GENIE GS-1530 (01) PDF DOCUMENT

Do Not Operate the GENIE GS-1530 Unless:

• You learn and practice the principles of safe machine operation contained in the operator’s manual.

• You avoid hazardous situations.

• You always perform a pre-operation inspection.

• You always perform function tests prior to use.

• You inspect the workplace.

• You only use the machine as it was intended.

• You read, understand and obey the manufacturer’s instructions and safety rules, employer’s safety rules, and applicable governmental regulations.

• You are properly trained to safely operate the machine.

This machine is not electrically insulated and will not provide protection from contact with or proximity to electrical current. To avoid electrocution hazards:

• 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 be aware 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.

To prevent tip-over hazards with the GENIE GS-1530, always adhere to the following rules:

• Do not exceed the maximum platform capacity. Occupants and equipment must not exceed the specified limits for the platform retracted or extended.

• 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. If the tilt alarm sounds, lower the platform and move the machine to a firm, level surface.

• Do not drive over 0.5 mph / 0.7 km/h with the platform raised.

• Do not operate in strong or gusty winds or increase the surface area of the platform or load.

• Use extreme care and slow speeds when driving in the stowed position across uneven terrain, debris, or near holes and drop-offs.

• Do not push off or pull toward any object outside of the platform.

• Do not place or attach fixed or overhanging loads to any part of the machine.

• Do not place ladders or scaffolds in the platform or against any part of the machine.

• Do not use the machine on a moving or mobile surface or vehicle.

• Ensure all tires are in good condition and hardware is properly installed.

• Do not use batteries that weigh less than the original equipment (65 pounds / 29.5 kg each), as they are critical for counterweight and machine stability.

• Do not use the machine as a crane or push other objects with the platform.

• Do not operate with the chassis trays open.

Maximum Capacity – GENIE GS-1530

Maximum occupants – Australia

• Indoor use only: 2

• Outdoor use: 1

Maximum allowable manual force – Australia

• 2 person: 90 lbs / 400 N

• 1 person: 45 lbs / 200 N

To prevent falls from the platform of the GENIE GS-1530:

• Occupants should wear a safety belt or harness and attach the lanyard to the anchor provided in the platform, complying with applicable governmental regulations.

• 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 it is raised.

• 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.

Collision Hazards:

• Be aware of limited sight distance and blind spots when driving or operating.

• Be aware of the extended platform position when moving the machine.

• The machine must be on a level surface or secured before releasing the brakes.

• Operators should wear an approved hard hat.

• Check the work area for overhead obstructions or other possible hazards.

• Observe and use the color-coded direction arrows on the platform controls for drive and steer functions.

• No stunt driving or horseplay while operating the machine.

• Limit travel speed according to ground surface condition, congestion, slope, and location of personnel.

• Do not lower the platform unless the area below is clear of personnel and obstructions.

Crushing Hazards:

• Keep hands and limbs out of the scissors mechanism.

• Be aware of crushing hazards when grasping the platform guard rail.

• Use common sense and maintain safe distances between the operator, the machine, and fixed objects when operating with the controller from the ground.

Burn Hazards:

• Batteries contain acid. Always wear protective clothing and eyewear when working with them.

• Avoid spilling or contacting battery acid. Neutralize spills with baking soda and water.

Explosion Hazards:

• Keep sparks, flames, and lighted tobacco away from batteries as they emit an explosive gas.

• The battery tray should remain open during the entire charging cycle.

• Do not contact battery terminals or 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 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.

• Avoid electrical shock by removing all rings, watches, and other jewelry when working with batteries.

Tip-over Hazard:

• Do not use batteries that weigh less than the original equipment. Each battery must weigh 65 pounds / 29.5 kg to act as a proper counterweight.

Lifting Hazard:

• Use the appropriate number of people and proper lifting techniques when lifting batteries.

Before each work shift, perform the following visual inspection:

1. Be sure that the operator’s, safety, and responsibilities manuals are complete, legible, and in the storage container on the platform.

2. Be sure that all decals are legible and in place.

3. Check for hydraulic oil leaks and proper oil level. Add oil if needed.

4. Check for battery fluid leaks and proper fluid level. Add distilled water if needed.

5. Check the following components for damage, modifications, and improperly installed or missing parts:

• Electrical components, wiring, and electrical cables

• Hydraulic power unit, tank, hoses, fittings, cylinders, and manifolds

• Battery pack and connections

• Drive motors

• Wear pads

• Tires and wheels

• 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

• Pothole guards

• Platform extension

• Scissor pins and retaining fasteners

• Platform control joystick

6. Check the entire machine for:

• Cracks in welds or structural components

• Dents or damage to the machine

• All structural and critical components are present with all fasteners and pins in place and properly tightened.

7. Be sure side rails are installed and bolts are fastened.

8. Be sure that the chassis trays are in place, latched, and properly connected.

Perform this procedure with the platform in the stowed position.

1. Visually inspect the oil level in the hydraulic tank through the sight gauge in the side of the power unit module.

2. The hydraulic oil level should be within the full and add marks on the oil level indicator decal.

3. Add oil if necessary. Do not overfill. Use Dexron equivalent hydraulic oil.

This procedure is not needed for machines with sealed or maintenance-free batteries. Perform this test after fully charging the batteries.

1. Put on protective clothing and eyewear.

2. Be sure that the battery cable connections are free of corrosion.

3. Be sure that the battery hold downs and cable connections are tight.

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.

1. Select a test area that is firm, level, and free of obstruction.

2. Be sure the battery pack is connected.

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 diagnostic LED readout. The LED should read — or 23.

Test Emergency Stop:

1. Push in the ground red Emergency Stop button to the OFF position. No functions should operate.

2. Pull out the red Emergency Stop button to the ON position.

Test the Up/Down Functions:

1. Activate the up function. The platform should raise.

2. Activate the down function. The platform should lower, and the descent alarm should sound.

Test the Manual Lowering:

1. Raise the platform approximately 2 feet / 60 cm.

2. Pull the manual lowering knob located next to the ground controls. The platform should lower, but the descent alarm will not sound.

3. After testing, turn the key switch to platform control.

Test Emergency Stop:

1. Push in the platform red Emergency Stop button to the OFF position. No functions should operate.

2. Pull the red Emergency Stop button out to the ON position.

Test the Horn:

1. Push the horn button. The horn should sound.

Test the Function Enable Switch:

1. Do not hold the function enable switch. Slowly move the control handle. No functions should operate.

Test the Up/Down Functions:

1. Press the lift function select button.

2. Press and hold the function enable switch on the control handle.

3. Slowly move the control handle in the direction indicated by the blue arrow. The platform should raise and the pothole guards should deploy.

4. Release the control handle. The platform should stop raising.

5. Press and hold the function enable switch and slowly move the control handle in the direction indicated by the yellow arrow. The platform should lower and the descent alarm should sound.

Test the Steering:

1. Stand in the platform facing the steer end of the machine.

2. Press the drive function select switch.

3. Press and hold the function enable switch.

4. Depress the thumb rocker switch. The steer wheels should turn in the direction indicated by the triangles on the control panel.

Test Drive and Braking:

1. Press and hold the function enable switch.

2. Slowly move the control handle in the direction of the blue arrow until the machine moves, then return to center. The machine should move and then come to an abrupt stop.

3. Repeat for the yellow arrow direction. The drive brakes must be able to hold the machine on any slope it is able to climb.

Test Limited Drive Speed:

1. Press the lift function select button.

2. Press and hold the function enable switch and raise the platform approximately 4 feet / 1.2 m from the ground. The pothole guards should deploy.

3. Press the drive function select switch.

4. Press and hold the function enable switch and slowly move the control handle to the full drive position. The maximum achievable drive speed with the platform raised should not exceed 0.7 feet per second / 20 cm/s.

Test the Tilt Sensor Operation (from the ground):

1. Fully lower the platform.

2. Place a 2×4 or similar piece of wood under both wheels on one side and drive the machine up onto them.

3. Raise the platform approximately 7 feet / 2.1 m. The platform should stop and the tilt alarm will sound at 600 beeps per minute. The drive function should not work in either direction.

4. Lower the platform and remove the wood.

Test the Pothole Guards:

1. Raise the platform. When the platform is raised 4 feet / 1.2 m, the pothole guards should deploy.

2. Press on the pothole guards on one side, then the other. They should not move.

3. Lower the platform. The pothole guards should return to the stowed position.

4. Place a 2×4 or similar piece of wood under a pothole guard and raise the platform. Before the platform is raised 7 feet / 2.1 m, an alarm should sound and the drive function should not work.

5. Lower the platform and remove the 2×4.

The operator should perform a workplace inspection prior to moving the GENIE GS-1530 to the worksite. Be aware of and avoid the following hazardous situations:

• drop-offs or holes

• bumps, floor obstructions or debris

• 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

1. Turn the key switch to ground control.

2. Pull out both ground and platform red Emergency Stop buttons to the ON position.

3. Be sure the battery pack is connected.

4. To position the platform, move the up/down toggle switch according to the markings on the control panel.

Note: Drive and steer functions are not available from the ground controls.

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 the battery pack is connected.

To Position Platform (Up/Down):

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 Drive:

1. Press the drive function select button.

2. Press and hold the function enable switch on the control handle.

3. To increase speed, slowly move the control handle off center. To decrease speed, slowly move the control handle toward center. To stop, return the control handle to center or release the function enable switch.

If the error indicator light is on, push in and pull out the red Emergency Stop button to reset the system. If the light stays on, tag and remove the machine from service.

Do not stand on the platform extension while trying to extend it.

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.

4. To retract, 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.

1. Select a safe parking location—a 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.

Observe the following:

• Do not use an external charger or booster battery.

• Charge the battery in a well-ventilated area.

• Use proper AC input voltage for charging as indicated on the charger.

• Use only Genie authorized battery and charger.

To Charge Battery:

1. Be sure the batteries are connected before charging.

2. Open the battery compartment. The compartment should remain open for the entire charging cycle.

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. Turn the battery charger on.

7. The charger will indicate when the battery is fully charged.

8. 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.

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. Turn the brake release knob counterclockwise to open the brake valve.

4. Pump the brake release pump knob.

After the machine is loaded:

1. Chock the wheels to prevent the machine from rolling.

2. Turn the brake release knob clockwise to reset the brakes.

Note: Towing is not recommended. If the machine must be towed, do not exceed 2 mph / 3.2 km/h.

Securing to Truck or Trailer for Transit:

1. Always chock the machine wheels in preparation for transport.

2. Use the tie-down points on the chassis for anchoring down to the transport surface.

3. Use chains or straps of ample load capacity.

4. Turn the key switch to the OFF position and remove the key before transporting.

5. Inspect the entire machine for loose or unsecured items.