Terex Genie S-3200, Operator'S Manual

Page 1: ...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 ...

Page 2: ... you have any questions contact us Contact Us Internet www genielift com E mail awp techpub terex com 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 E...

Page 3: ...le 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 operati...

Page 4: ...r 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 Repl...

Page 5: ...learance 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 1 Retr...

Page 6: ...d 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 ...

Page 7: ...h 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 ...

Page 8: ...Operator s Manual First Edition Fourth Printing General Safety 6 S 3200 S 3800 Part No T111109 114473 A 12 5 m sec 82604 C 82547 B 340 kg 340 kg 82487 C 82487 114473 82547 82604 ...

Page 9: ... 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 ...

Page 10: ...e 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 manufactur...

Page 11: ... 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...

Page 12: ...e 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...

Page 13: ...t 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...

Page 14: ...rm 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 are...

Page 15: ...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...

Page 16: ...ocated 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 spillin...

Page 17: ...rm 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 protec...

Page 18: ... 3200 S 3800 Part No T111109 Legend 1 Non steer tire 2 Steer tire 3 Ground controls 4 Boom 5 Platform controls 6 Platform 7 Platform bumpers 8 Lanyard anchorage point 9 Sliding mid rail 10 Manual storage container 11 Foot switch 1 2 6 7 7 3 4 5 8 9 10 8 11 9 8 ...

Page 19: ...readout screen 8 Diesel models Glow plug button Gasoline LPG models Choke button 9 Red 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 rig...

Page 20: ...CD readout screen a low fuel indicator b engine oil pressure indicator c water temperature indicator d auxiliary power indicator e high engine rpm indicator f hour meter 8 Diesel models Glow plug button Gasoline LPG models Choke button Press the glow plug button and hold for 3 to 5 seconds 9 Red Emergency Stop button Push in the red Emergency Stop button to the off position to stop all functions a...

Page 21: ...nable button to enable the functions on the ground control panel to operate at low speed 15 Alarm 16 Platform level up down buttons Press the platform level up button and the level of the platform will raise Press the platform level down button and the level of the platform will lower 17 Not used 18 Platform rotate left right buttons Press the platform rotate left button and the platform will rota...

Page 22: ... Not used 9 Emergency power button with indicator light 10 Diesel models Glow plug button with indicator light Gasoline LPG models Choke button with indicator light 11 Engine start button with indicator light 12 Engine idle rpm select button with indicator lights Rabbit foot switch foot switch activated high idle Turtle low idle Rabbit high idle 13 Not used 14 Fault indicator light 15 Low fuel ind...

Page 23: ...e speed select button with indicator lights Machine on incline symbol Low range operation for inclines Machine on level surface symbol High range operation for maximum drive speed 23 Single axis proportional control handle for boom extend retract function 24 Axle extend button with indicator light 25 Axle retract button with indicator light 26 Used for optional equipment 27 Drive enable button wit...

Page 24: ...t To continue lowering retract boom until the indicator light goes out 6 Raise boom indicator light To continue extending raise the boom until the indicator light goes out 7 Horn button Press this button and the horn will sound Release the button and the horn will stop 8 Not used 9 Emergency power button with indicator light Use emergency power if the primary power source engine fails Simultaneous...

Page 25: ...function Move the control handle in the direction indicated by the blue arrow on the control panel and the machine will drive forward Move the control handle in the direction indicated by the yellow arrow and the machine will drive backwards Move the control handle in the direction indicated by the blue triangle and the machine will steer to the left Move the control handle in the direction indica...

Page 26: ...le the axles are extending and stay on when the axles are fully extended 25 Axle retract button with indicator light Press the axle retract button to retract the axles The indicator light will flash while the axles are retracting and stay on when the axles are fully retracted 26 Used for optional equipment 27 Drive enable button with indicator light Light on indicates that the primary boom has mov...

Page 27: ...ion 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 procedures are required Only routine maintenance items specified in this manual may be performed by the operator Refer to the list on the next page and check each of the items If damage or any unautho...

Page 28: ...heck the following components or areas for damage improperly installed or missing parts and unauthorized modifications Electrical components wiring and electrical cables Hydraulic hoses fittings cylinders and manifolds Fuel and hydraulic tanks Drive and turntable motors and drive hubs Wear pads Tires and wheels Engine and related components Limit switches and horn Alarms and beacons if equipped Nu...

Page 29: ...use 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 instructions to test all machine functions A malfunctioning machine must never be used If malfunctions are discovered the machine must be tagged and removed from service Repairs to the machine may...

Page 30: ...indicator light should be green 9 Close and secure the tank side turntable cover 10 Press the engine idle speed select button until the indicator light next to low idle turtle symbol is on Test the Extendable Axles Note Start this test with the axles retracted 11 At the ground controls press and hold a function enable speed select button and press the boom up button Result The boom should raise to...

Page 31: ...ction button Result All boom and platform functions should operate through a full cycle The descent alarm should sound while the boom is lowering Test Emergency Controls 19 Turn the key switch to ground control and shut the engine off 20 Pull out the red Emergency Stop button to the on position 21 Simultaneously press and hold the emergency power button and press each boom function button or activ...

Page 32: ...BOOM LENGTH is displayed 29 Extend the boom and observe the LCD screen Result The LCD screen should display at 0 0 75 100 100 30 Retract the boom At the Platform Controls Test Emergency Stop 31 Turn the key switch to platform control 32 Push in the platform red Emergency Stop button to the off position Result The engine should shut off and no functions should operate 33 Pull out the red Emergency ...

Page 33: ...row steer 45 Press down the foot switch 46 Slowly move the drive control handle in the direction indicated by the blue triangle on the control panel OR press the thumb rocker switch in the direction indicated by the blue triangle Result The square end wheels should turn in the direction that the blue triangles point on the drive chassis 47 Slowly move the control handle in the direction indicated ...

Page 34: ...assis 56 Press the steer mode select switch for coordinated steer 57 Press down the foot switch 58 Slowly move the drive control handle in the direction indicated by the blue triangle on the control panel OR press the thumb rocker switch in the direction indicated by the blue triangle Result The square end wheels should turn in the direction that the blue triangles point on the drive chassis The c...

Page 35: ...s not moved within two seconds of pressing the drive enable button the drive function will not operate Test Limited Drive Speed 66 Press down the foot switch 67 Raise the boom to 10 above horizontal 68 Slowly move the drive control handle to the full drive position Result The maximum achievable drive speed with the primary boom raised should not exceed 30 cm s Note The machine will travel 12 m in ...

Page 36: ...rgency Stop button to the on position 76 Press down the foot switch 77 Simultaneously press and hold the emergency power button and activate each function control handle toggle switch or button Note To conserve battery power test each function through a partial cycle Result All boom functions should operate Drive functions should not operate with auxiliary power ...

Page 37: ...erator 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 and remember the workplace hazards then watch for and avoid them while moving setting up and operating the machine Workplace Inspection Checklist Be aware of and avoid the following hazardous situati...

Page 38: ...c Oil Level 1 97815 Label Lower Mid rail 1 114112 Label Transport Diagram 2 114249 Label Tip over Hazard Tires 4 114251 Label Explosion Hazard 1 Part No Decal Description Qty 114252 Label Tip over Hazard Limit Switches 4 114473 Label Tilt Alarm 1 133067 Label Electrocution Hazard 4 133205 Label Electrocution Burn Hazard 1 215005 Label Lifting Point 4 215006 Label CG and Lifting Capacity S 3200 2 2...

Page 39: ...First Edition Fourth Printing Operator s Manual Inspections Part No T111109 S 3200 S 3800 37 ...

Page 40: ... the 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 their tools and materials to an aerial work site is unsafe and dangerous Only trained and authorized personnel should be permitted to operate a machine If more than one operator is expected to use...

Page 41: ...draulic system damage In extreme cold conditions 18 C and below machines should be equipped with optional cold start kits Attempting to start the engine when temperatures are below 18 C may require the use of a booster battery Emergency Stop Push in the red Emergency Stop button to the off position at the ground controls or the platform controls to stop all machine functions and turn the engine of...

Page 42: ... press the appropriate button according to the markings on the control panel To Steer 1 Press down the foot switch 2 Select the steer mode by pressing a steer mode button The indicator light above the current steer mode will be on 3 Slowly move the drive control handle in the direction indicated by blue or yellow triangles OR press the thumb rocker switch located on top of the drive control handle...

Page 43: ...light next to the machine on incline symbol is on To determine the slope grade Measure the slope with a digital inclinometer OR use the following procedure You will need carpenter s level straight piece of wood at least 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 and lift the end until the piece of wood is level Wh...

Page 44: ... on Rabbit and foot switch symbol foot switch activated high idle Turtle symbol low idle Rabbit symbol high idle Check Engine Light Light on and engine stopped Tag the machine and remove from service Light on and engine still running Contact service personnel within 24 hours Operating Envelope Indicator Lights The operating envelope indicator lights will come on to notify the operator that a funct...

Page 45: ...inue operation Raise Boom indicator light is flashing Use the Emergency Power Unit at the platform to raise the boom until the indicator light is off Restart the engine to continue operation If the Emergency Power Unit at the platform does not function a trained operator on the ground will need to lower the platform from the ground controls Please see the Service Bypass Recovery Key Switch section...

Page 46: ...revent rolling while the machine is being loaded Be sure the vehicle capacity loading surfaces and chains or straps are sufficient to withstand the machine weight Genie lifts are very heavy relative to their size See the serial label for the machine weight Be sure the turntable is secured with the turntable rotation lock before transporting Be sure the unlock the turntable for operation Do not dri...

Page 47: ... remove the key before transporting Inspect the entire machine for loose or unsecured items Securing the Chassis Use chains of ample load capacity Use a minimum of 5 chains Adjust the rigging to prevent damage to the chains Securing the Platform Lower the boom to the stowed position Raise the platform as far as it will go see below Run a strap through the platform support between the plates next t...

Page 48: ...ting Instructions Fully lower and retract the boom Move the jib boom if equipped parallel with the ground Remove all loose items on the machine Use the turntable rotation lock to secure the turntable 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 lifting points on the...

Page 49: ... or more of the symbols appear at the beginning of a maintenance 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 Indicates that a cold engine is required before performing this procedure Check the Engine Oil Level Maintaining the proper engine oil level is essential to good en...

Page 50: ... the top 5 cm of the sight gauge 3 Add oil as needed Do not overfill Hydraulic oil specifications Hydraulic oil type Chevron Rando HD equivalent Check the Engine Coolant Level Liquid Cooled Models Maintaining the engine coolant at the proper level is essential to engine service life Improper coolant level will affect the engine s cooling capability and damage engine components Daily checks will al...

Page 51: ... acid spills with baking soda and water 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 the battery hold down brackets are in place and secure Note Adding terminal protectors and a corrosion preventative sealant will help eliminate the corrosion on the battery terminals and cables Scheduled Maintenance Maintenanc...

Page 52: ...ers Weight 18 035 kg Machine weights vary with option configurations See serial label for specific machine weight Drive speeds Drive speed stowed all models 4 8 km h 12 2 m 9 1 sec Drive speed raised or extended all models 1 1 km h 12 2 m 40 sec Drive speed fully extended all models 0 6 km h 12 2 m 70 sec Maximum slope rating stowed position 2WD Counterweight uphill 25 14 Counterweight downhill 25...

Page 53: ...ght 20 548 kg Machine weights vary with option configurations See serial label for specific machine weight Drive speeds Drive speed stowed all models 4 8 km h 12 2 m 9 1 sec Drive speed raised or extended all models 1 1 km h 12 2 m 40 sec Drive speed fully extended all models 0 6 km h 12 2 m 70 sec Maximum slope rating stowed position 2WD Counterweight uphill 25 14 Counterweight downhill 25 14 Sid...

Page 54: ...al First Edition Fourth Printing Specifications 52 S 3200 S 3800 Part No T111109 S 3200 Range of Motion Chart S 3800 Range of Motion Chart S 3200 S 3800 Part No T111109 Operator s Manual First Edition Fourth Printing ...

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