Terex Genie S-40 TRAX Operator's Manual
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Terex Genie S-40 TRAX Operator's Manual

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Operator's Manual
S
-40 XC
®
S
-45 XC
®
S
-40 TRAX
®
S
-45 TRAX
®
Serial Number Range
™
™
™
™
from S40XCH-101
from S45XCH-101
AUS
Australia
with
Maintenance
Information
Original Instructions
First Edition
Second Printing
Part No. 1274726GT

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Summary of Contents for Terex Genie S-40 TRAX

  • Page 1 Operator's Manual Serial Number Range -40 XC ® ™ from S40XCH-101 from S45XCH-101 Australia -45 XC ® ™ -40 TRAX ® ™ -45 TRAX ® ™ with Maintenance Information Original Instructions First Edition Second Printing Part No. 1274726GT...

  • Page 2: Table Of Contents

    First Edition: Second 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 AS1418.10 -40/45 XC •...

  • Page 3: Introduction

    First Edition • Second 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.
  • Page 4 Operator's Manual First Edition • Second 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.
  • Page 5 First Edition • Second 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.
  • Page 6 Operator's Manual First Edition • Second 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.

  • Page 7: Symbol And Hazard Pictorials Definitions

    First Edition • Second 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.
  • Page 8 Operator's Manual First Edition • Second 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.
  • Page 9 First Edition • Second 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 or boom during manual...

  • Page 10: General Safety

    Operator's Manual First Edition • Second 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.
  • Page 11 First Edition • Second 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.
  • Page 12 Operator's Manual First Edition • Second 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.

  • Page 13: Personal Safety

    First Edition • Second Printing Operator's Manual 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.

  • Page 14: Work Area Safety

    Operator's Manual First Edition • Second Printing Work Area Safety Allow for platform movement, electrical line sway Work Ar ea Safety Pictures in this manual may show a boom with or sag, and beware of strong or gusty winds. tires and wheels instead of tracks. All safety information and operating instructions still apply to Keep away from the the S-40 TRAX and the S-45 TRAX, even if the...
  • Page 15 First Edition • Second Printing Operator's Manual Work Area Safety Do not attach a platform rated at 300 kg If the tilt alarm sounds when the platform is raised, (unrestricted range of motion) or 454 kg (restricted use extreme caution. The machine not level range of motion) to machines with any other rated indicator light will come on and the drive function load.
  • Page 16 Operator's Manual First Edition • Second Printing Work Area Safety Do not operate the machine in strong or gusty Do not alter or disable machine components that winds. Do not increase the surface area of the in any way affect safety and stability. platform or the load.
  • Page 17 First Edition • Second 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.
  • Page 18 Operator's Manual First Edition • Second 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.
  • Page 19 First Edition • Second Printing Operator's Manual Work Area Safety Bodily Injury Hazard Observe and use the color-coded direction arrows on the platform controls and drive chassis for drive Always operate the machine in a well-ventilated and steer functions. area to avoid carbon monoxide poisoning. Do not lower the boom Do not operate the machine with a hydraulic oil or unless the area below is...
  • Page 20 Operator's Manual First Edition • Second Printing Work Area Safety Damaged Machine Hazards Battery Safety Do not use a damaged or malfunctioning machine. Burn Hazards Conduct a thorough pre-operation inspection of Batteries contain acid. the machine and test all functions before each Always wear protective work shift.
  • Page 21 First Edition • Second Printing Operator's Manual Work Area Safety Contact Alarm Safety Pipe Cradle Safety Read, understand and obey all warnings and Read, understand, and obey all warnings and instructions provided with the contact alarm. instructions provided with the pipe cradles. Do not exceed the rated platform capacity.
  • Page 22 Operator's Manual First Edition • Second Printing Work Area Safety Panel Cradle Safety Tow Package Safety Read, understand and obey all warnings and Read, understand and obey all warnings and instructions provided with the panel cradles. instructions provided with the tow package. Do not exceed the rated platform capacity.
  • Page 23 First Edition • Second Printing Operator's Manual 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.

  • Page 24: Legend

    Operator's Manual First Edition • Second Printing Legend Legend 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.

  • Page 25: Controls

    First Edition • Second Printing Operator's Manual 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.
  • Page 26 Operator's Manual First Edition • Second Printing 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.
  • Page 27 First Edition • Second Printing Operator's Manual 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.
  • Page 28 Operator's Manual First Edition • Second Printing Controls Platform Control Panel -40/45 XC • S -40/45 TRAX Part No. 1274726GT ® ™ ® ™...
  • Page 29 First Edition • Second Printing Operator's Manual Controls Part No. 1274726GT -40/45 XC • S -40/45 TRAX ® ™ ® ™...
  • Page 30 Operator's Manual First Edition • Second Printing 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.
  • Page 31 First Edition • Second Printing Operator's Manual 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.
  • Page 32 Operator's Manual First Edition • Second Printing Controls 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.

  • Page 33: Inspections

    First Edition • Second Printing Operator's Manual Inspections Pre-operation Inspection Ins pections 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.
  • Page 34 Operator's Manual First Edition • Second Printing Inspections Pre-operation Inspection  Primary boom angle sensor  Turntable level sensor  Be sure that the operator’s manual is  String pot length sensor complete, legible and in the storage container located in the platform. ...
  • Page 35 First Edition • Second 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.
  • Page 36 Operator's Manual First Edition • Second Printing Inspections At the Ground Controls Test Machine Functions Do not push the function Select a test area that is firm, level and free of enable button. Attempt to hazards. activate each boom and Turn the key switch to ground control.
  • Page 37 First Edition • Second 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.
  • Page 38 Operator's Manual First Edition • Second 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.
  • Page 39 First Edition • Second Printing Operator's Manual Inspections Test the Drive Enable System Test Limited Drive Speed 35 Press down the foot switch and lower the 39 Press down the foot switch. boom to the stowed position. 40 Raise the boom approximately 10° above 36 Rotate the turntable until the boom moves past horizontal.
  • Page 40 Operator's Manual First Edition • Second Printing Inspections Test Drive Tilt Cutout 54 Return to level ground and stow the boom. 55 Press down the foot switch. 45 Press down the foot switch. 56 With the boom fully stowed, drive the machine 46 With the boom fully stowed, drive the machine onto a slope where the roll angle is greater onto a slope where the machine pitch angle is...
  • Page 41 First Edition • Second Printing Operator's Manual Inspections Test Auxiliary Power 72 Insert the actuator into the switch socket. Result: The lights and horn will turn off. 65 Shut the engine off. 73 Activate the foot switch by pressing the foot 66 Pull out the red Emergency Stop button to the switch down and press on the contact alarm on position.
  • Page 42 Operator's Manual First Edition • Second Printing Inspections Test Aircraft Protection Package (if equipped) Note: Two people may be required to perform this test. 77 Move the yellow bumper at the bottom of the platform 10 cm in any direction. 78 Activate each function control handle or toggle switch.
  • Page 43 First Edition • Second Printing Operator's Manual 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 ...
  • Page 44 Operator's Manual First Edition • Second Printing 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 &...
  • Page 45 First Edition • Second Printing Operator's Manual Inspections 1278982 1267121 114258 114390 1263543 1272242 52865 31060 1278542 72086 *97548 72086 *215527 *822131 *822004 *215526 **72086 52475 *97602 *217561 *1284014 *1296287 *217561 **72086 *1284014 *1296287 52475 *1274729 *1274729 27205 *1274730 *1274730 27207 *1295235 *1295235...
  • Page 46 Operator's Manual First Edition • Second Printing Inspections Inspection for Decals with Words Part No. Decal Description 1282361 Label – Protector, Clear Determine whether the decals on your machine 1283345 Label – XC, XTRA Capacity have words or symbols. Use the appropriate inspection to verify that all decals are legible and 1283577 Label –...
  • Page 47 First Edition • Second Printing Operator's Manual Inspections 1278982 1267121 114258 114390 1263543 52865 31060 1272242 1278542 72086 *97548 72086 *215527 *822131 *822004 *215526 52475 *97602 *217561 *1284014 *1296287 *217561 52475 *1284014 *1296287 *1274729 *1274730 *1274729 27205 *1295235 *1274730 *1295236 27207 *1295235 52475...

  • Page 48: Operating Instructions

    Operator's Manual First Edition • Second Printing 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.
  • Page 49 First Edition • Second Printing Operator's Manual Operating Instructions Starting the Engine Emergency Stop Push in the red Emergency Stop button to the off Diesel models position at the ground controls or the platform controls to stop all machine functions and turn the At the ground controls, turn the key switch to engine off.
  • Page 50 Operator's Manual First Edition • Second Printing Operating Instructions Operation from Ground Platform Overload Indicator Light Light flashing indicates the platform is overloaded. Turn the key switch to ground control. The engine will stop and no functions will operate. Pull out the red Emergency Stop button to the Remove weight from the platform until the light on position.
  • Page 51 First Edition • Second Printing Operator's Manual Operating Instructions Operation from Platform To Steer Press down the foot switch. Turn the key switch to platform control. Slowly move the drive control handle in the Pull out both ground and platform red direction indicated by blue or yellow triangles Emergency Stop buttons to the on position.
  • Page 52 Operator's Manual First Edition • Second Printing Operating Instructions Driving on a slope To determine the slope grade: Determine the uphill, downhill and side slope Measure the slope with a digital inclinometer OR ratings for the machine and determine the slope use the following procedure.
  • Page 53 First Edition • Second Printing Operator's Manual Operating Instructions Engine RPM Select Drive Enable Select engine RPM using the symbols on the Light flashing indicates that the control panel. boom has moved just past either non-steer wheel and the When the foot switch is not pressed, the engine drive function has been will idle at the lowest rpm.
  • Page 54 Operator's Manual First Edition • Second Printing Operating Instructions Platform Overload Indicator Light Operating Envelope Indicator Lights The operating envelope indicator lights will come Light flashing indicates the platform on to notify the operator that a function has been is overloaded. The engine will stop interrupted and/or an action is required by the and no functions will operate.
  • Page 55 First Edition • Second Printing Operator's Manual Operating Instructions Platform Capacity Range S-40 XC and S-40 TRAX Range of Motion Chart Range of motion is controlled automatically based on platform load. Unrestricted Range of Motion: When the platform load is less than 300 kg. Restricted Range of Motion: When the platform load is 301-454 kg.
  • Page 56 Operator's Manual First Edition • Second Printing Operating Instructions Tilt Sensor Activation Settings – S-40 XC, The range of motion light is on S-40 TRAX, S-45 XC, S-45 TRAX when the platform load exceeds 300 kg. Tilt/Slope Maximum Boom Angle/ Model (front to back) Platform Load...
  • Page 57 First Edition • Second Printing Operator's Manual Operating Instructions LCD Screen Aircraft Protection Package Operation (if equipped) The LCD screen at the ground controls displays hour meter, voltage, oil pressure and coolant If the platform bumper comes into contact with an temperature.
  • Page 58 Operator's Manual First Edition • Second Printing 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.
  • Page 59 First Edition • Second Printing Operator's Manual 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.
  • Page 60 Operator's Manual First Edition • Second Printing 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.
  • Page 61 First Edition • Second Printing Operator's Manual 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.

  • Page 62: Towing Instructions

    Operator's Manual First Edition • Second Printing Towing Instructions Towing Ins truc tions Using the Tow Package After Towing: 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.
  • Page 63 First Edition • Second Printing Operator's Manual Transport and Lifting Instructions 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. Be information and operating instructions still apply to sure to unlock the turntable for operation.
  • Page 64 Operator's Manual First Edition • Second Printing Transport and Lifting Instructions Securing to Truck or Trailer for Securing the Platform – S-40 XC, S-40 HF, S-40 TRAX Transit Make sure the platform is in the stowed position. Always use the turntable rotation lock pin each time the machine is transported.
  • Page 65 First Edition • Second 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.

  • Page 66: Maintenance

    Operator's Manual First Edition • Second Printing Maintenance Maintenanc e Check the Engine Oil Level Maintaining the proper engine oil level is essential to good engine performance and service life. Operating the machine with an improper oil level Observe and Obey: can damage engine components.
  • Page 67 First Edition • Second 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.
  • Page 68 Operator's Manual First Edition • Second 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.
  • Page 69 First Edition • Second 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.

  • Page 70: Specifications

    Operator's Manual First Edition • Second Printing Specifications Specific ati ons Model S-40 XC Maximum slope rating, stowed position, 4WD Height, working maximum 13.87 m Platform uphill 45% (24°) Platform downhill 45% (24°) Height, platform maximum 12.04 m Side slope 25% (14°) Horizontal reach, platform 9.47 m...
  • Page 71 First Edition • Second Printing Operator's Manual Specifications Model S-45 XC Maximum slope rating, stowed position, 4WD Height, working maximum 15.39 m Platform uphill 45% (24°) Height, platform maximum 13.56 m Platform downhill 45% (24°) Side slope 25% (14°) Horizontal reach, platform 11.02 m maximum Note: Slope rating is subject to ground conditions with...
  • Page 72 Operator's Manual First Edition • Second Printing Specifications Model S-40 TRAX Maximum slope rating, stowed position, 4WD Height, working maximum 13.87 m Platform uphill 45% (24°) Height, platform maximum 12.04 m Platform downhill 45% (24°) Side slope 25% (14°) Horizontal reach, platform 9.47 m maximum Note: Slope rating is subject to ground conditions with...
  • Page 73 First Edition • Second Printing Operator's Manual Specifications Model S-45 TRAX Maximum slope rating, stowed position, 4WD Height, working maximum 15.39 m Platform uphill 45% (24°) Platform downhill 45% (24°) Height, platform maximum 13.56 m Side slope 25% (14°) Horizontal reach, platform 11.02 m Note: Slope rating is subject to ground conditions with maximum...
  • Page 74 Operator's Manual First Edition • Second Printing Specifications S-40 XC, S-40 TRAX Range of Motion Chart S-45 XC, S-45 TRAX Range of Motion Chart S®-40/45 XC ™ • S®-40/45 TRAX™ Part No. 1274726GT Operator's M anual First Edition • Sec ond Printi ng -40/45 XC •...

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Genie s-45 xcGenie s-40 xcGenie s-45 trax

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