Genie GS-2632, Operators Manual With Maintenance Information

Page 1: ...Operator s Manual Fourth Edition Third Printing Part No 1000033 with Maintenance Information ...

Page 2: ... 1999 Printed on recycled paper Printed in U S A 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 Industri...

Page 3: ... 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 safe...

Page 4: ...g Extension only 250 lbs 113 kg Platform only 550 lbs 249 kg 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 ...

Page 5: ...latform 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 drive the machine on a slope that exceeds the slope and side slope rating of the machine Slope rating applies to machines in the stowed position Maximum slope rating stowed position 30 17 Maximum side slope rat...

Page 6: ...hine components that in any way affect safety and stability 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 Outdoor Use Do not raise the platform when...

Page 7: ...ntry chain or close the entry gatebeforeoperating Do not operate the machine unless the guard rails are properly installed and the entry is secured for operation Collision Hazards Be aware of limited sight distance and blind spots whendrivingoroperating 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 O...

Page 8: ...e 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 comp...

Page 9: ...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 Bodily Injury ...

Page 10: ...e Do not contact the battery terminals or the cable clamps with tools that may cause sparks 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 ...

Page 11: ...xtension release pedal 5 GFCI outlet 6 Platform controls 7 Manual storage container 8 Tilt alarm under cover 9 Auxiliary lowering lever 10 Transport tie down 11 Steer tire 12 Pothole guard 13 LED diagnostic readout 14 Ground controls 15 Non steer tire 16 Brake release pump knob and releaseknob 17 Batterycharger on opposite side of machine 18 Entryladder transport tie down 19 Safety arm ...

Page 12: ...rols 1 Red Emergency Stop button 2 LED diagnostic readout Battery charge indicator 3 Lift function select button 4 Horn button 5 Proportional control handle and function enable switch for lift and drive functions 6 Thumb rocker switch for steer functions 7 Drive speed button 8 Drive function select button ...

Page 13: ...inting Part No 1000033 GS 2032 GS 2632 11 CONTROLS Ground Control Panel 1 7 amp breaker for electrical circuits 2 Key switch for platform off ground selection 3 Hour meter 4 Platform up down toggle switch 5 Red Emergency Stop button 1 2 3 4 5 ...

Page 14: ...gned 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 varia...

Page 15: ...tings cylinders and manifolds Battery pack and connections Drive motors Wear pads Tires and wheels Ground strap Limit switches alarms and horn Nuts bolts and other fasteners Platform entry chain or gate Beacon and alarms if equipped Brake release components Safety arm Pothole guards Platform extension Scissor pins and retaining fasteners Platform control joystick Check entire machine for Cracks in...

Page 16: ...edure 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 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 ...

Page 17: ...ng 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 retaining fasteners 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...

Page 18: ...ce 5 Only use the machine as it was intended 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 onl...

Page 19: ...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 sho...

Page 20: ...he direction that the yellow triangle points on the control panel 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 sel...

Page 21: ...rive function should not work in either direction 34 Lower the platform and remove both pieces of wood 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 mo...

Page 22: ...ve the machine from service 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 6 feet 1 8 m an alarm sounds and the machine will not drive 39 Raise the platform Result When the platform is rais...

Page 23: ...erator 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 It 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 Workplace Inspection Be aware of and avoid the following hazardous situations drop o...

Page 24: ...or 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 ...

Page 25: ...y 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 battery level indicator is flashing 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 fun...

Page 26: ...The drive controls can operate in two different drive speed modes When the drive speed button light is on slow drive speed mode is active When the button light is off fast drive speed mode is active Press the drive speed button to select the desired drive speed Driving on a slope Determine the slope and side slope ratings for the machine and determine the slope grade Maximum slope rating stowed po...

Page 27: ...ware of the direction the machine will travel when using the controller Battery Level Indicator Use the LED diagnostic readout to determine the battery level 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 ...

Page 28: ...lled 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 Dry Battery Filling and Charging ...

Page 29: ...re lowered Do not drive the machine on a slope that exceeds the slope or side slope rating See Driving on a Slope in the Operating Instructions section If the slope of the transport vehicle bed exceeds the maximum slope rating the machine must be loaded and unloaded using a winch as described Brake Release Operation 1 Chock the wheels to prevent the machine from rolling 2 Be sure the winch line is...

Page 30: ...ms on the machine Determine the center of gravity of your machine using the table and the picture on this page Attach the rigging only to the designated lifting points on the machine There are two 1 inch 2 5 cm holes on the front of the machine and two holes in the ladder for lifting Adjust the rigging to prevent damage to the machine and to keep the machine level Y Axis X Axis Center of gravity X...

Page 31: ...ays use the extension deck lock when the machine is transported Turn the key switch to the off position 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 TRANSPORT AND LIFTING INSTRUCTIONS ...

Page 32: ...U Fault Codes 1 62055 Cosmetic Genie GS 2032 2 Part No Description Quantity 72143 Label Emergency Stop 1 72853 Danger Improper Use Hazard 1 72970 Notice Battery Charger Operating Instructions 1 72973 Cosmetic Genie GS 2632 2 82307 Notice Side Force GS 2632 Australia 1 82366 Label Chevron Rykon 1 82447 Label Auxiliary Lowering 1 82557 Label Platform Controls Location 1 82558 Warning Skin Injection ...

Page 33: ...Operator s Manual Fourth Edition Third Printing Part No 1000033 GS 2032 GS 2632 31 DECALS Battery Side Ground Controls Side ...

Page 34: ...own 5 62055 Cosmetic Genie GS 2032 2 72143 Label Emergency Stop 1 72973 Cosmetic Genie GS 2632 2 82472 Warning Crushing Hazard 1 82474 Warning Safety Chock 2 82476 Danger Electrocution Hazard 2 82481 Danger Battery Charger Safety 1 82482 Label Auxiliary Lowering 1 Part No Description Quantity 82487 Notice Read the Manual 2 82495 Danger Brake Release Safety Operating Instructions 1 82496 Danger Max...

Page 35: ...Operator s Manual Fourth Edition Third Printing Part No 1000033 GS 2032 GS 2632 33 DECALS Battery Side Ground Controls Side ...

Page 36: ...89 x 311 4 in 2 26 m x 79 4 cm Platform extension length 39 in 99 cm Continuous improvement of our products is a Genie policy Product specifications are subject to change without notice or obligation AC outlet in platform standard Maximum hydraulic pressure 3500 psi 241 3 bar functions System voltage 24V Tires size 15 x 5 x 111 4 Airborne noise emissions 70 dB Maximum sound level at normal operati...

Page 37: ...11 4 in 2 26 m x 79 4 cm Platform extension length 39 in 99 cm Continuous improvement of our products is a Genie policy Product specifications are subject to change without notice or obligation AC outlet in platform standard Maximum hydraulic pressure 3500 psi 241 3 bar functions System voltage 24V Tires size 15 x 5 x 111 4 Airborne noise emissions 70 dB Maximum sound level at normal operating wor...