Genie GS-69 Series - User Manual

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SAFETY NOTICE

110008

Terex Aerial Work Platform, 18340 NE 76th Street Redmond WA 98052, Ph: 800-536-1800, 425-881-1800

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Date: November 17, 2011

Models GS-2669

GS-3369

GS-4069

Serial Numbers Affected: GS6911-101 to GS6912-412

Subject: Machine Instability

Allowable Hours: 1 hour

Issue:

Genie has determined that some of the machines in the serial range listed above may have been

manufactured incorrectly in the following ways:

• The hydraulic circuit in the oscillation system may have been assembled incorrectly causing

the oscillating axles to function improperly. Improperly functioning oscillating axles can

result in loss of machine stability.

• Axle pivot pins that are out of specifications may have been installed, allowing the axles to

be partially supported. Axles that are partially supported can result in loss of machine

stability.

Action Required:

This notice requires the removal of all affected machines from service until the following

actions are completed:

• Rewiring and replumbing of the oscillate system

• Inspection of the axle pivot pins

1. Locate all machines within the model and serial numbers given above.

2. Inspect the axle pivot pins and oscillate system using the enclosed instructions.

3. Fill out and sign the Completion Form included in the Inspection and Repair instructions and

return to Genie. This will verify that this safety notice has been completed on your machine.

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The Genie GS-69 RT Models, specifically the GS-2669, GS-3369, and GS-4069, are aerial work platforms designed for various elevated work applications. This document, Safety Notice 110008, addresses critical safety concerns related to machine instability in certain serial ranges (GS6911-101 to GS6912-412) manufactured between November 17, 2011, and the date of this notice. The primary function of these machines is to provide a stable and elevated platform for workers and their tools.

Function Description:

The Genie GS-69 RT models are rough terrain scissor lifts, meaning they are designed to operate on uneven or challenging ground conditions. A key feature enabling this is the oscillation system, which allows the axles to articulate and maintain tire contact with the ground, thereby enhancing stability. The platform can be raised and lowered to various heights, providing access to elevated work areas. The machine is controlled from both ground and platform control boxes, offering flexibility in operation. Emergency stop buttons are present at both control locations for immediate shutdown in hazardous situations.

Important Technical Specifications:

The safety notice highlights two critical areas that, if improperly manufactured, can lead to machine instability:

Hydraulic Circuit in the Oscillation System: The hydraulic circuit is responsible for controlling the oscillating axles. An incorrectly assembled circuit can cause the axles to function improperly, directly impacting machine stability.
Axle Pivot Pins: These pins are crucial for supporting the axles. If they are out of specification, the axles may be only partially supported, again leading to a loss of stability. The inspection procedure specifies a critical measurement for the pivot pin: the distance from the chassis bulkhead to the tapered end of the pivot pin towards the center of the machine must be 0.250 inches / 6.35 mm or greater. If it is less, the pin is out of specification.

The platform can be raised to approximately 10 ft / 3 m for certain inspection procedures and between 7 ft / 213 cm to 9 ft / 274 cm for elevated oscillation system testing.

Usage Features:

The machines are designed for operation from both ground and platform controls. The key switch allows selection between these control modes. Emergency stop buttons are a standard safety feature, requiring activation (pulled out) for operation and deactivation (pushed in) for emergency shutdown. The oscillation system is a vital operational feature for maintaining stability on rough terrain. The operator's manual provides detailed instructions for function tests, which are crucial for safe operation.

Maintenance Features:

This safety notice itself is a critical maintenance directive. It mandates the removal of affected machines from service until specific actions are completed, emphasizing the importance of proactive maintenance for safety.

The required maintenance actions include:

Rewiring and Replumbing of the Oscillate System: This involves correcting any errors in the hydraulic circuit and electrical wiring related to the oscillation system. The inspection procedure details checking the white/black wire from connector J2 pin C9 and the white wire from connector J2 pin C8 to the terminal strip in the ground control box. It also involves verifying the continuity of the 3-pin and 4-pin connector harnesses for the oscillate limit switches. If continuity issues are found, swapping harnesses between the non-steer and engine sides of the machine is a troubleshooting step.
Inspection of the Axle Pivot Pins: This involves a precise measurement of the pivot pins at both the non-steer and steer ends of the machine. If the measurement is less than 0.250 inches / 6.35 mm, the pins are out of specification and require replacement. Genie's parts department must be contacted for a replacement pin kit, referencing Safety Notice 110008.

Daily/Every 8-Hour Procedure:

Genie specifications require a daily or every 8-hour test of the oscillate system, whichever comes first. This test is crucial for ensuring proper axle oscillation and machine stability. The test involves:

Stowed Position Test: Driving the left front wheel and then the right steer tire up onto a 4 in / 10 cm high ramp. In both cases, the three remaining tires should stay in firm contact with the ground.
Elevated Position Test: Raising the platform between 7 ft / 213 cm and 9 ft / 274 cm and repeating the ramp test. If the oscillate system does not operate as stated, further investigation of wiring, limit switches, and hydraulic hoses is required.

Safety Precautions:

The document emphasizes several safety precautions:

Procedures must be completed by trained and qualified personnel.
Damaged or malfunctioning machines must be immediately tagged and removed from service.
All machine damage or malfunction must be repaired before operation.
Operators must read, understand, and obey safety rules and operating instructions from the operator's manual.
All necessary tools and parts must be available before starting work.
Attempting shortcuts may produce hazardous conditions.
A specific warning is given regarding hydraulic oil: "Bodily injury hazard. Spraying hydraulic oil can penetrate and burn skin. Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually. Do not allow oil to squirt or spray."

Documentation and Warranty:

Completion of the safety notice requires filling out a "Completion Form" and submitting it to Genie's Warranty department. This form verifies that the specified modifications and inspections have been performed and is necessary for warranty claims. Labor for inspection and installation is covered under warranty at a rate of $60.00 U.S. per hour, and travel is reimbursed at $.50 U.S. per mile. Owners of affected machines who are not authorized Genie dealers are instructed to contact their nearest Genie dealer for assistance. Genie and ANSI regulations require sellers to report the model, serial number, and new owner information within 60 days of sale, and manufacturers' safety notices must be completed.