Terex Genie S-45 Trax User manual

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

Operator's Manual Second Edition • First Printing
S-40 TRAX • S-45 TRAX Part No. 1259841
Front Matter
Important
Read, understand and obey these safety rules and
operating instructions before operating this
machine. Only trained and authorized personnel
shall be permitted to operate this 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 us.
Contact Us:
Internet: www.genielift.com
E-mail: [email protected]
Contents
Introduction ........................................................... 1
Symbol and Hazard Pictorials Definitions............. 4
General Safety ...................................................... 6
Personal Safety..................................................... 9
Work Area Safety................................................ 10
Legend ................................................................ 19
Controls............................................................... 20
Inspections.......................................................... 26
Operating Instructions......................................... 36
Transport and Lifting Instructions ....................... 46
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

Second Edition • First Printing Operator's Manual
Introduction
Part No. 1259841 S-40 TRAX • S-45 TRAX 1
Introducti on
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:
1 Comply with employer, job site and
governmental rules.
2 Read, understand and follow the instructions
in this and other manuals supplied with this
machine.
3 Use good safe work practices in a
commonsense way.
4 Only have trained/certified operators,
directed by informed and knowledgeable
supervision, running the machine.
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.

Operator's Manual Second Edition • First Printing
Introduction
2 S-40 TRAX • S-45 TRAX Part No. 1259841
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, could result
in minor or moderate injury.
Indicates a property damage
message.
Intended Use
This machine is intended to be used only to lift
personnel, along with their tools and materials to
an aerial work site.
DANGER
WARNING
CAUTION
NOTICE

Second Edition • First Printing Operator's Manual
Introduction
Part No. 1259841 S-40 TRAX • S-45 TRAX 3
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.

Operator's Manual Second Edition • First Printing
Symbol and Hazard Pictorials Definitions
4 S-40 TRAX • S-45 TRAX Part No. 1259841
Symbol and Hazard P ictorials Definiti ons
Crush hazard Keep away from
moving parts
Explosion hazard No smoking.
No flame.
Stop engine
Electrocution hazard
Maintain required
clearance
Crush hazard Keep away from path
of moving platform
Fall hazard Keep off this surface.
Tip-over hazard Platform downhill:
1Retract boom.
2Lower boom.
Platform uphill:
1Lower boom.
2Retract boom.
Tip-over hazard Replace tracks with
same tracks.
Tip-over hazard Read the operator’s
manual
Only trained
maintenance
personnel should
access
compartments
Tip-over hazard See serial label for
rated capacity.

Second Edition • First Printing Operator's Manual
Symbol and Hazard Pictorials Definitions
Part No. 1259841 S-40 TRAX • S-45 TRAX 5
Lanyard attachment
point
Tracks load Voltage rating for
power to platform
Pressure rating for air
line to platform
Have fire extinguisher
near.
Electrocution hazard Avoid contact Tie-down instructions Read the service
manual
Tie-down instructions Explosion / Burn
hazard
Explosion hazard Do not use ether or
other high energy
starting aids on
machines equipped
with glow plugs
Keep open flames
away.
Fire hazard Weight of welder
reduces capacity
+
+

Operator's Manual Second Edition • First Printing
General Safety
6 S-40 TRAX • S-45 TRAX Part No. 1259841
General Safety
114389
114258
28161
28161
114390
28177
97875
52865
217561
217561
28177
114258
28161
28161 C
Crush Hazard
Contact with moving parts can
result in death or serious
injury.
WARNING
Keep away from moving parts.
Crush Hazard
Death or serious
injury may result
from platform
crushing
personnel
against boom.
WARNING
28177 C
Keep away from
path of moving
platform.
Burn Hazard
Fuel and fumes
can explode
and burn.
DANGER
No smoking. No
flame. Stop
engine.
114258 A
114390
DANGER
DANGER
114389
WARNING
52865 97875

Second Edition • First Printing Operator's Manual
General Safety
Part No. 1259841 S-40 TRAX • S-45 TRAX 7

Operator's Manual Second Edition • First Printing
General Safety
8 S-40 TRAX • S-45 TRAX Part No. 1259841

Second Edition • First Printing Operator's Manual
Personal Safety
Part No. 1259841 S-40 TRAX • S-45 TRAX 9
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.
All PFPE must comply with applicable
governmental regulations, and must be inspected
and used in accordance with the PFPE
manufacturer’s instructions.

Operator's Manual Second Edition • First Printing
Work Area Safety
10 S-40 TRAX • S-45 TRAX Part No. 1259841
WorkArea Safety
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.
Electrocution Hazards
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,
the required clearance
contained in the chart
below must be followed.
Line Voltage Required Clearance
0 to 50KV 3.05 m
50 to 200KV 4.60 m
200 to 350KV 6.10 m
350 to 500KV 7.62 m
500 to 750KV 10.67 m
750 to 1000KV 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.
Maximum platform capacity 227 kg
Maximum occupants 2
The weight of options and accessories, such as
pipe cradles, panel 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.

Second Edition • First Printing Operator's Manual
Work Area Safety
Part No. 1259841 S-40 TRAX • S-45 TRAX 11
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.
If the tilt alarm sounds when the platform is raised,
use extreme caution. 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.
If the tilt alarm sounds with the
platform uphill:
1Lower the boom.
2Retract the boom.
If the tilt alarm sounds with the
platform downhill:
1Retract the boom.
2Lower the boom.
Do not raise the boom
when wind speeds may
exceed 12.5 m/s. If wind
speeds exceed 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.
Do not drive the machine on or near uneven terrain,
unstable surfaces or other hazardous conditions
with the boom raised or extended.

Operator's Manual Second Edition • First Printing
Work Area Safety
12 S-40 TRAX • S-45 TRAX Part No. 1259841
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 allowable
manual force – AUS
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.
Do not replace tracks with tires.
Do not modify or alter an aerial 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.
Do not place or attach
fixed or overhanging
loads to any part of this
machine.
Do not place ladders or
scaffolds in the platform
or against any part of this
machine.
Do not transport tools and materials unless they
are evenly distributed and can be safely handled
by person(s) in the platform.
Do not use the machine on a moving or mobile
surface or vehicle.
Be sure all track lug nuts are properly tightened.
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.

Second Edition • First Printing Operator's Manual
Work Area Safety
Part No. 1259841 S-40 TRAX • S-45 TRAX 13
Operation on Slopes Hazards
Do not drive the machine on a slope that exceeds
the maximum uphill, downhill or side slope rating of
the machine. Slope rating applies only to machines
in the stowed position.
Maximum slope rating, stowed position, 4WD
Platform downhill 40% (22°)
Platform uphill 40% (22°)
Side slope 25% (14°)
Note: Slope rating is subject to ground conditions
and adequate traction. See Driving on a Slope in
the Operating Instructions section.
Fall Hazards
Occupants must wear a
safety belt or harness in
accordance with
governmental regulations.
Attach the lanyard to the
anchor provided in the
platform.
Do not sit, stand or climb
on the platform guard
rails. Maintain a firm
footing on the platform
floor at all times.
Do not climb down from
the platform when raised.
Keep the platform floor clear of debris.
Lower the platform entry mid-rail or close the entry
gate before operating.
Do not enter or exit the platform unless the
machine is in the stowed position and the platform
is at ground level.

Operator's Manual Second Edition • First Printing
Work Area Safety
14 S-40 TRAX • S-45 TRAX Part No. 1259841
Collision Hazards
Be aware of limited sight
distance and blind spots
when driving or operating.
Be aware of the boom position and tailswing when
rotating the turntable.
Check the work area for
overhead obstructions or
other possible hazards.
Be aware of crushing
hazards when grasping
the platform guard rail.
Operators must comply with employer, job site and
governmental rules regarding use of personal
protective equipment.
Observe and use the color-coded direction arrows
on the platform controls and drive chassis for drive
and steer functions.
Stay clear of all Trax rotating or moving parts such
as sprockets and rollers.
Do not lower the boom
unless the area below is
clear of personnel and
obstructions.
Limit travel speed
according to the
condition of the ground
surface, congestion,
slope, location of
personnel, and any othe
r
factors which may cause
collision.
Do not operate a boom in the path of any crane
unless the controls of the crane have been locked
out and/or precautions have been taken to prevent
any potential collision.
No stunt driving or horseplay while operating a
machine.

Second Edition • First Printing Operator's Manual
Work Area Safety
Part No. 1259841 S-40 TRAX • S-45 TRAX 15
Bodily Injury Hazard
Do not operate the machine with a hydraulic oil or
air leak. An air leak or hydraulic leak can penetrate
and/or burn skin.
Always operate the machine in a well-ventilated
area to avoid carbon monoxide poisoning.
Do not allow any object to come near moving parts.
The object could be thrown out of the Trax
undercarriage.
Improper contact with components under any
cover will cause serious injury. Only trained
maintenance personnel should access
compartments. Access by the operator is only
advised when performing a pre-operation
inspection. All compartments must remain closed
and secured during operation.
Explosion and Fire Hazards
Do not start the engine if you smell or detect liquid
petroleum gas (LPG), gasoline, diesel fuel or other
explosive substances.
Do not refuel the machine with the engine running.
Refuel the machine and charge the battery only in
an open, well-ventilated area away from sparks,
flames and lighted tobacco.
Do not operate the machine or charge the battery
in hazardous locations or locations where
potentially flammable or explosive gases or
particles may be present.
Do not spray ether into engines equipped with
glow plugs.
Damaged Machine Hazards
Do not use a damaged or malfunctioning machine.
Conduct a thorough pre-operation inspection of the
machine and test all functions before each work
shift. Immediately tag and remove from service a
damaged or malfunctioning machine.
Be sure all maintenance has been performed as
specified in this manual and the appropriate Genie
service manual.
Be sure all decals are in place and legible.
Be sure the operator's, safety and responsibilities
manuals are complete, legible and in the storage
container located on the machine.
Component Damage Hazards
Do not use any battery or charger greater than 12V
to jump-start the engine.
Do not use the machine as a ground for welding.

Operator's Manual Second Edition • First Printing
Work Area Safety
16 S-40 TRAX • S-45 TRAX Part No. 1259841
Battery Safety
Burn Hazards
Batteries contain acid.
Always wear protective
clothing and eye wear when
working with batteries.
Avoid spilling or contacting
battery acid. Neutralize
battery acid spills with
baking soda and water.
Explosion Hazards
Keep sparks, flames and
lighted tobacco away from
batteries. Batteries emit
explosive gas.
Electrocution Hazard
Avoid contact with electrical terminals.
Welder Safety
Read, understand and obey all warnings and
instructions provided with the welding power unit.
Do not connect weld leads or cables unless the
welding power unit is turned off at the platform
controls.
Do not operate unless the weld cables are properly
connected and the welder is properly grounded.
The weight of the welder will reduce the rated
platform capacity and must be factored into the
total platform load. The welder power supply
weighs 34 kg.
Do not operate the welder unless a fire
extinguisher is immediately available for instant
use, per OSHA regulation 1926.352(d).
Weld Line to Platform Safety
Read, understand and obey all warnings and
instructions provided with the welding power unit.
Do not connect weld leads or cables unless the
welding power unit is turned off at the platform
controls.
Do not operate unless the weld cables are properly
connected.
Connect the positive lead to the twist-lock
connector at the turntable and platform.
Clamp the negative lead to the ground post at the
turntable and platform.

Second Edition • First Printing Operator's Manual
Work Area Safety
Part No. 1259841 S-40 TRAX • S-45 TRAX 17
Pipe Cradle Safety
Read, understand and obey all warnings and
instructions provided with the pipe cradles.
Do not exceed the rated platform capacity. The
pipe cradle assembly and the weight in the pipe
cradles will reduce rated platform capacity and
must be factored into total platform load.
The pipe cradle assembly weighs 9.5 kg.
The maximum capacity of the pipe cradle
assembly is 91 kg.
The weight of the pipe cradle assembly and the
load in the pipe cradles may limit the maximum
number of occupants in platform.
Center the load within the perimeter of the
platform.
Secure the load to the platform.
Do not obstruct the entrance or the exit of the
platform.
Do not obstruct the ability to operate the platform
controls or the red Emergency Stop button.
Do not operate unless you are adequately
instructed and are aware of all of the hazards
associated with movement of the platform with an
overhanging load.
Do not cause a horizontal force or side load to
machine by raising or lowering a fixed or
overhanging load.
Electrocution Hazard: Keep pipes away from all
energized electrical conductors.
Panel Cradle Safety
Read, understand and obey all warnings and
instructions provided with the panel cradles.
Do not exceed the rated platform capacity. The
combined weight of the cradles, panels, occupants,
tools and any other equipment must not exceed
rated capacity.
The panel cradle assembly weighs 13.6 kg.
The maximum capacity of the panel cradles is
113 kg.
The weight of the panel cradles and the load in the
panel cradles may limit the maximum number of
occupants in platform to one person.
Secure the cradles to the platform. Secure the
panel(s) to the platform railing using the straps
provided.
Do not operate unless you are adequately
instructed and are aware of all hazards associated
with lifting panels.
Do not cause a horizontal force or side load to
machine by raising or lowering a fixed or
overhanging load.
Maximum vertical height of panels: 1.2 m
Maximum wind speed: 6.7 m/sec
Maximum panel area: 3 m2

Operator's Manual Second Edition • First Printing
Work Area Safety
18 S-40 TRAX • S-45 TRAX Part No. 1259841
Lockout After Each Use
1Select a safe parking location—firm level
surface, clear of obstruction and traffic.
2Retract and lower the boom to the stowed
position.
3Rotate the turntable so that the boom is
between the non-steer wheels.
4Turn the key switch to the off position and
remove the key to secure from unauthorized
use.