Terex Genie GS-1530 User manual

Operator's Manual
GS-1530/32 • GS-1930/32 Part No. T107027
Seventh Edition • First Printing
Copyright © 1997 by Genie Industries
Seventh Edition: First Printing, February 2011
"Genie" is a registered trademark of
Genie Industries in the U.S.A. and many other
countries. "GS" is a trademark of Genie
Industries.
Complies with EC Directive 2006/42/EC
See EC Declaration of Conformity
Printed on recycled paper
Printed in U.S.A.
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, call Genie Industries.
Contents
Page
Introduction ................................................................ 1
Symbol and Hazard Pictorials Definitions .................. 3
General Safety .......................................................... 5
Personal Safety ......................................................... 7
Work Area Safety ...................................................... 8
Legend ..................................................................... 14
Controls .................................................................... 15
Inspections ............................................................... 18
Operating Instructions .............................................. 28
Transport and Lifting Instructions.............................. 35
Maintenance ............................................................. 39
Specifications ........................................................... 41
Contact us:
Internet: www.genielift.com
e-mail: [email protected]

Operator's Manual
Seventh Edition • First Printing
Part No. T107027 GS-1530/32 • GS-1930/32 1
Introduction
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 work site regulations.
You read, understand and obey all applicable
governmental regulations.
You are properly trained to safely operate the
machine.
Owners, Users and Operators:
Genie appreciates your choice of 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 common
sense way.
4 Only have trained/certified operators,
directed by informed and knowledgeable
supervision, running the machine.
If there is anything in this manual that is not clear
or which you believe should be added, please
contact us.
Internet: www.genielift.com
E-mail: [email protected]

Operator's Manual Seventh Edition • First Printing
2 GS-1530/32 • GS-1930/32 Part No. T107207
Intended Use
This machine is intended to be used only to lift
personnel, along with their tools and materials to
an aerial work site.
Introduction
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.
Hazard Classification
Genie uses 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 property damage
message.
Red
Orange
Yellow
Blue

Operator's Manual
Seventh Edition • First Printing
Part No. T107027 GS-1530/32 • GS-1930/32 3
Symbol and Hazard Pictorials Definitions
Read the
operator’s manual
Read the
service
manual
Tip-over hazard
Crush hazard Crush hazard Collision hazard
Tip-over hazardTip-over hazard Tip-over hazard Electrocution
hazard
Electrocution
hazard
Explosion hazard Fire hazard Burn hazard Skin injection
hazard
Keep away from
moving parts
Engage safety
arm
Keep clear of
outriggers and
tires
Move machine to
level ground
Lower the
platform
Maintain required
clearance
Do not set up
where it cannot
be leveled with
outriggers
Close chassis
tray
Only trained
maintenance
personnel should
access
compartments
Use a piece of
cardboard or
paper to search
for leaks

Operator's Manual Seventh Edition • First Printing
4 GS-1530/32 • GS-1930/32 Part No. T107207
Symbol and Hazard Pictorials Definitions
Wheel load
Voltage rating for
power to platform
Pressure rating for
air line to platform
Grounded AC
3-wire only
Replace damaged
wires and cords
No smoking
Batteries used as
counterweights
Lanyard
attachment pointTiedown
Chock the wheels Release brakes
Transport
diagram
Wind speed
Manual force
Maximum capacity IndoorOutdoor
X1

Operator's Manual
Seventh Edition • First Printing
Part No. T107027 GS-1530/32 • GS-1930/32 5
General Safety
Safety signs and locations

Operator's Manual Seventh Edition • First Printing
6 GS-1530/32 • GS-1930/32 Part No. T107207
General Safety
Safety signs and locations

Operator's Manual
Seventh Edition • First Printing
Part No. T107027 GS-1530/32 • GS-1930/32 7
Personal Safety
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.

Operator's Manual Seventh Edition • First Printing
8 GS-1530/32 • GS-1930/32 Part No. T107207
Electrocution Hazards
This machine is not electrically insulated and will
not provide protection from contact with or
proximity to electrical current.
Maintain safe distances from electrical power lines
and apparatus in accordance with applicable
governmental regulations and the following chart.
Line Voltage Required
Clearance
0 to 50KV 3.05 m
50KV to 200KV 4.60 m
200KV to 350KV 6.10 m
350KV to 500KV 7.62 m
500KV to 750KV 10.67 m
750KV 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 must not
exceed the maximum platform capacity.
Maximum Capacity
GS-1530 and GS-1532 272 kg
GS-1930 and GS-1932 227 kg
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 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.
Work Area Safety

Operator's Manual
Seventh Edition • First Printing
Part No. T107027 GS-1530/32 • GS-1930/32 9
Work Area Safety
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 a 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.
Do not push off or pull toward any object outside of
the platform.
Maximum allowable manual force
Maximum
Model Manual Force Occupants
GS-1530 400 N Indoor use only - 2
GS-1532 400 N Indoor - 2
200 N Outdoor - 1
GS-1930 400 N Indoor use only - 2
GS-1932 400 N Indoor - 2
200 N Outdoor - 1
Do not alter or disable the limit switches.
Do not alter or disable machine components that in
any way affect safety and stability.

Operator's Manual Seventh Edition • First Printing
10 GS-1530/32 • GS-1930/32 Part No. T107207
Work Area Safety
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 box
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 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.
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.
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.
Maximum Maximum
slope rating side slope rating
Model stowed position 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°)
Note: Slope rating is subject to ground conditions
and adequate traction.

Operator's Manual
Seventh Edition • First Printing
Part No. T107027 GS-1530/32 • GS-1930/32 11
Work Area Safety
Fall Hazards
The guard rail system provides fall protection. If
occupants 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.
Keep the platform floor clear of debris.
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.
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.
Do not enter or exit the platform unless the
machine is in the stowed position.
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.
Check the work area for overhead obstructions or
other possible hazards.
Be aware of crushing hazards when grasping the
platform guard rail.
Operators must comply with employer, job site and
governmental rules regarding use of personal
protective equipment.

Operator's Manual Seventh Edition • First Printing
12 GS-1530/32 • GS-1930/32 Part No. T107207
Work Area Safety
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.
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
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 • First Printing
Part No. T107027 GS-1530/32 • GS-1930/32 13
Work Area Safety
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 an
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.
Lifting Hazard
Use the appropriate number of people and proper
lifting techniques when lifting batteries.
Lockout After Each Use
1 Select a safe parking location—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.

Operator's Manual Seventh Edition • First Printing
14 GS-1530/32 • GS-1930/32 Part No. T107207
GS-1530
GS-1532
GS-1930
GS-1932
Legend
1 Platform guard rails
2 Lanyard anchorage point
3 Platform controls
4 Platform extension
5 Manual storage container
6 Transport tie-down
7 Steer tire
8 Pothole guard
9 Ground controls
10 LCD readout
11 Non-steer tire
12 Emergency lowering knob
13 Brake release pump
14 Entry ladder/transport tie-down
15 Battery charger
(on opposite side of machine)
16 Tilt alarm
17 Inverter (option)
18 Safety arm
19 Air line to platform (option)
20 Platform extension release pedal
21 GFCI outlet
22 Platform entry chain or gate

Operator's Manual
Seventh Edition • First Printing
Part No. T107027 GS-1530/32 • GS-1930/32 15
Controls
Ground Control Panel
1 Menu escape button
2 Menu up button
3 LCD diagnostic readout
4 Menu down button
5 Menu enter button
6 Key switch for platform/off/ground selection
Turn the key switch to the platform position and
the platform controls will operate. Turn the key
switch to the off position and the machine will
be off. Turn the key switch to the ground
position and the ground controls will operate.
7 Red Emergency Stop button
Push in the red Emergency Stop button to the
off position to stop all functions. Pull out the red
Emergency Stop button to the on position to
operate the machine.
8 7 amp breaker for electric circuits
9 Platform down button
10 Lift function enable button
Press and hold this button to activate the lift
function.
11 Platform up button

Operator's Manual Seventh Edition • First Printing
16 GS-1530/32 • GS-1930/32 Part No. T107207
Controls
Platform Control Panel without Outrigger Function
1 Thumb rocker switch for steer functions
2 LED diagnostic readout/battery charge indicator
3 Platform up button
4 Numeric keypad (if equipped)
5 Platform down button
6 Red Emergency Stop button
7 Low speed lift enable button
8 High speed lift enable button
9 Drive speed select button
10 Horn button
11 Proportional control handle and function enable
switch for drive and steer functions

Operator's Manual
Seventh Edition • First Printing
Part No. T107027 GS-1530/32 • GS-1930/32 17
Controls
Platform Control Panel
1 Thumb rocker switch for steer function
Press the left side of the thumb
rocker and the machine will turn in
the direction the blue triangle points
on the platform control panel.
Press the right side of the thumb
rocker and the machine will turn in
the direction the yellow triangle
points on the platform control panel.
2 LED diagnostic readout/battery charge indicator
3 Platform up button
Press and hold the platform up
button and the platform will raise.
4 Numeric keypad (if equipped)
5 Platform down button
Press and hold the platform down
button and the platform will lower.
6 Red Emergency Stop button
Push in the red Emergency Stop button to the
off position to stop all functions. Pull out the red
Emergency Stop button to the on position to
operate the machine.
7 Low speed lift enable button
Press and hold this button to
activate the low speed platform
function.
8 High speed lift enable button
Press and hold this button to
activate the high speed platform
function.
9 Drive speed button
Press this button to activate the
slow drive function. The indicator
light will be on when slow drive is
selected.
10 Horn Button
Press the horn button and the horn
will sound. Release the horn button
and the horn will not sound.
11 Proportional control handle and function enable
switch for drive and steer functions
Press and hold the function enable switch on
the platform control handle to activate the drive
or steer function.
Move the control handle in the direction
indicated by the blue arrow on the platform
control panel and the machine will move in the
direction the blue arrow points. Move the
control handle in the direction indicated by the
yellow arrow on the platform control panel and
the machine will move in the direction the
yellow arrow points.

Operator's Manual Seventh Edition • First Printing
18 GS-1530/32 • GS-1930/32 Part No. T107207
Inspections
Do Not Operate Unless:
You learn and practice the principles of safe
machine operation contained in this operator's
manual.
1 Avoid hazardous situations.
2 Always perform a pre-operation
inspection.
Know and understand the pre-operation
inspection before going on to the next
section.
3 Always perform function tests prior to use.
4 Inspect the workplace.
5 Only use the machine as it was intended.
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.
The inspection 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 unauthorized variation from
factory delivered condition is discovered, the
machine must be tagged and removed from
service.
Repairs to the machine may only be made by a
qualified service technician, according to the
manufacturer's specifications. After repairs are
completed, the operator must perform a
pre-operation inspection again before going on to
the function tests.
Scheduled maintenance inspections shall be
performed by qualified service technicians,
according to the manufacturer's specifications and
the requirements listed in the responsibilities
manual.