Terex Genie GS-3369BE Operator'S Manual Download

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Operator's Manual

Serial Number Range

™

-2669

from GS69F-18000

™

-3369

™

-4069

Bi-Energy Power

with
Maintenance
Information

Original Instructions
Third Edition
First Printing
Part No. 1305656GT

Summary of Contents for Genie GS-3369BE

Page 1: ...Operator s Manual Serial Number Range GS 2669 from GS69F 18000 CE GS 3369 GS 4069 Bi Energy Power with Maintenance Information Original Instructions Third Edition First Printing Part No 1305656GT ...

Page 2: ...and Hazard Pictorials Definitions 5 General Safety 8 Personal Safety 11 Work Area Safety 12 Legend 20 Controls 21 Inspections 24 Operating Instructions 36 Transport and Lifting Instructions 46 Maintenance 49 Specifications 52 Copyright 2013 Terex 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 i...

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 wit...

Page 4: ...nction 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 p...

Page 5: ... 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 Qu...

Page 6: ...les 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 C...

Page 7: ...369BE GS 4069BE 5 Symbol and 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 ...

Page 8: ...gers 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 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...

Page 9: ...E GS 4069BE 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 ...

Page 10: ...Operator s Manual Third Edition First Printing General Safety 8 GS 2669BE GS 3369BE GS 4069BE Part No 1305656GT General Safety ...

Page 11: ...Third Edition First Printing Operator s Manual General Safety Part No 1305656GT GS 2669BE GS 3369BE GS 4069BE 9 ...

Page 12: ...Operator s Manual Third Edition First Printing General Safety 10 GS 2669BE GS 3369BE GS 4069BE Part No 1305656GT ...

Page 13: ...rotection 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: ...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...

Page 15: ...ecrease 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 attempt...

Page 16: ...o 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 ...

Page 17: ... 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 a...

Page 18: ...ther 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 o...

Page 19: ...ery only in an open well ventilated area away from sparks flames and lighted tobacco 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 Do not spray ether into engine Damaged Machine Hazards Do not use a damaged or malfunctioning machine Conduct a thorough pre operation inspection of the ma...

Page 20: ...er 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 g...

Page 21: ...ipment Batteries are used as counterweight and are critical to machine stability For GS 2669 and GS 3369 machines with standard battery option each battery must weigh 63 lbs 29 kg For GS 4069 machines and machines with high capacity battery option each battery must weigh 72 lbs 32 7 kg Lifting Hazard Use the appropriate number of people and proper lifting techniques when lifting batteries ...

Page 22: ...n 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 Engine under cover 18 Battery compartment covers...

Page 23: ...erate 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 controls circ...

Page 24: ...osition to operate the machine 2 Lift function button Push this button to activate the lift function 3 Horn button Press the horn button and the horn will sound Release the horn button and the horn will not sound 4 Engine start stop button with indicator light Press the engine start button to start the engine The engine start button indicator light will be on when the button is being pressed Light...

Page 25: ...ble the outrigger function on the platform control handle Move the control handle in the direction indicated by the blue arrow and the outriggers will retract Move the control handle in the direction indicated by the yellow arrow and the outriggers will extend 6 Thumb rocker switch for steer function Press the left side of the thumb rocker and the machine will turn in the direction the blue triang...

Page 26: ...e 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 each of the items If damage or an...

Page 27: ...ydraulic power unit reservoir hoses fittings cylinders and manifolds Generator and related components Fuel and hydraulic tanks Drive motors Wear pads Tires and wheels Engine and related components Limit switches angle sensor alarms and horn Lanyard anchorage points Alarms and beacons if equipped Nuts bolts and other fasteners Brake release components Safety arm Platform extension Scissor pins and ...

Page 28: ...e 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 ma...

Page 29: ...perate 9 Pull out the red Emergency Stop button to the on position and restart the engine 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 10 Do not press the lift function enable...

Page 30: ...y Stop button to the on position 26 Press the horn button Result The horn should sound Test the Function Enable Switch and the Up Down Functions 27 Do not hold the function enable switch on the control handle 28 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 29 Press the lift functio...

Page 31: ... 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 42 Press the drive function button 43 Press and hold the function enable switch on the control handle 44 Slowly move the control handle in the direction indicated by the blue arrow on the control panel until the machine...

Page 32: ...rive function button 50 Press and hold the function enable switch on the control handle 51 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 52 Lower the platform and remove both pieces of wood Test Elevated Drive Speed 53 Raise the platform a...

Page 33: ...utrigger 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 60 Press and hold the function enable switch on the control handle 61 Move the control handle in the direction indicated b...

Page 34: ...rm Result The platform should raise Raise the platform to approximately 8 ft 2 4 m and stop 70 Fully lower the platform 71 Press the outrigger function button 72 Wait seven seconds for the outrigger function enable to time out 73 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 7...

Page 35: ... 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 hazardous situ...

Page 36: ...133149 Label Electrocution Hazard 1 133537 Label Crushing Hazard 1 137605 Label Emergency Stop Platform Control 1 137656 Label Drive Steer Direction Platform Control 1 216031 Label Runaway Hazard Slope 1 229828 Warning Hot Surface 1 237925 Label Tip over Hazard Batteries T105 1 824263 Label Wheel Load GS 2669BE 4 824264 Label Wheel Load GS 3369BE 4 Part No Decal Description Qty 824265 Label Wheel ...

Page 37: ...Third Edition First Printing Operator s Manual Inspections Part No 1305656GT GS 2669BE GS 3369BE GS 4069BE 35 ...

Page 38: ...on It is the operator s responsibility to follow all the safety rules and instructions in the operator s safety and responsibilities manuals 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 expecte...

Page 39: ...ted before operating the machine 3 Be sure both ground and platform control red Emergency Stop buttons are pulled out to the on position Auxiliary Lowering 1 Turn the key switch to ground control 2 Pull out the platform and ground red Emergency Stop button to the on position 3 Move and hold the auxiliary lowering function enable toggle switch 4 Move and hold the auxiliary lowering toggle switch Op...

Page 40: ...ton indicator light is on and the LED screen is animated the engine may restart when a function is activated To turn the Engine Restart System off press the engine start button briefly while the engine is running The engine start button indicator light and LED animation will be off When the Engine Restart system is turned off the machine will use battery power only When the engine start button ind...

Page 41: ...ns Not all outriggers are in contact with the ground All four outriggers are in contact with the ground but the machine is not level Error code Note If the outrigger enable and extend buttons are released too soon during extension the outrigger indicator lights will continue to flash green indicating the outriggers are not contacting the ground Note If the outrigger lights are solid green the mach...

Page 42: ...n symbol will turn on If the control handle is not moved within seven seconds of pushing the drive function button the circle below the drive function symbol will turn off and drive function will not operate Press the drive function button again 2 Press and hold the function enable switch on the control handle 3 Increase speed Slowly move the control handle off center Decrease speed Slowly move th...

Page 43: ...l 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 the ground Divide the tape measure distance rise b...

Page 44: ... 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 Mode Operat...

Page 45: ...ly 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 level Note When a blinking L...

Page 46: ...orm extension lock handles to extend the platform to the desired position Do not stand on the platform extension while trying to extend it 3 Lower the platform extension lock handles and make sure the extension deck is locked Tilt Sensor Activation Settings Chassis Angle on Wheels Chassis Angle side to side 2 Chassis Angle front to back 3 Chassis Angle on Outriggers Chassis Angle side to side 0 8 ...

Page 47: ...y shut off when the charging cycle is complete Charging Batteries with External Power 1 Connect the battery charger to a grounded AC circuit The charger will automatically shut off when the charging cycle is complete 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 and Charging Instruc...

Page 48: ...ecured to prevent rolling while the machine is being 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 u...

Page 49: ...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 with...

Page 50: ...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 2669BE without outriggers 38 1 in 97 3 cm 30 1 in 76 cm GS 3369BE without outrigge...

Page 51: ...egend The following symbols have been used in this manual to help communicate the intent of the instructions When one or more of the symbols appear at the beginning of a maintenance 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 Engine Oil Level Maintaining the prop...

Page 52: ...pe Chevron Rando HD equivalent Check the Batteries Proper battery condition is essential to good machine performance and operational safety Improper fluid levels or damaged cables and connections can result in component damage and hazardous conditions Electrocution hazard Contact with hot or live circuits may result in death or serious injury Remove all rings watches and other jewelry Bodily injur...

Page 53: ...ormed quarterly annually and every two years must be completed by a person trained and qualified to perform maintenance on this machine according to the procedures found in the service manual for this machine Machines that have been out of service for more than three months must receive the quarterly inspection before they are put back into service ...

Page 54: ...Maximum hydraulic pressure functions 3500 psi 241 bar Tire size 26 x 12 in Total vibration value to which the hand arm system is subjected does not exceed 2 5 m s2 Highest root mean square value of weighted acceleration to which the whole body is subjected does not exceed 1 6 ft s2 or 0 5 m s2 Airborne noise emissions Sound pressure level at ground workstation 75 dBA Sound pressure level at platfo...

Page 55: ...um hydraulic pressure functions 3500 psi 241 bar Tire size 26 x 12 in Total vibration value to which the hand arm system is subjected does not exceed 2 5 m s2 Highest root mean square value of weighted acceleration to which the whole body is subjected does not exceed 1 6 ft s2 or 0 5 m s2 Airborne noise emissions Sound pressure level at ground workstation 75 dBA Sound pressure level at platform wo...

Page 56: ... functions 3500 psi 241 bar Tire size 26 x 12 in Total vibration value to which the hand arm system is subjected does not exceed 2 5 m s2 Highest root mean square value of weighted acceleration to which the whole body is subjected does not exceed 1 6 ft s2 or 0 5 m s2 Airborne noise emissions Sound pressure level at ground workstation 74 dBA Sound pressure level at platform workstation 71 dBA Guar...

Page 57: ... engine only Test Report This machine has been tested and passed the following categories per EN 280 2013 A1 2015 clause 6 3 prior to entering the market 1 BRAKES Brakes working properly in forward and reverse 2 OVERLOAD Overload tested at XXX rated load 3 FUNCTIONAL Smooth operation at XXX rated load 4 FUNCTIONAL All safety devices working correctly 5 FUNCTIONAL Speeds set within permitted specif...

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