Schumacher 3010 Battery Charger User Manual
Contents
1. Genie Operator s Manual with Maintenance Information Third Edition Second Printing Part No 1000032 GS 1530 GS 1532 GS 1930 GS 1932 CE Models Operator s Manual Third Edition Second Printing 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 Safety RUES ececssicccceeseeveteccasussetdessuavdsseeseeieesaleveesaee 1 E a a a E E E O N 9 CONTOS serrer verre EANA E 10 Pre operation INSPECTION sssseeerreersrresseerreerrernns 12 Maintenance cccccecceeeeeeeeeeeeeeeeeeeeeeeeneensneaaeeaeeees 14 FUNGCHON TES S iroot e E 16 Workplace Inspection sssesssessseerrsssesrrrssrsensssns 20 Operating Instructions seeeeeeeeeeeeee esenee eenen 21 DOGAIS icr E A ER i 26 Transport and Lifting Instructions eee 28 SPOCIICALIONS cessionis sranta aatinaa 31 Contact us Internet http www genielift com E mail techpub genieind com Genie A TEREX COMPANY GS 1530 GS 1532 GS 1930 GS 1932 Copyright 1997 by Genie Industries First Edition Eleventh Printing January 2002 Second Edition Fourth Printing July 202. A TEREX COMPANY 30 GS 1530 GS 1532 GS 1930 GS 1932 Part No 1000032 Third Edition Second Printing Operator s Manual Specifications Model GS 1530 Platform dimensions 1 6 m x 74cm length x width Height working maximum 6 4 m Platform extension length 90 4 cm Height platform maximum 4 6m AC outlet in platform standard Height stowed maximum 1 96 m Rails up Maximum hydraulic pressure 241 bar functions Height stowed maximum 1 92 m Rails lowered Tires size 12x4 5x8in Height stowed maximum 97 cm Airborne noise emissions lt 70 dB Rails off Maximum sound level at normal operating workstations A weighted Height guard rails 99 1 cm Maximum slope rating Width 76 2CM stowed position 30 17 Length stowed 1 82m Maximum side slope rating ie 3 s Length platform extended 2 73 m Slowed position 30 15 Maximum load capacity 272 484 kg Note Slope rating is subject to ground conditions and adequate traction varies with height of machine Maximum wind speed 12 5 m s Drive speeds Wheelbase 1 32 m Stowed maximum 4 0 km h F f Platform 0 8 km h Turning radius outside om raised maximum 12 5 m 55 sec Turning radius inside oem Floor Loading Information Ground
3. Ground Control Panel 7 amp breaker for electrical circuits Key switch for platform off ground selection Hour meter Platform up down toggle switch Red Emergency Stop button oa AOON CONTROLS A TEREX COMPANY Part No 1000032 GS 1530 GS 1532 GS 1930 GS 1932 11 Operator s Manual Third Edition e Second Printing Pre operation Inspection Do Not Operate Unless M 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 A TEREX CO 12 GS 1530 GS 1532 GS 1930 GS 1932 MPANY 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
4. If more than one operator is expected to use a machine at different times in the same work shift they must all be qualified operators and are all expected to follow all safety rules and instructions in the operator s safety and responsibilities manuals That means every new operator should perform a pre operation inspection function tests and a workplace inspection before using the machine Part No 1000032 GS 1530 GS 1532 GS 1930 GS 1932 21 Operator s Manual Third Edition e Second Printing OPERATING INSTRUCTIONS Emergency Stop Push in the red Emergency Stop button to the off position at the ground controls or the platform controls to stop all functions Repair any function that operates when either Emergency Stop button is pushed in Auxiliary Lowering 1 Pull the auxiliary lowering knob Operation From Ground 1 Turn the key switch to ground control 2 Pullout both ground and platform red Emergency Stop buttons to the on position 3 Be sure the battery pack is connected before operating the machine To Position Platform 1 Move the up down toggle switch according to the markings on the control panel Drive and steer functions are not available from the ground controls A TEREX CO 22 GS 1530 GS 1532 GS 1930 GS 1932 Operation From Platform 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
5. 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 Lifting Hazard Use the appropriate number of people and proper lifting techniques when lifting batteries Operator s Manual Third Edition e Second Printing eee Decal Legend Genie product decals use symbols color coding and signal words to identify the following Safety alert symbol used to alert personnel to potential personal injury hazards Obey all safety messages that follow this symbol to avoid possible injury or death Red used to indicate the ADANGER presence of an imminently hazardous situation which if not avoided will result in death or serious injury 4 AWARNING Orange used to indicate the presence of a potentially A hazardous situation which if not avoided could result in death or serious injury Yellow with safety alert symbol ACAUTION used to indicate the presence of a A potentially hazardous situation which if not avoided may cause minor or moderate injury Yellow without safety alert CAUTION symbol used to indicate the presence of a potentially hazardous situation which if not avoided may result in property damage Green used to indicate operation or maintenance information A TEREX COMPANY 8 GS 1530 GS 1532
6. 74cm length x width Height working maximum 6 4m Platform extension length 90 4 cm Height platform maximum 46m AC outlet in platform standard Height stowed maximum 2 02 m Rails up Maximum hydraulic pressure 241 bar functions Height stowed maximum 1 73 m Rails folded Tires size 12x4 5x8in Height stowed maximum 97 cm Airborne noise emissions lt 70 dB Rails off Maximum sound level at normal operating workstations A weighted Height guard rails 1 1m Maximum slope rating Width 81 3CM stowed position 30 17 Length stowed 1 82m Maximum side slope rating me 3 s Length platform extended 2 73 m Slowed position 30 15 Maximum load capacity 272 484 kg Note Slope rating is subject to ground conditions and adequate traction varies with height of machine Maximum wind speed 12 5 m s Drive speeds Wheelbase 1 32 m Stowed maximum 4 0 km h F f Platform 0 8 km h Turning radius outside om raised maximum 12 5 m 55 sec Turning fadi s inside oem Floor loading information Ground clearance 6 1 cm Tire Ibad maximum 547 kg a i seas ved on Tire contact pressure 9 43 kg cm2 othole guards deploye 924 kPa Weight See Serial Label Occupied floor pressure 1142 kg m2 Machine weights vary with option configurations 11 20 kPa Power source 4 Batteries 6V 225AH System voltage 24V Controls Proportional Part No 1000032 A TEREX CON GS 1530 GS 1532 GS 1930 GS 1932 33 MPANY No
7. Length stowed 1 82m Maximum side slope rating iti O o Length platform extended 2 73 m Slowed position eave I Maximum load capacity 227 435 kg Note Slope rating is subject to ground conditions and adequate traction varies with height of machine Maximum wind speed 12 5 m s Drive speeds Wheelbase 1 32 m Stowed maximum 4 0 km h F f Platform 0 8 km h Turning radius outside ead raised maximum 12 5 m 55 sec Turning fadi s inside oromi Floor Loading Information Ground clearance 6 1 cm Tire Load maximum 600 kg Ground clearance 1 9 cm Pothole guards deployed Weight See Serial Label Machine weights vary with option configurations Tire Contact Pressure 10 35 kg cm2 1014 kPa 1391 kg m2 13 65 kPa Occupied Floor Pressure Power source 4 Batteries 6V 225AH System voltage 24V Controls Proportional 32 A TEREX COMI GS 1530 GS 1532 GS 1930 GS 1932 Note Floor loading information is approximate and does not incorporate different option configurations It should be used only with adequate safety factors Continuous improvement of our products is a Genie policy Product specifications are subject to change without notice or obligation Part No 1000032 Third Edition Second Printing Operator s Manual SPECIFICATIONS Model GS 1532 Platform dimensions 1 6m x
8. from the ground Result The platform should stop and the tilt alarm will sound at 600 beeps per minute Part No 1000032 Third Edition Second Printing Operator s Manual 33 Move the drive control handle in the direction indicated by the blue arrow then move the drive control handle in the direction indicated by the yellow arrow Result The drive function should not work in either direction 34 Lower the platform and remove both pieces of wood Test Limited Drive Speed 35 Press the lift function select button 36 Press and hold the function enable switch Raise the platform approximately 1 2 m from the ground Result The pothole guards should deploy 37 Press the drive function select switch 38 Press and hold the function enable switch Slowly move the control handle to the full drive position Result The maximum achievable drive speed with the platform raised should not exceed 20 cm s If the drive speed with the platform raised exceeds 20 cm s immediately tag and remove the machine from service Part No 1000032 A TEREX CON GS 1530 GS 1532 GS 1930 GS 1932 19 MPANY FUNCTION TESTS Test the Pothole Guards Note The pothole guards should automatically deploy when the platform is raised The pothole guards activate another limit switch which allows the machine to continue to function If the pothole guards do not deploy an alarm sounds and the machine will not d
9. in the direction that the blue triangle points on the control panel 26 Depress the thumb rocker switch in the direction identified by the yellow triangle on the control panel Result The steer wheels should turn in the direction that the yellow triangle points on the control panel A TEREX CO 18 GS 1530 GS 1532 GS 1930 GS 1932 Test Drive and Braking 27 Press and hold the function enable switch 28 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 Result The machine should move in the direction that the blue arrow points on the control panel then come to an abrupt stop 29 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 Result The machine should move in the direction that the yellow arrow points on the control panel then come to an abrupt stop Note The brakes must be able to hold the machine on any slope it is able to climb Test the Tilt Sensor Operation Note Perform this test from the ground with the platform controller Do not stand in the platform 30 Fully lower the platform 31 Place a 2x4 or similar piece of wood under both wheels on one side and drive the machine up onto them 32 Raise the platform approximately 2 1 m
10. or pull toward any object outside of the platform Maximum allowable manual force GS 1532 and GS 1932 2 person 400 N 1 person 200 N GS 1530 and GS 1930 2 person 400 N Indoor use only Operator s Manual Third Edition e Second Printing SAFETY RULES Do not alter or disable machine components that in any way affect safety and stability 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 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 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 Do not drive the machine on or near uneven terrain unstable surfaces or other hazardous conditions with the platform raised Do not replace items critical to machine stability with items of different weight or specification A TEREX COMI 4 GS 1530 GS 1532 GS 1930 GS 1932 Do not place or attach fixed or overhanging loads to any part of this machine Do not transport tools and materials unless
11. the LED diagnostic readout displays an error code such as LL push in and pull out the red Emergency Stop button to reset the system To Extend and Retract Platform 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 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 Platform Overload 1 Pushin the Red Emergency stop button to the off position Flashing OL in the LED diagnostic readout indicates the platform is overloaded and no functions will operate An alarm will sound 2 Remove weight from the platform 3 Pull out the Red Emergency stop button to the on position Operation From Ground with Controller Maintain safe distances between the operator machine and fixed objects Be aware of the direction the machine will travel when using the controller A TEREX COMI 24 GS 1530 GS 1532 GS 1930 GS 1932 Battery Level Indicator Full Low Use the LED diagnostic readout to determine the battery level Fall Protection Personal fall protection equipment PFPE is not required when operating this machine If PFPE is required by j
12. the battery is fully charged Part No 1000032 A TEREX CON GS 1530 GS 1532 GS 1930 GS 1932 25 MPANY OPERATING INSTRUCTIONS Standard Batteries 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 The charger will indicate when the battery is fully charged 7 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 Dry Battery Filling and Charging Instructions 1 Remove the battery vent caps and permanently remove the plastic seal from the battery vent openings 2 Fill each cell with battery acid electrolyte until the level is sufficient to cover the plates Do not fill to maximum level until the battery charge cycle is complete Overfilling can cause the battery acid to overflow during charging Neutralize battery acid spills with baking soda and water 3 Install the battery vent caps 4 Charge the battery 5 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 Operator s Manual Third Edition e Second Printing Decals Decal Inspection Use the pictures on the next page to verify that all d
13. the battery pack is connected before operating the machine To Position Platform 1 Press the lift function select button 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 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 reduce drive speed The drive controls can operate in two different drive speed modes When the drive speed button light is on slow drive speed mode is active When the button light is off fast drive speed mode is active Press the drive speed button to select the desired drive speed Part No 1000032 Third Edition Second Printing Operator s Manual To Drive 1 Press the drive function select button 2 Press and hold the function enable switch on the control handle 3 Increase speed Slowly move the control handle off center Decrease speed Slowly move the control handle toward center Stop Return the control handle to center or release the function enable switch Use the color coded direction arrows on the platform controls and on the platform to identify the direction the machine will travel Machine travel speed is restricted when the platform is raised Battery condition will affect machine performance Machi
14. they are evenly distributed and can be safely handled by person s in the platform Sw Do not place ladders or scaffolds in the platform or against any part of this machine 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 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 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 Part No 1000032 Third Edition Second Printing Operator s Manual 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 equipment and its use shall be in accordance with the PFPE manufacturer s instructions and applicable governmental requirements Do not sit stand or climb on the platform guard rails Maintain a firm footing on the platform floor at all times a e ez E gt a vo Do not climb down from the platform when
15. 04 Third Edition Second Printing February 2006 Genie is a registered trademark of Genie Industries in the U S A and many other countries GS is a trademark of Genie Industries Z Printed on recycled paper rd Printed in U S A Part No 1000032 Third Edition Second Printing Operator s Manual Safety Rules Danger Failure to obey the instructions and safety rules in this manual will result in death or serious injury Do Not Operate Unless M 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 MI You read understand and obey the manufacturer s instructions and safety rules safety and operator s manuals and machine decals M You read understand and obey employer s safety rules and worksite regulations M You read understand and obey all applicable governmental regulations M You are properly trained to safely operate the machine A TEREX COMPANY Part No 1000032 GS 1530 GS 1532 GS 1930 GS 1932 1 Operator s Manual Third Edition e Second Printing SAFETY RULES Electrocution Hazards This machine is not electrically insulated and will not pr
16. 20 kg 1m 227 kg Do not raise the platform unless the machine is on a firm level surface al 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 alter or disable the limit switches Do not drive over 0 7 km h with the platform raised Part No 1000032 A TEREX CON GS 1530 GS 1532 GS 1930 GS 1932 MPANY SAFETY RULES 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 a slope that exceeds the slope and side slope rating of the machine Maximum slope rating stowed position GS 1530 and GS 1530 30 17 GS 1930 and GS 1932 25 14 Maximum side slope rating stowed position GS 1530 and GS 1530 30 17 GS 1930 and GS 1932 25 14 Note Slope rating is subject to ground conditions and adequate traction Do not use the platform controls to free a platform that is caught snagged or otherwise prevented from normal motion by an adjacent structure All personnel must be removed from the platform before attempting to free the platform using the ground controls Do not push off
17. GS 1930 GS 1932 Part No 1000032 Third Edition Second Printing Operator s Manual Legend a J p j Y M HAS Y ie A lige gt Y y WY ry wal A ooo C 0 amp O O 00W 1 Lanyardanchorage point 8 Transporttie down 16 Entry ladder transport 2 Platform extension release 9 Steer tire tie down pedal 17 Battery charger on opposite 10 LED diagnostic readout side afmachine GFCl outlet 11 Pothole guard Manual storage container 12 Ground controls 18 Safety arm Platform controls Pe ceri 19 Platform entry chain or gate 20 Platform guard rails Platform extension 14 Auxiliary lowering knob i N OO BR WwW Tilt alarm under cover 15 Brake release pump A TEREX COMPANY Part No 1000032 GS 1530 GS 1532 GS 1930 GS 1932 9 Operator s Manual Third Edition e Second Printing Controls Platform Controls 1 Red Emergency Stop button 5 Proportional control handle and function enable 2 LED diagnostic readout Platform overload switch for lift and drive functions indicator Battery charge indicator 6 Thumb rocker switch for steer functions 3 Lift function select button 7 Drive speed button 4 Hornbutton 8 Drive function select button Genie A TEREX COMPANY 10 GS 1530 GS 1532 GS 1930 GS 1932 Part No 1000032 Third Edition Second Printing Operator s Manual Me ee
18. Legend The following symbols have been used in this manual to help communicate the intent of the instructions When one or more of the symbols appear at the beginning of amaintenance procedure it conveys the meaning below Indicates that tools will be required to perform this procedure Indicates that new parts will be required to SA perform this procedure A TEREX COMI 14 GS 1530 GS 1532 GS 1930 GS 1932 Check the Hydraulic Oil Level Maintaining the hydraulic oil at the proper levels is essential to machine operation Improper hydraulic oil levels can damage hydraulic components Daily checks allow the inspector to identify changes in oil level that might indicate the presence of hydraulic system problems Perform this procedure with the platform in the stowed position 1 Visually inspect the oil level in the hydraulic tank Result The hydraulic oil level should be as marked on the tank 2 Add oil if necessary Do not overfill Hydraulic oil specifications Hydraulic oil type Chevron Rykon Premium MV equivalent Part No 1000032 Third Edition Second Printing Operator s Manual Check the Batteries Proper battery condition is essential to good machine performance and operational safety Improper fluid levels or damaged cables and connections can result in component damage and hazardous conditions This procedure does not need to be performed on machines with sealed o
19. 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 performa 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 Part No 1000032 Third Edition e Second Printing Operator s Manual Pre operation Inspection Be sure that the operator s safety and responsibilities manuals are complete legible and in the storage container located on the platform Be sure that all decals are legible and in place See Decals section Check for hydraulic oil leaks and proper oil level Add oil if needed See Maintenance section Check for battery fluid leaks and proper fluid level Add distilled water if needed See Maintenance section Check the following components or areas for damage improperly installed or missing parts and unauthorized modifications Electrical components wiring and electrical cables Hydraulic power unit tank hoses fittings cylinders and manifolds Battery pack and connections Drive m
20. are sufficient to withstand the machine weight See the serial plate for the machine weight MI The machine must be on a level surface or secured before releasing the brakes Do not drive the machine on a slope that exceeds the slope or side slope rating See Driving the Machine on a Slope in the Operating Instructions section MI If the slope of the transport vehicle bed exceeds the maximum slope rating the machine must be loaded and unloaded using a winch as described A TEREX CO 28 GS 1530 GS 1532 GS 1930 GS 1932 Brake Release Operation 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 Push in the black brake release knob to open the brake valve 4 Pump the red brake release pump knob After the machine is loaded 1 Chock the wheels to prevent the machine from rolling 2 Press the drive function select button Press and hold the function enable switch on the control handle Move the control handle off center to reset the brakes Towing the Genie GS 1530 the GS 1930 the GS 1532 and the GS 1932 is not recommended If the machine must be towed do not exceed 3 2 km h Part No 1000032 Third Edition Second Printing Operator s Manual TRANSPORT AND LIFTING INSTRUCTIONS Center of gravity X Axis Y Axis GS 1530 and GS 1532 49 8 cm 47 2 cm GS 1930 a
21. ase Safety amp 97719 Label Safety Arm 1 Operating Instructions 1 97772 Platform Control Panel 1 Please reference the chart on page 2 to determine the capacity of your machine Genie 26 GS 1530 GS 1532 GS 1930 GS 1932 A TEREX COMPANY Part No 1000032 Third Edition Second Printing Operator s Manual DECALS Ground Battery Controls Side Side 40434 43618 82287 or 82568 or 62053 or 62054 97772 82668 D or 82669 i SA L A 82487 Les 40434 43618 Hi daio 28174 a or 28235 P or 82665 82562 82568 or 82476 or 62053 or 62054 o 44981 28174 or 28235 97719 Serial Label 82562 82570 or 82571 82476 82474 247 one 82570 or 82571 82567 82482 72143 82495 ee 52475 AS papel 82487 82560 52475 82570 82570 or 82571 or 8257 43658 82481 or 44980 Genie A TEREX COMPANY Part No 1000032 GS 1530 GS 1532 GS 1930 GS 1932 27 Operator s Manual Third Edition Second Printing Transport and Lifting Instructions Observe and Obey MI Common sense and planning must be applied to control the movement of the machine when lifting it with a crane or forklift MI The transport vehicle must be parked on a level surface MI The transport vehicle must be secured to prevent rolling while the machine is being loaded MI Be sure the vehicle capacity loading surfaces and chains or straps
22. clearance 6 1 cm Tire load maxim m 547 kg a i seas ved on Tire contact pressure 9 40 kg cm2 othole guards deploye 921 kPa Weight See Serial Label Occupied floor pressure 1216 kg m2 Machine weights vary with option configurations 11 92 kPa Power source 4 Batteries 6V 225AH System voltage 24V Controls Proportional Part No 1000032 A TEREX CON GS 1530 GS 1532 GS 1930 GS 1932 31 MPANY Note Floor loading information is approximate and does not incorporate different option configurations It should be used only with adequate safety factors Continuous improvement of our products is a Genie policy Product specifications are subject to change without notice or obligation Operator s Manual Third Edition Second Printing SPECIFICATIONS Model GS 1930 Platform dimensions 1 6mx 74cm length x width Height working maximum 7 6m Platform extension length 90 4 cm Height platform maximum 5 8m AC outlet in platform standard Height stowed maximum 1 99 m Rails up Maximum hydraulic pressure 241 bar functions Height stowed maximum 1 95 m Rails lowered Tires size 12x4 5x8in Height stowed maximum 1 0m Airborne noise emissions lt 70 dB Rails off Maximum sound level at normal operating workstations A weighted Height guard rails 99 1 cm Maximum slope rating Width 76 2CM stowed position 25 14
23. ecals are legible and in place Below is a numerical list with quantities and descriptions Part No Description Quantity PartNo Description Quantity 28174 Label Power to Platform 230V 2 82497 Danger Manual Force 200 400 N 28235 Label Power to Platform 115V 2 ep peered ae 1822 40434 Label Lanyard Anchorage 3 82502 Label LED Diagnostic Readout 1 43618 Label Directional Arrows 2 82560 Warning Skin Injection Hazard 1 43658 Label Power to Charger 230V 1 Petes Dangers Crushing Hazara 44980 Label Power to Charger 115V 1 8236 7 ctatound Control Panel i 44981 Label Air to Platform 110 PSI aye DADB EOSO Genie ASA 2 52475 Label Transport Tie down go AEU ARR eR Egad a 3 62053 Cosmetic Genie GS 1530 2 82571 Label Wheel Load GS 1932 4 B 7 82664 Danger Maximum Capacity 62054 Cosmetic Genie GS 1930 2 GS 1530 and GS 1532 1 72143 tapel Emergency Stop 1 92665 Danger Maximum Capacity 82287 Cosmetic Genie GS 1932 2 GS 1930 and GS 1932 1 82474 Warning Safety Chock 2 82668 Label Capacity Indicator 82476 Danger Electrocution Hazard 2 GS 1530 and GS 1532 1 82481 Danger Battery Charger Safety 4 82669 Label Capacity Indicator GS 1930 and GS 1932 1 82482 Label Auxiliary Lowering 1 97582 Danger Manual Force 400 N 82487 Notice Operating Instructions 2 GS 1530 and GS 1930 1 82495 Danger Brake Rele
24. for and avoid them while moving setting up and operating the machine Workplace Inspection 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 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 Part No 1000032 Third Edition Second Printing Operator s Manual Operating Instructions Do Not Operate Unless M 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 3 Always perform function tests prior to use 4 Inspect the workplace 5 Only use the machine as it was intended TEREX COMPANY 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 Using the machine for anything other than lifting personnel along with their tools and materials to an aerial work site is unsafe and dangerous Only trained and authorized personnel should be permitted to operate a machine
25. inside oromi Floor loading information Ground clearance 6 1 cm Tire Ibad maximum 600 kg Ground clearance 0 8 in 1 9 cm Pothole guards deployed Weight See Serial Label Machine weights vary with option configurations Tire contact pressure 10 35 kg cm2 1014 kPa 1313 kg m2 12 88 kPa Occupied floor pressure Power source 4 Batteries 6V 225AH System voltage 24V Controls Proportional A TEREX COMI 34 GS 1530 GS 1532 GS 1930 GS 1932 Note Floor loading information is approximate and does not incorporate different option configurations It should be used only with adequate safety factors Continuous improvement of our products is a Genie policy Product specifications are subject to change without notice or obligation Part No 1000032
26. nd GS 1932 50 8 cm 49 5 cm Observe and Obey M Only qualified riggers should rig and lift the machine M Be sure the crane capacity loading surfaces and straps or lines are sufficient to withstand the machine weight See serial plate 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 Attach the rigging only to the designated lifting points on the machine There are two 2 5 cm holes on the front of the machine and two holes in the ladder for lifting Adjust the rigging to prevent damage to the machine and to keep the machine level A TEREX COMPANY Part No 1000032 GS 1530 GS 1532 GS 1930 GS 1932 29 Operator s Manual Third Edition e Second Printing TRANSPORT AND LIFTING INSTRUCTIONS Securing to Truck or Trailer for Transit Always use the extension deck lock when the machine is transported Turn the key switch to the off position and remove the key before transporting Inspect the entire machine for loose or unsecured items Use chains or straps of ample load capacity Use a minimum of 2 chains or straps Adjust the rigging to prevent damage to the chains
27. ne drive speed and function speed will drop when the battery level indicator is flashing Driving on a slope Determine the slope and side slope ratings for the machine and determine the slope grade Maximum slope rating stowed lt GS 1530 and GS 1930 30 17 GS 1930 and GS 1932 25 14 Maximum side slope rating stowed pil GS 1530 and GS 1930 30 17 Rime GS 1930andGs 1932 25 14 Note Slope rating is subject to ground conditions and adequate traction Press the drive speed button to the fast drive speed mode Part No 1000032 A TEREX COM GS 1530 GS 1532 GS 1930 GS 1932 23 OPERATING INSTRUCTIONS To determine the slope grade Measure the slope with a digital inclinometer OR use the following procedure You will need carpenter s level straight piece of wood at least 1 m long tape measure Lay the piece of wood on the slope At the downhill end lay the level on the top edge of the piece of wood and lift the end until the piece of wood is level While holding the piece of wood level measure the distance from the bottom of the piece of wood to the ground Divide the tape measure distance rise by the length of the piece of wood run and multiply by 100 Example rise Run 3 6 m run Rise 0 3 m 0 3 m 3 6 m 0 083 x 100 8 3 Operator s Manual Third Edition e Second Printing OPERATING INSTRUCTIONS Error Indicator Readout If
28. nery unless the controls of the crane have been locked out and or precautions have been taken to prevent any potential collision Crushing Hazards Keep hands and limbs out of scissors 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 Component Damage Hazard Do not use the machine as a ground for welding Explosion and Fire Hazard 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 A TEREX CON 6 GS 1530 GS 1532 GS 1930 GS 1932 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 Bodily Injury Hazard Do not operate the machine with a hydraulic oil or air leak An air leak or hydraulic leak can penetrate and
29. ob 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 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 How to use the Safety Arm 1 Raise the platform approximately 2 4 m from the ground 2 Rotate the safety arm away from the machine and let it hang down 3 Lower the platform until the safety arm rests securely on the link Keep clear of the safety arm when lowering the platform Part No 1000032 Third Edition Second Printing Operator s Manual Battery and Charger Instructions Observe and Obey M Do not use an external charger or booster battery M Charge the battery in a well ventilated area M Use proper AC input voltage for charging as indicated on the charger M Use only a Genie authorized battery and charger To Charge Battery 1 Be sure the batteries are connected before charging the batteries Open the battery compartment The compartment should remain open for the entire charging cycle Maintenance free batteries 3 Connect the battery charger to a grounded AC circuit The charger will indicate when
30. 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 Part No 1000032 Third Edition e Second Printing Operator s Manual SAFETY RULES Battery Safety Burn Hazards Batteries contain acid Always wear protective clothing and eyewear 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 a a 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 Part No 1000032 A TEREX CON GS 1530 GS 1532 GS 1930 GS 1932 7 MPANY 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 cord cables and wires Replace damaged items before operating i Avoid electrical shock from contact with battery terminals
31. otors Wearpads Tires and wheels Groundstrap 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 Part No 1000032 A TEREX CON GS 1530 GS 1532 GS 1930 GS 1932 13 PRE OPERATION INSPECTION Pothole guards Platform extension Scissor pins and retaining fasteners Platform control joystick Check entire machine for Cracks in welds or structural components Dents or damage to machine Excessive rust corrosion or oxidation 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 closed and latched and the batteries are properly connected Note If the platform must be raised to inspect the machine make sure the safety arm is in place See Operating Instructions section Operator s Manual Third Edition e Second Printing Maintenance Observe and Obey M Only routine maintenance items specified in this manual shall be performed by the operator M Scheduled maintenance inspections shall be completed by qualified service technicians according to the manufacturer s specifications and the requirements specified in the responsibilities manual Maintenance Symbols
32. ovide protection from contact with or proximity to electrical current He owm Ta Maintain safe distances from electrical power lines and apparatus in accordance with applicable governmental regulations and the following chart 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 or the maximum capacity of the platform extension Maximum capacity GS 1530 and GS 1532 Height of Platform Maximum Capacity Voltage Minimum Safe Phase to Phase Approach Distance 46m 272 kg Meters 4m 390 kg 0 to 300V Avoid Contact 2 8m 484 kg 300V to 50KV 3 05 1 6m 390 kg 50KV to 200KV 4 60 1m 344 kg 200KV to 350KV 6 10 350KV to 500KV 7 62 500KV to 750KV 10 67 750KV to 1000KV 13 72 Genie 2 GS 1530 GS 1532 GS 1930 GS 1932 A TEREX COMI Part No 1000032 Third Edition Second Printing Operator s Manual Maximum capacity GS 1930 and GS 1932 Height of Platform Maximum Capacity 5 8m 227 kg 5 2m 320 kg 3 7m 435 kg 1 6m 3
33. position 15 Push the horn button Result The horn should sound Test the Function Enable Switch 16 Do not hold the function enable switch on the control handle 17 Slowly move the control handle in the direction indicated by the blue arrow then in the direction indicated by the yellow arrow Result No functions should operate Testthe Up Down Functions 18 Press the lift function select button 19 Press and hold the function enable switch on the control handle 20 Slowly move the control handle in the direction indicated by the blue arrow Result The platform should raise The pothole guards should deploy Operator s Manual Third Edition e Second Printing FUNCTION TESTS 21 Release the control handle Result The platform should stop raising 22 Press and hold the function enable switch Slowly move the control handle in the direction indicated by the yellow arrow Result The platform should lower The descent alarm should sound while the platform is lowering Test the Steering Note When performing the steer and drive function tests stand in the platform facing the steer end of the machine 23 Press the drive function select switch 24 Press and hold the function enable switch on the control handle 25 Depress the thumb rocker switch on top of the control handle in the direction identified by the blue triangle on the control panel Result The steer wheels should turn
34. r maintenance free batteries AWARNING hot or live circuits may result in Electrocution hazard Contact with MAINTENANCE Scheduled Maintenance Maintenance performed quarterly annually and every two years must be completed by a person trained and qualified to perform maintenance on this machine according to the procedures found in the service manual for this machine Machines that have been out of service for more than three months must receive the quarterly inspection before they are put back into service death or serious injury Remove all rings watches and other jewelry Bodily injury hazard Batteries contain acid Avoid spilling or AWARNING contacting battery acid Neutralize battery acid spills with baking soda and water Perform this test after fully charging the batteries 1 Put on protective clothing and eye wear 2 Be sure that the battery cable connections are tight and free of corrosion 3 Be sure that the battery hold down bars are in place and secure 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 Part No 1000032 A TEREX COMPANY GS 1530 GS 1532 GS 1930 GS 1932 Operator s Manual Third Edition e Second Printing Function Tests Do Not Operate Unless M You learn and practice the principle
35. 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 Collision Hazards Be aware of limited sight distance and blind spots when driving or operating L Be aware of extended platform position when moving the machine The machine must be on a level surface or secured before releasing the brakes Part No 1000032 A TEREX CON GS 1530 GS 1532 GS 1930 GS 1932 5 MPANY SAFETY RULES Operators must comply with employer job site and governmental rules regarding use of personal protective quipment 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 platform decal plate for drive and steer functions No stunt driving or horseplay while operating a machine 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 Operator s Manual Third Edition Second Printing SAFETY RULES Do not operate a machine in the path of any crane or moving overhead machi
36. rive 39 Raise the platform Result When the platform is raised 1 2 m from the ground the pothole guards should deploy 40 Press on the pothole guards on one side and then the other Result The pothole guards should not move 41 Lower the platform Result The pothole guards should return to the stowed position 42 Place a 2x4 or similar piece of wood under a pothole guard Raise the platform Result Before the platform is raised 2 1 m from the ground an alarm should sound and the drive function should not work 43 Lower the platform and remove the 2x4 Operator s Manual Third Edition e Second Printing Workplace Inspection Do Not Operate Unless M 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 3 Always perform function tests prior to use 4 Inspect the workplace Know and understand the workplace inspection before going on to the next section 5 Only use the machine as it was intended COMPANY 20 GS 1530 GS 1532 GS 1930 GS 1932 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 It is the operator s responsibility to read and remember the workplace hazards then watch
37. s of safe machine operation contained in this operator s manual 1 Avoid hazardous situations 2 Always perform a pre operation inspection 3 Always perform function tests prior to use Know and understand the function tests before going on to the next section 4 Inspect the workplace 5 Only use the machine as it was intended 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 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 and function tests again before putting the machine into service 1 Select a test area that is firm level and free of obstruction 2 Be sure the battery pack is connected At the Ground Controls 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 LED diagnostic readout on the platform controls Result The LED should look like the picture at right Test Emergency Stop 6 Push inthe ground red Emergency Stop button to the off position Result No functions sho
38. te Floor loading information is approximate and does not incorporate different option configurations It should be used only with adequate safety factors Continuous improvement of our products is a Genie policy Product specifications are subject to change without notice or obligation Operator s Manual Third Edition Second Printing SPECIFICATIONS Model GS 1932 Platform dimensions 1 6 m x 74cm length x width Height working maximum 7 6m Platform extension length 90 4 cm Height platform maximum 5 8m AC outlet in platform standard Height stowed maximum 2 11 m Rails up Maximum hydraulic pressure 241 bar functions Height stowed maximum 1 76 m Rails folded Tires size 12x4 5x8in Height stowed maximum 1 0 m Airborne noise emissions lt 70 dB Rails off Maximum sound level at normal operating workstations A weighted Height guard rails 99 1 cm Maximum slope rating Width 81 3cm stowed position 25 14 Length stowed 1 82m Maximum side slope rating iti 9 o Length platform extended 2 73 m Slowed position eave I Maximum load capacity 227 435 kg Note Slope rating is subject to ground conditions and adequate traction varies with height of machine Maximum wind speed 12 5 m s Drive speeds Wheelbase 1 32 m Stowed maximum 4 0 km h F f Platform 0 8 km h Turning radius outside ead raised maximum 12 5 m 55 sec Turning fadi s
39. uld operate 7 Pull out the red Emergency Stop button to the on position 16 GS 1530 GS 1532 GS 1930 GS 1932 Part No 1000032 Third Edition Second Printing Operator s Manual Test the Up Down Functions The audible warnings on this machine and the standard horn all come from the same central alarm The horn is a constant tone The descent alarm sounds at 60 beeps per minute The alarm that goes off when the pothole guards have not deployed sounds at 300 beeps per minute The alarm that goes off when the machine is not level sounds at 600 beeps per minute An optional automotive style horn is also available 8 Activate the up function Result The platform should raise 9 Activate the down function Result The platform should lower The descent alarm should sound while the platform is lowering Test the Auxiliary Lowering 10 Activate the up function and raise the platform approximately 60 cm 11 Pull the auxiliary lowering knob located behind the entry ladder Result The platform should lower The descent alarm will not sound 12 Turn the key switch to platform control Part No 1000032 MPANY GS 1530 GS 1532 GS 1930 GS 1932 17 FUNCTION TESTS At the Platform Controls Test Emergency Stop 13 Push in the platform red Emergency Stop button to the off position Result No functions should operate Test the Horn 14 Pull the red Emergency Stop button out to the on
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