Genie S-40 Boom Lifts For Sale Instruction Manual
- August 19, 2024
- GENIE
Table of Contents
Genie S-40 Boom Lifts For Sale
Specifications
- Serial Number Range: S-40 S-45 (From 14678)
- Regions: North America, South America, Asia
- Edition: Fifth Edition, Sixth Printing
- Part Number: 133026
- Compliance: ANSI/SIA 92.5 CSA B.354.4
Safety Rules and Operating Instructions
Before operating the machine, ensure you have read, understood, and obeyed the safety rules and operating instructions provided in the manual. Only trained and authorized personnel should operate the machine.
Important Points to Note
- This manual is an essential part of the machine and should be kept with the machine at all times.
- Contact the provided support in case of any questions.
Hazard Classification
The machine’s decals use symbols, color coding, and signal words to indicate different levels of hazards. Pay attention to these warnings to avoid injury or damage.
Intended Use
The machine is designed to lift personnel, tools, and materials to aerial work sites. It should be used for this specific purpose only.
FAQs
Q: What should I do before operating the machine?
A: Before operating, ensure you have learned and practiced safe machine
operation principles, performed a pre-operation inspection, conducted function
tests, inspected the workplace, and are properly trained to operate the
machine.
Q: What do the different hazard symbols mean?
A: The symbols indicate potential hazards – DANGER signifies a hazardous
situation leading to death or serious injury, WARNING indicates potential
serious injury, CAUTION warns of minor/moderate injury, and NOTICE conveys
property damage messages.
Introduction
Owners, Users and Operators:
Thank you for choosing our machine for your application. Our number one
priority is user safety, which is best achieved by our joint efforts. We feel
that you make a major contribution to safety if you, as the equipment users
and operators:
1 Comply with employer, job site and governmental rules.
2 Read, understand and follow the instructions in this and other manuals
supplied with this machine.
3 Use good safe work practices in a commonsense way.
4 Only have trained/certified operators, directed by informed and
knowledgeable supervision, running the machine.
Symbol and Hazard Pictorials Definitions
Danger
Failure to obey the instructions and safety rules in this manual will result
in death or serious injury.
Do Not Operate Unless:
You learn and practice the principles of safe
machine operation contained in this operator’s manual.
1 Avoid hazardous situations.
Know and understand the safety rules before going on to the next section.
2 Always perform a pre-operation inspection.
3 Always perform function tests prior to use.
4 Inspect the workplace.
5 Only use the machine as it was intended.
You read, understand and obey the
manufacturer’s instructions and safety rules–safety and operator’s manuals and
machine decals.
You read, understand and obey employer’s
safety rules and worksite regulations.
You read, understand and obey all applicable
governmental regulations.
You are properly trained to safely operate the
machine.
General Safety
Fifth Edition · Sixth Printing
Hazard Classification
Decals on this machine use symbols, color coding and signal words to identify
the following:
Safety alert symbol–used to alert you to potential personal injury hazards.
Obey all safety messages that follow this symbol to avoid possible injury or
death.
DANGER Indicates a hazardous situation
which, if not avoided, will result in death or serious injury.
WARNING Indicates a hazardous situation
which, if not avoided, could result in death or serious injury.
CAUTION Indicates a hazardous situation
which, if not avoided, could result in minor or moderate injury.
NOTICE Indicates a property damage
message.
Intended Use
This machine is intended to be used only to lift personnel, along with their
tools and materials to an aerial work site.
Safety Sign Maintenance
Replace any missing or damaged safety signs. Keep operator safety in mind at
all times. Use mild soap and water to clean safety signs. Do not use solvent-
based cleaners because they may damage the safety sign material.
WARNING
Crush Hazard Death or serious injury may result from platform crushing
personnel against boom.
Keep away from path of moving platform.
DANGER
Tip-over Hazard Altering or disabling limit switches can result in machine
tip-over. Machine tip-over will result in death or serious injury.
Do not alter or disable limit switch(s).
31060 C
28181
WARNING
97602
WARNING
Keep away from moving parts.
28161 C
Fall Hazard Death or serious injury may result from climbing or riding on boom.
Keep off this surface.
97875
28181 C
Explosion Hazard Death or serious injury can result from the use of ether or
other high energy starting aids.
31788
Do not use ether or other high energy starting aids on machines equipped with
glow plugs.
97602 B
DANGER
Explosion / Burn Hazard Ignition of explosive gases or contact with corrosive
acid will cause death, burns or blindness
Keep all open flames and sparks away. Wear personal protective equipment,
including face shield, gloves and long sleeve shirt.
READ MANUALS Read all manuals prior to operation.
DO NOT OPERATE equipment if you do not understand the information in the
manuals.
Consult your supervisor, the owner or the manufacturer.
31788 C
28181
114390 31060
28177
97875
114390
97602 28175 31788 28161
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Operator’s Manual
General Safety
82487 133067 82472
114251
82472
Fifth Edition · Sixth Printing
82671 82548
114251
133067
114251 A
82548
82472
82487
82487 B
82671
82472 B
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Operator’s Manual
General Safety
Part No. 133026
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Operator’s Manual
General Safety
114247
82548
82671
82473
82473 B
82472
82481
82481 B 82472 B
133067
Fifth Edition · Sixth Printing 114252
114252 A
114247 82548
82671
133067
133067 114252
82473 82481 82472
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Personal Safety
Personal Fall Protection
Personal fall protection equipment (PFPE) is required when operating this
machine. Occupants must wear a safety belt or harness in accordance with
governmental regulations. Attach the lanyard to the anchor provided in the
platform. Operators must comply with employer, job site and governmental rules
regarding the use of personal protective equipment. All PFPE must comply with
applicable governmental regulations, and must be inspected and used in
accordance with the PFPE manufacturer’s instructions.
Operator’s Manual
Personal Safety
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Operator’s Manual
Work Area Safety
Fifth Edition · Sixth Printing
Work Area Safety
Electrocution Hazards
This machine is not electrically insulated and will not provide protection
from contact with or proximity to electrical current.
Obey all local and governmental regulations regarding required clearance from
electrical power lines. At a minimum, the required clearance contained in the
chart below must be followed.
Keep away from the machine if it contacts energized power lines. Personnel on
the ground or in the platform must not touch or operate the machine until
energized power lines are shut off.
Do not operate the machine during lightning or storms.
Do not use the machine as a ground for welding.
Line Voltage 0 to 50KV 50 to 200KV 200 to 350KV 350 to 500KV 500 to 750KV 750 to 1000KV
Required Clearance
10 ft
3.05 m
15 ft
4.60 m
20 ft
6.10 m
25 ft
7.62 m
35 ft
10.67 m
45 ft
13.72 m
Allow for platform movement, electrical line sway or sag, and beware of strong or gusty winds.
Tip-over Hazards
Occupants, equipment and materials shall not exceed the maximum platform
capacity for the restricted or unrestricted range of motion.
Maximum platform capacity Maximum occupants
500 lbs 227 kg 2
The weight of options and accessories, such as pipe cradles, panel cradles and
welders, will reduce the rated platform capacity and must be subtracted from
the platform capacity. See the decals with the options and accessories.
If using accessories, read, understand and obey the decals, instructions and
manuals with the accessory.
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Operator’s Manual
Work Area Safety
Do not raise or extend the boom unless the machine is on a firm, level
surface.
Do not depend on the tilt alarm as a level indicator. The tilt alarm sounds in
the platform only when the machine is on a severe slope. If the tilt alarm
sounds when the platform is raised, use extreme caution. Identify the
condition of the boom on the slope as shown below. Follow the steps to lower
the boom before moving to a firm, level surface. Do not rotate the boom while
lowering.
If the tilt alarm sounds with the platform uphill: 1 Lower the boom. 2 Retract
the boom.
If the tilt alarm sounds with the platform downhill: 1 Retract the boom. 2
Lower the boom.
Do not raise the boom when wind speeds may exceed 28 mph / 12.5 m/s. If wind
speeds exceed 28 mph / 12.5 m/s when the boom is raised, lower the boom and do
not continue to operate the machine.
Do not operate the machine in strong or gusty winds. Do not increase the
surface area of the platform or the load. Increasing the area exposed to the
wind will decrease machine stability.
Use extreme care and slow speeds while driving the machine in the stowed
position across uneven terrain, debris, unstable or slippery surfaces and near
holes and drop-offs.
Do not drive the machine on or near uneven terrain, unstable surfaces or other
hazardous conditions with the boom raised or extended.
Do not use the machine as a crane.
Do not push the machine or other objects with the boom.
Do not contact adjacent structures with the boom.
Do not tie the boom or platform to adjacent structures.
Do not place loads outside the platform perimeter.
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Work Area Safety
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Do not push off or pull toward any object outside of the platform.
Maximum allowable side force ANSI & CSA 150 lbs / 667 N
Maximum allowable manual force AUS 90 lbs / 400N
Do not alter or disable machine components that in any way affect safety and
stability.
Do not replace items critical to machine stability with items of different
weight or specification.
Do not replace factory-installed tires with tires of different specification
or ply rating.
Do not modify or alter an aerial work platform without prior written
permission from the manufacturer. Mounting attachments for holding tools or
other materials onto the platform, toeboards or guard rail system can increase
the weight in the platform and the surface area of the platform or the load.
Do not place or attach fixed or overhanging loads to any part of this machine.
Do not place ladders or scaffolds in the platform or against any part of this
machine.
Do not transport tools and materials unless they are evenly distributed and
can be safely handled by person(s) in the platform. Do not use the machine on
a moving or mobile surface or vehicle. Be sure all tires are in good
condition, air-filled tires are properly inflated and lug nuts are properly
tightened. Do not use the platform controls to free a platform that is caught,
snagged or otherwise prevented from normal motion by an adjacent structure.
All personnel must be removed from the platform before attempting to free the
platform using the ground controls.
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Operation on Slopes Hazards
Do not drive the machine on a slope that exceeds the maximum uphill, downhill
or side slope rating of the machine. Slope rating applies only to machines in
the stowed position.
Maximum slope rating, stowed position, 2WD
Platform downhill Platform uphill Side slope
30% (17°) 15% (9°)
25% (14°)
Maximum slope rating, stowed position, 4WD
Platform downhill
40% (22°)
Platform uphill
40% (22°)
Side slope
25% (14°)
Note: Slope rating is subject to ground conditions and adequate traction. See Driving on a Slope in the Operating Instructions section.
Operator’s Manual
Work Area Safety
Fall Hazards
Occupants must wear a safety belt or harness in accordance with governmental
regulations. Attach the lanyard to the anchor provided in the platform.
Do not sit, stand or climb on the platform guard rails. Maintain a firm
footing on the platform floor at all times.
Do not climb down from the platform when raised.
Keep the platform floor clear of debris.
Lower the platform entry mid-rail or close the entry gate before operating.
Do not enter or exit the platform unless the machine is in the stowed position
and the platform is at ground level.
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Work Area Safety
Collision Hazards
Be aware of limited sight distance and blind spots when driving or operating.
Fifth Edition · Sixth Printing
Do not lower the boom unless the area below is clear of personnel and
obstructions.
Be aware of the boom position and tailswing when rotating the turntable.
Check the work area for overhead obstructions or other possible hazards.
Limit travel speed according to the condition of the ground surface, congestion, slope, location of personnel, and any other factors which may cause collision.
Be aware of crushing hazards when grasping the platform guard rail.
Do not operate a boom in the path of any crane unless the controls of the
crane have been locked out and/or precautions have been taken to prevent any
potential collision.
No stunt driving or horseplay while operating a machine.
Operators must comply with employer, job site and governmental rules regarding
use of personal protective equipment.
Observe and use the color-coded direction arrows on the platform controls and
drive chassis for drive and steer functions.
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Work Area Safety
Bodily Injury Hazard
Always operate the machine in a well-ventilated area to avoid carbon monoxide
poisoning.
Do not operate the machine with a hydraulic oil or air leak. An air leak or
hydraulic leak can penetrate and/or burn skin.
Improper contact with components under any cover will cause serious injury.
Only trained maintenance personnel should access compartments. Access by the
operator is only advised when performing a pre-operation inspection. All
compartments must remain closed and secured during operation.
Explosion and Fire Hazards
Do not start the engine if you smell or detect liquid petroleum gas (LPG),
gasoline, diesel fuel or other explosive substances.
Do not refuel the machine with the engine running.
Refuel the machine and charge the battery only in an open, well-ventilated
area away from sparks, flames and lighted tobacco.
Do not operate the machine or charge the battery in hazardous locations or
locations where potentially flammable or explosive gases or particles may be
present.
Do not spray ether into engines equipped with glow plugs.
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Work Area Safety
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Damaged Machine Hazards
Do not use a damaged or malfunctioning machine.
Conduct a thorough pre-operation inspection of the machine and test all
functions before each work shift. Immediately tag and remove from service a
damaged or malfunctioning machine.
Be sure all maintenance has been performed as specified in this manual and the
appropriate Genie service manual.
Be sure all decals are in place and legible.
Be sure the operator’s, safety and responsibilities manuals are complete,
legible and in the storage container located on the machine.
Component Damage Hazards
Do not use any battery or charger greater than 12V to jump-start the engine.
Do not use the machine as a ground for welding.
Do not operate the machine where extremely high magnetic fields may be
present.
Battery Safety
Burn Hazards
Batteries contain acid. Always wear protective clothing and eye wear when
working with batteries.
Avoid spilling or contacting battery acid. Neutralize battery acid spills with
baking soda and water.
Explosion Hazards
Keep sparks, flames and lighted tobacco away from batteries. Batteries emit
explosive gas.
Electrocution Hazard Avoid contact with electrical terminals.
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Work Area Safety
Welder Safety
Read, understand and obey all warnings and instructions provided with the
welding power unit.
Do not connect weld leads or cables unless the welding power unit is turned
off at the platform controls.
Do not operate unless the weld cables are properly connected and the welder is
properly grounded.
The weight of the welder will reduce the rated platform capacity and must be
factored into the total platform load. The welder power supply weighs 75 lbs /
34 kg.
Do not operate the welder unless a fire extinguisher is immediately available
for instant use, per OSHA regulation 1926.352(d).
Weld Line to Platform Safety
Read, understand and obey all warnings and instructions provided with the
welding power unit.
Do not connect weld leads or cables unless the welding power unit is turned
off at the platform controls.
Do not operate unless the weld cables are properly connected.
Connect the positive lead to the twist-lock connector at the turntable and
platform.
Clamp the negative lead to the ground post at the turntable and platform.
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Work Area Safety
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Pipe Cradle Safety
Read, understand and obey all warnings and instructions provided with the pipe
cradles.
Do not exceed the rated platform capacity. The pipe cradle assembly and the
weight in the pipe cradles will reduce rated platform capacity and must be
factored into total platform load.
The pipe cradle assembly weighs 21 lbs / 9.5 kg.
The maximum capacity of the pipe cradle assembly is 200 lbs / 91 kg.
The weight of the pipe cradle assembly and the load in the pipe cradles may
limit the maximum number of occupants in platform.
Center the load within the perimeter of the platform.
Secure the load to the platform.
Do not obstruct the entrance or the exit of the platform.
Do not obstruct the ability to operate the platform controls or the red
Emergency Stop button.
Do not operate unless you are adequately instructed and are aware of all of
the hazards associated with movement of the platform with an overhanging load.
Do not cause a horizontal force or side load to machine by raising or lowering
a fixed or overhanging load.
Electrocution Hazard: Keep pipes away from all energized electrical
conductors.
Panel Cradle Safety
Read, understand and obey all warnings and instructions provided with the
panel cradles.
Do not exceed the rated platform capacity. The combined weight of the cradles,
panels, occupants, tools and any other equipment must not exceed rated
capacity.
The panel cradle assembly weighs 30 lbs / 13.6 kg.
The maximum capacity of the panel cradles is 250 lbs / 113 kg.
The weight of the panel cradles and the load in the panel cradles may limit
the maximum number of occupants in platform to one person.
Secure the cradles to the platform. Secure the panel(s) to the platform
railing using the straps provided.
Do not operate unless you are adequately instructed and are aware of all
hazards associated with lifting panels.
Do not cause a horizontal force or side load to machine by raising or lowering
a fixed or overhanging load.
Maximum vertical height of panels: 4 ft / 1.2 m
Maximum wind speed:15 mph / 6.7 m/sec
Maximum panel area: 32 sq ft / 3 m2
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Work Area Safety
Tow Package Safety
Read, understand and obey all warnings and instructions provided with the tow
package.
When vehicle is in free-wheel configuration, there are no brakes and machine
may move, resulting in death, serious injury or property damage.
Do not exceed maximum towing speed, or maximum towing time.
Maximum tow speed
Maximum towing time at 6 mph / 10 km/h
Maximum towing time at 4.5 mph / 7.2 km/h
6 mph / 10 km/h 30 minutes 60 minutes
Lockout After Each Use
1 Select a safe parking location–firm level surface, clear of obstruction and
traffic.
2 Retract and lower the boom to the stowed position.
3 Rotate the turntable so that the boom is between the non-steer wheels.
4 Turn the key switch to the off position and remove the key to secure from
unauthorized use.
Ground Control Panel
1 LCD readout screen
Screen displays hour meter, voltage, oil pressure and coolant temperature.
Screen also displays fault codes and other service information.
2 Not used
3 Gasoline/LPG models: Fuel select switch
Move the fuel select switch to the gasoline position to select gasoline. Move
the fuel select switch to the LPG position to select LPG.
4 Check engine light
Light on and engine stopped: Tag the machine and remove from service. Light on
and engine still running: Contact service personnel within 24 hours.
5 Function enable switch
Move the function enable switch to either side to enable the functions on the
ground control panel to operate.
6 Engine start switch
Move the engine start switch to either side to start the engine.
7 Emergency power switch
Use emergency power if the primary power source (engine) fails. Simultaneously
hold the emergency power switch to either side and activate the desired
function.
8 Machine malfunction indicator light
Light on indicates all functions have stopped. See the instructions in the
Operating Instructions section.
9 Boom up/down switch
Move the boom up/down switch up and the boom will raise. Move the boom up/down
switch down and the boom will lower.
10 Function enable button
Press and hold the function enable button to enable the functions on the
ground control panel to operate.
11 Circuit breakers
12 Key switch for off/ground/platform selection
Turn the key switch to the off position and the machine will be off. Turn the
key switch to the ground position and the ground controls will operate. Turn
the key switch to the platform position and the platform controls will
operate.
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Operator’s Manual
Controls
13 Red Emergency Stop button
Push in the red Emergency Stop button to the off position to stop all
functions and turn the engine off. Pull out the red Emergency Stop button to
the on position to operate the machine.
14 Not used
15 Jib boom up/down switch
Move the jib boom switch up and the jib boom will raise. Move the jib boom
switch down and the jib boom will lower.
16 Platform level switch
Move the platform level switch up and the level of the platform will raise.
Move the platform level switch down and the level of the platform will lower.
17 Boom extend/retract switch
Move the boom extend/retract switch to the right and the boom will extend.
Move the boom extend/retract switch to the left and the boom will retract.
18 Platform rotate switch
Move the platform rotate switch to the right and the platform will rotate to
the right. Move the platform rotate switch to the left and the platform will
rotate to the left.
19 Turntable rotate switch
Move the turntable rotate switch to the right and the turntable will rotate to
the right. Move the turntable rotate switch to the left and the turntable will
rotate to the left.
20 Gasoline/LPG models: Coolant temperature gauge Models equipped with Deutz
diesel engine: Oil temperature gauge. Models equipped with Perkins diesel
engine: Coolant temperature gauge.
21 Oil pressure gauge
22 Voltage gauge
23 Hour meter
The hour meter displays the number of hours the machine has operated.
24 Deutz Diesel Models: Glow plug switch (if equipped)
Move the glow plug switch to either side and hold for 3 to 5 seconds.
Perkins Models: Glow plug indicator light.
25 15A breaker for engine electrical circuits
26 20A breaker for oil cooler and options
27 15A breaker for control electrical circuits
28 Not used
DRIVE ENABLE OPERATION
Light on indicates that boom has moved past a non-steer tire and drive
function is turned off. To drive, hold drive enable switch to side and slowly
move drive control handle. Machine may drive in opposite direction that drive
and steer controls are moved.
Use color-coded direction arrows on this panel and drive chassis to identify
the direction machine will travel.
Fifth Edition · Sixth Printing
Platform Control Panel
1 Horn button
Press this button and the horn will sound. Release the button and the horn
will stop.
2 Platform level switch
Move the platform level switch up and the level of the platform will raise.
Move the platform level switch down and the level of the platform will lower.
3 Platform rotate switch
Move the platform rotate switch to the right and the platform will rotate to
the right. Move the platform rotate switch to the left and the platform will
rotate to the left.
4 Jib boom up/down switch
Move the jib boom switch up and the jib boom will raise. Move the jib boom
switch down and the jib boom will lower.
5 Emergency power switch
Use emergency power if the primary power source (engine) fails. Simultaneously
hold the emergency power switch to either side and activate the desired
function.
6 Drive speed select switch
Machine on incline symbol: Low range operation for inclines. Machine on level
surface symbol: High range operation for maximum drive speed.
7 Deutz Diesel Models: Glow plug switch (if equipped)
Move the glow plug switch to either side and hold for 3 to 5 seconds.
Perkins Models: Glow plug indicator light.
8 Engine start switch
Move the engine start switch to either side to start the engine.
9 Engine idle (rpm) select switch
Move the engine idle select switch to the turtle position for foot switch
activated low idle. Move the engine idle select switch to the rabbit position
for foot switch activated high idle.
10 Gasoline/LPG models: Fuel select switch
Move the fuel select switch to the gasoline position to select gasoline. Move
the fuel select switch to the LPG position to select LPG.
11 Models with LCD screen: Engine shut-down indicator light
Light on indicates that the engine has shut down. Contact service personnel.
12 Red Emergency Stop button
Push in the red Emergency Stop button to the off position to stop all
functions and turn the engine off. Pull out the red Emergency Stop button to
the on position to operate the machine.
13 Dual axis proportional control handle for drive and steer functions OR
Proportional control handle for drive function and thumb rocker for steer
function.
Move the control handle in the direction indicated by the blue arrow on the
control panel and the machine will drive forward. Move the control handle in
the direction indicated by the yellow arrow and the machine will drive
backwards. Move the control handle in the direction indicated by the blue
triangle and the machine will steer to the left. Move the control handle in
the direction indicated by the yellow triangle and the machine will steer to
the right. OR Move the control handle in the direction indicated by the blue
arrow on the control panel and the machine will drive forward. Move the
control handle in the direction indicated by the yellow arrow and the machine
will drive backwards. Press the left side of the thumb rocker and the machine
will steer to the left. Press the right side of the thumb rocker and the
machine will steer to the right.
14 Not used
15 Machine not level indicator light (if equipped)
The machine not level indicator light will come on when the tilt alarm sounds.
16 Drive enable indicator light
Light on indicates that the boom has moved just past either non-steer wheel
and drive function has been interrupted.
17 Drive enable switch
To drive when the drive enable light is on, hold the drive enable switch to
either side and slowly move the drive control handle off center. Be aware that
the machine may move in the opposite direction that the drive and steer
controls are moved.
18 Boom extend/retract switch
Move the boom extend/retract switch to the right and the boom will extend.
Move the boom extend/retract switch to the left and the boom will retract.
19 Used for optional equipment
20 Dual axis proportional control handle for boom up/down and turntable rotate
left/right functions
Move the control handle up and the boom will raise. Move the control handle
down and the boom will lower.
Move the control handle to the right and the turntable will rotate to the
right. Move the control handle to the left and the turntable will rotate to
the left.
Inspections
Do Not Operate Unless:
You learn and practice the principles of safe
machine operation contained in this operator’s manual. 1 Avoid hazardous
situations. 2 Always perform a pre-operation
inspection. Know and understand the pre-operation inspection before going on
to the next section. 3 Always perform function tests prior to use. 4 Inspect
the workplace. 5 Only use the machine as it was intended.
Pre-operation Inspection Fundamentals
It is the responsibility of the operator to perform a pre-operation inspection
and routine maintenance.
The pre-operation inspection is a visual inspection performed by the operator
prior to each work shift. The inspection is designed to discover if anything
is apparently wrong with a machine before the operator performs the function
tests.
The pre-operation inspection also serves to determine if routine maintenance
procedures are required. Only routine maintenance items specified in this
manual may be performed by the operator.
Refer to the list on the next page and check each of the items.
If damage or any unauthorized variation from factory delivered condition is
discovered, the machine must be tagged and removed from service.
Repairs to the machine may only be made by a qualified service technician,
according to the manufacturer’s specifications. After repairs are completed,
the operator must perform a pre-operation inspection again before going on to
the function tests.
Scheduled maintenance inspections shall be performed by qualified service
technicians, according to the manufacturer’s specifications and the
requirements listed in the responsibilities manual.
Pre-operation Inspection
Be sure that the operator’s, safety and responsibilities manuals are complete,
legible and in the storage container located in the platform.
Be sure that all decals are legible and in place. See Inspections section.
Check for hydraulic oil leaks and proper oil level. Add oil if needed. See
Maintenance section.
Check for battery fluid leaks and proper fluid level. Add distilled water if
needed. See Maintenance section.
Check for engine oil leaks and proper oil level. Add oil if needed. See
Maintenance section.
Check for engine coolant leaks and proper level of coolant. Add coolant if
needed. See Maintenance section.
Check for proper tire pressure. Add air if needed. See Maintenance section.
Check the following components or areas for damage, improperly installed or
missing parts and unauthorized modifications:
Electrical components, wiring and electrical cables
Hydraulic hoses, fittings, cylinders and manifolds
Fuel and hydraulic tanks
Drive and turntable motors and drive hubs
ear pads Tires and wheels Engine and related components Limit switches and
horn Alarms and beacons (if equipped) Nuts, bolts and other fasteners Platform
entry mid-rail or gate
Check entire machine for:
Cracks in welds or structural components Dents or damage to machine Excessive
rust, corrosion or oxidation Be sure that all structural and other critical
components are present and all associated fasteners and pins are in place and
properly tightened. After you complete your inspection, be sure that all
compartment covers are in place and latched.
Do Not Operate Unless:
You learn and practice the principles of safe
machine operation contained in this operator’s manual.
1 Avoid hazardous situations.
2 Always perform a pre-operation inspection.
3 Always perform function tests prior to use.
Know and understand the function tests before going on to the next section.
4 Inspect the workplace.
5 Only use the machine as it was intended.
Function Test Fundamentals
The function tests are designed to discover any malfunctions before the
machine is put into service. The operator must follow the step-by-step
instructions to test all machine functions.
A malfunctioning machine must never be used. If malfunctions are discovered,
the machine must be tagged and removed from service. Repairs to the machine
may only be made by a qualified service technician, according to the
manufacturer’s specifications.
After repairs are completed, the operator must perform a pre-operation
inspection and function tests again before putting the machine into service.
At the Ground Controls
1 Select a test area that is firm, level and free of obstruction.
2 Turn the key switch to ground control.
3 Pull out the red Emergency Stop button to the on position.
Result: The beacons (if equipped) should flash.
4 Start the engine. See Operating Instructions section.
Test Emergency Stop
5 Push in the red Emergency Stop button to the off position.
Result: The engine should shut off and no functions should operate.
6 Pull out the red Emergency Stop button to the on position and restart the
engine.
Test the Hydraulic Return Filter
7 Move the engine idle select switch to high idle (rabbit symbol).
8 Locate and check the hydraulic filter condition indicator.
Result: The filter should be operating with the plunger or the needle in the
green area.
9 Move the engine idle select switch to foot switch activated high idle
(rabbit and foot switch symbol).
Test Machine Functions
10 Do not push the function enable button. Attempt to activate each boom and
platform function toggle switch.
OR
Do not hold the function enable switch to either side. Attempt to activate
each boom and platform function toggle switch.
Result: No boom and platform functions should operate.
11 Push and hold the function enable button and activate each boom and
platform function toggle switch. or
Push and hold the function enable switch to either side and activate each boom
and platform function toggle switch.
Result: All boom and platform functions should operate through a full cycle.
The descent alarm (if equipped) should sound while the boom is lowering.
Test the Tilt Sensor 12 Pull out the platform red Emergency Stop
button to the on position. Turn the key switch to platform control.
13 Open the tank side turntable cover and locate the tilt sensor next to the
control box.
14 Press down one side of the tilt sensor.
Result: The alarm, located in the platform, should sound.
Test Emergency Controls 15 Turn the key switch to ground control and shut
the engine off. 16 Pull out the red Emergency Stop button to the
on position.
17 Simultaneously hold the emergency power switch on and activate each boom
function toggle switch.
OR
At the Platform Controls
Test Emergency Stop 1 Enter the platform and pull out the red
Emergency Stop button. Start the engine. 2 Push in the platform red Emergency
Stop
button to the off position. Result: The engine should shut off and no
functions should operate. 3 Pull out the red Emergency Stop button and restart
the engine.
Test the Horn 4 Press the horn button.
Result: The horn should sound.
Note: To conserve battery power, test each function through a partial cycle.
Result: All boom functions should operate.
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Test the Foot Switch
5 Push in the platform red Emergency Stop button to the off position.
6 Pull out the red Emergency Stop button to the on position and do not start
the engine.
7 Press down the foot switch and attempt to start the engine by moving the
start toggle switch to either side.
Result: The engine should not start.
8 Do not press down the foot switch and restart the engine.
Result: The engine should start.
9 Do not press down the foot switch and test each machine function.
Result: No functions should operate.
Test Machine Functions
10 Press down the foot switch.
11 Activate each machine function control handle, toggle switch or button.
Result: All functions should operate through a full cycle.
Test the Steering
12 Press down the foot switch.
13 Press the thumb rocker switch on top of the drive control handle in the
direction indicated by the blue triangle on the control panel OR slowly move
the control handle in the direction indicated by the blue triangle.
Result: The steer wheels should turn in the direction that the blue triangles
point on the drive chassis.
14 Press the thumb rocker switch in the direction indicated by the yellow
triangle on the control panel OR slowly move the control handle in the
direction indicated by the yellow triangle.
Result: The steer wheels should turn in the direction that the yellow
triangles point on the drive chassis.
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Test Drive and Braking
15 Press down the foot switch.
16 Slowly move the drive control handle in the direction indicated by the blue
arrow on the control panel until the machine begins to move, then return the
handle to the center position.
Result: The machine should move in the direction that the blue arrow points on
the drive chassis, then come to an abrupt stop.
17 Slowly move the control handle in the direction indicated by the yellow
arrow on the control panel until the machine begins to move, then return the
handle to the center position.
Result: The machine should move in the direction that the yellow arrow points
on the drive chassis, then come to an abrupt stop.
Note: The brakes must be able to hold the machine on any slope it is able to
climb.
Test the Oscillating Axle (if equipped)
18 Start the engine from the platform controls.
19 Drive the right steer tire up onto a 6 in / 15 cm block or curb.
Result: The three remaining tires should stay in firm contact with the ground.
20 Drive the left steer tire up onto a 6 in / 15 cm block or curb.
Result: The three remaining tires should stay in firm contact with the ground.
21 Drive both steer tires up onto a 6 in / 15 cm block or curb.
Result: The non-steer tires should stay in firm contact with the ground.
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Test the Drive Enable System
22 Press down the foot switch and lower the boom to the stowed position.
23 Rotate the turntable until the boom moves past one of the non-steer tracks.
Result: The drive enable indicator light should come on and remain on while
the boom is anywhere in the range shown.
24 Move the drive control handle off center.
Result: The drive function should not operate.
25 Move and hold the drive enable toggle switch to either side and slowly move
the drive control handle off center.
Result: The drive function should operate.
Note: When the drive enable system is in use, the machine may drive in the
opposite direction that the drive and steer control handle is moved.
Use the color-coded direction arrows on the platform controls and the drive
chassis to identify the direction of travel.
Test Limited Drive Speed 26 Press down the foot switch. 27 Raise the boom to
just above horizontal.
28 Slowly move the control handle to full drive position. Result: The maximum
achievable drive speed with the boom raised should not exceed 1 ft / 30 cm per
second.
29 Lower the boom to the stowed position. 30 Extend the boom 1 foot / 30 cm.
31 Slowly move the control handle to full drive
position. Result: The maximum achievable drive speed with the boom extended
should not exceed 1 ft / 30 cm per second. If the drive speed with the boom
raised or extended exceeds 1 ft / 30 cm per second, immediately tag and remove
the machine from service.
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Test Emergency Controls
32 Shut off the engine.
33 Pull out the red Emergency Stop button to the on position.
34 Press down the foot switch.
35 Simultaneously hold the emergency power switch on and activate each
function control handle or toggle switch.
Note: To conserve battery power, test each function through a partial cycle.
Result: All boom and steer functions should operate. Drive functions should
not operate with emergency power.
Test the Lift/Drive Select Function (if equipped)
36 Press down the foot switch.
37 Move the drive control handle off center and activate a boom function
toggle switch.
Result: No boom functions should operate. The machine will move in the
direction indicated on the control panel.
Repair any malfunctions before operating the machine.
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Do Not Operate Unless:
You learn and practice the principles of safe
machine operation contained in this operator’s manual.
1 Avoid hazardous situations.
2 Always perform a pre-operation inspection.
3 Always perform function tests prior to use.
4 Inspect the workplace.
Know and understand the workplace inspection before going on to the next
section.
5 Only use the machine as it was intended.
Workplace Inspection Checklist
Be aware of and avoid the following hazardous situations:
drop-offs or holes bumps, floor obstructions or debris sloped surfaces
unstable or slippery surfaces overhead obstructions and high voltage
conductors hazardous locations inadequate surface support to withstand all
load forces imposed by the machine wind and weather conditions the presence of
unauthorized personnel other possible unsafe conditions
Workplace Inspection Fundamentals
The workplace inspection helps the operator determine if the workplace is
suitable for safe machine operation. It should be performed by the operator
prior to moving the machine to the workplace.
It is the operator’s responsibility to read and remember the workplace
hazards, then watch for and avoid them while moving, setting up and operating
the machine.
References
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