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Terex Genie S-45 TRAX Operator's Manual

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Operator's Manual
S-40 T
RAX
S-45 T
RAX
AUS
Australia
with
Maintenance
Information
Second Edition
First Printing
Part No. 1259841

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Summary of Contents for Terex Genie S-45 TRAX

  • Page 1 Operator's Manual S-40 T Australia S-45 T with Maintenance Information Second Edition First Printing Part No. 1259841...

  • Page 2: Table Of Contents

    Maintenance ............49 Specifications ............52 Copyright © 2012 by Terex Corporation Second Edition: First Printing, October 2014 Genie and "S" are registered trademark of Terex South Dakota, Inc. in the U.S.A. and many other countries. These machines comply with AS1418.10 S-40 TRAX •...

  • Page 3: Introduction

    Second Edition • First Printing Operator's Manual Introduction 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: Danger 1 Comply with employer, job site and...
  • Page 4 Operator's Manual Second Edition • First Printing Introduction Hazard Classification Intended Use This machine is intended to be used only to lift Decals on this machine use symbols, color coding personnel, along with their tools and materials to and signal words to identify the following: an aerial work site.
  • Page 5 Second Edition • First Printing Operator's Manual 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 6: Symbol And Hazard Pictorials Definitions

    Operator's Manual Second Edition • First Printing Symbol and Hazard Pictorials Definitions Symbol and Hazard Pictorials Definitions Keep away from No smoking. Crush hazard Explosion hazard Electrocution hazard moving parts No flame. Stop engine Maintain required Crush hazard Keep away from path Fall hazard Keep off this surface.
  • Page 7 Second Edition • First Printing Operator's Manual Symbol and Hazard Pictorials Definitions Lanyard attachment Tracks load Voltage rating for Pressure rating for air Have fire extinguisher point power to platform line to platform near. Electrocution hazard Avoid contact Tie-down instructions Read the service manual Tie-down instructions...

  • Page 8: General Safety

    Operator's Manual Second Edition • First Printing General Safety General Safety 114390 28161 217561 52865 114389 97875 114258 28161 28177 217561 114389 DANGER 114390 DANGER 114258 DANGER Burn Hazard No smoking. No Fuel and fumes flame. Stop can explode engine. and burn.
  • Page 9 Second Edition • First Printing Operator's Manual General Safety Part No. 1259841 S-40 TRAX • S-45 TRAX...
  • Page 10 Operator's Manual Second Edition • First Printing General Safety S-40 TRAX • S-45 TRAX Part No. 1259841...

  • Page 11: Personal Safety

    Second Edition • First Printing Operator's Manual Personal Safety 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.

  • Page 12: Work Area Safety

    Operator's Manual Second Edition • First Printing Work Area Safety Work Area Safety Pictures in this manual may show a boom with Keep away from the tires and wheels instead of tracks. All safety machine if it contacts information and operating instructions still apply to energized power lines.
  • Page 13 Second Edition • First Printing Operator's Manual Work Area Safety Do not raise the boom Do not raise or extend the when wind speeds may boom unless the machine exceed 12.5 m/s. If wind is on a firm, level surface. speeds exceed 12.5 m/s when the boom is raised, lower the boom and do...
  • Page 14 Operator's Manual Second Edition • First Printing Work Area Safety Do not use the machine as a crane. Do not place or attach fixed or overhanging Do not push the machine or other objects with the loads to any part of this boom.
  • Page 15 Second Edition • First Printing Operator's Manual Work Area Safety Operation on Slopes Hazards Fall Hazards Do not drive the machine on a slope that exceeds Occupants must wear a the maximum uphill, downhill or side slope rating of safety belt or harness in the machine.
  • Page 16 Operator's Manual Second Edition • First Printing Work Area Safety Collision Hazards Do not lower the boom unless the area below is Be aware of limited sight clear of personnel and distance and blind spots obstructions. when driving or operating. Be aware of the boom position and tailswing when rotating the turntable.
  • Page 17 Second Edition • First Printing Operator's Manual Work Area Safety Bodily Injury Hazard Damaged Machine Hazards Do not operate the machine with a hydraulic oil or Do not use a damaged or malfunctioning machine. air leak. An air leak or hydraulic leak can penetrate Conduct a thorough pre-operation inspection of the and/or burn skin.
  • Page 18 Operator's Manual Second Edition • First Printing Work Area Safety Battery Safety Welder Safety Read, understand and obey all warnings and Burn Hazards instructions provided with the welding power unit. Batteries contain acid. Do not connect weld leads or cables unless the Always wear protective welding power unit is turned off at the platform clothing and eye wear when...
  • Page 19 Second Edition • First Printing Operator's Manual 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.
  • Page 20 Operator's Manual Second Edition • First 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.

  • Page 21: Legend

    Second Edition • First Printing Operator's Manual Legend Legend Foot switch Ground controls Manual storage container Boom Sliding mid-rail Platform controls Lanyard anchorage points 10 Platform Non-steer track 11 Jib boom Steer track Part No. 1259841 S-40 TRAX • S-45 TRAX...

  • Page 22: Controls

    Operator's Manual Second Edition • First Printing Controls Controls Ground Control Panel Gasoline/LPG models: Fuel select switch Move the fuel select switch to the gasoline Pictures in this manual may show a boom with position to select gasoline. Move the fuel tires and wheels instead of tracks.
  • Page 23 Second Edition • First Printing Operator's Manual Controls Engine idle (rpm) select switch 13 Platform overload indicator light Move the engine idle select switch to the turtle Light flashing indicates the platform is position for low idle. overloaded. The engine will stop and no Move the engine idle select switch to the rabbit functions will operate.
  • Page 24 Operator's Manual Second Edition • First Printing Controls Platform Control Panel S-40 TRAX • S-45 TRAX Part No. 1259841...
  • Page 25 Second Edition • First Printing Operator's Manual Controls Part No. 1259841 S-40 TRAX • S-45 TRAX...
  • Page 26 Operator's Manual Second Edition • First Printing Controls Emergency power switch Platform Control Panel Use emergency power if the primary power Pictures in this manual may show a boom with source (engine) fails. tires and wheels instead of tracks. All safety Simultaneously hold the emergency power information and operating instructions still apply to switch to either side and activate the desired...
  • Page 27 Second Edition • First Printing Operator's Manual Controls 12 Dual axis proportional control handle for drive 16 Drive enable switch and steer functions To drive when the drive enable light is on, hold OR Proportional control handle for drive the drive enable switch to either side and function and thumb rocker for steer function.

  • Page 28: Inspections

    Operator's Manual Second Edition • First Printing Inspections Inspections 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. Do Not Operate Unless: The inspection is designed to discover if anything is apparently wrong with a machine before the...
  • Page 29 Second Edition • First Printing Operator's Manual Inspections Pre-operation Inspection  Limit switches and horn  Alarms and beacons (if equipped)  Be sure that the operator’s, safety and  Nuts, bolts and other fasteners responsibilities manuals are complete, legible and in the storage container located in the ...
  • Page 30 Operator's Manual Second Edition • First Printing 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 malfunctions are discovered, the machine must be Do Not Operate Unless: tagged and removed from service.
  • Page 31 Second Edition • First Printing Operator's Manual Inspections Test Machine Functions At the Ground Controls 10 Do not hold the function enable Select a test area that is firm, level and free of switch to either side. Attempt to obstruction. activate each boom and platform Turn the key switch to ground control.
  • Page 32 Operator's Manual Second Edition • First Printing Inspections Test Emergency Controls Test the Horn 15 Turn the key switch to ground control and shut 21 Press the horn button. the engine off. Result: The horn should sound. 16 Pull out the red Emergency Stop button to the on position.
  • Page 33 Second Edition • First Printing Operator's Manual Inspections Test the Steering Test the Oscillating Axle (if equipped) 29 Press down the foot switch. 35 Start the engine from the platform controls. 30 Press the thumb rocker switch on top of the 36 Drive the right steer tire up onto a 15 cm block drive control handle in the direction indicated or curb.
  • Page 34 Operator's Manual Second Edition • First Printing Inspections Test Limited Drive Speed Test Emergency Controls 43 Press down the foot switch. 49 Shut off the engine. 44 Raise the boom to just above horizontal. 50 Pull out the red Emergency Stop button to the on position.
  • Page 35 Second Edition • First 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  sloped surfaces Do Not Operate Unless:  unstable or slippery surfaces ...
  • Page 36 Warning – Improper Operation 217557 Cosmetic – Genie S-40 Trax 30080 Instructions – Max Load, 500 lbs / 217558 Cosmetic – Genie S-45 Trax 227 kg 217559 Label – Wheel Load, S-40 Trax 31060 Danger – Tip-over Hazard, Limit Switch 217560 Label –...
  • Page 37 Second Edition • First Printing Operator's Manual Inspections 226515 28160 28161 82237 114390 52865 28174 Serial 219723 Label or 28235 114389 97875 114258 40434 28158 or 28159 82366 82237 25994 28177 28161 217561 72867 217559 46468 or 217560 114416 114099 97579 82767 217559...

  • Page 38: Operating Instructions

    Operator's Manual Second Edition • First Printing Operating Instructions Operating Instructions Fundamentals The Operating Instructions section provides instructions for each aspect of machine operation. It is the operator’s responsibility to follow all the safety rules and instructions in the operator’s, safety and responsibilities manuals.
  • Page 39 Second Edition • First Printing Operator's Manual Operating Instructions Starting the Engine All models At the ground controls, turn the key switch to If the engine fails to start after 15 seconds of the desired position. cranking, determine the cause and repair any malfunction.
  • Page 40 Operator's Manual Second Edition • First Printing 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.
  • Page 41 Second Edition • First Printing Operator's Manual Operating Instructions To Drive Operation from Platform Press down the foot switch. Turn the key switch to platform control. Increase speed: Slowly move the control Pull out both ground and platform red handle off center. Emergency Stop buttons to the on position.
  • Page 42 Operator's Manual Second Edition • First Printing Operating Instructions To determine the slope grade: Drive Enable Measure the slope with a digital inclinometer OR Light on indicates that the boom use the following procedure. has moved just past either non-steer wheel and the drive You will need: function has been interrupted.
  • Page 43 Second Edition • First Printing Operator's Manual Operating Instructions Engine Idle Select (rpm) Check Engine Light (if equipped) Select engine idle (rpm) using the symbols on the Light on and engine stopped: Tag the control panel. machine and remove from service. When the foot switch is not pressed, the engine Light on and engine still running: will idle at the lowest rpm.
  • Page 44 Operator's Manual Second Edition • First 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 45 Second Edition • First 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 46 Operator's Manual Second Edition • First Printing Operating Instructions Installation of Padding Install the 2 pieces of padding on the platform rubber rails. Position the padding to protect the panels bumper 2 from contact with the platform rails. Installation of Strap rubber bumper 1 U-bolt...
  • Page 47 Second Edition • First 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 48: Transport And Lifting Instructions

    Operator's Manual Second Edition • First Printing Transport and Lifting Instructions Transport and Lifting Instructions  Be sure the turntable is secured with the turntable rotation lock before transporting. Be sure to unlock the turntable for operation.  Do not drive the machine on a slope that exceeds the uphill, downhill or side slope rating.
  • Page 49 Second Edition • First Printing Operator's Manual Transport and Lifting Instructions Securing the Platform - S-40 Trax Securing to Truck or Trailer for Transit Place a block under the platform rotator. Do not allow the block to contact the platform cylinder. Always use the turntable rotation lock pin each Secure the platform with a nylon strap placed time the machine is transported.
  • Page 50 Operator's Manual Second Edition • First Printing Transport and Lifting Instructions Lifting Instructions Fully lower and retract the boom. Move the jib boom parallel with the ground. Remove all loose items on the machine. Use the turntable rotation lock to secure the turntable.

  • Page 51: Maintenance

    Second Edition • First Printing Operator's Manual Maintenance Maintenance 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 52 Operator's Manual Second Edition • First Printing Maintenance Check the Hydraulic Oil Level Check the Engine Coolant Level – Liquid Cooled Models Maintaining the hydraulic oil at the proper level is essential to machine operation. Improper hydraulic Maintaining the engine coolant at the proper level oil levels can damage hydraulic components.
  • Page 53 Second Edition • First Printing Operator's Manual Maintenance Check the Batteries Scheduled Maintenance Maintenance performed quarterly, annually and every two years must be completed by a person trained and qualified to perform maintenance on Proper battery condition is essential to good this machine according to the procedures found in machine performance and operational safety.

  • Page 54: Specifications

    Operator's Manual Second Edition • First Printing Specifications Specifications Model S-40 TRAX Airborne noise emissions Height, working maximum 14.2 m Sound pressure level at ground workstation <84 dBA Height, platform maximum` 12.2 m Sound pressure level at platform workstation <76 dBA Height, stowed maximum 2.49 m Guaranteed sound power level...
  • Page 55 Second Edition • First Printing Operator's Manual Specifications Model S-45 TRAX Airborne noise emissions Height, working maximum 15.7 m Sound pressure level at ground workstation <84 dBA Height, platform maximum 13.7 m Sound pressure level at platform workstation <76 dBA Height, stowed maximum 2.49 m Guaranteed sound power level...
  • Page 56 Operator's Manual Second Edition • First Printing Specifications S-40 TRAX Range of Motion S-45 TRAX Range of Motion S-40 TRAX • S-45 TRAX Part No. 1259841 Operator's Manual Second Edition • First Printing S-40 TRAX • S-45 TRAX Part No. 1259841...
  • Page 57 California Proposition 65 Warning The exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects or other reproductive harm. www.genielift.com...

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