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Parts ManualRefer to inside cover for additional serial number information(from serial number 7001)Part No. 89721Rev DOctober 2006
October 2006Technical PublicationsSerial Number InformationGenie Industries has endeavored to deliver the highestdegree of accuracy possible. However, continuousimprovement of our products is a Genie policy.Therefore, product specifications are subject to changewithout notice.Genie Industries offers the following Parts Manuals forthese models:Readers are encouraged to notify Genie of errors andsend in suggestions for improvement. Allcommunications will be carefully considered for futureprintings of this and all other manuals.TitlePart No.Genie S-40 Parts Manual(before serial number 831) . 32223Genie S-40 and S-45 Parts Manual(from serial number 831 to 7000) . 52090Contact Us:Copyright 2004 by Genie Industries89721 Rev D October 2006Third Edition, Fourth Printingwww.genieindustries.come-mail: techsup@genieind.com"Genie" and "S" are registered trademarks ofGenie Industries in the USA and many othercountries.Printed on recycled paperPrinted in U.S.A.iiS-40 S-45Part No. 89721
October 2006How To Read Your Serial NumberModel: S-40S4006-12345Serial number:Model year: 2006 Manufacture date: 01/05/06Electrical schematic number: ES0274Machine unladen weight:Rated work load (including occupants): 500 lb / 227 kgMaximum number of platfrm occupants: 2Maximum allowable side force : 150 lb / 670 NMaximum allowable inclination of the chassis:0 degMaximum wind speed : 28 mph/ 12.5 m/sMaximum platform height : 60 ft 6 in/ 18.3 mS40 06 - 12345SequencenumberModelMaximum platform reach : 34 ft 3 in/ 10.4 mGradeability: N/AModel yearCountry of manufacture: USAThis machine complies with:ANSI A92.5CAN B.354.4Genie Industries18340 NE 76th StreetRedmond, WA 98052USASequence number(stamped on chassis)Serial label(located under cover)PN - 77055Part No. 89721S-40 S-45iii
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October 2006Table of Contents200 Drive Chassis Components, ContinuedThis manual is updated frequently. Each partsfigure listed below has a figure number and arevision letter. If a figure is updated with newinformation, the revision letter or ‘Rev’ isupdated (example: from Rev A to Rev B).Figure101.1Rev DescriptionB DecalsIf you have a printed manual, you can keep itup to date by downloading new figures from theGenie website at www.genieindustries.com.How To Read Your Serial Number . iiiParts Stocking List . ixHow To Order Parts . xiiOrder Form . xiiiElectronic VersionClick on the figure description below to viewthe figure.207.2B4WD Non-steer Axle(after serial number 7568)208.1BOscillation Control Valve300 Turntable Components301.1DHydraulic and Fuel Tanks Gasoline/LPG302.1EHydraulic and Fuel Tanks - Diesel303.1DFunction Manifold, Plug to Platformand Auxiliary Power Unit304.1GTurntable Rotator and HydraulicRotary Coupler Installation305.1CTurntable Rotation Drive Hub306.1BGround Control Box - View 1307.1BGround Control Box - View 2308.1DTurntable Covers - View 1(Tank Side)309.1DTurntable Covers - View 2(Engine Side)310.1DTurntable Covers - View 3311.1AWire Harness and Power CableAssemblies100 Decals101.1FDecals with Words102.1FDecals with Symbols400 Engine Components200 Drive Chassis Components401.1CPerkins 704-30 Engine - View 1(before serial number 7472)402.1APerkins 704-30 Engine - View 2(before serial number 7472)201.1B2WD Steer Axle Linkage,Oscillating Models403.1A202.1A2WD Steer Axle Linkage,Non-oscillating ModelsPerkins 704-30 Engine - View 3(before serial number 7472)404.1A203.1B2WD Steer Axle, Wheels and HubsPerkins 704-30 Engine - View 4(before serial number 7472)204.1D2WD Non-steer Axle(before serial number 7569)405.1DPerkins 404-22 Engine - View 1(after serial number 7471)204.2B2WD Non-steer Axle(after serial number 7568)406.1BPerkins 404-22 Engine - View 2(after serial number 7471)205.1B4WD Steer Axle Linkage407.1EPerkins 404-22 Engine - View 3(after serial number 7471)206.1C4WD Steer Axle - Wheels and Hubs408.1C207.1E4WD Non-steer Axle(before serial number 7569)Deutz F3L 1011F Engine - View 1(before serial number 7544)Part No. 89721Table of Contents continues on the next page.S-40 S-45v
October 2006Table of Contents409.1BDeutz F3L 1011F Engine - View 2(before serial number 7544)600 Platform Components601.1 DPlatform Installation - View 1410.1DDeutz F3L 1011F Engine - View 3(before serial number 7544)602.1EPlatform Installation - View 2603.1BPlatform Control Box - View 1411.1FDeutz F3L 2011 Engine - View 1(after serial number 7543)604.1FPlatform Control Box - View 2412.1EDeutz F3L 2011 Engine - View 2(after serial number 7543)605.1AJoystick Controllers700 Hydraulic Components413.1DFord LRG-425 EFI Engine - View 1(before serial number 7597)414.1BFord LRG-425 EFI Engine - View 2(before serial number 7597)415.1CFord LRG-425 EFI Engine - View 3(before serial number 7597)416.1GFord LRG-425 EFI Engine - View 1(from serial number 7597 to 11066)417.1DFord LRG-425 EFI Engine - View 2(from serial number 7597 to 11066)418.1EFord LRG-425 EFI Engine - View 3(from serial number 7597 to 11066)419.1AFord DSG-423 EFI Engine - View 1(after serial number 11066)420.1AFord DSG-423 EFI Engine - View 2(after serial number 11066)421.1AFord DSG-423 EFI Engine - View 3(after serial number 11066)422.1AFord DSG-423 EFI Engine - View 4(after serial number 11066)423.1BEngine Tray, Battery and FilterInstallation500 Boom Components501.1EBoom Lift and Master LevelingCylinder Installation502.1BBoom Assembly, S-40503.1BBoom Assembly, S-45504.1DCable Track Installation505.1DSlave Cylinder and Platform Rotator,S-40506.1DJib Boom and Platform Rotator,S-45vi701.1FFunction Manifold702.1BTraction Manifold(before serial number 7569)702.2BTraction Manifold(after serial number 7568)703.1BTwo-Speed/Brake Manifold704.1BJib Select, Platform Rotate andGenerator Manifolds705.1AOil Diverter Manifold (welder option)706.1AHydraulic Pumps707.1BHydraulic Hoses and Fittings - 2WDDrive and Steer System(before serial number 7569)707.2BHydraulic Hoses and Fittings - 2WDDrive and Steer System(after serial number 7568)708.1AHydraulic Hoses and Fittings - 4WDDrive and Steer System(before serial number 7569)708.2AHydraulic Hoses and Fittings - 4WDDrive and Steer System(after serial number 7568)709.1AHydraulic Hoses and Fittings Oscillate System710.1CHydraulic Hoses and Fittings Turntable711.1BHydraulic Hoses and Fittings Boom Components, S-40712.1BHydraulic Hoses and Fittings Boom Components, S-45713.1AHydraulic Hose and FittingCross-referenceS-40 S-45Part No. 89721
October 2006Table of Contents800 Accessories801.1DAlarm and Beacon Package,Drive Light Option802.1EPlatform Options803.1CGround and Platform Control BoxCovers Options804.1CPlatform Overload - European Models805.1CPlatform Half-Mesh and Pipe Cradle806.1BAir Line to Platform807.1BCold Start Package808.1GGenerator and Second LPG TankOptions809.1BHydraulic Hoses and Fittings Generator810.1CGauge Option811.1DPanel Cradle812.1BWelder Option, Chassis Components View 1813.1DWelder Option, Platform Components View 2814.1BHoses and Fittings - Welder815.1BHydraulic Oil Cooler Option816.1BHostile Environment Package - View 1817.1BHostile Environment Package - View 2818.1DHostile Environment Package - View 3819.1BHostile Environment Package - View 4820.1BHostile Environment Package - View 5Part No. 89721S-40 S-45vii
October 2006NotesviiiS-40 S-45Part No. 89721
October 2006Parts Stocking ListFord LRG-425 Models(from serial number 7597 to 11066):DescriptionRequired PartsThe following parts are required to performmaintenance procedures as outlined in theGenie S-40 and S-45 Service Manual.Part No.Fuel Pre-Filter . 52179Fuel Pressure Regulator Filter . 58967Perkins 704-30 Models (before serial number 7472):DescriptionPart No.Engine Oil Filter . 28656Air Filter Element . 62420Serpentine Belt . 52580Fuel Filter Element . 62421PCV Valve . 33957Fuel/water Separator Filter . 65853Spark Plug (pack of 4) . 106490Engine Oil Filter . 62422Ford DSG-423 EFI Models(after serial number 11066):DescriptionV-Belt . 62423Perkins 404-22 Models (after serial number 7471):DescriptionPart No.Air Filter Element . 62420Fuel Filter Element . 62421Air Filter Element . 77295Part No.Fuel Pre-Filter . 52761Fuel Pressure Regulator Filter . 119491Engine Oil Filter . 119139Fuel/water Separator Element . 62433Air Filter Element . 77295Engine Oil Filter . 94762Serpentine Belt . 119138V-Belt . 89765PCV Valve . 119474Deutz F3L-1011F Models (before serial number 7544):DescriptionPart No.Spark Plug . 119467Air Filter Element . 62420Spark Plug (pack of 4) . 119495Fuel/water Separator Filter . 29560Recommended PartsEngine Oil Filter . 49924Genie Gray Paint, 12 Ounce / 355ml Aerosol . 1268V-Belt . 32698Deutz F3L-2011 Models (after serial number 7543):DescriptionPart No.Air Filter Element . 62420In-line Fuel Strainer . 70496Genie Blue Paint, 12 Ounce / 355ml Aerosol . 1484Genie Blue Paint, 1 gallon / 3.78 liters . 32150Genie Gray Paint, 1 gallon / 3.78 liters . 32151Parts Stocking List continues on the next page.Fuel/water Separator Filter . 29560Engine Oil Filter . 49924V-Belt . 32698Ford LRG-425 Models (before serial number 7597):DescriptionPart No.Fuel Pre-Filter . 52179Fuel Pressure Regulator Filter . 58967Engine Oil Filter . 28656Air Filter Element . 62420Serpentine Belt . 52580PCV Valve . 33957Spark Plug . 28647Part No. 89721S-40 S-45ix
October 2006Parts Stocking ListManualsGenie Industries offers the following supportdocuments for these models:TitlePart No.Genie S-40, S-45Operator’s Manual(before serial number 7190) . 43645Genie S-40, S-45Operator’s Manual(from serial number 7190 to 9752) . 82500Genie S-40, S-45Operator’s Manual(after serial number 9752) . 1000056Genie S-40Service Manual(before serial number 3804) . 32222Genie S-40Service Manual(from serial number 3804 to 4728) . 52271Genie S-40, S-45Service Manual(from serial number 4728 to 7000) . 72136Genie S-40, S-45Service Manual(from serial number 7001) . 102521EMI Safety Manual . 27581Manual of ResponsibilitiesANSI A92.5 . 31779xS-40 S-45Part No. 89721
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October 2006How To Order PartsPlease be prepared with the following informationwhen ordering replacement parts for your Genieproduct:Machine model numberMachine serial numberGenie part numberPart description and quantityPurchase order number"Ship to" addressDesired method of shipmentName and telephone number of the authorizedGenie Distributor in your areaUse the Service Parts Fax Order Form on the nextpage and fax your order to our Parts Department.Genie North AmericaTelephone (425) 556-6551Toll Free (877) 367-5606 in U.S.A. and CanadaFax (425) 556-8659Genie UKParts Telephone (44) (0) 1476 584352Parts Fax (44) (0) 1476 584340Genie AustraliaParts Telephone (617) 03375 1660Parts Fax (617) 03375 1002Genie FranceParts Telephone (33) (0) 237 26 09 99Parts Fax (33) (0) 237 31 50 10Genie GermanyParts Telephone (49) (0) 4202 885223Parts Fax (49) (0) 4202 885225Machine InformationModelSerial NumberDate of PurchaseAuthorized Genie DistributorPhone NumberGenie ScandinaviaParts Telephone (46) (31) 3409612Parts Fax (46) (31) 3409613Genie IbericaParts Telephone (34) (93) 5795042Genie BrazilParts Telephone (55) (114) 1665755Parts Fax (55) (114) 1665754Genie JapanParts Telephone
412.1 E Deutz F3L 2011 Engine - View 2 (after serial number 7543) 413.1 D Ford LRG-425 EFI Engine - View 1 (before serial number 7597) 414.1 B Ford LRG-425 EFI Engine - View 2 (before serial number 7597) 415.1 C Ford LRG-425 EFI Engine - View 3 (before serial number 7597) 416.1 G Ford LRG-425 EFI Engine - View 1 (from serial number 7597 to 11066)
