Genie GS-2646 AV User manual

Operator's Manual
GS™
-
2
646 AV ANSI/CSA
North America
South America
Asia
GS™
-
2
646 AV35
with
Maintenance
Information
Second Edition
Second Printing
Part No. 1274894GT

Operator's Manual Second Edition • Second Printing
GS-2646 AV • GS-2646 AV35 Part No. 1274894GT
Front Matter
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, contact us.
Contact Us:
Internet: www.genielift.com
E-mail: [email protected]
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: Second Printing, November 2017
Genie is a registered trademark of Terex South Dakota, Inc. in
the U.S.A. and many other countries. “GS” is a trademark of
Terex South Dakota, Inc.
These machines comply with
ANSI/SIA A92.6
CAN B.354.2

Second Edition • Second Printing Operator's Manual
Introduction
Part No. 1274894GT GS-2646 AV • GS-2646 AV35 1
Introducti on
Owners, Users and Operators:
Thank you for choosing 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:
1 Comply with employer, job site and
governmental rules.
2 Read, understand and follow the instructions
in this and other manuals supplied with this
machine.
3 Use good safe work practices in a
commonsense way.
4 Only have trained/certified operators,
directed by informed and knowledgeable
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-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.

Operator's Manual Second Edition • Second Printing
Introduction
2 GS-2646 AV • GS-2646 AV35 Part No. 1274894GT
Hazard Classification
Decals on this machine use 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 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
Replace any missing or damaged safety signs.
Keep operator safety in mind at all times. Use mild
soap and water to clean safety signs. Do not use
solvent-based cleaners because they may damage
the safety sign material.
DANGER
WARNING
CAUTION
NOTICE

Second Edition • Second Printing Operator's Manual
Symbol and Hazard Pictorials Definitions
Part No. 1274894GT GS-2646 AV • GS-2646 AV35 3
Symbol and Hazard P ictorials Definiti ons
Read the operator’s
manual
Read the service
manual
Crush hazard Crush hazard Collision hazard
Tip-over hazard Tip-over 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
maintenance
personnel should
access
compartments
Use a piece of
cardboard or paper to
search for leaks

Operator's Manual Second Edition • Second Printing
Symbol and Hazard Pictorials Definitions
4 GS-2646 AV • GS-2646 AV35 Part No. 1274894GT
Batteries 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

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.

Operator's Manual Second Edition • Second Printing
General Safety
6 GS-2646 AV • GS-2646 AV35 Part No. 1274894GT

Second Edition • Second Printing Operator's Manual
General Safety
Part No. 1274894GT GS-2646 AV • GS-2646 AV35 7

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.

Second Edition • Second Printing Operator's Manual
General Safety
Part No. 1274894GT GS-2646 AV • GS-2646 AV35 9

Operator's Manual Second Edition • Second Printing
General Safety
10 GS-2646 AV • GS-2646 AV35 Part No. 1274894GT

Second Edition • Second Printing Operator's Manual
Personal Safety
Part No. 1274894GT GS-2646 AV • GS-2646 AV35 11
Personal Safety
Personal Fall Protection
Personal fall protection equipment (PFPE) is not
required when operating this machine provided the
operator remains inside the perimeter of the
platform guardrail system. 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.
Requirements for Exiting an Elevated Work
Platform
Operators must use personal fall protection
equipment when exiting and entering an
elevated platform through the front gate. When
exiting or entering an elevated platform, the
platform must be positioned as close as possible
to the surface of the exit or entry point, but not
more than 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 Elevated Platform Through the
Front Gate
1Attach primary lanyard to a platform anchor
point.
2Attach secondary lanyard to an approved
adjacent anchor point.
3Detach the primary lanyard from the platform
anchor point.
The primary lanyard can not remain attached to
the platform anchor point after attaching the
secondary lanyard to the adjacent anchor point.
Do not operate the machine while the secondary
lanyard is attached to the adjacent anchor point.
Entering an Elevated Platform Through the
Front Gate
1Attach primary lanyard to a platform anchor
point.
2Detach secondary lanyard from the adjacent
anchor point.
3Detach the primary lanyard from the platform
anchor point.

Operator's Manual Second Edition • Second Printing
Work Area Safety
12 GS-2646 AV • GS-2646 AV35 Part No. 1274894GT
WorkArea Safety
Electrocution Hazards
This machine is not electrically insulated and will
not provide protection from contact with or
proximity to electrical current.
Obey all local and
governmental regulations
regarding required
clearance from electrical
power lines. At a
minimum, the required
clearance contained in the
chart below must be
followed.
Line Voltage Required Clearance
0 to 50KV 10 ft 3.05 m
50 to 200KV 15 ft 4.60 m
200 to 350KV 20 ft 6.10 m
350 to 500KV 25 ft 7.62 m
500 to 750KV 35 ft 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 ground for welding.
Tip-over Hazards
Occupants, equipment and materials shall not
exceed the maximum platform capacity or the
maximum platform capacity of the platform
extension.
Maximum capacity
Platform extended
Model Platform
retracted
Platform
only
Extension
only
Maximum
occupants
GS-264 AV
GS-264 AV35
900 lbs
408 kg
600 lbs
272 kg
300 lbs
136 kg
3
Platform retracted Platform extended
Extension only Platform only

Second Edition • Second Printing Operator's Manual
Work Area Safety
Part No. 1274894GT GS-2646 AV • GS-2646 AV35 13
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 only when the
machine is on a severe 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.
Do not drive over 0.5 mph / 0.8 km/h with the
platform raised.
GS-2646 AV
Do not raise the platform when wind speeds may
exceed 28 mph / 12.5 m/s. If 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. 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
the machine. Refer to instructional decal and serial
label for specific wind speed rating.
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 and near
holes and drop-offs.

Operator's Manual Second Edition • Second Printing
Work Area Safety
14 GS-2646 AV • GS-2646 AV35 Part No. 1274894GT
Do not drive the machine on or near uneven terrain,
unstable surfaces or other hazardous conditions
with the platform raised.
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.
Do not operate the machine with the chassis trays
open.
Do not push off or pull
toward any object outside
of the platform.
Model Maximum allowable
side force
Maximum
occupants
GS-2646 AV
GS-2646 AV35
150 lbs / 667 N 3
Do not alter or disable the limit switches or
proximity switches.
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 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 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 transport tools and materials unless they
are evenly distributed and can be safely handled
by person(s) in the platform.
Do not use the machine on a moving or mobile
surface or vehicle.
Be sure all tires are in good condition, castle nuts
are properly tightened and cotter pins are properly
installed.

Second Edition • Second Printing Operator's Manual
Work Area Safety
Part No. 1274894GT GS-2646 AV • GS-2646 AV35 15
Crushing Hazard
Keep hands and limbs out of scissors.
Keep hands clear when folding rails.
Do not work under the platform or in the scissor
links without the safety arm in place.
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.
Operation on Slopes Hazards
Do not drive the machine on a slope that exceeds
the slope and side slope rating of the machine.
Slope rating applies to machines in the stowed
position.
Model Maximum slope
rating, stowed
position
Maximum side
slope rating,
stowed position
GS-2646 AV 25% (14°) 25% (14°)
GS-2646 AV35 20% (11°) 20% (11°)
Note: 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 attachment
point provided.
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.
Do not enter or exit the platform through the rear
gate, unless the machine is in the stowed position.
Follow the procedure on page 8 to exit or enter an
elevated platform through the front gate.
Close the entry gates before operating.
Do not operate the machine unless the guard rails
are properly installed and the entries are secured
for operation.

Operator's Manual Second Edition • Second Printing
Work Area Safety
16 GS-2646 AV • GS-2646 AV35 Part No. 1274894GT
Collision Hazards
Be aware of limited sight
distance and blind spots
when driving or operating.
Be aware of 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, 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 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 personnel, and
any other factors which
may cause collision.
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.

Second Edition • Second Printing Operator's Manual
Work Area Safety
Part No. 1274894GT GS-2646 AV • GS-2646 AV35 17
Bodily Injury Hazard
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.
Explosion and Fire Hazards
Do not operate the machine or charge the 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 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 machine.
Component Damage Hazards
Do not use any battery charger greater than 24V to
charge the batteries.
Do not use the machine as a ground for welding.

Operator's Manual Second Edition • Second Printing
Work Area Safety
18 GS-2646 AV • GS-2646 AV35 Part No. 1274894GT
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.
Do not expose the batteries or the charger to water
or rain during charging.
Explosion Hazards
Keep sparks, flames, and
lighted tobacco away from
batteries. Batteries emit
explosive gas.
The battery tray should
remain open during the
entire charging cycle.
Do not contact the battery
terminals or the cable
clamps with tools that may
cause sparks.
Component Damage Hazard
Do not use any battery charger greater than 24V to
charge the batteries.
Electrocution/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
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.
Lifting Hazard
Use the appropriate number of people and proper
lifting techniques when lifting batteries.
Lockout After Each Use
1Select a safe parking location—firm level
surface, clear of obstruction and traffic.
2Lower the platform.
3Turn the selector switch to the off position. If
equipped, remove the key.
4Disconnect the battery pack and lock the
battery tray to secure from unauthorized use.
5Charge the batteries.