Terex Genie GS-2032 Page 1 Operator'S Manual Download | Manualshive

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Operator's Manual

GS

™

-1530/32

CE

GS

™

-1930/32

GS

™

-2032

GS

™

-2632

GS

™

-3232

with
Maintenance
Information

GS

™

-2046

GS

™

-2646

GS

™

-3246

Fifth Edition
Fifth Printing
Part No. 114313GT

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Summary of Contents for Genie GS-2032

Page 1: ...Operator s Manual GS 1530 32 CE GS 1930 32 GS 2032 GS 2632 GS 3232 with Maintenance Information GS 2046 GS 2646 GS 3246 Fifth Edition Fifth Printing Part No 114313GT ...

Page 2: ...e at all times If you have any questions contact us Contact Us Internet www genielift com E mail awp techpub terex com Contents Introduction 1 Symbol and Hazard Pictorials Definitions 3 General Safety 5 Personal Safety 7 Work Area Safety 8 Legend 16 Controls 19 Inspections 23 Operating Instructions 38 Transport and Lifting Instructions 46 Maintenance 50 Specifications 52 Copyright 1997 Terex Corpo...

Page 3: ...able supervision running the machine 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 machine operation contained in this operator s manual 1 Avoid hazardous situations Know and understand the safety rules before going on to the next section 2 Always perform a pre opera...

Page 4: ... or serious injury Indicates a hazardous situation which if not avoided could result in death or serious injury Indicates a hazardous situation which if not avoided could result in minor or moderate injury Indicates a property damage message Intended Use This machine is intended to be used only to lift personnel along with their tools and materials to an aerial work site Safety Sign Maintenance Re...

Page 5: ...ard Tip over hazard Tip over hazard Electrocution hazard Electrocution hazard Explosion hazard Fire hazard Burn hazard Skin injection hazard Engage safety arm Keep away from moving parts Keep clear of outriggers and tires Move machine to level ground Close chassis tray Lower the platform Do not set up where it cannot be leveled with outriggers Maintain required clearance Only trained maintenance p...

Page 6: ... Batteries used as counterweights Chock the wheels Release brakes Grounded AC 3 wire only Replace damaged wires and cords Wheel load Transport diagram Tiedown Lanyard anchorage points No smoking Voltage rating for power to platform Pressure rating for air line to platform Side force Wind speed Maximum capacity Outdoor Indoor ...

Page 7: ...Fifth Edition Fifth Printing Operator s Manual General Safety Part No 114313GT GS 30 GS 32 GS 46 5 General Safety ...

Page 8: ...Operator s Manual Fifth Edition Fifth Printing General Safety 6 GS 30 GS 32 GS 46 Part No 114313GT ...

Page 9: ...nal 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 must be inspected and used in accordance with the manufacturer s instructions ...

Page 10: ...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 use the machine as a ground for welding Tip over Hazards Occupants equipment and materials shall not exceed the maximum platform capacity or the maximum platform capacity of the platform extension Models w...

Page 11: ... kg 2 8 m 409 kg 1 m 281 kg Maximum capacity GS 3232 Height of platform Maximum capacity 9 8 m 227 kg 9 1 m 344 kg 5 4 m 498 kg 3 5 m 433 kg 1 m 227 kg Maximum capacity GS 2046 Height of platform Maximum capacity 6 m 544 kg 5 7 m 744 kg 3 5 m 985 kg 2 4 m 873 kg 1 m 635 kg Maximum capacity GS 2646 Height of platform Maximum capacity 7 9 m 454 kg 5 9 m 744 kg 4 5 m 798 kg 2 8 m 701 kg 1 m 454 kg Ma...

Page 12: ... operate the machine Indoor use When raising the platform follow ratings for allowable side force and number of occupants on the next page 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 Use extreme care and slow speeds while driving the machine in the stowed pos...

Page 13: ...ication 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 29 5 kg Battery tray including batteries must weigh a minimum of 152 kg Do not modify or alter an aerial work platform without prior written permission from the manufacturer Mounting attachments for holding tools or other materia...

Page 14: ...stowed position GS 1530 30 17 30 17 GS 1532 30 17 30 17 GS 1930 25 14 25 14 GS 1932 25 14 25 14 GS 2032 30 17 30 17 GS 2632 25 14 25 14 GS 3232 25 14 25 14 GS 2046 30 17 30 17 GS 2646 30 17 30 17 GS 3246 25 14 25 14 Note Slope rating is subject to ground conditions and adequate traction Fall Hazards The guard rail system provides fall protection If occupant s of the platform are required to wear p...

Page 15: ...ssible hazards Be aware of crushing hazards when grasping the platform guard rail Observe and use color coded direction arrows on the platform controls and the platform decal plate for drive and steer functions Do not lower the platform unless the area below is clear of personnel and obstructions Limit travel speed according to the condition of the ground surface congestion slope location of perso...

Page 16: ...ttery in hazardous locations or locations where potentially flammable or explosive gases or particles may be present Damaged Machine Hazards Do not use a damaged or malfunctioning machine 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 bee...

Page 17: ...er than 24V to charge the batteries Electrocution Burn Hazards Connect the battery charger to a grounded AC 3 wire electrical outlet only Inspect daily for damaged cords 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 e...

Page 18: ...sion 7 Transport tie down 8 Steer tire 9 Pothole guard 10 LED readout 11 Ground controls 12 Non steer tire 13 Emergency lowering knob 14 Brake release pump 15 Entry ladder transport tie down 16 Battery charger on battery side of machine 17 Tilt alarm under cover 18 Inverter optional 19 Safety arm 20 GFCI outlet 21 Capacity indicator if equipped 22 Platform extension release pedal 23 Platform entry...

Page 19: ... Transport tie down 10 Steer tire 11 Outrigger GS 3232 models 12 Pothole guard 13 LED readout 14 Ground controls 15 Non steer tire 16 Brake release pump 17 Entry ladder transport tie down 18 Battery charger on battery side of machine 19 Tilt alarm under cover 20 Inverter optional 21 Safety arm 22 GFCI outlet 23 Platform extension release pedal 24 Capacity indicator if equipped 25 Platform entry ch...

Page 20: ...ansport tie down 8 Steer tire 9 Pothole guard 10 LED readout 11 Ground controls 12 Non steer tire 13 Emergency lowering knob 14 Brake release pump 15 Entry ladder transport tie down 16 Battery charger on battery side of machine 17 Tilt alarm under cover 18 Inverter optional 19 Safety arm 20 GFCI outlet 21 Platform extension release pedal 22 Capacity indicator if equipped 23 Platform entry chain or...

Page 21: ...off position and the machine will be off Turn the key switch to the ground position and the ground controls will operate 3 Hour meter The hour meter displays the number of hours the machine has operated 4 Platform up down toggle switch Move the switch up and the platform will raise Move the switch down and the platform will lower 5 Red Emergency Stop button Push in the red Emergency Stop button to...

Page 22: ...14313GT Platform Control Panel 1 Thumb rocker switch for steer function 2 Drive speed button 3 Drive function select button 4 Red Emergency Stop button 5 LED 6 Lift function select button 7 Horn button 8 Proportional control handle and function enable switch for lift and drive functions ...

Page 23: ... 6 Lift function select button Press this button to activate the lift function 7 Horn button Press this button and the horn will sound Release the button and the horn will stop 8 Proportional control handle and function enable switch for lift and drive functions Lift function Move the control handle in the direction indicated by the blue arrow and the platform will raise Move the control handle in...

Page 24: ...hat the up down functions cannot be operated 3 Individual outrigger function indicator lights Turns solid green to indicate the outriggers made contact with the ground Flashes red or solid red to indicate an error 4 Function enable button Press and hold the button to activate the outrigger extend or outrigger retract button 5 Outrigger extend button Press this button and the outriggers will extend...

Page 25: ...ction is designed 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 unaut...

Page 26: ...pads Tires and wheels Limit switches alarms and horn Alarms and beacons if equipped Nuts bolts and other fasteners Brake release components Safety arm Platform extension Scissor pins and retaining fasteners Platform control joystick Outrigger housing and footpads if equipped Battery pack and connections Ground strap Platform entry chain or gate Platform overload components Pothole guards Lanyard a...

Page 27: ...y use the machine as it was intended Function Test 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 m...

Page 28: ...nt alarm sounds 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 d...

Page 29: ...escent alarm should sound while the platform is lowering When lowering the platform the platform should stop when it is approximately 2 1 m from the ground The descent delay lights will flash and the alarm will sound Be sure the area below the platform is clear of personnel and obstructions before continuing To continue lowering release the control handle and then move the control handle again Tes...

Page 30: ... Result The machine should move in the direction that the yellow arrow points on the control panel then come to an abrupt stop Note The brakes must be able to hold the machine on any slope it is able to climb Test the Tilt Sensor Operation Note Perform this test from the ground with the platform controller Do not stand in the platform 30 Fully lower the platform 31 Place a 2x4 or similar piece of ...

Page 31: ...achine from service Test the Pothole Guards Note The pothole guards should automatically deploy when the platform is raised The pothole guards activate limit switches that allow the machine to continue to function If the pothole guards do not deploy an alarm sounds and the machine will not drive or steer 39 Raise the platform Result When the platform is raised 1 2 m from the ground the pothole gua...

Page 32: ...extend buttons until the lift enable indicator light turns green and a beep is heard The machine is now level At this point the drive and steer functions are disabled 53 Press and hold the function enable switch on the control handle 54 Slowly move the control handle in the direction indicated by the blue arrow 55 Result The platform should raise to 9 8 m and stop 56 Fully lower the platform 57 Pr...

Page 33: ...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 Workplace Inspection Checklist Be aware of and avoid the following hazardous situa...

Page 34: ...1 82487 Label Read the Manual 2 82495 Label Brake Release Safety and Operating Instructions 2 82497 Label Manual Force 200 N Outdoors 400 N Indoors GS 1532 GS 1932 1 Part No Decal Description Qty 82502 Label LED Diagnostic Readout 1 82560 Label Skin Injection Hazard 1 82562 Label Crushing Hazard 4 82567 Ground Control Panel 1 82568 Cosmetic Genie GS 1532 2 82570 Label Wheel Load GS 1530 and GS 153...

Page 35: ...370 114372 114334 52475 82474 82562 28174 or 28235 43658 or 44980 82502 82476 52475 82482 82495 82570 or 82571 97772 97582 or 82497 40434 43618 40434 28174 or 28235 62503 or 62054 or 82568 or 82887 82481 82570 or 82571 44981 82664 or 82665 or 133239 or 133240 114361 114361 Serial label 114338 82487 82570 or 82571 82668 or 82669 62503 or 62054 or 82568 or 82887 43618 72086 72086 72086 43658 or 4498...

Page 36: ...497 Label Manual Force 200 N Outdoors 400 N Indoors GS 2032 1 82502 Label LED Diagnostic Readout 1 82560 Label Skin Injection Hazard 1 82562 Label Crushing Hazard 4 Part No Decal Description Qty 82567 Ground Control Panel 1 97582 Label Manual Force 400 N Indoor Use Only GS 2632 and GS 3232 1 97683 Label Capacity Indicator GS 2032 if equipped 1 97684 Label Capacity Indicator GS 2632 if equipped 1 9...

Page 37: ...337 114372 114370 114337 52475 82474 82562 44981 40434 114136 43618 40434 28174 or 28235 62055 or 72973 or 114324 28174 or 28235 97692 or 97693 or 114362 43658 or 44980 97692 or 97693 or 114362 82502 82476 72086 72086 72086 43658 or 44980 133531 133531 82475 114337 133531 82475 82481 82495 97685 or 97686 or 114434 or 133241 or 133242 114361 62055 or 72973 or 114324 114361 Serial label 114338 82487...

Page 38: ...ase Safety and Operating Instructions 1 82497 Label Manual Force 200 N Outdoors 400 N Indoors GS 3246 1 82502 Label LED Diagnostic Readout 1 Part No Decal Description Qty 82560 Label Skin Injection Hazard 1 82562 Label Crushing Hazard 4 82567 Ground Control Panel 1 82703 Label Wheel Load GS 2046 4 82704 Label Wheel Load GS 2646 4 82705 Label Wheel Load GS 3246 4 82787 Label Maximum Capacity GS 204...

Page 39: ...174 or 28235 82703 or 82704 or 82705 43658 or 44980 82502 82495 82787 or 82788 or 82789 or 133243 or 133244 or 133245 82905 or 82497 40434 43618 28174 or 28235 62056 or 62057 or 62058 72086 72086 72086 43658 or 44980 114334 82481 97772 40434 44981 82476 82703 or 82704 or 82705 82703 or 82704 or 82705 82703 or 82704 or 82705 62056 or 62057 or 62058 Serial label 114361 82562 114361 114338 82487 8279...

Page 40: ...is the operator 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 u...

Page 41: ...rding to the markings on the control panel Drive and steer functions are not available from the ground controls Operation from Platform 1 Be sure the battery pack is connected before operating the machine 2 Turn the key switch to platform control 3 Pull out both ground and platform red Emergency Stop buttons to the on position To Position Platform 1 Press the lift function select button 2 Press an...

Page 42: ...n and drive functions are disabled The lift error indicator light will turn red under the following conditions The platform is raised to 6 7 m and the outriggers are not deployed Not all outriggers are in contact with the ground All four outriggers are in contact with the ground but the machine is not level Error code To Retract Outriggers 1 Press and hold the function enable button 2 Press and ho...

Page 43: ...ntrol handle toward center Stop Return the control handle to center or release the function enable switch Use the color coded direction arrows on the platform controls and on the platform to identify 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 ...

Page 44: ...o determine the slope grade Measure the slope with a digital inclinometer OR use the following procedure You will need carpenter s level straight piece of wood at least 1 m long tape measure Lay the piece of wood on the slope At the downhill end lay the level on the top edge of the piece of wood and lift the end until the piece of wood is level While holding the piece of wood level measure the ver...

Page 45: ...lt 68 Low Battery Voltage LL Off Level OL Overload Cutout For more information please consult the appropriate Genie Service Manual Operation from Ground with Controller Maintain safe distances between the operator machine and fixed objects Be aware of the direction the machine will travel when using the controller Platform Overload Flashing OL in the LED diagnostic readout indicates the platform i...

Page 46: ...o each side rail bracket Note To assist in the removal and replacement of the wire lock pins pull or push back on the railing to compress the rubber bumpers GS 2046 GS 2646 GS 3246 The platform railing system consists of three fold down rail sections for the extension deck and three sections for the main deck All six sections are held in place by four wire lock pins 1 Fully lower the platform and ...

Page 47: ...istilled water to cover the plates Do not overfill prior to the charge cycle 2 Replace the battery vent caps 3 Connect the battery charger to a grounded AC circuit 4 The charger will indicate when the battery is fully charged 5 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 Charg...

Page 48: ...not allow the rails to fall when the snap pins are removed Maintain a firm grasp on the rails when the rails are lowered Do not drive the machine on a slope that exceeds the uphill downhill 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...

Page 49: ...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 GS 1530 GS 1532 GS 1930 GS 1932 GS 2032 GS 2046 GS 2632 GS 2646 GS 3232 GS 3246 ...

Page 50: ...ting the Machine with a Forklift Be sure the extension deck controls and component trays are secure Remove all loose items on the machine Fully lower the platform The platform must remain lowered during all loading and transport procedures Use the forklift pockets located on both sides of the ladder Position the forklift forks in position with the forklift pockets Drive forward to the full extent ...

Page 51: ...ure on this page Attach the rigging only to the designated lifting points on the machine There are two 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 Center of Gravity Table Model X Axis Y Axis GS 1530 49 8 cm 47 2 cm GS 1532 49 8 cm 47 2 cm GS 1930 50 8 cm 49 5 cm GS 1932 50 8 cm 49...

Page 52: ...enance procedure 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 level is essential to machine operation Improper hydraulic oil levels can damage hydraulic components Daily checks allow the inspector to identify c...

Page 53: ...da and water Note 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 hold down brackets are in place and secure Note Adding terminal protectors and a corrosion preventative sealant will help eliminate the corrosion on the battery terminals and cables S...

Page 54: ...hine weight Power source 4 Batteries 6V 225AH System voltage 24V Controls Proportional AC outlet in platform Standard Maximum hydraulic pressure functions 241 bar Tire size 12 x 4 5 x 8 in Airborne noise emissions Maximum sound level at normal operating workstations A weighted 70 dB Vibration value does not exceed 2 5 m s2 Maximum slope rating stowed position 30 17 Maximum side slope rating stowed...

Page 55: ...t Power source 4 Batteries 6V 225AH System voltage 24V Controls Proportional AC outlet in platform Standard Maximum hydraulic pressure functions 241 bar Tire size 12 x 4 5 x 8 in Airborne noise emissions Maximum sound level at normal operating workstations A weighted 70 dB Vibration value does not exceed 2 5 m s2 Maximum slope rating stowed position 25 14 Maximum side slope rating stowed position ...

Page 56: ...serial label for specific machine weight Power source 4 Batteries 6V 225AH Controls Proportional System voltage 24V AC outlet in platform Standard Maximum hydraulic pressure functions 241 bar Tire size 15 x 5 x 11 25 in Airborne noise emissions Maximum sound level at normal operating workstations A weighted 70 dB Vibration value does not exceed 2 5 m s2 Maximum slope rating stowed position 30 17 M...

Page 57: ...ial label for specific machine weight Power source 4 Batteries 6V 225AH Controls Proportional System voltage 24V AC outlet in platform Standard Maximum hydraulic pressure functions 241 3 bar Tire size 15 x 5 x 11 25 in Airborne noise emissions Maximum sound level at normal operating workstations A weighted 70 dB Vibration value does not exceed 2 5 m s2 Maximum slope rating stowed position 25 14 Ma...

Page 58: ...h option configurations See serial label for specific machine weight Power source 4 Batteries 6V 225AH Controls Proportional System voltage 24V AC outlet in platform Standard Maximum hydraulic pressure functions 241 3 bar Tire size 15 x 5 x 11 25 in Airborne noise emissions Maximum sound level at normal operating workstations A weighted 70 dB Vibration value does not exceed 2 5 m s2 Maximum slope ...

Page 59: ... serial label for specific machine weight Power source 4 Batteries 6V 225AH Controls Proportional System voltage 24V AC outlet in platform Standard Maximum hydraulic pressure functions 241 bar Tire size 15 x 5 x 11 25 in Airborne noise emissions Maximum sound level at normal operating workstations A weighted 70 dB Vibration value does not exceed 2 5 m s2 Maximum slope rating stowed position 30 17 ...

Page 60: ...erial label for specific machine weight Power source 4 Batteries 6V 225AH Controls Proportional System voltage 24V AC outlet in platform Standard Maximum hydraulic pressure functions 241 bar Tire size 15 x 5 x 11 25 in Airborne noise emissions Maximum sound level at normal operating workstations A weighted 70 dB Vibration value does not exceed 2 5 m s2 Maximum slope rating stowed position 30 17 Ma...

Page 61: ...ower source 4 Batteries 6V 225AH Controls Proportional System voltage 24V AC outlet in platform Standard Maximum hydraulic pressure functions 241 bar Tire size 15 x 5 x 11 25 in Airborne noise emissions Maximum sound level at normal operating workstations A weighted 70 dB Vibration value does not exceed 2 5 m s2 Maximum slope rating stowed position 25 14 Maximum side slope rating stowed position 2...

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