Terex Genie S-3200 User manual

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

Operator's Manual First Edition • Fourth Printing
S-3200 • S-3800 Part No. T111109
Front Matter
Important
Read, understand and obey these safety rules
and operating instructions before operating this
machine. Only trained and authorized personnel
shall be permitted to operate this machine. This
manual should be considered a permanent part of
your machine and should remain with the machine
at all times. If you have any questions, contact us.
Contact Us:
Internet: www.genielift.com
E-mail: [email protected]
Contents
Introduction ........................................................... 1 
Symbol and Hazard Pictorials Definitions............. 3 
General Safety ...................................................... 5 
Personal Safety..................................................... 8 
Work Area Safety.................................................. 9 
Legend ................................................................ 16 
Controls............................................................... 17 
Inspections.......................................................... 25 
Operating Instructions......................................... 38 
Transport and Lifting Instructions ....................... 44 
Maintenance ....................................................... 47 
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

First Edition • Fourth Printing Operator's Manual
Introduction
Part No. T111109 S-3200 • S-3800 1
Introducti on
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:
1 Comply with employer, job site and
governmental rules.
2 Read, understand and follow the instructions
in this and other manuals supplied with this
machine.
3 Use good safe work practices in a
commonsense way.
4 Only have trained/certified operators,
directed by informed and knowledgeable
supervision, running the machine.
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.
1 Avoid hazardous situations.
Know 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 machine as it was intended.
You read, understand and obey the
manufacturer’s instructions and safety
rules—safety and operator’s manuals and
machine decals.
You read, understand and obey employer’s
safety rules and worksite regulations.
You read, understand and obey all applicable
governmental regulations.
You are properly trained to safely operate the
machine.

Operator's Manual First Edition • Fourth Printing
Introduction
2 S-3200 • S-3800 Part No. T111109
Hazard Classification
Decals 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 symbol
to avoid possible injury or death.
Indicates a hazardous situation
which, if not avoided, will result in
death or serious injury.
Indicates a hazardous situation
which, if not avoided, could result
in death or serious injury.
Indicates a hazardous situation
which, if not avoided, could result
in minor or moderate injury.
Indicates a property damage
message.
Intended Use
This machine is intended to be used only to lift
personnel, along with their tools and materials to
an aerial work site.
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.
DANGER
WARNING
CAUTION
NOTICE

First Edition • Fourth Printing Operator's Manual
Symbol and Hazard Pictorials Definitions
Part No. T111109 S-3200 • S-3800 3
Symbol and Hazard P ictorials Definiti ons
Crush hazard Keep away from
moving parts
Explosion hazard No smoking.
No flame.
Stop engine
Electrocution hazard
Maintain required
clearance
Crush hazard Keep away from path
of moving platform
Fall hazard Keep off this surface.
Only trained
maintenance
personnel should
access compartments
Read the operator’s
manual
Replace tires with
tires of same
specification.
Replace extension
cylinder cover before
operating machine.
Tip-over hazard
Recovery procedure if tilt alarm sounds while
elevated.
Tip-over hazard Platform downhill:
1Retract boom.
2Lower boom.
Platform uphill:
1Lower boom.
2Retract boom.
Tip-over hazard Fall hazard

Operator's Manual First Edition • Fourth Printing
Symbol and Hazard Pictorials Definitions
4 S-3200 • S-3800 Part No. T111109
Lanyard attachment
point
Wheel load Fire hazard Have fire extinguisher
near.
Voltage rating for
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
other high energy
starting aids on
machines equipped
with glow plugs
Explosion / Burn
hazard
Keep open flames
away.
Read the service
manual
No step

First Edition • Fourth Printing Operator's Manual
General Safety
Part No. T111109 S-3200 • S-3800 5
General Safety
82472
82487
133067
114249 114249
133067
T114286
82472 T114286
114252
82487 82548
82472
133067
133067 A
114249
T114286
114252
82548

Operator's Manual First Edition • Fourth Printing
General Safety
6 S-3200 • S-3800 Part No. T111109
114473A
12.5 m/sec
82604 C
82547 B
340 kg
+
<=
340 kg
82487 C
82487
114473
82547
82604

First Edition • Fourth Printing Operator's Manual
General Safety
Part No. T111109 S-3200 • S-3800 7
82472 114251
82473
133067
82472
82548
T110471
114252
133205
114249
114249
82548
133067
82472
133205
T110471
82473
114251
133067
114252 T114286
T114286
T114286
82481
82481
114252
82472
114249
T110471 A

Operator's Manual First Edition • Fourth Printing
Personal Safety
8 S-3200 • S-3800 Part No. T111109
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.
All PFPE must comply with applicable govern-
mental regulations, and must be inspected and
used in accordance with the PFPE manufacturer’s
instructions.

First Edition • Fourth Printing Operator's Manual
Work Area Safety
Part No. T111109 S-3200 • S-3800 9
WorkArea Safety Electrocution Hazards
This machine is not electrically insulated and will
not provide protection from contact with or
proximity to electrical current.
Obey all local and
governmental regulations
regarding required
clearance from electrical
power lines. At a minimum,
the required clearance
contained in the chart
below must be followed.
Line Voltage Required Clearance
0 to 50KV 3.05 m
50 to 200KV 4.60 m
200 to 350KV 6.10 m
350 to 500KV 7.62 m
500 to 750KV 10.67 m
750 to 1000KV 13.72 m
Allow for platform movement, electrical line sway
or sag, and beware of strong or gusty winds.
Keep away from the
machine if it 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
storms.
Do not use the machine as a ground for welding.
Tip-over Hazards
Occupants, equipment and materials shall not
exceed the maximum platform capacity.
Maximum platform capacity 340 kg
Maximum occupants 2
The weight of options and accessories, such as
pipe cradles, panel cradles and welders, will
reduce the rated platform capacity and must be
subtracted from the platform capacity. See the
decals with the options and accessories.
If using accessories, read, understand and obey
the decals, instructions and manuals with the
accessory.
Do not raise or extend the
boom unless the machine
is on a firm, level surface.
Do not depend on the tilt alarm as a level indicator.
The tilt alarm sounds in the platform only when the
machine is on a severe slope.

Operator's Manual First Edition • Fourth Printing
Work Area Safety
10 S-3200 • S-3800 Part No. T111109
If the tilt alarm sounds while the boom is lowered:
Do not extend, rotate or raise the boom above
horizontal. Move the machine to a firm, level
surface before raising the platform.
If the tilt alarm sounds when the platform is raised,
use extreme caution. Identify the condition of the
boom on the slope as shown below. Follow the
steps to lower the boom before moving to a firm,
level surface. Do not rotate the boom while
lowering.
If the tilt alarm sounds with the
platform uphill:
1Lower the boom.
2Retract the boom.
If the tilt alarm sounds with the
platform downhill:
1Retract the boom.
2Lower the boom.
Do not raise the boom
when wind speeds may
exceed 12.5 m/s. If wind
speeds exceed 12.5 m/s
when the boom is raised,
lower the boom and do not
continue to operate the
machine.
Do not operate the machine in strong or gusty
winds. Do not increase the surface area of the
platform or the load. Increasing the area exposed
to the wind will decrease machine stability.
Use extreme care and
slow speeds while driving
the machine in the
stowed position across
uneven terrain, debris,
unstable or slippery
surfaces and near holes
and drop-offs.
Do not drive the machine on or near uneven terrain,
unstable surfaces or other hazardous conditions
with the boom raised or extended.
Do not use the machine as a crane.
Do not push the machine or other objects with the
boom.
Do not contact adjacent structures with the boom.
Do not tie the boom or platform to adjacent
structures.
Do not place loads outside the platform perimeter.
Do not push off or pull
toward any object outside
of the platform.
Maximum allowable
manual force – 400 N
Do not alter or disable machine components that in
any way affect safety and stability.

First Edition • Fourth Printing Operator's Manual
Work Area Safety
Part No. T111109 S-3200 • S-3800 11
Do not replace items critical to machine stability
with items of different weight or specification.
Do not alter or disable the limit switches.
Do not modify or alter an aerial work platform
without prior written permission from the
manufacturer. Mounting attachments for holding
tools or other materials onto the platform,
toeboards or guard rail system can increase the
weight in the platform and the surface area of the
platform or the load.
Do not place or attach
fixed or overhanging loads
to any part of this
machine.
Do not place ladders or
scaffolds in the platform or
against any part of this
machine.
Do not transport tools and materials unless they
are evenly distributed and can be safely handled
by person(s) in the platform.
Do not use the machine on a moving or mobile
surface or vehicle.
Do not use air-filled tires. These machines are
equipped with solid tires. Wheel weight is critical
to stability.
Be sure the tires are in good condition and the lug
nuts tightened.
Do not use the platform controls to free a platform
that is caught, snagged or otherwise prevented
from normal motion by an adjacent structure. All
personnel must be removed from the platform
before attempting to free the platform using the
ground controls.
Operation on Slopes Hazards
Do not drive the machine on a slope that exceeds
the maximum uphill, downhill or side slope rating of
the machine. Slope rating applies only to machines
in the stowed position.
Maximum slope rating, stowed position, 2WD
Platform downhill 25% (14°)
Platform uphill 25% (14°)
Side slope 25% (14°)
Maximum slope rating, stowed position, 4WD
Platform downhill 40% (22°)
Platform uphill 40% (22°)
Side slope 25% (14°)
Note: Slope rating is subject to ground conditions
and adequate traction. See Driving on a Slope in
the Operating Instructions section.

Operator's Manual First Edition • Fourth Printing
Work Area Safety
12 S-3200 • S-3800 Part No. T111109
Fall Hazards
Occupants must wear a
safety belt or harness in
accordance with
governmental regulations.
Attach the lanyard to the
anchor provided in the
platform.
Do not sit, stand or climb
on the platform guard
rails. Maintain a firm
footing on the platform
floor at all times.
Do not climb down from
the platform when raised.
Keep the platform floor clear of debris.
Lower the platform entry mid-rail or close the entry
gate before operating.
Do not enter or exit the platform unless the
machine is in the stowed position and the platform
is at ground level.
Collision Hazards
Be aware of limited sight
distance and blind spots
when driving or operating.
Be aware of the boom position and tailswing when
rotating the turntable.
Check the work area for
overhead obstructions or
other possible hazards.
Be aware of crushing
hazards when grasping
the platform guard rail.
Operators must comply with employer, job site and
governmental rules regarding use of personal
protective equipment.

First Edition • Fourth Printing Operator's Manual
Work Area Safety
Part No. T111109 S-3200 • S-3800 13
Observe and use the color-coded direction arrows
on the platform controls and drive chassis for drive
and steer functions.
Do not lower the boom
unless the area below is
clear of personnel and
obstructions.
Limit travel speed
according to the
condition of the ground
surface, congestion,
slope, location of
personnel, and any othe
r
factors which may cause
collision.
Do not operate a boom in the path of any crane
unless the controls of the crane have been locked
out and/or precautions have been taken 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 leak can penetrate
and/or burn skin.
Always operate the machine in a well-ventilated
area to avoid carbon monoxide poisoning.
Do not operate the machine unless the secondary
extend cylinder cover is properly installed.
Improper contact with components under any
cover will cause serious injury. Only trained
maintenance personnel should access
compartments. Access by the operator is only
advised when performing a pre-operation
inspection. All compartments must remain closed
and secured during operation.
Explosion and Fire Hazards
Do not start the engine if you smell or detect liquid
petroleum gas (LPG), gasoline, diesel fuel or other
explosive substances.
Do not refuel the machine with the engine running.
Refuel the machine and charge the battery only in
an open, well-ventilated area away from sparks,
flames and lighted tobacco.
Do not operate the machine or charge the battery
in hazardous locations or locations where
potentially flammable or explosive gases or
particles may be present.
Do not spray ether into engines equipped with
glow plugs.

Operator's Manual First Edition • Fourth Printing
Work Area Safety
14 S-3200 • S-3800 Part No. T111109
Damaged Machine Hazards
Do not use a damaged or malfunctioning machine.
Conduct a thorough pre-operation inspection of the
machine and test all functions before each work
shift. Immediately tag and remove from service a
damaged or malfunctioning machine.
Be sure all maintenance has been performed as
specified in this manual and the appropriate Genie
service manual.
Be sure all decals are in place and legible.
Be sure the operator’s, safety and responsibilities
manuals are complete, legible and in the storage
container located on the platform.
Component Damage Hazards
Do not use any battery or charger greater than 12V
to jump-start the engine.
Do not use the machine as a ground for welding.
Do not operate the machine in locations where
extremely high magnetic fields may be present.
Battery Safety
Burn Hazards
Batteries contain acid.
Always wear protective
clothing and eye wear when
working with batteries.
Avoid spilling or contacting
battery acid. Neutralize
battery acid spills with
baking soda and water.
Explosion Hazards
Keep sparks, flames and
lighted tobacco away from
batteries. Batteries emit
explosive gas.
The battery tray should
remain open during the
entire charging cycle.
Do not contact the battery
terminals or the cable
clamps with tools that may
cause sparks.
Electrocution/Burn Hazards
Avoid contact with electrical terminals.

First Edition • Fourth Printing Operator's Manual
Work Area Safety
Part No. T111109 S-3200 • S-3800 15
Overhead Platform Protection
Safety
The maximum weight for overhead platform
protection is 11.5 kg and does not have to be
subtracted from the total capacity of the platform.
Do not exceed the rated platform capacity. If the
weight of overhead platform protection exceeds
11.5 kg, it will reduce the rated platform capacity of
the machine and must be factored into the total
platform load.
The weight of the overhead platform protection
may limit the maximum number of occupants in the
platform.
Secure overhead platform protection to the
provided platform attachment points.
Do not obstruct the entrance or exit of the platform.
Do not obstruct the ability to operate the platform
controls or the red Emergency Stop button.
Do not operate unless you are adequately
instructed and are aware of all the hazards
associated with movement with platform overhead
protection.
Lower Platform Protection
Safety
The maximum weight for lower platform protection
is 13 kg and does not have to be subtracted from
the total capacity of the platform.
Do not exceed the rated platform capacity. If the
weight of lower platform protection exceeds 13 kg,
it will reduce the rated platform capacity of the
machine and must be factored into the total
platform load.
The weight of the lower platform protection may
limit the maximum number of occupants in the
platform.
Secure lower platform protection to the provided
platform attachment points.
Do not obstruct the entrance or exit of the platform.
Do not obstruct the ability to operate the platform
controls or the red Emergency Stop button.
Do not operate unless you are adequately
instructed and are aware of all the hazards
associated with movement with platform overhead
protection.
Lockout After Each Use
1Select a safe parking location—firm level
surface, clear of obstruction and traffic.
2Retract and lower the boom to the stowed
position.
3Rotate the turntable so that the boom is
between the non-steer wheels.
4Turn the key switch to the off position and
remove the key to secure from unauthorized
use.
5Chock the wheels.

Operator's Manual First Edition • Fourth Printing
Legend
16 S-3200 • S-3800 Part No. T111109
Legend
1Non-steer tire
2Steer tire
3Ground controls
4Boom
5Platform controls
6Platform
7Platform bumpers
8Lanyard anchorage point
9Sliding mid-rail
10 Manual storage container
11 Foot switch
1
2
6
7
7
3
4
5
8
9
10
8
11
9
8

First Edition • Fourth Printing Operator's Manual
Controls
Part No. T111109 S-3200 • S-3800 17
Controls
Ground Control Panel
1Boom down button
2Boom extend/retract buttons
3Boom up button
4Engine speed select button
5LCD screen control buttons
6Not used
7LCD readout screen
8Diesel models: Glow plug button
Gasoline/LPG models: Choke button
9Red Emergency Stop button
10 Key switch for off/platform/ground selection
11 Engine start button
12 Emergency power button
13 High speed function enable button
14 Low speed function enable button
15 Alarm
16 Platform level up/down buttons
17 Not used
18 Platform rotate left/right buttons
19 Turntable rotate left/right buttons
STOP
19
2
4
5
6
3
15
14
11
10
8
9
7
13
12
1
18 17 16

Operator's Manual First Edition • Fourth Printing
Controls
18 S-3200 • S-3800 Part No. T111109
Ground Control Panel
1Boom down button
Press the boom down button and
the boom will lower.
2Boom extend/retract buttons
Press the boom
extend button and the
boom will extend.
Press the boom
retract button and the
boom will retract.
3Boom up button
Press the boom up button and the
boom will raise.
4Engine speed select button
Press the engine speed select button to select
the engine speed. When the arrow above the
rabbit is lit, the engine is in high idle speed.
When the arrow above the turtle is lit, the
engine is in low idle speed.
5LCD screen control buttons
6Not used
7LCD readout screen
alow fuel indicator
bengine oil pressure indicator
cwater temperature indicator
dauxiliary power indicator
ehigh engine rpm indicator
fhour meter
8Diesel models: Glow plug button
Gasoline/LPG models: Choke button
Press the glow plug button and hold for 3 to
5 seconds.
9Red Emergency Stop button
Push in the red Emergency Stop button to the
off position to stop all functions and turn the
engine off. Pull out the red Emergency Stop
button to the on position to operate the
machine.
10 Key switch for off/platform/ground selection
Turn the key switch to the off position and the
machine will be off. Turn the key switch to the
platform position and the platform controls will
operate. Turn the key switch to the ground
position and the ground controls will operate.
11 Engine start button
Press the engine start button to start the
engine.
abc def