Terex 43032 User manual

Operator's Manual
Serial Number Range
GS-3384
from
43032
GS-3390
from
47263
GS-4390
from
47263
GS-5390
from
47263
North America
South America
Asia
AUS
Australia
with
Maintenance
Information
ourth
Edition
ourth
Printing
Part No. 133564

Operator's Manual Fourth Edition • Fourth Printing
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. his
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..............4
General Safety............................................................6
Personal Safety........................................................10
Work Area Safety......................................................11
Legend.......................................................................19
Controls......................................................................20
Inspections................................................................25
Operating Instructions..............................................38
ransport and Lifting Instructions...........................44
Maintenance..............................................................47
Specifications............................................................51
Copyright © 2002 by erex Corporation
Fourth Edition: Fourth Printing, November 2015
Genie is a registered trademark of erex South Dakota, Inc.
in the U.S.A. and many other countries. “GS” is a trademark
of erex South Dakota, Inc.
hese machines comply with
ANSI/SIA 92.6
CAN B.354.4
GS-3384 • GS-3390• GS-4390• GS-5390 Part No. 133564

Fourth Edition • Fourth Printing
Owners, Users and Operators:
hank 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 ave trained/certified operators,
directed by informed and knowledgeable
supervision, running the machine.
Operator's Manual
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.
1 Avoid azardous situations.
Know and understand t e safety rules
before going on to t e 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.
Part No. 133564 GS-3384 • GS-3390• GS-4390• GS-5390 1

Operator's Manual
Introduction
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
DANGER
which, if not avoided, will result in
death or serious injury.
Indicates a hazardous situation
WARNING
which, if not avoided, could result
in death or serious injury.
Indicates a hazardous situation
CAUTION
which, if not avoided, could result
in minor or moderate injury.
Indicates a property damage
NOTICE
message.
Fourth Edition • Fourth Printing
Intended Use
his machine is intended to be used only to lift
personnel, along with their tools and materials
to an aerial work site.
2 GS-3384 • GS-3390• GS-4390• GS-5390 Part No. 133564

Fourth 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.
Part No. 133564 GS-3384 • GS-3390• GS-4390• GS-5390 3

Operator's Manual Fourth Edition • Fourth Printing
Symbol and Hazard Pictorials Definitions
Read the operator’s Read the service Crush hazard Crush hazard Collision hazard
manual manual
ip-over hazard ip-over hazard ip-over hazard ip-over hazard Electrocution hazard
Electrocution hazard Explosion hazard Fire hazard Burn hazard Skin injection hazard
Engage safety arm Keep away from Keep clear of Move machine to Close chassis tray
moving parts outriggers and tires level ground
Lower the platform Do not set up where it Maintain required Only trained Use a piece of
cannot be leveled clearance maintenance cardboard or paper to
with outriggers personnel should search for leaks
access
compartments
4 GS-3384 • GS-3390• GS-4390• GS-5390 Part No. 133564

Fourth Edition • Fourth Printing Operator's Manual
Symbol and Hazard Pictorials Definitions
Chock the wheels Release brakes iedown Lanyard attachment No smoking
point
Wheel load ransport diagram Side force Wind speed Outrigger load
Voltage rating for Pressure rating for air Maximum Crushing hazard Hold rail while lowering
power to platform line to platform capacity
Collision hazard Chock the wheels
Part No. 133564 GS-3384 • GS-3390• GS-4390• GS-5390 5

Operator's Manual Fourth Edition • Fourth Printing
General Safety
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Fourth Edition • Fourth Printing Operator's Manual
General Safety
Part No. 133564 GS-3384 • GS-3390• GS-4390• GS-5390 7

Operator's Manual Fourth Edition • Fourth Printing
General Safety
8 GS-3384 • GS-3390• GS-4390• GS-5390 Part No. 133564

Fourth Edition • Fourth Printing Operator's Manual
General Safety
Part No. 133564 GS-3384 • GS-3390• GS-4390• GS-5390 9

Operator's Manual Fourth Edition • Fourth Printing
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
instructions.
10 GS-3384 • GS-3390• GS-4390• GS-5390 Part No. 133564

Fourth Edition • Fourth Printing Operator's Manual
Electrocution Hazards
his 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 10 ft 3.05 m
50 to 200KV 15 ft 4.60 m
200 to 350KV 20 ft 6.10 m
350 to 500KV 25 ft 7.62 m
500 to 750KV 35 ft 10.67 m
750 to 1000KV 45 ft 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.
Work Area Safety
Tip-over Hazards
Occupants, equipment and materials shall not
exceed the maximum platform capacity or the
maximum platform capacity of the platform
extension.
Maximum capacity – GS-3384 and GS-3390
Maximum occupants 7
Models wit one platform extension
Platform 2500 lbs 1134 kg
retracted
Platform only 2000 lbs 907 kg
Extension only 500 lbs 227 kg
Extension only Platform only
500 lbs / 227 kg 2000 lbs / 907 kg
Models wit two platform extensions
Platform retracted 2500 lbs 1134 kg
Platform with one 2000 lbs 907 kg
extension out
Platform with two 1500 lbs 680 kg
extensions out
Each extension 500 lbs 227 kg
only
Extension only Platform only Extension only
500 lbs / 227 kg 1500 lbs / 500 lbs / 227 kg
680 kg
Part No. 133564 GS-3384 • GS-3390• GS-4390• GS-5390 11

Operator's Manual Fourth Edition • Fourth Printing
Work Area Safety
Maximum capacity - GS-4390
Maximum occupants 7
Models wit one platform extension
Platform retracted 1500 lbs 680 kg
Platform only 1000 lbs 454 kg
Extension only 500 lbs 227 kg
Extension only Platform only
500 lbs / 227 kg 1000 lbs / 454 kg
Models wit two platform extensions
Platform retracted 1500 lbs 680 kg
Platform with one 1000 lbs 454 kg
extension out
Platform with two 500 lbs 227 kg
extensions out
Extension only 500 lbs 227 kg
Extension only Platform only Extension only
500 lbs / 227 kg 500 lbs / 227 kg 500 lbs / 227 kg
Maximum capacity – GS-5390
Maximum occupants - ANSI & CSA 6
Maximum occupants - Australia 4
Models wit one platform extension
Platform 1500 lbs 680 kg
retracted
Platform only 1000 lbs 454 kg
Extension only 500 lbs 227 kg
Extension only Platform only
500 lbs / 227 kg 1000 lbs / 454 kg
Models wit two platform extensions
Platform retracted 1500 lbs 680 kg
Platform with one 1000 lbs 454 kg
extension out
Platform with two 500 lbs 227 kg
extensions out
Each extension 500 lbs 227 kg
only
Extension only Platform only Extension only
500 lbs / 227 kg 500 lbs / 227 kg 500 lbs / 227 kg
12 GS-3384 • GS-3390• GS-4390• GS-5390 Part No. 133564

Fourth Edition • Fourth Printing Operator's Manual
Work Area Safety
Do not raise the platform
unless the machine is on a
firm, level surface.
Do not push off or pull
toward any object outside
of the platform.
Do not depend on the tilt alarm as a level indicator.
he tilt alarm sounds on the chassis only when the
machine is on a severe slope.
If the tilt alarm sounds:
Lower the platform. Move the machine to a firm,
level surface. If the tilt alarm sounds when the
platform is raised, use extreme caution to lower
the platform.
Do not alter or disable the limit switches.
Do not drive over 0.7 mph / 1.1 km/h with the
platform raised.
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.
Maximum allowable side force - ANSI and CSA
GS-3384 350 lbs / 1557 N
GS-3390 350 lbs / 1557 N
GS-4390 350 lbs / 1557 N
GS-5390 300 lbs / 1335 N
Maximum manual force –
Australia 90 lbs / 400 N
Do not use the machine as a crane.
Do not push the machine or other objects with
the platform.
Do not contact adjacent structures with the
platform.
Do not tie the platform to adjacent structures.
Do not place loads outside the platform perimeter.
Do not raise the platform when wind speeds may
exceed 28 mph / 12.5 m/s. If wind speeds exceed
28 mph / 12.5 m/s when the platform is raised,
lower the platform and do not continue to operate
the machine.
Part No. 133564 GS-3384 • GS-3390• GS-4390• GS-5390 13

Operator's Manual Fourth Edition • Fourth Printing
Work Area Safety
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.
Do not drive the
machine on or near
uneven terrain,
unstable surfaces or
other hazardous
conditions with the
platform raised.
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.
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 alter or disable machine components that in
any way affect safety and stability.
Do not replace items critical to machine stability
with items of different weight or specification.
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 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.
Be sure all tires are in good condition, air-filled
tires are properly inflated and lug nuts are
properly tightened.
14 GS-3384 • GS-3390• GS-4390• GS-5390 Part No. 133564

Fourth Edition • Fourth Printing Operator's Manual
Operation on Slopes Hazards
Do not drive the machine on a slope that
exceeds the slope and side slope rating of the
machine. Slope rating applies to machines in the
stowed position.
Model Maximum slope Maximum side slope
rating, stowed rating, stowed
position position
GS-3384 50% (26°) 50% (26°)
GS-3390
GS-4390
GS-5390 40% (22°) 40% (22°)
Note: Slope rating is subject to ground
conditions and adequate traction.
Work Area Safety
Fall Hazards
he guard rail system provides fall protection. If
occupant(s) of the platform are required to wear
personal fall protection equipment (PFPE) due to
job site or employer rules, PFPE and its use shall
be in accordance with the PFPE manufacturer’s
instructions and applicable governmental
requirements. Use approved lanyard attachment
point provided.
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.
Do not enter or exit the platform unless the
machine is in the stowed position.
Attach the platform entry chain or close the entry
gate before operating.
Do not operate the machine unless the guard rails
are properly installed and the entry is secured for
operation.
Part No. 133564 GS-3384 • GS-3390• GS-4390• GS-5390 15

Operator's Manual
Work Area Safety
Collision Hazards
Be aware of limited sight
distance and blind spots
when driving or operating.
Be aware of extended platform position
when moving the machine.
he machine must be on a level surface or
secured before releasing the brakes.
Operators must comply with employer, job site and
governmental rules regarding use of personal
protective equipment.
Check the work area for
overhead obstructions or
other possible hazards.
Be aware of crushing
hazards when grasping
the platform guard rail.
Fourth Edition • Fourth Printing
Observe and use color-coded direction arrows
on the platform controls and the platform decal
plate for drive and steer functions.
Do not lower the platform
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 other factors which
may cause collision.
Do not operate a machine in the path of any crane
or moving overhead machinery 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.
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Fourth Edition • Fourth Printing Operator's Manual
Bodily Injury Hazard
Always operate the machine in a well-ventilated
area to avoid carbon monoxide poisoning.
Do not operate the machine with a hydraulic oil or
air leak. An air leak or hydraulic leak can penetrate
and/or burn skin.
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.
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.
Work Area Safety
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.
Damaged Mac ine 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 machine.
Part No. 133564 GS-3384 • GS-3390• GS-4390• GS-5390 17