Genie GS-2632, CE, GS-2032, 82784 User Manual

Operator’s Manual

with Maintenance Information

CE Models

Second Edition

Second Printing

Part No. 82784

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

Safety ........................................................................ 1

Legend ....................................................................... 9

Controls .................................................................... 10

Pre-operation Inspection ........................................... 12

Maintenance ............................................................. 14

Function Tests.......................................................... 16

Workplace Inspection................................................ 21

Operating Instructions............................................... 22

Transport Instructions ............................................... 27

Decals ...................................................................... 28

Specifications ........................................................... 30

Internet: http://www.genielift.com e-mail: techpub@genieind.com

Genie Industries in the U.S.A. and many other countries. "GS" is a trademark of Genie Industries.

These machines comply with ANSI/SIA 92.6-1999.

Printed on recycled paper

Printed in U.S.A.

Genie GS-2032 and Genie GS-2632 Part No. 82784

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Operator's Manual

Safety Rules

Danger

Failure to obey the instructions and safety rules in this manual will result in death or serious injury.

Do Not Operate Unless:

You learn and practice the principles of safe

machine operation contained in this operator's manual.

1 Avoid hazardous situations. Know and understand the safety rules

before going on to the next section.

2 Always perform a pre-operation inspection. 3 Always perform function tests prior to use. 4 Inspect the workplace. 5 Only use the machine as it was intended.

You read, understand and obey the

manufacturer's instructions and safety rules— safety and operator's manuals and machine decals

You read, understand and obey employer's

safety rules and worksite regulations

You read, understand and obey all applicable

governmental regulations

You are properly trained to safely operate the

machine.

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SAFETY RULES

Electrocution Hazards

This machine is not electrically insulated and will not provide protection from contact with or

proximity to electrical current.

Maintain safe distances from electrical power lines and apparatus in accordance with applicable governmental regulations and the following chart.

Voltage Minimum Safe Phase to Phase Approach Distance

Meters

0 to 300V Avoid Contact

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.

300V to 50KV 3.05 50KV to 200KV 4.60 200KV to 350KV 6.10 350KV to 500KV 7.62 500KV to 750KV 10.67 750KV to 1000KV 13.72

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SAFETY RULES

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 6 m 363 kg

4.75 m 520 kg

3.5 m 677 kg

2.25 m 520 kg 1 m 363 kg

Maximum capacity - GS-2632

Height of Platform Maximum Capacity

7.9 m 227 kg

6.2 m 367 kg

Do not raise the platform unless the machine is on a firm, level surface.

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 sounds when the platform is raised, use extreme caution to lower the platform.

Do not alter or disable the limit switches. Do not drive over 0.7 km/h with the platform raised.

4.5 m 508 kg

2.7 m 367 kg 1 m 227 kg

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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-offs.

Do not push off or pull toward any object outside of the platform.

Maximum allowable manual force

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.

Do not transport tools and materials unless they are evenly distributed and can be safely handled by person(s) in the platform.

Do 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 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.

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

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Operator's Manual

SAFETY RULES

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.

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.

Do not climb down from the platform when raised. Keep the platform floor clear of debris.

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.

Part No. 82784 Genie GS-2032 and Genie GS-2632 5

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.

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

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.

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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.

Second Edition • Second Printing

Operator's Manual

SAFETY RULES

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.

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.

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 presence of an imminently hazardous situation which, if not avoided, will result in death or serious injury.

Orange—used to indicate the presence of a potentially hazardous situation which, if not avoided, could result in death or serious injury.

Yellow with safety alert symbol— used to indicate the presence of 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.

Green—used to indicate operation or maintenance information.

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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

Keep sparks, flames and lighted tobacco away from batteries. Batteries emit an explosive gas.

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.

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 30 kg.

Lifting Hazard

Use the appropriate number of people and proper lifting techniques when lifting batteries.

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.

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Operator's Manual

Legend

1 Platform entry chain or entry

gate 2 Platform entry rail 3 Platform guard rails 4 Lanyard anchorage point 5 Manual storage container 6 Platform controls 7 GFCI outlet 8 Platform extension

Part No. 82784 Genie GS-2032 and Genie GS-2632 9

9 Platform extension release

pedal 1 0 Tilt alarm (under cover) 11 Transport tie-down 1 2 Steer tire 13 Ground controls 1 4 Auxiliary lowering knob or

button or switch 1 5 LED diagnostic readout 1 6 Hydraulic oil level indicator

17 Pothole guard 18 Non-steer tire 19 Entry ladder/transport

tie-down 20 Battery charger 21 Brake release pump knob 22 Brake release knob 23 Safety arm

+ 23 hidden pages