Genie GS-4655 Operator's Manual
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Genie GS-4655 Operator's Manual

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Operator's Manual
GS
-4655
™
Serial Number Range
from GS55D-101
AUS
Australia
with
Information
First Edition
First Printing
Part No. 1294977GT

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Summary of Contents for Genie GS-4655

  • Page 1 Operator's Manual Serial Number Range -4655 ™ from GS55D-101 Australia with Maintenance Information First Edition First Printing Part No. 1294977GT...

  • Page 2: Table Of Contents

    Specifications ............51 Copyright © 2019 Terex Corporation First Edition First Printing, May 2019 Genie is registered trademarks of Terex South Dakota, Inc. in the U.S.A. and many other countries. “GS” is a trademark of Terex South Dakota, Inc. These machines comply with AS 1418.10...

  • Page 3: Introduction

    This book is an operation and daily maintenance aerial work site. Before operating the machine, it’s manual for the user or operator of a Genie the operator’s responsibility to read and machine. understand this familiarization guide.
  • Page 4 Operator's Manual First Edition • First Printing Introduction Platform controls symbology and related Ground controls symbology and related machine movement: machine movement: Lift function enable button Lift function enable button Drive function enable button Platform up/down button Platform up/down (when lift Sequential functions and movement: function selected) ...
  • Page 5 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 • First Printing Introduction 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.
  • Page 7 First 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 8: Symbol And Hazard Pictorials Definitions

    Operator's Manual First Edition • First Printing Symbol and Hazard Pictorials Definitions Symbol and Hazard Pictorials Definitions Read the operator’s Read the service Crush hazard Crush hazard Collision hazard manual manual Tip-over hazard Tip-over hazard Tip-over hazard Tip-over hazard Electrocution hazard Electrocution hazard Explosion hazard Fire hazard...
  • Page 9 First Edition • First Printing Operator's Manual Symbol and Hazard Pictorials Definitions Batteries used as Chock the wheels No smoking Grounded AC Replace damaged counterweights 3-wire only wires and cords Lifting & tie down Lifting & tie down Lanyard anchorage Wheel load Wind speed instructions...

  • Page 10: General Safety

    Operator's Manual First Edition • First Printing General Safety General Safety 82561 1294707 31060 1263543 1290675 1292748 DANGER Tip-over hazard. Failure to replace batteries with proper weight batteries will result Batteries are used as counterweight and are critical to must weigh 82 lbs / 37 kg. Battery box including batteries must weigh a minimum of 415 lbs /...
  • Page 11 First Edition • First Printing Operator's Manual General Safety 1294707 82561 1292960 DANGER 1263543 1 Make sure machine is on a firm, level surface or secured. 2 Chock wheels. Collision Hazard Failure to secure machine before 3 Release brakes. releasing brakes will result in death or serious injury.
  • Page 12 Operator's Manual First Edition • First Printing General Safety 1294707 44736 28236 1294635 1293165 1290655 ™ -4655 Part No. 1294977GT...

  • Page 13: Personal Safety

    First Edition • First Printing Operator's Manual Personal Safety Personal Safety Personal Fall Protection Personal fall protection equipment (PFPE) is not required when operating this machine. If PFPE is required by job site or employer rules, the following shall apply: All PFPE must comply with applicable governmental regulations and must be inspected and used in accordance with the manufacturer’s...

  • Page 14: Work Area Safety

    Platform Extension Maximum electrical power lines. At Model retracted only only occupants a minimum, the required GS-4655 350 kg 214 kg 136 kg clearance contained in the chart below must be Platform retracted Platform extended followed. Line Voltage Required Clearance 0 to 50KV 3.05 m...
  • Page 15 First Edition • First Printing Operator's Manual Work Area Safety Do not raise the platform Do not operate the unless the machine is on machine in strong or a firm, level surface. gusty winds. Do not increase the surface area of the platform or the load.
  • Page 16 Batteries are used as counterweight and are critical to machine stability. Do not use the machine on a moving or mobile For GS-4655 machines,each battery must weigh surface or vehicle. 37 kg. the battery tray including batteries must Be sure all tires are in good condition, castle nuts weigh a minimum of 188 kg.
  • Page 17 Model GS-4655 25% (14°) 25% (14°) Note: Slope rating is subject to ground conditions with one person in the platform and adequate traction. Additional platform weight may reduce slope rating. See Driving on a Slope in the Operating Instructions section.
  • Page 18 Operator's Manual First Edition • First Printing Work Area Safety Observe and use color-coded direction arrows on Collision Hazards the platform controls and the platform decal plate for drive and steer functions. Be aware of limited sight distance and blind spots Do not lower the when driving or operating.
  • Page 19 Be sure all maintenance has been performed as compartments. Access by the operator is only specified in this manual and the appropriate Genie advised when performing a pre-operation service manual. inspection. All compartments must remain closed and secured during operation.
  • Page 20 Operator's Manual First Edition • First Printing Work Area Safety Component Damage Hazard Battery Safety Do not use any battery charger greater than 24V to Burn Hazards charge the batteries. Batteries contain acid. Electrocution/Burn Hazards Always wear protective clothing and eye wear when Connect the battery charger to a working with batteries.
  • Page 21 First Edition • First Printing Operator's Manual Work Area Safety Lockout After Each Use Select a safe parking location—firm level surface, clear of obstruction and traffic. Lower the platform. Turn the key switch to the off position and remove the key to secure from unauthorized use.

  • Page 22: Legend

    Operator's Manual First Edition • First Printing Legend Legend Lanyard anchorage points Platform guard rails Platform extension release pedal Manual storage container Platform controls Platform extension Transport tie-down Emergency lowering knob Flashing beacon 10 Steer tire 11 Pothole guard 12 LCD readout 13 Ground controls 14 Brake release switch (hydraulic side) 15 Non-steer tire...

  • Page 23: Controls

    First Edition • First Printing Operator's Manual Controls Controls The ground control station is to be used as a means to raise the platform for functions tests and for storage purposes. The ground control station can be used in the event of an emergency to rescue an incapacitated person in the platform Ground Control Panel Menu escape button...
  • Page 24 Operator's Manual First Edition • First Printing Controls 1283810 A 1283810 A Platform Control Panel Horn button Red Emergency Stop button Push in the red Emergency Stop button to the Press the horn button and the horn off position to stop all functions. Pull out the will sound.
  • Page 25 First Edition • First Printing Operator's Manual Controls Proportional control handle and function Thumb rocker switch for steer function enable switch for drive, steer, and lift functions Press the left side of the thumb Lift function: Press and hold the function rocker and the machine will turn in enable switch to enable the lift function on the the direction the blue triangle...

  • Page 26: Inspections

    Operator's Manual First 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 27 First Edition • First Printing Operator's Manual Inspections Pre-operation Inspection  Safety arm  Platform extension  Be sure that the operator’s, safety, and  Scissor pins and retaining fasteners responsibilities manuals are complete, legible and in the storage container located in the ...
  • Page 28 Operator's Manual First 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 29 First Edition • First Printing Operator's Manual Inspections Test the Up/Down Functions At the Ground Controls This machine uses both flashing lights and audible Select a test area that is firm, level and free of alarms. Descent alarm: Lights flash and alarm obstruction.
  • Page 30 Operator's Manual First Edition • First Printing Inspections Test Emergency Lowering At the Platform Controls 15 Activate the up function by pressing the lift Test Emergency Stop enable button and platform up button, and raise the platform approximately 60 cm. 19 Push in the platform red Emergency Stop button to the off position.
  • Page 31 First Edition • First Printing Operator's Manual Inspections 27 Press the lift function button. Test the Outdoor and Indoor Use Buttons 28 Press and hold the function enable switch on 31 Do not press and hold the function enable the control handle. Slowly move the control switch on control handle.
  • Page 32 Operator's Manual First Edition • First Printing Inspections Test the Drive Function Button Test Drive and Braking 39 Press the drive function button. 46 Press the drive function button. 40 Wait seven seconds for the drive function to 47 Press and hold the function enable switch on time out.
  • Page 33 First Edition • First Printing Operator's Manual Inspections 58 Raise the platform approximately 2.78 m from Test Drive Tilt Cutout the ground. Note: Perform this test from the ground with the Result: The platform should stop and the tilt platform controller. Do not stand in the platform. alarm will sound at 180 beeps per minute.
  • Page 34 Operator's Manual First Edition • First Printing Inspections 68 Lower the platform. Test Elevated Drive Speed Result: The pothole guards should return to 63 Raise the platform approximately 2.78 m from the stowed position. the ground. 69 Place a 2x4 or similar piece of wood under a 64 Press the drive function button.
  • Page 35 First Edition • First Printing Operator's Manual Inspections Workplace Inspection Fundamentals The workplace inspection helps the operator determine if the workplace is suitable for safe machine operation. It should be performed by the operator prior to moving the machine to the workplace.
  • Page 36 1292051 Label – Emergency Lowering 52475 Label – Transport Tie-down 1292275 Label – Electric Drive, E-Drive 72086 Label – Lifting Point 1292746 Label – Wheel Load, GS-4655 72143 Label – Emergency Stop 1292747 Label - Tire Specification 82557 Label – Platform Controls Location 1292748 Label –...
  • Page 37 First Edition • First Printing Operator's Manual Inspections 1283810 82557 1294707 44736 1293165 281175 137605 137656 28236 1294706 1296034 43618 1294635 1290655 44981 *1292047 *1292048 1281175 44981 1296034 43618 43619 82561 1294707 82561 1292990 1294707 1290664 1292960 72086 1263543 1272242 72086 52475 *1295049...

  • Page 38: Operating Instructions

    Operator's Manual First 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 First Edition • First Printing Operator's Manual Operating Instructions To Position Platform Emergency Stop Press the lift function button. On Push in the red Emergency Stop button to the off the LCD screen, a circle below the position at the ground controls or the platform lift function symbol will turn on.
  • Page 40 Operator's Manual First Edition • First Printing Operating Instructions Increase speed: Slowly move the control To Steer handle off center. Press the drive function button. On the LCD Decrease speed: Slowly move the control screen, a circle below the drive function handle toward center.
  • Page 41 You will need: Maximum slope rating, stowed position:  carpenter’s level GS-4655 14°  straight piece of wood, at least 1 m long Maximum side slope rating, stowed position: ...
  • Page 42 Overload Recovery For further information, please consult the If the ground controls LCD diagnostic readout appropriate Genie Service Manual. A code and a displays Overload Recovery, the emergency description of a code can also be viewed at the lowering system has been used while the platform ground controls LCD display.
  • Page 43 First Edition • First Printing Operator's Manual Operating Instructions Operation from Ground with How to Use the Safety Arm Controller Raise the platform approximately 4.24 m from the ground. Maintain safe distances between the operator, machine and fixed objects. Rotate the safety arm away from the machine and let it hang down.
  • Page 44 Operator's Manual First Edition • First Printing Operating Instructions Fold down left side rail assembly. Keep hands How to Fold Down the Guardrails clear of pinch points. The platform railing system consists of three fold Fold down right side rail assembly. Keep down rail sections for the extension deck and three hands clear of pinch points.
  • Page 45 Use proper AC input voltage for charging as indicated on the charger. Dry Battery Filling and Charging  Use only a Genie authorized battery and Instructions charger. Remove the battery vent caps and permanently remove the plastic seal from the To Charge Battery battery vent openings.

  • Page 46: Transport And Lifting Instructions

     Genie customers needing to containerize any lift or Genie product should source a qualified freight forwarder with expertise in preparing, loading and securing construction and lifting equipment for international shipment. ...
  • Page 47 Push the red Emergency stop button at both ground and platform controls to off position. Open the hydraulic tray. Towing the Genie GS-4655 is not recommended. Remove the protective cover If the machine must be towed, do not exceed from the toggle switch.
  • Page 48 Operator's Manual First Edition • First Printing Transport and Lifting Instructions Inspect the entire machine for loose or unsecured Securing to Truck or Trailer for items. Transit Use chains or straps of ample load capacity. Always use the extension deck lock when the Use a minimum of 2 chains or straps.
  • Page 49 First Edition • First Printing Operator's Manual Transport and Lifting Instructions Lifting the Machine with a Forklift Be sure the extension deck, controls and component trays are secure. Remove all loose items on the machine. Fully lower the platform. The platform must remain lowered during all loading and transport Observe and Obey: procedures.
  • Page 50 Adjust the rigging to prevent damage to the machine and to keep the machine level. Center of Gravity Table Model X Axis Y Axis 110.7 cm 94.4 cm GS-4655 X Axis Y Axis ™ -4655 Part No. 1294977GT...

  • Page 51: Maintenance

    FULL governmental regulations. Add oil as needed. Do not overfill.  Use only Genie approved replacement parts. Hydraulic oil specifications Hydraulic oil type Chevron Rando HD equivalent Maintenance Symbols Legend The following symbols have been used in this manual to help communicate the intent of the instructions.
  • Page 52 Operator's Manual First Edition • First Printing 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 53: Specifications

    3700 kg should be used only with adequate safety factors. (Machine weights vary with option configurations. See Continuous improvement of our products is a Genie serial label for specific machine weight.) policy. Product specifications are subject to change 24V 300AH without notice or obligation.

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