Operator’s Manual with Maintenance Information Third Edition Third Printing Part No.
Operator's Manual Third Edition • Third Printing Important Read, understand and 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 Safety ........................................................................
Third Edition • Third Printing Operator's Manual Safety Rules 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.
Operator's Manual Third Edition • Third Printing SAFETY RULES Electrocution Hazards Tip-over Hazards This machine is not electrically insulated and will not provide protection from contact with or proximity to electrical current. Occupants, equipment and materials shall not exceed the maximum platform capacity or the maximum capacity of the platform extension.
Third Edition • Third Printing Operator's Manual SAFETY RULES Do not alter or disable the limit switches. Do not drive over 0.5 mph / 0.8 km/h with the platform raised. 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. 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.
Operator's Manual Third Edition • Third Printing SAFETY RULES Do not modify or alter an aerial work platform without 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 loads outside the platform perimeter.
Third Edition • Third Printing Operator's Manual SAFETY RULES Do not lower the platform unless the area below is clear of personnel and obstructions. Collision Hazards Be aware of limited sight distance and blind spots when driving or operating. Be aware of the extended platform position when moving the machine. The machine must be on a level surface or secured before releasing the brakes.
Operator's Manual Third Edition • Third Printing SAFETY RULES Explosion and Fire Hazards Decal Legend Do not operate the machine in hazardous locations or locations where potentially flammable or explosive gases or particles may be present. Genie product decals use symbols, color coding and signal words to identify the following: Damaged Machine Hazards Do not use a damaged or malfunctioning machine.
Third Edition • Third Printing Operator's Manual SAFETY RULES Battery Safety Component Damage Hazard Burn Hazards Do not use any battery charger greater than 48V to charge the batteries. Batteries contain acid. Always wear protective clothing and eye wear when working with batteries. Electrocution Hazards Connect the battery charger to a grounded, AC 3-wire electrical outlet only. Inspect daily for damaged cord, cables and wires. Replace damaged items before operating.
Operator's Manual Third Edition • Third Printing Legend 1 2 3 4 5 6 7 8 8 Platform entry gate Platform guard rails Lanyard anchorage point Platform extension lock handle Manual storage container Platform controls Platform extension Battery side cover 9 Steer tire 10 Power to platform pigtail 11 Power to charger pigtail and battery charger (under cover) 12 Non-steer tire 13 Tilt alarm (under cover) 14 Entry ladder/transport tie-down 15 Ground controls with manual lowering and LED diagnostic readout 16
Third Edition • Third Printing Operator's Manual Controls Platform Controls 1 Horn button 2 Machine on incline button with indicator light: Low speed operation for inclines 7 Proportional control handle for lift and drive functions and thumb rocker for steer function 8 Error indicator light 3 Lift function select button with indicator light 9 Power light 4 Drive function select button with indicator light 10 Battery level indicator 5 Red Emergency Stop button 6 Function enable switch Part No.
Operator's Manual Third Edition • Third Printing CONTROLS 1 2 3 4 STOP 00009.9 9 8 7 6 5 Ground Control Panel 1 LED diagnostic readout 6 Function enable button 2 Hour meter 7 3 Red Emergency Stop button Key switch for platform/off/ground control selection 4 7 amp circuit breaker for controls circuit 8 Platform up button 5 Platform down button 9 Auxiliary lowering button (if equipped) 10 Genie GS-2668 DC and Genie GS-3268 DC Part No.
Third Edition • Third Printing Operator's Manual Pre-operation Inspection Fundamentals It is the responsibility of the operator to perform a pre-operation inspection and routine maintenance. Do Not Operate Unless: You learn and practice the principles of safe machine operation contained in this operator's manual. 1 Avoid hazardous situations. 2 Always perform a pre-operation inspection. Know and understand the pre-operation inspection before going on to the next section.
Operator's Manual Third Edition • Third Printing PRE-OPERATION INSPECTION Pre-operation Inspection o Be sure that the operator's, safety and responsibilities manuals are complete, legible and in the storage container located on the platform. o Platform extension o Be sure that all decals are legible and in place. See Decals section. o Inverter (if equipped) o Check for hydraulic oil leaks and proper oil level. Add oil if needed. See Maintenance section.
Third Edition • Third Printing Operator's Manual Maintenance Check the Hydraulic Oil Level Observe and Obey: Only routine maintenance items specified in this manual shall be performed by the operator. Scheduled maintenance inspections shall be completed by qualified service technicians, according to the manufacturer's specifications and the requirements specified in the responsibilities manual. Maintaining the hydraulic oil at the proper level is essential to machine operation.
Operator's Manual Third Edition • Third Printing MAINTENANCE Check the Batteries Scheduled Maintenance Proper battery condition is essential to good performance and operational safety. Improper fluid levels or damaged cables and connections can result in component damage and hazardous conditions. This procedure does not need to be performed on machines with sealed or maintenance-free batteries.
Third Edition • Third Printing Operator's Manual Function Tests 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. Do Not Operate Unless: You learn and practice the principles of safe machine operation contained in this operator's manual. A malfunctioning machine must never be used.
Operator's Manual Third Edition • Third Printing FUNCTION TESTS 1 Select a test area that is firm, level and free of obstruction. 2 Be sure the battery pack is connected. At the Ground Controls 3 Pull out the platform and ground red Emergency Stop buttons to the on position. 4 Turn the key switch to ground control. 5 Observe the diagnostic LED readout. Result: The LED should look like the picture at right. Test the Emergency Stop 6 Push in the ground red Emergency Stop button to the off position.
Third Edition • Third Printing Operator's Manual FUNCTION TESTS At the Platform Controls Test the Up/Down Functions Test Emergency Stop 22 Press the lift function select button. 17 Push in the platform red Emergency Stop button to the off position. 23 Press and hold the function enable switch on the control handle. Result: No functions should operate. 18 Pull the red Emergency Stop button out to the on position. Result: The green power light should come on.
Operator's Manual Third Edition • Third Printing FUNCTION TESTS Test the Steering Test Drive and Braking Note: When performing the steer and drive function tests, stand in the platform facing the steer end of the machine. 31 Press and hold the function enable switch on the control handle. 27 Press the drive function select button. 28 Press and hold the function enable switch on the control handle.
Third Edition • Third Printing Operator's Manual FUNCTION TESTS Test Limited Drive Speed Test the Tilt Sensor Operation 35 Press the lift function select button. Note: Perform this test from the ground with the platform controller. Do not stand in the platform. 36 Press and hold the function enable switch on the control handle. 37 Slowly move the control handle in the direction indicated by the blue arrow. Raise the platform approximately 8 feet / 2.4 m from the ground.
Operator's Manual Third Edition • Third Printing Workplace Inspection Workplace Inspection Be aware of and avoid the following hazardous situations: Do Not Operate Unless: You learn and practice the principles of safe machine operation contained in this operator's manual.
Third Edition • Third Printing Operator's Manual Operating Instructions Fundamentals The Operating Instructions section provides instructions for each aspect of machine operation. It is the operator's responsibility to follow all the safety rules and instructions in the operator's, safety and responsibilities manuals. Do Not Operate Unless: You learn and practice the principles of safe machine operation contained in this operator's manual. 1 Avoid hazardous situations.
Operator's Manual Third Edition • Third Printing OPERATING INSTRUCTIONS Auxiliary Lowering Operation From Platform Machines equipped with a separate auxiliary lowering button next to the ground control panel: 1 Turn the key switch to platform control. 1 Turn the key switch to ground control. 2 Pull out the ground red Emergency Stop button to the on position. 3 Push and hold the auxiliary lowering button.
Third Edition • Third Printing Operator's Manual OPERATING INSTRUCTIONS Drive Select Switch Fall Protection Machine on incline symbol: Low range operation for inclines Error Indicator Light On If the error indicator light is on, push in and pull out the red Emergency Stop button to reset the system. If the light stays red, tag and remove the machine from service. To Extend and Retract Platform (Manual Platform Extension) 1 Lift the platform extension lock handle to the horizontal position.
Operator's Manual Third Edition • Third Printing OPERATING INSTRUCTIONS Dry Battery Filling and Charging Instructions 1 Remove the battery vent caps and permanently remove the plastic seal from the battery vent openings. Battery and Charger Instructions 2 Fill each cell with battery acid (electrolyte) until the level is sufficient to cover the plates. Observe and Obey: Do not use an external charger or booster battery. Do not fill to maximum level until the battery charge cycle is complete.
Third Edition • Third Printing Operator's Manual Transport and Lifting Instructions Brake Release Operation 1 Chock the wheels to prevent the machine from rolling. Observe and Obey: Common sense and planning must be applied to control the movement of the machine when lifting it with a crane or forklift. The transport vehicle must be parked on a level surface. The transport vehicle must be secured to prevent rolling while the machine is being loaded.
Operator's Manual Third Edition • Third Printing TRANSPORT AND LIFTING INSTRUCTIONS Center of gravity X Axis Y Axis GS-2668 DC 34.4 in 87.4 cm 25.8 in 65.5 cm GS-3268 DC 33.3 in 84.6 cm 27.3 in 69.3 cm Observe and Obey: Only qualified riggers should rig and lift the machine. Be sure the crane capacity, loading surfaces and straps or lines are sufficient to withstand the machine weight. See the serial plate for the machine weight. Lifting Instructions Fully lower the platform.
Third Edition • Third Printing Operator's Manual TRANSPORT AND LIFTING INSTRUCTIONS Securing to Truck or Trailer for Transit Use chains or straps of ample load capacity. Retract and secure the extension deck. Adjust the rigging to prevent damage to the chains. Turn the key switch to the off position and remove the key before transporting. If the railings have been folded down, secure them with straps before transporting. Use a minimum of 2 chains or straps.
Operator's Manual Third Edition • Third Printing Decals Inspection for Decals with Words Part No. Description Determine whether the decals on your machine have words or symbols. Use the appropriate inspection to verify that all decals are legible and in place.
Third Edition • Third Printing Operator's Manual DECALS 82557 40434 43091 52494 78673 82273 Shading indicates decal is hidden from view, i.e.
Operator's Manual Third Edition • Third Printing DECALS Inspection for Decals with Symbols Determine whether the decals on your machine have words or symbols. Use the appropriate inspection to verify that all decals are legible and in place. Part No. Description Quantity Part No.
Third Edition • Third Printing Operator's Manual DECALS 82487 78673 40434 28235 or 28174 43618 40434 62061 or 62062 82753 62061 or 62062 Battery Side 44981 82751 or 82752 82562 Ground Controls Side 82476 82474 97719 28171 52966 82748 or 82749 52475 82562 82560 82924 82476 28235 or 28174 44981 82481 43658 or 44980 82748 or 82749 52475 82748 or 82749 52475 82495 52966 82474 82482 Serial 82748 82487 82261 Plate or 82749 Part No.
Operator's Manual Third Edition • Third Printing Specifications Model GS-2668 DC Maximum hydraulic pressure (functions) 3500 psi 241 bar Height, working maximum 32 ft 9.9 m Height, platform maximum 26 ft 7.9 m Height, stowed maximum Rails up 92 in 2.34 m Height, stowed maximum Rails lowered 641/2 in 1.64 m Height, stowed maximum Rails off 461/2 in 1.18 m Height, guard rails 40 in 1.02 m Stowed, maximum Width 68 in 1.73 m Platform raised, maximum 0.5 mph 0.8 km/h 40 ft/54.
Third Edition • Third Printing Operator's Manual SPECIFICATIONS Model GS-3268 DC Maximum hydraulic pressure (functions) 3500 psi 241 bar Height, working maximum 38 ft 11.8 m Height, platform maximum 32 ft 9.8 m Height, stowed maximum Rails up 97 in 2.46 m Height, stowed maximum Rails lowered 691/2 in 1.77 m Platform length x width Height, stowed maximum Rails off 511/2 in 1.31 m Platform extension length Height, guard rails 40 in 1.02 m Width 68 in 1.
Phone 425.881.1800 Toll Free USA and Canada 800.536.1800 Fax 425.883.3475 Genie Australia Pty Ltd. Phone +61 7 3375 1660 Fax +61 7 3375 1002 Genie Scandinavia Phone +46 31 575100 Fax +46 31 579020 Genie France Phone +33 (0)2 37 26 09 99 Fax +33 (0)2 37 26 09 98 Genie Iberica Phone +34 93 579 5042 Fax +34 93 579 5059 Genie Germany Phone +49 (0)4202 88520 Fax +49 (0)4202 8852-20 Genie U.K.
