Genie 82784 Utility Vehicle User Manual
Contents
1. 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 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 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 Part No 82784 SAFETY RULES 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 hazard2. r Second Edition Operator S Manual Second Printing with Maintenance Information Part No 82784 GS 2032 GS 2632 CE Models Operator s Manual Second Edition Second 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 call Genie Industries Contents Page of TEE EEE AE ee eee en da 1 ECO CNG O WO PER CO 9 CONTOS auroro E EE EE 10 Pre operation Inspection cseeceeeeeeeeeseeeeeeeeneeeesees 12 Maintenance wora ORA O W Z cia 14 Function Tests uniesienie dc taa 16 Workplace Inspection esaaa aaa aaa a aaaaaazanaananai 21 Operating Instructions cccccceeeeeeeeeeeeeeeeeeeeeeeeeeaes 22 Transport Instructions esaaae ea aaa a aaaaaazanaananii 27 DOC sara a endi 28 SDSCIICATIONS 6 cui waayd cay wok EA 30 Contact us Internet http www genielift com e mail techpub genieind com Genie GS 2032 and Genie GS 2632 Copyright 1997 by Genie Industries First Edition Seventeenth Printing October 2002 Second Edition Second Printing March 2004 Genie is a registered trademark of Genie Industries in the U S A and many other countries GS is a trademark of Genie Industrie
3. 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 Turn the key switch to ground control 5 Observe the diagnostic LED readout Result LED should read 23 or Test Emergency Stop 6 Pushin the ground red Emergency Stop button to the off position Result No functions should operate 7 Pullout the red Emergency Stop button to the on position Test the Up Down Functions The audible warnings on this machine and the standard horn all come from the same central alarm The horn is a constant tone The descent alarm sounds at 60 beeps per minute The alarm that goes off when the pothole guards have not deployed sounds at 300 beeps per minute The alarm that goes off when the machine is not level sounds at 600 beeps per minute An optional automotive style horn is also available 8 Activate the up function Result The platform should raise 9 Activate the down function Result The platform should lower The descent alarm should sound while the platform is lowering Part No 82784 FUNCTION TESTS Test Auxiliary Lowering Manual Lowering 10 Activate the up function and raise the platform approximately 60 cm 11 Activate the auxiliary lowering manual lowering function Move the toggle switch OR pull the knob OR push the button Result The platform should lower The descent alarm will not sound 12 Tu
4. Height stowed maximum Rails off Height guard rails CE Width Length stowed Length platform extended Maximum load capacity varies with height of platform Wheelbase Turning radius outside Turning radius inside Ground clearance Ground clearance Pothole guards deployed Weight GS 2032 8 1 m 6 1m 2 1m 1 94 m 99 cm 1 1m 81 3 cm 2 44 m 3 44 m 363 677 kg 1 85 m 2 34 m 0 cm 10 2 cm 2 2 cm See Serial Plate Machine weights vary with option configurations Gradeability Airborne noise emissions 30 lt 0 dB Maximum sound level at normal operating workstations A weighted Power source Controls 4 Batteries 6V 225AH Proportional AC outlet in platform Maximum hydraulic pressure functions Tires size Platform dimensions Length x width Platform extension length Drive speeds Stowed maximum Platform raised maximum Floor Loading Information GVW Rated Load Axle load maximum Wheel load maximum Localized pressure per tire Occupied pressure standard 241 3 bar 15x5x111 4 2 26 m x 79 4 cm 99 cm 3 5 km h 0 8 km h 12 2 m 54 5 sec 1952 kg 1111 kg 555 kg 8 62 kg cm 845 kPa 10 42 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 a
5. 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 82784 Second Edition Second Printing Operator s Manual Transport 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 MI 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 M The machine must be on a level surface or secured before releasing the brakes Securing to Truck or Trailer for Transit Turn the key switch to the off positlon and remove the key before transporting Inspect the entire machine for loose or unsecured items 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 Part No 82784 Brake Release Operation 1 Chock the wheels to prevent the machine from rolling 2 Be sure the winch line is properly secured to the drive chassis tie points and the path is clear of all obstructions 3 Turn the brake release knob counterclockwis
6. 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 2032 and Genie GS 2632 15 Operator s Manual Second Edition Second Printing 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 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 After repairs are completed the operator must 2 Always perform a pre operation inspection perform a pre operation inspection and function 3 Always perform function tests prior to tests again before putting the machine into service 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 16 Genie GS 2032 and Genie GS 2632 Part No 82784 Second Edition Second Printing Operator s Manual 1 Select a test area that is firm level and free of obstruction
7. not place ladders or scaffolds in the platform or against any part of this machine Do not modify or alter an aerial work platform without prior written permission from the manufacturer Mounting attachments forholding 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 Part No 82784 Second Edition Second Printing Operator s Manual Do not replace items critical to machine stability with items of different weight or specification 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 cotter pins are properly installed 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 30 kg 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 Do not place loads outside the platform perimeter Do not operate the machine with the chassis trays open 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 platfo
8. this 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 authorized 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 22 Genie GS 2032 and Genie GS 2632 Part No 82784 Second Edition Second Printing Operator s Manual 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 Auxiliary Lowering M
9. 2731 kg 1696 kg 848 kg 13 15 kg cm2 1289 kPa 14 57 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 Part No 82784 Genie GS 2032 and Genie GS 2632 31 Genie Scandinavia Phone 46 31 3409612 Fax 46 31 3409613 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 10 220 7911 Fax 31 10 220 6642
10. 7 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 38 Lower the platform and remove both pieces of wood Genie GS 2032 and Genie GS 2632 19 Operator s Manual Second Edition Second Printing FUNCTION TESTS Test the Pothole Guards Note The pothole guards should automatically deploy when the platform is raised The pothole guards activate two limit switches which control the machine drive speed If the pothole guards do not deploy and the platform is raised above 1 8 m an alarm sounds and the machine will not drive 39 Raise the platform Result When the platform is raised 1 2 m from the ground the pothole guards should deploy 40 Press on the pothole guards on one side and then the other Result The pothole guards should not move 41 Lower the platform Result The pothole guards should return to the stowed position 42 Place a 2x4 or similar piece of wood under a pothole guard Raise the platform Result Before the platform is raised 2 1 m from the ground an alarm should sound and the drive function should not work 43 Lower the platform and remove the 2x4 20 Genie GS 2032 and Genie GS 2632 Part No 82784 Second Edition Second Printing Operator s Manual Workplace Inspection Workplace Inspection
11. Be aware of and avoid the following hazardous situations 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 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 remember the workplace hazards then watch for and avoid them while moving setting up and operating the machine Part No 82784 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 Genie GS 2032 and Genie GS 2632 21 Operator s Manual Second Edition Second Printing Operating Instructions Do Not Operate Unless M You learn and practice the principles of safe machine operation contained in
12. alent Part No 82784 Second Edition Second Printing Operator s Manual Check the Batteries Proper battery condition is essential to good engine performance and operational safety Improper fluid levels or damaged cables and connections can result in engine component damage and hazardous conditions AWARNING AWARNING This procedure does not need to be performed on machines with sealed or maintenance free batteries Electrocution hazard 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 Put on protective clothing and eye wear Be sure that the battery cable connections are tight and free of corrosion Be sure that the battery retaining fasteners are in place and secure Remove the battery vent caps 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 Part No 82784 Install the vent caps MAINTENANCE Scheduled Maintenance Maintenance performed 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
13. anual Lowering 1 Activate the auxiliary lowering manual lowering function Move the toggle switch OR pull the knob OR push the button Operation From Ground 1 Turn the key switch to ground control 2 Pullout both ground and platform red Emergency Stop buttons to the on position 3 Be sure the battery pack is connected before operating the machine To Position Platform 1 Move the up down toggle switch according to the markings on the control panel Drive and steer functions are not available from the ground controls Operation From Platform 1 Turn the key switch to platform control 2 Pulloutthe ground and platform red Emergency Stop buttons to the on position 3 Be sure the battery pack is connected before operatingthe machine OPERATING INSTRUCTIONS To Position Platform Press the lift function select button Press and hold the function enable switch on the control handle Move the control handle according to the markings on the control panel When lowering the platform the platform should stop when it is 2 1 m from the ground Be sure the area below the platform is clear of personnel and obstructions before continuing To continue lowering release the control handle wait 5 seconds then move the control handle again To Steer 4 2 Press the drive function select button Press and hold the function enable switch on the control handle Turn the steer wheels with the thumb rocker switch lo
14. cated on the top of the control handle Part No 82784 Genie GS 2032 and Genie GS 2632 23 Operator s Manual Second Edition Second Printing OPERATING INSTRUCTIONS To Drive 1 Press the drive function select button 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 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 condition will affect machine performance Machine drive speed and function speed will drop when the low battery indicator light is on or when the last light on the battery level indicator is flashing 24 Genie GS 2032 and Genie GS 2632 Error Indicator Light On AL A If the light stays on tag and remove the machine from service If the error indicator light is on push in and pull out the red Emergency Stop button to reset the system Error Indicator Light Flashing ke Pig Push in and pull out the red Emergency Stop button The error indicator light will be off If the error indicator light is flashing the platform is overloaded and no functions will operate An alarm will sound at t
15. ches 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 30 kg Lifting Hazard Use the appropriate number of people and proper lifting techniques when lifting batteries Part No 82784 Second Edition Second Printing Operator s Manual Legend SIS D GD CD G 8 1 Platform entry chain or entry 9 Platform extension release 17 Pothole guard gate pedal 18 Non steertire 2 Platform entry rail 10 Tilt alarm under cover 19 Entry ladder transport 3 Platform guard rails 11 Transporttie down tie down 4 Lanyardanchorage point 12 Steer tire 20 Battery charger 5 Manualstorage container 13 Ground controls 21 Brake release pump knob 6 Platform controls 14 Auxiliary lowering knob or 22 Brake release knob 7 GFCloutlet button or switch 23 Safety arm 8 Platform extension 15 LED diagnostic readout 16 Hydraulic oil level indicator Part No 82784 Genie GS 2032 and Genie GS 2632 9 Operator s Manual Second Edition Second Printing LU Controls CONTROLS Auxili H H loy wo STOP gt GS Om OC O c Hour Meter STOP A Ground Control Panel 3 Red Emergency Stop button 6 Key switch for platform off ground selection 1 Auxiliary lowering manual lowering toggle sw
16. e to open the brake valve 4 Pump the brake release pump knob After the machine is loaded 1 Chockthe wheels to prevent the machine from rolling 2 Turnthe brake release knob clockwise to reset the brakes Towing the Genie GS 2032 or the GS 2632 is not recommended If the machine must be towed do not exceed 3 2 km h Genie GS 2032 and Genie GS 2632 27 Operator s Manual Decals Decal Inspection Use the pictures on the next page to verify that all decals are legible and in place Below is a numerical list with quantities and descriptions Part No Description 28174 Label Power to Platform 230V 28235 Label Power to Platform 115V 40434 Label Lanyard Anchorage 43618 Label Directional Arrows 43658 Label Power to Charger 230V 44980 Label Power to Charger 115V 52475 Label Transport Tie down 62055 Cosmetic Genie GS 2032 65058 Label Controller Indentification 72973 Cosmetic Genie GS 2632 78673 Platform Control Panel 82448 Ground Control Panel 82472 Warning Crushing Hazard 82474 Warning Safety Chock 82476 Danger Electrocution Hazard 82481 Danger Battery Charger Safety 82482 Label Auxiliary Lowering 28 Genie GS 2032 and Genie GS 2632 Quantity N NP lt NP NP O1 N DND D Part No 82487 82488 82495 82497 82502 82560 82562 82690 82691 82778 82779 82786 82956 97582 Second Edition Second Printing Description Notice Operating I
17. ection 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 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 any unauthorized 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 on to 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 12 Genie GS 2032 and Genie GS 2632 Part No 82784 Second Edition Second Printing SSS O SK RCI 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 Be sure that all decals are legible and in place See Decals section Li Check for hydraulic oil leaks and proper oi
18. from electrical power lines and apparatus in accordance with applicable governmental regulations and the following chart 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 Onn w Voltage Minimum Safe Phase to Phase Approach Distance Meters 0 to 300V Avoid Contact 300V to 50KV 3 05 S0KV to 200KV 4 60 200KV to 350KV 6 10 350KV to 500KV 7 62 500KV to 750KV 10 67 750KV to 1000KV 13 72 2 Genie GS 2032 and Genie GS 2632 Part No 82784 Second Edition Second Printing Operator s Manual Tip over Hazards Occupants equipment and materials must not exceed the maximum platform capacity The maximum capacity varies with the height of the platform Maximum capacity GS 2032 Height of Platform Maximum Capacity 6m 363 kg 4 75m 520 kg 3 5 m 677 kg 2 25 m 520 kg 1m 363 kg Maximum capacity GS 2632 Height of Platform Maximum Capacity SAFETY RULES Do not raise the platform unless the machine is on a firm level surface a i Do not depend on the tilt alarm as a level indicator The tilt alarm sounds on the chassis only when the machine is on a slope If the tilt alarm sounds Lower the platform Move the machine to a firm level surface If the tilt alarm s
19. he platform controls Remove weight from the platform If the platform is still overloaded the light will flash again a Drive Select Switch Machine on incline symbol Low range operation for inclines Part No 82784 Second Edition Second Printing Operator s Manual To Extend and Retract Platform 1 Step on the platform extension release pedal on the platform toeboard 2 Grasp the platform guard rails and carefully push to extend the platform to the mid position stop 3 Step on the release pedal again and push to fully extend the platform Do not stand on the platform extension while trying to extend it 4 Step on the platform extension release pedal and pull to retract the platform to the mid position stop Step again to fully retract the platform Part No 82784 OPERATING INSTRUCTIONS 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 After Each Use 1 Select a safe parking location firm level surface clear of obstruction and traffic 2 Lower the platform 3 Turn the key switch to the off position and remove the key to secure from unauthorized use 4 Chock the wheels 5 Charge the batteries Genie GS 2032 and Genie GS 2632 25 Operator s Manual Second Edition Second Printing OPERATINGINSTRUCTIONS Battery and Charger Instruc
20. intenance 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 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 M perform this procedure Indicates that new parts will be required to perform this procedure 14 Genie GS 2032 and Genie GS 2632 Check the Hydraulic Oil Level Maintaining the hydraulic oil at the proper levels 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 oil level in the hydraulic tank through the sight gauge in the side of the power unit module Result The hydraulic oil level should be within the full and add marks 2 Add oil if necessary Do not overfill Hydraulic oil specifications Hydraulic oil type Chevron Rykon Premium MV equiv
21. irection arrows on the platform controls and platform decal plate for drive and steer functions 6 Genie GS 2032 and Genie GS 2632 No stunt driving or horseplay while operating a machine 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 of personnel and any other factors which may cause collision 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 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 Part No 82784 Second Edition Second Printing Operator s Manual Component Damage Hazard Do not use the machine as a ground for welding Explosion and Fire Hazard 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
22. itch or 4 Breaker for electrical circuits knob or button 5 Platform up down toggle 2 Hourmeter switch 10 Genie GS 2032 and Genie GS 2632 Part No 82784 Second Edition Second Printing QO Operator s Manual CONTROLS se Genie s m w Platform Controls 4 2 Part No 82784 Horn button Machine on incline symbol Low speed operation for inclines Lift function select button with indicator light Drive function select button with indicator light Red Emergency Stop button 6 Function enable switch 7 Proportional control handle for lift and drive functions and thumb rocker for steer function 8 Error indicator light 9 Powerlight 10 Battery level indicator Genie GS 2032 and Genie GS 2632 Ome 11 Operator s Manual Second Edition Second Printing 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 operationinspection and routine maintenance The pre operation insp
23. l level Add oil if needed See Maintenance section LG 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 amp GO C E O G 0O 0 O OC C O Electrical components 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 chain if equipped Platform entry gate if equipped Beacon and alarms if equipped Brake release components Safety arm Pothole guards Part No 82784 Genie GS 2032 and Genie GS 2632 13 Operator s Manual PRE OPERATION INSPECTION Platform extension Scissor pins and retaining fasteners Platform control joystick LLU CC Generator if equipped U Counterweight if equipped Check entire machine for Li 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 I Side rails are installed and bolts are fastened Li Be sure that the chassis trays are in place latched and properly connected Operator s Manual Second Edition Second Printing Ma
24. nstructions Notice Error Indicator Light Danger Brake Release Safety amp Operating Instructions Danger Manual Force GS 2032 Label LED Diagnostic Readout Warning Skin Injection Hazard Danger Crushing Hazard Label Wheel Load GS 2032 Label Wheel Load GS 2632 Danger Maximum Capacity GS 2032 Label Capacity Indicator GS 2032 Danger Maximum Capacity GS 2632 Label Capacity Indicator GS 2632 Danger Manual Force GS 2632 Quantity Part No 82784 Second Edition Second Printing Operator s Manual ss DECALS 40434 62055 43618 40434 28174 or 72973 or 28235 82956 or 82779 78673 82487 89778 82488 or 82786 65058 Ground AA Controls Side 40434 43618 gt 62055 82487 82497 ee W or 97582 82476 i Serial plate Es na 82472 52475 FAN T gt 28174 a gt Battery Side Or 82690 82562 or 82691 lt NY 28171 Z 82560 Z 82474 82474 Z 82495 82482 EB 52475 82502 43658 82690 or 82691 82690 8269 52475 or 82691 82481 82476 or 82691 Part No 82784 Genie GS 2032 and Genie GS 2632 29 Operator s Manual Second Edition Second Printing Specifications Model Height working maximum Height platform maximum Height stowed maximum Rails up CE Height stowed maximum Rails lowered
25. ounds when the platform is raised use extreme caution to lower the platform Do not alter or disable the limit switches REM SA Do not drive over 0 7 km h with the platform raised 6 2 m 367 kg 4 5 m 508 kg 2 7m 367 kg 1m 227 kg Part No 82784 Genie GS 2032 and Genie GS 2632 3 Operator s Manual Second Edition Second Printing 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 decrease 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 a stowed position across uneven terrain debris unstable or slippery surfaces and near holes and drop olfs Do not push off or pull toward any object outside of the platform 2 aY o J O Maximum allowable l aw manual force GS 2032 CE Indoor use only 2 person 400 N CE Outdoor use 1 person 200 N GS 2632 CE Indoor use only 2 person 400 N 4 Genie GS 2032 and Genie GS 2632 Do not alter or disable machine components that in any way affect safety and stability Do not place or attach fixed or overhanging loads to any part of this machine w Do not transport tools and materials unless they are evenly distributed and can be safely handled by person s in the platform Do
26. ous 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 Genie GS 2032 and Genie GS 2632 7 Operator s Manual Second Edition Second Printing SAFETY RULES 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 during charging Explosion Hazards 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 8 Genie GS 2032 and Genie GS 2632 Component Damage Hazard Do not use any battery charger greater than 24V 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 wat
27. re subject to change without notice or obligation 30 Genie GS 2032 and Genie GS 2632 Part No 82784 Second Edition Second Printing Operator s Manual Model Height working maximum Height platform maximum Height stowed maximum Height stowed maximum Rails folded Platform height Stowed maximum Height guard rails CE Width Length stowed Length platform extended Maximum load capacity varies with height of platform Wheelbase Turning radius outside Turning radius inside Ground clearance Ground clearance Pothole guards deployed Weight GS 2632 9 9m 7 9 m 2 29 m 1 73 m 1 17 m 1 4m 81 3 cm 2 44 m 3 44 m 227 508 kg 1 85 m 2 34 m 0 cm 10 2 cm 2 2 cm See Serial Plate Machine weights vary with option configurations Gradeability Airborne noise emissions 25 lt 0 dB Maximum sound level at normal operating workstations A weighted Power source Controls 4 Batteries 6V 225AH Proportional AC outlet in platform Maximum hydraulic pressure functions Tires size Platform dimensions Length x width Platform extension length Drive speeds Stowed maximum Platform raised maximum Floor Loading Information GVW Rated Load Axle load maximum Wheel load maximum Localized pressure per tire Occupied pressure SPECIFICATIONS standard 241 3 bar 15x5x111 4 2 26 m x 79 4 cm 99 cm 3 5 km h 0 8 km h 12 2 m 54 5 sec
28. rm using the groundcontrols Part No 82784 Genie GS 2032 and Genie GS 2632 SAFETY RULES 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 da Do not climb down from the platform when raised Keep the platform floor clear of debris Attach the platform entry chain or 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 Operator s Manual Second Edition Second Printing SAFETY RULES 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 Operators must comply with employer job site and governmental rules regarding use of personal protective quipment 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 d
29. rn the key switch to platform control At the Platform Controls Test Emergency Stop 13 Push in the platform red Emergency Stop button to the off position Result No functions should operate Test the Horn 14 Pull the red Emergency Stop button out to the on position 15 Push the horn button Result The horn should sound Genie GS 2032 and Genie GS 2632 17 Operator s Manual Second Edition Second Printing FUNCTION TESTS Test the Function Enable Switch 16 Do not hold the function enable switch on the control handle 17 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 Test the Up Down Functions 18 Press the lift function select button 19 Press and hold the function enable switch on the control handle 20 Slowly move the control handle in the direction indicated by the blue arrow Result The platform should raise The pothole guards should deploy 21 Release the control handle Result The platform should stop raising 22 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 When lowering the platform the platform should stop when it is 2 1 m from the ground Be sure the area below the platform i
30. s These machines comply with ANSI SIA 92 6 1999 g Printed on recycled paper Printed in U S A Part No 82784 Second Edition Second 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 inthis 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 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 82784 Genie GS 2032 and Genie GS 2632 1 Operator s Manual Second Edition Second Printing A SAFETY RULES Electrocution Hazards Allow for platform movement electrical line sway or sag and beware of strong or gusty winds This machine is not electrically insulated and will not provide protection from contact with or proximity to electrical current Maintain safe distances
31. s clear of personnel and obstructions before continuing To continue lowering release the control handle wait 5 seconds then move the control handle again 18 Genie GS 2032 and Genie GS 2632 Test the Steering Note When performing the steer and drive function tests stand in the platform facing the steer end of the machine 23 Press the drive function select switch 24 Press and hold the function enable switch on the control handle 25 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 26 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 Part No 82784 Second Edition Second Printing Operator s Manual Test Drive and Braking 27 Press and hold the function enable switch on the control handle 28 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 should move in the direction that the blue arrow points on the control panel then come to an abrupt stop 29 Slowly move the control handle in the direction indica
32. ted 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 Test Limited Drive Speed 30 Press the lift function select button 31 Press and hold the function enable switch on the control handle Raise the platform approximately 1 2 m from the ground Result The pothole guards should deploy Part No 82784 FUNCTION TESTS 32 Press the drive function select switch 33 Press and hold the function enable switch on the control handle Slowly move the control handle to the full drive position Result The maximum achievable drive speed with the platform raised should not exceed 23 cm per second If the drive speed with the platform raised exceeds 23 Cm per second immediately tag and remove the machine from service Test the Tilt Sensor Operation Note Perform this test from the ground with the platform controller Do not stand in the platform 34 Fully lower the platform 35 Place a 2x4 or similar piece of wood under both wheels on one side and drive the machine up onto them 36 Raise the platform approximately 2 1 m from the ground Result The platform should stop and the tilt alarm will sound at 600 beeps per minute 3
33. tions 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 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 Replace the battery vent caps 5 Connect the battery charger to a grounded AC circuit 6 Turn the battery charger on The charger will indicate when the battery is fully charged 8 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 26 Genie GS 2032 and Genie GS 2632 Dry Battery Filling and Charging Instructions 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
Download Pdf Manuals
Related Search