Genie GS-2646 AV, Operator'S Manual

Page 1: ...Operator s Manual GS 2646 AV ANSI CSA North America South America Asia GS 2646 AV35 with Maintenance Information Second Edition Second Printing Part No 1274894GT ...

Page 2: ...e 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 11 Work Area Safety 12 Legend 19 Controls 20 Inspections 24 Operating Instructions 38 Transport and Lifting Instructions 46 Maintenance 51 Specifications 53 Copyright 2012 Terex Corporation Second Edition S...

Page 3: ...edgeable 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 o...

Page 4: ...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 Maintenan...

Page 5: ...r 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 Only trained maintena...

Page 6: ...es used as counterweights Chock the wheels Release brakes Release brakesGrounded AC 3 wire only Replace damaged wires and cords Wheel load Transport diagram Tiedown Lanyard anchorage points No smoking Voltage rating for power to platform Pressure rating for air line to platform Side force Wind speed Maximum capacity Fall hazard 100 Restraint ...

Page 7: ...Second Edition Second Printing Operator s Manual General Safety Part No 1274894GT GS 2646 AV GS 2646 AV35 5 General Safety These decals are model option or configuration specific ...

Page 8: ...Operator s Manual Second Edition Second Printing General Safety 6 GS 2646 AV GS 2646 AV35 Part No 1274894GT ...

Page 9: ...Second Edition Second Printing Operator s Manual General Safety Part No 1274894GT GS 2646 AV GS 2646 AV35 7 ...

Page 10: ...Operator s Manual Second Edition Second Printing General Safety 8 GS 2646 AV GS 2646 AV35 Part No 1274894GT These decals are model option or configuration specific ...

Page 11: ...Second Edition Second Printing Operator s Manual General Safety Part No 1274894GT GS 2646 AV GS 2646 AV35 9 ...

Page 12: ...Operator s Manual Second Edition Second Printing General Safety 10 GS 2646 AV GS 2646 AV35 Part No 1274894GT ...

Page 13: ...han 12 inches 30 cm away from the surface of the exit or entry point Operators are required to wear approved PFPE at all times when exiting and entering an elevated platform through the front gate and must use a lanyard designed to allow 100 tie off when exiting and entering an elevated platform through the front gate Do not exit or enter an elevated platform through the rear gate Exiting an Eleva...

Page 14: ...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 grou...

Page 15: ...ind speeds exceed 28 mph 12 5 m s when the platform is raised lower the platform and do not continue to operate the machine Refer to instructional decal and serial label for specific wind speed rating GS 2646 AV35 Do not raise the platform when wind speeds may exceed 35 mph 15 6 m s If wind speeds exceed 35 mph 15 6 m s when the platform is raised lower the platform and do not continue to operate ...

Page 16: ...achine 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 65 lbs 29 5 kg Battery tray including batteries must weigh a minimum of 335 lbs 152 kg Do not modify or alter an aerial work platform without prior written permission from ...

Page 17: ...te Slope rating is subject to ground conditions and adequate traction 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 a...

Page 18: ...er 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 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 ...

Page 19: ...e battery in hazardous locations or locations where potentially flammable or explosive gases or particles may be present 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...

Page 20: ...lectrocution Burn Hazards Connect the battery charger to a grounded AC 3 wire electrical outlet only Inspect daily for damaged cords cables and wires Replace damaged items before operating Avoid electrical shock from contact with battery terminals Remove all rings watches and other jewelry Tip over Hazard Do not use batteries that weigh less than the original equipment Batteries are used as counte...

Page 21: ...r 6 Platform controls 7 Front entry gate 8 Extension deck bumper 9 Transport tie down 10 Emergency lowering knob 11 Steer tire 12 Pothole guard 13 Ground controls 14 LCD readout 15 Non steer tire 16 Brake release pump 17 Entry ladder transport tie down 18 Battery charger on battery side of machine 19 Tilt alarm 20 Inverter optional 21 Safety arm 22 Platform extension 23 Air line to platform option...

Page 22: ...sition and the platform controls will operate Turn the selector switch to the off position and the machine will be off Turn the selector switch to the ground position and the ground controls will operate 7 Red Emergency Stop button Push in the red Emergency Stop button to the off position to stop all functions Pull out the red Emergency Stop button to the on position to operate the machine 8 7A br...

Page 23: ...ill be off Turn the selector switch to the ground position and the ground controls will operate 7 Red Emergency Stop button Push in the red Emergency Stop button to the off position to stop all functions Pull out the red Emergency Stop button to the on position to operate the machine 8 7A breaker for electrical circuits 9 Powered extension deck extend button 10 Powered extension deck retract butto...

Page 24: ... to stop all functions Pull out the red Emergency Stop button to the on position to operate the machine 2 Lift function button Push this button to activate the lift function 3 Horn button Press this button and the horn will sound Release the button and the horn will stop 4 Drive speed select button Press this button to activate the slow drive function The indicator light will be on when slow drive...

Page 25: ...ion indicated by the yellow arrow on the control panel and the machine will move in the direction that the yellow arrow points Platform extend retract function Press and hold the function enable switch to enable the platform extend retract function on the platform control handle Move the control handle in the direction indicated by the blue arrow and the platform will extend Move the control handl...

Page 26: ...inspection 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 ...

Page 27: ...tors Wear pads Tires and wheels Limit switches proximity switches alarms and horn Alarms and beacons if equipped Nuts bolts and other fasteners Brake release components Safety arm Platform extension Scissor pins and retaining fasteners Platform control joystick Outrigger housing and footpads if equipped Battery pack and connections Ground strap Platform entry chain or gate Pothole guards Lanyard a...

Page 28: ...5 Only 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 mach...

Page 29: ...n position Test the Up Down Functions The audible warnings on this machine and the standard horn all come from the same central alarm The horn is a constant tone The descent alarm sounds at 60 beeps per minute The alarm sounds at 180 beeps per minute when the pothole guards have not deployed and when the machine is not level An optional automotive style horn is also available 9 Do not press the li...

Page 30: ...ns 21 Do not hold the function enable switch on the control handle 22 Slowly move the control handle in the direction indicated by the blue arrow then in the direction indicated by the yellow arrow Result No functions should operate 23 Press the lift function button 24 Wait seven seconds for the lift function to time out 25 Slowly move the control handle in the direction indicated by the blue arro...

Page 31: ...l handle in the direction indicated by the blue arrow then in the direction indicated by the yellow arrow Result The lift function should not operate 38 Press the powered extension deck function button 39 Press and hold the function enable switch on the control handle Slowly move the control handle in the direction indicated by the yellow arrow Result The powered extension deck should retract If e...

Page 32: ...nel then come to an abrupt stop when the control handle is returned to the center position Note The brakes must be able to hold the machine on any slope it is able to climb Test the Entry Gate Cut out Function 51 Raise the platform approximately 4 ft 1 2 m from the ground 52 Extend the powered extension deck 2 ft 0 6 m if equipped 53 Open the rear entry gate and prop open 54 Press the drive functi...

Page 33: ... not operate 69 Activate the platform extend function and the platform retract function Result The platform extend function and the platform retract function should not work 70 Close the front entry gate 71 Fully retract the powered extension deck to the stowed position if equipped Fully lower the platform to the stowed position Test the Tilt Sensor Operation Note Perform this test from the ground...

Page 34: ...hole guards should deploy 83 Press on the pothole guards on one side and then the other Result The pothole guards should not move 84 Lower the platform Result The pothole guards should return to the stowed position 85 Place a 2x4 or similar piece of wood under a pothole guard 86 Raise the platform Result Before the platform is raised 7 ft 2 1 m from the ground an alarm should sound The platform co...

Page 35: ... the operator 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 ...

Page 36: ...tion Diagram 1 114360 Danger Tip over Hazard Batteries 1 114361 Label Transport Diagram 2 114385 Danger Electrocution Hazard 2 114386 Danger General Safety Rules GS 2646 AV 1 Part No Decal Description Qty 133234 Danger General Safety Rules GS 2646 AV35 1 133276 Label Emergency Lowering 1 137605 Label Emergency Stop Platform Control 1 137656 Label Drive Steer Direction Platform Control 1 162518 Lab...

Page 37: ...Second Edition Second Printing Operator s Manual Inspections Part No 1274894GT GS 2646 AV GS 2646 AV35 35 ...

Page 38: ... Injection Hazard 1 82562 Label Crushing Hazard 4 82735 Label Side Force 667 N GS 2646 2 97719 Label Safety Arm 1 114334 Label Electrocution Hazard Plug 1 Part No Decal Description Qty 114337 Label Tip over Hazard Limit Switch 1 114338 Label Tip over Hazard Tilt Alarm 1 114361 Label Transport Diagram 2 114370 Label Tip over Hazard Batteries 1 114372 Label Tip over Hazard Open Trays 2 137605 Label ...

Page 39: ...Second Edition Second Printing Operator s Manual Inspections Part No 1274894GT GS 2646 AV GS 2646 AV35 37 ...

Page 40: ... It is 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 ...

Page 41: ...atform Operation from Ground 1 Be sure the battery pack is connected before operating the machine 2 Turn the selector switch to ground control 3 Pull out both ground and platform red Emergency Stop buttons to the on position To Position Platform 1 Press and hold the lift enable button 2 Press the platform up or platform down button Drive and steer functions are not available from the ground contro...

Page 42: ... Move the control handle in the direction indicated on the control panel Note The drive and lift function are disabled when the extension deck is deployed and or when the platform gates are in the open position The extension deck must be in the stowed position and the platform gates fully closed before operating the drive and lift functions Note The powered extension deck extend and retract functi...

Page 43: ...f the control handle is not moved within seven seconds of pushing the drive function button the circle below the drive function symbol will turn off and drive function will not operate Press the drive function button again 2 Machines equipped with foot switch Press and hold the foot switch and press and hold the function enable switch on the control handle at the same time 3 Increase speed Slowly ...

Page 44: ...ote Slope rating is subject to ground conditions and adequate traction Press the drive speed button to the fast drive speed mode 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 3 feet 1 m long tape measure Lay the piece of wood on the slope At the downhill end lay the level on ...

Page 45: ...uck nd No Drive option dE Deck Extended PED only lift and drive disabled Fd Function Disabled all functions For further information please consult the appropriate Genie Service Manual A code and a description of a code can also be viewed at the ground controls LCD display Operation from Ground with Controller Maintain safe distances between the operator machine and fixed objects Be aware of the di...

Page 46: ...5 Part No 1274894GT How to Use the Safety Arm 1 Raise the platform approximately 8 ft 2 4 m from the ground 2 Rotate the safety arm away from the machine and let it hang down 3 Lower the platform until the safety arm rests securely on the link Keep clear of the safety arm when lowering the platform ...

Page 47: ... vent caps and check the battery acid level If necessary add only enough distilled water to cover the plates Do not overfill prior to the charge cycle 2 Replace the battery vent caps 3 Connect the battery charger to a grounded AC circuit 4 The onboard charger will automatically shut off when charging cycle is complete 5 Check the battery acid level when the charging cycle is complete Replenish wit...

Page 48: ... should move the machine on or off the truck The transport vehicle must be parked on a level surface The transport vehicle must be secured to prevent 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 ...

Page 49: ...e machine is loaded 1 Chock the wheels to prevent the machine from rolling 2 Pull out the red Emergency Stop button at both the ground and platform controls to the on position and turn the key switch to the platform position 3 Press the drive function button if equipped 4 Press and hold the function enable switch on the control handle Move the control handle off center and immediately release it t...

Page 50: ...uck or Trailer for Transit Always use the extension deck lock when the machine is transported Turn the selector switch to the off position before transporting Inspect the entire machine for loose or unsecured items Use chains or straps of ample load capacity Use a minimum of 2 chains or straps Adjust the rigging to prevent damage to the chains ...

Page 51: ... loose items on the machine Fully lower the platform The platform must remain lowered during all loading and transport procedures Use the forklift pockets located on both sides of the ladder Align the forklift forks with the forklift pockets Drive forward to the full extent of the forks Raise the machine 16 in 0 4 m and then tilt the forks back slightly to keep the machine secure Be sure the machi...

Page 52: ... 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 1 inch 2 5 cm holes on the front of the machine and two holes in the ladder for lifting Adjust the rigging to prevent damage to the machine and to keep the machine level Center of Gravity Table Model X Axis Y Axis GS 264...

Page 53: ...aintenance 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 Check the Hydraulic Oil Level Maintaining the hydraulic oil at the proper level is essential to machine operation Improper hydraulic oil levels can damage hydraulic components Daily checks allow the inspector to identi...

Page 54: ...g soda and water Note Perform this test after fully charging the batteries 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 cabl...

Page 55: ... voltage 24V AC outlet in platform Standard Maximum hydraulic pressure functions 3500 psi 241 bar Tire size 15 x 5 x 11 25 in Vibration value does not exceed 2 5 m s 2 Operating Temperature Minimum 20 F 29 C Maximum 150 F 66 C Airborne noise emissions Sound pressure level at ground workstation 70 dBA Sound pressure level at platform workstation 70 dBA Maximum slope rating stowed position 25 14 Max...

Page 56: ...hydraulic pressure functions 3500 psi 241 bar Tire size 15 x 5 x 11 25 in Vibration value does not exceed 2 5 m s 2 Operating Temperature Minimum 20 F 29 C Maximum 150 F 66 C Airborne noise emissions Sound pressure level at ground workstation 70 dBA Sound pressure level at platform workstation 70 dBA Maximum slope rating stowed position 20 11 Maximum side slope rating stowed position 20 11 Note Sl...

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