Terex Genie GS-2669DC Operator'S Manual Download

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Operator's Manual

Serial Number Range

™

-2669DC

from GS69F-18000

from GS69M-101

AUS

Australia

™

-3369DC

™

-4069DC

with
Maintenance
Information

Original Instructions
Second Edition
Second Printing
Part No. 1305659GT

Summary of Contents for Genie GS-2669DC

Page 1: ...or s Manual Serial Number Range GS 2669DC from GS69F 18000 from GS69M 101 AUS Australia GS 3369DC GS 4069DC with Maintenance Information Original Instructions Second Edition Second Printing Part No 1305659GT ...

Page 2: ... 11 Work Area Safety 12 Legend 21 Controls 22 Inspections 27 Operating Instructions 39 Transport and Lifting Instructions 50 Maintenance 53 Specifications 55 Copyright 2011 by Terex Corporation Second Edition Second Printing May 2022 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...

Page 3: ... 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 wi...

Page 4: ...unction 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 ...

Page 5: ...y 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 Q...

Page 6: ...ules 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 ...

Page 7: ... 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 ...

Page 8: ...r 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 Transport diagram Manual force Wind speed Outrigger load ...

Page 9: ...ymbol and Hazard Pictorials Definitions Part No 1305659GT GS 2669DC GS 3369DC GS 4069DC 7 Voltage rating for power to platform Pressure rating for air line to platform Maximum capacity Fall hazard Platform overloaded Crushing hazard Auxiliary lowering ...

Page 10: ...Operator s Manual Second Edition Second Printing General Safety 8 GS 2669DC GS 3369DC GS 4069DC Part No 1305659GT General Safety ...

Page 11: ...Second Edition Second Printing Operator s Manual General Safety Part No 1305659GT GS 2669DC GS 3369DC GS 4069DC 9 ...

Page 12: ...Operator s Manual Second Edition Second Printing General Safety 10 GS 2669DC GS 3369DC GS 4069DC Part No 1305659GT ...

Page 13: ...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 ...

Page 14: ...ectrical 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 ...

Page 15: ...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 stowe...

Page 16: ...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 plat...

Page 17: ...igh 62 lbs 28 1 kg 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 dr...

Page 18: ...ed 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 ...

Page 19: ...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 ...

Page 20: ...chine 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 a...

Page 21: ...9GT GS 2669DC GS 3369DC GS 4069DC 19 Lockout After Each Use 1 Select a safe parking location firm level surface clear of obstruction and traffic 2 Lower the platform 3 Turn the key switch to the off position and remove the key to secure from unauthorized use 4 Charge the batteries ...

Page 22: ...zard 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 batt...

Page 23: ...on 8 Battery charger behind cover at the ground controls side 9 Ground controls side cover 10 Hydraulic tank behind cover 11 Tilt alarm behind cover 12 Hydraulic oil level indicator behind cover 13 Ground controls with LCD readout screen 14 Outrigger housing if equipped with outriggers 15 Outrigger footpad if equipped with outriggers 16 Steer tire 17 Inverter optional 18 Battery compartment covers...

Page 24: ...trols will operate Turn the key switch to the off position and the machine will be off Turn the key switch to the ground position and the ground controls will operate 5 Red Emergency Stop button 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 operate the machine 6 Menu down button 7 Alarm 8 7A breaker for ...

Page 25: ...Second Edition Second Printing Operator s Manual Controls Part No 1305659GT GS 2669DC GS 3369DC GS 4069DC 23 Platform Control Panel ...

Page 26: ... platform control handle Move the control handle in the direction indicated by the blue arrow on the control panel and the machine will move in the direction that the blue arrow points Move the control handle in the direction indicated by the yellow arrow on the control panel and the machine will move in the direction that the yellow arrow points 6 Thumb rocker switch for steer function Press the ...

Page 27: ...le switch for drive steer lift and outrigger functions Lift function Press and hold the function enable switch to enable the lift function on the platform control handle Move the control handle in the direction indicated by the blue arrow and the platform will raise Move the control handle in the direction indicated by the yellow arrow and the platform will lower The descent alarm should sound whi...

Page 28: ...GS 3369DC GS 4069DC Part No 1305659GT 16 LED diagnostic readout battery charge indicator and lift drive mode indicator 17 Drive function button Push this button to activate the drive function 18 Outrigger function button Press this button to activate the outrigger function ...

Page 29: ...or prior to each work shift The inspection is designed to discover if anything is apparently wrong with a machine before the operator performs the function tests The pre operation inspection also serves to determine if routine maintenance procedures are required Only routine maintenance items specified in this manual may be performed by the operator Refer to the list on the next page and check eac...

Page 30: ...folds Drive motors Wear pads Tires and wheels Outrigger limit switches angle sensor alarms and horn Alarms and beacons if equipped Nuts bolts and other fasteners Brake release components Safety arm Platform extension Scissor pins and retaining fasteners Lanyard anchorage points Platform control joystick Outrigger housing and footpads if equipped Battery pack and connections Ground strap Platform e...

Page 31: ...ce 5 Only use the machine as it was intended Function Test 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 malfunctions are discovered the machine must be tagged and removed from service Repairs to the m...

Page 32: ...Pull out the red Emergency Stop button to the on position Test the Up Down Functions The audible warnings on this machine and the standard horn all come from the same central alarm The horn is a constant tone The descent alarm sounds at 60 beeps per minute The alarm sounds at 180 beeps per minute when the machine is not level 9 Do not press the lift function enable button 10 Press the platform up ...

Page 33: ... horn should sound Test the Function Enable Switch and the Up Down Functions 24 Do not hold the function enable switch on the control handle 25 Slowly move the control handle in the direction indicated by the blue arrow then in the direction indicated by the yellow arrow Result No functions should operate 26 Press the lift function button 27 Wait seven seconds for the lift function to time out 28 ...

Page 34: ... handle in the direction indicated by the yellow triangle on the control panel Result The steer wheels should turn in the direction indicated by the yellow triangle Test Drive and Braking 39 Press the drive function button if equipped 40 Press and hold the function enable switch on the control handle 41 Slowly move the control handle in the direction indicated by the blue arrow on the control pane...

Page 35: ...on button if equipped 47 Press and hold the function enable switch on the control handle 48 Move the control handle in the direction indicated by the blue arrow then move the control handle in the direction indicated by the yellow arrow Result The drive function should not work in either direction 49 Lower the platform and remove both pieces of wood Test Elevated Drive Speed 50 Raise the platform ...

Page 36: ...elow the outrigger function symbol will turn on If the control handle is not moved within seven seconds of pushing the outrigger function button the circle below the outrigger function symbol will turn off and outrigger function will not operate Press the outrigger function button again 57 Press and hold the function enable switch on the control handle 58 Move the control handle in the direction i...

Page 37: ...orm Result The platform should raise Raise the platform to approximately 8 ft 2 4 m and stop 67 Fully lower the platform 68 Press the outrigger function button 69 Wait seven seconds for the outrigger function enable to time out 70 Slowly move the control handle in the direction indicated by the blue arrow then in the direction indicated by the yellow arrow Result The outriggers should not retract ...

Page 38: ...lps the operator determine if the workplace is suitable for safe machine operation It should be performed by the operator prior to moving the machine to the workplace It is the operator s responsibility to read and remember the workplace hazards then watch for and avoid them while moving setting up and operating the machine Workplace Inspection Checklist Be aware of and avoid the following hazardo...

Page 39: ...agram 2 137605 Label Emergency Stop Platform Control 1 137656 Label Drive Steer Direction Platform Control 1 216027 Danger Runaway Hazard Slope 1 Part No Decal Description Qty 229827 Warning Hot Surface 1 236360 Overlay Platform Control Panel without outriggers 1 237116 Label Operational Indicator Codes 1 237117 Danger Tip over Hazard Batteries J305 1 237118 Instructions Battery Connection Diagram...

Page 40: ...Operator s Manual Second Edition Second Printing Inspections 38 GS 2669DC GS 3369DC GS 4069DC Part No 1305659GT 1272242 38149 1293324 1258104 1302876 ...

Page 41: ...each aspect of machine operation It is the operator s responsibility to follow all the safety rules and instructions in the operator s manual Using the machine for anything other than lifting personnel along with their tools and materials to an aerial work site is unsafe and dangerous Only trained and authorized personnel should be permitted to operate a machine If more than one operator is expect...

Page 42: ... connected before operating the machine 2 Turn the key switch to ground control 3 Pull out both ground and platform red Emergency Stop buttons to the on position To Position Platform 1 At the control panel press and hold the lift function enable button 2 Press the platform up or down button Drive and steer functions are not available from the ground controls Operation from Platform 1 Be sure the b...

Page 43: ...indicator lights will turn off as the corresponding outrigger retracts Machine functions are restored once the outrigger are off the ground Note Drive function is disabled while the outriggers are down To Steer 1 Press and hold the drive steer function enable switch on the control handle 2 Turn the steer wheels with the thumb rocker switch located on the top of the control handle To Drive 1 Press ...

Page 44: ...ble switch on the control handle 3 Move the control handle in the direction indicated by the yellow arrow The outriggers will begin to extend The individual outrigger indicator light will turn solid green as the corresponding outrigger makes contact with the ground Continue moving the control handle until the lift enable indicator light turns green and a beep is heard The machine is now level When...

Page 45: ...bol will turn off and drive function will not operate Press the drive function button again 2 Turn the steer wheels with the thumb rocker switch located on the top of the control handle To Drive 1 Press the drive function button On the LCD screen a circle below the drive function symbol will turn on If the control handle is not moved within seven seconds of pushing the drive function button the ci...

Page 46: ...nclinometer OR use the following procedure You will need carpenter s level straight piece of wood at least 3 feet 1 m long tape measure Lay the piece of wood on the slope At the downhill end lay the level on the top edge of the piece of wood and lift the end until the piece of wood is level While holding the piece of wood level measure the vertical distance from the bottom of the piece of wood to ...

Page 47: ...cator codes If the platform controls LED or ground controls LCD diagnostic readout displays an operational indicator code such as LL the fault condition must be repaired or removed before resuming machine operation Push in and pull out the red Emergency Stop button to reset the system LED Readout LCD Readout Operational Indicator Codes Code Condition LL Off Level OL Platform Overloaded CH Chassis ...

Page 48: ... to cool for approximately 5 minutes before resuming machine operation 3 Pull out the red Emergency Stop button to the on position Operation from Ground with Controller Maintain safe distances between the operator machine and fixed objects Be aware of the direction the machine will travel when using the controller Battery Level Indicator Use the LED diagnostic readout to determine the battery leve...

Page 49: ... 1305659GT GS 2669DC GS 3369DC GS 4069DC 47 After Each Use 1 Select a safe parking location firm level surface clear of obstruction and traffic 2 Lower the platform 3 Turn the key switch to the off position and remove the key to secure from unauthorized use 4 Charge the batteries ...

Page 50: ...estore drive and lift functionality Return the machine to level ground to restore lift functions How to Use the Safety Arm 1 Raise the platform approximately 8 ft 2 4 m from the ground 2 Rotate the safety arm away from the machine and let it hang down 3 Lower the platform until the safety arm rests securely on the link Keep clear of the safety arm when lowering the platform To Extend and Retract P...

Page 51: ...enough distilled water to cover the plates Do not overfill prior to the charge cycle 2 Replace the battery vent caps 3 Connect the battery charger to a grounded AC circuit 4 The charger will indicate when the battery is fully charged 5 Check the battery acid level when the charging cycle is complete Replenish with distilled water to the bottom of the fill tube Do not overfill Dry Battery Filling a...

Page 52: ...loaded Be sure the vehicle capacity loading surfaces and chains or straps are sufficient to withstand the machine weight Genie lifts are very heavy relative to their size See the serial label for the machine weight The machine must be on a level surface or secured before releasing the brakes Do not drive the machine on a slope that exceeds the uphill downhill or side slope rating See Driving on a ...

Page 53: ... transport Retract and secure the extension deck Use the tie down points on the chassis for anchoring down to the transport surface Use a minimum of 2 chains or straps Use chains or straps of ample load capacity Turn the key switch to the off position and remove the key before transporting Inspect the entire machine for loose or unsecured items If the railings have been folded down secure them wit...

Page 54: ...move all loose items on the machine Determine the center of gravity of your machine using the table and the picture on this page Attach the rigging only to the designated lifting points on the machine Adjust the rigging to prevent damage to the machine and to keep the machine level Center of gravity X Axis Y Axis GS 2669DC without outriggers 38 3 in 97 3 cm 29 9 in 76 cm GS 3369DC without outrigge...

Page 55: ...e procedure it conveys the meaning below Indicates that tools will be required to perform this procedure Indicates that new parts will be required to perform this procedure 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 checks allow the inspector to identify change...

Page 56: ...king soda and water Note Perform this test after fully charging the batteries 1 Put on protective clothing and eye wear 2 Be sure that the battery cable connections are tight and free of corrosion 3 Be sure that the battery hold down brackets are in place and secure Note Adding terminal protectors and a corrosion preventative sealant will help eliminate the corrosion on the battery terminals and c...

Page 57: ...x 63 in 2 79 x 1 6 m Platform extension length 170 in 4 32 m Drive speeds Stowed maximum forward 4 5 mph 40 ft 6 06 sec 7 2 km h 40 ft 6 06 sec Stowed maximum reverse 3 mph 40 ft 9 09 sec 4 8 km h 40 ft 9 09 sec Platform raised maximum 0 3 mph 40 ft 90 sec 0 5 km h 12 2 m 90 sec Maximum hydraulic pressure functions 3500 psi 241 bar Tire size 26x12D380 Maximum slope rating stowed position Extension...

Page 58: ...in 2 79 x 1 6 m Platform extension length 170 in 4 32 m Drive speeds Stowed maximum forward 4 5 mph 40 ft 6 06 sec 7 2 km h 40 ft 6 06 sec Stowed maximum reverse 3 mph 40 ft 9 09 sec 4 8 km h 40 ft 9 09 sec Platform raised maximum 0 3 mph 40 ft 90 sec 0 5 km h 12 2 m 90 sec Maximum hydraulic pressure functions 3500 psi 241 bar Tire size 26x12D380 Maximum slope rating stowed position Extension deck...

Page 59: ...wed maximum forward 4 5 mph 40 ft 6 06 sec 7 2 km h 40 ft 6 06 sec Stowed maximum reverse 3 mph 40 ft 9 09 sec 4 8 km h 40 ft 9 09 sec Platform raised maximum 0 3 mph 40 ft 90 sec 0 5 km h 12 2 m 90 sec Maximum hydraulic pressure functions 3500 psi 241 bar Tire size 26x12D380 Maximum slope rating stowed position Extension deck uphill 35 19 Extension deck downhill 15 9 Side slope 35 19 Note Slope r...

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