Genie GS-2032 Setup guide

Operator’sManual FourthEdition
SecondPrinting
PartNo.1000033
withMaintenanceInformation

Operator's Manual Fourth Edition • Second Printing
GS-2032•GS-2632 PartNo.1000033
Copyright © 1997 by Genie Industries
First Edition: Seventeenth Printing, October 2002
Second Edition: First Printing, October 2003
Third Edition: Second Printing, July 2004
Fourth Edition: Second Printing, February 2006
"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,understand andobey thesesafety rulesand
operatinginstructionsbeforeoperatingthismachine.
Onlytrainedandauthorizedpersonnelshallbe
permitted to operate this machine. This manual should
beconsidereda permanent partofyour machine and
should remain with the machine at all times. If you have
any questions, call Genie Industries.
Contents
Page
Safety Rules .............................................................. 1
Legend ....................................................................... 9
Controls .................................................................... 10
Pre-operationInspection ........................................... 12
Maintenance ............................................................. 14
Function Tests.......................................................... 16
WorkplaceInspection................................................ 21
OperatingInstructions............................................... 22
Transportand LiftingInstructions .............................. 27
Decals ...................................................................... 30
Specifications ........................................................... 34
Contact us:
Internet:http://www.genielift.com
e-mail:[email protected]

Operator'sManual
Fourth Edition • Second Printing
PartNo.1000033 GS-2032•GS-2632 1
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 Avoidhazardoussituations.
Knowandunderstandthesafetyrulesbefore
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, understandandobeythe
manufacturer'sinstructionsand safetyrules—
safetyandoperator'smanualsandmachine
decals.
Youread,understandandobeyemployer's
safety rules and worksite regulations.
Youread,understandandobeyallapplicable
governmentalregulations.
Youare properlytrained tosafely operate the
machine.

Operator'sManual Fourth Edition • Second Printing
2 GS-2032•GS-2632 PartNo.1000033
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
Feet Meters
0 to 300V Avoid Contact
300V to 50KV 10 3.05
50KV to 200KV 15 4.60
200KV to 350KV 20 6.10
350KV to 500KV 25 7.62
500KV to 750KV 35 10.67
750KV to 1000KV 45 13.72 800 lbs / 363 kg 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
energizedpowerlines. Personnelonthegroundor
in the platform must not touch or operate the
machine until energized power lines are shut off.
Donotoperatethemachineduringlightningor
storms.
Do not use the machine as a ground for welding.
Tip-over Hazards
Occupants, equipment and materials must not
exceed the maximum platform capacity or the
maximum capacity of the platform extension.
Maximum capacity - GS-2032
Platform retracted 800 lbs 363 kg
Platform extended - Platform only 550 lbs 249 kg
Platform extended - Extension only 250 lbs 113 kg
Maximum occupants - ANSI and CSA 2
Maximum occupants - Australia
Outdoor use 1
Indoor use only 2

Operator'sManual
Fourth Edition • Second Printing
PartNo.1000033 GS-2032•GS-2632 3
SAFETY RULES
Maximum capacity - GS-2632
Platform retracted 500 lbs 227 kg
Platform extended - Platform only 250 lbs 113 kg
Platform extended - Extension only 250 lbs 113 kg
Maximum occupants - ANSI and CSA 2
Maximum occupants - Australia
Indoor use only 2
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.
500 lbs / 227 kg Extension only
250 lbs / 113 kg Platform only 250 lbs / 113 kg
Do not drive over 0.5 mph / 0.7 km/h with the
platformraised.
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 drive the machine on a slope that exceeds
the slope and side slope rating of the
machine.Slope rating applies to machines in the
stowedposition.
Maximum slope rating, stowed position 30% (17°)
Maximum side slope rating,
stowedposition 30% (17°)
Note: Slope rating is subject to ground conditions
andadequatetraction.
Do not use the platform controls to free a platform
thatiscaught, snaggedorotherwise prevented
from normal motion by an adjacent structure. All
personnelmust beremoved from theplatform
before attempting to free the platform using the
groundcontrols.
Do not push off or pull
towardanyobject outside
of the platform.
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

Operator'sManual Fourth Edition • Second Printing
4 GS-2032•GS-2632 PartNo.1000033
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 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.Batteries areusedas
counterweight and are critical to machine stability.
Each battery must weigh 65 pounds / 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 alter or disable machine components that in
any way affect safety and stability.
Do not modify or alter an aerial work platform
withoutpriorwrittenpermission fromthe
manufacturer.Mountingattachmentsforholding
toolsor other materialsonto 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 raise the platform when wind speeds may
exceed 28 mph / 12.5 m/s. If wind speeds exceed
28 mph / 12.5 m/s when the platform is raised,
lowerthe platformand donot continueto operate
themachine.
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.
Donot drivethe machine on or nearuneven terrain,
unstablesurfacesorotherhazardousconditions
with the platform raised.
Do not replace items critical to machine stability
with items of different weight or specification.
Do not place or attach fixed or overhanging loads to
any part of this machine.
SAFETY RULES

Operator'sManual
Fourth Edition • Second Printing
PartNo.1000033 GS-2032•GS-2632 5
SAFETY RULES
Fall Hazards
The guard rail system provides fall protection. If
occupantsof theplatform are requiredto wear
personalfallprotection 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.
Collision Hazards
Be aware of limited sight
distance and blind spots
whendrivingoroperating.
Beaware oftheextended platformposition when
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 areafor overheadobstructionsor
otherpossiblehazards.
Beawareofcrushinghazardswhengraspingthe
platformguardrail.
Observeandusethecolor-codeddirectionarrows
on the platform controls and platform decal plate for
drive and steer functions.
Nostunt driving orhorseplay whileoperatinga
machine.

Operator'sManual Fourth Edition • Second Printing
6 GS-2032•GS-2632 PartNo.1000033
SAFETY RULES
Crushing Hazards
Keep hands and limbs out of scissors.
Do not work under the platform or in the scissor
links without the safety arm in place.
Usecommonsenseandplanningwhenoperating
themachine with the controller fromthe ground.
Maintainsafe distancesbetweenthe operator,the
machine and fixed objects.
Component Damage Hazard
Do not use the machine as a ground for welding.
Explosion and Fire Hazard
Donot operatethe machinein hazardous locations
orlocationswherepotentiallyflammableor
explosive gases or particles may be present.
Damaged Machine Hazards
Donot usea damaged ormalfunctioning machine.
Conductathoroughpre-operationinspectionofthe
machine and test all functions before each work
shift. Immediately tag and remove from service a
damagedormalfunctioningmachine.
Besure allmaintenance hasbeen 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
manualsare complete, legible and inthe storage
containerlocated onthe platform.
Do not lower the platform unless the area below is
clearofpersonnel andobstructions.
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 overheadmachinery unlessthecontrols
of the crane have been locked out and/or
precautionshave been takento prevent any
potentialcollision.

Operator'sManual
Fourth Edition • Second Printing
PartNo.1000033 GS-2032•GS-2632 7
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.
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.
Impropercontactwith 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.

Operator'sManual Fourth Edition • Second Printing
8 GS-2032•GS-2632 PartNo.1000033
SAFETY RULES
Battery Safety
Burn Hazards
Batteries contain acid. Always wear protective
clothingandeyewearwhen working 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 water
orrainduringcharging.
Explosion Hazards
Keep sparks, flames
andlightedtobacco
awayfrombatteries.
Batteries emit an
explosive gas.
The battery tray should
remainopenduringthe
entirecharging 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,
cablesandwires.Replace
damageditemsbefore
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
originalequipment.Batteries areusedas
counterweight and are critical to machine stability.
Each battery must weigh 65 pounds / 30 kg.
Lifting Hazard
Usetheappropriatenumberofpeopleandproper
lifting techniques when lifting batteries.

Operator'sManual
Fourth Edition • Second Printing
PartNo.1000033 GS-2032•GS-2632 9
Legend
1 Platform entry chain or entry
gate
2 Platformguardrails
3 Lanyardanchoragepoint
4 Platformextensionrelease
pedal
5 GFCIoutlet
6 Platformcontrols
7 Manualstoragecontainer
8 Tiltalarm(undercover)
9 Auxiliaryloweringlever
10 Transporttie-down
11 Steertire
12 Potholeguard
13 LEDdiagnosticreadout
14 Groundcontrols
15 Non-steertire
16 Brakereleasepumpknoband
releaseknob
17 Batterycharger(onopposite
sideof machine)
18 Entryladder/transport
tie-down
19 Safety arm

Operator'sManual Fourth Edition • Second Printing
10 GS-2032•GS-2632 PartNo.1000033
Controls
PlatformControls
1 RedEmergencyStopbutton
2 LED diagnostic readout / Battery charge
indicator
3 Lift function select button
4 Hornbutton
5 Proportionalcontrolhandleandfunctionenable
switch for lift and drive functions
6 Thumb rocker switch for steer functions
7 Drivespeedbutton
8 Drive function select button

Operator'sManual
Fourth Edition • Second Printing
PartNo.1000033 GS-2032•GS-2632 11
CONTROLS
GroundControl Panel
1 7 amp breaker for electrical circuits
2 Key switch for platform/off/ground selection
3 Hourmeter
4 Platformup/downtoggleswitch
5 RedEmergencyStopbutton
1
2
3
4
5

Operator'sManual Fourth Edition • Second Printing
12 GS-2032•GS-2632 PartNo.1000033
Pre-operation Inspection
Do Not Operate Unless:
You learn and practice the principles of safe
machineoperationcontainedinthisoperator's
manual.
1 Avoidhazardous situations.
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-operation inspection is a visualinspection
performed by the operator prior to each work shift.
The inspection is designed to discover if anything
isapparently wrongwitha machinebefore 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.
Ifdamageor any unauthorizedvariationfrom
factory delivered condition is discovered, the
machinemust betaggedand removedfrom
service.
Repairs to the machine may only be made by a
qualified service technician, according to the
manufacturer'sspecifications.Afterrepairsare
completed,theoperator must performa
pre-operationinspectionagainbeforegoingonto
the function tests.
Scheduledmaintenanceinspectionsshallbe
performedby qualifiedservice technicians,
accordingto themanufacturer'sspecifications and
the requirements listed in the responsibilities
manual.

Operator's Manual
Fourth Edition • Second Printing
Part No. 1000033 GS-2032 • GS-2632 13
Pre-operation Inspection
•Be sure that the operator's, safety and
responsibilities manuals are complete, legible
and in the storage container located on the
platform.
•Be sure that all decals are legible and in place.
See Decals section.
•Check for hydraulic oil leaks and proper oil
level. Add oil if needed. See Maintenance
section.
•Check for battery fluid leaks and proper fluid
level. Add distilled water if needed. See
Maintenance section.
Check the following components or areas for
damage, improperly installed or missing parts and
unauthorized modifications:
•Electrical components, wiring and electrical
cables
•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 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 welds or structural components
•Dents or damage to machine
•Excessive rust, corrosion or oxidation
•Be sure that all structural and other critical
components are present and all associated
fasteners and pins are in place and properly
tightened.
•Be sure side rails are installed and bolts are
fastened
•Be sure that the chassis trays are closed and
latched and the batteries are properly
connected.
Note: If the platform must be raised to inspect the
machine, make sure the safety arm is in place.
See Operating Instructions section.

Operator'sManual Fourth Edition • Second Printing
14 GS-2032•GS-2632 PartNo.1000033
Observe and Obey:
Only routine maintenance items specified in this
manualshallbeperformedbytheoperator.
Scheduledmaintenanceinspectionsshallbe
completed by qualified service technicians,
accordingto the manufacturer'sspecifications
andthe requirements specified in the
responsibilitiesmanual.
MaintenanceSymbolsLegend
Thefollowing symbolshavebeen
used in this manual to help
communicate the intent of the
instructions. When one or more of
the symbols appear at the
beginningofamaintenance
procedure,it conveysthe meaning
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.
Performthisprocedurewith the
platform in the stowed position.
1 Visually inspect the oil level in the hydraulic
tank.
Result: The hydraulic oil level should be at the
FULL mark on the tank.
2 Add oil if necessary. Do not overfill.
Hydraulic oil specifications
Hydraulic oil type Chevron Rykon
Premium MV equivalent
Maintenance

Operator'sManual
Fourth Edition • Second Printing
PartNo.1000033 GS-2032•GS-2632 15
Check the Batteries
Proper battery condition is essential to good
performanceandoperationalsafety.Improperfluid
levels or damaged cables and connections can
resultincomponentdamageandhazardous
conditions.
Thisprocedure doesnot need to
beperformedonmachineswith
sealedormaintenance-free
batteries.
Electrocutionhazard.Contactwith
hot or live circuits may result in
death or serious injury. Remove all
rings,watchesand otherjewelry.
Bodily injury hazard. Batteries
contain acid. Avoid spilling or
contactingbattery acid.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,replenish withdistilled waterto 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
trainedandqualifiedto performmaintenanceonthis
machineaccording tothe proceduresfound inthe
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.

Operator'sManual Fourth Edition • Second Printing
16 GS-2032•GS-2632 PartNo.1000033
Function Tests
Do Not Operate Unless:
You learn and practice the principles of safe
machineoperationcontainedinthisoperator's
manual.
1 Avoidhazardous situations.
2 Alwaysperformapre-operationinspection.
3 Alwaysperformfunctiontestspriorto
use.
Knowandunderstandthefunctiontests
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 followthe 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 only be made by a qualified service
technician,according tothemanufacturer's
specifications.
Afterrepairs arecompleted, the operatormust
performapre-operationinspectionandfunction
tests again before putting the machine into service.

Operator'sManual
Fourth Edition • Second Printing
PartNo.1000033 GS-2032•GS-2632 17
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 theplatform and groundred Emergency
Stop buttons to the on position.
4 Turn the key switch to ground control.
5 ObservethediagnosticLEDreadout.
Result: The LED should look like
the picture at right.
TestEmergencyStop
6 Push in the ground red Emergency Stop button
to the off position.
Result:No functionsshould operate.
7 Pull out the red Emergency Stop button to
the on position.
TesttheUp/DownFunctions
Theaudible warningson thismachine 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
deployedsounds at300 beepsper 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 shouldlower. The descent
alarm should sound while the platform is
lowering.
FUNCTIONTESTS
TestAuxiliaryLowering
10 Activate the up function and raise the platform
approximately 2 feet / 60 cm.
11 Pull the auxiliary lowering knob.
Result:The platform shouldlower. 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:No functionsshould operate.
TesttheHorn
14 Pull the red Emergency Stop button out to the
onposition.
15 Push the horn button.
Result:Thehorn shouldsound.

Operator'sManual Fourth Edition • Second Printing
18 GS-2032•GS-2632 PartNo.1000033
TesttheSteering
Note:Whenperforming the steeranddrive function
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 control
handle.
25 Depress the thumb rocker switch on top of the
control handle in the direction identified by the
bluetriangle on thecontrol 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.
FUNCTIONTESTS
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
indicatedby theyellow arrow.
Result:No functionsshould operate.
TesttheUp/DownFunctions
18 Press the lift function select
button.
19 Press and hold the function
enable switch on the control
handle.
20 Slowly move the control handle in the direction
indicatedby thebluearrow.
Result:The platform shouldraise. The pothole
guardsshoulddeploy.
21 Releasethecontrolhandle.
Result: The platform should stop raising.
22 Press and hold the function enable switch.
Slowly move the control handle in the direction
indicatedby theyellow arrow.
Result:The platform shouldlower. The descent
alarm should sound while the platform is
lowering.