Terex Genie S-3200 Operator's Manual
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Terex Genie S-3200 Operator's Manual

Terex Genie S-3200 Operator's Manual

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Operator's Manual
S-3200
S-3800
Serial Number Range
from S320011D-0101
from S380011D-0101
CE
with
Maintenance
Information
Original Instructions
First Edition
Fourth Printing
Part No. T111109

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Summary of Contents for Terex Genie S-3200

  • Page 1 Operator's Manual Serial Number Range S-3200 from S320011D-0101 S-3800 from S380011D-0101 with Maintenance Information Original Instructions First Edition Fourth Printing Part No. T111109...

  • Page 2: Table Of Contents

    Specifications ............50 Copyright © 2011 by Terex Corporation First Edition: Fourth Printing, April 2013 Genie is aregistered trademarks of Terex South Dakota, Inc. in the U.S.A. and many other countries. Complies with EC Directive 2006/42/EC See EC Declaration of Conformity S-3200 •...

  • Page 3: Introduction

    First Edition • Fourth 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 First Edition • Fourth 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: Symbol And Hazard Pictorials Definitions

    First Edition • Fourth Printing Operator's Manual Symbol and Hazard Pictorials Definitions Symbol and Hazard Pictorials Definitions Crush hazard Keep away from Explosion hazard No smoking. Electrocution hazard moving parts No flame. Stop engine Maintain required Keep away from path Crush hazard Fall hazard Keep off this surface.
  • Page 6 Operator's Manual First Edition • Fourth Printing Symbol and Hazard Pictorials Definitions Lanyard attachment Wheel load Fire hazard Have fire extinguisher Voltage rating for point near. power to platform Electrocution hazard Avoid contact Tie-down instructions Tie-down instructions Pressure rating for air line to platform Explosion hazard Do not use ether or...

  • Page 7: General Safety

    First Edition • Fourth Printing Operator's Manual General Safety General Safety 82472 82487 82548 133067 114252 133067 A 114249 T114286 133067 T114286 82487 114252 133067 114249 82472 114249 82472 T114286 82548 Part No. T111109 S-3200 • S-3800...
  • Page 8 Operator's Manual First Edition • Fourth Printing General Safety 114473 82487 114473 A 82487 C 82604 82547 340 kg 12.5 m/sec < = 82604 C 340 kg 82547 B S-3200 • S-3800 Part No. T111109...
  • Page 9 First Edition • Fourth Printing Operator's Manual General Safety 82548 114252 T114286 82472 114251 82481 133067 T110471 133067 133205 82473 114252 114249 82472 82472 T114286 114249 82472 82473 82481 133067 82548 114251 133205 114249 T110471 T114286 114252 T110471 A Part No. T111109 S-3200 •...

  • Page 10: Personal Safety

    Operator's Manual First Edition • Fourth Printing 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 11: Work Area Safety

    First Edition • Fourth Printing Operator's Manual Work Area Safety Work Area Safety Tip-over Hazards Electrocution Hazards Occupants, equipment and materials shall not This machine is not electrically insulated and will exceed the maximum platform capacity. not provide protection from contact with or proximity to electrical current.
  • Page 12 Operator's Manual First Edition • Fourth Printing Work Area Safety If the tilt alarm sounds while the boom is lowered: Use extreme care and Do not extend, rotate or raise the boom above slow speeds while driving horizontal. Move the machine to a firm, level the machine in the surface before raising the platform.
  • Page 13 First Edition • Fourth Printing Operator's Manual Work Area Safety Do not replace items critical to machine stability Do not use air-filled tires. These machines are with items of different weight or specification. equipped with solid tires. Wheel weight is critical to stability.
  • Page 14 Operator's Manual First Edition • Fourth Printing Work Area Safety Fall Hazards Collision Hazards Occupants must wear a Be aware of limited sight safety belt or harness in distance and blind spots accordance with when driving or operating. governmental regulations. Attach the lanyard to the anchor provided in the platform.
  • Page 15 First Edition • Fourth Printing Operator's Manual Work Area Safety Observe and use the color-coded direction arrows Bodily Injury Hazard on the platform controls and drive chassis for drive Do not operate the machine with a hydraulic oil or and steer functions. air leak.
  • Page 16 Operator's Manual First Edition • Fourth 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 the Batteries contain acid. machine and test all functions before each work Always wear protective shift.
  • Page 17 First Edition • Fourth Printing Operator's Manual Work Area Safety Overhead Platform Protection Lower Platform Protection Safety Safety The maximum weight for overhead platform The maximum weight for lower platform protection protection is 11.5 kg and does not have to be is 13 kg and does not have to be subtracted from subtracted from the total capacity of the platform.

  • Page 18: Legend

    Operator's Manual First Edition • Fourth Printing Legend Legend Platform bumpers Non-steer tire Lanyard anchorage point Steer tire Sliding mid-rail Ground controls 10 Manual storage container Boom 11 Foot switch Platform controls Platform S-3200 • S-3800 Part No. T111109...

  • Page 19: Controls

    First Edition • Fourth Printing Operator's Manual Controls Controls STOP Ground Control Panel 10 Key switch for off/platform/ground selection Boom down button 11 Engine start button Boom extend/retract buttons 12 Emergency power button Boom up button 13 High speed function enable button Engine speed select button 14 Low speed function enable button LCD screen control buttons...
  • Page 20 Operator's Manual First Edition • Fourth Printing Controls LCD readout screen Ground Control Panel Boom down button Press the boom down button and the boom will lower. a low fuel indicator b engine oil pressure indicator c water temperature indicator Boom extend/retract buttons d auxiliary power indicator Press the boom...
  • Page 21 First Edition • Fourth Printing Operator's Manual Controls 12 Emergency power button 18 Platform rotate left/right buttons Use emergency power if the primary power Press the platform rotate left source (engine) fails. button and the platform will Simultaneously hold the emergency power rotate left.
  • Page 22 Operator's Manual First Edition • Fourth Printing Controls Platform Control Panel 10 Diesel models: Glow plug Platform rotate switch 13 Not used button with indicator light Platform level switch 14 Fault indicator light Gasoline/LPG models: Choke Platform not level indicator 15 Low fuel indicator light button with indicator light light...
  • Page 23 First Edition • Fourth Printing Operator's Manual Controls 22 Drive speed select button with 25 Axle retract button with 18 Dual axis proportional control indicator lights: indicator light handle for drive and steer Machine on incline symbol: functions 26 Used for optional equipment Low range operation for OR Proportional control 27 Drive enable button with...
  • Page 24 Operator's Manual First Edition • Fourth Printing Controls Raise boom indicator light Platform Control Panel To continue extending, raise the boom until the Platform rotate switch indicator light goes out. Move the platform rotate Horn button switch to the right and the platform will rotate to Press this button and the horn will sound.
  • Page 25 First Edition • Fourth Printing Operator's Manual Controls 12 Engine idle (rpm) select button with indicator 18 Dual axis proportional control handle for drive lights and steer functions OR Proportional control handle for drive Press this button to select the engine idle rpm function and thumb rocker for steer function.
  • Page 26 Operator's Manual First Edition • Fourth Printing Controls 21 Steer mode select buttons with indicator lights 26 Used for optional equipment Press the steer mode select button to choose 27 Drive enable button with indicator light steer mode. The indicator light next to the Light on indicates that the primary boom has current steer mode will be on.

  • Page 27: Inspections

    First Edition • Fourth Printing Operator's Manual 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 28 Operator's Manual First Edition • Fourth Printing Inspections  Wear pads Pre-operation Inspection  Tires and wheels  Be sure that the operator’s, safety and  Engine and related components responsibilities manuals are complete, legible and in the storage container located in the ...
  • Page 29 First Edition • Fourth Printing Operator's Manual 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 30 Operator's Manual First Edition • Fourth Printing Inspections Test the Extendable Axles At the Ground Controls Note: Start this test with the axles retracted. Select a test area that is firm, level and free of obstruction. 11 At the ground controls, press and hold a function enable/speed select Turn the key switch to ground control.
  • Page 31 First Edition • Fourth Printing Operator's Manual Inspections 15 Return to the ground controls. Turn the key Test Emergency Controls switch to ground control. Press and hold a 19 Turn the key switch to ground control and shut function enable/speed select button and press the engine off.
  • Page 32 Operator's Manual First Edition • Fourth Printing Inspections Test the Operating Envelope At the Platform Controls 25 Simultaneously press and Test Emergency Stop then release the LCD screen control buttons 31 Turn the key switch to platform control. shown to activate status 32 Push in the platform red Emergency Stop mode.
  • Page 33 First Edition • Fourth Printing Operator's Manual Inspections 46 Slowly move the drive control handle in the Test the Foot Switch direction indicated by the blue triangle on the 37 Push in the platform red Emergency Stop control panel OR press the thumb rocker button to the off position.
  • Page 34 Operator's Manual First Edition • Fourth Printing Inspections 51 Slowly move the drive control handle in the 58 Slowly move the drive control handle in the direction indicated by the blue triangle on the direction indicated by the blue triangle on the control panel OR press the thumb rocker control panel OR press the thumb rocker switch in the direction indicated by the blue...
  • Page 35 First Edition • Fourth Printing Operator's Manual Inspections Test the Drive Enable System Test Limited Drive Speed 62 Press down the foot switch and lower the 66 Press down the foot switch. boom to the stowed position. 67 Raise the boom to 10° above horizontal. 63 Rotate the turntable until the boom moves past 68 Slowly move the drive control handle to the full one of the circle-end tires.
  • Page 36 Operator's Manual First Edition • Fourth Printing Inspections Test Emergency Controls 74 Shut the engine off. 75 Pull out the red Emergency Stop button to the on position. 76 Press down the foot switch. 77 Simultaneously press and hold the emergency power button and activate each function control handle, toggle switch or button.
  • Page 37 First Edition • Fourth 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 machine operation contained in this operator’s ...
  • Page 38 Label – Range of Motion, S-3200 and 82547 Label – Maximum Capacity, 340 kg S-3800 82548 Label – Platform Rotate T114156 Cosmetic – Genie S-3200 82577 Label – Platform Overload Patch T114157 Cosmetic – Genie S-3800 82604 Label – Max Manual Force, 400 N T114158 Cosmetic –...
  • Page 39 First Edition • Fourth Printing Operator's Manual Inspections Part No. T111109 S-3200 • S-3800...

  • Page 40: Operating Instructions

    Operator's Manual First Edition • Fourth 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 41 First Edition • Fourth Printing Operator's Manual Operating Instructions Starting the Engine Emergency Stop At the ground controls, turn the key switch to Push in the red Emergency Stop button to the off the desired position. position at the ground controls or the platform controls to stop all machine functions and turn the Be sure both ground and platform control red engine off.
  • Page 42 Operator's Manual First Edition • Fourth Printing Operating Instructions To Steer Operation from Ground Press down the foot switch. Turn the key switch to ground control. Select the steer mode by pressing a steer Pull out the red Emergency Stop button to the mode button.
  • Page 43 First Edition • Fourth Printing Operator's Manual Operating Instructions Lay the piece of wood on the slope. Driving on a slope Determine the uphill, downhill and side slope At the downhill end, lay the level on the top edge of ratings for the machine and determine the slope the piece of wood and lift the end until the piece of grade.
  • Page 44 Operator's Manual First Edition • Fourth Printing Operating Instructions Drive Enable Check Engine Light Light on indicates that the boom Light on and engine stopped: Tag the has moved past either machine and remove from service. circle-end wheel and the drive Light on and engine still running: function has been interrupted.
  • Page 45 First Edition • Fourth Printing Operator's Manual Operating Instructions Platform Overload Indicator Light After Each Use Select a safe parking location—firm level Light flashing indicates the surface, clear of obstruction and traffic. platform is overloaded and no functions will operate. Retract and lower the boom to the stowed position.

  • Page 46: Transport And Lifting Instructions

    Operator's Manual First Edition • Fourth Printing Transport and Lifting Instructions Transport and Lifting Instructions  Be sure the turntable is secured with the turntable rotation lock before transporting. Be sure the unlock the turntable for operation.  Do not drive the machine on a slope that exceeds the uphill, downhill or side slope rating.
  • Page 47 First Edition • Fourth Printing Operator's Manual Transport and Lifting Instructions Securing the Platform Securing to Truck or Trailer for Transit Lower the boom to the stowed position. Raise the platform as far as it will go (see below). Always use the turntable rotation lock pin each time the machine is transported.
  • Page 48 Operator's Manual First Edition • Fourth Printing Transport and Lifting Instructions Lifting Instructions Fully lower and retract the boom. Move the jib boom (if equipped) parallel with the ground. Remove all loose items on the machine. Use the turntable rotation lock to secure the turntable.

  • Page 49: Maintenance

    First Edition • Fourth 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 50 Operator's Manual First Edition • Fourth 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 51 First Edition • Fourth 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 52: Specifications

    Operator's Manual First Edition • Fourth Printing Specifications Specifications S-3200 Drive speeds Height, working maximum 32.5 m Drive speed, stowed – all models 4.8 km/h 12.2 m/9.1 sec Height, platform maximum 30.5 m Drive speed, raised or extended – 1.1 km/h Height, stowed maximum 3.1 m all models...
  • Page 53 First Edition • Fourth Printing Operator's Manual Specifications S-3800 Drive speeds Height, working maximum 38.6 m Drive speed, stowed – all models 4.8 km/h 12.2 m/9.1 sec Height, platform maximum 36.6 m Drive speed, raised or extended – 1.1 km/h Height, stowed maximum 3.2 m all models...
  • Page 54 Operator's Manual First Edition • Fourth Printing Specifications S-3200 Range of Motion Chart S-3800 Range of Motion Chart S-3200 • S-3800 Part No. T111109 Operator's Manual First Edition • Fourth Printing S-3200 • S-3800 Part No. T111109...
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