Terex Genie GS-4655 User manual

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

Operator's Manual First Edition • Third Printing
GS™-4655 Part No. 1294978GT
Front Matter
Contents
Introduction ........................................................... 1
Symbol and Hazard Pictorials Definitions............. 6
General Safety ...................................................... 8
Personal Safety................................................... 13
Work Area Safety................................................ 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, May 2022
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.
These machines comply with
ANSI/SAIA A92.20
CAN/CSA B354.6

First Edition • Third Printing Operator's Manual
Introduction
Part No. 1294978GT GS™-4655 1
Introducti on
About this manual
Genie appreciates your choice of our machine for
your application. Our number one priority is user
safety, which is best achieved by our joint efforts.
This book is an operation and daily maintenance
manual for the user or operator of a Genie
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 Genie.
Product Identification
The machine serial number is located on the serial
label.
Serial number stamped
on chassis
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 machine, it’s
the operator’s responsibility to read and
understand this familiarization guide.
Each person must be trained to operate a
Mobile Elevating Work Platform (MEWP).
Familiarization with the MEWP must be given
to each person who is authorized, competent
and trained.
Only trained and authorized personnel should
be permitted to operate the machine.
The operator is responsible to read,
understand, and obey the manufacturer’s
instructions and safety rules provided in the
Operator’s Manual.
The Operator’s Manual is located in the
manual storage container, at the platform.
For specific product applications, see
Contacting The Manufacturer.

Operator's Manual First Edition • Third Printing
Introduction
2 GS™-4655 Part No. 1294978GT
Platform controls symbology and related
machine movement:
Lift function enable button
Drive function enable button
Platform
up/down (when lift
function selected)
Drive forward/reverse (when
drive function selected)
Steer right/left (when drive
function selected)
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 and movement:
•Drive and steer.
Interlocked functions:
•Elevated drive speed.
•Elevated drive in an off-level condition.
•All platform and ground controls.
Limitations of use:
•The intended use of this machine is to lift
personnel, including tools, and materials to an
aerial work site.
•Do not elevate the platform unless the machine
is on firm level ground.

First Edition • Third Printing Operator's Manual
Introduction
Part No. 1294978GT GS™-4655 3
Bulletin Distribution and
Compliance
Safety of product users is of paramount
importance to Genie. Various bulletins are used by
Genie to communicate important safety and
product information to dealers and machine
owners.
The information contained in the bulletins is tied to
specific machines using the machine model and
serial number.
Distribution of bulletins is based on the most
current owner on record along with their
associated dealer, so it is important to register
your machine and keep your contact information
up to date.
To ensure safety of personnel and the reliable
continued operation of your machine, be sure to
comply with the action 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.
When you do, be ready to supply the model
number and serial number of your machine, along
with your name and contact information. At
minimum, Genie should be contacted for:
Accident reporting
Questions regarding product applications and
safety
Standards and regulatory compliance information
Current owner updates, such as changes in
machine ownership or changes in your contact
information. See Transfer of Ownership, below.
Transfer of Machine Ownership
Taking a few minutes to update owner information
will ensure that you receive important safety,
maintenance and operating information that
applies to your machine.
Please register your machine by visiting us on the
web at www.genielift.com or by calling us toll free
at 1-800-536-1800.

Operator's Manual First Edition • Third Printing
Introduction
4 GS™-4655 Part No. 1294978GT
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.

First Edition • Third Printing Operator's Manual
Introduction
Part No. 1294978GT GS™-4655 5
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.
Hazard Classification
Decals on this machine use symbols, color coding,
and signal words to identify the following:
Safety alert symbol
—
used to alert
yo
u 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.

Operator's Manual First Edition • Third Printing
Symbol and Hazard Pictorials Definitions
6 GS™-4655 Part No. 1294978GT
Symbol and Hazard Pic torials Definiti ons
Read the operator’s
manual
Read the service
manual
Crush hazard Crush hazard Collision hazard
Tip-over hazard Tip-over hazard 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 of
outriggers and tires
Move machine to
level ground
Close chassis tray
Lower the platform. Do not set up where
it cannot be leveled
with outriggers
Maintain required
clearance
Access by trained
and authorized
personnel only
Use a piece of
cardboard or paper to
search for leaks

First Edition • Third Printing Operator's Manual
Symbol and Hazard Pictorials Definitions
Part No. 1294978GT GS™-4655 7
Batteries used as
counterweights
Chock 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 Engage brake Voltage rating for
power to platform
Pressure rating for air
line to platform
Maximum capacity Manual force Indoor
Outdoor Platform Overload

Operator's Manual First Edition • Third Printing
General Safety
8 GS™-4655 Part No. 1294978GT
General Safety

First Edition • Third Printing Operator's Manual
General Safety
Part No. 1294978GT GS™-4655 9

Operator's Manual First Edition • Third Printing
General Safety
10 GS™-4655 Part No. 1294978GT

First Edition • Third Printing Operator's Manual
General Safety
Part No. 1294978GT GS™-4655 11

Operator's Manual First Edition • Third Printing
General Safety
12 GS™-4655 Part No. 1294978GT

First Edition • Third Printing Operator's Manual
Personal Safety
Part No. 1294978GT GS™-4655 13
Personal Safet y
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.

Operator's Manual First Edition • Third Printing
Work Area Safety
14 GS™-4655 Part No. 1294978GT
Work Area Safet y
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 10 f
t
3.05
m
5
0 to 200KV 15 f
t
4.60
m
20
0 to 350KV 20 f
t
6.10
m
35
0 to 500KV 25 f
t
7.62
m
50
0 to 750KV 35 f
t
10.67
m
75
0 to 1000KV 45 f
t
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 or the
maximum platform capacity of the platform
extension.
Maximum capacity
Platform extended
Model
Platform
retracted
Platform
only
Extension
only
Maximum
occupants
GS
-4655 770
lbs
350
kg
470
lbs
214
kg
300
lbs
136
kg
Indoor -
3
Outdoor -
2
Platform retracted Platform extended
Extension only Platform only
The weight of options and accessories, such as
panel carriers, 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.

First Edition • Third Printing Operator's Manual
Work Area Safety
Part No. 1294978GT GS™-4655 15
Do not raise the platform
unless the machine is on a
firm, level surface.
Do not depend on the tilt alarm as a level indicator.
The 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 drive over 0.5 mph / 0.8 km/h with the
platform raised.
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.
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
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 platform raised.
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 operate the machine with the chassis trays
open.

Operator's Manual First Edition • Third Printing
Work Area Safety
16 GS™-4655 Part No. 1294978GT
Follow ratings for allowable manual force and
number of occupants shown below.
Do not push off or pull
toward any object outside
of the platform.
Model
Maximum allowable
manual force:
Maximum
occupants
GS
-4655 90 l
bs/400N
Indoor -
3
Outdoor -
2
Do not alter or disable the limit switches.
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 use batteries that weigh less than the
original equipment. Batteries are used as
counterweight and are 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 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.
Be sure the tires are in good condition and the lug
nuts tightened.

First Edition • Third Printing Operator's Manual
Work Area Safety
Part No. 1294978GT GS™-4655 17
Crushing Hazard
Keep hands and limbs out of scissors.
Keep hands clear when folding rails.
Do not work under the platform or in the scissor
links without the safety arm in place.
Use common sense and planning when operating
the machine with the controller from the ground.
Maintain safe distances between the operator, the
machine and fixed objects.
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
rating, stowed
position
Maximum side slope
rating, sto
wed
position
GS
-4655 25% (14°)
25% (14°)
Note: Slope rating is subject to ground conditions
with one person in the platform and adequate
traction. Additional platform weight may reduce
slope rating. See Driving on a Slope in the
Operating Instructions section.
Fall Hazards
The 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.

Operator's Manual First Edition • Third Printing
Work Area Safety
18 GS™-4655 Part No. 1294978GT
Keep the platform floor clear of debris.
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.
Do not enter or exit the platform unless the
machine is in the stowed position.
Hazards related with the specific product
application of exiting at height have been
considered in the design of the machine, for
further 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 position when
moving the machine.
The 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.
Observe and use color-coded direction arrows on
the platform controls and the platform decal plate
for drive and steer functions.