Terex Genie GS-4655 Operator'S Manual Download Page 1

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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

Summary of Contents for Genie GS-4655

Page 1: ...Operator s Manual Serial Number Range GS 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: ...14 Legend 22 Controls 23 Inspections 26 Operating Instructions 40 Transport and Lifting Instructions 49 Maintenance 54 Specifications 56 Copyright 2019 Terex Corporation First Edition Third Printing M...

Page 3: ...Serial label located on chassis Intended Use and Familiarization Guide The intended use of this machine is to lift personnel including tools and materials to an aerial work site Before operating the m...

Page 4: ...Area of operation indoor use button Area of operation outdoor use button Ground controls symbology and related machine movement Lift function enable button Platform up down button Sequential functions...

Page 5: ...tion indicated in a respective bulletin To view any open bulletins for your machine visit us on the web at www genielift com Contacting the Manufacturer At times it may be necessary to contact Genie W...

Page 6: ...w 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 ma...

Page 7: ...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...

Page 8: ...azard Tip over hazard Tip over hazard Electrocution hazard Electrocution hazard Explosion hazard Fire hazard Burn hazard Skin injection hazard Engage safety arm Keep away from moving parts Keep clear...

Page 9: ...ck the wheels No smoking Grounded AC 3 wire only Replace damaged wires and cords Wheel load Lifting and tie down instructions Lifting point Lanyard anchorage points Wind speed Tiedown Release brakes E...

Page 10: ...Operator s Manual First Edition Third Printing General Safety 8 GS 4655 Part No 1294978GT General Safety...

Page 11: ...First Edition Third Printing Operator s Manual General Safety Part No 1294978GT GS 4655 9...

Page 12: ...Operator s Manual First Edition Third Printing General Safety 10 GS 4655 Part No 1294978GT...

Page 13: ...First Edition Third Printing Operator s Manual General Safety Part No 1294978GT GS 4655 11...

Page 14: ...Operator s Manual First Edition Third Printing General Safety 12 GS 4655 Part No 1294978GT...

Page 15: ...all 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...

Page 16: ...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...

Page 17: ...o not continue to operate the machine Outdoor use Do not operate the machine outdoors with the indoor use button selected Do not operate the machine in strong or gusty winds Do not increase the surfac...

Page 18: ...e critical to machine stability Each battery must weigh 82 lbs 37 kg Battery tray including batteries must weigh a minimum of 415 lbs 188 kg Do not modify or alter a mobile elevated work platform with...

Page 19: ...mum slope rating stowed position Maximum side slope rating stowed position GS 4655 25 14 25 14 Note Slope rating is subject to ground conditions with one person in the platform and adequate traction A...

Page 20: ...urther information contact Genie see section Contacting the Manufacturer Collision Hazards Be aware of limited sight distance and blind spots when driving or operating Be aware of extended platform po...

Page 21: ...to prevent any potential collision No stunt driving or horseplay while operating a machine Bodily Injury Hazard Do not operate the machine with a hydraulic oil or air leak An air leak or hydraulic lea...

Page 22: ...e legible and in the storage container located on the machine Component Damage Hazards Do not use any battery charger greater than 24V to charge the batteries Do not use the machine as a ground for we...

Page 23: ...l rings watches and other jewelry Tip over Hazard Do not use batteries that weigh less than the original equipment Batteries are used as counterweight and are critical to machine stability Each batter...

Page 24: ...ols 6 Platform extension 7 Transport tie down 8 Auxiliary lowering knob 9 Flashing beacon 10 Steer tire 11 Pothole guard 12 LCD readout 13 Ground controls 14 Brake release switch hydraulic side 15 Non...

Page 25: ...switch for platform off ground selection Turn the key switch to the platform position and the platform controls will operate Turn the key switch to the off position and the machine will be off Turn th...

Page 26: ...tions Pull out the red Emergency Stop button to the on position to operate the machine 2 Lift function button Push this button to activate the lift function 3 Horn button Press the horn button and the...

Page 27: ...ction that the blue arrow points Move the control handle in the direction indicated by the yellow arrow on the control panel and the machine will move in the direction that the yellow arrow points 6 T...

Page 28: ...is designed to discover if anything is apparently wrong with a machine before the operator performs the function tests The pre operation inspection also serves to determine if routine maintenance pro...

Page 29: ...ds Drive motors Wear pads Tires and wheels Limit switches alarms and horn Alarms and beacons if equipped Nuts bolts and other fasteners Brake release components Safety arm Platform extension Scissor p...

Page 30: ...the machine as it was intended 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...

Page 31: ...dible warnings on this machine and the standard horn all come from the same central alarm The horn is a constant tone The descent alarm sounds at 60 beeps per minute The alarm sounds at 180 beeps per...

Page 32: ...ess the horn button Result The platform alarm chassis alarm and automotive horn if equipped should sound Test the Function Enable Switch and the Up Down Functions 22 Do not hold the function enable sw...

Page 33: ...d The platform controls LED readout should display OHL and the ground controls LCD should display OHL OUTDOOR HEIGHT LIMIT Test the Drive Function Button 35 Press the drive function button 36 Wait sev...

Page 34: ...yellow arrow points on the control panel then come to an abrupt stop when the control handle is returned to the center position Note The brakes must be able to hold the machine on any slope it is able...

Page 35: ...e blue arrow then move the control handle in the direction indicated by the yellow arrow Result The drive function should not work in either direction 61 Fully lower the platform 62 Drive the machine...

Page 36: ...of wood under a pothole guard 72 Raise the platform Result Before the platform is raised 12 4 ft 3 78 m from the ground an alarm should sound The platform controls LED readout should display PHS and...

Page 37: ...tor 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 It is the operator s responsibility to read an...

Page 38: ...281174 Label Lanyard Anchorage Point Fall Arrest Fall Restrained 5 1283810 Label Platform Control Panel GS 4655 1 Part No Decal Description Qty 1290655 Instructions Maximum Side Force 1 1290659 Danger...

Page 39: ...1292747 1292746 82666 72086 72086 52475 1290699 1272242 31060 44736 1294707 1293165 82666 1292747 1292746 1292051 1296034 82557 28236 1301158 1283810 137656 137605 1281174 44981 1292047 1292048 129603...

Page 40: ...tform Control 1 137656 Label Drive Steer Direction Platform Control 1 1263542 Label Compartment Access 2 1265361 Label Battery Charger Indicator 1 Part No Decal Description Qty 1272242 Label Machine R...

Page 41: ...292746 82666 1263542 1292750 1292746 82666 72086 72086 52475 1290699 1272242 114337 114338 1293217 82666 1292052 1292746 1296034 82487 1283810 137656 137605 1281174 44981 1292961 1296034 43618 97719 8...

Page 42: ...operator s responsibility to follow all the safety rules and instructions in the operator s safety and responsibilities manuals Using the machine for anything other than lifting personnel along with...

Page 43: ...eration from Platform 1 Be sure the battery pack is connected before operating the machine 2 Turn the key switch to platform control 3 Pull out both ground and platform red Emergency Stop buttons to t...

Page 44: ...ion button again 2 Machines equipped with foot switch Press and hold the foot switch and press and hold the function enable switch on the control handle at the same time 3 Increase speed Slowly move t...

Page 45: ...ou will need carpenter s level straight piece of wood at least 3 feet 1 m long tape measure Lay the piece of wood on the slope At the downhill end lay the level on the top edge of the piece of wood an...

Page 46: ...viewed at the ground controls LCD display Platform Overload If the platform controls LED diagnostic readout displays a flashing OL and the ground controls LCD diagnostic readout displays OL Platform...

Page 47: ...Tilted and the tilt alarm sounds at 180 beeps per minute the following functions are affected drive steer and elevate functions are disabled Return the machine to level ground to restore lift functio...

Page 48: ...e batteries How to Fold Down the Guardrails The platform railing system consists of three fold down rail sections for the extension deck and three sections for the main deck All six sections are held...

Page 49: ...e the two wire lock pins Keep hands free of pinch points 9 Fold down the rear gate and entry side rails as one unit Keep hands clear of pinch points 10 Reinsert the two removed pins back into each sid...

Page 50: ...partment should remain open for the entire charging cycle Maintenance free batteries 1 Connect the battery charger to a grounded AC circuit 2 The charger will indicate when the battery is fully charge...

Page 51: ...should move the machine on or off the truck The transport vehicle must be parked on a level surface The transport vehicle must be secured to prevent rolling while the machine is being loaded Be sure t...

Page 52: ...switch to ground mode 4 Open the hydraulic tray 5 Remove the protective cover from the toggle switch 6 Move the toggle switch as indicated in the image to engage the brakes The alarm will turn on when...

Page 53: ...r Transit Always use the extension deck lock when the machine is transported Turn the key switch to the off position and remove the key before transporting Inspect the entire machine for loose or unse...

Page 54: ...achine 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 loa...

Page 55: ...hine Determine the center of gravity of your machine using the table and the picture on this page Attach the rigging only to the designated lifting points on the machine There are two 1 7 in 4 4 cm ho...

Page 56: ...procedure it conveys the meaning below Indicates that tools will be required to perform this procedure Indicates that new parts will be required to perform this procedure Check the Hydraulic Oil Leve...

Page 57: ...water Note Perform this test after fully charging the batteries 1 Put on protective clothing and eye wear 2 Be sure that the battery cable connections are tight and free of corrosion 3 Be sure that t...

Page 58: ...rial label for specific machine weight Power source 24V 300AH System voltage 24V AC outlet in platform Standard Maximum hydraulic pressure functions 2900 psi 200 bar Tire size 15 x 5 in Maximum slope...

Page 59: ......

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