Terex Genie S-40XC User manual

Operator's Manual
Serial Number Range
S®-40 XC™
from S40XCH-101
from S45XCH-
101
ANSI/CSA
North America
South America
Asia
S®-45 XC™
S®-40 HF
S®-45 HF
S®-40 TRAX™
with
Maintenance
Information
S®-45 TRAX™
Original Instructions
First Edition
Third Printing
Part No. 1274724GT

Operator's Manual First Edition • Third Printing
S®-40/45 XC™• S®-40/45 HF • S®-40/45 TRAX™Part No. 1274724GT
FrontMatter
Contents
Introduction ............................................................1
Symbol and Hazard Pictorials Definitions..............5
General Safety .......................................................8
Personal Safety................................................... 14
Work Area Safety................................................ 15
Legend ................................................................ 27
Controls............................................................... 28
Inspections.......................................................... 35
Operating Instructions......................................... 55
Towing Instructions ............................................. 71
Transport and Lifting Instructions ....................... 72
Maintenance ....................................................... 76
Specifications...................................................... 80
Copyright © 2019 by Terex Corporation
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
Part No. 1274724GT S®-40/45 XC™• S®-40/45 HF • S®-40/45 TRAX™1
Intr od ucti o n
About this manual
Genie appreciates your choice of our machine for
your application. Our number one priority is user
safety, which is best achieved by our joint efforts.
This book is an operation and daily maintenance
manual for the user or operator of a Genie
machine.
This manual should be considered a permanent
part of your machine and should remain with the
machine at all times. If you have any questions,
contact Genie.
Product Identification
The machine serial number is located on the serial
label.
Serial label
(located under cover)
Serial number stamped on
chassis
Intended Use and Familiarization
Guide
The intended use of this machine is to lift
personnel, including tools, and materials to an
aerial work site. Before operating the machine, it’s
the operator’s responsibility to read and
understand this familiarization guide.
Each person must be trained to operate a
Mobile Elevating Work Platform (MEWP).
Familiarization with the MEWP must be given
to each person who is authorized, competent
and trained.
Only trained and authorized personnel should
be permitted to operate the machine.
The operator is responsible to read,
understand, and obey the manufacturer’s
instructions and safety rules provided in the
Operator’s Manual.
The Operator’s Manual is located in the
manual storage container, at the platform.
For specific product applications, see
Contacting The Manufacturer.

Operator's Manual First Edition • Third Printing
Introduction
2 S®-40/45 XC™• S®-40/45 HF • S®-40/45 TRAX™Part No. 1274724GT
Platform controls symbology and related
machine movement:
Platform level
Platform rotate
Jib boom up/down
Boom up/down
Boom extend/retract
Turntable rotate
Drive forward/reverse
Steer right/left
Ground controls symbology and related
machine movement:
Platform level, jib boom
up/down, boom
extend/retract,and boom
up/down
Turntable rotate and
platform rotate
Sequential functions and movement:
•Drive and steer.
Interlocked functions:
•Elevated drive speed.
•Elevated lift and drive in an off-level condition.
•Drive enable when the boom is rotated past the
non-steer wheels, or non-steer tracks.
•All platform and ground controls.
Limitations of use:
•The intended use of this machine is to lift
personnel, including tools, and materials to an
aerial work site.
•Do not elevate the platform unless the machine
is on firm level ground.
Stability enhancing means:
•Foam filled tires
•Tracks
Restricted operating envelope:
•1,000 lbs/454 kg platform capacity.

First Edition • Third Printing Operator's Manual
Introduction
Part No. 1274724GT S®-40/45 XC™• S®-40/45 HF • S®-40/45 TRAX™3
Bulletin Distribution and
Compliance
Safety of product users is of paramount
importance to Genie. Various bulletins are used by
Genie to communicate important safety and
product information to dealers and machine
owners.
The information contained in the bulletins is tied to
specific machines using the machine model and
serial number.
Distribution of bulletins is based on the most
current owner on record along with their
associated dealer, so it is important to register
your machine and keep your contact information
up to date.
To ensure safety of personnel and the reliable
continued operation of your machine, be sure to
comply with the action indicated in a respective
bulletin.
Transfer of Machine Ownership
Taking a few minutes to update owner information
will ensure that you receive important safety,
maintenance and operating information that
applies to your machine.
Please register your machine by visiting us on the
web at www.genielift.com or by calling us toll free
at 1-800-536-1800.
To view any open bulletins for your machine, visit
us on the web at www.genielift.com.
Contacting the Manufacturer
At times it may be necessary to contact Genie.
When you do, be ready to supply the model
number and serial number of your machine, along
with your name and contact information. At
minimum, Genie should be contacted for:
Accident reporting
Questions regarding product applications and
safety
Standards and regulatory compliance information
Current owner updates, such as changes in
machine ownership or changes in your contact
information. See Transfer of Ownership, below.

Operator's Manual First Edition • Third Printing
Introduction
4 S®-40/45 XC™• S®-40/45 HF • S®-40/45 TRAX™Part No. 1274724GT
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.
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.
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.
Indicates a hazardous situation
which, if not avoided, will result in
death or serious injury.
Indicates a hazardous situation
which, if not avoided, could result
in death or serious injury.
Indicates a hazardous situation
which, if not avoided, coul
d result
in minor or moderate injury.
Indicates a property damage
message.

First Edition • Third Printing Operator's Manual
Symbol and Hazard Pictorials Definitions
Part No. 1274724GT S®-40/45 XC™• S®-40/45 HF • S®-40/45 TRAX™5
Symb ol and H az ard Pict or i als De fi nit i on s
Fire hazard Explosion hazard Explosion hazard Do not use ether or
other high energy
starting aids on
machines equipped
with glow plugs.
No smoking.
No flame.
Stop engine.
Fire extinguisher No smoking Explosion hazard Electrocution hazard Maintain required
clearance
Tip-over hazard Tip-over hazard Tip-over hazard Tip-over hazard Tire specifications

Operator's Manual First Edition • Third Printing
Symbol and Hazard Pictorials Definitions
6 S®-40/45 XC™• S®-40/45 HF • S®-40/45 TRAX™Part No. 1274724GT
Wheel load Wind speed Maximum capacity Manual force Weight of welder
reduces capacity
Tie-down point Lifting point Platform tie-down
instructions
Lifting and tie down
instructions
Lanyard anchorage
points
Corrosive acid. Color coded direction
arrows
Runaway hazard Collision hazard Overhead obstruction

First Edition • Third Printing Operator's Manual
Symbol and Hazard Pictorials Definitions
Part No. 1274724GT S®-40/45 XC™• S®-40/45 HF • S®-40/45 TRAX™7
Electrocution hazard Avoid contact Disconnect battery Voltage rating for
power to platform
Pressure rating for air
line to platform
Crush hazard Support the platform
or boom during
maintenance
Read the service
manual
Explosion hazard Relieve all pressure
Recovery procedure if tilt alarm sounds while
elevated.
Platform downhill:
1 Retract boom.
2 Lower boom.
Platform uphill:
1 Lower boom.
2 Retract boom.
Read the operator’s
manual
Auxiliary lowering Access by trained and
authorized personnel
only
Replace tracks with
same tracks.
Tracks load

Operator's Manual First Edition • Third Printing
General Safety
8 S®-40/45 XC™• S®-40/45 HF • S®-40/45 TRAX™Part No. 1274724GT
Gener al Saf et y
* 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.

First Edition • Third Printing Operator's Manual
General Safety
Part No. 1274724GT S®-40/45 XC™• S®-40/45 HF • S®-40/45 TRAX™9
* 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
General Safety
10 S®-40/45 XC™• S®-40/45 HF • S®-40/45 TRAX™Part No. 1274724GT
* 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.

First Edition • Third Printing Operator's Manual
General Safety
Part No. 1274724GT S®-40/45 XC™• S®-40/45 HF • S®-40/45 TRAX™11
* 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
General Safety
12 S®-40/45 XC™• S®-40/45 HF • S®-40/45 TRAX™Part No. 1274724GT
* 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.

First Edition • Third Printing Operator's Manual
General Safety
Part No. 1274724GT S®-40/45 XC™• S®-40/45 HF • S®-40/45 TRAX™13
* 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
14 S®-40/45 XC™• S®-40/45 HF • S®-40/45 TRAX™Part No. 1274724GT
Pers on al Safe ty
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.

First Edition • Third Printing Operator's Manual
Work Area Safety
Part No. 1274724GT S®-40/45 XC™• S®-40/45 HF • S®-40/45 TRAX™15
Work Ar ea Saf ety
Electrocution Hazards
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.
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,
t
he required clearance
contained in the chart
below must be followed.
Line Voltage
Required Clearance
0
to 50KV 10 f
t
3.05
m
5
0 to 200KV 15 f
t
4.60
m
20
0 to 350KV 20 f
t
6.10
m
35
0 to 500KV 25 f
t
7.62
m
50
0 to 750KV 35 f
t
10.67
m
75
0 to 1000KV 45 f
t
13.72
m
Allow for platform movement, electrical line sway
or sag, and beware of strong or gusty winds.
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.
Tip-over Hazards
Occupants, equipment and materials shall not
exceed the maximum platform capacity for the
restricted or unrestricted range of motion.
S
-40/45 XC and S-40/45 TRAX
Maximum platform capacity
Unrestricted range of motion
660 l
bs
300 k
g
S-40/45 HF
Maximum platform capacity
Unrestricted range of motion
600 l
bs
272 k
g
Maximum
occupants
2
S-40/45 XC and S-40/45 TRAX
Maximum platform capacity
Restricted range of motion
1,000 l
bs
454 k
g
Maximum occupants
3

Operator's Manual First Edition • Third Printing
Work Area Safety
16 S®-40/45 XC™• S®-40/45 HF • S®-40/45 TRAX™Part No. 1274724GT
S-40 XC, S-45 XC, S-40 TRAX, S-45 TRAX: If the
platform load is greater than 660 lbs/300 kg, do
not move the platform into the unrestricted range
of motion zone.'
Do not exceed the maximum platform capacity.
S-40 XC, S-45 XC, S-40 TRAX, S-45 TRAX: Do
not attach a platform rated at 660 lbs/300 kg
(unrestricted range of motion) or 1000 lbs/454 kg
(restricted range of motion) to machines with any
other rated load. See the serial label for the
maximum rated load.
S-40 HF, S-45 HF: Do not attach a platform rated
at 600 lbs/272 kg (unrestricted range of motion) to
machines with any other rated load. See the serial
label for the maximum rated load.
The weight of options and accessories such as
pipe 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.
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.

First Edition • Third Printing Operator's Manual
Work Area Safety
Part No. 1274724GT S®-40/45 XC™• S®-40/45 HF • S®-40/45 TRAX™17
If the tilt alarm sounds when the platform is raised,
use extreme caution. The machine not level
indicator light will come on and the drive function
in one or both directions will not operate. 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.
The recovery mode should be used only by trained
and authorized personnel.
If th
e 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.

Operator's Manual First Edition • Third Printing
Work Area Safety
18 S®-40/45 XC™• S®-40/45 HF • S®-40/45 TRAX™Part No. 1274724GT
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.
Do not push off or pull
toward any object outside
of the platform.
Maximum manual force
–
ANSI and CSA
9
0 lbs/400 N
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.
S-40 XC and S-45 XC: Do not replace factory-
installed tires with tires of different specification or
ply rating. Do not use air-filled tires. These
machines are equipped with foam-filled tires.
Wheel weight is critical to stability.
S-40 TRAX and S-45 TRAX: Do not replace
tracks with tires. Track weight is critical to stability.
Do not replace factory-installed tracks with tracks
of different specification.
Do not allow any object to come near moving
parts. The object could be thrown out of the Trax
undercarriage.
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.
Do not modify or alter a mobile elevated 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.