Genie GS-2668 DC Utility Vehicle User Manual
Contents
1. 9 Steer tire 16 Ground controls side cover 10 Power to platform pigtail 17 Hydraulic oil level indicator 11 Power to charger pigtail and under cover battery charger under cover 18 Brake release pump knob and 12 Non steertire brake release knob hidden 13 Tilt alarm under cover 14 Entry ladder transport 19 Safety arm tie down 20 GFCI outlet 15 Ground controls with manual lowering and LED diagnostic readout Genie GS 2668 DC and Genie GS 3268 DC from view in this picture Part No 82750 Third Edition Third Printing Operator s Manual o Ff 2 Te Controls se Genie ey o A c ELA O E U Platform Controls 4 2 O OT R Hornbutton 7 Proportional control handle for lift and drive Machine on incline button with indicator light functions and thumb rocker for steer function Low speed operation for inclines 8 Error indicator light Lift function select button with indicator light 9 Powerlight Drive function select button with indicator light 10 Battery level indicator Red Emergency Stop button Function enable switch Part No 82750 Genie GS 2668 DC and Genie GS 3268 DC 9 Operator s Manual Third Edition Third Printing2. NA ee 28235 or 28236 fa 28174 44736 m 43618 40434 a a S 62061 O o or 62062 2 62061 a Za 52673 or 62062 o 5 2 6 A M or Z Battery Side or 52803 O m o 44981 A 5 44255 5 i gt Z 72970 or gt 44255 Ground Controls PEC Side e 28175 43619 o gt a 28164 44255 we m s 52966 82559 s o 82748 82558 s or 82749 25994 gt oN 52475 O 52070 43696 28171 31060 28235 82748 gt pO Soy or 281 74 or 82749 44981 52475 82270 52070 A A 82239 44220 A 43617 or 97712 48727 82561 52966 43658 82561 or 44980 82748 or 82749 52070 Seria gt 52475 43091 82263 82482 Tate peut 82239 52431 65052 82261 or 82749 52475 Part No 82750 Genie GS 2668 DC and Genie GS 3268 DC 29 Operator s Manual 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 28171 28174 28235 40434 43618 43658 44980 44981 52475 52966 62061 62062 78673 82261 82474 30 Description Label No Smoking Label Power to Platform 230V Label Power to Platform 115V Label Lanyard Anchorage Label Directional Arrows Label Power to Charger 230V Lab
3. DECALS 82487 78673 40434 28235 or 28174 43618 p 40434 7 7 62061 2 2 or 62062 gt lt 62061 gt 82753 or 62062 5 gt 2266 Z Battery Side or o o Ground Controls 82562 Side lt lt SP 82476 O 82474 97719 e z i oz O 4 28171 82562 2 Poe a 52966 82560 82748 82924 E or 82749 O 52475 82476 AE a 28235 82748 or 82749 or 28174 52475 44981 Ob ye 82481 82495 7 43658 or 44980 82748 52966 or 82749 82474 52475 Shading indicates decal is 32482 Serial 82748 ne from view i e under 82487 82261 Plate or82749 52475 Part No 82750 Genie GS 2668 DC and Genie GS 3268 DC 31 Operator s Manual Third Edition Third Printing Specifications Model Height working maximum Height platform maximum Height stowed maximum Rails up Height stowed maximum Rails lowered Height stowed maximum Rails off Height guard rails Width Length platform retracted Length platform extended Maximum load capacity Wheelbase Turning radius outside Turning radius inside Ground clearance Weight Gradeability Airborne noise emissions 32 ft 26 ft 92 in 641 2 in 461 2 in 40 in 68 in 105 in 165 in 1250 Ibs 73 in 145 in 60 in 71 2 in GS 2668 DC 9 9m 7 9 m 2 34 m 1 64 m 1 18 m 1 02 m 1 73 m 2 67 m 4 2 m 567 kg 1 85 m 3 68 m 1 52 m 19 cm See Serial Plate
4. CONTROLS Q a R O Z STOP zda z C pe Ground Control Panel 1 LED diagnostic readout 6 Function enable button 2 Hourmeter 7 Key switch for platform off ground control 3 RedEmergency Stop button 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 82750 Third Edition Third Printing Operator s Manual Pre operation Inspection Do Not Operate Unless M You learn and practice the principles of safe machine operation contained inthis 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 3 Always perform function tests prior to use 4 Inspect the workplace 5 Only use the machine as it was intended Fundamentals lt is the responsibility of the operator to perform a pre operation inspection and routine maintenance The pre operation inspection is a visual inspection performed by the operator 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
5. Result The platform should stop raising 26 Press and hold the function enable switch Slowly move the control handle in the direction indicated by the yellow arrow Result The platform should lower The descent alarm should sound while the platform is lowering Genie GS 2668 DC and Genie GS 3268 DC 17 Operator s Manual Third Edition Third Printing FUNCTION TESTS Test the Steering Note When performing the steer and drive function tests stand in the platform facing the steer end of the machine 2 Press the drive function select button 28 Press and hold the function enable switch on the control handle 29 Depress the thumb rocker switch on top of the control handle in the direction identified by the blue triangle on the control panel Result The steer wheels should turn in the direction that the blue triangle points on the control panel 30 Depress the thumb rocker switch in the direction identified by the yellow triangle on the control panel Result The steer wheels should turn in the direction that the yellow triangle points on the control panel 18 Genie GS 2668 DC and Genie GS 3268 DC Test Drive and Braking 31 Press and hold the function enable switch on the control handle 32 Slowly move the control handle in the direction indicated by the blue arrow on the control panel until the machine begins to move then return the handle to the center position Result The machine sh
6. Machine weights vary with option configurations 30 80 dB Maximum sound level at normal operating workstations A weighted Power source Controls AC outlet in platform 8 Batteries 225AH Proportional standard Maximum hydraulic pressure functions System voltage Tires size Platform dimensions Platform length x width Platform extension length Drive speeds Stowed maximum Platform raised maximum 3500 psi 241 bar 48V 23 x 10 5 x 360 99 in x 61in 60 in 3 3 mph 0 5 mph 2 5 x 1 55 m 1 52 m 5 3 km h 0 8 km h 40 ft 54 6 sec 12 2 m 54 6 sec Floor Loading Information GVW Rated Load Axle load maximum Wheel load maximum Localized pressure per tire Occupied pressure 8100 Ibs 4120 lbs 2060 Ibs 86 psi 158 psf 3674 kg 1868 kg 934 kg 6 04 kg cm 592 kPa 7 56 kPa Note Floor loading information is approximate and does not incorporate different option configurations It should be used only with adequate safety factors Continuous improvement of our products is a Genie policy Product specifications are subject to change without notice or obligation 32 Genie GS 2668 DC and Genie GS 3268 DC Part No 82750 Third Edition Third Printing Model Height working maximum Height platform maximum Height stowed maximum Rails up Height stowed maximum Rails lowered Height stowed maximum Rails off Height guard rails Width Length plat
7. condition will affect machine performance When the battery charge indicator light flashes the machine drive speed is limited and the lift function is disabled Part No 82750 Third Edition Third Printing Operator s Manual Drive Select Switch 4 Error Indicator Light On Machine on incline symbol Low range operation for inclines If the error indicator light is on push in and pull out the red Emergency Stop button to reset the system NA Or 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 2 Push the platform extension lock handle to extend the platform to the desired position Do not stand on the platform extension while trying to extend it 3 Lowerthe platform extension lock handle Operation From Ground with Controller Maintain safe distances between the operator the machine and fixed objects Be aware of the direction the machine will travel when using the controller Part No 82750 OPERATINGINSTRUCTIONS 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 governmental regulations and must be inspected and used in accordance with the manufacturer s instr
8. serious injury Only trained maintenance personnel should access compartments Access by the operator is only advised when performing a pre operation inspection All compartments must remain closed and secured during operation Component Damage Hazards Do not use the machine as a ground for welding Genie GS 2668 DC and Genie GS 3268 DC 5 Operator s Manual Third Edition Third Printing SAFETY RULES Explosion and Fire Hazards Do not operate the machine 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 all maintenance has been performed as specified in this manual and the appropriate service manual Be sure all decals are in place and legible Be sure the operator s safety and responsibilities manuals are complete legible and in the storage container located on the platform Crushing Hazards Keep hands and limbs out of scissors 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 Maintain a firm grasp on the platform rail when pulling the snap pin Do not allow the platf
9. this manual may be performed by the operator Refer to the list on the next page and check each of the items lf damage or any variation from factory delivered condition is discovered the machine must be tagged and removed from service Repairs to the machine may only be made by a qualified service technician according to the manufacturer s specifications After repairs are completed the operator must perform a pre operation inspection again before going onto the function tests Scheduled maintenance inspections shall be performed by qualified service technicians according to the manufacturer s specifications and the requirements listed in the responsibilities manual Part No 82750 Genie GS 2668 DC and Genie GS 3268 DC 11 Operator s Manual a a gt gt PRE OPERATION INSPECTION Pre operation Inspection Li Be sure that the operator s safety and responsibilities manuals are complete legible and in the storage container located on the platform LI Li Check for hydraulic oil leaks and proper oil level Be sure that all decals are legible and in place See Decals section Add oil if needed See Maintenance section LI Check for battery fluid leaks and proper fluid level Add distilled water if needed See Maintenance section Check the following components or areas for damage improperly installed or missing parts and unauthorized modifications LI L G O C O G O E amp E C C L Electrical compon
10. Extension only 300 lbs 136 kg Maximum occupants ANSI and CSA 4 Maximum occupants Australia Outdoor use 2 Indoor use only 4 1000 Ibs 454 kg Platform only 700 Ibs 318 kg Extension only 300 Ibs 136 kg Part No 82750 Third Edition Third Printing Operator s Manual 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 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 di Do not raise the platform unless the machine is on a firm level surface 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 attempting to free the platform using the ground controls 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 SAFETY RULES 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 de
11. M 7 of E NA m M Third Edition Operators Manua pieron with Maintenance Information AA ak GS 2668 DC GS 3268DC Operator s Manual Third Edition Third Printing o 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 Sy ao dee ia OSA e AWS EO EA O 1 PSO CHG NO CENE 8 COMO aaa AR EA AEG RAE 9 Pre operation Inspection saaaeaaaaaaaaaaaazanac 11 Maintenance es ee aaa aa aaa anawa aaa a aaaaaaaaazaaaazaaaziaca ia 13 FPUNCUON TO IG GO aoc r EA ee erent 15 Workplace Inspection ssaaa ua aaa aa aaaaazanaananai 20 Operating Instructions sssaaaaaa aaa aaaaaasaazaanaki 21 Transport and Lifting Instructions 111 22111 25 De ETON 28 ODEGIICAUON S asa ai ARCE AC Ok GA 32 Contact US Copyright 1999 by Genie Industries First Edition Sixth Printing January 2002 Internet http www genielift com i iel Edition Printing March 2002 e mail techpub genieind com Second Edition Second Printing March 200 Third Edition Third Printing October 2004 Genie is a registered trademark of Genie Industries in the U S A
12. Printing Operator s Manual Collision Hazards Be aware of limited sight distance and blind spots when driving or operating Be aware ofthe extended platform position when moving the machine The machine must be on a level surface or secured before releasing the brakes Operators must comply with employer job site and governmental rules regarding the use of personal protective equipment Check the work area for overhead obstructions or other possible hazards Be aware of crushing hazards when grasping the platform guard rail Observe and use the color coded direction arrows on the platform controls and platform decal plate for drive and steer functions Do not operate a machine in the path of any crane or moving overhead machinery unless the controls of the crane have been locked out and or precautions have been taken to prevent any potential collision No stunt driving or horseplay while operating a machine Part No 82750 SAFETY RULES Do not lower the platform unless the area below is clear of personnel and obstructions Limit travel soeed according to the condition of the ground surface congestion slope location of personnel and any other factors which may cause collision Bodily Injury Hazard Do not operate the machine with a hydraulic oil or air leak An air leak or hydraulic leak can penetrate and or burn skin Improper contact with components under any cover will cause
13. and many other countries GS is a trademark of Genie Industries These machines comply with ANSI SIA 92 6 1999 4 Printed on recycled paper Printed in U S A Genie GS 2668 DC and Genie GS 3268 DC Part No 82750 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 M 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 apre operation inspection 3 Always perform function tests prior to use 4 Inspect the workplace 5 Only use the machine as it was intended M You read understand and obey the manufacturer s instructions and safety rules safety and operator s manuals and machine decals M You read understand and obey employer s safety rules and worksite regulations M You read understand and obey all applicable governmental regulations M You are properly trained to safely operate the machine Part No 82750 Genie GS 2668 DC and Genie GS 3268 DC 1 Operator s Manual Third Edition Third Printing SAFETY RULES Electrocution Hazards This machine is not electrically insulated and will not provide protection from contact with or proximity to electrical current Maintain saf
14. azard Contact with hot or live circuits may result in death or serious injury Remove all rings watches and other jewelry Bodily injury hazard Batteries contain acid Avoid spilling or contacting battery acid Neutralize battery acid spills with baking soda and water 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 4 Remove the battery vent caps 5 Check the battery acid level of each battery If needed replenish with distilled water to the bottom of the battery fill tube Do not overfill 6 Install the vent caps Adding terminal protectors anda corrosion preventative sealant will help eliminate corrosion on the battery terminals and cables Scheduled Maintenance Maintenance performed quarterly annually and every two years must be completed by a person trained and qualified to perform maintenance on ths 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 Genie GS 2668 DC and Genie GS 3268 DC Part No 82750 Third Edition Third Printing Operator s Manual Do Not Operate Unless M You learn and practice the principles of safe mach
15. azards E Keep sparks flames and lighted tobacco away from batteries Batteries emit an 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 Part No 82750 SAFETY RULES Component Damage Hazard Do not use any battery charger greater than 48V to charge the 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 ir 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 original equipment Batteries are used as counterweight and are critical to machine stability Each battery must weigh 65 pounds 29 5 kg Lifting Hazard Use the appropriate number of people and proper lifting techniques when lifting batteries Genie GS 2668 DC and Genie GS 3268 DC 7 Operator s Manual Legend 9006 RO N CO N O OT Platform entry gate Platform guard rails Lanyard anchorage point Platform extension lock handle Manual storage container Platform controls Platform extension Battery side cover Third Edition Third Printing
16. crease machine stability Do not drive the machine on or near uneven terrain unstable surfaces or other hazardous conditions with the platform raised 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 olis Do not push off or pull toward any object outside z of the platform 2 GS 2668 DC ANSI amp CSA 4 person Australia Indoor use only 4 person Australia Outdoor use 4 person 200 Ibs 890 N 90 Ibs 400 N 90 Ibs 400 N GS 3268 DC ANSI amp CSA 4 person 200 Ibs 890 N Australia Indoor use only 4 person 90 Ibs 400 N Australia Outdoor use 2 person 90 Ibs 400 N Part No 82750 Genie GS 2668 DC and Genie GS 3268 DC 3 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 w 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 perso
17. d platform red Emergency Stop buttons to the on position 3 Be sure the battery pack is connected before operatingthe machine To Position Platform 1 Pushand hold the function enable button 2 Activate the platform up or the platform down function Drive and steer functions are not available from the ground controls 22 Genie GS 2668 DC and Genie GS 3268 DC Operation From Platform 1 Turn the key switch to platform control 2 Pulloutthe ground and platiorm red Emergency Stop buttons to the on position 3 Be sure the battery pack is connected before operatingthe machine To Position Platform 1 Press the lift function select button 2 Press and hold the function enable switch on the control handle 3 Move the control handle according to the markings on the control panel To Steer 1 Press and hold the function enable switch on the control handle 2 Turnthe steer wheels with the thumb rocker switch located on the top of the control handle To Drive 1 Press and hold the function enable switch 2 Increase speed Slowly move the control handle off center Decrease speed Slowly move the control handle toward center Stop Return the control handle to center or release the function enable switch Use the color coded direction arrows on the platform controls and on the platform to identify the direction the machine will travel Machine travel speed is restricted when the platform is raised Battery
18. e Max Side Force 200 lbs 890 N GS 2668 DC ANSI amp CSA Notice Max Side Force 90 lbs 400 N GS 2668 DC Australia Notice Max Capacity 1000 Ibs 454 kg GS 3268 DC Notice Max Side Force 200 lbs 890 N GS 3268 DC ANSI amp CSA Notice Max Side Force 90 Ibs 400 N GS 3268 DC Australia Cosmetic 4 x 2 Label Fault Codes Cosmetic Genie GS 2668 DC Cosmetic Genie GS 3268 DC Notice Charger Instructions Platform Control Panel Label Latch Ground Control Panel Notice Operating Instructions Ground Notice Battery Connection Diagram Notice Operating Instructions Platform Label Chevron Rykon Label Auxiliary Lowering Label Platform Controls Location Warning Skin Injection Hazard Notice Annual Inspection Danger Crushing Hazard Label Wheel Load GS 2668 DC Label Wheel Load GS 3268 DC Danger Notice Brake Release Safety amp Operating Instructions 1 PD MO R IR D Part No 82750 Third Edition Third Printing Operator s Manual 82557 40434 78673 43091 52494 82273 DECALS Shading indicates decal is hidden from view i e under covers
19. e distances from electrical power lines and apparatus in accordance with applicable governmental regulations and the following chart Om w Voltage Minimum Safe Phase to Phase Approach Distance Feet Meters 0 to 300V Avoid Contact 300V to 50KV 10 3 05 50KV to 200KV 15 4 60 200KV to 350KV 20 6 10 350KV to 500KV 25 7 62 500KV to 750KV 35 10 67 750KV to 1000KV 45 13 72 Allow for platform movement electrical 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 2 Genie GS 2668 DC and Genie GS 3268 DC 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 Ibs 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 1250 lbs 567 kg Extension only Platform only 300 Ibs 136 kg 950 lbs 431kg Maximum capacity GS 3268 DC Platform retracted 1000 Ibs 454 kg Platform extended Platform only 700 Ibs 318 kg Platform extended
20. ed personnel should be permitted to operate a machine If more than one operator is expected to use a machine at different times in the same work shift they must all be qualified operators and are all expected to follow all safety rules and instructions in the operator s safety and responsibilities manuals That means every new operator should perform a pre operation inspection function tests and a workplace inspection before using the machine Emergency Stop Push in the red Emergency Stop button to the off position at the ground controls or the platform controls to stop all functions Repair any function that operates when either red Emergency Stop button is pushed in Part No 82750 Genie GS 2668 DC and Genie GS 3268 DC 21 Operator s Manual Third Edition Third Printing OPERATINGINSTRUCTIONS Auxiliary Lowering Machines equipped with a separate auxiliary lowering button next to the ground control panel 2 Pullout the ground red Emergency Stop button to the on position 1 Turn the key switch to ground control 3 Pushand hold the auxiliary lowering button Machines not equipped with a separate auxiliary lowering button 1 Turn the key switch to ground control 2 Pullout the ground red Emergency Stop button to the on position 3 Push and hold the function enable button 4 Activate the platform down function Operation From Ground 1 Turn the key switch to ground control 2 Pullout both ground an
21. el Power to Charger 115V Label Air Line to Platform Label Transport Tie down Cosmetic 4 x 2 Cosmetic Genie GS 2668 DC Cosmetic Genie GS 3268 DC Platform Control Panel Ground Control Panel Danger Safety Chock Genie GS 2668 DC and Genie GS 3268 DC Quantity i 3 3 2 Part No 82476 82481 82482 82487 82495 82560 82562 82751 82752 82753 82748 82749 82924 97719 Third Edition Third Printing Description Danger Electrocution Hazard Danger Battery Safety Label Auxiliary Lowering Label Read the Manual Danger Brake Release Safety amp Operating Instructions Warning Skin Injection Hazard Danger Crushing Hazard Danger Max Capacity 567 kg GS 2668 RT amp DC Danger Max Capacity 454 kg GS 3268 RT amp DC Danger Max Side Force 890 N Label Wheel Load GS 2668 DC Label Wheel Load GS 3268 DC Caution Component Damage Label Safety Arm Quantity 2 4 4 Part No 82750 Third Edition Third Printing Operator s Manual
22. ents wiring and electrical cables Hydraulic power unit tank hoses fittings cylinders and manifolds Battery pack and connections Drive motors Wear pads Tires and wheels Limit switches alarms and horn Nuts bolts and other fasteners Platform entry gate Beacon and alarms if equipped Brake release components Safety arm Third Edition Third Printing LG Platform extension LJ Scissor pins and retaining fasteners Li Platform control joystick LG Inverter if equipped Check entire machine for LG Cracks in welds or structural components Li Dents or damage to machine LG Be sure that all structural and other critical components are present and all associated fasteners and pins are in place and properly tightened LG Be sure side rails are installed and snap pins and bolts are fastened Li Be sure that the chassis trays are in place latched and properly connected Genie GS 2668 DC and Genie GS 3268 DC Part No 82750 Third Edition Third Printing Operator s Manual Observe and Obey M Only routine maintenance items specified in this manual shall be performed by the operator M Scheduled maintenance inspections shall be completed by qualified service technicians according to the manufacturer s specifications and the requirements specified in the responsibilities manual Maintenance Symbols Legend The following symbols have been used in this manual to help communicate the intent of the instruct
23. form retracted Length platform extended Maximum load capacity Wheelbase Turning radius outside Turning radius inside Ground clearance Weight Gradeability Airborne noise emissions 38 ft 32 ft 97 in 691 2 in 511 2 in 40 in 68 in 105 in 165 in 1000 Ibs 73 in 145 in 60 in 71 2 in GS 3268 DC 11 8 m 9 8 m 2 46 m 1 77 m 1 31 m 1 02 m 1 73 m 2 67 m 4 19 m 454 kg 1 85 m 3 68 m 1 52 m 19 cm See Serial Plate Machine weights vary with option configurations 25 80 dB Maximum sound level at normal operating workstations A weighted Power source Controls AC outlet in platform 8 Batteries 225AH Proportional standard Operator s Manual C gt SPECIFICATIONS Maximum hydraulic pressure 3500 psi 241 bar functions System voltage 48V Tires size Platform dimensions 23 x 10 5 x 360 Platform length x width 99 in x 61 in 2 5X1 5m Platform extension length 60 in 1 5m Drive speeds Stowed maximum 3 3 mph 5 3 km h Platform raised maximum 0 5 mph 0 8 km h AO ft 54 6 sec 12 2 m 54 6 sec Floor Loading Information GVW Rated Load 8580 Ibs 3892 kg Axle load maximum 3940 lbs 1787 kg Wheel load maximum 1970 lbs 893 kg Localized pressure per tire 82 psi 5 78 kg cm 566 kPa Occupied pressure 173 psf 8 29 kPa Note Floor loading information is approximate and does not incorporate different option configurations It should be used only with adequate safe
24. h the platform controller Do not stand in the platform 41 Fully lower the platform 42 Drive both wheels on one side onto a 4 inch 10 cm block or onto a curb 43 Raise the platform approximately 8 feet 2 4 m from the ground Result The platform should stop and the tilt alarm will sound at 180 beeps per minute 44 Push the drive select button 45 Move the drive control handle in the direction indicated by the blue arrow then move the drive control handle in the direction indicated by the yellow arrow Result The drive function should not work in either direction 46 Lower the platform and drive the machine off the block Genie GS 2668 DC and Genie GS 3268 DC 19 Operator s Manual Third Edition Third Printing Workplace Inspection Do Not Operate Unless M You learn and practice the principles of safe machine operation contained inthis operator s manual 1 Avoid hazardous situations 2 Always perform a pre operation inspection 3 Always perform function tests prior to use 4 Inspectthe workplace Know and understand the workplace inspection before going on to the next section 5 Only use the machine as it was intended Fundamentals The workplace inspection helps 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 lt is the operator s responsibility to read and re
25. hassis tie points and the path is clear of all obstructions 3 Before serial number 43180 Turn the brake release knob counterclockwise to open the brake valve After serial number 43179 Push in the brake release knob to open the brake valve 4 Pump the brake release pump knob After the machine is loaded 1 Chock the wheels to prevent the machine from rolling 2 Before serial number 43180 Turn the brake release knob clockwise to reset the brakes After serial number 43179 Press and hold the function enable switch on the control handle Move the control handle off center to reset the brakes Towing the Genie GS 2668 DC or the Genie GS 3268 DC is not recommended If the machine must be towed do not exceed 2 mph 3 2 km h Genie GS 2668 DC and Genie GS 3268 DC 25 Operator s Manual Third Edition Third Printing TRANSPORT AND LIFTING INSTRUCTIONS Center of gravity X Axis Y Axis GS 2668 DC 34 4 in 25 8 in 87 4 cm 65 5 cm GS 3268 DC 33 3 in 27 3 in 84 6 cm 69 3 cm Observe and Obey M Only qualified riggers should rig and lift the machine M 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 Be sure the extension deck controls and covers are secure Remove all loose items on the machine Determine the center of gravity of your machine using
26. he Emergency Stop 6 Pushin the ground red Emergency Stop button to the off position Result No functions should operate 7 Pull out the red Emergency Stop button to the on position Test the Up Down Functions The descent alarm and the motion alarm sound at 60 beeps per minute and sound at the chassis The alarm that goes off when the machine is not level sounds at 180 beeps per minute and sounds at the chassis and in the platform 8 Donothold the function enable button Activate the platform up function Result No function should operate 9 Push and hold the function enable button and activate the platform up function Result The platform should raise 16 Genie GS 2668 DC and Genie GS 3268 DC 10 Push and hold the function enable button and activate the platform down function Result The platform should lower The descent alarm should sound while the platform is lowering 34 11 Push and hold the function enable button and activate the platform up function Raise the platform approximately 2 feet 60 cm Test the Auxiliary Lowering To test machines equipped with a separate auxiliary lowering button next to the ground control panel perform steps 11 through 13 For machines that are not equipped with a separate button skip to step 14 12 Push and hold the auxiliary lowering button Result The platform should lower The descent alarm will not sound 13 Turn the key switch to
27. ine operation contained inthis operator s manual 1 Avoid hazardous situations 2 Always perform apre operation inspection 3 Always perform function tests prior to use Know and understand the function tests before going on to the next section 4 Inspect the workplace 5 Only use the machine as it was intended Part No 82750 Genie GS 2668 DC and Genie GS 3268 DC 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 A malfunctioning machine must never be used If malfunctions are discovered the machine must be tagged and removed from service Repairs to the machine may only be made by a qualified service technician according to the manufacturer s specifications After repairs are completed the operator must perform a pre operation inspection and function tests again before putting the machine into service 15 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 Pullout the platform and ground red Emergency Stop buttons to the on position 4 Turnthe key switch to ground control LES 5 Observe the diagnostic LED readout Result The LED should look like the picture at right Test t
28. ions 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 Part No 82750 Maintenance 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 changes in oil level that might indicate the presence of hydraulic system problems Perform this procedure with the platform in the stowed position 1 Visually inspect the sight gauge located on the side of the hydraulic tank Result The hydraulic oil level should be within the top 2 inches 5 cm of the sight gauge 2 Add oil if necessary Do not overfill Hydraulic oil specifications Hydraulic oil type Chevron Rykon Premium MV equivalent Genie GS 2668 DC and Genie GS 3268 DC 13 Operator s Manual Third Edition Third Printing MAINTENANCE Check the Batteries 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 AWARNING AWARNING This procedure does not need to be performed on machines with sealed or maintenance free batteries Electrocution h
29. member the workplace hazards then watch for and avoid them while moving setting up and operating the machine 20 Genie GS 2668 DC and Genie GS 3268 DC Workplace Inspection Be aware of and avoid the following hazardous situations drop offs or holes bumps floor obstructions or debris sloped surfaces unstable or slippery surfaces overhead obstructions and high voltage conductors hazardous locations inadequate surface support to withstand all load forces imposed by the machine wind and weather conditions the presence of unauthorized personnel other possible unsafe conditions Part No 82750 Third Edition Third Printing Operator s Manual Operating Instructions Do Not Operate Unless M You learn and practice the principles of safe machine operation contained inthis operator s manual 1 Avoid hazardous situations 2 Always perform apre operation inspection 3 Always perform function tests prior to use 4 Inspect the workplace 5 Only use the machine as it was intended 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 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 authoriz
30. n 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 nuts are properly tightened and lock plates are properly 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 tie the platform to adjacent structures 4 Genie GS 2668 DC and Genie GS 3268 DC Do not place loads outside the platform perimeter Do not use batteries that weigh less than the original equipment Batteries are used as counterweight and are critical to machine stability Each battery must weigh 65 pounds 29 5 kg Fall Hazards The guard rail system provides fall protection If occupants of the platform are required to wear personal fall protection equipment PFPE due to job site or employer rules PFPE equipment and its use shall be in accordance with the PFPE manufacturer s instructions and applicable governmental requirements Do not sit stand or climb on the platform guard rails Maintain a firm footing on the platform floor at all times D i S i Wozy Do not climb down from the platform when raised Keep the platform floor clear of debris Close the entry gate before operating Do not operate the machine unless the guard rails are properly installed and the entry is secured for operation Part No 82750 Third Edition Third
31. orm guard rails to fall 6 Genie GS 2668 DC and Genie GS 3268 DC Decal Legend Genie product decals use symbols color coding and signal words to identify the following Safety alert symbol used to alert personnel to potential personal injury hazards Obey all safety messages that follow this symbol to avoid possible injury or death Red used to indicate the A DANGER presence of an imminently hazardous situation which if not avoided will result in death or serious injury AWARNING Orange used to indicate the presence of a potentially A hazardous situation which if not avoided could result in death or serious injury Yellow with safety alert symbol ACAUTION used to indicate the presence of a A potentially hazardous situation which if not avoided may cause minor or moderate injury Yellow without safety alert symbol used to indicate the presence of a potentially hazardous situation which if not avoided may result in property damage CAUTION Green used to indicate operation or maintenance information Part No 82750 Third Edition Third Printing Operator s Manual Battery Safety Burn Hazards Batteries contain acid Always wear protective clothing and eye wear when working with batteries Avoid spilling or contacting battery acid Neutralize battery acid spills with baking soda and water Do not expose the batteries or the charger to water or rain Explosion H
32. ould move in the direction that the blue arrow points on the control panel then come to an abrupt stop 33 Press and hold the function enable switch 34 Slowly move the control handle in the direction indicated by the yellow arrow on the control panel until the machine begins to move then return the handle to the center position Result The machine should move in the direction that the yellow arrow points on the control panel then come to an abrupt stop Note The brakes must be able to hold the machine on any slope it is able to climb Part No 82750 Third Edition Third Printing Operator s Manual Test Limited Drive Speed 35 Press the lift function select button 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 38 Press the drive function select button 39 Press and hold the function enable switch on the control handle 40 Slowly move the control handle to the full drive position Result The maximum achievable drive speed with the platform raised should not exceed 0 73 feet 22 cm per second If the drive speed with the platform raised exceeds 0 73 feet 22 cm per second immediately tag and remove the machine from service Part No 82750 FUNCTION TESTS Test the Tilt Sensor Operation Note Perform this test from the ground wit
33. platform control and go to step 17 Machines not equipped with a separate auxiliary lowering button 14 Push and hold the function enable button and activate the platform up function Raise the platform approximately 2 feet 60 cm 15 Push and hold the function enable button Activate the down function Result The platform should lower The descent alarm will not sound 16 Turn the key switch to platform control Part No 82750 Third Edition Third Printing Operator s Manual At the Platform Controls Test Emergency Stop 17 Push in the platform red Emergency Stop button to the off position 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 Testthe Horn 19 Push the horn button Result The horn should sound Test the Function Enable Switch 20 Do not hold the function enable switch on the control handle 21 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 Part No 82750 FUNCTION TESTS Test the Up Down Functions 22 Press the lift function select button 23 Press and hold the function enable switch on the control handle 24 Slowly move the control handle in the direction indicated by the blue arrow Result The platform should raise 25 Release the control handle
34. the appropriate inspection to verify that all decals are legible and in place Part No 25994 28164 28171 28174 28175 28176 28235 28236 31060 31508 40434 43091 43617 43618 43619 43658 43696 44220 44255 44736 44980 44981 48727 49911 52070 28 Description Caution Component Damage Notice Hazardous Materials Label No Smoking Label Power to Platform 230V Caution Compartment Access Notice Missing Manuals Label Power to Platform 115V Warning Failure To Read Danger Do Not Alter Limit Switch Notice Power to Charger Label Lanyard Anchorage Danger General Safety Rules Danger Tip over Hazard Label Directional Arrows Label Safety Arm Label Power to Charger 230V Danger Electrocution Hazard Danger Notice Brake Release Safety 8 Operating Instructions Danger Crushing Hazard Danger Tilt Alarm Label Power to Charger 115V Label Air Line to Platform Danger Battery Safety Notice Max Capacity 1250 lbs 567 kg GS 2668 DC Notice Tire Specifications Genie GS 2668 DC and Genie GS 3268 DC Quantity 1 1 1 Part No 52431 92475 92494 92673 92674 52682 52802 52803 52966 65052 62061 62062 72970 18673 82239 82261 82263 82270 82273 82366 82482 82557 82558 82559 82561 82748 82749 97712 Description Quantity Label Ground Control Panel 1 Label Transport Tie down 4 Caution Crushing Hazard Rails Notic
35. the table and the picture on this page Attach the rigging only to the designated lifting points on the machine There are two lifting points on each end of the machine Adjust the rigging to prevent damage to the machine and to keep the machine level 26 Genie GS 2668 DC and Genie GS 3268 DC Part No 82750 Third Edition Third Printing Operator s Manual Securing to Truck or Trailer for Transit Retract and secure the extension deck Turn the key switch to the off positlon and remove the key before transporting Inspect the entire machine for loose or unsecured items TRANSPORT ANDLIFTINGINSTRUCTIONS Use chains or straps of ample load capacity Use a minimum of 2 chains or straps Adjust the rigging to prevent damage to the chains If the railings have been folded down secure them with straps before transporting Part No 82750 Genie GS 2668 DC and Genie GS 3268 DC 27 Operator s Manual Third Edition Third Printing Decals inspection for Decals with Words Determine whether the decals on your machine have words or symbols Use
36. ty factors Continuous improvement of our products is a Genie policy Product specifications are subject to change without notice or obligation Part No 82750 Genie GS 2668 DC and Genie GS 3268 DC 33 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 G rmany Phone 49 0 4202 88520 Fax 49 0 4202 8852 20 Genie U K Phone 44 0 1476 584333 Fax 44 0 1476 584334 Genie Mexico City Phone 52 55 5666 5242 Fax 52 55 5666 3241 Genie North America 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 China Phone 86 21 53852570 Fax 86 21 53852569 Genie Malaysia Phone 65 98 480 775 Fax 65 67 533 544 Genie Japan Phone 81 3 3453 6082 Fax 81 3 3453 6083 Genie Korea Phone 82 25 587 267 Fax 82 25 583 910 Genie Brasil Phone 55 11 41 665 755 Fax 55 11 41 665 754 Genie Holland Phone 31 183 581 102 Fax 31 183 581 566
37. uctions After Each Use 1 Select a safe parking location firm level surface clear of obstructions and traffic 2 Lowerthe platform 3 Turn the key switch to the off position and remove the key to secure from unauthorized use 4 Chock the wheels 5 Chargethe batteries Genie GS 2668 DC and Genie GS 3268 DC 23 Operator s Manual Third Edition Third Printing OPERATING INSTRUCTIONS Battery and Charger Instructions Observe and Obey M Do not use an external charger or booster battery M Charge the battery in a well ventilated area M Use proper AC input voltage for charging as indicated on the charger M Use only a Genie authorized battery and charger To Charge Battery 1 Be sure the batteries are connected before charging the batteries 2 Open the battery compartment The compartment should remain open for the entire charging cycle 3 Remove the battery vent caps and check the battery acid level If necessary add only enough distilled water to cover the plates Do not overfill prior to the charge cycle 4 Replace the battery vent caps 5 Connect the battery charger to a grounded AC circuit 6 The charger will indicate when the battery is fully charged 7 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 24 Genie GS 2668 DC and Genie GS 3268 DC Dry Battery Filling and Charging Instr
38. uctions 1 Remove the battery vent caps and permanently remove the plastic seal from the battery vent openings 2 Fill each cell with battery acid electrolyte until the level is sufficient to cover the plates Do not fill to maximum level until the battery charge cycle is complete Overfilling can cause the battery acid to overflow during charging Neutralize battery acid spills with baking soda and water 3 Install the battery vent caps 4 Charge the battery 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 Part No 82750 Third Edition Third Printing Operator s Manual Transport and Lifting Instructions Observe and Obey M Common sense and planning must be applied to control the movement of the machine when lifting it with a crane or forklift M The transport vehicle must be parked on a level surface M The transport vehicle must be secured to prevent rolling while the machine is being loaded M Be sure the vehicle capacity loading surfaces and chains or straps are sufficient to withstand the machine weight See the serial plate for the machine weight VI The machine must be on a level surface or secured before releasing the brakes Part No 82750 Brake Release Operation a 1 Chock the wheels to prevent the machine from rolling 2 Be sure the winch line is properly secured to the drive c
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