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

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Operator's Manual
GS
-4655
™
Serial Number Range
from GS55D-101
ANSI/CSA
North America
South America
Asia
with
Maintenance
Information
Original Instructions
First Edition
Third Printing
Part No. 1294978GT

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Summary of Contents for Terex Genie GS-4655

  • Page 1 Operator's Manual Serial Number Range -4655 ™ from GS55D-101 ANSI/CSA North America South America Asia with Maintenance Information Original Instructions First Edition Third Printing Part No. 1294978GT...

  • Page 2: Table Of Contents

    Specifications ............56 Copyright © 2019 Terex Corporation First Edition: Third Printing, May 2022 Genie is a registered trademark of Terex South Dakota, Inc. in the U.S.A. and many other countries. “GS” is a trademark of Terex South Dakota, Inc.

  • Page 3: Introduction

    First Edition • Third Printing Operator's Manual Introduction Introduction 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 • Third 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) Drive and steer.
  • Page 5 First Edition • Third 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 • Third 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 • Third 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 • Third 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 • Third 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 Wheel load Lifting and tie down Lifting point Lanyard anchorage Wind speed instructions points...

  • Page 10: General Safety

    Operator's Manual First Edition • Third Printing General Safety General Safety ™ -4655 Part No. 1294978GT...
  • Page 11 First Edition • Third Printing Operator's Manual General Safety Part No. 1294978GT ™ -4655...
  • Page 12 Operator's Manual First Edition • Third Printing General Safety ™ -4655 Part No. 1294978GT...
  • Page 13 First Edition • Third Printing Operator's Manual General Safety Part No. 1294978GT ™ -4655...
  • Page 14 Operator's Manual First Edition • Third Printing General Safety ™ -4655 Part No. 1294978GT...

  • Page 15: Personal Safety

    First Edition • Third 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 16: Work Area Safety

    Operator's Manual First Edition • Third Printing Work Area Safety Tip-over Hazards Work Area Safety Electrocution Hazards Occupants, equipment and materials shall not This machine is not electrically insulated and will exceed the maximum platform capacity or the not provide protection from contact with or maximum platform capacity of the platform proximity to electrical current.
  • Page 17 First Edition • Third Printing Operator's Manual Work Area Safety Do not raise the platform Do not operate the unless the machine is on a machine in strong or gusty firm, level surface. winds. Do not increase the surface area of the platform or the load.
  • Page 18 Operator's Manual First Edition • Third Printing Work Area Safety Follow ratings for allowable manual force and Do not place or attach number of occupants shown below. fixed or overhanging loads to any part of this Do not push off or pull machine.
  • Page 19 First Edition • Third Printing Operator's Manual Work Area Safety Crushing Hazard Fall Hazards Keep hands and limbs out of scissors. The guard rail system provides fall protection. If occupant(s) of the platform are required to wear Keep hands clear when folding rails. personal fall protection equipment (PFPE) due to job site or employer rules, PFPE and its use shall Do not work under the platform or in the scissor...
  • Page 20 Operator's Manual First Edition • Third Printing Work Area Safety Collision Hazards Keep the platform floor clear of debris. Close the entry gate before operating. Be aware of limited sight distance and blind spots Do not operate the machine unless the guard rails when driving or operating.
  • Page 21 First Edition • Third Printing Operator's Manual Work Area Safety Bodily Injury Hazard Do not lower the platform unless the area below is Do not operate the machine with a hydraulic oil or clear of personnel and air leak. An air leak or hydraulic leak can penetrate obstructions.
  • Page 22 Operator's Manual First Edition • Third 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 23 First Edition • Third Printing Operator's Manual Work Area Safety Lockout After Each Use Component Damage Hazard Do not use any battery charger greater than 24V Select a safe parking location—firm level to charge the batteries. surface, clear of obstruction and traffic. Lower the platform.

  • Page 24: Legend

    Operator's Manual First Edition • Third Printing Legend Legend Lanyard anchorage points Platform guard rails Platform extension release pedal Manual storage container Platform controls Platform extension Transport tie-down Auxiliary 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 25: Controls

    First Edition • Third Printing Operator's Manual Controls Controls The ground control station is to be used as a means to raise the platform for function 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.
  • Page 26 Operator's Manual First Edition • Third Printing Controls Platform Control Panel Red Emergency Stop button Horn 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 27 First Edition • Third 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 28: Inspections

    Operator's Manual First Edition • Third 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 First Edition • Third 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 30 Operator's Manual First Edition • Third 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 First Edition • Third Printing Operator's Manual Inspections At the Ground Controls Test the Up/Down Functions The audible warnings on this machine and the Select a test area that is firm, level and free of standard horn all come from the same central hazards.
  • Page 32 Operator's Manual First Edition • Third Printing Inspections Test Auxiliary Lowering Test the Function Enable Switch and the Up/Down Functions 15 Activate the up function by pressing the lift enable button and platform up button, and 22 Do not hold the function enable switch on the raise the platform approximately 2 ft.
  • Page 33 First Edition • Third Printing Operator's Manual Inspections Test the Drive Function Button 29 Release the control handle. Result: The platform should stop raising. 35 Press the drive function button. 30 Press and hold the function enable switch on the control handle. Slowly move the control 36 Wait seven seconds for the drive function to handle in the direction indicated by the yellow time out.
  • Page 34 Operator's Manual First Edition • Third Printing Inspections Test Drive and Braking Test Drive Tilt Cutout Note: Perform this test from the ground with the 41 Press the drive function button. platform controller. Do not stand in the platform. 45 Fully lower the platform. 42 Press and hold the function enable switch on 46 Drive the machine onto a slope where the the control handle.
  • Page 35 First Edition • Third Printing Operator's Manual Inspections 54 Drive the machine onto a slope where the 61 Fully lower the platform. pitch angle is greater than 1.5° side to side. 62 Drive the machine. Result: The machine should stop once the Result: The machine should drive.
  • Page 36 Operator's Manual First Edition • Third Printing Inspections Test the Pothole Guards 73 Press the drive function button. Note: The pothole guards should automatically deploy when the platform is raised. The pothole 74 Press and hold the function enable switch on guards activate limit switches that allow the the control handle.
  • Page 37 First Edition • Third 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 You learn and practice the principles of safe ...
  • Page 38 Operator's Manual First Edition • Third Printing Inspections Inspection for Decals with Words Part No. Decal Description GS-4655 1290655 Instructions – Maximum Side Force 1290659 Danger – Electrocution Hazard Determine whether the decals on your machine 1290662 Label – Chevron Rando have words or symbols.
  • Page 39 First Edition • Third Printing Operator's Manual Inspections 137605 1283810 137656 28236 1301158 82557 1296034 1293165 44736 1294707 43618 1294635 1281174 1290655 1294398 44981 *1292047 *1292048 1296034 43618 43619 82561 1294707 82561 1292990 1294707 1290664 72086 1292960 1263543 72086 52475 *1292049 1292275 *1292050...
  • Page 40 Operator's Manual First Edition • Third Printing Inspections Inspection for Decals with Part No. Decal Description Symbols GS-4655 1272242 Label – Machine Registration/Owner Transfer Determine whether the decals on your machine 1281174 Label – Lanyard Anchorage Point, Fall have words or symbols. Use the appropriate Arrest/Fall Restrained inspection to verify that all decals are legible and 1283810 Label –...
  • Page 41 First Edition • Third Printing Operator's Manual Inspections 137605 1283810 137656 82487 1296034 1293217 114338 43618 1293166 1281174 1292751 1294688 44981 1292961 1296034 43618 97719 82474 1293217 82474 1292990 72086 1293217 72086 52475 1292962 1292275 1292750 1272242 114337 1265361 1290699 1292746 1292746 1292961...

  • Page 42: Operating Instructions

    Operator's Manual First Edition • Third 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 43 First Edition • Third Printing Operator's Manual Operating Instructions Emergency Stop Operation from Platform Push in the red Emergency Stop button to the off Be sure the battery pack is connected before position at the ground controls or the platform operating the machine.
  • Page 44 Operator's Manual First Edition • Third Printing Operating Instructions To Steer Increase speed: Slowly move the control 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 45 First Edition • Third Printing Operator's Manual Operating Instructions Driving on a slope Lay the piece of wood on the slope. Determine the slope and side slope ratings for the At the downhill end, lay the level on the top edge machine and determine the slope grade.
  • Page 46 Operator's Manual First Edition • Third Printing Operating Instructions Platform Overload Operational indicator codes If the platform controls LED or ground controls If the platform controls LED diagnostic readout LCD diagnostic readout displays an operational displays a flashing OL and the ground controls indicator code such as LL, the fault condition must LCD diagnostic readout displays OL: Platform repaired or removed before resuming machine...
  • Page 47 First Edition • Third Printing Operator's Manual Operating Instructions Battery Level Indicator Tilt Sensor Activation Settings Chassis Angle (side to side) 1.5° Use the LED diagnostic readout to determine the battery level. Chassis Angle (front to back) 3° If the tilt alarm sounds while Note: When a blinking LO code appears on the raising the platform, lower the platform controls LED display, the machine must...
  • Page 48 Operator's Manual First Edition • Third Printing Operating Instructions How to Use the Safety Arm How to Fold Down the Guardrails Raise the platform approximately 14 ft / 4.24 m The platform railing system consists of three fold down rail sections for the extension deck and three from the ground.
  • Page 49 First Edition • Third Printing Operator's Manual Operating Instructions How to Raise the Guardrails Fold down left side rail assembly together with front rail. Follow the fold down instructions but in reverse Keep hands free of pinch points. order, ensuring all lock pins are in place and installed properly.
  • Page 50 Operator's Manual First Edition • Third Printing Operating Instructions Standard Batteries Remove the battery vent caps and check the battery acid level. If necessary, add only enough distilled water to cover the plates. Do not overfill prior to the charge cycle. Replace the battery vent caps.

  • Page 51: Transport And Lifting Instructions

    First Edition • Third Printing Operator's Manual Transport and Lifting Instructions Transport and Lifting Instructions  The machine must be on a level surface or secured before releasing the brakes.  Do not allow the rails to fall when the snap pins are removed.
  • Page 52 Open the hydraulic tray. Towing the Genie GS-4655 is not recommended. If the machine must be towed, do not exceed Remove the protective cover 2.5 mph/4 km/h.
  • Page 53 First Edition • Third Printing Operator's Manual Transport and Lifting Instructions Securing to Truck or Trailer for Inspect the entire machine for loose or unsecured items. Transit Use chains or straps of ample load capacity. Always use the extension deck lock when the machine is transported.
  • Page 54 Operator's Manual First Edition • Third Printing 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 55 First Edition • Third Printing Operator's Manual Transport and Lifting Instructions Lifting Instructions Fully lower the platform. Be sure the extension deck, controls and component trays are secure. Remove all loose items on the machine. Determine the center of gravity of your machine using the table and the picture on this page.

  • Page 56: Maintenance

    Operator's Manual First Edition • Third Printing Maintenance Check the Hydraulic Oil Level Maintenance Maintaining the hydraulic oil at the proper level is essential to machine operation. Improper hydraulic Observe and Obey: oil levels can damage hydraulic components. Daily checks allow the inspector to identify changes in ...
  • Page 57 First Edition • Third 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 58: Specifications

    Operator's Manual First Edition • Third Printing Specifications Specifications Model 24V 300AH GS-4655 Power source Height, working maximum System voltage Indoor 51 ft 9 in 15.95 m AC outlet in platform Standard Outdoor 27.5 ft 8.55 m 2900 psi 200 bar Maximum hydraulic pressure (functions) Height, platform maximum...

This manual is also suitable for:

Gs55d-101

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