Operator’s Manual with Maintenance Information CE Models Third Edition Second Printing Part No.
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 Rules ..............................................................
Operator's Manual Third Edition • Second Printing 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: 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.
Operator's Manual Third Edition • Second Printing SAFETY RULES Electrocution Hazards Tip-over Hazards This machine is not electrically insulated and will not provide protection from contact with or proximity to electrical current. Occupants, equipment and materials must not exceed the maximum platform capacity. Weight in trays and in each bike rack is part of the total platform load.
Operator's Manual Third Edition • Second Printing SAFETY RULES Do not raise the platform unless the machine is on a firm, level surface. Maximum capacity - GR-20 Standard platform Maximum occupants Stock Picker platform 159 kg 1 159 kg Adjustable work station tray 68 kg Bike rack (option) (each) 20 kg Maximum occupants AWP and fiberglass platform Maximum occupants 1 159 kg 1 Do not depend on the tilt alarm as a level indicator. The tilt alarm sounds only when the machine is on a slope.
Operator's Manual Third Edition • Second Printing SAFETY RULES 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 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.
Operator's Manual Third Edition • Second Printing SAFETY RULES 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 28 kg. Collision Hazards Be aware of limited sight distance and blind spots when driving or operating. Do not use the machine as a crane. Do not push the machine or other objects with the platform. Be aware of the extended platform position when moving the machine.
Operator's Manual Third Edition • Second Printing SAFETY RULES Do not lower the platform unless the area below is clear of personnel and obstructions. 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. Damaged Machine Hazards Do not use a damaged or malfunctioning machine.
Operator's Manual Third Edition • Second Printing SAFETY RULES Battery Safety Component Damage Hazard Burn Hazards Do not use any battery charger greater than 24V to charge the batteries. Batteries contain acid. Always wear protective clothing and eye wear when working with 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.
Operator's Manual Third Edition • Second Printing SAFETY RULES 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 presence of an imminently hazardous situation which, if not avoided, will result in death or serious injury.
Operator's Manual Third Edition • Second Printing Legend 11 Work station tray (if equipped) 19 Bike rack (if equipped) 3 Manual lowering valve 12 Brake release pump knob (under covers) 21 GFCI outlet 4 Transport tie-down 13 Mid-rail entry bar 5 Forklift pocket 14 Adjustable work station tray 6 Battery charger display 15 Platform controls 7 Covers 16 Dual-entry gate 8 Ground controls 17 Lanyard anchorage 9 Hydraulic oil level indicator 26 Platform extension release pedal 18 Parcel tray (i
Operator's Manual Third Edition • Second Printing Controls Platform Controls 1 Red Emergency Stop button 2 LED diagnostic readout / Platform overload indicator / Battery charge indicator 5 Proportional control handle and function enable switch for lift and drive functions 6 Thumb rocker switch for steer functions 3 Lift function select button 7 Drive speed button 4 Horn button (if equipped) 8 Drive function select button 10 GR-12 • GR-15 • GR-20 Part No.
Operator's Manual Third Edition • Second Printing CONTROLS 1 2 00009.9 3 4 STOP 5 Ground Control Panel 1 2 3 4 5 7 amp breaker for electrical circuits Key switch for platform/off/ground selection Hour meter Platform up/down toggle switch Red Emergency Stop button Part No.
Operator's Manual Third Edition • Second Printing Pre-operation Inspection Fundamentals It is the responsibility of the operator to perform a pre-operation inspection and routine maintenance. 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.
Operator's Manual Third Edition • Second Printing PRE-OPERATION INSPECTION Check the entire machine for: Pre-operation Inspection o Be sure that the operator's, safety and responsibilities manuals are complete, legible and in the storage container located on the platform. o Be sure that all decals are legible and in place. See Decals section.
Operator's Manual Third Edition • Second Printing Maintenance Check the Hydraulic Oil Level Maintaining the hydraulic oil at the proper level is essential to safe 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. Observe and Obey: Only routine maintenance items specified in this manual shall be performed by the operator.
Operator's Manual Third Edition • Second Printing MAINTENANCE 7 Remove the battery vent caps. Check the Batteries Proper battery condition is essential to good 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 or maintenance - free batteries. Electrocution hazard. Contact with hot or live circuits could result in death or serious injury.
Operator's Manual Third Edition • Second Printing Function Tests 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. Do Not Operate Unless: You learn and practice the principles of safe machine operation contained in this operator's manual. 1 Avoid hazardous situations. A malfunctioning machine must never be used.
Operator's Manual Third Edition • Second Printing FUNCTION TESTS 1 Select a test area that is firm, level and free of obstruction. At the Platform Controls Test Emergency Stop 2 Be sure the battery pack is connected. 13 Push in the platform red Emergency Stop button to the off position. 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 diagnostic LED readout on the platform controls.
Operator's Manual Third Edition • Second Printing FUNCTION TESTS 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.
Operator's Manual Third Edition • Second Printing FUNCTION TESTS 36 Raise the platform. Test the Pothole Guards Result: Before the platform is raised approximately 30 cm, the lift function should stop, an alarm should sound and the LED readout should display LL. 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.
Operator's Manual Third Edition • Second Printing Workplace Inspection Workplace Inspection Be aware of and avoid the following hazardous situations: 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. 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.
Operator's Manual Third Edition • Second Printing Operating Instructions 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.
Operator's Manual Third Edition • Second Printing OPERATING INSTRUCTIONS Emergency Stop To Position Platform Push in the red Emergency Stop button to the off position at the ground or platform controls to stop all machine functions. 1 Press the lift function select button. Repair any function that operates when either red Emergency Stop button is pushed in. Auxiliary Lowering 2 Press and hold the function enable switch on the control handle.
Operator's Manual Third Edition • Second Printing OPERATING INSTRUCTIONS To Reduce Drive Speed To determine the slope grade: 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. Measure the slope with a digital inclinometer OR use the following procedure. Press the drive speed button to select the desired drive speed.
Operator's Manual Third Edition • Second Printing OPERATING INSTRUCTIONS Error Indicator display Battery Level Indicator If 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 (if equipped) 1 Step on the platform extension release pedal. 2 Grasp the platform guard rails carefully and push to extend the platform.
Operator's Manual Third Edition • Second Printing OPERATING INSTRUCTIONS Standard Batteries 1 Put on protective clothing and eye wear. 2 Raise the platform approximately 1.5 m. 3 Open the battery cover. Rest the cover against the chassis. Battery and Charger Instructions 4 Lower the platform until the mast just contacts the battery cover. Observe and Obey: Do not use an external charger or booster battery. Charge the battery in a well-ventilated area.
Operator's Manual Third Edition • Second Printing Transport and Lifting Instructions 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. Observe and Obey: Common sense and planning must be applied to control the movement of the machine when lifting it with a crane or forklift. The transport vehicle must be parked on a level surface.
Operator's Manual Third Edition • Second Printing TRANSPORT AND LIFTING INSTRUCTIONS Loading the Machine With a Crane Securing to Truck or Trailer for Transit Use the lifting eye mounted on the rear mast column. Always chock the machine wheels in preparation for transport. Make sure the mast is fully lowered. Turn the key switch to the off position and remove the key before transporting. Inspect the machine and remove any loose or unsecured items.
Operator's Manual Third Edition • Second Printing Decals Inspection for Decals with Symbols Standard and AWP Platforms Determine whether the decals on your machine have words or symbols. Use the appropriate inspection to verify that all decals are legible and in place. Part No. Description Quantity Part No.
Operator's Manual Third Edition • Second Printing DECALS Shading indicates decal is hidden from view, i.e., under covers. Note: Platform decals may be in diffferent locations on optional AWP and fiberglass platforms. Part No.
Operator's Manual Third Edition • Second Printing DECALS Inspection for Decals with Symbols Stock Picker Platform Determine whether the decals on your machine have words or symbols. Use the appropriate inspection to verify that all decals are legible and in place. Part No. Description Quantity Part No.
Operator's Manual Third Edition • Second Printing DECALS Shading indicates decal is hidden from view, i.e., under covers. Part No.
Operator's Manual Third Edition • Second Printing Specifications GR-12 Power source 4 Batteries, 6V 225AH Height, working maximum 5.31 m Controls Height, platform maximum 3.48 m AC outlet in platform Height, stowed maximum 1.72 m Tire size Height, stowed maximum standard platform with work station tray 1.62 m Height, stowed maximum stock picker platform with work station tray 1.
Operator's Manual Third Edition • Second Printing SPECIFICATIONS GR-15 Power source 4 Batteries, 6V 225AH Height, working maximum 6.30 m Controls Height, platform maximum 4.47 m AC outlet in platform Height, stowed maximum 1.72 m Tire size Height, stowed maximum standard platform with work station tray 1.62 m Height, stowed maximum stock picker platform with work station tray 1.
Operator's Manual Third Edition • Second Printing SPECIFICATIONS GR-20 AC outlet in platform Standard Height, working maximum 7.90 m Tire size Height, platform maximum 6.07 m Height, stowed maximum 1.98 m Airborne noise emissions 70 dB Maximum sound level at normal operating workstations (A-weighted) Height, stowed maximum stock picker platform with bike racks 1.60 m Maximum slope rating, stowed position 30% (17°) Maximum side slope rating 30% (17°) Width 80 cm 25.4 x 7.6 x 2.
Operator's Manual Third Edition • Second Printing SPECIFICATIONS Platform dimensions, all models (length x width) Standard platform 88 x 75 cm Standard platform with extension 1.4 m x 75 cm Stock picker platform Stock picker platform including adjustable tray Standard AWP platform Narrow AWP platform 88 x 73 cm 1.4 m x 73 cm 69 x 51 cm 66 cm x 51 cm Standard fiberglass platform 74 x 67 cm Narrow fiberglass platform 66 x 56 cm Part No.
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