Operator’s Manual |
Second Edition |
Third Printing |
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with Maintenance Information |
Part No. 82828 |
CE Models
Operator's Manual |
Second Edition • Third Printing |
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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, please call Genie Industries.
Contents |
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Page |
Safety ........................................................................ |
1 |
Legend ....................................................................... |
8 |
Controls ..................................................................... |
9 |
Pre-operation Inspection ........................................... |
11 |
Maintenance ............................................................. |
13 |
Function Tests .......................................................... |
16 |
Workplace Inspection ................................................ |
20 |
Operating Instructions ............................................... |
21 |
Transport and Lifting Instructions .............................. |
25 |
Decals ...................................................................... |
28 |
Specifications ........................................................... |
30 |
Contact us: |
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Internet: http://www.genielift.com |
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e-mail: techpub@genieind.com |
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Copyright © 2002 by Genie Industries
First Edition: First Printing, January 2002
Second Edition: Third Printing, March 2008
"Genie" is a registered trademark of
Genie Industries in the U.S.A. and many other countries. "GS" is a trademark of Genie Industries.
Printed on recycled paper
Printed in U.S.A.
Genie GS-3384 and GS-3390 and GS-4390 and GS-5390 |
Part No.82828 |
Second Edition • Third Printing |
Operator's Manual |
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Safety Rules
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.
Part No.82828 |
Genie GS-3384 & GS-3390 & GS-4390 & GS-5390 |
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Operator's Manual |
Second Edition • Third Printing |
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SAFETY RULES
Electrocution Hazards
This machine is not electrically insulated and will not provide protection from contact with or proximity to electrical current.
Maintain safe distances from electrical power lines and apparatus in accordance with applicable governmental regulations and the following chart.
Voltage |
Minimum Safe |
Phase to Phase |
Approach Distance |
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Meters |
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0 to 300V |
Avoid Contact |
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300V to 50KV |
3.05 |
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50KV to 200KV |
4.60 |
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200KV to 350KV |
6.10 |
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350KV to 500KV |
7.62 |
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500KV to 750KV |
10.67 |
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750KV to 1000KV |
13.72 |
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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 must not exceed the maximum platform capacity.
Machines without capacity indicator
Maximum capacity
GS-3384 and GS-3390 |
1134 kg |
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GS-4390 |
680 kg |
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GS-4390 with extra capacity option |
816 kg |
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GS-5390 |
680 kg |
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Maximum occupants |
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GS-3384 and GS-3390 |
7 |
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GS-4390 |
7 |
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GS-4390 with extra capacity option |
7 |
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GS-5390 |
4 |
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Machines with capacity indicator
The maximum capacity varies with the height of the platform.
Maximum capacity - GS-3384 and GS-3390
Maximum occupants |
7 |
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Height of Platform |
Maximum Capacity |
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10.1 m |
1134 kg |
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8 m |
1505 kg |
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6 m |
1878 kg |
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4 m |
1505 kg |
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2 m |
1134 kg |
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Genie GS-3384 & GS-3390 & GS-4390 & GS-5390 |
Part No.82828 |
Second Edition • Third Printing |
Operator's Manual |
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Maximum capacity - GS-4390
Maximum occupants |
7 |
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Height of Platform |
Maximum Capacity |
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13.1 m |
680 kg |
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10.6 m |
984 kg |
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8 m |
1286 kg |
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5.4 m |
984 kg |
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2.9 m |
680 kg |
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Maximum capacity - GS-4390 |
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with extra capacity option |
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Maximum occupants |
7 |
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Height of Platform |
Maximum Capacity |
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13.1 m |
816 kg |
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10.6 m |
1118 kg |
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8 m |
1421 kg |
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5.4 m |
1118 kg |
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2.9 m |
816 kg |
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Maximum capacity - GS-5390 |
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Maximum occupants |
4 |
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Height of Platform |
Maximum Capacity |
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16.2 m |
680 kg |
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12.8 m |
1046 kg |
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9.4 m |
1410 kg |
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5.9 m |
1046 kg |
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2.5 m |
680 kg |
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SAFETY RULES
Do not alter or disable the limit switches.
Do not drive over 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.
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 and in the platform when the machine is on a 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.
Part No.82828 |
Genie GS-3384 & GS-3390 & GS-4390 & GS-5390 |
3 |
Operator's Manual |
Second Edition • Third Printing |
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SAFETY RULES
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.
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 push off or pull toward any object outside of the platform.
Maximum allowable manual force
400 N
Do not transport tools and materials unless they are evenly distributed and can be safely handled by person(s) in the platform.
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 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 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.
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.
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Genie GS-3384 & GS-3390 & GS-4390 & GS-5390 |
Part No.82828 |
Second Edition • Third Printing |
Operator's Manual |
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SAFETY RULES
Fall Hazards |
Collision Hazards |
The guardrail 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 equipment and its use shall be in accordance with the PFPE manufacturer’s instructions and applicable governmental requirements.
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.
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.
Be aware of limited sight distance and blind spots when driving or operating.
Be aware of extended platform position(s) when moving the machine.
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 platform decal plate for drive and steer functions.
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.
Part No.82828 |
Genie GS-3384 & GS-3390 & GS-4390 & GS-5390 |
5 |
Operator's Manual |
Second Edition • Third Printing |
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SAFETY RULES
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.
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.
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 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 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 in the platform.
Crushing Hazards
Keep hands and limbs out of scissors.
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.
Maintain a firm grasp on the platform rail when removing the rail pins. Do not allow the platform guard rails to fall.
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.
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Genie GS-3384 & GS-3390 & GS-4390 & GS-5390 |
Part No.82828 |
Second Edition • Third Printing |
Operator's Manual |
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Outrigger Safety
Tip-over Hazards
Do not lower the outriggers unless the machine is on a firm surface. Avoid drop-offs, holes, unstable or slippery surfaces and other possible hazardous conditions.
When the auto level function is not being used and the outriggers are being lowered individually, the steer-end outriggers must be lowered first.
Do not raise the platform unless the machine is level. Do not set the machine up on a surface where it cannot be leveled using only the outriggers.
Do not raise the platform unless all four outriggers are properly lowered, the footpads are in firm contact with the ground and the machine is level.
Do not adjust the outriggers while the platform is raised.
Do not drive while the outriggers are lowered.
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 Hazard
Keep sparks, flames and lighted tobacco away from batteries. Batteries emit explosive gas.
Electrocution Hazard
Avoid contact with electrical terminals.
SAFETY RULES
Decal Legend
Genie product decals use symbols, color coding and signal words to identify the following:
Safety alert symbol—used to alert personnel to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death.
Red—used to indicate the presence of an imminently hazardous situation which, if not avoided, will result in death or serious injury.
Orange—used to indicate the presence of a potentially hazardous situation which, if not avoided, could result in death or serious injury.
Yellow with safety alert symbol— used to indicate the presence of a potentially hazardous situation which, if not avoided, may cause minor or moderate injury.
Yellow without safety alert symbol—used to indicate the presence of a potentially hazardous situation which, if not avoided, may result in property damage.
Green—used to indicate operation or maintenance information.
Part No.82828 |
Genie GS-3384 & GS-3390 & GS-4390 & GS-5390 |
7 |
Operator's Manual |
Second Edition • Third Printing |
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Legend
1Lanyard anchorage point
2GFCI outlet
3Platform controls
4Platform entry gate
5Platform extension lock handle
6Platform guard rails
7Manual storage container
8Platform extension
9Outrigger housing (if equipped)
10Outrigger footpad (if equipped)
11Ground controls with LCD readout screen
12Tilt alarm (behind ground control panel)
13Entry ladder
14Steer tire
15LPG tank
16Fuel tank (behind cover)
17Non-steer tire
18Hydraulic tank (behind cover)
19Power to platform (hidden from view)
20Safety arm (hidden from view)
21Capacity indicator (if equipped)
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Genie GS-3384 & GS-3390 & GS-4390 & GS-5390 |
Part No.82828 |
Second Edition • Third Printing |
Operator's Manual |
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Controls
Ground Control Panel
1Key switch for platform/off/ground control selection
2Engine start button
3Gasoline/LPG models: Choke button Diesel models: Glow plug button
4Platform down button
5Idle select button with indicator light
6Gasoline/LPG models: LPG select button with indicator light
7LCD readout screen
8Platform up button
9Lift function enable button
10Backup auxiliary function enable button
1120 amp circuit breaker for controls circuit
12Backup auxiliary down button
13Hour meter
14Red Emergency Stop button
Part No.82828 |
Genie GS-3384 & GS-3390 & GS-4390 & GS-5390 |
9 |
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