GS 2632 operators manual
GS 2632 operators manual
Third 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 and Lifting Instructions .............................. 27
Decals ...................................................................... 30
Specifications ........................................................... 34
Printed in U.S.A.
Safety Rules
Danger
Failure to obey the instructions and
safety rules in this manual will
result in death or serious injury.
SAFETY RULES
SAFETY RULES
Maximum occupants - ANSI and CSA 2 Do not depend on the tilt alarm as a level indicator.
The tilt alarm sounds on the chassis only when the
Maximum occupants - Australia
machine is on a slope.
Outdoor use 1
Indoor use only 2 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.
800 lbs / 363 kg Extension only Platform only Do not alter or disable the limit switches.
250 lbs / 113 kg 550 lbs / 249 kg
Do not drive over 0.5 mph / 0.7 km/h with the
Maximum capacity - GS-2632 platform raised.
Platform retracted 500 lbs 227 kg
SAFETY RULES
Do not operate the machine in strong or gusty Do not alter or disable machine components that in
winds. Do not increase the surface area of the any way affect safety and stability.
platform or the load. Increasing the area exposed to
the wind will decrease machine stability. Do not place or attach fixed or overhanging loads to
any part of this machine.
Do not push off or pull Do not modify or alter an aerial work platform
toward any object outside without prior written permission from the
of the platform. 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.
Maximum allowable
manual force
GS-2032
ANSI & CSA - 2 person 120 lbs / 534 N
Australia - Indoor use only - 2 person 90 lbs / 400 N
Australia - Outdoor use - 1 person 45 lbs / 200 N
GS-2632
ANSI & CSA - 2 person 100 lbs / 445 N
Australia - Indoor use only - 2 person 90 lbs / 400 N
SAFETY RULES
SAFETY RULES
Operators must comply with employer, job site and Do not lower the platform unless the area below is
governmental rules regarding use of personal clear of personnel and obstructions.
protective quipment.
Limit travel speed according to the condition of the
ground surface, congestion, slope, location of
personnel, and any other factors which may cause
collision.
Crushing Hazards
Check the work area for overhead obstructions or Keep hands and limbs out of scissors.
other possible hazards.
Use common sense and planning when operating
Be aware of crushing hazards when grasping the the machine with the controller from the ground.
platform guard rail. Maintain safe distances between the operator, the
Observe and use the color-coded direction arrows machine and fixed objects.
on the platform controls and platform decal plate for
drive and steer functions.
SAFETY RULES
SAFETY RULES
Legend
Controls
CONTROLS
Platform Controls
1 Horn button 6 Function enable switch
2 Machine on incline symbol: Low speed operation 7 Proportional control handle for lift and drive
for inclines functions and thumb rocker for steer function
3 Lift function select button with indicator light 8 Error indicator light
4 Drive function select button with indicator light 9 Power light
5 Red Emergency Stop button 10 Battery level indicator
Pre-operation Inspection
Fundamentals
It is the responsibility of the operator to perform a
pre-operation inspection and routine maintenance.
PRE-OPERATION INSPECTION
Pre-operation Inspection
Pothole guards
Be sure that the operator's, safety and
responsibilities manuals are complete, legible Platform extension
and in the storage container located on the
Scissor pins and retaining fasteners
platform.
Platform control joystick
Be sure that all decals are legible and in place.
See Decals section. Generator (if equipped)
Check for hydraulic oil leaks and proper oil level. Check entire machine for:
Add oil if needed. See Maintenance section.
Cracks in welds or structural components
Check for battery fluid leaks and proper fluid
level. Add distilled water if needed. See Dents or damage to machine
Maintenance section. Be sure that all structural and other critical
Check the following components or areas for components are present and all associated
damage, improperly installed or missing parts and fasteners and pins are in place and properly
unauthorized modifications: tightened.
Side rails are installed and bolts are fastened
Electrical components, wiring and electrical
cables Be sure that the chassis trays are in place,
latched and properly connected.
Hydraulic power unit, tank, hoses,
fittings, 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 (if equipped)
Platform entry gate (if equipped)
Beacon and alarms (if equipped)
Brake release components
Safety arm
Maintenance
MAINTENANCE
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.
FUNCTION TESTS
1 Select a test area that is firm, level and free of Test Auxiliary Lowering
obstruction.
10 Activate the up function and raise the platform
2 Be sure the battery pack is connected. approximately 2 feet / 60 cm.
3 Pull out the platform and ground red Emergency Result: The platform should lower. The descent
Stop buttons to the on position. alarm will not sound.
4 Turn the key switch to ground control. 12 Turn the key switch to platform control.
FUNCTION TESTS
FUNCTION TESTS
Test Drive and Braking 32 Press the drive function select switch.
27 Press and hold the function enable switch on the 33 Press and hold the function enable switch on the
control handle. control handle. Slowly move the control handle
to the full drive position.
28 Slowly move the control handle in the direction
indicated by the blue arrow on the control panel Result: The maximum achievable drive speed
until the machine begins to move, then return with the platform raised should not exceed
the handle to the center position. 0.75 feet / 23 cm per second.
Result: The machine should move in the If the drive speed with the platform raised exceeds
direction that the blue arrow points on the 0.75 feet / 23 cm per second, immediately tag and
control panel, then come to an abrupt stop. remove the machine from service.
29 Slowly move the control handle in the direction Test the Tilt Sensor Operation
indicated by the yellow arrow on the control
panel until the machine begins to move, then Note: Perform this test from the ground with the
return the handle to the center position. platform controller. Do not stand in the platform.
Result: The machine should move in the 34 Fully lower the platform.
direction that the yellow arrow points on the 35 Place a 2x4 or similar piece of wood under both
control panel, then come to an abrupt stop. wheels on one side and drive the machine up
Note: The brakes must be able to hold the machine onto them.
on any slope it is able to climb. 36 Raise the platform approximately 7 feet / 2.1 m
Test Limited Drive Speed from the ground.
Result: The platform should stop and the tilt
30 Press the lift function select button.
alarm will sound at 600 beeps per minute.
31 Press and hold the function enable switch on the
37 Move the drive control handle in the direction
control handle. Raise the platform approximately
indicated by the blue arrow, then move the drive
4 feet / 1.2 m from the ground.
control handle in the direction indicated by the
Result: The pothole guards should deploy. yellow arrow.
Result: The drive function should not work in
either direction.
38 Lower the platform and remove both pieces of
wood.
FUNCTION TESTS
Workplace Inspection
Workplace Inspection
Be aware of and avoid the following hazardous
situations:
· drop-offs or holes
· bumps, floor obstructions or debris
Do Not Operate Unless: · sloped surfaces
You learn and practice the principles of safe · unstable or slippery surfaces
machine operation contained in this operator's · overhead obstructions and high voltage
manual. conductors
1 Avoid hazardous situations. · hazardous locations
2 Always perform a pre-operation · inadequate surface support to withstand all load
inspection. forces imposed by the machine
3 Always perform function tests prior to use. · wind and weather conditions
4 Inspect the workplace. · the presence of unauthorized personnel
Know and understand the workplace · other possible unsafe conditions
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.
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.
Operating Instructions
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.
OPERATING INSTRUCTIONS
Push in the red Emergency Stop button to the off 1 Press the lift function select button.
position at the ground controls or the platform 2 Press and hold the function enable switch on the
controls to stop all functions. control handle.
Repair any function that operates when either red 3 Move the control handle according to the
Emergency Stop button is pushed in. markings on the control panel.
OPERATING INSTRUCTIONS
OPERATING INSTRUCTIONS
OPERATING INSTRUCTIONS
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.
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.
Brake Release
Operation
1 Chock the wheels to prevent the machine from
rolling.
2 Be sure the winch line is properly secured to the
Observe and Obey: drive chassis tie points and the path is clear of
all obstructions.
Common sense and planning must be applied to
control the movement of the machine when 3 Before serial number GS04-52789: Turn the
lifting it with a crane or forklift. black brake release knob counterclockwise to
open the brake valve.
The transport vehicle must be parked on a level
surface. After serial number GS04-52788: Push in the
black brake release knob to open the brake
The transport vehicle must be secured to valve.
prevent rolling while the machine is being
loaded. 4 Pump the red brake release pump knob.
Be sure the vehicle capacity, loading surfaces After the machine is loaded:
and chains or straps are sufficient to withstand 1 Chock the wheels to prevent the machine from
the machine weight. See the serial plate for the rolling.
machine weight.
2 Before serial number GS04-52789: Turn the
The machine must be on a level surface or brake release knob clockwise to close the brake
secured before releasing the brakes. valve.
Do not allow the rails to fall when the snap pins After serial number GS04-52788: Press the
are removed. Maintain a firm grasp on the rails drive function select button. Press and hold the
when the rails are lowered. function enable switch on the control handle.
Move the control handle off center to reset the
brakes.
Towing the Genie GS-2032 and the GS-2632 is not
recommended. If the machine must be towed, do
not exceed 2 mph / 3.2 km/h.
Australia models
Only qualified riggers should rig and lift the
machine. GS-2032 31.9 in 21.2 in
80.9 cm 53.9 cm
Be sure the crane capacity, loading surfaces
and straps or lines are sufficient to withstand GS-2632 32.4 in 23.3 in
the machine weight. See the serial plate for the 82.2 cm 59.3 cm
machine weight.
Lifting Instructions
Fully lower the platform. Be sure the extension
deck, controls and component trays are secure.
Remove all loose items on the machine.
Y Axis
X Axis
Decals
31060 Danger - Do Not Alter Limit Switch 1 78673 Platform Control Panel 1
31508 Notice - Power to Battery Charger 1 82307 Notice - Side Force, GS-2632, Australia 1
43090 Notice - Operating Instructions, Platform 1 82557 Label - Platform Controls Location 1
43091 Danger - General Safety Rules 1 82558 Warning - Skin Injection Hazard 1
43619 Label - Safety Arm 1 82563 Notice - Max Cap 500 lbs / 227 kg,
GS-2632 1
43658 Label - Power to Charger, 230V 1
82567 Ground Control Panel 1
43696 Danger - Electrocution Hazard 2
82569 Danger/Notice - Brake Release Safety &
44255 Danger - Crushing Hazard 4 Operating Instructions 1
44736 Danger - Tilt Alarm 1 82657 Notice - Battery Connection Diagram 1
44737 Danger - Tip-over, Trays Open 2 82693 Notice - Max Cap 800 lbs / 363 kg,
44753 Label - LED Diagnostic Readout 1 GS-2032 1
44980 Label - Power to Charger, 115V 1 82694 Notice - Side Force, GS-2032, ANSI & CSA 1
46238 Notice - Error Indicator Light 1 82695 Notice - Side Force, GS-2632, ANSI & CSA 1
46262 Danger - Battery/Charger Safety 1 97692 Label - Wheel Load, GS-2032 4
46287 Notice - Tire Specification 4 97693 Label - Wheel Load, GS-2632 4
52475 Label - Transport Tie-down 5 97694 Notice - Side Force, GS-2032, Australia 1
97712 Danger/Notice - Brake Release Safety &
Operating Instructions 1
DECALS
Ground
Controls Side
Battery Side
DECALS
43658 Label - Power to Charger, 230V 1 82496 Danger - Max Cap 500 lbs / 227 kg 1
44980 Label - Power to Charger, 115V 1 82502 Label - LED Diagnostic Readout 1
78673 Platform Control Panel 1 82699 Danger - Max Cap 800 lbs / 363 kg 1
DECALS
Ground
Controls Side
Battery Side
Specifications
Height, working maximum 26 ft 8.1 m Maximum hydraulic pressure 3500 psi 241.3 bar
(functions)
Height, platform maximum 20 ft 6.1 m
System voltage 24V
Height, stowed maximum 791/2 in 2.01 m
Rails up - ANSI Tires size 15 x 5 x 111/4
Length, stowed 961/4 in 2.44 m Platform raised, maximum 0.5 mph 0.8 km/h
40 ft/54.5 sec 12.2 m/54.5 sec
Length, platform extended 1311/4 in 3.33 m
Floor Loading Information ANSI
Maximum load capacity 800 lbs 363 kg & CSA Australia
SPECIFICATIONS
Height, working maximum 32 ft 9.9 m Maximum hydraulic pressure 3500 psi 241.3 bar
(functions)
Height, platform maximum 26 ft 7.9 m
System voltage 24V
Height, stowed maximum 843/4 in 2.15 m
Tires size 15 x 5 x 111/4
Height, stowed maximum 751/4 in 1.91 m
Rails folded Platform dimensions
Maximum load capacity 500 lbs 227 kg Floor Loading Information ANSI
& CSA Australia
Wheelbase 73 in 1.85 m
GVW+Rated Load 4913 lbs 5234 lbs
Turning radius (outside) 831/2 in 2.12 m 2228 kg 2374 kg
Turning radius (inside) 4 in 10.2 cm Axle load, maximum 2930 lbs 3535 lbs
1329 kg 1604 kg
Ground clearance 31/2 in 8.9 cm
3 /4 Wheel load, maximum 1465 lbs 1768 lbs
Ground clearance in 1.9 cm
664 kg 802 kg
Pothole guards deployed
Localized pressure per tire 147 psi 118 psi
Weight See Serial Plate
10.3 kg/cm2 8.29 kg/cm2
(Machine weights vary with option configurations)
1016 kPa 813 kPa
Gradeability 25%
Occupied pressure 249 psf 272 psf
Airborne noise emissions <70 dB 12 kPa 13 kPa
Maximum sound level at normal operating workstations
(A-weighted)
Note: Floor loading information is approximate and
Power source 4 Batteries, 6V 225AH does not incorporate different option configurations.
Controls Proportional
It should be used only with adequate safety factors.