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

Terex Genie GS-4655 Operator's Manual

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Operator's Manual
GS
-4655
™
Serial Number Range
from GS55F-101
from GS55D-101
CE
with
Maintenance
Information
Original Instructions
First Edition
Fourth Printing
Part No. 1294976GT

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Summary of Contents for Terex Genie GS-4655

  • Page 1 Operator's Manual Serial Number Range -4655 ™ from GS55F-101 from GS55D-101 with Maintenance Information Original Instructions First Edition Fourth Printing Part No. 1294976GT...

  • Page 2: Table Of Contents

    NG31 6BH Copyright © 2019 Terex Corporation First Edition: Fourth Printing, February 2024 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. Complies with EC Directive 2006/42/EC...

  • Page 3: Introduction

    First Edition • Fourth Printing Operator's Manual Introduction Intr oducti on 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 • Fourth 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 • Fourth 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 • Fourth 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 • Fourth 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 • Fourth Printing Symbol and Hazard Pictorials Definitions Symbol and H az ard Pictorials Definiti ons 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...
  • Page 9 First Edition • Fourth 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 • Fourth Printing General Safety Gener al Safety -4655 Part No. 1294976GT ™...
  • Page 11 First Edition • Fourth Printing Operator's Manual General Safety Part No. 1294976GT -4655 ™...

  • Page 12: Personal Safety

    Operator's Manual First Edition • Fourth Printing Personal Safety Pers onal 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 13: Work Area Safety

    First Edition • Fourth Printing Operator's Manual Work Area Safety Tip-over Hazards Work Ar ea 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 14 Operator's Manual First Edition • Fourth Printing 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 15 First Edition • Fourth Printing Operator's Manual Work Area Safety Follow ratings for allowable manual force and Do not place or attach fixed or overhanging loads number of occupants shown below. to any part of this Do not push off or pull machine.
  • Page 16 Operator's Manual First Edition • Fourth Printing Work Area Safety Crushing Hazard Do not sit, stand, or climb on the platform guard Keep hands and limbs out of scissors. rails. Maintain a firm footing on the platform Keep hands clear when folding rails. floor at all times.
  • Page 17 First Edition • Fourth Printing Operator's Manual Work Area Safety Collision Hazards Do not lower the platform unless the area below is Be aware of limited sight clear of personnel and distance and blind spots obstructions. when driving or operating. Be aware of extended platform position when moving the machine.
  • Page 18 Operator's Manual First Edition • Fourth Printing Work Area Safety Bodily Injury Hazard Damaged Machine Hazards Do not operate the machine with a hydraulic oil or Do not use a damaged or malfunctioning machine. air leak. An air leak or hydraulic leak can penetrate Conduct a thorough pre-operation inspection of and/or burn skin.
  • Page 19 First Edition • Fourth Printing Operator's Manual Work Area Safety Battery Safety Component Damage Hazard Do not use any battery charger greater than 24V Burn Hazards to 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 20 Operator's Manual First Edition • Fourth Printing 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 21: Legend

    First Edition • Fourth Printing Operator's Manual 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 22: Controls

    Operator's Manual First Edition • Fourth Printing 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 23 First Edition • Fourth Printing Operator's Manual Controls 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 24 Operator's Manual First Edition • Fourth Printing 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 25: Inspections

    First Edition • Fourth Printing Operator's Manual Inspections Ins pections 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 26 Operator's Manual First Edition • Fourth Printing Inspections Pre-operation Inspection  Safety arm  Platform extension  Be sure that the operator’s manual is  Scissor pins and retaining fasteners complete, legible and in the storage container located in the platform. ...
  • Page 27 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 28 Operator's Manual First Edition • Fourth Printing Inspections At the Ground Controls Test the Up/Down Functions 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 hazards.
  • Page 29 First Edition • Fourth Printing Operator's Manual Inspections At the Platform Controls 14 Press and hold the lift function enable button, and press the platform down button. Test Emergency Stop Result: The platform should lower. The descent alarm should sound while the platform 19 Push in the platform red Emergency Stop is lowering.
  • Page 30 Operator's Manual First Edition • Fourth Printing Inspections 27 Press the lift function button. 33 Press the lift function enable button. 28 Press and hold the function enable switch on 34 Press and hold the drive/steer function enable the control handle. Slowly move the control switch on the control handle.
  • Page 31 First Edition • Fourth Printing Operator's Manual Inspections 39 Press the thumb rocker switch on top of the 44 Slowly move the control handle in the direction control handle in the direction indicated by the indicated by the yellow arrow on the control blue triangle on the control panel.
  • Page 32 Operator's Manual First Edition • Fourth Printing Inspections 50 Move the control handle in the direction 58 Press the drive function button. indicated by the blue arrow, then move the 59 Press and hold the drive/steer function enable control handle in the direction indicated by the switch on the control handle.
  • Page 33 First Edition • Fourth Printing Operator's Manual Inspections 67 Press and hold the function enable switch on 72 Raise the platform. the control handle.Slowly move the control Result: Before the platform is raised handle to full drive position. 12.4 ft/3.78 m from the ground, an alarm Result: The maximum achievable drive speed should sound.
  • Page 34 Operator's Manual First Edition • Fourth Printing 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 35 First Edition • Fourth Printing Operator's Manual Inspections Inspection for Decals with Part No. Decal Description Symbols GS-4655 1265361 Label – Battery Charger Indicator 1272242 Label – Machine Registration/Owner Determine whether the decals on your machine Transfer have words or symbols. Use the appropriate 1281175 Label –...
  • Page 36 Operator's Manual First Edition • Fourth Printing Inspections 137605 1283810 137656 82487 1296034 1293217 114338 43618 1293166 1281175 1292751 1294688 44981 1292047 1292048 1296034 43618 97719 82474 1293217 82474 1292990 72086 1293217 72086 52475 1292049 1292275 1292750 1292050 1272242 114337 1265361 1290699 1292746...

  • Page 37: Operating Instructions

    First Edition • Fourth Printing Operator's Manual Operating Instructions Operati ng Instr ucti ons 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 manual.
  • Page 38 Operator's Manual First Edition • Fourth Printing 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 39 First Edition • Fourth Printing Operator's Manual 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 40 Operator's Manual First Edition • Fourth Printing 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 41 First Edition • Fourth Printing Operator's Manual 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 42 Operator's Manual First Edition • Fourth Printing Operating Instructions Battery Level Indicator Tilt Sensor Activation Settings Chassis Angle Use the LED diagnostic readout to determine the 1.5° (side to side) battery level. Chassis Angle (front to back) 3° Note: When a blinking LO code appears on the If the tilt alarm sounds while platform controls LED display, the machine must raising the platform, lower the...
  • Page 43 First Edition • Fourth Printing Operator's Manual Operating Instructions How to Use the Safety Arm Fold down left side rail assembly together with front rail. Raise the platform approximately 14 ft / 4.24 m Keep hands free of pinch points. from the ground.
  • Page 44 Operator's Manual First Edition • Fourth 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 45 First Edition • Fourth Printing Operator's Manual Operating Instructions After Each Use Machine Storage Select a safe parking location—firm level Properly preparing and stowing the machine for surface, clear of obstruction and traffic. extended storage will make it easier to put the machine back into service.

  • Page 46: Transport And Lifting Instructions

    Operator's Manual First Edition • Fourth Printing Transport and Lifting Instructions Trans port and Lifti ng Instr ucti ons  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 47 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 48 Operator's Manual First Edition • Fourth Printing 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 49 First Edition • Fourth 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 Operator's Manual First Edition • Fourth Printing 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 51: Maintenance

    First Edition • Fourth Printing Operator's Manual Maintenance Maintenanc e Check the Hydraulic Oil Level Maintaining the hydraulic oil at the proper level is essential to machine operation. Improper hydraulic oil levels can damage hydraulic components. Daily Observe and Obey: checks allow the inspector to identify changes in oil level that might indicate the presence of ...
  • Page 52 Operator's Manual First Edition • Fourth 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

    First Edition • Fourth Printing Operator's Manual Specifications Specific ati ons 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)
  • Page 54 Operator's Manual First Edition • Fourth Printing Specifications Contents of EC Declaration of Conformity - 1 <Manufacturer’s name> hereby declares that the machinery described below complies with the provisions of the following Directives: 1. EC Directive 2006/42/EC, Machinery Directive, under consideration of harmonized European standard EN280 as described in EC type-examination certificate <variable field>...
  • Page 55 First Edition • Fourth Printing Operator's Manual Specifications Contents of EC Declaration of Conformity - 2 <Manufacturer’s name> hereby declares that the machinery described below complies with the provisions of the following Directives: 1. EC Directive 2006/42/EC, Machinery Directive, Conformity assessment procedure: art.12 (3) (a), with the application of European Harmonized Standard EN 280:2013+A1:2015.
  • Page 56 Operator's Manual First Edition • Fourth Printing Specifications Contents of UK Declaration of Conformity - 1 <Manufacturer’s name> hereby declares that the machinery described below complies with the provisions of the following Legislation: 1. Supply of Machinery (Safety) Regulations 2008 (SI 2008/1597) as amended (SI 2011/1043, SI 2011/2157, SI 2019/696) under consideration of designated standard EN280 as described in type- examination certificate <variable field>...
  • Page 57 First Edition • Fourth Printing Operator's Manual Specifications Contents of UK Declaration of Conformity - 2 <Manufacturer’s name> hereby declares that the machinery described below complies with the provisions of the following Legislation: 1. Supply of Machinery (Safety) Regulations 2008 (SI 2008/1597) as amended (SI 2011/1043, SI 2011/2157, SI 2019/696) conformity assessment procedure according to Part 3, 11.

This manual is also suitable for:

Genie gs55f-101Genie gs55d-101

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