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Terex Genie GS-2668DC Operator's Manual

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Summary of Contents for Terex Genie GS-2668DC

  • Page 2: Table Of Contents

    Operator's Manual Fifth Edition • First Printing 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.

  • Page 3: Introduction

    Fifth Edition · First Printing Operator's Manual 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 contribution to safety if you, as the equipment users and operators: Danger...
  • Page 4 Operator's Manual Fifth Edition · First Printing Introduction Hazard Classification Intended Use Genie uses symbols, color coding and signal words This machine is intended to be used only to lift to identify the following: personnel, along with their tools and materials to an aerial work site.

  • Page 5: Symbols And Hazard Pictorials Definitions

    Fifth Edition · First Printing Operator's Manual Symbol and Hazard Pictorials Definitions Read the Read the operator’s manual service manual Crush hazard Crush hazard Collision hazard Electrocution Tip-over hazard Tip-over hazard Tip-over hazard Tip-over hazard hazard Electrocution Skin injection hazard Explosion hazard Fire hazard hazard...
  • Page 6 Operator's Manual Fifth Edition · First Printing Symbol and Hazard Pictorials Definitions Lanyard No smoking Tiedown attachment point Chock the wheels Release brakes Hold rail while Transport lowering Crushing hazard Side force Wheel load diagram Voltage rating for Pressure rating for Maximum capacity power to platform air line to platform...

  • Page 7: General Safety

    Fifth Edition · First Printing Operator's Manual General Safety Part No. 133556 GS-2668 DC • GS-3268 DC...
  • Page 8 Operator's Manual Fifth Edition · First Printing General Safety GS-2668 DC • GS-3268 DC Part No. 133556...
  • Page 9 Fifth Edition · First Printing Operator's Manual General Safety Part No. 133556 GS-2668 DC • GS-3268 DC...
  • Page 10 Operator's Manual Fifth Edition · First Printing General Safety GS-2668 DC • GS-3268 DC Part No. 133556...

  • Page 11: Personal Safety

    Fifth Edition · First Printing Operator's Manual Personal Safety 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.Safety...

  • Page 12: Work Area Safety

    Operator's Manual Fifth Edition · First Printing Work Area Safety Electrocution Hazards Tip-over Hazards This machine is not electrically insulated and will Occupants, equipment and materials shall not not provide protection from contact with or exceed the maximum platform capacity or the proximity to electrical current.
  • Page 13 Fifth Edition · First Printing Operator's Manual Work Area Safety Do not raise the platform unless the machine is on Do not use the platform controls to free a platform a firm, level surface. that is caught, snagged or otherwise prevented from normal motion by an adjacent structure.
  • Page 14 Operator's Manual Fifth Edition · First Printing Work Area Safety Do not tie the platform to adjacent structures. Do not place or attach fixed or overhanging loads to any part of this machine. Do not place loads outside the platform perimeter. Do not alter or disable machine components that in any way affect safety and stability.
  • Page 15 Fifth Edition · First Printing Operator's Manual Work Area Safety Operation on Slopes Hazards Fall Hazards Do not drive the machine on a slope that exceeds The guard rail system provides fall protection. If the slope and side slope rating of the machine. occupant(s) of the platform are required to wear Slope rating applies to machines in the stowed personal fall protection equipment (PFPE) due to...
  • Page 16 Operator's Manual Fifth Edition · First Printing Work Area Safety Collision Hazards No stunt driving or horseplay while operating a machine. Be aware of limited sight Do not lower the platform unless the area below is distance and blind spots clear of personnel and obstructions.
  • Page 17 Fifth Edition · First Printing Operator's Manual Work Area Safety Explosion and Fire Hazards Do not operate the machine 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.
  • Page 18 Operator's Manual Fifth Edition · First Printing Work Area Safety Electrocution/Burn Hazards Battery Safety Connect the battery charger to a Burn Hazards grounded, AC 3-wire electrical outlet only. Batteries contain acid. Always wear protective clothing and Inspect daily for damaged eye wear when working with cords, cables and wires.

  • Page 19: Legend

    Fifth Edition · First Printing Operator's Manual Legend 1 Platform entry gate 9 Steer tire 16 Ground controls with manual lowering and LED diagnostic 2 Platform guard rails 10 Power to platform pigtail readout 3 Lanyard anchorage point 11 Power to charger pigtail and 17 Ground controls side cover battery charger (under cover) 4 Platform extension lock...

  • Page 20: Controls

    Operator's Manual Fifth Edition · First Printing Controls Platform Control Panel 1 Thumb rocker switch for steer functions 5 LED 2 Drive speed button 6 Lift function select button 3 Drive function select button 7 Horn button 4 Red Emergency Stop button 8 Proportional control handle and function enable switch for lift and drive functions GS-2668 DC •...
  • Page 21 Fifth Edition · First Printing Operator's Manual Controls Platform Control Panel 7 Horn Button 1 Thumb rocker switch for steer functions Push the horn button and the horn will sound. Release the horn button and the horn will stop. Press the thumb rocker switch in either direction to activate steer function.
  • Page 22 Operator's Manual Fifth Edition · First Printing Controls STOP 00009.9 Ground Control Panel LED diagnostic readout Function enable button Hour meter Key switch for platform/off/ground control selection Red Emergency Stop button Platform up button 7 amp circuit breaker for controls circuit Emergency lowering button Platform down button GS-2668 DC •...
  • Page 23 Fifth Edition · First Printing Operator's Manual Controls Ground Control Panel 1 LED diagnostic readout 2 Hour meter Indicates the number of hours the machine been put into use. 3 Red Emergency Stop button Push in the red Emergency Stop button to the off position to stop all functions.

  • Page 24: Inspections

    Operator's Manual Fifth Edition · First Printing Inspections Pre-Operation Inspection Fundamentals It is the responsibility of the operator to perform a pre-operation inspection and routine maintenance. The pre-operation inspection is a visual inspection Do Not Operate Unless: performed by the operator prior to each work shift. The inspection is designed to discover if anything You learn and practice the principles of safe is apparently wrong with a machine before the...
  • Page 25 Fifth Edition · First Printing Operator's Manual Inspections Pre-operation Inspection Platform extension Be sure that the operator’s, safety and responsibilities manuals are complete, legible Scissor pins and retaining fasteners and in the storage container located in the Platform control joystick platform.
  • Page 26 Operator's Manual Fifth Edition · First Printing Inspections 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 Do Not Operate Unless: malfunctions are discovered, the machine must be tagged and removed from service.
  • Page 27 Fifth Edition · First Printing Operator's Manual Inspections 1 Select a test area that is firm, level and free of Test the Up/Down Functions obstruction. The descent alarm and the motion alarm sound at 2 Be sure the battery pack is connected. 60 beeps per minute and sound at the chassis.
  • Page 28 Operator's Manual Fifth Edition · First Printing Inspections At the Platform Controls 21 Release the control handle. Result: The platform should stop raising. Test Emergency Stop 22 Press and hold the function enable switch. 13 Push in the platform red Emergency Stop button Slowly move the control handle in the direction to the off position.
  • Page 29 Fifth Edition · First Printing Operator's Manual Inspections Test Drive and Braking Test the Tilt Sensor Operation 27 Press and hold the function enable switch. Note: Perform this test from the ground with the platform controller. Do not stand in the platform. 28 Slowly move the control handle in the direction indicated by the blue arrow on the control panel 30 Fully lower the platform.
  • Page 30 Operator's Manual Fifth Edition · First Printing Inspections Test Limited Drive Speed 35 Press the lift function select button. 36 Press and hold the function enable switch. Raise the platform approximately 8 ft / 2.4 m from the ground. 37 Press the drive function select switch. 38 Press and hold the function enable switch.
  • Page 31 Fifth Edition · First Printing Operator's Manual Inspections Workplace Inspection Be aware of and avoid the following hazardous situations: · drop-offs or holes · bumps, floor obstructions or debris Do Not Operate Unless: · sloped surfaces You learn and practice the principles of safe ·...
  • Page 32 Operator's Manual Fifth Edition · First Printing Inspections Inspection for Decals with Words Determine whether the decals on your machine have words or symbols. Use the appropriate inspection to verify that all decals are legible and in place. Part No. Description Quantity Part No.
  • Page 33 Fifth Edition · First Printing Operator's Manual Inspections Part No. 133556 GS-2668 DC • GS-3268 DC...
  • Page 34 Operator's Manual Fifth Edition · First Printing Inspections Inspection for Decals with Symbols Determine whether the decals on your machine have words or symbols. Use the appropriate inspection to verify that all decals are legible and in place. Part No. Decal Description Part No.
  • Page 35 Fifth Edition · First Printing Operator's Manual Inspections Shading indicates decal is hidden from view, i.e. under covers Part No. 133556 GS-2668 DC • GS-3268 DC...

  • Page 36: Operating Instructions

    Operator's Manual Fifth Edition · First Printing Operating Instructions Fundamentals The Operating Instructions section provides instructions for each aspect of machine operation. 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 Do Not Operate Unless: personnel, along with their tools and materials, to...
  • Page 37 Fifth Edition · First Printing Operator's Manual Operating Instructions Emergency Stop Operation From Platform Push in the red Emergency Stop button to the off 1 Turn the key switch to platform control. position at the ground controls or the platform 2 Pull out the ground and platform red Emergency controls to stop all functions.
  • Page 38 Operator's Manual Fifth Edition · First Printing Operating Instructions To Drive 1 Press and hold the function enable switch. 2 Increase speed: Slowly move the control handle off center. Decrease speed: Slowly move the control handle toward center. Stop: Return the control handle to center or release the function enable switch.
  • Page 39 Fifth Edition · First Printing Operator's Manual Operating Instructions Driving on a slope While holding the piece of wood level, measure the distance from the bottom of the piece of wood to Determine the slope and and side slope ratings for the ground.
  • Page 40 Operator's Manual Fifth Edition · First Printing Operating Instructions Error Indicator Readout Operation From Ground with Controller If the LED diagnostic readout displays a fault code, such as LL, Maintain safe distances between the operator, the push in and pull out the red machine and fixed objects.
  • Page 41 Fifth Edition · First Printing Operator's Manual Operating Instructions Dry Battery Filling and Charging Instructions 1 Remove the battery vent caps and permanently remove the plastic seal from the battery vent openings. 2 Fill each cell with battery acid (electrolyte) until Battery and Charger Instructions the level is sufficient to cover the plates.

  • Page 42: Transport And Lifting Instructions

    Operator's Manual Fifth Edition · First Printing Transport and Lifting Instructions Brake Release Operation 1 Chock the wheels to prevent the machine from rolling. 2 Be sure the winch line is properly secured to the Observe and Obey: drive chassis tie points and the path is clear of all obstructions.
  • Page 43 Fifth Edition · First Printing Operator's Manual Transport and Lifting Instructions Securing to Truck or Trailer for Use chains or straps of ample load capacity. Transit Use a minimum of 2 chains or straps. Adjust the rigging to prevent damage to the chains. Retract and secure the extension deck.
  • Page 44 Operator's Manual Fifth Edition · First Printing Transport and Lifting Instructions Center of gravity X Axis Y Axis GS-2668 DC 34.4 in 25.8 in 87.4 cm 65.5 cm GS-3268 DC 33.3 in 27.3 in 84.6 cm 69.3 cm Observe and Obey: Only qualified riggers should rig and lift the machine.

  • Page 45: Maintenance

    Fifth Edition · First Printing Operator's Manual 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 Observe and Obey: checks allow the inspector to identify changes in oil level that might indicate the presence of hydraulic Only routine maintenance items specified in this system problems.
  • Page 46 Operator's Manual Fifth Edition · First Printing Maintenance Check the Batteries Scheduled Maintenance Maintenance performed quarterly, annually and every two years must be completed by a person trained and qualified to perform maintenance on this Proper battery condition is essential to good machine according to the procedures found in the machine performance and operational safety.

  • Page 47: Specifications

    Fifth Edition · First Printing Operator's Manual Specifications GS-2668 DC Drive speeds Height, working maximum 32 ft 9.8 m Stowed, maximum 3.0 mph 4.8 km/h Height, platform maximum 26 ft 7.9 m Platform raised, maximum 0.5 mph 0.8 km/h 40 ft/54.6 sec 12.2 m/54.6 sec Height, stowed maximum, Rails up 92 in...
  • Page 48 Operator's Manual Fifth Edition · First Printing Specifications GS-3268 DC Drive speeds Height, working maximum 38 ft 11.8 m Stowed, maximum 3.0 mph 4.8 km/h Height, platform maximum 32 ft 9.8 m Platform raised, maximum 0.5 mph 0.8 km/h 40 ft/54.6 sec 12.2 m/54.6 sec Height, stowed maximum, Rails up 101 in...

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Genie gs-3268dc

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