Genie Lift Guard GS-30, Lift Guard GS-32, Lift Guard GS-47, Lift Guard GS-46 Operator's Manual Supplement
Page 1
Operator's Manual Supplement
Lift Guard
GS™-30
GS™-32
GS™-46
GS™-47
First Edition
First
Part No. 1288739GT
™
Contact Alarm
Printing
Page 2
Page 3
First Edition • First Printing Operator's Manual Supplement
Introduction
Introducti on
Lift Guard Contact Alarm System
The Lift Guard Contact Alarm system is designed
to alert the operator, occupants and ground
personnel to a potential hazard when an
obstruction makes contact with the secondary
guarding system. Machine movement will be
interrupted, an audible alarm sounds and the
beacon lights flash.
After the contact alarm is activated, the operator
can acknowledge the hazard and continue
operating the machine. The operator must release
the function enable switch and return the joystick to
the center position. Functions will resume
operation at reduced speeds allowing the operator
to continue to raise or drive the machine. The
audible alarm and beacons will deactivate when
the red Emergency Stop button is pushed in to the
off position.
Danger
Failure to obey the instructions and safety rules in this manual will result in death or serious injury.
Note: These installation instructions only apply to the Genie models listed below:
GS-1530, GS-1532, GS-1930, GS-1932, GS-2032,
GS-2632, GS-3232, GS-2046, GS-2646, GS-3246,
GS-4047
Part No. 1288739GT Lift Guard™ Contact Alarm 1
Page 4
Operator's Manual Supplement First Edition • First Printing
Standard contact Alarm
configuration weight.
2
Each additional contact alarm
assembly.
3
Read the supplement manual,
part number 1288739GT.
Introduction
Contact Alarm Safety
Read, understand and obey all warnings and
instructions provided with the contact alarm.
Do not exceed the rated platform capacity. The
weight of the contact alarm assembly will reduce
the rated platform capacity and must be subtracted
from the total platform load.
The standard contact alarm configuration weighs
20 lbs/9 kg. Each additional contact alarm
assembly added to the platform weighs 3 lbs/1.4
kg.
Note: The standard configuration consist of two
contact alarm assemblies attached to the platform.
Be sure the contact alarm is securely installed.
When the contact alarm assembly is attached, this
manual should be considered a permanent part of
your machine and should remain with the machine
at all times.
The contact alarm assembly should never be
mounted above the decal plate of the extension
deck or above the platform entry.
Pre-operation Inspection
Be sure that the operator’s, safety manual,
responsibilities manual and any necessary
supplements are complete, legible and in the
storage container located in the platform.
Be sure that all decals are legible and in place.
Check the Contact Alarm for damage, improperly
installed or missing parts and unauthorized
modifications.
Nuts, bolts and other fasteners
Wiring, cables and Contact Alarm
components
Cracks in structural components
Dents or damage to the Contact Alarm
Symbol and Hazard Pictorials Definitions
2 Lift Guard™ Contact Alarm Part No. 1288739GT
0 lbs/9 kg.
lbs/1.4 kg
Page 5
First Edition • First Printing Operator's Manual Supplement
Introduction
Function Test
Note: Perform this procedure from the platform
controls in an area free of obstructions.
1 Activate platform up. Move and hold the
contact alarm in any direction.
Platform up function stops, the beacons flash
and the alarm sounds.
2 While holding the contact alarm, release the
joystick. Activate platform up.
Platform up function resumes at a reduced
speed. The beacons flash and the alarm
sounds.
3 Release the joystick and the contact alarm.
Activate platform up.
Normal platform function speed resumes, the
beacons and alarm turn off.
4 Activate the drive function. Move and hold the
contact alarm in any direction.
Drive function stops, the beacons flash and the
alarm sounds.
5 While holding the contact alarm, release the
joystick. Activate drive.
Drive function resumes at a reduced speed.
The beacons flash and the alarm sounds.
6 Release the joystick and contact alarm.
Activate drive.
Normal drive function resumes, the beacons
and alarm turn off.
Part No. 1288739GT Lift Guard™ Contact Alarm 3
Page 6
Operator's Manual Supplement First Edition • First Printing
Operating Instructions
Operating I nstr ucti ons
Operating Instructions
Contact alarm activated, beacon lights flash and an
audible alarm sounds. Lift and drive functions will
not operate from the platform controls.
Note: The potential hazard must be acknowledged
by the operator to continue operating the machine.
After the potential hazard has been acknowledged,
machine functions will resume operation at
reduced speeds.
Platform Controls Operation
1 Return the joystick to the center position and
release the function enable switch to
acknowledge the potential hazard.
2 Continue machine functions to reach the
working location or to move the machine away
from the potential hazard.
Note: To restore machine functions after the
Contact Alarm has been activated, the machine
must be driven or lowered until the actuator arm is
deactivated. Pushing in the red Emergency Stop
button to the off position will not restore machine
functions, this action will only turn off the Contact
Alarm lights and alarm.
4 Lift Guard™ Contact Alarm Part No. 1288739GT
Page 7
First Edition • First Printing Operator's Manual Supplement
Installation Instructions
Installatio n Ins truc tio ns
Attention:
Observe and Obey:
This procedure shall be completed by a person
authorized to install the Contact Alarm.
Immediately tag and remove from service a
damaged or malfunctioning machine.
Repair any machine damage or malfunction
before operating the machine.
Before Starting Installation:
Read, understand and obey the safety rules
and operating instructions in the appropriate
operator's manual.
Be sure that all necessary tools and parts are
available and ready for use.
Read this procedure completely and adhere to
the instructions. Attempting shortcuts may
produce hazardous conditions.
The Lift Guard™ Contact Alarm can only be
installed on machines with the "Proportional Lift"
control system.
It is not compatible with "2 Speed Lift" control
systems.
Refer to the illustrations to determine which control
system is on the machine.
2 Speed Lift
Proportional Lift
Part No. 1288739GT Lift Guard™ Contact Alarm 5
Page 8
Operator's Manual Supplement First Edition • First Printing
Genie part
Genie part
Installation Instructions
Tools Required:
3/8 inch wrench
7/16 inch wrench
3/8 inch socket
7/16 inch socket
Ratchet
Cable tie gun or wire cutters
Center punch
Deburring tool
17/64 inch / 6,7 mm drill bit
Drill motor
Locking C-Clamp
Torx T10 screwdriver
Cat5 Ethernet Cable
PC or Laptop with an Ethernet Port and Internet
Browser
Contents of Kit 1288736GT
GS-1530 / GS-1532
Description
number
Cable tie, 7.375 inch / 19 cm 6578GT 40
Button cable tie, 14.75 inch / 37,5 cm 56361GT
Cable tie mount, 6.5 inch / 16,5 cm 110149GT
Flange nut, 1/4-20, G, ZAG 824027GT
Screw, HHF, 1/4-20 x .75, 8, ZAG 824078GT
Assembly, lift guard 1287673GT
Harness, GS30 platform 1288570GT
Cable, chassis to platform 1288571GT
Cable, 20 inch link 1288572GT
Harness, ESTOP splice 1288573GT
Cable, 45 inch link 1288574GT
Forming, cable guide 1288732GT
Manual, Supplement 1288739GT
Qty.
Contents of Kit 1288737GT
8
2
4
4
2
1
1
1
1
1
2
1
GS-1930 / GS-1932
Description
Cable tie, 7.375 inch / 19 cm 6578GT 40
Button cable tie, 14.75 inch / 37,5 cm 56361GT
Cable tie mount, 6.5 inch / 16,5 cm 110149GT
Flange nut, 1/4-20, G, ZAG 824027GT
Screw, HHF, 1/4-20 x .75, 8, ZAG 824078GT
Assembly, lift guard 1287673GT
Harness, GS30 platform 1288570GT
Cable, 20 inch link 1288572GT
Harness, ESTOP splice 1288573GT
Cable, 45 inch link 1288574GT
Cable, chassis to platform 1288726GT
Forming, cable guide 1288732GT
Manual, Supplement 1288739GT
6 Lift Guard™ Contact Alarm Part No. 1288739GT
number
Qty.
8
2
4
4
2
1
1
1
1
1
2
1
Page 9
First Edition • First Printing Operator's Manual Supplement
number
Genie part
number
Genie part
Installation Instructions
Contents of Kit 1288738GT
Contents of Kit 1289294GT
GS-2032
Description Genie part
Cable tie, 7.375 inch / 19 cm 6578GT 40
Button cable tie, 14.75 inch / 37,5 cm 56361GT 8
Cable tie mount, 6.5 inch / 16,5 cm 110149GT 2
Flange nut, 1/4-20, G, ZAG 824027GT 4
Screw, HHF, 1/4-20 x .75, 8, ZAG 824078GT 4
Assembly, lift guard 1287673GT 2
Cable, 20 inch link 1288572GT 1
Harness, ESTOP splice 1288573GT 1
Cable, 45 inch link 1288574GT 1
Cable, chassis to platform 1288727GT 1
Forming, cable guide 1288733GT 2
Harness, GS32 platform 1288740GT 1
Manual, Supplement 1288739GT 1
Qty.
Contents of Kit 1289293GT
GS-2632
Description Genie part
number
Cable tie, 7.375 inch / 19 cm 6578GT 40
Button cable tie, 14.75 inch / 37,5 cm 56361GT 8
Cable tie mount, 6.5 inch / 16,5 cm 110149GT 2
Flange nut, 1/4-20, G, ZAG 824027GT 4
Screw, HHF, 1/4-20 x .75, 8, ZAG 824078GT 4
Assembly, lift guard 1287673GT 2
Cable, 20 inch link 1288572GT 1
Harness, ESTOP splice 1288573GT 1
Cable, 45 inch link 1288574GT 1
Cable, chassis to platform 1288728GT 1
Forming, cable guide 1288733GT 2
Harness, GS32 platform 1288740GT 1
Manual, Supplement 1288739GT 1
Qty.
GS-3232
Description
Cable tie, 7.375 inch / 19 cm 6578GT 40
Button cable tie, 14.75 inch / 37,5 cm 56361GT
Cable tie mount, 6.5 inch / 16,5 cm 110149GT
Flange nut, 1/4-20, G, ZAG 824027GT
Screw, HHF, 1/4-20 x .75, 8, ZAG 824078GT
Assembly, lift guard 1287673GT
Cable, 20 inch link 1288572GT
Harness, ESTOP splice 1288573GT
Cable, 45 inch link 1288574GT
Cable, chassis to platform 1288729GT
Forming, cable guide 1288733GT
Harness, GS32 platform 1288740GT
Manual, Supplement 1288739GT
Qty.
Contents of Kit 1289420GT
GS-2046
Description
number
Cable tie, 7.375 inch / 19 cm 6578GT 40
Button cable tie, 14.75 inch / 37,5 cm 56361GT
Cable tie mount, 6.5 inch / 16,5 cm 110149GT
Flange nut, 1/4-20, G, ZAG 824027GT
Screw, HHF, 1/4-20 x .75, 8, ZAG 824078GT
Assembly, lift guard 1287673GT
Cable, 20 inch link 1288572GT
Harness, ESTOP splice 1288573GT
Cable, 45 inch link 1288574GT
Cable, chassis to platform 1288727GT
Forming, cable guide 1288734GT
Forming, cable guide 1288735GT
Harness, GS46 platform 1288741GT
Manual, Supplement 1288739GT
Qty.
8
2
4
4
2
1
1
1
1
2
1
1
8
2
6
6
2
1
1
1
1
1
1
1
1
Part No. 1288739GT Lift Guard™ Contact Alarm 7
Page 10
Operator's Manual Supplement First Edition • First Printing
number
Genie part
number
Installation Instructions
Contents of Kit 1289421GT
Contents of Kit 1289422GT
GS-2646
Description Genie part
Cable tie, 7.375 inch / 19 cm 6578GT 40
Button cable tie, 14.75 inch / 37,5 cm 56361GT 8
Cable tie mount, 6.5 inch / 16,5 cm 110149GT 2
Flange nut, 1/4-20, G, ZAG 824027GT 6
Screw, HHF, 1/4-20 x .75, 8, ZAG 824078GT 6
Assembly, lift guard 1287673GT 2
Cable, 20 inch link 1288572GT 1
Harness, ESTOP splice 1288573GT 1
Cable, 45 inch link 1288574GT 1
Cable, chassis to platform 1288728GT 1
Forming, cable guide 1288734GT 1
Forming, cable guide 1288735GT 1
Harness, GS46 platform 1288741GT 1
Manual, Supplement 1288739GT 1
Qty.
GS-3246
Description
Cable tie, 7.375 inch / 19 cm 6578GT 40
Button cable tie, 14.75 inch / 37,5 cm 56361GT
Cable tie mount, 6.5 inch / 16,5 cm 110149GT
Flange nut, 1/4-20, G, ZAG 824027GT
Screw, HHF, 1/4-20 x .75, 8, ZAG 824078GT
Assembly, lift guard 1287673GT
Cable, 20 inch link 1288572GT
Harness, ESTOP splice 1288573GT
Cable, 45 inch link 1288574GT
Cable, chassis to platform 1288729GT
Forming, cable guide 1288734GT
Forming, cable guide 1288735GT
Harness, GS46 platform 1288741GT
Manual, Supplement 1288739GT
Qty.
8
2
6
6
2
1
1
1
1
1
1
1
1
8 Lift Guard™ Contact Alarm Part No. 1288739GT
Page 11
First Edition • First Printing Operator's Manual Supplement
number
Installation Instructions
Contents of Kit 1289295GT
GS-4047
Description Genie part
Cable tie, 7.375 inch / 19 cm 6578GT 40
Button cable tie, 14.75 inch / 37,5 cm 56361GT 8
Cable tie mount, 6.5 inch / 16,5 cm 110149GT 2
Flange nut, 1/4-20, G, ZAG, 824027GT 6
Screw, HHF, 1/4-20 x .75, 8, ZAG 824078GT 6
Assembly, lift guard 1287673GT 2
Cable, 20 inch link 1288572GT 1
Harness, ESTOP splice 1288573GT 1
Cable, 45 inch link 1288574GT 1
Cable, chassis to platform 1288730GT 1
Forming, cable guide 1288734GT 1
Forming, cable guide 1288735GT 1
Harness, GS46 platform 1288741GT 1
Manual, Supplement 1288739GT 1
Qty.
Part No. 1288739GT Lift Guard™ Contact Alarm 9
Page 12
Operator's Manual Supplement First Edition • First Printing
Crushing hazard. Keep hands
clear of the safety arm when
lowering the platform.
Installation Instructions
Note: Perform this procedure on a firm, level
surface.
1 Turn the key switch to ground control and pull
out the red Emergency Stop button to the on
position at both ground and platform controls.
2 Raise the platform 7 to 8 feet / 2.1 to 2.4 m.
3 Lift the safety arm, move it to the center of the
scissor arm and rotate down to a vertical
position.
4 Lower the platform onto the safety arm.
11 Remove the white wire from the harness
assembly and discard.
12 Remove the white plug from connector J1 pin
11 and discard.
13 Connect the black wire of the ESTOP splice
harness to connector J1 pin 11. Genie part
number 1288573GT.
5 Turn the key switch to the off position and push
in the red Emergency Stop button to the off
position at the ground controls.
6 Open the ground control compartment.
7 Cut and discard any cable ties securing the
harnesses from the ground controls.
8 Disconnect the gray J1 connector from the
back of the ground controls.
models without
outriggers
models with
outriggers
14 Connect the white wire of the harness to J1 pin
3 and pin 2 of the 6 pin connector.
15 Install the receptacle locks set aside in step 10.
16 Secure the harness inside the wire loom.
17 Install the harness back into the machine.
Secure the harnesses using cable ties. Genie
part number 6578GT.
18 Following the existing cables and harnesses
route the 2 pin connector of the chassis to
platform cable down through the top of the
drive chassis and into the ground controls
compartment.
Model Genie part number
GS-1530 / GS-1532 1288571GT
GS-1930 / GS-1932 1288726GT
GS-2032 / GS-2046 1288727GT
GS-2632 / GS-2646 1288728GT
1 J1 connector
9 Disconnect the opposite end of the harness
from the 6 pin connector. Remove the harness
from the machine.
10 Remove the receptacle locks from both
connectors and set aside.
10 Lift Guard™ Contact Alarm Part No. 1288739GT
GS-3232 / GS-3246 1288729GT
GS-4047 1288730GT
Page 13
First Edition • First Printing Operator's Manual Supplement
Installation Instructions
19 Connect the cable to the ESTOP splice
harness.
20 Route the cable through the link stack to the
platform with the existing cables. Secure the
cable using cable ties. Genie part number
6578GT.
25 Secure the cable guide to the platform using
the provided retaining fasteners. Do not tighten
at this time. Genie part number 824078GT,
824027GT.
26 Mark and drill the location for the cable guide
at the steer end of the machine.
Note: Only route and secure the cable as far up as
the top link. Route the cable so it hangs on the
outside of the link stack.
21 Raise the platform and rotate the safety arm to
the stowed position.
22 Fully lower the platform to the stowed position.
Note: Do not allow the cable to get damaged while
lowering the platform.
23 On the ground control side of the machine,
clamp the cable guide forming to the bottom
edge of the platform. Genie part number
1288732GT or 1288733GT or 1288735GT.
Note: Refer to the illustrations on page 13 for
installing the cable guide forming's.
24 Using a center punch, mark the location to be
drilled at the non-steer end of the machine.
Drill a 17/64 inch / 6,7 mm hole in the side of
the platform. Deburr the hole.
27 Secure the cable guide to the platform using
the provided retaining fasteners. Do not tighten
at this time.
Note: GS-46 and GS-47 models, repeat the drilling
procedure for the center hole of the cable guide.
Do not install the retaining fasteners at this time.
28 Repeat the drilling procedure for the battery
side of the machine. Genie part number
1288732GT or 1288733GT or 1288734GT.
29 Remove the retaining fasteners securing both
cable guides at the non-steer end of the
machine and set aside. Let the cable guides
hang down.
30 Route the 6 pin and the two 2 pin connectors of
the contact alarm harness down through the
slot in the platform that the platform controls
harness is routed through.
31 Secure the coil cord to the hole located under
the AC power outlet using a cable tie. Genie
part number 6578GT.
32 Route the longer part of the harness assembly
to the battery side of the machine.
33 Route the harness under the platform towards
the non-steer of the machine. Secure the
harness to the cable guide using button cable
ties. Do not tighten the cable ties at this. Genie
Part No. 1288739GT Lift Guard™ Contact Alarm 11
part number 56361GT.
Page 14
Operator's Manual Supplement First Edition • First Printing
Installation Instructions
34 Secure the cable guide to the platform with the
retaining fasteners set aside. Torque to 136
in-lbs / 15,5 Nm.
35 Gently pull the harness towards the non-steer
end of the machine. Tighten the cable ties.
42 Connect the lift guard assembly to the harness
in the cable guide at the non-steer end of the
machine with the 45 inch link cable. Genie part
number 1288574GT.
43 Secure the cable to the platform railing.
36 Route the loose end of the harness assembly
towards the non-steer end of the machine.
Secure the harness to the cable guide using
button cable ties. Do not tighten the cable ties
at this. Genie part number 56361GT.
37 Secure the cable guide to the platform with the
retaining fasteners set aside. Torque to 136
in-lbs / 15,5 Nm.
38 Gently pull the harness towards the non-steer
end of the machine. Tighten the cable ties.
39 Mount the lift guard assemblies to the platform
railings. Refer to the illustrations on page
14 for mounting locations.
40 Connect the lift guard assembly to the coil cord
at the steer end of the machine with the 20 inch
link cable. Genie part number 1288572GT.
41 Secure the cable to the platform railing using
cable ties.
Models with a chain gate: Secure the cable
to the upright post of the platform railing.
Models with a swing gate: Secure the cable
to the upright post of the platform railing using
cable tie mounts. Genie part number
110149GT.
44 Update the control system software (if
required). Refer to the Software Update
section.
12 Lift Guard™ Contact Alarm Part No. 1288739GT
Page 15
First Edition • First Printing Operator's Manual Supplement
Installation Instructions
GS-30 and GS-32 models
Part No. 1288739GT Lift Guard™ Contact Alarm 13
GS-46 and GS-47 models
Page 16
Operator's Manual Supplement First Edition • First Printing
Installation Instructions
14 Lift Guard™ Contact Alarm Part No. 1288739GT
Page 17
First Edition • First Printing Operator's Manual Supplement
Software Update
Software Upd ate
Machines with a control system software revision
of "P" or higher do not require a software upgrade.
Machines with revision of "N" or lower, and is
equipped with proportional lift control, will require a
software upgrade.
Software Version
Note: Before proceeding verify the version of
software installed on your machine. The
software revision is displayed at the GCON
LCD.
1 Turn the key switch to ground controls or
platform controls and pull out the red
Emergency Stop button to the on position at
both ground and platform controls.
Result: The PCON LCD will show "CH".
2 Press the ground control scroll down button.
Result: The GCON LCD will show the software
revision and hour meter information. After
5 seconds, the ground controls LCD will return
to machine model and hour meter information.
Result: The GCON LCD will show the machine
model and hour meter information. After
3 seconds, the machine model will not show
on the display.
1 GCON LCD
2 scroll down button
3 Push in the red Emergency Stop button to the
off position at both the ground and platform
controls and turn the key switch to the off
position.
Result: Revision "P" or higher, test the contact
alarm. Refer to Function Test.
Result: Revision "N" or lower, update the
machine software. Refer to Firmware Site
Download.
Part No. 1288739GT Lift Guard™ Contact Alarm 15
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Operator's Manual Supplement First Edition • First Printing
Software Update
Firmware Site Download
Note: Access to the internet is required to
perform this procedure.
1 Click on the Hyperlink below or open an
internet browser and copy and paste the link
into the address bar and press enter.
http://firmware.genielift.com
2 Select Machine Model. Select Search.
3 Under Application Firmware, select the
Firmware File for PROP LIFT and save it to
your desktop.
4 Locate and open the file saved on your
desktop.
5 Right click on the .zip file and select extract
all.
Activating or Deactivating the Contact Alarm
Note: The contact alarm must be activated in the
options menu for the machine to function properly
when it has been installed on the machine.
Note: The contact alarm must be deactivated in the
options menu for the machine to function properly
when it has been removed from the machine.
1 Turn the key switch to the ground controls
position and pull out the red Emergency Stop
button to the on position at the platform
controls.
2 Press and hold the ground control scroll up and
scroll down buttons.
Note: Verify the Show extracted files when
complete box is checked.
6 Select and open instructions 216767 under
Application Firmware.
7 Refer to Machine Application Mode procedure
to complete the software upgrade.
8 Download the Instructions and follow the
procedures to update the machine software.
Note: After the control system software has been
updated, the contact alarm option must be
activated at the ground controls to function
properly. Refer to Activatingor Deactivating the
Contact Alarm.
16 Lift Guard™ Contact Alarm Part No. 1288739GT
1 scroll down button
2 enter button
3 scroll up button
4 escape button
5 LCD display
Page 19
First Edition • First Printing Operator's Manual Supplement
Lift Guard
™
Part No. 1288739GT Operator's M an ual Sup pl ement First Edition • Fir st Printi ng
Software Update
3 Pull out the red Emergency Stop button to the
on position at the ground controls.
Result: The ground controls LCD display will
show the following:
4 Use the ground control menu buttons to select
machine Options. Follow the menu structure
indicated on the ground control LCD display to
activate the contact alarm.
5 If the contact alarm has been activated, this
Operator's Manual Supplement must be
inserted into the manual box located on the
machine.
Contact Al arm
Part No. 1288739GT Lift Guard™ Contact Alarm 17
Page 20
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