Terex Genie GS-2668DC, Operator'S Manual

Page 1: ......

Page 2: ... 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 Page Introduction 1 Symbols and Hazard Pictorials Definitions 3 GeneralSafety 5 Per...

Page 3: ... employer s safety rules and worksite regulations You read understand and obey all applicable governmentalregulations You are properly trained to safely operate the machine Introduction Owners Users and Operators 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 We feel that you make a major contribu...

Page 4: ...al Hazard Classification Genie uses 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 which if not avoided will result in death or serious injury Indicates a hazardous situation which if not avoid...

Page 5: ...d Tip overhazard Electrocution hazard Electrocution hazard Explosionhazard Firehazard Burnhazard Skin injection hazard Keep away from moving parts Engage safety arm Keep clear of outriggersand tires Move machine to levelground Lowertheplatform Maintainrequired clearance Do not set up where it cannot be leveled with outriggers Close chassis tray Onlytrained maintenance personnelshould access compar...

Page 6: ...heelload Voltage rating for power to platform Pressure rating for air line to platform No smoking Lanyard attachment point Tiedown Chock the wheels Releasebrakes Transport diagram Side force Maximum capacity Crushinghazard Hold rail while lowering Symbol and Hazard Pictorials Definitions ...

Page 7: ...Operator s Manual Fifth Edition First Printing PartNo 133556 GS 2668 DC GS 3268 DC 5 General Safety ...

Page 8: ...Operator s Manual Fifth Edition First Printing 6 GS 2668 DC GS 3268 DC PartNo 133556 General Safety ...

Page 9: ...Operator s Manual Fifth Edition First Printing PartNo 133556 GS 2668 DC GS 3268 DC 7 General Safety ...

Page 10: ...Operator s Manual Fifth Edition First Printing 8 GS 2668 DC GS 3268 DC PartNo 133556 General Safety ...

Page 11: ...l 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 Safety Personal Safety ...

Page 12: ...h 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 1250 lbs 567 kg Platform only 950 lbs 431kg Extension only 300 lbs 136 kg 1000 lbs 454 kg Platform only 700 lbs 318 kg Extension only 300 lbs 136 kg Tip over Hazards Occupants equipment and materials shall not exceed...

Page 13: ... N Australia Indoor use only 4 person 90 lbs 400 N Australia Outdoor use 2 person 90 lbs 400 N 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 severe slope If the tilt alarm sounds Lower the platform Move the machine to a firm level surface ...

Page 14: ...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 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 co...

Page 15: ...e 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 equipment and its use shall be in accordance with the PFPE manufacturer s instructions and applicable governmentalrequirements Do not sit stand or climb on the platform guard rails Maintain a firm footing on the platform floo...

Page 16: ...ents must remain closed and secured during operation Component Damage Hazards Do not use the machine as a ground for welding Collision Hazards Be aware of limited sight distance and blind spots whendrivingoroperating Be aware of the 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 jo...

Page 17: ...intenance 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 platform Crushing Hazards Keep hands and limbs out of scissors Use common sense and planning when operating the machine with the contr...

Page 18: ...any battery charger greater than 24V to charge the batteries Electrocution Burn Hazards Connect the battery charger to a grounded AC3 wireelectrical outlet only Inspect daily for damaged cords cables and wires Replacedamageditemsbefore 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...

Page 19: ...nsion 8 Battery side cover 9 Steer tire 10 Power to platform pigtail 11 Power to charger pigtail and batterycharger undercover 12 Non steertire 13 Tilt alarm under cover 14 Entryladder transport tie down 15 Brake release pump knob and brake release knob 16 Ground controls with manual lowering and LED diagnostic readout 17 Ground controls side cover 18 Hydraulic oil level indicator undercover 19 Sa...

Page 20: ...Controls Platform Control Panel 1 Thumb rocker switch for steer functions 2 Drive speed button 3 Drive function select button 4 Red Emergency Stop button 5 LED 6 Lift function select button 7 Hornbutton 8 Proportional control handle and function enable switch for lift and drive functions ...

Page 21: ...ift function select button Press this button to activate the lift function 7 HornButton Push the horn button and the horn will sound Release the horn button and the horn will stop 8 Proportional control handle and function enable switch for lift and drive functions Lift function Move the control handle in the direction indicated by the blue arrow and the platform will raise Move the control handle...

Page 22: ...d Control Panel 1 LEDdiagnosticreadout 2 Hourmeter 3 Red Emergency Stop button 4 7 amp circuit breaker for controls circuit 5 Platform down button 6 Functionenablebutton 7 Key switch for platform off ground control selection 8 Platform up button 9 Emergencyloweringbutton 1 2 4 3 7 8 9 6 5 00009 9 STOP ...

Page 23: ... amp circuit breaker for controls circuit 5 Platform down button Press this button and the platform will lower 6 Functionenablebutton Press this button to activate the lift function 7 Key switch for platform off ground control selection Turn the keyswitch to the platform position and the platform controls will operate Turn the keyswitch to the off position and the machine will be off Turn the keys...

Page 24: ...scover 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 unauthorized variation from ...

Page 25: ... Electrical components wiring and electrical cables R Hydraulic power unit tank hoses fittings cylinders and manifolds R Battery pack and connections R Drive motors R Wearpads R Tires and wheels R Limit switches alarms and horn R Platformoverloadcomponents R Nuts bolts and other fasteners R Platform entry gate R Beacon and alarms if equipped R Brakereleasecomponents R Safety arm R Platform extensi...

Page 26: ...hine as it was intended Function Tests 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 only be m...

Page 27: ...e motion alarm sound at 60 beeps per minute and sound at the chassis The alarm that goes off when the machine is not level sounds at 180 beeps per minute and sounds at the chassis and in the platform 8 Do not hold the function enable button Activate the platform up function Result No function should operate 9 Push and hold the function enable button and activate the platform up function Result The...

Page 28: ...rrow Result The platform should raise The pothole guards should deploy 21 Release the control handle Result The platform should stop raising 22 Press and hold the function enable switch Slowly move the control handle in the direction indicated by the yellow arrow Result The platform should lower The descent alarm should sound while the platform is lowering Test the Steering Note When performing th...

Page 29: ...move in the direction that the yellow arrow points on the control panel then come to an abrupt stop Note The brakes must be able to hold the machine on any slope it is able to climb Test the Tilt Sensor Operation Note Perform this test from the ground with the platform controller Do not stand in the platform 30 Fully lower the platform 31 Drive both wheels on one side onto a 4 in 10 cm block or on...

Page 30: ...ly 8 ft 2 4 m from the ground 37 Press the drive function select switch 38 Press and hold the function enable switch Slowly move the control handle to the full drive position Result The maximum achievable drive speed with the platform raised should not exceed 0 73 feet 22 cm per second If the drive speed with the platform raised exceeds 0 73 feet 22 cm per second immediately tag and remove the mac...

Page 31: ...ne 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 operatingthemachine Workplace Inspection Be aware of and avoid the following hazardous situations drop offs or holes bum...

Page 32: ...C ANSI CSA 1 52803 Notice Max Side Force GS 3268 DC Australia 1 Part No Description Quantity 52966 Cosmetic 4 x 2 2 65052 Label Fault Codes 1 62061 Cosmetic Genie GS 2668 DC 2 62062 Cosmetic Genie GS 3268 DC 2 72970 Instructions Charger Instructions 1 82239 Label Latch 2 82261 Ground Control Panel 1 82263 Instructions Operating Instructions Ground 1 82270 Instructions Battery Connection Diagram 1 ...

Page 33: ...Operator s Manual Fifth Edition First Printing PartNo 133556 GS 2668 DC GS 3268 DC 31 Inspections ...

Page 34: ... Chock 2 82476 Label Electrocution Hazard 2 82481 Label Battery Safety 1 82487 Label Read the Manual 2 82495 Label Brake Release Safety 1 82560 Label Skin Injection Hazard 1 82562 Label Crushing Hazard 4 Part No Decal Description Qty 82748 Label Wheel Load GS 2668 DC 4 82749 Label Wheel Load GS 3268 DC 4 82753 Danger Max Manual Force 1 82751 Label Maximum Capacity GS 2668 DC 1 82752 Label Maximum ...

Page 35: ...Operator s Manual Fifth Edition First Printing PartNo 133556 GS 2668 DC GS 3268 DC 33 Inspections Shading indicates decal is hidden from view i e under covers ...

Page 36: ...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 a machine at different times i...

Page 37: ...tch located on the top of the control handle Emergency Stop Push in the red Emergency Stop button to the off position at the ground controls or the platform controls to stop all functions Repair any function that operates when either red Emergency Stop button is pushed in Emergency Lowering 1 Turn the key switch to ground control 2 Pull out the ground red Emergency Stop button to the on position 3...

Page 38: ...orm controls and on the platform to identify the direction the machine will travel Machine travel speed is restricted when the platform is raised Battery condition will affect machine performance When the battery charge indicator light flashes the machine drive speed is limited To reduce drive speed The drive controls can operate in two different drive speed modes When the drive speed button light...

Page 39: ...ou will need carpenter slevel straight piece of wood at least 3 feet 1 m long tapemeasure 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 While holding the piece of wood level measure the distance from the bottom of the piece of wood to theground Divide the tape measure distance rise by the ...

Page 40: ... safe distances between the operator the machine and fixed objects Be aware of the direction the machine will travel when using the controller Battery Level Indicator Use the LED diagnostic readout on the platform controls to determine the battery level Fall Protection Personal fall protection equipment PFPE is not required when operating this machine If PFPE is required by job site or employer ru...

Page 41: ...place the battery vent caps 5 Connect the battery charger to a grounded AC circuit 6 The charger will indicate when the battery is fully charged 7 Check the battery acid level when the charging cycle is complete Replenish with distilled water to the bottom of the fill tube Do not overfill Dry Battery Filling and Charging Instructions 1 Remove the battery vent caps and permanently remove the plasti...

Page 42: ...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 See the Inspection section for the serial label location If the slope of the transport vehicle bed exceeds the uphill or downhill maximum slope rating the machine must be loaded and unloaded using a winch as described See the Specificatio...

Page 43: ... secure the extension deck Turn the key switch to the off position and remove the key 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 If the railings have been folded down secure them with straps before transporting ...

Page 44: ...ctions Fully lower the platform Be sure the extension deck controls and covers are secure Remove all loose items on the machine 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 each end of the machine Adjust the rigging to prevent damage to the machine...

Page 45: ...ng below Indicates that tools will be required to performthisprocedure Indicates that new parts will be required to performthisprocedure Maintenance 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 identify changes in oil level that migh...

Page 46: ...ls or damaged cables and connections can result in engine component damageandhazardousconditions Note This procedure does not need to be performed on machines with sealed or maintenance freebatteries Electrocution hazard Contact with hot or live circuits may result in death or serious injury Remove all rings watches and other jewelry Bodily injury hazard Batteries contain acid Avoid spilling or co...

Page 47: ...rations See serial label for specific machine weight Controls Proportional AC outlet in platform Standard Platform dimensions Platform length x width 99 x 61 in 2 5 x 1 5 m Platform extension length 60 in 1 5 m Drive speeds Stowed maximum 3 0 mph 4 8 km h Platform raised maximum 0 5 mph 0 8 km h 40 ft 54 6 sec 12 2 m 54 6 sec Maximum hydraulic pressure functions 3500 psi 241 3 bar Tires size 22 x ...

Page 48: ... configurations See serial label for specific machine weight Controls Proportional AC outlet in platform Standard Platform dimensions Platform length x width 2 5 x 1 5 m Platform extension length 1 5 m Drive speeds Stowed maximum 3 0 mph 4 8 km h Platform raised maximum 0 5 mph 0 8 km h 40 ft 54 6 sec 12 2 m 54 6 sec Maximum hydraulic pressure functions 3500 psi 241 3 bar Tires size 22 x 9 x 360 M...