hydraulic Tank
extinguisher within easy reach.
Explosion hazard. When
The work area and surfaces
transferring fuel, connect a
where this procedure will be
grounding wire between the
performed must be clean and
machine and pump or container.
free of debris that could get
1 Turn the manual fuel shutoff valve to the into the hydraulic system.
CLOSED position.
2 Remove the tank side turntable cover. See 4-1, or fitting, the O-ring on the fitting
How to Remove a Turntable Cover. and/or hose end must be replaced
3 Gasoline/LPG models: Disconnect, drain and
plug the fuel hose.
Deutz Diesel models: Disconnect, drain and Hose and Fitting Torque
plug the supply and return fuel lines. Cap the Specifications.
fuel return fitting on the fuel tank.
1 Remove the fuel tank. See 10-1, How to
4 Remove the retaining fasteners from the fuel Remove the Fuel Tank.
tank hold down straps. Remove the straps from
the fuel tank.
5 Support the fuel tank with 2 lifting straps. Place
one lifting strap at each end of the tank and
attach the lifting straps to an overhead crane.
6 Remove the fuel tank from the machine.
Crushing hazard. The fuel tank
if it is not properly supported and
secured to the overhead crane.
Clean the fuel tank and inspect
for rust and corrosion before
installing.
Part No. 52271 Genie S-40 7 - 53

FUEL AND HYDRAULIC TANKS
2 Close the two hydraulic shutoff valves located 10 Remove the hydraulic tank from the machine.
at the hydraulic tank.
Crushing hazard. The hydraulic
if it is not properly supported and
secured to the overhead crane.
11 Remove the suction strainers from the tank and
clean them using a mild solvent.
12 Rinse out the inside of the tank using a mild
solvent.
open closed
13 Install the suction strainers using a thread
Component damage hazard. The sealant on the threads.
engine must not be started with 14 Install the drain plug using a thread sealant on
the hydraulic tank shutoff valves in the threads.
damage will occur. If the tank 15 Install the hydraulic tank onto the machine.
valves are closed, remove the key 16 Install the two suction hoses and the supply
from the key switch and tag the hose for the auxiliary power unit.
17 Fill the tank with hydraulic oil until the level is
condition.
within the top 2 inches (5 cm) of the sight
3 Remove the drain plug from the hydraulic tank. gauge. Do not overfill.
4 Completely drain the tank into a suitable 18 Clean up any oil that may have spilled and open
container. See capacity specifications. the hydraulic tank valves.
5 Tag, disconnect and plug the two suction hoses Component damage hazard.
that are attached to the hydraulic tank Be sure to open the two hydraulic
shutoff valves. tank valves and prime the pump
after installing the hydraulic tank.
6 Disconnect and plug the T-fitting located at the
return filter with the 2 hoses connected to it. Always use pipe thread sealant
Cap the fitting on the return filter housing. when installing the drain plug.
7 Disconnect and plug the supply hose for the Use only Dexron II equivalent
auxiliary power unit. Cap the fitting on the hydraulic fluid.
hydraulic tank.
Hydraulic system
8 Remove the retaining fasteners from the
hydraulic tank hold down straps. Remove the
Hydraulic tank capacity 45 gallons
straps from the hydraulic tank. 170 liters
9 Support the hydraulic tank with 2 lifting straps.
Place one lifting strap at each end of the tank Hydraulic system 55 gallons
and attach the lifting straps to an overhead capacity (including tank) 208 liters
crane.
Hydraulic fluid Dexron equivalent
7 - 54 Genie S-40 Part No. 52271

FUEL AND HYDRAULIC TANKS
How to Prime the Pump Deutz Diesel models: Hold the manual fuel
shutoff valve clockwise to the CLOSED position.
Component damage hazard. Be
sure that the hydraulic tank shutoff a
valves are in the OPEN position
before priming the pump. The
engine must not be started with
the hydraulic tank shutoff valves in
valves are closed, remove the key
condition.
gauge to the test port on the drive pump.
a manual fuel shutoff valve
2 Gasoline/LPG models: Disconnect the
electrical connector at the ignition coils. The 3 Crank the engine with the starter motor for
ignition coils are located above the alternator. 15 seconds, wait 15 seconds, then crank the
engine an additional 15 seconds or until the
Electrocution hazard. pressure reaches 320 psi (22 bar).
Contact with electrically charged
circuits may cause death or 4 Connect the wiring and start the engine from
serious injury. Remove all rings, the ground controls. Check for hydraulic leaks.
watches and other jewelry.
Part No. 52271 Genie S-40 7 - 55

Turntable Rotation Components

from the motor, brake and manifold. Cap the
Rotation Hydraulic Motor fittings on the motor, brake and manifold.
Bodily injury hazard.
How to Remove the Rotation Spraying hydraulic oil can
Hydraulic Motor penetrate and burn skin. Loosen
hydraulic connections very slowly
to allow the oil pressure to
dissipate gradually. Do not
allow oil to squirt or spray.
during installation. Refer to 3 Remove the motor/brake mounting fasteners,
Section Two, Hydraulic Hose and then remove the motor from the brake.
Fitting Torque Specifications.
a b
1 Secure the turntable from rotating with the
d
f
Unlocked position
e
a motor/brake mounting bolts

b motor
c brake
d torque hub mounting bolts
e torque hub
f plug
Locked position
7 - 56 Genie S-40 Part No. 52271

TURNTABLE ROTATION COMPONENTS
How to Remove the Turntable 4 Remove the plug from the side of the torque
hub. Then drain the oil from the hub.
Rotation Brake or Torque Hub
5 Install the torque hub. Torque the hub mounting
1 Secure the turntable from rotating with the bolts to 180 foot-pounds (244 Newton meters).
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.
Turntable rotate torque hub
Capacity 8 fluid ounces

0.24 liters
unlocked locked
Type: SAE 90 multipurpose hypoid gear oil - API
2 Remove the motor/brake mounting bolts, and service classification GL5
then remove the motor and brake from the
torque hub and set them to the side.
Hoses can be damaged if they are
kinked or pinched.
a b
f
c
d
e
a motor/brake mounting bolt

b motor
c torque hub
d torque hub mounting bolt
e plug
f brake
3 Remove the torque hub mounting bolts, and

then use a lifting device to remove the torque
hub from the machine.
Part No. 52271 Genie S-40 7 - 57


12-1 5 Remove the lug nuts. Then remove the tire
and wheel assembly.
Yoke and Hub
yoke pivot pins.
How to Remove the Yoke
and Hub 7 Support the yoke/hub assembly with a lifting
jack.
1 Remove the pin retaining fastener from the
8 Use a slide hammer to remove the upper yoke
steering cylinder rod-end pivot pin and remove
pivot pin, then use a soft metal drift to drive the
the cotter pin from the tie rod clevis pin.
lower yoke pivot pin down and out.
Remove the pins.
Crushing hazard. The yoke/hub
Always use a new cotter pin when
assembly may become
installing a clevis pin.
unbalanced and fall when the yoke
a b c d pivot pins are removed if it is not
properly secured and supported
by the lifting jack.
Torque specifications
Lug nut torque, dry 125 ft-lbs

169.5 Nm
Lug nut torque, lubricated 94 ft-lbs

127.4 Nm
How to Remove the

Hub and Bearings
1 Loosen the wheel lug nuts. Do not remove
g f f e
them.
2 Block the non-steering wheels and place a
a tie rod lifting jack of ample capacity under the steering
b axle axle.
c yoke pivot pin
d yoke 3 Raise the machine 6 inches (15 cm) and place
e hub blocks under the chassis for support.
f pivot pin
g steering cylinder 4 Remove the lug nuts. Then remove the tire
and wheel assembly.
2 Loosen the wheel lug nuts. Do not
remove them. 5 Remove the dust cap, cotter pin and
slotted nut.
3 Block the non-steering wheels, and then
center a lifting jack of ample capacity under the 6 Pull the hub off the spindle. The washer and
steering axle. outer bearing should fall loose from the hub.
7 Place the hub on a flat surface and gently pry
4 Raise the machine 6 inches (15 cm) and place
the bearing seal out of the hub. Remove the
blocks under the chassis for support.
rear bearing.
7 - 58 Genie S-40 Part No. 52271
2WD STEERING AXLE COMPONENTS
How to Install the 12-2

Hub and Bearings Steering Cylinders
When replacing a wheel bearing,
both the inner and outer bearings How to Remove a
including the pressed-in races Steering Cylinder
must be replaced.
There are two identical steering cylinders that
1 Be sure that both bearings are packed work in parallel. They are part of the same
with clean, fresh grease. hydraulic circuit, but move in opposite directions.
2 Place the large inner bearing into the rear The tie rod maintains equal movement of the tires.
of the hub. When removing a hose assembly
3 Press the bearing seal evenly into the hub or fitting, the O-ring on the fitting
until it is flush. and/or hose end must be replaced
4 Slide the hub onto the yoke spindle. during installation.
Component damage. Do not Refer to Section Two, Hydraulic
apply excessive force or damage Hose and Fitting Torque
to the lip of the seal may occur. Specifications.
5 Place the outer bearing into the hub. 1 Tag, disconnect and plug the hydraulic hoses
from the steering cylinder. Cap the fittings on
6 Install the washer and slotted nut. the cylinder.
7 Tighten the slotted nut to 35 foot-pounds Bodily injury hazard. Spraying
(47 Nm) to seat the bearing. hydraulic oil can penetrate and
8 Loosen the slotted nut, then re-tighten to burn skin. Loosen hydraulic
8 foot-pounds (11 Nm). connections very slowly to allow
9 Install a new cotter pin. Bend the cotter pin gradually. Do not allow oil to
to lock it in. squirt or spray.
10 Install the dust cap, then the tire and wheel 2 Remove the pin retaining fastener from the rod-
assembly. Torque the wheel lug nuts to end pivot pin of the steer cylinder. Remove the
125 foot-pounds (169.5 Nm). pin.
3 Remove the cotter pin from the barrel-end
clevis pin of the steer cylinder then remove the
pin.
Always use a new cotter pin when
installing a clevis pin.
4 Remove the steering cylinder from the machine.
Part No. 52271 Genie S-40 7 - 59

12-3 6 Slide the tie rod off the yoke and adjust it by
turning the end.
Tie Rod
One half turn on the adjustable
end equals approximately 1/4 inch
How to Remove the Tie Rod (6.4 mm) change in the front
1 Remove the cotter pins from the clevis pins at and rear measurements.
each end of the tie rod, then remove the clevis 7 Slide the tie rod onto the yoke. Install the
pins. pivot pin, then install the retaining bolt.
2 Remove the tie rod. 8 Tighten the jam nut against the tie rod.
How to Perform the Toe-in 9 Lower the machine and recheck the
Adjustment front and back measurements (step 2).
If further adjustment is needed, repeat
Perform this procedure on a steps 3 through 8.
firm, level surface. Block the
non-steering tires and be sure Toe-in specification 0 ± 1/8 inch (6.35 mm)
that the machine is in the
stowed position.
1 Straighten the steer wheels.
2 Measure the steer tires, front to front and back
to back, using a measuring fixture.
3 Center a lifting jack of ample capacity under the

steering axle, then raise the machine.
4 Loosen the jam nut on the adjustable end
of the tie rod.
5 Remove the pin retaining fasteners, then
remove the pivot pin from the adjustable end of
the tie rod.
7 - 60 Genie S-40 Part No. 52271


from the drive motor. Cap the fittngs on the
Yoke and Hub drive motor.
How to Remove the Yoke hydraulic oil can penetrate and
and Hub burn skin. Loosen hydraulic
The yoke installation utilizes bushings and a thrust
washer that may require periodic replacement. The
yoke must be removed before the torque hub can
squirt or spray.
be removed.
3 Loosen the wheel lug nuts. Do not
When removing a hose assembly remove them.
and/or hose end must be replaced 4 Block the non-steering wheels, and then
and then torqued to specification center a lifting jack of ample capacity under the
during installation. steering axle.
Refer to Section Two, Hydraulic 5 Raise the machine 6 inches (15.2 cm) and
Hose and Fitting Torque place blocks under the chassis for support.
Specifications.
6 Remove the lug nuts, then remove the tire and
1 Remove the pin retaining fasteners from both wheel assembly.
the steering cylinder and the tie rod pivot pins.
Remove the pins. 7 Remove the hydraulic hose clamp retaining
a fastener from the top of the yoke.
8 Remove the drive motor mounting fasteners.
9 Slide the drive motor shaft out of the torque hub
and then remove the drive motor from the
b machine.
upper and lower yoke pivot pins.
11 Support the yoke/torque hub assembly with a
lifting jack. Secure the yoke/torque hub
c assembly to the lifting jack.
12 Use a slide hammer to remove the upper yoke
pivot pin, then use a soft metal drift to drive the
g f e d
lower yoke pivot pin down and out.
a oscillate cylinder
Crushing hazard. The yoke/hub
b yoke pivot pin
c torque hub assembly may become
d yoke unbalanced and fall when the yoke
e pivot pin pivot pins are removed if it is not
f steer cylinder
properly secured and supported
g tie rod
by the lifting jack.
Part No. 52271 Genie S-40 7 - 61

13 Place the yoke/torque hub assembly on a flat 13-2

surface with the torque hub facing down.
Steering Cylinders
14 Remove the torque hub mounting fasteners that
attach the yoke to the torque hub. Remove the
yoke weldment from the torque hub.
How to Remove a
Steering Cylinder
Replace the thrust washer when
installing the yoke/torque hub This procedure is the same as the 2WD procedure.
assembly onto the axle. See repair procedure 12-2,
How to Remove a Steering Cylinder.
Lug nut,
dry 125 ft-lbs 169.5 Nm 13-3
lubricated 94 ft-lbs 127.4 Nm
Tie Rod
Torque hub mounting bolts,
dry 120 ft-lbs 163 Nm How to Remove the Tie Rod
lubricated 90 ft-lbs 122 Nm
This procedure is the same as the 2WD procedure.
Drive motor mounting bolts, See Repair Procedure 12-3,
dry 75 ft-lbs 102 Nm How to Remove the Tie Rod.
How to Perform the Toe-in
Adjustment
This procedure is the same as the 2WD procedure.
See Repair Procedure 12-3,
How to Perform the Toe-in Adjustment.
7 - 62 Genie S-40 Part No. 52271

Oscillating Axle Components

14-1 3 Tag, disconnect and plug the oscillating axle
cylinder hydraulic hoses. Cap the fittings on the
Oscillating Axle oscillate cylinder.
Lock-out Cylinders Bodily injury hazard. Spraying
The oscillating axle cylinders extend and retract burn skin. Loosen hydraulic
between the drive chassis and the oscillating axle. connections very slowly to allow
The cylinders are equipped with counterbalance the oil pressure to dissipate
valves to prevent movement in the event of a gradually. Do not allow oil to squirt
hydraulic line failure. The valves are not or spray.
adjustable.
How to Remove an Oscillating rod-end pivot pin. Use a soft metal drift to
remove the pin.
Axle Cylinder
5 Attach a lifting strap from an overhead crane to
This procedure requires specific
the barrel end of the oscillating cylinder.
repair skills and a suitable
workshop. Attempting this 6 Remove the pin retaining fasteners from the
procedure without these skills barrel-end pivot pin. Use a soft metal drift to
and tools may result in death or remove the pin.
serious injury and significant
Crushing hazard. The oscillate
cylinder may become unbalanced
and fall when it is removed from
Perform this procedure on a firm, the machine if it is not properly
level surface with the boom in attached to the overhead crane.
the stowed position.
7 Remove the cylinder from the machine.
Specifications.
1 Rotate the boom until the boom is between the
steer tires.
2 Remove the fasteners from drive chassis cover
at the steer end. Remove the cover.
Part No. 52271 Genie S-40 7 - 63

Non-steering Axle Components

15-1 3 Remove the drive motor mounting fasteners.
Drive Motor 4 Slide the drive motor shaft out of the brake and
then remove the drive motor from the machine.
How to Remove a Drive Motor Torque specifications
Repairs to the motor should only Drive motor mounting bolts 75 ft-lbs
be performed by an authorized 102 Nm
Sundstrand-Sauer dealer.
Component damage hazard. The
work area and surfaces where this
procedure will be performed must
be clean and free of debris that 15-2
could get into the hydraulic system Torque Hub
and cause severe component
damage. Dealer service is
recommended. How to Remove a Drive
Torque Hub
or fitting, the O-ring on the fitting When removing a hose assembly
and/or hose end must be replaced or fitting, the O-ring on the fitting
and then torqued to specification and/or hose end must be replaced
during installation. and then torqued to specification
Refer to Section Two, Hydraulic during installation.
Hose and Fitting Torque Refer to Section Two, Hydraulic
Specifications. Hose and Fitting Torque
1 Remove the fasteners from cover on the non- Specifications.
steer axle. Remove the cover. 1 Remove the drive motor. See 16-1, How to
2 Tag, disconnect and plug the hydraulic hoses Remove a Drive Motor.
from the drive motor. Cap the fittings on the
2 Tag, disconnect and plug the hydraulic hose
drive motor.
from the brake. Then remove the hydraulic
Bodily injury hazard. Spraying fitting and the bleed valve.
burn skin. Loosen hydraulic 3 Loosen the wheel lug nuts. Do not remove
connections very slowly to allow them.
the oil pressure to dissipate 4 Center a lifting jack of ample capacity under the
gradually. Do not allow oil to squirt non-steering axle. Raise the machine and place
or spray. blocks under the drive chassis for support.
5 Remove the wheel lug nuts, then the tire and
wheel assembly.
6 Place a second lifting jack under the torque hub
for support and secure the torque hub to the
lifting jack.
7 - 64 Genie S-40 Part No. 52271

NON-STEERING AXLE COMPONENTS
7 Remove the torque hub mounting bolts that

attach the torque hub to the chassis. Remove
the torque hub.
Crushing hazard. The torque
hub may become unbalanced and
fall if it is not properly supported
and secured to the lifting jack.
Lug nut,
dry 125 ft-lbs 169.5 Nm
lubricated 94 ft-lbs 127.4 Nm
Torque hub mounting bolts,

dry 120 ft-lbs 163 Nm
Drive motor mounting bolts,

dry 75 ft-lbs 102 Nm
Part No. 52271 Genie S-40 7 - 65

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

Second Edition, First Printing

Important Genie North America

This service manual covers the Genie S-40 2WD

Basic mechanical, hydraulic and electrical skills

If you have any questions, please call Genie

ii Genie S-40 Part No. 52271

Many of the hazards identified in the operator's

Do Not Perform Maintenance

Part No. 52271 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. 52271

Section One Safety Rules

Section Two Specifications

Section Three Scheduled Maintenance Inspections

Section Four Scheduled Maintenance Procedures

Part No. 52271 Genie S-40 v

Section Four Scheduled Maintenance Procedures, continued

vi Genie S-40 Part No. 52271

Section Four Scheduled Maintenance Procedures, continued

Part No. 52271 Genie S-40 vii

Section Five Troubleshooting Flow Charts

viii Genie S-40 Part No. 52271

Section Five Troubleshooting Flow Charts, continued

Section Six Schematics

Part No. 52271 Genie S-40 ix

Section Seven Repair Procedures

x Genie S-40 Part No. 52271

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

Part No. 52271 Genie S-40 xi

Section Seven Repair Procedures, continued

xii Genie S-40 Part No. 52271

Width 7 ft 6 in 7 ft 6 in Tires and wheels 2WD

Wheelbase 7 ft 3 in 7 ft 3 in Lug nut torque

Part No. 52271 Genie S-40 2-1

Performance Specifications Boom function speeds, maximum

Gradeability (boom stowed) 2WD 4WD

Rough terrain 30% 40%

2-2 Genie S-40 Part No. 52271

Hydraulic Specifications Function pump

Hydraulic fluid Dexron equivalent Type: pressure balanced gear

Drive pump Displacement - static 1.14 cu in

4WD rear motor 5 to 15 gallons per minute Auxiliary pump

Part No. 52271 Genie S-40 2-3

Ford Engine LRG-423 Starter motor

Displacement 140 cu in Normal engine cranking speed 200 to 250 rpm

Compression ratio 9.4:1 Bolt torque 45 to 84 inch-pounds

Valve clearances - 0.035 to 0.055 inches Maximum commutator 0.005 inches

Lubrication system Battery

Oil pressure 40 to 60 psi Type 12V, Group 31

Oil viscosity requirements Reserve capacity @ 25A rate 200 minutes

Temperature below 60°F / 15.5°C 5W-30 Fuel pump

-10°F to 90°F / -23°C to 32°C 10W-30 Electronic solenoid 7 psi

Temperature above 20W-40 or 20W-50 Spark plug type Motorcraft AWSF-52C

2-4 Genie S-40 Part No. 52271