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Operator's Manual Serial Number Range -40 XC ® ™ from S40XCH-101 ANSI/CSA from S45XCH-101 North America -45 XC ® ™ South America Asia -40 HF ® -45 HF ® -40 TRAX ® ™ -45 TRAX with ® ™ Maintenance Information Original Instructions First Edition Third Printing...
First Edition: Third Printing, November 2022 Genie and "S" are registered trademarks of Terex South Dakota, Inc. in the U.S.A. and many other countries. "XC" and "TraX" are trademarks of Terex South Dakota, Inc. These machines comply with ANSI/SAIA A92.20 CAN/CSA B354.6...
First Edition • Third Printing Operator's Manual Introduction Intr oducti on About this manual Intended Use and Familiarization Guide Genie appreciates your choice of our machine for your application. Our number one priority is user The intended use of this machine is to lift safety, which is best achieved by our joint efforts.
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Operator's Manual First Edition • Third Printing Introduction Platform controls symbology and related Ground controls symbology and related machine movement: machine movement: Platform level Platform level, jib boom up/down, boom extend/retract,and boom up/down Platform rotate Turntable rotate and platform rotate Jib boom up/down Sequential functions and movement: Drive and steer.
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First Edition • Third Printing Operator's Manual Introduction Bulletin Distribution and Contacting the Manufacturer Compliance At times it may be necessary to contact Genie. When you do, be ready to supply the model Safety of product users is of paramount number and serial number of your machine, along importance to Genie.
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Operator's Manual First Edition • Third Printing Introduction 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.
First Edition • Third Printing Operator's Manual Symbol and Hazard Pictorials Definitions Symbol and H az ard Pictorials Definiti ons Fire hazard Explosion hazard Explosion hazard Do not use ether or No smoking. other high energy No flame. starting aids on Stop engine.
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Operator's Manual First Edition • Third Printing Symbol and Hazard Pictorials Definitions Wheel load Wind speed Maximum capacity Manual force Weight of welder reduces capacity Tie-down point Lifting point Platform tie-down Lifting and tie down Lanyard anchorage instructions instructions points Corrosive acid.
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First Edition • Third Printing Operator's Manual Symbol and Hazard Pictorials Definitions Electrocution hazard Avoid contact Disconnect battery Voltage rating for Pressure rating for air power to platform line to platform Crush hazard Support the platform Read the service Explosion hazard Relieve all pressure manual or boom during...
Operator's Manual First Edition • Third Printing General Safety Gener al Safety These decals are model, option or configuration specific. Pictures in this manual may show a boom with tires and wheels instead of tracks. All safety information and operating instructions still apply to the S-40 TRAX and the S-45 TRAX, even if the picture does not show the tracks.
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First Edition • Third Printing Operator's Manual General Safety These decals are model, option or configuration specific. Pictures in this manual may show a boom with tires and wheels instead of tracks. All safety information and operating instructions still apply to the S-40 TRAX and the S-45 TRAX, even if the picture does not show the tracks.
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Operator's Manual First Edition • Third Printing General Safety These decals are model, option or configuration specific. Pictures in this manual may show a boom with tires and wheels instead of tracks. All safety information and operating instructions still apply to the S-40 TRAX and the S-45 TRAX, even if the picture does not show the tracks.
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First Edition • Third Printing Operator's Manual General Safety These decals are model, option or configuration specific. Pictures in this manual may show a boom with tires and wheels instead of tracks. All safety information and operating instructions still apply to the S-40 TRAX and the S-45 TRAX, even if the picture does not show the tracks.
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Operator's Manual First Edition • Third Printing General Safety These decals are model, option or configuration specific. Pictures in this manual may show a boom with tires and wheels instead of tracks. All safety information and operating instructions still apply to the S-40 TRAX and the S-45 TRAX, even if the picture does not show the tracks.
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First Edition • Third Printing Operator's Manual General Safety These decals are model, option or configuration specific. Pictures in this manual may show a boom with tires and wheels instead of tracks. All safety information and operating instructions still apply to the S-40 TRAX and the S-45 TRAX, even if the picture does not show the tracks.
Operator's Manual First Edition • Third Printing Personal Safety Pers onal 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.
First Edition • Third Printing Operator's Manual Work Area Safety Allow for platform movement, electrical line sway Work Ar ea Safety Electrocution Hazards or sag, and beware of strong or gusty winds. Pictures in this manual may show a boom with Keep away from the tires and wheels instead of tracks.
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Operator's Manual First Edition • Third Printing Work Area Safety If using accessories, read, understand and obey S-40 XC, S-45 XC, S-40 TRAX, S-45 TRAX: If the the decals, instructions and manuals with the platform load is greater than 660 lbs/300 kg, do accessory.
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First Edition • Third Printing Operator's Manual Work Area Safety If the tilt alarm sounds when the platform is raised, Do not raise the boom use extreme caution. The machine not level when wind speeds may indicator light will come on and the drive function exceed 28 mph/12.5 m/s.
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Operator's Manual First Edition • Third Printing Work Area Safety Do not drive the machine on or near uneven S-40 XC and S-45 XC: Do not replace factory- terrain, unstable surfaces or other hazardous installed tires with tires of different specification or conditions with the boom raised or extended.
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First Edition • Third Printing Operator's Manual Work Area Safety Operation on Slopes Hazards Do not place or attach fixed or overhanging loads Do not drive the machine on a slope that exceeds to any part of this the maximum uphill, downhill or side slope rating machine.
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Operator's Manual First Edition • Third Printing Work Area Safety Fall Hazards Collision Hazards Occupants must wear a Be aware of limited sight safety belt or harness in distance and blind spots accordance with when driving or operating. governmental regulations. Attach the lanyard to the anchor provided in the platform.
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First Edition • Third Printing Operator's Manual Work Area Safety Do not operate a boom in the path of any crane Observe and use the color-coded direction arrows unless the controls of the crane have been locked on the platform controls and drive chassis for drive out and/or precautions have been taken to prevent and steer functions.
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Operator's Manual First Edition • Third Printing Work Area Safety Explosion and Fire Hazards Damaged Machine Hazards Do not start the engine if you smell or detect liquid Do not use a damaged or malfunctioning machine. petroleum gas (LPG), gasoline, diesel fuel or other Conduct a thorough pre-operation inspection of explosive substances.
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First Edition • Third Printing Operator's Manual Work Area Safety Battery Safety Contact Alarm Safety Read, understand and obey all warnings and Burn Hazards instructions provided with the contact alarm. Batteries contain acid. Do not exceed the rated platform capacity. The Always wear protective weight of the contact alarm assembly will reduce clothing and eye wear when...
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Operator's Manual First Edition • Third Printing Work Area Safety Pipe Cradle Safety Panel Cradle Safety Read, understand, and obey all warnings and Read, understand and obey all warnings and instructions provided with the pipe cradles. instructions provided with the panel cradles. Do not exceed the rated platform capacity.
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First Edition • Third Printing Operator's Manual Work Area Safety Tow Package Safety Welder Safety Read, understand and obey all warnings and Read, understand and obey all warnings and instructions provided with the tow package. instructions provided with the welding power unit. When vehicle is in free-wheel configuration, there Do not connect weld leads or cables unless the are no brakes and machine may move, resulting in...
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Operator's Manual First Edition • Third Printing Work Area Safety Lockout After Each Use Select a safe parking location—firm level surface, clear of obstruction and traffic. Retract and lower the boom to the stowed position. Rotate the turntable so that the boom is between the non-steer wheels.
Operator's Manual First Edition • Third Printing Controls Controls Pictures in this manual may show a boom with tires and wheels instead of tracks. All safety information and operating instructions still apply to the S-40 TRAX and the S-45 TRAX, even if the picture does not show the tracks.
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First Edition • Third Printing Operator's Manual Controls Ground Control Panel LCD readout screen Screen displays hour meter, voltage, oil Function enable button pressure and coolant temperature. Screen Press and hold the function enable button to also displays fault codes and other service enable the functions on the ground control information.
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Operator's Manual First Edition • Third Printing Controls 11 Key switch for off/ground/platform selection 16 Platform level down button Turn the key switch to the off position and the Press the platform level down button and the machine will be off. Turn the key switch to the level of the platform will lower.
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First Edition • Third Printing Operator's Manual Controls Platform Control Panel Part No. 1274724GT -40/45 XC • S -40/45 HF • S -40/45 TRAX ® ™ ® ® ™...
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Operator's Manual First Edition • Third Printing Controls -40/45 XC • S -40/45 HF • S -40/45 TRAX Part No. 1274724GT ® ™ ® ® ™...
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First Edition • Third Printing Operator's Manual Controls Platform Control Panel Fault indicator light Light on indicates a system fault. Horn button Press this button and the horn will sound. Restricted range of motion indicator light, Release the button and the horn will stop. weight.
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Operator's Manual First Edition • Third Printing Controls 11 Raise/retract boom indicator light 17 Dual axis proportional control handle for drive and steer functions. Raise/retract the boom until the light is off. Proportional control handle for drive function 12 Lower boom indicator light and thumb rocker for steer function.
First Edition • Third Printing Operator's Manual Inspections 19 Drive enable switch 24 Engine start switch To drive when the drive enable light is Move the engine start switch to either side to flashing, hold the drive enable switch to either start the engine.
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Operator's Manual First Edition • Third Printing Inspections Pre-operation Inspection Pictures in this manual may show a boom with tires and wheels instead of tracks. All safety Fundamentals information and operating instructions still apply to the S-40 TRAX and the S-45 TRAX, even if the It is the responsibility of the operator to perform a picture does not show the tracks.
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First Edition • Third Printing Operator's Manual Inspections Pre-operation Inspection Check the following components or areas for damage, improperly installed, or missing parts and unauthorized modifications: Be sure that the operator’s, safety, and responsibilities manuals are complete, legible Electrical components, wiring, and and in the storage container located in the electrical cables platform.
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Operator's Manual First Edition • Third Printing Inspections Check entire machine for: Cracks in welds or structural components Dents or damage to machine Excessive rust, corrosion or oxidation Verify that all structural and other critical components are present and all associated fasteners and pins are in place and properly tightened.
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First Edition • Third Printing Operator's Manual Inspections 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 Do Not Operate Unless: malfunctions are discovered, the machine must be tagged and removed from service.
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Operator's Manual First Edition • Third Printing Inspections At the Ground Controls Test Machine Functions Select a test area that is firm, level and free of Do not push the function hazards. enable button. Attempt to activate each boom and Turn the key switch to ground control.
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First Edition • Third Printing Operator's Manual Inspections Test Auxiliary Power Test Emergency Stop 10 Turn the key switch to ground control and shut 15 Start the engine. the engine off. 16 Push in the platform red Emergency Stop 11 Pull out the red Emergency Stop button to the button to the off position.
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Operator's Manual First Edition • Third Printing Inspections Test Machine Functions Test Drive and Braking 24 Press down the foot switch. 29 Press down the foot switch. 25 Activate each machine function control handle 30 Slowly move the drive control handle in the or toggle switch.
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First Edition • Third Printing Operator's Manual Inspections Test the Oscillating Axle Test the Drive Enable System 32 Drive the right steer tire up onto a 6 in/15 cm 35 Press down the foot switch and lower the block or curb. boom to the stowed position.
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Operator's Manual First Edition • Third Printing Inspections Test Limited Drive Speed Test Drive Tilt Cutout 39 Press down the foot switch. 45 Press down the foot switch. 40 Raise the boom approximately 15° above 46 S-40 XC, S-45 XC, S-40 TRAX , S-45 TRAX: horizontal.
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First Edition • Third Printing Operator's Manual Inspections 49 Retract the boom to the stowed position. 55 Press down the foot switch. Result: The machine should drive. 56 With the boom fully stowed, drive the machine onto a slope where the roll angle is greater 50 Return to level ground and raise the boom to than 5°...
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Operator's Manual First Edition • Third Printing Inspections Test the Contact Alarm (if equipped) 62 While on the slope, attempt to raise and extend the boom. 69 Do not activate the foot switch and press on Result: The boom raise and extend functions the contact alarm cable to release the actuator should not operate.
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First Edition • Third Printing Operator's Manual Inspections 74 Insert the actuator into the switch socket. Test Aircraft Protection Package (if equipped) Result: The lights and horn will turn off. Note: Two people may be required to perform this 75 Operate each machine function. test.
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Operator's Manual First Edition • Third Printing Inspections Workplace Inspection Checklist Be aware of and avoid the following hazardous situations: drop-offs or holes bumps, floor obstructions, or debris Do Not Operate Unless: sloped surfaces unstable or slippery surfaces ...
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First Edition • Third Printing Operator's Manual Inspections Inspection for Decals with Words Part No. Decal Description 82862 Danger – Fire Extinguisher, Welder Determine whether the decals on your machine (option) have words or symbols. Use the appropriate 97548 Instructions – Deutz Engine inspection to verify that all decals are legible and Specifications (F3L 2011 &...
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First Edition • Third Printing Operator's Manual Inspections Inspection for Decals with Words Part No. Decal Description 1281187 Label – Emergency Lowering, S-40 Determine whether the decals on your machine XC, S-40 TRAX have words or symbols. Use the appropriate 1281188 Label –...
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First Edition • Third Printing Operator's Manual Inspections Inspection for Decals with Part No. Decal Description Symbols 1256425 Label – Danger, Electrocution Hazard 1258949 Ground Control Panel, S-45 XC, S-45 Determine whether the decals on your machine have HF, S-45 TRAX words or symbols.
First Edition • Third Printing Operator's Manual Operating Instructions Fundamentals Operati ng Instr ucti ons Pictures in this manual may show a boom with tires and wheels instead of tracks. All safety The Operating Instructions section provides information and operating instructions still apply to instructions for each aspect of machine operation.
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Operator's Manual First Edition • Third Printing Operating Instructions Starting the Engine Gasoline/LPG models At the ground controls, turn the key switch to Diesel models the desired position. At the ground controls, turn the key switch to Be sure both ground and platform control red the desired position.
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First Edition • Third Printing Operator's Manual Operating Instructions Emergency Stop Operation from Ground Push in the red Emergency Stop button to the off Turn the key switch to ground control. position at the ground controls or the platform Pull out the red Emergency Stop button to the controls to stop all machine functions and turn the on position.
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Operator's Manual First Edition • Third Printing Operating Instructions To Position Platform Platform Overload Indicator Light Light flashing indicates the platform is overloaded. Press down the foot switch. The engine will stop and no functions will operate. Slowly move the appropriate function control handle or toggle switch or press the Remove weight from the platform until the light appropriate button according to the markings...
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First Edition • Third Printing Operator's Manual Operating Instructions To Drive Driving on a slope Determine the uphill, downhill and side slope Press down the foot switch. ratings for the machine and determine the slope Increase speed: Slowly move the control grade.
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Operator's Manual First Edition • Third Printing Operating Instructions To determine the slope grade: Drive Enable Measure the slope with a digital inclinometer OR Light flashing indicates that the use the following procedure. boom has moved just past either non-steer wheel and the You will need: drive function has been interrupted.
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First Edition • Third Printing Operator's Manual Operating Instructions Engine RPM Select Operating Envelope Indicator Lights Select engine RPM using the symbols on the The operating envelope indicator lights will come on to notify the operator that a function has been control panel.
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Operator's Manual First Edition • Third Printing Operating Instructions Machine Malfunction Indicator Light If the tilt alarm sounds with Light on indicates a system fault. the platform uphill: Lower the boom. Retract the boom. Push in and then pull out the red Emergency Stop button.
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First Edition • Third Printing Operator's Manual Operating Instructions S-40 HF Range of Motion Chart S-40 XC and S-40 TRAX Range of Motion Chart S-45 HF Range of Motion Chart S-45 XC and S-45 TRAX Range of Motion Chart Part No. 1274724GT -40/45 XC •...
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Operator's Manual First Edition • Third Printing Operating Instructions Tilt Sensor Activation Settings S-40 HF, S-45 HF S-40 XC, S-45 XC, S-40 TRAX, S-45 TRAX Model Tilt/Slope Maximum Boom Angle/ (front to back) Platform Load Model Tilt/Slope Maximum Boom Angle/ 600 lbs/272 kg (front to back) Platform Load...
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First Edition • Third Printing Operator's Manual Operating Instructions LCD Screen S-40 XC, S-45 XC, S-40 TRAX, S-45 TRAX The LCD screen at the ground controls displays The range of motion light is on hour meter, voltage, oil pressure and coolant when the platform load exceeds temperature.
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Operator's Manual First Edition • Third Printing Operating Instructions Aircraft Protection Package Operation (if equipped) If the platform bumper comes into contact with an object, the machine will shut down and no functions will operate. Aircraft Protection Override (Platform Controls) Move and hold the aircraft protection function override switch.
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First Edition • Third Printing Operator's Manual Operating Instructions Pipe Cradle Instructions Observe and Obey: The pipe cradle assembly consists of 2 pipe Pipe cradles must be installed on the inside of cradles positioned at either side of the platform the platform.
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Operator's Manual First Edition • Third Printing Operating Instructions Pipe Cradle Operation Panel Cradle Assembly Be sure the pipe cradle assembly and Apply the warning decal to the front of each installation instructions have been followed panel cradle (if needed). properly and that the pipe cradles are secured Install rubber bumper 1 in the panel cradle to the platform railings.
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First Edition • Third Printing Operator's Manual Operating Instructions Installation of Padding Install the 2 pieces of padding on the platform rails. Position the padding to protect the panels from contact with the platform rails. Installation of Strap Open the clamp and install it around a vertical platform rail tube.
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Operator's Manual First Edition • Third Printing Operating Instructions After Each Use Select a safe parking location—firm level surface, clear of obstruction and traffic. Retract and lower the boom to the stowed position. Rotate the turntable so that the boom is between the non-steer wheels.
First Edition • Third Printing Operator's Manual Towing Instructions After Towing: Towing Ins truc tions Using the Tow Package Immediately after towing, chock the wheels, Before Towing: detach the tow bar and reverse the drive hub Position the machine on a level surface. disconnect caps.
Operator's Manual First Edition • Third Printing Transport and Lifting Instructions Trans port and Lifti ng Instr ucti ons Pictures in this manual may show a boom with Be sure the turntable is secured with the tires and wheels instead of tracks. All safety turntable rotation lock before transporting.
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First Edition • Third Printing Operator's Manual Transport and Lifting Instructions Free-wheel Configuration for Securing to Truck or Trailer for Winching Transit Chock the wheels to prevent the machine from Always use the turntable rotation lock pin each rolling. time the machine is transported. Release the wheel brakes by turning over all four drive hub disconnect...
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Operator's Manual First Edition • Third Printing Transport and Lifting Instructions Securing the Platform – S-45 XC, S-45 HF, Securing the Chassis S-45 TRAX Use chains of ample load capacity. Make sure the jib and platform are in the stowed Use a minimum of 6 chains.
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First Edition • Third Printing Operator's Manual Transport and Lifting Instructions Lifting Instructions Fully lower and retract the boom. Fully lower the jib. (if equipped) Determine the center of gravity of your machine using the table and the picture on this page. Observe and Obey: Attach the rigging only to the designated lifting points on the machine.
Operator's Manual First Edition • Third Printing Maintenance Check the Engine Oil Level Maintenanc e Maintaining the proper engine oil level is essential to good engine performance and service life. Observe and Obey: Operating the machine with an improper oil level can damage engine components.
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First Edition • Third Printing Operator's Manual Maintenance Diesel Fuel Requirements Check the Hydraulic Oil Level Satisfactory engine performance is dependent on Maintaining the hydraulic oil at the proper level is the use of a good quality fuel. The use of a good essential to machine operation.
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Operator's Manual First Edition • Third Printing Maintenance Check the Engine Coolant Level – Check the Batteries Liquid Cooled Models Proper battery condition is essential to good machine performance and operational safety. Maintaining the engine coolant at the proper level Improper fluid levels or damaged cables and is essential to engine service life.
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First Edition • Third Printing Operator's Manual Maintenance Scheduled Maintenance Maintenance performed commissioning, quarterly, annually and every two years must be completed by a person trained and qualified to perform maintenance on this machine according to the procedures found in the service and maintenance manuals for this machine.
Operator's Manual First Edition • Third Printing Specifications Specific ati ons Model S-40 XC Maximum slope rating, stowed position, 4WD Height, working maximum 45 ft 6 in 13.87 m Platform uphill 45% (24°) Height, platform maximum 39 ft 6 in 12.04 m Platform downhill 45% (24°)
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First Edition • Third Printing Operator's Manual Specifications Model S-45 XC Maximum slope rating, stowed position, 4WD Height, working maximum 50 ft 6 in 15.39 m Platform uphill 45% (24°) Height, platform maximum 44 ft 6 in 13.56 m Platform downhill 45% (24°) Horizontal reach, platform maximum 36 ft 2 in 11.02 m Side slope...
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Operator's Manual First Edition • Third Printing Specifications Model S-40 TRAX Maximum slope rating, stowed position, 4WD Height, working maximum 45 ft 6 in 13.87 m Platform uphill 45% (24°) Height, platform maximum 39 ft 6 in 12.04 m Platform downhill 45% (24°) Horizontal reach, platform 31 ft 1 in...
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First Edition • Third Printing Operator's Manual Specifications Model S-45 TRAX Maximum slope rating, stowed position, 4WD Height, working maximum 50 ft 6 in 15.39 m Platform uphill 45% (24°) Height, platform maximum 44 ft 6 in 13.56 m Platform downhill 45% (24°) Horizontal reach, platform maximum 36 ft 2 in 11.02 m Side slope...
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Operator's Manual First Edition • Third Printing Specifications Model S-40 HF Maximum slope rating, stowed position, 4WD Height, working maximum 45 ft 6 in 13.87 m Platform uphill 45% (24°) Height, platform maximum 39 ft 6 in 12.04 m Platform downhill 45% (24°) Horizontal reach, platform 28 ft 11 in...
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First Edition • Third Printing Operator's Manual Specifications Model S-45 HF Maximum slope rating, stowed position, 4WD Height, working maximum 50 ft 6 in 15.39 m Platform uphill 45% (24°) Height, platform maximum 44 ft 6 in 13.56 m Platform downhill 45% (24°) Horizontal reach, platform 34 ft...
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Operator's Manual First Edition • Third Printing Specifications S-40 XC AND S-40 TRAX Range of Motion S-45 XC and S-45 TRAX Range of Motion Chart Chart -40/45 XC • S -40/45 HF • S -40/45 TRAX Part No. 1274724GT ® ™...
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First Edition • Third Printing Operator's Manual Specifications S-40 HF Range of Motion Chart S-45 HF Range of Motion Chart S®-40/45 XC ™ • S®-40/45 HF • S®- 40/45 TR AX™ Part No. 1274724GT Operator's M anual First Edition • Thir d Pri nting Part No.