Terex Genie GS30MD-101 Operator'S Manual Download

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Operator's Manual

Serial Number Range

™

-1330m

from GS30MD-101

to GS30MD-3168

with
Maintenance
Information

Original Instructions
First Edition
Third Printing
Part No. 1290847GT

Summary of Contents for Genie GS30MD-101

Page 1: ...Operator s Manual Serial Number Range GS 1330m from GS30MD 101 to GS30MD 3168 CE with Maintenance Information Original Instructions First Edition Third Printing Part No 1290847GT ...

Page 2: ...tion 1 Symbol and Hazard Pictorials Definitions 6 General Safety 8 Personal Safety 10 Work Area Safety 11 Legend 18 Controls 19 Inspections 22 Operating Instructions 34 Transport and Lifting Instructions 42 Maintenance 47 Specifications 49 Copyright 2019 Terex Corporation First Edition Third Printing May 2020 Genie is a registered trademark of Terex South Dakota Inc in the U S A and many other cou...

Page 3: ...the serial label Serial number stamped on chassis Serial label located on chassis Intended Use and Familiarization Guide The intended use of this machine is to lift personnel including tools and materials to an aerial work site Before operating the machine it s the operator s responsibility to read and understand this familiarization guide Each person must be trained to operate a MEWP Familiarizat...

Page 4: ...bology and related machine movement Lift function enable button Platform up down button Sequential functions and movement Drive and steer Interlocked functions Elevated drive speed Elevated drive in an off level condition All platform and ground controls Limitations of use The intended use of this machine is to lift personnel including tools and materials to an aerial work site Do not elevate the ...

Page 5: ...ction indicated in a respective bulletin To view any open bulletins for your machine visit us on the web at www genielift com Contacting the Manufacturer At times it may be necessary to contact Genie When you do be ready to supply the model number and serial number of your machine along with your name and contact information At minimum Genie should be contacted for Accident reporting Questions reg...

Page 6: ...ow 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 ...

Page 7: ...e 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 se...

Page 8: ...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 Access by trained and a...

Page 9: ...d as counterweights Chock the wheels Release brakes Grounded AC 3 wire only Replace damaged wires and cords Wheel load Lifting tie down instructions Tiedown Lanyard anchorage points No smoking Voltage rating for power to platform Pressure rating for air line to platform Manual force Engage brake Wind speed Maximum capacity Indoor ...

Page 10: ...0 to 500KV 7 6 m 2 500 to 750KV 10 6 m 7 750 to 1000KV 13 7 m 2 1293217 1293217 A 0 to 50KV 3 0 m 5 50 to 200KV 4 6 m 0 200 to 350KV 6 1 m 0 350 to 500KV 7 6 m 2 500 to 750KV 10 6 m 7 750 to 1000KV 13 7 m 2 1293217 1292053 B 0 m sec 400 N GS 1 30 3 m 227 kg 227 kg 9 kg 1 1 kg 36 1293166 1292053 1290672 1290673 1290672 1290672 1 93166 A 2 1 93166 A 2 82487 82495 114338 1294686 82474 1294688 ...

Page 11: ...ual General Safety Part No 1290847GT GS 1330m 9 1290670 6 5 2 kg 1290670 A 1293217 A 0 to 50KV 3 0 m 5 50 to 200KV 4 6 m 0 200 to 350KV 6 1 m 0 350 to 500KV 7 6 m 2 500 to 750KV 10 6 m 7 750 to 1000KV 13 7 m 2 1293217 82474 114337 82481 1294686 ...

Page 12: ...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 ...

Page 13: ... 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 plat...

Page 14: ...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 d...

Page 15: ... Battery tray including batteries must weigh a minimum of 62 5 kg Do not modify or alter a mobile elevating 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 fixe...

Page 16: ...erson in the platform and adequate traction Additional platform weight may reduce slope rating See Driving on a Slope in the Operating Instructions section 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 manuf...

Page 17: ...le 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...

Page 18: ...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 machine Component Damage Hazards Do no...

Page 19: ...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 a minimum of 21 kg Battery tray including batteries must weigh a minimum of 62 5kg Lifting Hazard Use the appropriate number of people and proper lifting techniques when lifting batteri...

Page 20: ...e 9 Pothole guard 10 Ground controls 11 LCD readout 12 Non steer tire 13 Inverter optional 14 Brake release pump 15 Emergency lowering knob 16 Entry ladder transport tie down 17 Battery charger on battery side of machine 18 Tilt alarm 19 Safety arm 20 Air line to platform optional 21 Platform extension release pedal 22 GFCI outlet 23 Platform entry chain or gate 24 Foot switch if equipped 1 5 9 2 ...

Page 21: ...y 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 ...

Page 22: ... the red Emergency Stop button to the on position to operate the machine 2 Lift function button Push this button to activate the lift function 3 Horn button Press the horn button and the horn will sound Release the horn button and the horn will not sound 4 Drive speed select button Press this button to activate the slow drive function The indicator light will be on when slow drive is selected 1376...

Page 23: ...ction on the platform control handle Move the control handle in the direction indicated by the blue arrow on the control panel and the machine will move in the direction that the blue arrow points Move the control handle in the direction indicated by the yellow arrow on the control panel and the machine will move in the direction that the yellow arrow points 6 Thumb rocker switch for steer functio...

Page 24: ...n 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 unauthori...

Page 25: ...olds Drive motors Wear pads Tires and wheels Limit switches alarms and horn Alarms and beacons if equipped Nuts bolts and other fasteners Brake release components Safety arm Platform extension Scissor pins and retaining fasteners Platform control joystick Battery pack and connections Ground strap Platform entry gate Pothole guards Lanyard anchorage points Platform overload components Check entire ...

Page 26: ...e the machine as it was intended Function Test Fundamentals The function tests are designed to discover any malfunctions before the machine is put into service The operator must follow the step by step instructions to test all machine functions A malfunctioning machine must never be used If malfunctions are discovered the machine must be tagged and removed from service Repairs to the machine may o...

Page 27: ...ns should operate 8 Pull out the red Emergency Stop button to the on position Test the Up Down Functions This machine uses both flashing lights and audible alarms Descent alarm Lights flash and alarm sounds at 60 flashes beeps per minute Descent delay alarm Lights flash and alarm sounds at 180 flashes beeps per minute Pothole guards not deployed Lights flash and alarm sounds at 180 flashes beeps p...

Page 28: ...s will flash and the alarm will sound Be sure the area below the platform is clear of personnel and obstructions before continuing To continue lowering release the control handle and then move the control handle again Test Emergency Lowering 15 Activate the up function by pressing the lift enable button and platform up button and raise the platform approximately 60 cm 16 Pull the emergency lowerin...

Page 29: ...indicated by the yellow arrow Result No functions should operate 24 Press the lift function button 25 Wait seven seconds for the lift function to time out 26 Slowly move the control handle in the direction indicated by the blue arrow then in the direction indicated by the yellow arrow Result The lift function should not operate 27 Press the lift function button 28 Press and hold the function enabl...

Page 30: ...witch on top of the control handle in the direction indicated by the yellow triangle on the control panel Result The steer wheels should turn in the direction indicated by the yellow triangle Test Drive and Braking 37 Press the drive function button 38 Press and hold the function enable switch on the control handle Machines equipped with foot switch Press and hold the foot switch and press and hol...

Page 31: ...in the direction indicated by the blue arrow then move the control handle in the direction indicated by the yellow arrow Result The drive function should not work in either direction 47 Fully lower the platform 48 Drive the machine onto a slope where the chassis angle is greater than 2 5 front to back 49 Raise the platform approximately 2 1 m from the ground Result The platform should stop and the...

Page 32: ...loy 58 Press on the pothole guards on one side and then the other Result The pothole guards should not move 59 Lower the platform Result The pothole guards should return to the stowed position 60 Place a 2x4 or similar piece of wood under a pothole guard 61 Raise the platform Result Before the platform is raised 2 1 m from the ground an alarm should sound The platform controls LED readout should d...

Page 33: ...ator 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 for and avoid them while moving setting up and operating the machine Workplace Inspection Checklist Be aware of and avoid the following hazardous situation...

Page 34: ...de 1 1278704 Label Battery Charger Indicator 1 1281175 Label Lanyard Anchorage Point Fall Restrained 3 Part No Decal Description Qty 1283878 Label Tech Pro Link 1 1290669 Label Wheel Load GS 1530 4 1290670 Label Tip over Hazard Batteries 1 1290673 Label Electrocution Hazard Plug 1 1290699 Label Transport Diagram 2 1292047 Label Power to Platform 115V 2 1292048 Label Power to Platform 230V 2 129204...

Page 35: ...First Edition Third Printing Operator s Manual Inspections Part No 1290847GT GS 1330m 33 ...

Page 36: ...he 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 If more than one operator is expected to use a...

Page 37: ...tton Drive and steer functions are not available from the ground controls Operation from Platform 1 Be sure the battery pack is connected before operating the machine 2 Turn the key switch to platform control 3 Pull out both ground and platform red Emergency Stop buttons to the on position To Position Platform 1 Press the lift function button On the LCD screen a circle below the lift function symb...

Page 38: ...tion button again 2 Machines equipped with foot switch Press and hold the foot switch and press and hold the function enable switch on the control handle at the same time 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 a...

Page 39: ...pe 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 vertical distance from the bottom of the piece...

Page 40: ...the ground controls LCD display Platform Overload If the platform controls LED diagnostic readout displays a flashing OL and the ground controls LCD diagnostic readout displays OL Platform Overloaded the platform is overloaded and no functions will operate An alarm will sound 1 Push in the red Emergency Stop button to the off position 2 Remove weight from the platform 3 Pull out the red Emergency ...

Page 41: ...hine must be taken out of service and charged otherwise all machine functions will be disabled Full Charge Half Charge Low Charge LO Flashing 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 lower...

Page 42: ...f the unit 5 At the rear of the main deck remove the two main deck lock pins Keep hands free of pinch points 6 From the middle of the unit fold down the main deck railing assembly toward the front of the unit 7 Connect entry swing frame with left main rail by the pin Keep hands free of pinch points 8 Carefully open the gate and exit the platform 9 Remove the two pins from one side of the main rail...

Page 43: ...lled water to cover the plates Do not overfill prior to the charge cycle 2 Replace the battery vent caps 3 Connect the battery charger to a grounded AC circuit 4 The charger will indicate when the battery is fully charged 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 Dry Battery Filling and Charging ...

Page 44: ...s should move the machine on or off the truck The transport vehicle must be parked on a level surface The transport vehicle must be secured to prevent rolling while the machine is being loaded Be sure the vehicle capacity loading surfaces and chains or straps are sufficient to withstand the machine weight Genie lifts are very heavy relative to their size See the serial label for the machine weight...

Page 45: ...e 4 Open the hydraulic tray 5 Remove the protective cover from the toggle switch 6 Move the toggle switch as indicated in the image to release the brakes The alarm will turn on when the brakes are released After the machine is loaded 1 Chock the wheels to prevent the machine from rolling 2 Move the toggle switch as indicated in the image to engage the brakes 3 Place the protective cover on the tog...

Page 46: ...or 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 ...

Page 47: ... the Machine with a Forklift Be sure the extension deck controls and component trays are secure Remove all loose items on the machine Fully lower the platform The platform must remain lowered during all loading and transport procedures Use the forklift pockets located on both sides of the ladder Position the forklift forks in position with the forklift pockets Drive forward to the full extent of t...

Page 48: ... 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 Center of Gravity Table Model X Axis Y Axi...

Page 49: ... at the beginning of a maintenance procedure it conveys the meaning below Indicates that tools will be required to perform this procedure Indicates that new parts will be required to perform this procedure Check the Hydraulic Oil Level Maintaining the hydraulic oil at the proper level is essential to machine operation Improper hydraulic oil levels can damage hydraulic components Daily checks allow...

Page 50: ...nd water Note 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 brackets are in place and secure Note Adding terminal protectors and a corrosion preventative sealant will help eliminate the corrosion on the battery terminals and cables Sched...

Page 51: ...l vibration value to which the hand arm system is subjected does not exceed 2 5 m s 2 Highest root mean square value of weighted acceleration to which the whole body is subjected does not exceed 0 5 m s 2 Operating temperature Minimum 29 C Maximum 66 C Airborne noise emissions Sound pressure level at ground workstation 70 dBA Sound pressure level at platform workstation 70 dBA Maximum slope rating...

Page 52: ... engine only Test Report This machine has been tested and passed the following categories per EN 280 2013 A1 2015 clause 6 3 prior to entering the market 1 BRAKES Brakes working properly in forward and reverse 2 OVERLOAD Overload tested at XXX rated load 3 FUNCTIONAL Smooth operation at XXX rated load 4 FUNCTIONAL All safety devices working correctly 5 FUNCTIONAL Speeds set within permitted specif...

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