Genie gS-1530/32 User manual

Operator's Manual
Serial Number Range
GS-1530/32
from GS3010A-110000
AUS
Australia
GS-1930/32
from GS3010A-110000
GS-2032
from GS3211A-110000
GS-2632
from GS3211A-110000
GS-3232
from GS3211A-110000
with
Maintenance
Information
GS-2046
from GS4612A-110000
GS-2646
from GS4612A-110000
GS-3246
from GS4612A-110000
GS-4047
from GS4712C-101
Seventh Edition
Fifth Printing
Part No. T107028

Operator's Manual Seventh Edition • Fifth Printing
GS-30 • GS-32 • GS-46 • GS-47 Part No. T107028
FrontMatter
Important
Read, understand and obey these safety rules
and operating instructions before operating this
machine. Only trained and authorized personnel
shall be permitted to operate this machine. This
manual should be considered a permanent part of
your machine and should remain with the machine
at all times. If you have any questions, contact us.
Contact Us:
Internet: www.genielift.com
E-mail: [email protected]
Contents
Introduction ........................................................... 1
Symbol and Hazard Pictorials Definitions............. 3
General Safety ...................................................... 5
Personal Safety..................................................... 8
Work Area Safety.................................................. 9
Legend ................................................................ 17
Controls............................................................... 20
Inspections.......................................................... 26
Operating Instructions......................................... 42
Transport and Lifting Instructions ....................... 50
Maintenance ....................................................... 55
Specifications...................................................... 57
Copyright © 2012 Terex Corporation
Seventh Edition: Fifth Printing, October 2012
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.
These machines comply with
AS 1418.10

Seventh Edition • Fifth Printing Operator's Manual
Introduction
Part No. T107028 GS-30 • GS-32 • GS-46 • GS-47 1
Introducti 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
governmental rules.
2 Read, understand and follow the instructions
in this and other manuals supplied with this
machine.
3 Use good safe work practices in a
commonsense way.
4 Only have trained/certified operators,
directed by informed and knowledgeable
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-operation inspection.
3 Always perform function tests prior to use.
4 Inspect the workplace.
5 Only use the machine as it was intended.
You read, understand and obey the
manufacturer’s instructions and safety
rules—safety and operator’s manuals and
machine decals.
You read, understand and obey employer’s
safety rules and worksite regulations.
You read, understand and obey all applicable
governmental regulations.
You are properly trained to safely operate the
machine.

Operator's Manual Seventh Edition • Fifth Printing
Introduction
2 GS-30 • GS-32 • GS-46 • GS-47 Part No. T107028
Hazard Classification
Decals on this machine use symbols, color coding
and signal words to identify the following:
Safety alert symbol—used to alert
you to potential personal injury
hazards. Obey all safety
messages that follow this symbol
to avoid possible injury or death.
Indicates a hazardous situation
which, if not avoided, will result in
death 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
Replace any missing or damaged safety signs.
Keep operator safety in mind at all times. Use mild
soap and water to clean safety signs. Do not use
solvent-based cleaners because they may damage
the safety sign material.
DANGER
WARNING
CAUTION
NOTICE

Seventh Edition • Fifth Printing Operator's Manual
Symbol and Hazard Pictorials Definitions
Part No. T107028 GS-30 • GS-32 • GS-46 • GS-47 3
Symbol and Hazard Pic torials Definiti ons
Read the operator’s
manual
Read the service
manual
Crush hazard Crush hazard Collision hazard
Tip-over hazard Tip-over hazard 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
personnel should
access
compartments
Use a piece of
cardboard or paper to
search for leaks

Operator's Manual Seventh Edition • Fifth Printing
Symbol and Hazard Pictorials Definitions
4 GS-30 • GS-32 • GS-46 • GS-47 Part No. T107028
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 attachment
point
No smoking
Voltage rating for
power to platform
Pressure rating for air
line to platform
Manual force Wind speed
Maximum capacity

Seventh Edition • Fifth Printing Operator's Manual
General Safety
Part No. T107028 GS-30 • GS-32 • GS-46 • GS-47 5
General Safety

Operator's Manual Seventh Edition • Fifth Printing
General Safety
6 GS-30 • GS-32 • GS-46 • GS-47 Part No. T107028

Seventh Edition • Fifth Printing Operator's Manual
General Safety
Part No. T107028 GS-30 • GS-32 • GS-46 • GS-47 7

Operator's Manual Seventh Edition • Fifth Printing
Personal Safety
8 GS-30 • GS-32 • GS-46 • GS-47 Part No. T107028
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
instructions.

Seventh Edition • Fifth Printing Operator's Manual
Work Area Safety
Part No. T107028 GS-30 • GS-32 • GS-46 • GS-47 9
WorkArea Safety
Electrocution Hazards
This machine is not electrically insulated and will
not provide protection from contact with or
proximity to electrical current.
Obey all local and
governmental
regulations regarding
required clearance from
electrical power lines. At
a minimum, the required
clearance contained in
the chart below must be
followed.
Line Voltage Required Clearance
0 to 50KV 3.05 m
50 to 200KV 4.60 m
200 to 350KV 6.10 m
350 to 500KV 7.62 m
500 to 750KV 10.67 m
750 to 1000KV 13.72 m
Allow for platform movement, electrical line sway or
sag, and beware 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.
Tip-over Hazards
Occupants, equipment and materials shall not
exceed the maximum platform capacity or the
maximum platform capacity of the platform
extension.
Maximum capacity
Platform extended
Model
Platform
retracted
Platform
only
Extension
only
Maximum
occupants
GS-1530 272 kg 159 kg 113 kg 2
GS-1532 272 kg 159 kg 113 kg 2
GS-1930 227 kg 113 kg 113 kg 2
GS-1932 227 kg 113 kg 113 kg 2
GS-2032 363 kg 249 kg 113 kg 2
GS-2632 227 kg 113 kg 113 kg 2
GS-3232 227 kg 113 kg 113 kg 2
GS-2046 544 kg 431 kg 113 kg 2
GS-2646 454 kg 340 kg 113 kg 2
GS-3246 318 kg 204 kg 113 kg 2
GS-4047 350 kg 237 kg 113 kg 2
Platform retracted Platform extended
Extension only Platform only

Operator's Manual Seventh Edition • Fifth Printing
Work Area Safety
10 GS-30 • GS-32 • GS-46 • GS-47 Part No. T107028
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 severe 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 drive over 0.8 km/h with the platform raised.
Outdoor Use: Do not raise the platform when wind
speeds may exceed 12.5 m/s. If wind speeds
exceed 12.5 m/s when the platform is raised, lower
the platform and do not continue to 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
position across uneven
terrain, debris, unstable
or slippery surfaces and
near holes and drop-offs.
Do not drive the machine on or near uneven terrain,
unstable surfaces or other hazardous conditions
with the platform raised.
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.

Seventh Edition • Fifth Printing Operator's Manual
Work Area Safety
Part No. T107028 GS-30 • GS-32 • GS-46 • GS-47 11
Do not push off or pull
toward any object outside
of the platform.
Maximum allowable manual force – AUS
Model Manual Force
Maximum
occupants
GS-1530 400 N Indoor use only – 2
GS-1532 400 N
200 N
Indoor – 2
Outdoor – 1
GS-1930 400 N Indoor use only – 2
GS-1932 400 N
200 N
Indoor – 2
Outdoor – 1
GS-2032 400 N
200 N
Indoor – 2
Outdoor – 1
GS-2632 400 N Indoor use only – 2
GS-3232 400 N Indoor use only – 2
GS-2046 400 N Indoor / Outdoor – 2
GS-2646 400 N Indoor / Outdoor – 2
GS-3246 400 N
200 N
Indoor – 2
Outdoor – 1
GS-4047 400 N Indoor use only – 3
Do not alter or disable the limit switches.
Do not alter or disable machine components that in
any way affect safety and stability.
Do not replace items critical to machine stability
with items of different weight or specification.
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.
For GS-4047 machines, each battery must weigh
37 kg. Battery tray including batteries must weigh a
minimum of 181 kg.
Do not modify or alter an aerial work platform
without prior written permission from the
manufacturer. Mounting attachments for holding
tools or other materials onto the platform,
toeboards or guard rail system can increase the
weight in the platform and the surface area of the
platform or the load.

Operator's Manual Seventh Edition • Fifth Printing
Work Area Safety
12 GS-30 • GS-32 • GS-46 • GS-47 Part No. T107028
Do not place or attach
fixed or overhanging loads
to any part of this
machine.
Do not place ladders or
scaffolds in the platform or
against any part of this
machine.
Do not transport tools and materials unless they
are evenly distributed and can be safely handled
by person(s) in the platform.
Do not use the machine on a moving or mobile
surface or vehicle.
Be sure all tires are in good condition, castle nuts
are properly tightened and cotter pins are properly
installed.
If equipped with outriggers
Do not set the machine up where it cannot be
leveled using only the outriggers.
Do not adjust the outriggers while the platform is
raised.
Do not drive while the outriggers are lowered.

Seventh Edition • Fifth Printing Operator's Manual
Work Area Safety
Part No. T107028 GS-30 • GS-32 • GS-46 • GS-47 13
Crushing Hazard
Keep hands and limbs out of scissors.
Keep hands clear when folding rails.
Do not work under the platform or in the scissor
links without the safety arm in place.
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.
Operation on Slopes Hazards
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 stowed
position.
Model
Maximum
slope rating,
stowed position
Maximum
side slope rating,
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°)
GS-4047 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
personal fall protection equipment (PFPE) due to
job site or employer rules, PFPE and its use shall
be in accordance with the PFPE manufacturer’s
instructions and applicable governmental
requirements. Use approved lanyard attachment
point provided.
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.
Do not enter or exit the platform unless the
machine is in the stowed position.
Attach the platform entry chain or 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.

Operator's Manual Seventh Edition • Fifth Printing
Work Area Safety
14 GS-30 • GS-32 • GS-46 • GS-47 Part No. T107028
Collision Hazards
Be aware of limited sight
distance and blind spots
when driving or operating.
Be aware of extended platform position when
moving the machine.
The machine must be on a level surface or secured
before releasing the brakes.
Operators must comply with employer, job site and
governmental rules regarding use of personal
protective equipment.
Check the work area for
overhead obstructions or
other possible 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
personnel, and any
other factors which may
cause collision.
Do not operate a machine in the path of any crane
or moving overhead machinery unless the controls
of the crane have been locked out and/or
precautions have been taken to prevent any
potential collision.
No stunt driving or horseplay while operating a
machine.

Seventh Edition • Fifth Printing Operator's Manual
Work Area Safety
Part No. T107028 GS-30 • GS-32 • GS-46 • GS-47 15
Bodily Injury Hazard
Do not operate the machine with a hydraulic oil or
air leak. An air leak or hydraulic leak can penetrate
and/or burn skin.
Improper contact with components under any
cover will cause serious injury. Only trained
maintenance personnel should access
compartments. Access by the operator is only
advised when performing a pre-operation
inspection. All compartments must remain closed
and secured during operation.
Explosion and Fire Hazards
Do not operate the machine or charge the battery
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 been performed as
specified in this manual and the appropriate Genie
service manual.
Be sure all decals are in place and legible.
Be sure the operator’s, safety and responsibilities
manuals are complete, legible and in the storage
container located on the platform.
Component Damage Hazards
Do not use any battery charger greater than 24V to
charge the batteries.
Do not use the machine as a ground for welding.

Operator's Manual Seventh Edition • Fifth Printing
Work Area Safety
16 GS-30 • GS-32 • GS-46 • GS-47 Part No. T107028
Battery Safety
Burn Hazards
Batteries contain acid.
Always wear protective
clothing and eye wear when
working with batteries.
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
or rain during charging.
Explosion Hazards
Keep sparks, flames and
lighted tobacco away from
batteries. Batteries emit
explosive gas.
The battery tray should
remain open during the
entire charging 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
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 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. For GS-4047 machines, each battery must
weigh 37 kg. Battery tray including batteries must
weigh a minimum of 181 kg.
Lifting Hazard
Use the appropriate number of people and proper
lifting techniques when lifting batteries.
Lockout After Each Use
1Select a safe parking location—firm level
surface, clear of obstruction and traffic.
2Lower the platform.
3Turn the key switch to the off position and
remove the key to secure from unauthorized
use.
4Chock the wheels.
5Charge the batteries.

Seventh Edition • Fifth Printing Operator's Manual
Legend
Part No. T107028 GS-30 • GS-32 • GS-46 • GS-47 17
Legend
1Platform guard rails
2Lanyard anchorage point
3Platform controls
4Manual storage container
5Platform extension
6Transport tie-down
7Steer tire
8Pothole guard
9Ground 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)
17 Tilt alarm
18 Safety arm
19 Air line to platform (optional)
20 Platform extension release pedal
21 GFCI outlet
22 Platform entry chain or gate
15
11
12 3 45
6
7
8
9
10
612
13
14
16
17
18
19
22
21
20
6
GS-1530
GS-1532
GS-1930
GS-1932

Operator's Manual Seventh Edition • Fifth Printing
Legend
18 GS-30 • GS-32 • GS-46 • GS-47 Part No. T107028
1Platform guard rails
2Lanyard anchorage point
3Platform extension release pedal
4Platform controls
5Platform extension
6Manual storage container
7Outrigger
8Transport tie-down
9Emergency lowering knob
10 Steer tire
11 Pothole guard
12 Ground controls
13 LCD readout
14 Non-steer tire
15 Brake release pump
16 Entry ladder / transport tie-down
17 Battery charger (on battery side of machine)
18 Tilt alarm
19 Inverter (optional)
20 Safety arm
21 Air line to platform (optional)
22 GFCI outlet
23 Platform entry chain or gate