GENIE GS-1932 (01) PDF DOCUMENT

Before operating the GENIE GS-1932, you must read, understand, and obey the safety rules and operating instructions. Only trained and authorized personnel are permitted to operate this machine. The operator’s manual should be considered a permanent part of your machine and remain with it at all times.

You must not operate the GENIE GS-1932 unless you:

Learn and practice the principles of safe machine operation contained in the operator’s manual.

Avoid hazardous situations.

Always perform a pre-operation inspection.

Always perform function tests prior to use.

Inspect the workplace.

Only use the machine as it was intended.

Read, understand, and obey the manufacturer’s instructions and safety rules, employer’s safety rules, worksite regulations, and applicable governmental regulations.

Are properly trained to safely operate the machine.

The GENIE GS-1932 is not electrically insulated and will not provide protection from contact with or proximity to electrical current. To avoid electrocution, maintain safe distances from electrical power lines and apparatus in accordance with applicable governmental regulations and the following chart:

Additionally:

Allow for platform movement, electrical line sway or sag, and be aware of strong or gusty winds.

Keep away from the machine if it contacts energized power lines. Personnel on the ground or in the platform must not touch or operate the machine until energized power lines are shut off.

Do not operate the machine during lightning or storms.

Do not use the machine as a ground for welding.

To prevent tip-over hazards with the GENIE GS-1932, operators must adhere to the following rules:

Do not exceed the maximum platform capacity. For the GS-1932, the capacity is:

Do not raise the platform unless the machine is on a firm, level surface.

If the tilt alarm sounds, lower the platform and move the machine to a firm, level surface.

Do not drive over 0.5 mph / 0.7 km/h with the platform raised.

Do not operate in strong or gusty winds. Do not increase the surface area of the platform or the load.

Use extreme care and slow speeds when driving in a stowed position across uneven terrain, debris, unstable or slippery surfaces, and near holes or drop-offs.

Do not push off or pull toward any object outside of the platform. The maximum allowable manual force in Australia is 90 lbs / 400 N for 2 people, and 45 lbs / 200 N for 1 person.

Do not alter or disable machine components that affect safety and stability.

Do not drive the machine on or near uneven terrain, unstable surfaces, or other hazardous conditions with the platform raised.

To mitigate fall hazards when using the GENIE GS-1932, operators must follow these safety rules:

Occupants should wear a safety belt or harness and comply with applicable governmental regulations. Attach the lanyard to the anchor provided in the platform.

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 it is raised.

Keep the platform floor clear of debris.

Attach the platform entry chain and close the entry gate before operating.

Do not operate the machine unless the guard rails are properly installed and the entry is secured for operation.

Do not place or attach fixed or overhanging loads to any part of the machine.

Do not place ladders or scaffolds in the platform or against any part of the machine.

Do not use the machine on a moving or mobile surface or vehicle.

Do not place loads outside the platform perimeter.

Collision Hazards:

Be aware of limited sight distance and blind spots when driving or operating.

Do not lower the platform unless the area below is clear of personnel and obstructions.

Be aware of the extended platform position when moving the machine.

The machine must be on a level surface or secured before releasing the brakes.

It is recommended that operators wear an approved hard hat.

Check the work area for overhead obstructions or other possible hazards.

Observe and use the color-coded direction arrows on the platform controls for drive and steer functions.

Limit travel speed according to ground surface condition, congestion, slope, and location of personnel.

Do not operate in the path of any crane or moving overhead machinery unless its controls have been locked out.

Crushing Hazards:

Keep hands and limbs out of the scissors mechanism.

Use common sense and planning when operating the machine with the controller from the ground. Maintain safe distances between the operator, the machine, and fixed objects.

Be aware of the crushing hazard when grasping the platform guard rail.

Burn Hazards:

Batteries contain acid. Always wear protective clothing and eyewear when working with them.

Avoid spilling or contacting battery acid. Neutralize spills with baking soda and water.

Explosion Hazards:

Keep sparks, flames, and lighted tobacco away from batteries as they emit an explosive gas.

The battery tray should remain open during the entire charging cycle.

Do not contact battery terminals or cable clamps with tools that may cause sparks.

Component Damage Hazard:

Do not use any battery charger greater than 24V to charge the batteries.

Electrocution Hazards:

Connect the battery charger to a grounded, AC 3-wire electrical outlet only.

Inspect daily for damaged 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 equipment. Batteries are used as counterweight. Each battery must weigh 65 pounds / 29.5 kg.

Lifting Hazard:

Use the appropriate number of people and proper lifting techniques when lifting batteries.

The Joystick Controller on the GENIE GS-1932 has the following functions:

The Pre-operation Inspection is a visual inspection performed by the operator before each work shift. You must check the following:

Be sure that the operator’s, safety, and responsibilities manuals are complete, legible, and in the storage container on the platform.

Be sure that all decals are legible and in place.

Check for hydraulic oil leaks and proper oil level. Add oil if needed.

Check for battery fluid leaks and proper fluid level. Add distilled water if needed.

Check the following components or areas for damage, modifications, and improperly installed or missing parts:

– 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

– 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 the entire machine for:

– Cracks in welds or structural components

– Dents or damage to the machine

– 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 in place, latched, and properly connected.

Perform this procedure with the platform in the stowed position.

1. Visually inspect the oil level in the hydraulic tank through the sight gauge on the side of the power unit module.

Result: The hydraulic oil level should be within the full and add marks on the oil level indicator decal.

2. Add oil if necessary. Do not overfill.

Hydraulic oil specification: Dexron equivalent

This procedure does not need to be performed on machines with sealed or maintenance-free batteries. Perform this test after fully charging the batteries.

1. Put on protective clothing and eyewear.

2. Be sure that the battery cable connections are free of corrosion.

3. Be sure that the battery hold downs and cable connections are tight.

4. Remove the battery vent caps.

5. Check the battery acid level of each battery. If needed, replenish with distilled water to the bottom of the battery fill tube. Do not overfill.

6. Install the vent caps.

1. Select a test area that is firm, level, and free of obstruction.

2. Be sure the battery pack is connected.

3. Pull out the platform and ground red Emergency Stop buttons to the ON position.

4. Turn the key switch to ground control.

5. Observe the diagnostic LED readout. The LED should read — or 23.

Test Emergency Stop:

6. Push in the ground red Emergency Stop button to the OFF position. No functions should operate.

7. Pull out the red Emergency Stop button to the ON position.

Test the Up/Down Functions:

8. Activate the up function. The platform should raise.

9. Activate the down function. The platform should lower, and the descent alarm should sound.

Test the Manual Lowering:

10. Activate the up function and raise the platform approximately 2 feet / 60 cm.

11. Pull the manual lowering knob located next to the ground controls. The platform should lower, but the descent alarm will not sound.

12. Turn the key switch to platform control.

Test Emergency Stop:

1. Push in the platform red Emergency Stop button to the OFF position. No functions should operate.

Test the Horn:

2. Pull the red Emergency Stop button out to the ON position.

3. Push the horn button. The horn should sound.

Test the Function Enable Switch:

4. Do not hold the function enable switch on the control handle.

5. Slowly move the control handle in the direction indicated by the blue arrow, then in the direction indicated by the yellow arrow. No functions should operate.

Test the Up/Down Functions:

6. Press the lift function select button (or press and hold the lift function enable button, or move the lift/drive selector switch to the lift position, depending on your controller).

7. Press and hold the function enable switch on the control handle.

8. Slowly move the control handle in the direction indicated by the blue arrow. The platform should raise, and the pothole guards should deploy.

9. Release the control handle. The platform should stop raising.

10. Press and hold the function enable switch. Slowly move the control handle in the direction indicated by the yellow arrow. The platform should lower, and the descent alarm should sound.

Note: When performing these tests, stand in the platform facing the steer end of the machine.

Test the Steering:

1. Press the drive function select switch (or move the lift/drive selector to the drive position).

2. Press and hold the function enable switch on the control handle.

3. Depress the thumb rocker switch on top of the control handle. The steer wheels should turn in the direction that the blue and yellow triangles point on the control panel.

Test Drive and Braking:

4. Press and hold the function enable switch.

5. Slowly move the control handle in the direction indicated by the blue arrow on the control panel until the machine begins to move, then return the handle to the center position. The machine should move in the direction of the arrow and then come to an abrupt stop.

6. Slowly move the control handle in the direction indicated by the yellow arrow on the control panel until the machine begins to move, then return the handle to the center position. The machine should move in the direction of the arrow and then come to an abrupt stop.

Note: The drive brakes must be able to hold the machine on any slope it is able to climb.

Test Limited Drive Speed:

1. Select the lift function.

2. Press and hold the function enable switch and raise the platform approximately 4 feet / 1.2 m from the ground. The pothole guards should deploy.

3. Select the drive function.

4. Press and hold the function enable switch. Slowly move the control handle to the full drive position. The maximum achievable drive speed with the platform raised should not exceed 0.7 feet per second / 20 cm/s.

Test the Tilt Sensor Operation (perform from the ground):

5. Fully lower the platform.

6. Place a 2×4 or similar piece of wood under both wheels on one side and drive the machine up onto them.

7. Raise the platform approximately 7 feet / 2.1 m. The platform should stop raising and the tilt alarm will sound at 600 beeps per minute. The drive function should not work in either direction.

8. Lower the platform and remove the wood.

Test the Pothole Guards:

9. Raise the platform. When the platform is raised 4 feet / 1.2 m, the pothole guards should deploy.

10. Press on the pothole guards on one side, then the other. They should not move.

11. Lower the platform. The pothole guards should return to the stowed position.

12. Place a 2×4 or similar piece of wood under a pothole guard. Raise the platform. Before the platform is raised 7 feet / 2.1 m, an alarm should sound and the drive function should not work.

13. Lower the platform and remove the 2×4.

Before moving the GENIE GS-1932 to the workplace, the operator must perform a workplace inspection to be aware of and avoid the following hazardous situations:

Drop-offs or holes

Bumps, floor obstructions, or debris

Overhead obstructions and high voltage conductors

Hazardous locations

Inadequate surface support to withstand all load forces imposed by the machine

Wind and weather conditions

The presence of unauthorized personnel

Other possible unsafe conditions

1. Turn the key switch to ground control.

2. Pull out both ground and platform red Emergency Stop buttons to the ON position.

3. Be sure the battery pack is connected before operating.

4. To position the platform, move the up/down toggle switch according to the markings on the control panel.

Note: Drive and steer functions are not available from the ground controls.

1. Turn the key switch to platform control.

2. Pull out the ground and platform red Emergency Stop buttons to the ON position.

3. Be sure the battery pack is connected before operating.

To Position Platform (Up/Down):

1. Press the lift function select button (or related lift enable button/switch).

2. Press and hold the function enable switch on the control handle.

3. Move the control handle according to the markings on the control panel.

To Steer:

1. Press the drive function select button (or move selector switch to drive).

2. Press and hold the function enable switch on the control handle.

3. Turn the steer wheels with the thumb rocker switch located on the top of the control handle.

To Drive:

1. Press the drive function select button (or move selector switch to drive).

2. Press and hold the function enable switch on the control handle.

3. To increase speed, slowly move the control handle off center. To decrease speed, slowly move the control handle toward center. To stop, return the control handle to center or release the function enable switch.

If the error indicator light is on, push in and pull out the red Emergency Stop button to reset the system. If the light stays on, tag and remove the machine from service.

1. Step on the platform extension release pedal on the platform toeboard.

2. Grasp the platform guard rails carefully and push to extend the platform to the mid-position stop.

3. Step on the release pedal again and push to fully extend the platform. Do not stand on the platform extension while trying to extend it.

4. To retract, step on the platform extension release pedal and pull to retract the platform to the mid-position stop. Step again to fully retract the platform.

1. Select a safe parking location—a firm level surface, clear of obstruction and traffic.

2. Lower the platform.

3. Turn the key switch to the OFF position and remove the key to secure from unauthorized use.

4. Chock the wheels.

5. Charge the batteries.

Before charging, observe the following:

Do not use an external charger or booster battery.

Charge the battery in a well-ventilated area.

Use proper AC input voltage for charging as indicated on the charger.

Use only Genie authorized battery and charger.

Charging Procedure:

1. Be sure the batteries are connected before charging.

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. Turn the battery charger on.

7. The charger will indicate when the battery is fully charged.

8. 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 for Loading:

1. Chock the wheels to prevent the machine from rolling.

2. Be sure the winch line is properly secured to the drive chassis tie points and the path is clear of all obstructions.

3. Turn the brake release knob counterclockwise to open the brake valve.

4. Pump the brake release pump knob.

After the machine is loaded:

1. Chock the wheels to prevent the machine from rolling.

2. Turn the brake release knob clockwise to reset the brakes.

Towing the GENIE GS-1932 is not recommended. If the machine must be towed, do not exceed 2 mph / 3.2 km/h.

Securing to Truck or Trailer for Transit:

1. Always chock the machine wheels in preparation for transport.

2. Use the tie-down points on the chassis for anchoring down to the transport surface.

3. Use chains or straps of ample load capacity.

4. Turn the key switch to the OFF position and remove the key before transporting.

5. Inspect the entire machine for loose or unsecured items.