Terex Genie GS-1930/32 Operator's Manual
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Operator's Manual
GS-1530/32
GS-1930/32
GS-2032
GS-2632
GS-3232
GS-2046
GS-2646
GS-3246
GS-4047
Serial Number Range
from GS3010A-110000
from GS3011C-10000
from GS3014D-101
from GS3010A-110000
F
from GS3011C-10000
from GS3014D-101
from GS3211A-110000
from GS3212C-10000
from GS3211A-110000
from GS3212C-10000
from GS3211A-110000
from GS3212C-10000
from GS4612A-110000
from GS4612C-10000
from GS4616D-101
from GS4612A-110000
from GS4612C-10000
from GS4616D-101
from GS4612A-110000
from GS4612C-10000
from GS4616D-101
from GS4712C-101
from GS4716D-101
AUS
Australia
with
Maintenance
Information
Seventh Edition
Eighth Printing
Part No. T107028
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Table of Contents
Related Manuals for Terex Genie GS-1930/32
Summary of Contents for Terex Genie GS-1930/32
- Page 1 Operator's Manual Serial Number Range GS-1530/32 from GS3010A-110000 from GS3011C-10000 Australia from GS3014D-101 GS-1930/32 from GS3010A-110000 from GS3011C-10000 from GS3014D-101 GS-2032 from GS3211A-110000 from GS3212C-10000 GS-2632 from GS3211A-110000 from GS3212C-10000 GS-3232 from GS3211A-110000 from GS3212C-10000 GS-2046 with from GS4612A-110000 from GS4612C-10000 Maintenance from GS4616D-101 GS-2646...
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Page 2: Table Of Contents
16 Specifications ..........62 Copyright © 2012 Terex Corporation Seventh Edition: Eighth Printing, May 2018 Genie is registered trademarks of Terex South Dakota, Inc. in the U.S.A. and many other countries.“GS” is a trademark of Terex South Dakota, Inc. These machines comply with AS 1418.10... -
Page 3: Introduction
Seventh Edition • Eight Printing Operator's Manual Introduction Introduction 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: Danger 1 Comply with employer, job site and... - Page 4 Operator's Manual Seventh Edition • Eight 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.
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Page 5: Symbol And Hazard Pictorials Definitions
Seventh Edition • Eight Printing Operator's Manual Symbol and Hazard Pictorials Definitions Symbol and Hazard Pictorials Definitions 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 Explosion hazard Fire hazard... - Page 6 Operator's Manual Seventh Edition • Eight 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 anchorage No smoking points Voltage rating for Pressure rating for Manual force...
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Page 7: General Safety
Seventh Edition • Eight Printing Operator's Manual General Safety General Safety Part No. T107028_78 GS-30 • GS-32 • GS-46 • GS-47... - Page 8 Operator's Manual Seventh Edition • Eight Printing General Safety GS-30 • GS-32 • GS-46 • GS-47 Part No. T107028_78...
- Page 9 Seventh Edition • Eight Printing Operator's Manual General Safety 1290657 DANGER Tip-over hazard. Failure to replace batteries with proper weight batteries will result in death or serious injury. Batteries are used as counterweight and are critical to machine stability. Each battery 1290675 lbs / 2 must weigh...
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Page 10: Personal Safety
Operator's Manual Seventh Edition • Eight Printing Personal Safety Personal 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 11: Work Area Safety
Seventh Edition • Eight Printing Operator's Manual Work Area Safety Work Area 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 12 Operator's Manual Seventh Edition • Eight Printing Work Area Safety Do not raise the platform Do not operate the unless the machine is on a machine in strong or gusty firm, level surface. winds. Do not increase the surface area of the platform or the load.
- Page 13 Seventh Edition • Eight Printing Operator's Manual 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 14 Operator's Manual Seventh Edition • Eight Printing 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 15 Seventh Edition • Eight Printing Operator's Manual 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 16 Operator's Manual Seventh Edition • Eight Printing Work Area Safety Collision Hazards Do not lower the platform unless the area below is Be aware of limited sight clear of personnel and distance and blind spots obstructions. when driving or operating. Be aware of extended platform position when moving the machine.
- Page 17 Seventh Edition • Eight Printing Operator's Manual Work Area Safety Bodily Injury Hazard Damaged Machine Hazards Do not operate the machine with a hydraulic oil or Do not use a damaged or malfunctioning machine. air leak. An air leak or hydraulic leak can penetrate Conduct a thorough pre-operation inspection of the and/or burn skin.
- Page 18 Operator's Manual Seventh Edition • Eight Printing Work Area Safety Battery Safety Electrocution/Burn Hazards Burn Hazards Connect the battery charger to a grounded, AC 3-wire electrical Batteries contain acid. outlet only. Always wear protective clothing and eye wear when Inspect daily for damaged cords, working with batteries.
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Page 19: Legend
Seventh Edition • Eight Printing Operator's Manual Legend GS-1530 Legend Platform guard rails GS-1532 Lanyard anchorage points GS-1930 Platform controls GS-1932 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... - Page 20 Operator's Manual Seventh Edition • Eight Printing Legend Platform guard rails Lanyard anchorage points 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 21 Seventh Edition • Eight Printing Operator's Manual Legend GS-2046 Lanyard anchorage points GS-2646 Platform guard rails GS-3246 Platform extension release pedal GS-4047 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...
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Page 22: Controls
Operator's Manual Seventh Edition • Eight Printing 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 23 Seventh Edition • Eight Printing Operator's Manual Controls 137636 S T O P S T O P 137636 137636 S T O P S T O P Platform Control Panel Red Emergency Stop button Low speed lift enable button Push in the red Emergency Stop button to the Press and hold this button to off position to stop all functions.
- Page 24 Operator's Manual Seventh Edition • Eight Printing Controls High speed lift enable button Thumb rocker switch for steer function Press and hold this button to Press the left side of the thumb activate the high speed platform rocker and the machine will turn in function.
- Page 25 Seventh Edition • Eight Printing Operator's Manual Controls 12 Platform up OR outrigger retract button 16 Proportional control handle and function enable switch for drive, steer, lift and outrigger Press and hold this button and the functions platform will raise OR the Lift function: Press and hold the function outriggers will retract.
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Page 26: Inspections
Operator's Manual Seventh Edition • Eight Printing Inspections Inspections 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 27 Seventh Edition • Eight Printing Operator's Manual Inspections Pre-operation Inspection Outrigger housing and footpads (if 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 28 Operator's Manual Seventh Edition • Eight Printing 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 29 Seventh Edition • Eight Printing Operator's Manual Inspections Test Emergency Stop At the Ground Controls Push in the ground red Emergency Stop Select a test area that is firm, level and free of button to the off position. obstruction. Result: No functions should operate. Be sure the batteries are connected.
- Page 30 Operator's Manual Seventh Edition • Eight Printing Inspections Test Emergency Lowering At the Platform Controls 15 Activate the up function by pressing the lift Test Emergency Stop enable button and platform up button, and raise the platform approximately 60 cm. 18 Push in the platform red Emergency Stop button to the off position.
- Page 31 Seventh Edition • Eight Printing Operator's Manual Inspections 23 Do not press the high speed or low speed lift 35 Release the low speed lift enable button or the enable buttons. platform up button. 24 Press the platform up or platform down button. Result: The platform should stop raising.
- Page 32 Operator's Manual Seventh Edition • Eight Printing Inspections 44 Press the lift function button. Test the Steering 45 Press and hold the function enable switch on Note: When performing the steer and drive the control handle. Slowly move the control function tests, stand in the platform facing the steer handle in the direction indicated by the blue end of the machine.
- Page 33 Seventh Edition • Eight Printing Operator's Manual Inspections Test Drive and Braking Test the Tilt Sensor Operation Note: Perform this test from the ground with the 55 Press the drive function button (if platform controller. Do not stand in the platform. equipped).
- Page 34 Operator's Manual Seventh Edition • Eight Printing Inspections 72 Place a 2x4 or similar piece of wood under a Test Elevated Drive Speed pothole guard. 66 Raise the platform approximately 1.2 m from 73 Raise the platform. the ground. Result: Before the platform is raised 2.1 m 67 Press the drive function button (if from the ground, an alarm should sound.
- Page 35 Seventh Edition • Eight Printing Operator's Manual Inspections Note: If the outrigger enable, foot switch (if Use the button pattern on the platform equipped) and extend buttons are released too controls to determine which of these next soon after the outriggers have contacted the two function tests to perform.
- Page 36 Operator's Manual Seventh Edition • Eight Printing Inspections 94 Press and hold the outrigger retract button. Use this function test procedure if the decal on your platform controls has these buttons. Result: The outriggers should not retract. 95 Press and hold the outrigger enable button. 96 Press and hold the outrigger retract button.
- Page 37 Seventh Edition • Eight Printing Operator's Manual Inspections Note: If the control handle or foot switch (if 110 Raise the platform. equipped) are released too soon after the Result: The platform should raise to 9.8 m and outriggers have contacted the ground, a long beep stop.
- Page 38 Operator's Manual Seventh Edition • Eight Printing Inspections Workplace Inspection Fundamentals The workplace inspection helps the 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.
- Page 39 Seventh Edition • Eight 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 unstable or slippery surfaces overhead obstructions and high voltage conductors ...
- Page 40 Operator's Manual Seventh Edition • Eight Printing Inspections Inspection for Decals with Words Part No.Decal Description GS-1530, GS-1532, GS-1930 and 82558 Warning – Skin Injection Hazard 82559 Instructions – Annual Inspection GS-1932 82561 Danger – Crushing Hazard Use the pictures on the next page to verify that all 82563 Instructions –...
- Page 41 Seventh Edition • Eight Printing Operator's Manual Inspections 40434 137636 1257923 28236 114386 43618 28176 137605 137656 44736 T107032 133596 or 1256702 or 1257184 82557 44981 40434 28174 or 28235 82566 or 97618 62053 or 62054 82563 or 82287 or 82564 or 82568 62053 or 62054...
- Page 42 Operator's Manual Seventh Edition • Eight Printing Inspections Inspection for Decals with Words Part No.Decal Description GS-2032, GS-2632 and GS-3232 82563 Instructions – Max Cap, 500 lbs / 227 kg, GS-2632 and GS-3232 Use the pictures on the next page to verify that all 82657 Instructions –...
- Page 43 Seventh Edition • Eight Printing Operator's Manual Inspections 137605 137656 1257923 28236 114386 114359 40434 137636 or 133596 or 44736 228929 43618 28176 137693 or 233477 or 1257187 1256702 or 1256704 82557 28174 or 28235 40434 82307 or 97694 82563 or 82693 114428 62055...
- Page 44 Operator's Manual Seventh Edition • Eight Printing Inspections Inspection for Decals with Words Part No.Decal Description 82704 Label – Wheel Load, GS-2646 GS-2046, GS-2646, GS-3246 and 82705 Label – Wheel Load, GS-3246 GS-4047 82710 Instructions – Max Capacity, 1200 lbs / 544 kg, GS-2046 Use the pictures on the next page to verify that all 82726...
- Page 45 Seventh Edition • Eight Printing Operator's Manual Inspections 40434 28176 137636 133596 114386 43618 28236 137605 44736 228932 137656 or 1256702 1257923 or 214863 or 1257190 44981 28174 or 28235 40434 82710 or 82726 or 82727 or 214866 82557 97662 or 97663 or 214865 62056...
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Page 46: Operating Instructions
Operator's Manual Seventh Edition • Eight Printing Operating Instructions Operating Instructions 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 47 Seventh Edition • Eight 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 48 Operator's Manual Seventh Edition • Eight Printing Operating Instructions To Retract Outriggers: To Position Outriggers (GS-3232 models) To Extend Outriggers: Press and hold the outrigger enable Press and hold the button. outrigger enable button. Press and hold the outrigger retract button. The outriggers will begin to retract.
- Page 49 Seventh Edition • Eight Printing Operator's Manual Operating Instructions To Drive Controller Identification Press and hold the drive/steer function enable Use these instructions if the decal switch on the control handle. on your platform controls has these buttons. Increase speed: Slowly move the control handle off center.
- Page 50 Operator's Manual Seventh Edition • Eight Printing Operating Instructions Note: If the outrigger enable and extend buttons To Position Outriggers (GS-3232 models) are released too soon during extension, the To Extend Outriggers: outrigger indicator lights will continue to flash green, indicating the outriggers are not contacting Press the outrigger function button.
- Page 51 Seventh Edition • Eight Printing Operator's Manual Operating Instructions To Steer To Drive Press the drive function button. On the LCD Press the drive function button. On the LCD screen, a circle below the drive function screen, a circle below the drive function symbol will turn on.
- Page 52 Operator's Manual Seventh Edition • Eight Printing Operating Instructions To determine the slope grade: Driving on a slope Measure the slope with a digital inclinometer OR Determine the slope and side slope ratings for the use the following procedure. machine and determine the slope grade. You will need: Maximum slope rating, stowed position: ...
- Page 53 Seventh Edition • Eight Printing Operator's Manual Operating Instructions Operational indicator codes Platform Overload If the platform controls LED or ground controls If the platform controls LED diagnostic readout LCD diagnostic readout displays an operational displays a flashing OL and the ground controls indicator code such as LL, the fault condition must LCD diagnostic readout displays OL: Platform repaired or removed before resuming machine...
- Page 54 Operator's Manual Seventh Edition • Eight Printing Operating Instructions Battery Level Indicator How to Fold Down the Guardrails Use the LED diagnostic readout to determine the GS-1530, GS-1930, GS-2032, GS-2632 and battery level. GS-3232 Note: When a blinking LO code appears on the The platform railing system consists of one fold platform controls LED display, the machine must down rail section for the extension deck and one...
- Page 55 Seventh Edition • Eight Printing Operator's Manual Operating Instructions GS-2046, GS-2646, GS-3246 and GS-4047 How to Raise the Guardrails The platform railing system consists of three fold Follow the fold down instructions but in reverse down rail sections for the extension deck and three order, ensuring all lock pins are in place and sections for the main deck.
- Page 56 Operator's Manual Seventh Edition • Eight Printing Operating Instructions Standard Batteries 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. Replace the battery vent caps.
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Page 57: Transport And Lifting Instructions
Seventh Edition • Eight Printing Operator's Manual Transport and Lifting Instructions Transport and Lifting Instructions The machine must be on a level surface or secured before releasing the brakes. Do not allow the rails to fall when the snap pins are removed. - Page 58 Operator's Manual Seventh Edition • Eight Printing Transport and Lifting Instructions After the machine is loaded: Brake Release Operation Chock the wheels to prevent the machine from Chock the wheels to rolling. prevent the machine from rolling. Pull out the red Emergency Stop button at both the ground and platform controls to the on Be sure the winch line is properly secured to position.
- Page 59 Seventh Edition • Eight Printing Operator's Manual 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 60 Operator's Manual Seventh Edition • Eight Printing 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 61 Seventh Edition • Eight Printing Operator's Manual 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.
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Page 62: Maintenance
Operator's Manual Seventh Edition • Eight Printing Maintenance Maintenance 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 Observe and Obey: checks allow the inspector to identify changes in oil level that might indicate the presence of hydraulic ... - Page 63 Seventh Edition • Eight Printing Operator's Manual 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.
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Page 64: Specifications
Operator's Manual Seventh Edition • Eight Printing Specifications Specifications Model GS-1530 and GS-1532 Operating temperature Height, working maximum 6.4 m Minimum -29°C Height, platform maximum 4.6 m Maximum 66°C Height, stowed maximum 206 cm Airborne noise emissions Height, stowed maximum rails folded 172 cm Sound pressure level at ground workstation <70 dBA... - Page 65 Seventh Edition • Eight Printing Operator's Manual Specifications Model GS-1930 Operating temperature Height, working maximum 7.6 m Minimum -29°C Height, platform maximum 5.8 m Maximum 66°C Height, stowed maximum 210 cm Airborne noise emissions Height, stowed maximum rails folded 175 cm Sound pressure level at ground workstation <70 dBA Platform height, stowed maximum...
- Page 66 Operator's Manual Seventh Edition • Eight Printing Specifications Model GS-1932 Operating temperature Height, working maximum 7.5 m Minimum -29°C Height, platform maximum 5.6 m Maximum 66°C Height, stowed maximum 210 cm Airborne noise emissions Height, stowed maximum rails folded 175 cm Sound pressure level at ground workstation <70 dBA Platform height, stowed maximum...
- Page 67 Seventh Edition • Eight Printing Operator's Manual Specifications Model GS-2032 Operating temperature Height, working maximum 7.9 m Minimum -29°C Height, platform maximum 6.1 m Maximum 66°C Height, stowed maximum fixed rail 202 cm Airborne noise emissions Height, stowed maximum 212 cm Sound pressure level at ground workstation <70 dBA Height, stowed maximum rails folded...
- Page 68 Operator's Manual Seventh Edition • Eight Printing Specifications Model GS-2632 Operating temperature Height, working maximum 9.8 m Minimum -29°C Height, platform maximum 7.9 m Maximum 66°C Height, stowed maximum 225 cm Airborne noise emissions Height, stowed maximum rails folded 191 cm Sound pressure level at ground workstation <70 dBA Platform height, stowed maximum...
- Page 69 Seventh Edition • Eight Printing Operator's Manual Specifications Model GS-3232 Operating temperature Height, working maximum 11.6 m Minimum -29°C Height, working drivable 8.5 m Maximum 66°C Height, platform maximum 9.8 m Airborne noise emissions Height, platform drivable 6.7 m Sound pressure level at ground workstation <70 dBA Height, stowed maximum 238 cm...
- Page 70 Operator's Manual Seventh Edition • Eight Printing Specifications Model GS-2046 Operating temperature Height, working maximum 7.9 m Minimum -29°C Height, platform maximum 6.1 m Maximum 66°C Height, stowed maximum 213 cm Airborne noise emissions Height, stowed maximum rails folded 156 cm Sound pressure level at ground workstation <70 dBA Platform height, stowed maximum...
- Page 71 Seventh Edition • Eight Printing Operator's Manual Specifications Model GS-2646 Operating temperature Height, working maximum 9.8 m Minimum -29°C Height, platform maximum 7.9 m Maximum 66°C Height, stowed maximum 225 cm Airborne noise emissions Height, stowed maximum rails folded 168 cm Sound pressure level at ground workstation <70 dBA Platform height, stowed maximum...
- Page 72 Operator's Manual Seventh Edition • Eight Printing Specifications Model GS-3246 Operating temperature Height, working maximum 11.6 m Minimum -29°C Height, platform maximum 9.8 m Maximum 66°C Height, stowed maximum 238 cm Airborne noise emissions Height, stowed maximum rails folded 181 cm Sound pressure level at ground workstation <70 dBA Platform height, stowed maximum...
- Page 73 Seventh Edition • Eight Printing Operator's Manual Specifications Model GS-4047 Operating temperature Height, working maximum 13.7 m Minimum -29°C Height, platform maximum 11.7 m Maximum 66°C Height, stowed maximum 254 cm Airborne noise emissions Height, stowed maximum rails folded 195 cm Sound pressure level at ground workstation <70 dBA Platform height, stowed maximum...