Genie GS-1530/32 Operator's Manual

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Operator's manual (68 pages)

Operator's manual (69 pages)

Service and repair manual (343 pages)

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Page 1 Operator’s Manual Serial Number Range GS-1530/32 from GS3010A-110000 from GS3011C-10000 GS-1930/32 from GS3010A-110000 from GS3011C-10000 GS-2032 from GS3211A-110000 from GS3212C-10000 GS-2632 from GS3211A-110000 from GS3212C-10000 GS-3232 from GS3211A-110000 from GS3212C-10000 with GS-2046 from GS4611A-110000 Maintenance from GS4612C-10000 Information GS-2646 from GS4611A-110000...
Page 2: Table Of Contents
Seventh Edition: Third Printing, February 2012 at all times. If you have any questions, contact us. Genie is a registered trademark of Terex South Dakota, Inc. in the U.S.A. and many other countries. “GS” is a trademark of Terex South Dakota, Inc.
Page 3: Introduction
Seventh Edition • Third Printing Operator’s Manual Introduction Intr oducti on Owners, Users and Operators: Thank you for choosing our machine for your application. Our number one priority is user safety, which is best achieved by our joint efforts. We feel that you make a major contribution to safety if you, as the equipment users and operators: 1 Comply with employer, job site and...
Page 4 Operator’s Manual Seventh Edition • Third Printing Introduction Hazard Classification Intended Use This machine is intended to be used only to lift Decals on this machine use symbols, color coding personnel, along with their tools and materials to and signal words to identify the following: an aerial work site.
Page 5: Symbol And Hazard Pictorials Definitions
Seventh Edition • Third Printing Operator’s Manual Symbol and Hazard Pictorials Definitions Symbol and H az ard Pictorials Definiti ons Read the operator’s Read the service Crush hazard Crush hazard Collision hazard manual manual Tip-over hazard Tip-over hazard Tip-over hazard Tip-over hazard Electrocution hazard Electrocution hazard...
Page 6 Operator’s Manual Seventh Edition • Third Printing Symbol and Hazard Pictorials Definitions Batteries used as Chock the wheels Release brakes Grounded AC Replace damaged counterweights 3-wire only wires and cords Wheel load Transport diagram Tiedown Lanyard attachment No smoking point Voltage rating for Pressure rating for air Manual force...
Page 7: General Safety
Seventh Edition • Third Printing Operator’s Manual General Safety General Safety Part No. T107027 GS-30 • GS-32 • GS-46 • GS-47...
Page 8 Operator’s Manual Seventh Edition • Third Printing General Safety GS-30 • GS-32 • GS-46 • GS-47 Part No. T107027...
Page 9: Personal Safety
Seventh Edition • Third Printing Operator’s Manual Personal Safety Pers onal Safety Personal 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...
Page 10: Work Area Safety
Operator’s Manual Seventh Edition • Third Printing Work Area Safety Work Ar ea Safety Electrocution Hazards Tip-over Hazards This machine is not electrically insulated and will Occupants, equipment and materials shall not not provide protection from contact with or exceed the maximum platform capacity or the proximity to electrical current.
Page 11 Seventh Edition • Third Printing Operator’s Manual Work Area Safety Do not operate the Do not raise the platform machine in strong or unless the machine is on gusty winds. Do not a firm, level surface. increase the surface area of the platform or the load.
Page 12 Operator’s Manual Seventh Edition • Third Printing Work Area Safety Do not alter or disable the limit switches. Do not push off or pull toward any object outside Do not alter or disable machine components that in of the platform. any way affect safety and stability.
Page 13 Seventh Edition • Third Printing Operator’s Manual Work Area Safety If equipped with outriggers Do not place or attach fixed or overhanging loads Do not set the machine up where it cannot be to any part of this leveled using only the outriggers. machine.
Page 14 Operator’s Manual Seventh Edition • Third Printing Work Area Safety Operation on Slopes Hazards Fall Hazards Do not drive the machine on a slope that exceeds The guard rail system provides fall protection. If the slope and side slope rating of the machine. occupant(s) of the platform are required to wear Slope rating applies to machines in the stowed personal fall protection equipment (PFPE) due to...
Page 15 Seventh Edition • Third Printing Operator’s Manual Work Area Safety Collision Hazards Do not lower the platform unless the Be aware of limited sight area below is clear of distance and blind spots personnel and when driving or operating. obstructions. Be aware of extended platform position when moving the machine.
Page 16 Be sure all maintenance has been performed as compartments. Access by the operator is only specified in this manual and the appropriate Genie advised when performing a pre-operation service manual. inspection. All compartments must remain closed and secured during operation.
Page 17 Seventh Edition • Third Printing Operator’s Manual Work Area Safety Battery Safety Component Damage Hazard Do not use any battery charger greater than 24V to Burn Hazards charge the batteries. Batteries contain acid. Electrocution/Burn Hazards Always wear protective Connect the battery charger to a clothing and eye wear when grounded, AC 3-wire electrical working with batteries.
Page 18: Legend
Operator’s Manual Seventh Edition • Third Printing Legend Legend Platform guard rails Lanyard anchorage point Platform controls Manual storage container Platform extension Transport tie-down Steer tire Pothole guard Ground controls 10 LCD readout 11 Non-steer tire 12 Inverter (optional) 13 Brake release pump 14 Emergency lowering knob 15 Entry ladder / transport tie-down 16 Battery charger (on battery side of machine)
Page 19 Seventh Edition • Third Printing Operator’s Manual Legend Platform guard rails Lanyard anchorage point Platform extension release pedal Platform controls Platform extension Manual storage container Outrigger Transport tie-down Emergency lowering knob 10 Steer tire 11 Pothole guard 12 Ground controls 13 LCD readout 14 Non-steer tire 15 Brake release pump...
Page 20 Operator’s Manual Seventh Edition • Third Printing Legend Lanyard anchorage point Platform guard rails Platform extension release pedal Manual storage container Platform controls Platform extension Transport tie-down Emergency lowering knob Steer tire 10 Pothole guard 11 Ground controls 12 LCD readout 13 Non-steer tire 14 Brake release pump 15 Entry ladder / transport tie-down...
Page 21: Controls
Seventh Edition • Third Printing Operator’s Manual Controls Controls Ground Control Panel Menu escape button Red Emergency Stop button Menu up button Push in the red Emergency Stop button to the off position to stop all functions. Pull out the red LCD diagnostic readout Emergency Stop button to the on position to Menu down button...
Page 22 Operator’s Manual Seventh Edition • Third Printing Controls Platform Control Panel without Outrigger Function Thumb rocker switch for steer function Low speed lift enable button LED diagnostic readout / battery charge High speed lift enable button indicator Drive speed select button Platform up button 10 Horn button Numeric keypad (if equipped)
Page 23 Seventh Edition • Third Printing Operator’s Manual Controls Low speed lift enable button Platform Control Panel Thumb rocker switch for steer function Press and hold this button to activate the low speed platform Press the left side of the thumb function.
Page 24 Operator’s Manual Seventh Edition • Third Printing Controls Platform Control Panel with Outrigger Function, GS-3232 models Thumb rocker switch for steer function Red Emergency Stop button LED diagnostic readout / battery charge Low speed lift enable button indicator 10 High speed lift enable button Platform up OR outrigger retract button 11 Drive speed select button Numeric keypad (if equipped)
Page 25 Seventh Edition • Third Printing Operator’s Manual Controls Outrigger indicator lights Platform Control Panel Thumb rocker switch for steer function During outrigger extension, lights flash green. As each Press the left side of the thumb outrigger contacts the ground, rocker and the machine will turn in lights turn solid green.
Page 26 Operator’s Manual Seventh Edition • Third Printing Controls Low speed lift enable button 13 Proportional control handle and function enable switch for drive and steer functions Press and hold this button to activate the low speed platform Press and hold the function enable switch on function.
Page 27: Inspections
Seventh Edition • Third Printing Operator’s Manual Inspections Ins pections Pre-operation Inspection Fundamentals It is the responsibility of the operator to perform a pre-operation inspection and routine maintenance. The pre-operation inspection is a visual inspection performed by the operator prior to each work shift. Do Not Operate Unless: The inspection is designed to discover if anything is apparently wrong with a machine before the...
Page 28 Operator’s Manual Seventh Edition • Third Printing Inspections  Outrigger housing and footpads (if Pre-operation Inspection equipped)  Be sure that the operator’s, safety and  Battery pack and connections responsibilities manuals are complete, legible  Ground strap and in the storage container located in the platform.
Page 29 Seventh Edition • Third Printing Operator’s Manual Inspections 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 Do Not Operate Unless: tagged and removed from service.
Page 30 Operator’s Manual Seventh Edition • Third Printing Inspections At the Ground Controls Test the Up/Down Functions The audible warnings on this machine and the Select a test area that is firm, level and free of standard horn all come from the same central obstruction.
Page 31 Seventh Edition • Third Printing Operator’s Manual Inspections Test the Up/Down Functions At the Platform Controls 27 Press and hold the high speed lift enable Test Emergency Stop button. 18 Push in the platform red Emergency Stop 28 Press the platform up button. button to the off position.
Page 32 Operator’s Manual Seventh Edition • Third Printing Inspections Test the Steering Test Drive and Braking Note: When performing the steer and drive function 42 Press and hold the drive/steer function enable tests, stand in the platform facing the steer end of switch on the control handle.
Page 33 Seventh Edition • Third Printing Operator’s Manual Inspections Test the Tilt Sensor Operation Test Elevated Drive Speed Note: Perform this test from the ground with the 50 Press and hold the high or low speed lift platform controller. Do not stand in the platform. enable button.
Page 34 Operator’s Manual Seventh Edition • Third Printing Inspections 57 Press and hold the high or low speed lift Test the Pothole Guards enable button, and press the platform up Note: The pothole guards should automatically button to raise the platform. deploy when the platform is raised.
Page 35 Seventh Edition • Third Printing Operator’s Manual Inspections 72 Press and hold the outrigger enable button. Test the Outrigger Function (GS-3232) Press the outrigger extend button. 64 Press and hold the high speed lift enable Result: The outriggers should extend. The button.
Page 36 Operator’s Manual Seventh Edition • Third Printing Inspections 73 Press and hold the drive/steer function enable 79 Fully lower the platform. switch on the control handle. 80 Press and hold the outrigger enable button. 74 Slowly move the control handle in the direction Result: The outriggers should not retract.
Page 37 Seventh Edition • Third Printing Operator’s Manual Inspections Workplace Inspection Checklist Be aware of and avoid the following hazardous situations:  drop-offs or holes  bumps, floor obstructions or debris  sloped surfaces Do Not Operate Unless:  unstable or slippery surfaces ...
Page 38 Label – Skin Injection Hazard descriptions. 82562 Label – Crushing Hazard Part No. Decal Description 82568 Cosmetic – Genie GS-1532 28174 Label – Power to Platform, 230V 82570 Label – Wheel Load, GS-1530 and GS-1532 28235 Label – Power to Platform, 115V 82571 Label –...
Page 39 Seventh Edition • Third Printing Operator’s Manual Inspections Part No. T107027 GS-30 • GS-32 • GS-46 • GS-47...
Page 40 Label – Power to Platform, 230V 97719 Label – Safety Arm 28235 Label – Power to Platform, 115V 114324 Cosmetic – Genie GS-3232 40434 Label – Lanyard Anchorage Point 114334 Label – Electrocution Hazard, Plug 43618 Label – Directional Arrows 114337 Label –...
Page 41 Seventh Edition • Third Printing Operator’s Manual Inspections Part No. T107027 GS-30 • GS-32 • GS-46 • GS-47...
Page 42 Label – Air Line to Platform, 110 PSI 114370 Label – Tip-over Hazard, Batteries, 52475 Label – Transport Tie-down GS-2046, GS-2646 and GS-3246 62056 Cosmetic – Genie GS-2046 114372 Label – Tip-over Hazard, Open Trays 62057 Cosmetic – Genie GS-2646 137605 Label – Emergency Stop, Platform Control 62058 Cosmetic –...
Page 43 Seventh Edition • Third Printing Operator’s Manual Inspections Part No. T107027 GS-30 • GS-32 • GS-46 • GS-47...
Page 44: Operating Instructions
Operator’s Manual Seventh Edition • Third Printing Operating Instructions Operati ng Instr ucti ons Fundamentals The Operating Instructions section provides instructions for each aspect of machine operation. It is the operator’s responsibility to follow all the safety rules and instructions in the operator’s, safety and responsibilities manuals.
Page 45: Emergency Lowering
Seventh Edition • Third Printing Operator’s Manual Operating Instructions Emergency Stop Operation from Platform Push in the red Emergency Stop button to the off Be sure the battery pack is connected before position at the ground controls or the platform operating the machine.
Page 46 Operator’s Manual Seventh Edition • Third Printing Operating Instructions To Retract Outriggers: To Position Platform Press and hold the high or Press and hold the low speed lift enable button. outrigger enable button. Press the platform up or platform down button. Press and hold the outrigger retract button.
Page 47 Seventh Edition • Third Printing Operator’s Manual Operating Instructions To Steer To select drive speed Press and hold the drive/steer function enable The drive controls can operate in two different drive switch on the control handle. speed modes while in the stowed position. When the drive speed button light is on, slow drive speed Turn the steer wheels with the mode is active.
Page 48 For further information, please consult the Rise = 0.3 m appropriate Genie Service Manual. A code and a 0.3 m ÷ 3.6 m = 0.083 x 100 = 8.3% grade description of a code can also be viewed at the ground controls LCD display.
Page 49 Seventh Edition • Third Printing Operator’s Manual Operating Instructions Platform Overload Battery Level Indicator If the platform controls LED diagnostic readout Use the LED diagnostic readout to determine the displays a flashing OL and the ground controls battery level. LCD diagnostic readout displays OL: Platform Note: When a blinking LO code appears on the Overloaded, the platform is overloaded and no platform controls LED display, the machine must...
Page 50 Operator’s Manual Seventh Edition • Third Printing Operating Instructions How to Use the Safety Arm GS-2046, GS-2646, GS-3246 and GS-4047 The platform railing system consists of three fold Raise the platform approximately 2.4 m from down rail sections for the extension deck and three the ground.
Page 51 Use proper AC input voltage for charging as indicated on the charger. Dry Battery Filling and Charging  Use only a Genie authorized battery and Instructions charger. Remove the battery vent caps and To Charge Battery permanently remove the plastic seal from the battery vent openings.
Page 52: Transport And Lifting Instructions
Transportation regulations, other localized operation. regulations, and their company policy.  Genie customers needing to containerize any lift or Genie product should source a qualified freight forwarder with expertise in preparing, loading and securing construction and lifting equipment for international shipment. ...
Page 53 Pump the red brake release pump knob. position. Towing the Genie GS-1530, GS-1532, GS-1930, GS-1932, GS-2032, GS-2632, GS-3232, GS-2046, GS-2646, GS-3246 and GS-4047 is not recommended. If the machine must be towed, do not exceed 3.2 km/h.
Page 54 Operator’s Manual Seventh Edition • Third Printing Transport and Lifting Instructions Inspect the entire machine for loose or unsecured Securing to Truck or Trailer for items. Transit Use chains or straps of ample load capacity. Always use the extension deck lock when the Use a minimum of 2 chains or straps.
Page 55 Seventh Edition • Third Printing Operator’s Manual Transport and Lifting Instructions Lifting 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 Observe and Obey: procedures.
Page 56 Operator’s Manual Seventh Edition • Third Printing Transport and Lifting Instructions Lifting Instructions Fully lower the platform. Be sure the extension deck, controls and component trays are secure. Remove all loose items on the machine. Determine the center of gravity of your machine using the table and the picture on this page.
Page 57: Maintenance
Result: The hydraulic oil level should be between the ADD and FULL marks on the  Use only Genie approved replacement parts. tank. Add oil as needed. Do not overfill. Maintenance Symbols Legend Hydraulic oil specifications...
Page 58 Operator’s Manual Seventh Edition • Third Printing Maintenance Check the Batteries Scheduled Maintenance Maintenance performed quarterly, annually and every two years must be completed by a person trained and qualified to perform maintenance on Proper battery condition is essential to good this machine according to the procedures found in machine performance and operational safety.
Page 59: Specifications
It should be used only with adequate safety factors. Lift control 2 Speed Continuous improvement of our products is a Genie policy. AC outlet in platform standard Product specifications are subject to change without notice Maximum hydraulic pressure 241 bar or obligation.
Page 60 It should be used Lift control 2 Speed only with adequate safety factors. AC outlet in platform standard Continuous improvement of our products is a Genie policy. Product specifications are subject to change without notice 241 bar Maximum hydraulic pressure or obligation. (functions) Tire size 12 x 4.5 x 8 in...
Page 61 See serial label for specific machine weight.) only with adequate safety factors. Power source 4 Batteries, 6V 225AH Continuous improvement of our products is a Genie policy. System voltage Product specifications are subject to change without notice or obligation. Drive control...
Page 62 It should be used System voltage only with adequate safety factors. Drive control Proportional Continuous improvement of our products is a Genie policy. Lift control 2 Speed Product specifications are subject to change without notice or obligation.
Page 63 (Machine weights vary with option configurations. only with adequate safety factors. See serial label for specific machine weight.) Continuous improvement of our products is a Genie policy. Power source 4 Batteries, 6V 225AH Product specifications are subject to change without notice System voltage or obligation.
Page 64 See serial label for specific machine weight.) only with adequate safety factors. Power source 4 Batteries, 6V 225AH Continuous improvement of our products is a Genie policy. System voltage Product specifications are subject to change without notice Lift control Proportional or obligation.
Page 65 See serial label for specific machine weight.) only with adequate safety factors. Power source 4 Batteries, 6V 225AH Continuous improvement of our products is a Genie policy. System voltage Product specifications are subject to change without notice or obligation. Drive control...
Page 66 It should be used Power source 4 Batteries, 6V 225AH only with adequate safety factors. System voltage Continuous improvement of our products is a Genie policy. Product specifications are subject to change without notice Drive control Proportional or obligation.
Page 67 It should be used System voltage only with adequate safety factors. Drive Control Proportional Continuous improvement of our products is a Genie policy. Lift control 2 Speed Product specifications are subject to change without notice or obligation.

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Genie GS-1530/32 Operator's Manual

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