Terex Genie GS-2668 RT User manual

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Operator's Manual Fifth Edition · Second Printing
GS-2668RT•GS-3268RT PartNo.133534
Copyright © 1998 by Genie Industries
Fifth Edition: Second Printing, July 2010
"Genie" is a registered trademark of
Genie Industries in the U.S.A. and many other
countries. "GS" is a trademark of Genie
Industries.
Complies with EC Directive 2006/42/EC
See EC Declaration of Conformity
Printed on recycled paper
Printed in U.S.A.
Important
Read,understand andobey thesesafety rulesand
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
PersonalSafety ......................................................... 7
Work Area Safety....................................................... 8
Legend ...................................................................... 15
Controls .................................................................... 16
Inspections ............................................................... 21
OperatingInstructions............................................... 30
TransportandLifting Instructions .............................. 36
Maintenance ............................................................. 39
Specifications ........................................................... 42
Contact us:
Internet:http://www.genielift.com
e-mail:[email protected]
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Operator's Manual
Fifth Edition · Second Printing
PartNo.133534 GS-2668RT•GS-3268RT 1
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
machineoperationcontainedinthisoperator's
manual.
1 Avoidhazardoussituations.
Knowandunderstandthesafetyrulesbefore
going on to the next section.
2 Alwaysperformapre-operationinspection.
3 Always perform function tests prior to use.
4 Inspect the workplace.
5 Only use the machine as it was intended.
Youread, understandandobeythe
manufacturer'sinstructionsand safetyrules—
safetyandoperator'smanualsandmachine
decals.
Youread,understandandobeyemployer's
safety rules and worksite regulations.
Youread,understandandobeyallapplicable
governmentalregulations.
Youare properlytrained tosafely operate the
machine.
Introduction
Owners, Users and Operators:
Genieappreciates your choiceof our machinefor
yourapplication. Ournumber onepriority 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
governmentalrules.
2 Read, understand and follow the instructions
in this and other manuals supplied with this
machine.
3 Use good safe work practices ina common
sense way.
4 Onlyhavetrained/certifiedoperators,directed
byinformedandknowledgeablesupervision,
runningthemachine.
If there is anything in this manual that is not clear
orwhich youbelieve should be added, please
contact us.
Internet:www.genielift.com
E-mail:[email protected]
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Operator's Manual Fifth Edition · Second Printing
2 GS-2668RT•GS-3268RT PartNo.133534
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-basedcleanersbecausetheymaydamage
the safety sign material.
Hazard Classification
Genie uses symbols, color coding and signal words
to identify the following:
Safety alert symbol—used to alert
youto potentialpersonal injury
hazards. Obey all safety
messages that follow this symbol
to avoid possible injury or death.
Indicatesa hazardous situation
which, if not avoided, will result in
deathor seriousinjury.
Indicatesa hazardous situation
which, if not avoided, could result
in death or serious injury.
Indicatesa hazardous situation
which, if not avoided, could result
inminorormoderate injury.
Indicatesa hazardous situation
which, if not avoided, could result
inpropertydamage.
Red
Orange
Yellow
Blue
Introduction
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Operator's Manual
Fifth Edition · Second Printing
PartNo.133534 GS-2668RT• GS-3268 RT 3
Symbol and Hazard Pictorials Definitions
Readthe
operator’smanual Readthe service
manual
Tip-overhazard
Crushhazard Crushhazard Collisionhazard
Tip-overhazard Tip-overhazard Tip-overhazard Electrocution
hazard
Electrocution
hazard Explosionhazard Firehazard Burnhazard Skin injection
hazard
Keepawayfrom
movingparts
Engagesafety
arm
Keep clear of
outriggersand
tires Move machine to
levelground
Lowertheplatform Maintainrequired
clearance
Do not set up
whereit cannotbe
leveledwith
outriggers
Close chassis
tray
Onlytrained
maintenance
personnelshould
access
compartments
Use a piece of
cardboardor
papertosearch
for leaks
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Operator's Manual Fifth Edition · Second Printing
4 GS-2668RT•GS-3268RT PartNo.133534
Wheelload
Voltageratingfor
powertoplatform Pressureratingfor
air line to platform
Nosmoking
Lanyard
attachmentpointTiedown
Chockthewheels Releasebrakes
Transport
diagram Windspeed
Sideforce
Maximum capacity
Outriggerload
Crushinghazard
Holdrailwhilelowering
Symbol and Hazard Pictorials Definitions
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Operator's Manual
Fifth Edition · Second Printing
PartNo.133534 GS-2668RT• GS-3268 RT 5
General Safety
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Operator's Manual Fifth Edition · Second Printing
6 GS-2668RT•GS-3268RT PartNo.133534
General Safety
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Operator's Manual
Fifth Edition · Second Printing
PartNo.133534 GS-2668RT• GS-3268 RT 7
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
governmentalregulations,andmustbeinspected
andused inaccordancewith themanufacturer’s
instructions.Safety
Personal Safety
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Operator's Manual Fifth Edition · Second Printing
8 GS-2668RT•GS-3268RT PartNo.133534
Electrocution Hazards
This machine is not electrically insulated and will
not provide protection from contact with or
proximity to electrical current.
Maintain safe distances from electrical power lines
andapparatusinaccordancewithapplicable
governmentalregulationsandthefollowingchart.
LineVoltage Required Clearance
0 to 50KV 3.05 m
50KV to 200KV 4.60 m
200KV to 350KV 6.10 m
350KV to 500KV 7.62 m
500KV to 750KV 10.67 m
750KV to 1000KV 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
energizedpowerlines.Personnelonthegroundor
in the platform must not touch or operate the
machine until energized power lines are shut off.
Donotoperatethemachineduringlightningor
storms.
Do not use the machine as a ground for welding.
Tip-over Hazards
Occupants,equipment and materialsshall not
exceed the maximum platform capacity.
Machinewithoutcapacityindicator:
Maximum capacity
GS-2668 RT 567 kg
GS-3268 RT 454 kg
Machinewithcapacityindicator:
The maximum capacity varies with the height of the
platform.
Maximum capacity - GS-2668 RT
Maximum occupants 4
Height of Platform Maximum Capacity
7.9 m 567 kg
6.8 m 835 kg
4.8 m 975 kg
2.7 m 835 kg
1.7 m 567 kg
Maximum capacity - GS-3268 RT
Maximum occupants
Indoor use 4
Outdoor use 2
Height of Platform Maximum Capacity
9.8 m 454 kg
7.6 m 850 kg
5.8 m 919 kg
2.7 m 690 kg
1.8 m 454 kg
Work Area Safety
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Operator's Manual
Fifth Edition · Second Printing
PartNo.133534 GS-2668RT• GS-3268 RT 9
Do not use the platform controls to free a platform
thatis caught, snaggedorotherwise prevented
from normal motion by an adjacent structure. All
personnelmust beremoved fromtheplatform
before attempting to free the platform using the
groundcontrols.
Do not push off or pull toward any object outside of
theplatform.
Maximum manual force
GS-2668 RT
Indoor use - 4 person 400 N
Outdoor use - 4 person 400 N
GS-3268 RT
Indoor use only - 4 person 400 N
Outdoor use - 2 person 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. 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.
Do not drive over 0.8 km/h with the platform raised.
Use extreme care and slow speeds while driving
the machine in the stowed position across uneven
terrain,debris, unstableor slippery surfacesand
nearholesanddrop-offs.
Work Area Safety
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Operator's Manual Fifth Edition · Second Printing
10 GS-2668RT• GS-3268 RT PartNo.133534
Do not tie the platform to adjacent structures.
Do not place loads outside the platform perimeter.
Do not alter or disable machine components that in
any way affect safety and stability.
Do not modify or alter an aerial work platform
withoutpriorwrittenpermission fromthe
manufacturer.Mountingattachmentsforholding
toolsor other materialsonto 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 replace items critical to machine stability
with items of different weight or specification.
Do not raise the platform when wind speeds may
exceed 12.5 m/s. If wind speeds exceed 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.
Donot drivethe machine on or nearuneven terrain,
unstablesurfacesorotherhazardousconditions
with the platform raised.
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)intheplatform.
Do not use the machine on a moving or mobile
surface or vehicle.
Be sure all tires are in good condition, castle nuts
areproperlytightenedandcotterpinsareproperly
installed.
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.
Work Area Safety
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Operator's Manual
Fifth Edition · Second Printing
PartNo.133534 GS-2668RT• GS-3268 RT 11
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.
Maximum slope rating, stowed position
GS-2668RT 40% (22°)
GS-3268RT 35% (19°)
Maximum side slope rating, stowed position
GS-2668RT 40% (22°)
GS-3268RT 35% (19°)
Note: Slope rating is subject to ground conditions
andadequatetraction.
Fall Hazards
The guard rail system provides fall protection. If
occupant(s)oftheplatformare requiredto wear
personalfallprotection equipment(PFPE)due to
job site or employer rules, PFPE equipment and its
use shall be in accordance with the PFPE
manufacturer’sinstructionsandapplicable
governmentalrequirements.
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.
Closetheentrygatebeforeoperating.
Do not operate the machine unless the guard rails
are properly installed and the entry is secured for
operation.
Work Area Safety
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Operator's Manual Fifth Edition · Second Printing
12 GS-2668RT• GS-3268 RT PartNo.133534
Nostunt drivingorhorseplay whileoperatinga
machine.
Do not lower the platform unless the area below is
clearofpersonnel andobstructions.
Limit travel speed according to the condition of the
ground surface, congestion, slope, location of
personnel and any other factors which may cause
collision.
Bodily Injury Hazards
Alwaysoperate themachine ina well-ventilated
areatoavoidcarbonmonoxidepoisoning.
Do not operate the machine with a hydraulic oil or
air leak. An air leak or hydraulic leak can penetrate
and/orburnskin.
Impropercontact with componentsunderany cover
will cause serious injury. Only trained maintenance
personnel should access compartments. Access
by the operator is only advised when performing a
pre-operationinspection.Allcompartmentsmust
remainclosedandsecuredduringoperation.
Component Damage Hazards
Do not use any battery or charger greater than 12V
tojump-start theengine.
Do not use the machine as a ground for welding.
Collision Hazards
Be aware of limited sight
distance and blind spots
whendrivingoroperating.
Beaware oftheextended platformposition when
movingthe machine.
The machine must be on a level surface or secured
beforereleasingthebrakes.
Operators must comply with employer, job site and
governmentalrulesregardinguseofpersonal
protectiveequipment.
Checkthe workareafor overheadobstructions or
otherpossiblehazards.
Beawareofcrushinghazardswhengrasping the
platformguardrail.
Observeandusecolor-codeddirectionarrowson
the platform controls and platform decal plate for
drive and steer functions.
Do not operate a machine in the path of any crane
ormoving overheadmachinery unlessthe controls
of the crane have been locked out and/or
precautionshave been takento preventany
potentialcollision.
Work Area Safety
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Operator's Manual
Fifth Edition · Second Printing
PartNo.133534 GS-2668RT• GS-3268 RT 13
Explosion and Fire Hazards
Do not start the engine if you smell or detect liquid
petroleumgas (LPG),gasoline, diesel fuelor other
explosive substances.
Donot refuelthe machine withthe enginerunning.
Refuel the machine and charge the battery only in
anopen,well-ventilated areaawayfrom sparks,
flames and lighted tobacco.
Donot operatethe machinein hazardouslocations
orlocationswherepotentiallyflammable or
explosive gases or particles may be present.
Donot spray etherinto engines equippedwith glow
plugs.
Damaged Machine Hazards
Donot usea damagedormalfunctioning machine.
Conductathoroughpre-operationinspectionofthe
machine and test all functions before each work
shift. Immediately tag and remove from service a
damagedormalfunctioningmachine.
Besure allmaintenance hasbeen performedas
specifiedin thismanualand theappropriateGenie
servicemanual.
Be sure all decals are in place and legible.
Be sure the operator’s, safety and responsibilities
manualsare complete, legible and inthe storage
containerlocated onthe platform.
Work Area Safety
Crushing Hazards
Keep hands and limbs out of scissors.
Usecommonsenseandplanningwhenoperating
the machine with the controller from the ground.
Maintainsafe distancesbetweenthe operator,the
machine and fixed objects.
Maintain a firm grasp on the platform rail when
pulling the rail pins. Do not allow the platform guard
rails to fall.
Outrigger Safety
Tip-over Hazards
Do not lower the outriggers unless the machine is
on a firm surface. Avoid drop-offs, holes, unstable
orslippery surfaces andother possiblehazardous
conditions.
When the auto level function is not being used and
theoutriggersarebeingloweredindividually,the
steer-endoutriggersmustbeloweredfirst.
Do not raise the platform unless the machine is
level. Do not set the machine up on a surface
where it cannot be leveled using only the
outriggers.
Do not raise the platform unless all four outriggers
areproperlylowered, thefootpadsare in firm
contact with the ground and the machine is level.
Do not adjust the outriggers while the platform is
raised.
Donotdrivewhiletheoutriggersarelowered.
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Operator's Manual Fifth Edition · Second Printing
14 GS-2668RT• GS-3268 RT PartNo.133534
Work Area Safety
Battery Safety
Burn Hazards
Batteries contain acid. Always
wearprotectiveclothingand
eyewearwhenworkingwith
batteries.
Avoid spilling or contacting
batteryacid.Neutralize
battery acid spills with baking
sodaandwater.
Do not expose the batteries or
thechargerto waterorrain
duringcharging.
Explosion Hazards
Keep sparks, flames and
lightedtobacco awayfrom
batteries. Batteries emit an
explosive gas.
The battery tray should
remainopenduringtheentire
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
chargethebatteries.
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Operator's Manual
Fifth Edition · Second Printing
PartNo.133534 GS-2668RT• GS-3268 RT 15
1 Platform entry gate
2 Platformguardrails
3 Lanyardanchoragepoint
4 Platform extension lock
handle
5 Manualstoragecontainer
6 Platformcontrols
7 Platformextension
8 Outriggerhousing(ifequipped
withoutriggers)
9 Outriggerfootpad(ifequipped
withoutriggers)
10 LPG tank
11 Steertire
12 Engineside cover
13 Fuel tank
14 Non-steertire
15 Tiltalarm(undercover)
16 Entryladder/transport
tie-down
17 Brakereleasepump knoband
brakereleaseknob(hidden
from view in this picture)
18 Groundcontrolssidecover
19 GroundcontrolswithLCD
readoutscreen
20 Hydraulic oil level indicator
(undercover)
21 LPGtank(optional)
22 Safety arm
23 Capacity indicator (if
equipped)
24 GFCIoutlet
Legend
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Operator's Manual Fifth Edition · Second Printing
16 GS-2668RT• GS-3268 RT PartNo.133534
GroundControl Panel
1 Hourmeter
2 Enginestart button
3 Gasoline/LPG models: LPG select button with
indicatorlight
4 Engine idle select button with indicator light
5 20 amp circuit breaker for controls circuit
6 LCDreadoutscreen
7 Gasoline/LPGmodels:Chokebutton
Dieselmodels: Glow plugbutton
8 Platformup button
9 Liftfunction enable button
10 Emergencyloweringfunctionenablebutton
11 Emergencyloweringdownbutton
12 Platformdownbutton
13 Key switch for platform/off/ground control
selection
14 RedEmergencyStopbutton
00009.9
STOP
14
2
1
3
4
9
10
11
12
13
78
5
6
Controls
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Operator's Manual
Fifth Edition · Second Printing
PartNo.133534 GS-2668RT• GS-3268 RT 17
GroundControl Panel
1 Hourmeter
Indicates the number of hours the machine has
been put into use.
2 Enginestart button
Press this button to start the engine.
3 Gasoline/LPG models: LPG select button with
indicatorlight
Press this button to select fuel. Light on
indicates that LPG is selected. Light off
indicates gasoline is selected.
4 Engine idle select button with indicator light
Press this button to select the engine idle
setting. Light on indicates high idle is selected.
Light off indicates low idle is selected.
5 20 amp circuit breaker for controls circuit
6 LCDreadoutscreen
7 Gasoline/LPGmodels:Chokebutton
Press this button to activate the choke.
Dieselmodels: Glow plugbutton
Press this button to activate the glow plugs.
8 Platformup button
Press this button and the platform will raise.
9 Liftfunction enable button
Press this button to activate the lift function.
10 Emergencyloweringfunctionenablebutton
Press this button to activate the emergency
loweringfunction.
11 Emergencyloweringdownbutton
Press this button to activate the emergency
loweringdownfunction.
12 Platformdownbutton
Press this button and the platform will lower.
13 Key switch for platform/off/ground 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 keyswitch to the ground
positionandthe ground controlswilloperate.
14 RedEmergencyStopbutton
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
operatethemachine.
Controls
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Operator's Manual Fifth Edition · Second Printing
18 GS-2668RT• GS-3268 RT PartNo.133534
1 Outriggerfunctionenable
buttonwith indicator light
2 Outriggerautolevelbutton
3 Enginestart button
4 Engine idle select button with
indicatorlight
5 Gasoline/LPGmodels:
Chokebutton
Dieselmodels:Glowplug
button
6 Gasoline/LPGmodels:LPG
operationbuttonwith
indicatorlight
14 Thumb rocker switch for steer
function
15 Wrist rest
16 Lift function enable button
withindicator light
17 Proportionalrockerswitchfor
outriggerup/downand
platformup/down
PlatformControls
7 Hornbutton
8 Generatorselectbuttonwith
indicatorlight
9 Machineon incline button
withindicator light: Low
speedoperationforinclines
10 Greenpowerlight/
Rederrorindicatorlight
11 RedEmergencyStopbutton
12 Functionenableswitch
13 Proportionalcontrolhandlefor
drivefunction
Controls
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