Genie 82784 User manual

Operator’s Manual Second Edition
Second Printing
Part No. 82784
with Maintenance Information
CE Models

GenieGS-2032andGenieGS-2632 PartNo.82784
Operator's Manual Second Edition • Second Printing
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
Industries.
Thesemachines complywith
ANSI/SIA92.6-1999.
Printed on recycled paper
Printedin U.S.A.
Important
Read,understandandobeythesesafetyrulesand
operatinginstructionsbeforeoperatingthismachine.
Onlytrainedandauthorizedpersonnelshallbe
permitted to operate this machine. This manual should
beconsidered apermanentpart ofyourmachine 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-operationInspection ........................................... 12
Maintenance ............................................................. 14
Function Tests.......................................................... 16
WorkplaceInspection................................................ 21
OperatingInstructions............................................... 22
TransportInstructions ............................................... 27
Decals ...................................................................... 28
Specifications ........................................................... 30
Contact us:
Internet:http://www.genielift.com
e-mail:[email protected]

PartNo.82784 GenieGS-2032andGenieGS-2632 1
Operator's Manual
Second Edition • Second Printing
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
machineoperationcontainedinthisoperator's
manual.
1 Avoid hazardous situations.
Know and understand the safety rules
before going on to the next section.
2 Alwaysperformapre-operationinspection.
3 Always perform function tests prior to use.
4 Inspect the workplace.
5 Only use the machine as it was intended.
Youread,understandand obeythe
manufacturer'sinstructions and safetyrules—
safetyandoperator'smanualsandmachine
decals
Youread,understandandobeyemployer's
safetyrules and worksite regulations
Youread,understandandobeyallapplicable
governmentalregulations
Youareproperlytrainedtosafelyoperate the
machine.

2 GenieGS-2032andGenieGS-2632 PartNo.82784
Operator's Manual Second Edition • Second Printing
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
andapparatusinaccordancewithapplicable
governmentalregulationsandthefollowingchart.
Voltage Minimum Safe
Phase to Phase Approach Distance
Meters
0 to 300V Avoid Contact
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
Allow for platform movement, electrical line sway or
sag and beware of strong or gusty winds.
Keep away from the machine if it contacts
energizedpowerlines. Personnel onthegroundor
in the platform must not touch or operate the
machine until energized power lines are shut off.
Donotoperate themachineduringlightningor
storms.
Do not use the machine as a ground for welding.

PartNo.82784 GenieGS-2032andGenieGS-2632 3
Operator's Manual
Second Edition • Second Printing
SAFETY RULES
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.
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
4.5 m 508 kg
2.7 m 367 kg
1 m 227 kg

4 GenieGS-2032andGenieGS-2632 PartNo.82784
Operator's Manual Second Edition • Second Printing
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)intheplatform.
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
withoutprior writtenpermission fromthe
manufacturer.Mountingattachmentsforholding
toolsor 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.
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.
Donotdrivethe machine on or near uneven terrain,
unstablesurfacesor otherhazardousconditions
with the platform raised.
Use extreme care and slow speeds while driving
the machine in a stowed position across uneven
terrain,debris,unstableor slippery surfaces and
nearholesanddrop-offs.
Do not push off or pull
towardany object outside
of the platform.
Maximum allowable
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
SAFETY RULES

PartNo.82784 GenieGS-2032andGenieGS-2632 5
Operator's Manual
Second Edition • Second Printing
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
areproperlytightenedandcotterpinsareproperly
installed.
Do not use batteries that weigh less than the
originalequipment. Batteriesareused 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
thatis caught, snaggedorotherwise prevented
from normal motion by an adjacent structure. All
personnelmust be removed from the platform
before attempting to free the platform using the
groundcontrols.
Fall Hazards
The guard rail system provides fall protection. If
occupantsof the platform are required to wear
personalfall protection equipment(PFPE)due to
job site or employer rules, PFPE equipment and its
use shall be in accordance with the PFPE
manufacturer’sinstructionsandapplicable
governmentalrequirements.
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.
Attach the platform entry 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.

6 GenieGS-2032andGenieGS-2632 PartNo.82784
Operator's Manual Second Edition • Second Printing
SAFETY RULES
Nostunt driving or horseplaywhileoperatinga
machine.
Do not lower the platform unless the area below is
clearof personnelandobstructions.
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
ormoving overhead machinery unless the controls
of the crane have been locked out and/or
precautionshave been taken to prevent any
potentialcollision.
Crushing Hazards
Keep hands and limbs out of scissors.
Usecommonsenseandplanningwhenoperating
themachinewith the controller from the ground.
Maintainsafe distances between the operator, the
machine and fixed objects.
Collision Hazards
Be aware of limited sight
distance and blind spots
whendrivingoroperating.
Beaware of the extended platformpositionwhen
movingthe machine.
The machine must be on a level surface or secured
beforereleasingthebrakes.
Operators must comply with employer, job site and
governmentalrulesregardinguseofpersonal
protectivequipment.
Checkthe work area for overheadobstructionsor
otherpossiblehazards.
Beawareofcrushinghazardswhengrasping the
platformguardrail.
Observeandusethecolor-codeddirectionarrows
on the platform controls and platform decal plate for
drive and steer functions.

PartNo.82784 GenieGS-2032andGenieGS-2632 7
Operator's Manual
Second Edition • Second Printing
Component Damage Hazard
Do not use the machine as a ground for welding.
Explosion and Fire Hazard
Donotoperate the machine in hazardous locations
orlocationswherepotentiallyflammableor
explosive gases or particles may be present.
Damaged Machine Hazards
Donot use a damaged or malfunctioning machine.
Conductathoroughpre-operationinspectionofthe
machine and test all functions before each work
shift. Immediately tag and remove from service a
damagedormalfunctioningmachine.
Besureall 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
manualsarecomplete, legible and in the storage
containerlocated 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/orburnskin.
Impropercontact with componentsunderany cover
will cause serious injury. Only trained maintenance
personnel should access compartments. Access
by the operator is only advised when performing a
pre-operationinspection.Allcompartmentsmust
remainclosedandsecuredduringoperation.
SAFETY RULES
Decal Legend
Genie product decals use symbols, color coding
and signal words to identify the following:
Safety alert symbol—used to alert
personneltopotentialpersonal
injury hazards. Obey all safety
messages that follow this symbol
to avoid possible injury or death.
Red—usedtoindicatethe
presence of an imminently
hazardous situation which, if not
avoided, will result in death or
seriousinjury.
Orange—usedtoindicatethe
presence of a potentially
hazardous situation which, if not
avoided, could result in death or
seriousinjury.
Yellow with safety alert symbol—
used to indicate the presence of a
potentiallyhazardoussituation
which, if not avoided, may cause
minorormoderateinjury.
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—usedtoindicateoperation
ormaintenanceinformation.

8 GenieGS-2032andGenieGS-2632 PartNo.82784
Operator's Manual Second Edition • Second Printing
SAFETY RULES
Battery Safety
Burn Hazards
Batteries contain acid. Always wear protective
clothingandeyewear whenworking withbatteries.
Avoid spilling or contacting battery acid. Neutralize
battery acid spills with baking soda and water.
Do not expose the batteries or the charger to
waterorrainduringcharging.
Explosion Hazards
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.
Component Damage Hazard
Do not use any battery charger greater than 24V to
chargethebatteries.
Electrocution Hazards
Connect the battery charger to a
grounded,AC3-wireelectrical
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
Usetheappropriatenumberofpeopleandproper
lifting techniques when lifting batteries.

PartNo.82784 GenieGS-2032andGenieGS-2632 9
Operator's Manual
Second Edition • Second Printing
Legend
1 Platform entry chain or entry
gate
2 Platform entry rail
3 Platformguardrails
4 Lanyardanchoragepoint
5 Manualstoragecontainer
6 Platformcontrols
7 GFCIoutlet
8 Platformextension
9 Platformextensionrelease
pedal
10 Tiltalarm(undercover)
11 Transporttie-down
12 Steertire
13 Groundcontrols
14 Auxiliaryloweringknobor
button or switch
15 LEDdiagnosticreadout
16 Hydraulic oil level indicator
17 Potholeguard
18 Non-steertire
19 Entryladder/transport
tie-down
20 Battery charger
21 Brake release pump knob
22 Brake release knob
23 Safety arm

10 GenieGS-2032andGenieGS-2632 PartNo.82784
Operator's Manual Second Edition • Second Printing
Controls
Ground Control Panel
1 Auxiliarylowering/manual
loweringtoggleswitchor
knoborbutton
2 Hourmeter
3 5 6421
3 RedEmergencyStop button
4 Breaker for electrical circuits
5 Platformup/downtoggle
switch
6 Key switch for platform/off/
ground selection
3 5 6 421

PartNo.82784 GenieGS-2032andGenieGS-2632 11
Operator's Manual
Second Edition • Second Printing
CONTROLS
PlatformControls
1 Hornbutton
2 Machineon inclinesymbol:Low speedoperation
for inclines
3 Lift function select button with indicator light
4 Drive function select button with indicator light
5 RedEmergencyStop button
6 Functionenableswitch
7 Proportionalcontrol handle for liftanddrive
functions and thumb rocker for steer function
8 Errorindicatorlight
9 Powerlight
10 Battery level indicator

12 GenieGS-2032andGenieGS-2632 PartNo.82784
Operator's Manual Second Edition • Second Printing
Pre-operation Inspection
Do Not Operate Unless:
You learn and practice the principles of safe
machineoperationcontainedinthisoperator's
manual.
1 Avoidhazardoussituations.
2 Alwaysperformapre-operation
inspection.
Knowandunderstandthepre-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
It is the responsibility of the operator to perform a
pre-operationinspectionandroutinemaintenance.
Thepre-operationinspection is a visual inspection
performed by the operator prior to each work shift.
The inspection is designed to discover if anything
isapparently wrong with a machine before the
operator performs the function tests.
Thepre-operationinspectionalsoservesto
determineifroutinemaintenanceproceduresare
required.Onlyroutinemaintenanceitemsspecified
in this manual may be performed by the operator.
Refer to the list on the next page and check each
of the items.
Ifdamage oranyunauthorized variationfrom
factory delivered condition is discovered, the
machinemust be tagged and removed from
service.
Repairs to the machine may only be made by a
qualified service technician, according to the
manufacturer'sspecifications.After repairsare
completed,the operatormustperform a
pre-operationinspectionagainbeforegoingonto
the function tests.
Scheduledmaintenanceinspectionsshallbe
performedbyqualified service technicians,
accordingto the manufacturer's specifications and
the requirements listed in the responsibilities
manual.

PartNo.82784 GenieGS-2032andGenieGS-2632 13
Operator's Manual
Second Edition • Second Printing
PRE-OPERATIONINSPECTION
Pre-operation Inspection
oBe sure that the operator's, safety and
responsibilitiesmanualsarecomplete,legible
and in the storage container located on the
platform.
oBe sure that all decals are legible and in place.
See Decals section.
oCheck for hydraulic oil leaks and proper oil level.
Add oil if needed. See Maintenance section.
oCheck for battery fluid leaks and proper fluid
level. Add distilled water if needed. See
Maintenancesection.
Checkthefollowing components or areas for
damage,improperly installed or missingpartsand
unauthorizedmodifications:
oElectricalcomponents,wiringandelectrical
cables
oHydraulic power unit, tank, hoses,
fittings, cylinders and manifolds
oBattery pack and connections
oDrivemotors
oWearpads
oTiresandwheels
oLimit switches, alarms and horn
oNuts, bolts and other fasteners
oPlatformentrychain(if equipped)
oPlatformentrygate(ifequipped)
oBeaconandalarms(ifequipped)
oBrakereleasecomponents
oSafety arm
oPotholeguards
oPlatformextension
oScissor pins and retaining fasteners
oPlatform control joystick
oGenerator(ifequipped)
oCounterweight(ifequipped)
Checkentire machine for:
oCracks in welds or structural components
oDentsor damagetomachine
oBe sure that all structural and other critical
componentsare present andallassociated
fastenersand pins are in place and properly
tightened.
oSide rails are installed and bolts are fastened
oBe sure that the chassis trays are in place,
latchedandproperlyconnected.

14 GenieGS-2032andGenieGS-2632 PartNo.82784
Operator's Manual Second Edition • Second Printing
Observe and Obey:
Only routine maintenance items specified in this
manualshallbe performedbytheoperator.
Scheduledmaintenanceinspectionsshallbe
completed by qualified service technicians,
accordingto the manufacturer's specifications
andtherequirements specified in the
responsibilitiesmanual.
Maintenance Symbols Legend
Thefollowing 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
beginningofamaintenance
procedure,itconveysthemeaning
below.
Indicates that tools will be required to
performthisprocedure.
Indicates that new parts will be required to
performthisprocedure.
Check the Hydraulic Oil Level
Maintaining the hydraulic oil at the proper levels is
essentialtomachineoperation.Improperhydraulic
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.
Performthis procedurewith 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
powerunitmodule.
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 equivalent
Maintenance

PartNo.82784 GenieGS-2032andGenieGS-2632 15
Operator's Manual
Second Edition • Second Printing
Check the Batteries
Proper battery condition is essential to good engine
performanceandoperationalsafety.Improperfluid
levels or damaged cables and connections can
resultinenginecomponentdamageandhazardous
conditions.
Thisprocedure does not need to
beperformedonmachineswith
sealedormaintenance-free
batteries.
Electrocutionhazard. Contactwith
hot or live circuits may result in
death or serious injury. Remove all
rings,watches and otherjewelry.
Bodily injury hazard. Batteries
contain acid. Avoid spilling or
contactingbatteryacid.Neutralize
battery acid spills with baking soda
andwater.
Perform this test after fully
chargingthebatteries.
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,replenishwith distilled water to the
bottom of the battery fill tube. Do not overfill.
6 Install the vent caps.
MAINTENANCE
Scheduled Maintenance
Maintenanceperformedquarterly,annuallyand
every two years must be completed by a person
trainedand qualifiedtoperform maintenanceon this
machineaccordingtothe procedures found in the
service manual 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.

16 GenieGS-2032andGenieGS-2632 PartNo.82784
Operator's Manual Second Edition • Second Printing
Function Tests
Do Not Operate Unless:
You learn and practice the principles of safe
machineoperationcontainedinthisoperator's
manual.
1 Avoidhazardoussituations.
2 Alwaysperformapre-operationinspection.
3 Alwaysperformfunctiontestspriorto
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.
Fundamentals
The function tests are designed to discover any
malfunctions before the machine is put into service.
Theoperator must followthestep-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,accordingtothe manufacturer's
specifications.
Afterrepairs are completed, the operator must
performapre-operationinspectionandfunction
tests again before putting the machine into service.

PartNo.82784 GenieGS-2032andGenieGS-2632 17
Operator's Manual
Second Edition • Second Printing
1 Select a test area that is firm, level and free of
obstruction.
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 Observethediagnostic LEDreadout.
Result: LED should read 23 or --.
TestEmergencyStop
6 Push in the ground red Emergency Stop button
to the off position.
Result:Nofunctions should operate.
7 Pull out the red Emergency Stop button to
the on position.
TesttheUp/DownFunctions
Theaudible 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
deployedsoundsat300beepsperminute.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.
TestAuxiliaryLowering/ManualLowering
10 Activate the up function and raise the platform
approximately 60 cm.
11 Activatetheauxiliarylowering/manuallowering
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 Turn the key switch to platform control.
At the Platform Controls
TestEmergencyStop
13 Push in the platform red Emergency Stop button
to the off position.
Result:Nofunctions should operate.
TesttheHorn
14 Pull the red Emergency Stop button out to the
onposition.
15 Push the horn button.
Result:The hornshouldsound.
FUNCTIONTESTS

18 GenieGS-2032andGenieGS-2632 PartNo.82784
Operator's Manual Second Edition • Second Printing
Testthe Function Enable Switch
16 Do not hold the function enable switch on the
controlhandle.
17 Slowly move the control handle in the direction
indicated by the blue arrow, then in the direction
indicatedbytheyellowarrow.
Result:Nofunctions should operate.
TesttheUp/DownFunctions
18 Press the lift function select button.
19 Press and hold the function enable switch on the
controlhandle.
20 Slowly move the control handle in the direction
indicatedby 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.
Whenloweringtheplatform,theplatformshould
stop when it is 2.1 m from the ground. Be sure the
areabelow the platform is clear of personnel and
obstructionsbeforecontinuing.Tocontinue
lowering,releasethecontrol handle,wait 5
seconds, then move the control handle again.
TesttheSteering
Note:When performingthesteer anddrivefunction
tests, stand in the platform facing the steer end of
themachine.
23 Press the drive function select switch.
24 Press and hold the function enable switch on the
controlhandle.
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
controlpanel.
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
controlpanel.
FUNCTION TESTS