Terex Genie GS-2669DC User manual

Operator's Manual
Serial Number Range
GS™-2669DC
from GS69F-18000
CE
GS™-3369DC
GS™-4069DC
with
Maintenance
Information
Original Instructions
Third Edition
First Printing
Part No. 1305655GT
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Operator's Manual Third Edition • First Printing
GS™-2669DC • GS™-3369DC • GS™-4069DC Part No. 1305655GT
Front Matter
Manufacturer:
Terex South Dakota, Inc.
500 Oakwood Road
Watertown, SD 57201, USA
Authorized representative:
Genie Industries B. V.
Boekerman 5
4751 XK OUD GASTEL
The Netherlands
Contents
Introduction........................................................... 1
Symbol and Hazard Pictorials Definitions............. 5
General Safety...................................................... 8
Personal Safety................................................... 11
Work Area Safety................................................ 12
Legend................................................................ 19
Controls............................................................... 20
Inspections.......................................................... 24
Operating Instructions......................................... 36
Transport and Lifting Instructions ....................... 45
Maintenance ....................................................... 48
Specifications...................................................... 50
Copyright © 2011 by Trex Corporation
Third Edition: First Printing, August 2020
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.
Complies with EC Directive 2006/42/EC
See EC Declaration of Conformity
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Third Edition • First Printing Operator's Manual
Introduction
Part No. 1305655GT GS™-2669DC • GS™-3369DC • GS™-4069DC 1
Introduction
About this manual
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.
This book is an operation and daily maintenance
manual for the user or operator of a Genie
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 Genie.
Product Identification
The machine serial number is located on the serial
label.
Serial number stamped
on chassis
Serial label
(located under cover)
Intended Use and Familiarization
Guide
The intended use of this machine is to lift
personnel, including tools, and materials to an
aerial work site. Before operating the machine, it’s
the operator’s responsibility to read and
understand this familiarization guide.
Each person must be trained to operate a
Mobile Elevating Work Platform (MEWP).
Familiarization with the MEWP must be given
to each person who is authorized, competent
and trained.
Only trained and authorized personnel should
be permitted to operate the machine.
The operator is responsible to read,
understand, and obey the manufacturer’s
instructions and safety rules provided in the
Operator’s Manual.
The Operator’s Manual is located in the
manual storage container, at the platform.
For specific product applications, see
Contacting The Manufacturer.
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Operator's Manual Third Edition • First Printing
Introduction
2 GS™-2669DC • GS™-3369DC • GS™-4069DC Part No. 1305655GT
Platform contols symbology and releated
machine movement:
Lift function enable button
Drive function enable button
Outrigger function button
Platform up/down (when lift function
selected)
Drive forward/reverse (when drive function
selected)
Steer right/left (when drive function
selected)
Ground controls symbology and related
machine movement:
Lift function enable button
Platform up/down button
Sequential functions and movement:
Drive and steer.
Interlocked functions:
Elevated drive speed.
Elevated drive in an off-level condition.
All platform and ground controls.
Limitations of use:
The intended use of this machine is to lift
personnel, including tools, and materials to an
aerial work site.
Do not elevate the platform unless the machine
is on firm level ground.
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Third Edition • First Printing Operator's Manual
Introduction
Part No. 1305655GT GS™-2669DC • GS™-3369DC • GS™-4069DC 3
Bulletin Distribution and Compliance
Safety of product users is of paramount
importance to Genie. Various bulletins are used by
Genie to communicate important safety and
product information to dealers and machine
owners.
The information contained in the bulletins is tied to
specific machines using the machine model and
serial number.
Distribution of bulletins is based on the most
current owner on record along with their
associated dealer, so it is important to register
your machine and keep your contact information
up to date.
To ensure safety of personnel and the reliable
continued operation of your machine, be sure to
comply with the action indicated in a respective
bulletin.
To view any open bulletins for your machine, visit
us on the web at www.genielift.com.
Contacting the Manufacturer
At times it may be necessary to contact Genie.
When you do, be ready to supply the model
number and serial number of your machine, along
with your name and contact information. At
minimum, Genie should be contacted for:
Accident reporting
Questions regarding product applications and
safety
Standards and regulatory compliance information
Current owner updates, such as changes in
machine ownership or changes in your contact
information. See Transfer of Ownership, below.
Transfer of Machine Ownership
Taking a few minutes to update owner information
will ensure that you receive important safety,
maintenance and operating information that
applies to your machine.
Please register your machine by visiting us on the
web at www.genielift.com or by calling us toll free
at 1-800-536-1800.
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Operator's Manual Third Edition • First Printing
Introduction
4 GS™-2669DC • GS™-3369DC • GS™-4069DC Part No. 1305655GT
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.
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.
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.
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Third Edition • First PrintingOperator's Manual
Symbol and Hazard Pictorials Definitions
Part No. 1305655GT GS™-2669DC • GS™-3369DC • GS™-4069DC 5
Symboland Hazard Pictorials Definitions
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
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Operator's Manual Third Edition • First Printing
Symbol and Hazard Pictorials Definitions
6 GS™-2669DC • GS™-3369DC • GS™-4069DC Part No. 1305655GT
Lower the platform.
Do not set up where it
cannot be leveled with
outriggers
Maintain required
clearance
Access by trained
and authorized
personnel only
Use a piece of
cardboard or paper
to search for leaks
Chock the wheels
Release brakes
Tiedown
Lanyard anchorage
points
No smoking
Wheel load
Crush hazard
Side force
Wind speed
Outrigger load
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Third Edition • First Printing Operator's Manual
Symbol and Hazard Pictorials Definitions
Part No. 1305655GT GS™-2669DC • GS™-3369DC • GS™-4069DC 7
Voltage rating for
power to platform
Pressure rating for air
line to platform
Maximum capacity
Fall hazard
100% Restraint
Burn hazard stay
away
Fire hazard
Fire hazard
Collision hazard
Lanyard anchorage
points
Platform overloaded
Hold rail while lowering
Crushing hazard
Transport diagram
Battery as counterweight
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Operator's Manual Third Edition • First Printing
General Safety
8 GS™-2669DC • GS™-3369DC • GS™-4069DC Part No. 1305655GT
GeneralSafety
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Third Edition • First Printing Operator's Manual
General Safety
Part No. 1305655GT GS™-2669DC • GS™-3369DC • GS™-4069DC 9
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Operator's Manual Third Edition • First Printing
General Safety
10 GS™-2669DC • GS™-3369DC • GS™-4069DC Part No. 1305655GT
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Third Edition • First Printing Operator's Manual
Personal Safety
Part No. 1305655GT GS™-2669DC • GS™-3369DC • GS™-4069DC 11
PersonalSafety
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.
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Operator's Manual Third Edition • First Printing
Work Area Safety
12 GS™-2669DC • GS™-3369DC • GS™-4069DC Part No. 1305655GT
Work AreaSafety 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-2669DC
1500 lbs/
680 kg
1200 lbs/
544 kg
300 lbs/
136 kg
4
GS-3369DC
1000 lbs/
454 kg
700 lbs/
318 kg
300 lbs/
136 kg
Indoor –4
Outdoor –2
GS-4069DC
800 lbs/
363 kg
500 lbs/
227 kg
300 lbs/
136 kg
Indoor –3
Outdoor –2
Platform retracted
Platform extended
Extension only
Platform only
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Third Edition • First Printing Operator's Manual
Work Area Safety
Part No. 1305655GT GS™-2669DC • GS™-3369DC • GS™-4069DC 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 alter or disable the limit switches or angle
sensor.
Do not drive over 0.3 mph / 0.48 km/h with the
platform raised.
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.
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.
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 drive the machine on or near uneven
terrain, unstable surfaces or other hazardous
conditions with the platform raised.
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Operator's Manual Third Edition • First Printing
Work Area Safety
14 GS™-2669DC • GS™-3369DC • GS™-4069DC Part No. 1305655GT
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 push off or pull
toward any object outside
of the platform.
Maximum allowable side force –ANSI & CSA
GS-2669DC –4 person
GS-3369DC –4 person, indoor
GS-3369DC –2 person, outdoor
GS-4069DC –3 person, indoor
GS-4069DC –2 person, outdoor
90 lbs / 400 N
90 lbs / 400 N
90 lbs / 400 N
90 lbs / 400 N
90 lbs / 400 N
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 a mobile elevating 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.
Do not use batteries that weigh less than the
original equipment. Batteries are used as
counterweight and are critical to machine stability.
For GS-4069 machines, each battery must weigh
88 lbs / 39.9 kg. For each GS-2669 and GS-
3369 machine with high capacity battery option,
each battery must weigh 88 lbs / 39.9 kg. For GS-
2669 and GS-3369 machines with the standard
battery option, each battery must weigh 62 lbs /
28.1 kg.
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Third Edition • First Printing Operator's Manual
Work Area Safety
Part No. 1305655GT GS™-2669DC • GS™-3369DC • GS™-4069DC 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 maximum uphill, downhill or side slope rating
of the machine. Slope rating applies only to
machines in the stowed position.
Maximum slope rating, stowed position
Extension deck uphill
35% (19°)
Extension deck downhill
15% (9°)
Side slope
35% (19°)
Note: Slope rating is subject to ground conditions
with one person in the platform and adequate
traction. Additional platform weight may reduce
slope rating. See Driving on a Slope in the
Operating Instructions section.
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 unless the
machine is in the stowed position.
Attach the platform entry chain or 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.
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Operator's Manual Third Edition • First Printing
Work Area Safety
16 GS™-2669DC • GS™-3369DC • GS™-4069DC Part No. 1305655GT
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.
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Third Edition • First Printing Operator's Manual
Work Area Safety
Part No. 1305655GT GS™-2669DC • GS™-3369DC • GS™-4069DC 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 48V
to charge the batteries.
Do not use the machine as a ground for welding.
Lockout After Each Use
1Select a safe parking location—firm level
surface, clear of obstruction and traffic.
2Lower the platform.
3Turn the key switch to the off position and
remove the key to secure from unauthorized
use.
4Charge the batteries.
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Operator's Manual Third Edition • First Printing
Work Area Safety
18 GS™-2669DC • GS™-3369DC • GS™-4069DC Part No. 1305655GT
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 48V
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.
For GS-4069 machines, each battery must weigh
88 lbs / 39.9 kg. For each GS-2669 and GS-
3369 machine with high capacity battery option,
each battery must weigh 88 lbs / 39.9 kg. For GS-
2669 and GS-3369 machines with the standard
battery option, each battery must weigh 62 lbs /
28.1 kg.
Lifting Hazard
Use the appropriate number of people and proper
lifting techniques when lifting batteries.
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