Terex Genie GS-2668DC User manual

Operator's Manual Fifth Edition • First Printing
GS-2668DC•GS-3268DC PartNo.133556
Copyright © 1999 by Genie Industries
Fifth Edition: First Printing, January 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.
These machines comply with
ANSI/SIA 92.5
CAN B.354.4
Printed on recycled paper
Printed in U.S.A.
Important
Read,understandand 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, please call Genie
Industries.
Contents
Page
Introduction ................................................................ 1
Symbols and Hazard Pictorials Definitions................. 3
GeneralSafety........................................................... 5
PersonalSafety ......................................................... 9
Work Area Safety...................................................... 10
Legend ...................................................................... 17
Controls .................................................................... 18
Inspections ............................................................... 22
OperatingInstructions............................................... 34
TransportandLifting Instructions .............................. 40
Maintenance ............................................................. 43
Specifications ........................................................... 45
Contact us:
Internet:http://www.genielift.com
e-mail:[email protected]

Operator's Manual
Fifth Edition · First Printing
PartNo.133556 GS-2668DC•GS-3268DC 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'sinstructionsandsafety rules—
safetyandoperator'smanualsandmachine
decals.
Youread,understandandobeyemployer's
safety rules and worksite regulations.
Youread,understandandobeyallapplicable
governmentalregulations.
Youare properly trained to safely operatethe
machine.
Introduction
Owners, Users and Operators:
Genieappreciates your choice of our machine for
yourapplication. Our number one priority isuser
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 inacommon
sense way.
4 Onlyhavetrained/certifiedoperators,directed
byinformedandknowledgeablesupervision,
runningthemachine.
If there is anything in this manual that is not clear
orwhich you believe should beadded,please
contact us.
Internet:www.genielift.com
E-mail:[email protected]

Operator's Manual Fifth Edition · First Printing
2 GS-2668DC•GS-3268DC PartNo.133556
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 potential personal 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
deathorserious injury.
Indicatesa hazardous situation
which, if not avoided, could result
in death or serious injury.
Indicatesa hazardous situation
which, if not avoided, could result
inminor or moderateinjury.
Indicatesa hazardous situation
which, if not avoided, could result
inpropertydamage.
Red
Orange
Yellow
Blue
Introduction

Operator's Manual
Fifth Edition · First Printing
PartNo.133556 GS-2668DC•GS-3268DC 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
whereitcannotbe
leveledwith
outriggers
Close chassis
tray
Onlytrained
maintenance
personnelshould
access
compartments
Use a piece of
cardboardor
papertosearch
for leaks

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4 GS-2668DC•GS-3268DC PartNo.133556
Wheelload
Voltageratingfor
powertoplatform Pressureratingfor
air line to platform
Nosmoking
Lanyard
attachmentpointTiedown
Chockthewheels Releasebrakes
Transport
diagram Sideforce
Maximum capacity
Crushinghazard Holdrailwhile
lowering
Symbol and Hazard Pictorials Definitions

Operator's Manual
Fifth Edition · First Printing
PartNo.133556 GS-2668DC•GS-3268DC 5
General Safety

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6 GS-2668DC•GS-3268DC PartNo.133556
General Safety

Operator's Manual
Fifth Edition · First Printing
PartNo.133556 GS-2668DC•GS-3268DC 7
General Safety

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8 GS-2668DC•GS-3268DC PartNo.133556
General Safety

Operator's Manual
Fifth Edition · First Printing
PartNo.133556 GS-2668DC•GS-3268DC 9
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
andusedinaccordancewiththemanufacturer’s
instructions.Safety
Personal Safety

Operator's Manual Fifth Edition · First Printing
10 GS-2668DC•GS-3268DC PartNo.133556
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 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
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.
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 the maximum platform capacity or the
maximum capacity of the platform extension.
Maximum capacity - GS-2668 DC
Platform retracted 1250 lbs 567 kg
Platform extended - Platform only 950 lbs 431 kg
Platform extended - Extension only 300 lbs 136 kg
Maximum occupants - ANSI and CSA 4
Maximum occupants - Australia
Outdoor use 4
Indoor use only 4
Maximum capacity - GS-3268 DC
Platform retracted 1000 lbs 454 kg
Platform extended - Platform only 700 lbs 318 kg
Platform extended - Extension only 300 lbs 136 kg
Maximum occupants - ANSI and CSA 4
Maximum occupants - Australia
Outdoor use 2
Indoor use only 4

Operator's Manual
Fifth Edition · First Printing
PartNo.133556 GS-2668DC•GS-3268DC 11
Do not use the platform controls to free a platform
thatiscaught,snagged or otherwise prevented
from normal motion by an adjacent structure. All
personnelmustberemovedfromtheplatform
before attempting to free the platform using the
groundcontrols.
Do not push off or pull toward any object outside of
theplatform.
GS-2668 DC
ANSI & CSA - 4 person 200 lbs / 890 N
Australia - Indoor use only - 4 person 90 lbs / 400 N
Australia - Outdoor use - 4 person 90 lbs / 400 N
GS-3268 DC
ANSI & CSA - 4 person 200 lbs / 890 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. 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 0.5 mph / 0.8 km/h with the
platformraised.
Use extreme care and slow speeds while driving
the machine in the stowed position across uneven
terrain,debris, unstable or slippery surfacesand
nearholesanddrop-offs.
Work Area Safety

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12 GS-2668DC•GS-3268DC PartNo.133556
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
withoutprior written permissionfromthe
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 use batteries that weigh less than the
originalequipment.Batteries are used as
counterweight and are critical to machine stability.
Each battery must weight 65 lbs / 30 kg.
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,
lowertheplatform and do not continuetooperate
themachine.
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 drive the machine onor near uneven 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)in theplatform.
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.
Do not operate the machine with the chassis trays
open.
Work Area Safety

Operator's Manual
Fifth Edition · First Printing
PartNo.133556 GS-2668DC•GS-3268DC 13
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-2668DC 30% (17°)
GS-3268DC 25% (14°)
Maximum side slope rating,
stowedposition 30% (17°)
Note: Slope rating is subject to ground conditions
andadequatetraction.
Fall Hazards
The guard rail system provides fall protection. If
occupant(s)of theplatformarerequired towear
personalfallprotectionequipment (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.
Closetheentrygate beforeoperating.
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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14 GS-2668DC•GS-3268DC PartNo.133556
Nostuntdrivingorhorseplaywhileoperatinga
machine.
Do not lower the platform unless the area below is
clearofpersonnel 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.
Bodily Injury Hazards
Do not operate the machine with a hydraulic oil or
air leak. An air leak or hydraulic leak can penetrate
and/orburnskin.
Impropercontactwithcomponents 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-operationinspection.Allcompartmentsmust
remainclosedandsecuredduringoperation.
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.
Beawareoftheextendedplatformpositionwhen
movingthemachine.
The machine must be on a level surface or secured
beforereleasingthebrakes.
Operators must comply with employer, job site and
governmentalrulesregardinguseofpersonal
protectiveequipment.
Checktheworkareaforoverheadobstructionsor
otherpossiblehazards.
Beaware ofcrushinghazards whengraspingthe
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
ormovingoverheadmachineryunless the controls
of the crane have been locked out and/or
precautionshave been taken to prevent any
potentialcollision.
Work Area Safety

Operator's Manual
Fifth Edition · First Printing
PartNo.133556 GS-2668DC•GS-3268DC 15
Explosion and Fire Hazards
Donotoperatethe machine in hazardous locations
orlocations wherepotentiallyflammableor
explosive gases or particles may be present.
Damaged Machine Hazards
Donotuseadamagedor malfunctioning machine.
Conductathoroughpre-operationinspectionofthe
machine and test all functions before each work
shift. Immediately tag and remove from service a
damagedormalfunctioningmachine.
Besureallmaintenance has been performed as
specifiedinthismanualandtheappropriateGenie
servicemanual.
Be sure all decals are in place and legible.
Be sure the operator’s, safety and responsibilities
manualsare complete, legible and inthe storage
containerlocatedontheplatform.
Crushing Hazards
Keep hands and limbs out of scissors.
Usecommonsenseandplanningwhenoperating
themachine with the controllerfrom the ground.
Maintainsafedistancesbetweentheoperator,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.
Do not work under the platform or in the scissor
links without the safety arm in place.
Work Area Safety

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16 GS-2668DC•GS-3268DC PartNo.133556
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
thechargertowater or rain
duringcharging.
Explosion Hazards
Keep sparks, flames and
lightedtobaccoaway from
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.
Electrocution/Burn Hazards
Connect the battery charger to a
grounded,AC3-wireelectrical
outlet only.
Inspectdaily 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 than the
originalequipment.Batteries are used as
counterweight and are critical to machine stability.
Each battery must weigh 65 lbs / 30 kg.
Lifting Hazard
Usetheappropriatenumberofpeopleandproper
lifting techniques when lifting batteries.
Lockout After Each Use
1 Select a safe parking location—firm level
surface, clear of obstruction and traffic.
2 Lowertheplatform.
3 Turn the key switch to the off position and
remove the key to secure from unauthorized
use.
4 Chockthe wheels.
5 Chargethebatteries.

Operator's Manual
Fifth Edition · First Printing
PartNo.133556 GS-2668DC•GS-3268DC 17
Legend
1 Platform entry gate
2 Platformguardrails
3 Lanyardanchoragepoint
4 Platform extension lock
handle
5 Manualstoragecontainer
6 Platformcontrols
7 Platformextension
8 Battery side cover
9 Steertire
10 Powertoplatformpigtail
11 Powertochargerpigtailand
batterycharger(undercover)
12 Non-steertire
13 Tiltalarm(undercover)
14 Entryladder/transport
tie-down
15 Brakereleasepumpknoband
brakereleaseknob
16 Groundcontrolswithmanual
loweringandLEDdiagnostic
readout
17 Groundcontrols sidecover
18 Hydraulic oil level indicator
(undercover)
19 Safety arm
20 Capacity indicator (if
equipped)
21 GFCIoutlet

Operator's Manual Fifth Edition · First Printing
18 GS-2668DC•GS-3268DC PartNo.133556
Controls
PlatformControlPanel
1 Thumb rocker switch for steer functions
2 Drivespeedbutton
3 Drive function select button
4 RedEmergencyStopbutton
5 LED
6 Lift function select button
7 Hornbutton
8 Proportionalcontrolhandleandfunctionenable
switch for lift and drive functions