Operator's Manual Fifth Edition • First 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 Introduction ................................................................
Fifth Edition • First Printing Operator's Manual Introduction Owners, Users and Operators: Genie appreciates your choice of our machine for your application. Our number one priority is user safety, which is best achieved by our joint efforts. We feel that you make a major contribution to safety if you, as the equipment users and operators: 1 Comply with employer, job site and governmental rules. 2 Read, understand and follow the instructions in this and other manuals supplied with this machine.
Operator's Manual Fifth Edition • First Printing Introduction Hazard Classification Intended Use Genie uses symbols, color coding and signal words to identify the following: This machine is intended to be used only to lift personnel, along with their tools and materials to an aerial work site. 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.
Fifth Edition • First Printing Operator's Manual Symbol and Hazard Pictorials Definitions Read the operator’s manual Read the service manual Crush hazard No smoking Collision hazard Electrocution hazard Collision hazard Tip-over hazard Tip-over hazard Use a piece of cardboard or paper to search for leaks Electrocution hazard Explosion hazard Fire hazard Burn hazard Skin injection hazard Tiedown Keep away from moving parts Move machine to level ground Batteries used as counterweights On
Operator's Manual Fifth Edition • First Printing Symbol and Hazard Pictorials Definitions Replace damaged wires and cords Wheel load Side force Lanyard attachment point Voltage rating for power to platform Pressure rating for air line to platform Wind speed + + + 22 kg Maximum capacity including occupant 4 Maximum capacity including occupant, tools and tray GR-12 • GR-15 • GR-20 Part No.
Fifth Edition • First Printing Operator's Manual General Safety Safety signs and locations Decals with words Part No.
Operator's Manual Fifth Edition • First Printing General Safety Safety signs and locations Decals with words 6 GR-12 • GR-15 • GR-20 Part No.
Fifth Edition • First Printing Operator's Manual General Safety Safety signs and locations Decals with symbols Part No.
Operator's Manual Fifth Edition • First Printing General Safety Safety signs and locations Decals with symbols 8 GR-12 • GR-15 • GR-20 Part No.
Fifth Edition • First Printing Operator's Manual Personal Safety Fall Protection Personal fall protection equipment (PFPE) is not required when operating this machine. If PFPE is required by job site or employer rules, the following shall apply: All PFPE must comply with applicable governmental regulations, and must be inspected and used in accordance with the PFPE manufacturer’s instructions. Part No.
Operator's Manual Fifth Edition • First Printing Work Area Safety 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 or the maximum capacity of the platform extension. Weight in trays are part of the total platform load.
Fifth Edition • First Printing Operator's Manual Work Safety Do not raise the platform unless the machine is on a firm, level surface. Maximum capacity - GR-20 Standard platform Platform without extension 350 lbs 159 kg Platform retracted 350 lbs 159 kg Platform extended - Platform only 100 lbs Platform extended - Extension only 250 lbs 45 kg 113 kg Maximum occupants 350 lbs / 159 kg 1 Do not depend on the tilt alarm as a level indicator.
Operator's Manual Fifth Edition • First Printing Work Area Safety Do not raise the mast when wind speeds may exceed 28 mph / 12.5 m/s.If wind speeds exceed 28 mph / 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.
Fifth Edition • First Printing Operator's Manual Work Area Safety Do not place or attach fixed or overhanging loads to any part of this machine. Do not place ladders or scaffolds in the platform or against any part of this machine Do not transport tools and materials unless they are evenly distributed and can be safely handled by the person in the platform. Do not use the machine on a moving or mobile surface or vehicle.
Operator's Manual Fifth Edition • First Printing Work Area Safety Fall Hazards Collision Hazards The guard rail system provides fall protection. If the occupant of the platform is required to wear personal fall protection equipment (PFPE) due to job site or employer rules, PFPE and its use shall be in accordance with the PFPE manufacturer’s instructions and applicable governmental requirements. Use approved lanyard attachment point provided. Keep the platform floor clear of debris.
Fifth Edition • First Printing Operator's Manual Work Area Safety Operators must comply with employer, job site and governmental rules regarding use of personal protective equipment. 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 Fifth Edition • First Printing Work Area Safety Bodily Injury Hazard Damaged Machine Hazards Do not operate the machine with a hydraulic oil or air leak. An air leak or hydraulic leak can penetrate and/or burn skin. Improper contact with components under any cover will cause serious injury. Only trained maintenance personnel should access compartments. Access by the operator is only advised when performing a pre-operation inspection.
Fifth Edition • First Printing Operator's Manual Work Area Safety Electrocution/Burn Hazards Battery Safety Connect the battery charger to a grounded, AC 3-wire electrical outlet only. Burn Hazards Batteries contain acid. Always wear protective clothing and eye wear when working with batteries. Avoid spilling or contacting battery acid. Neutralize battery acid spills with baking soda and water. Do not expose the batteries or the charger to water or rain during charging.
Operator's Manual Fifth Edition • First Printing Legend 10 Power to platform/battery charger connection for optional inverter 17 GFCI outlet 11 Work station tray (if equipped) 19 Battery compartment cover 5 Forklift pocket 12 Brake release pump knob (under covers) 21 Steer tire 6 Battery charger display 13 Mid-rail entry bar 7 Covers 14 Platform controls 8 Ground controls 15 Lanyard anchorage point 9 Hydraulic oil level indicator 16 Mast 1 Pothole guard 2 Non-steer tire 3 Emergency lowerin
Fifth Edition • First Printing Operator's Manual Controls Ground Control Panel 7 Lift function enable button Press and hold this button to activate the lift function. 1 7 amp breaker for electric circuits 2 Red Emergency Stop button Push in the red Emergency Stop button to the off position to stop all functions. Pull out the red Emergency Stop button to the on position to operate the machine. 3 Menu down button 4 Menu enter button 5 Platform up button 6 Platform down button Part No.
Operator's Manual Fifth Edition • First Printing Controls Platform Control Panel 1 Thumb rocker switch for steer functions 6 Red Emergency Stop button 2 LED diagnostic readout/battery charge indicator 7 Low speed lift enable button 3 Platform up button 8 High speed lift enable button 4 Numeric keypad (if equipped) 9 Drive speed select button 5 Platform down button 10 Horn button 11 Proportional control handle and function enable switch for drive and steer functions 20 GR-12 • GR-15 • GR-20 Pa
Fifth Edition • First Printing Operator's Manual Controls Platform Control Panel 7 Low speed lift enable button 1 Thumb rocker switch for steer function Press the left side of the thumb rocker and the machine will turn in the direction the blue triangle points on the platform control panel. 8 High speed lift enable button Press and hold this button to activate the high speed platform function.
Operator's Manual Fifth Edition • First Printing Inspections 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.
Fifth Edition • First Printing Operator's Manual Inspections R Brake release components Pre-operation Inspection R Be sure that the operator's, safety and responsibilities manuals are complete, legible and in the storage container located on the platform. R Be sure that all decals are legible and in place. See Inspections section. R Check for hydraulic oil leaks and proper oil level. Add oil if needed. See Maintenance section.
Operator's Manual Fifth Edition • First Printing Inspections 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. 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.
Fifth Edition • First Printing Operator's Manual Inspections 1 Select a test area that is firm, level and free of obstruction. 2 Be sure the batteries are 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 readout should look like the picture below.
Operator's Manual Fifth Edition • First Printing Inspections At the Platform Controls Test the Up/Down Functions Test Emergency Stop 27 Press and hold the high speed lift enable button. 18 Push in the platform red Emergency Stop button to the off position. 28 Press the platform up button. Result: No functions should operate. Result: The platform should raise. The pothole guards should deploy. 29 Release the high speed lift enable button or the platform up button.
Fifth Edition • First Printing Operator's Manual Inspections Test the Steering Test the Tilt Sensor Operation Note: When performing the steer and drive function tests, stand in the platform facing the steer end of the machine. 45 Open the ground controls cover and locate the tilt sensor behind the ground controls panel. 39 Press and hold the drive/steer function enable switch on the control handle.
Operator's Manual Fifth Edition • First Printing Inspections Test Elevated Drive Speed 50 Press and hold the high or low speed lift enable button. 51 Press the platform up button and raise the platform approximately 2 ft / 60 cm from the ground. 52 Press and hold the drive/steer function enable switch on the control handle. Slowly move the control handle to the full drive position. Result: The maximum achievable drive speed with the platform raised should not exceed 0.72 ft / 0.22 m per second.
Fifth Edition • First Printing Operator's Manual Inspections 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 Fifth Edition • First Printing Inspections Inspection for Decals with Words 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.
Fifth Edition • First Printing Operator's Manual Inspections Shading indicates decal is hidden from view, i.e., under covers. Note: Platform decals may be in different locations on optional AWP platform. Part No.
Operator's Manual Fifth Edition • First Printing Inspections Inspection for Decals with Symbols Standard and AWP 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.
Fifth Edition • First Printing Operator's Manual Inspections Shading indicates decal is hidden from view, i.e., under covers. Note: Platform decals may be in different locations on optional AWP platform. Part No.
Operator's Manual Fifth Edition • First Printing Inspections 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. 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.
Fifth Edition • First Printing Operator's Manual 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 functions. 1 Press and hold the high or low speed lift enable button. Repair any function that operates when either red Emergency Stop button is pushed in. Emergency Lowering 2 Press the platform up or platform down button.
Operator's Manual Fifth Edition • First Printing Operating Instructions To select drive speed To determine the slope grade: The drive controls can operate in two different drive speed modes while in the stowed position. When the drive speed button light is on, slow drive speed mode is active. When the drive speed button light is off, fast drive speed mode is active. Measure the slope with a digital inclinometer OR use the following procedure.
Fifth Edition • First Printing Operator's Manual Operating Instructions Operational indicator codes If the platform controls LED or ground controls LCD diagnostic readout displays an operational indicator code such as LL, the fault condition must repaired or removed before resuming machine operation. 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.
Operator's Manual Fifth Edition • First Printing Operating Instructions Battery Level Indicator Use the LED diagnostic readout to determine the battery level. Note: When a blinking LO code appears on the platform controls LED diagnostic readout, the machine must be taken out of service and charged, otherwise all machines functions will be disabled. Battery and Charger Instructions Observe and Obey: Do not use an external charger or booster battery. Charge the battery in a well-ventilated area.
Fifth Edition • First Printing Operator's Manual Operating Instructions To Charge Battery 1 Be sure the batteries are connected before charging the batteries. 2 Open the battery compartment. The compartment should remain open for the entire charging cycle. 3 Rest the cover against the chassis. 4 Lower the platform until the mast just contacts the battery cover. Crushing hazard. Keep hands clear of the battery cover when lowering the platform.
Operator's Manual Fifth Edition • First Printing Transport and Lifting Instructions Do not drive the machine on a slope that exceeds the uphill, downhill or side slope rating. See Driving on a Slope in the Operating Instructions section. Observe and Obey: Genie Industries provides this securement information as a recommendation.
Fifth Edition • First Printing Operator's Manual Transport and Lifting Instructions Securing to Truck or Trailer for Transit Always chock the machine wheels in preparation for transport. 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. Part No. 133571 Inspect the entire machine for loose or unsecured items. Use the tie-down points on the chassis for anchoring down to the transport surface.
Operator's Manual Fifth Edition • First Printing Transport and Lifting Instructions Loading the Machine With a Crane Use the lifting eye mounted on the rear mast column. Make sure the mast is fully lowered. Observe and Obey: Inspect the machine and remove any loose or unsecured items. Only qualified riggers should rig and lift the machine. Always place the lifting hook through the lifting eye so that it points away from the machine.
Fifth Edition • First Printing Operator's Manual Maintenance Check the Hydraulic Oil Level Observe and Obey: Only routine maintenance items specified in this manual shall be performed by the operator. Scheduled maintenance inspections shall be completed by qualified service technicians, according to the manufacturer's specifications and the requirements specified in the responsibilities manual. Use only Genie approved replacement parts.
Operator's Manual Fifth Edition • First Printing Maintenance Scheduled Maintenance 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. Note: This procedure does not need to be performed on machines with sealed or maintenance - free batteries.
Fifth Edition • First Printing Operator's Manual Specifications GR-12 Airborne noise emissions Height, working maximum 17 ft 4 in 5.3 m Sound pressure level at ground workstation Height, platform maximum 11 ft 4 in 3.5 m Sound pressure level at platform workstation < 70 dBA 62 in 1.57 m Vibration value does not exceed 2.5 m/s2 Height, stowed maximum 64 in standard platform with work station tray 1.
Operator's Manual Fifth Edition • First Printing Specifications GR-15 Airborne noise emissions Height, working maximum 20 ft 7 in 6.3 m Sound pressure level at ground workstation Height, platform maximum 14 ft 8 in 4.5 m Sound pressure level at platform workstation < 70 dBA 62 in 1.57 m Vibration value does not exceed 2.5 m/s2 Height, stowed maximum 64 in standard platform with work station tray 1.
Fifth Edition • First Printing Operator's Manual Specifications GR-20 Airborne noise emissions Height, working maximum 25 ft 9 in 7.9 m Sound pressure level at ground workstation Height, platform maximum 19 ft 9 in 6.1 m Sound pressure level at platform workstation < 70 dBA 78 in 1.98 m 31.5 in 80 cm 53 in 1.35 m Length with standard platform 73.3 in optional platform extension extended 1.
Operator's Manual Fifth Edition • First Printing Specifications Platform dimensions, all models (length x width) Standard platform 35 x 29.5 in 88.9 x 74.9 cm Standard platform with extension 55 x 29.5 in 139.7 x 74.9 cm Standard AWP platform 27 x 26 in 69 x 51 cm Narrow AWP platform 26 x 20 in 66 x 51 cm Continuous improvement of our products is a Genie policy. Product specifications are subject to change without notice or obligation. 48 GR-12 • GR-15 • GR-20 Part No.
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