Genie GR-15, GR-20, GR-12 User Manual
Operator’s Manual
with Maintenance Information
CE Models
Third Edition
Second Printing
Part No. 97779
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 .............................................................. 1
Legend ....................................................................... 9
Controls .................................................................... 10
Pre-operation Inspection ........................................... 12
Maintenance ............................................................. 14
Function Tests .......................................................... 16
Workplace Inspection ................................................ 20
Operating Instructions ............................................... 21
Transport and Lifting Instructions .............................. 26
Decals ...................................................................... 28
Specifications ........................................................... 32
Contact us:
Internet: http://www.genielift.com
e-mail: techpub@genieind.com
Copyright © 2000 by Genie Industries
First Edition: Sixth Printing, October 2002
Second Edition: First Printing, August 2004
Third Edition: Second Printing, May 2005
"Genie" is a registered trademark of
Genie Industries in the U.S.A. and many other
countries. "Runabout" and "GR" are trademarks
of Genie Industries.
Printed on recycled paper
Printed in U.S.A.
2 GR-12 • GR-15 • GR-20 Part No. 97779
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:
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.
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 rules and worksite regulations.
You read, understand and obey all applicable
governmental regulations.
You are properly trained to safely operate the
machine.
Part No. 97779 GR-12 • GR-15 • GR-20 1
Operator's Manual Third Edition • Second Printing
SAFETY RULES
Electrocution Hazards
This machine is not electrically insulated and will
not provide protection from contact with or
proximity to electrical current.
Maintain safe distances from electrical power lines
and apparatus in accordance with applicable
governmental regulations and the following chart.
Voltage Minimum Safe
Phase to Phase Approach Distance
Meters
0 to 300V Avoid Contact
300V to 50KV 3.05
Tip-over Hazards
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.
Maximum capacity - GR-12 and GR-15
Standard platform 227 kg
Work station tray (option) 22 kg
Parcel tray (option) 68 kg
Maximum occupants 1
Stock Picker platform 227 kg
Adjustable work station tray 68 kg
Parcel tray (option) 68 kg
Bike rack (option) (each) 20 kg
Maximum occupants 1
AWP and fiberglass platform 159 kg
Maximum occupants 1
50KV to 200KV 4.60
200KV to 350KV 6.10
350KV to 500KV 7.62
500KV to 750KV 10.67
750KV to 1000KV 13.72
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.
2 GR-12 • GR-15 • GR-20 Part No. 97779
Third Edition • Second Printing
Operator's Manual
SAFETY RULES
Maximum capacity - GR-20
Standard platform 159 kg
Maximum occupants 1
Stock Picker platform 159 kg
Adjustable work station tray 68 kg
Bike rack (option) (each) 20 kg
Maximum occupants 1
AWP and fiberglass platform 159 kg
Maximum occupants 1
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.
The tilt alarm sounds only when the machine is on
a slope.
If the tilt alarm sounds:
Lower the platform immediately. 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 0.8 km/h with the platform raised.
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 drive the machine on a slope that exceeds
the slope and side slope rating of the
machine.Slope rating applies to machines in the
stowed position.
Maximum slope rating, stowed position 30% (17°)
Maximum side slope rating,
stowed position 30% (17°)
Note: Slope rating is subject to ground conditions
and adequate traction.
Part No. 97779 GR-12 • GR-15 • GR-20 3
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 push off or pull
toward any object
outside of the platform.
Maximum allowable
manual force
CE
200 N
Do not transport tools and materials unless they are
evenly distributed and can be safely handled by
person(s) in the platform.
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 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.
Do not use the machine on a moving or mobile
surface or vehicle.
Do not place or attach fixed or overhanging loads to
any part of this machine.
Do not raise the mast when wind speeds may
exceed 12.5 m/s. If wind speeds exceed 12.5 m/s
when the plaform is raised, lower the platform and
do not continue to operate the machine.
Do not place ladders or scaffolds in the platform or
against any part of this machine.
Be sure all tires are in good condition, castle nuts
are properly tightened and cotter pins are properly
installed.
4 GR-12 • GR-15 • GR-20 Part No. 97779
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Operator's Manual
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.
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.
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.
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.
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 the 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
Do not climb down from
the platform when raised.
Keep the platform floor clear of debris.
Lower the platform mid-rail bar or close the platform
entry gate before operating.
Part No. 97779 GR-12 • GR-15 • GR-20 5
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.
Limit travel speed according to the condition of the
ground surface, congestion, slope, location of
personnel, and any other factors which may cause
collision.
Do not operate a machine in the path of any crane
or moving overhead machinery unless the controls
of the crane have been locked out and/or
precautions have been taken to prevent any
potential collision.
Crushing Hazard
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.
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/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.
6 GR-12 • GR-15 • GR-20 Part No. 97779
Third Edition • Second Printing
Operator's Manual
SAFETY RULES
Battery Safety
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.
Explosion Hazards
Keep sparks, flames
and lighted tobacco
away from batteries.
Batteries emit an
explosive gas.
The battery tray should
remain open during the
entire charging cycle.
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 from contact with battery
terminals. 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 28 kg.
Lifting Hazard
Use the appropriate number of people and proper
lifting techniques when lifting batteries.
Do not contact the battery terminals or the cable
clamps with tools that may cause sparks.
Part No. 97779 GR-12 • GR-15 • GR-20 7
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.
Orange—used to indicate the
presence of a potentially
hazardous situation which, if not
avoided, could result in death or
serious injury.
Yellow with safety alert symbol—
used to indicate the presence of a
potentially hazardous situation
which, if not avoided, may cause
minor or moderate injury.
Yellow without safety alert
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.
8 GR-12 • GR-15 • GR-20 Part No. 97779
Third Edition • Second Printing
Operator's Manual
Legend
1 Pothole guard
2 Non-steer tire
3 Manual lowering valve
4 Transport tie-down
5 Forklift pocket
6 Battery charger display
7 Covers
8 Ground controls
9 Hydraulic oil level indicator
10 Power to platform/battery
charger connection for
optional inverter
Part No. 97779 GR-12 • GR-15 • GR-20 9
11 Work station tray
(if equipped)
12 Brake release pump knob
(under covers)
13 Mid-rail entry bar
14 Adjustable work station tray
15 Platform controls
16 Dual-entry gate
17 Lanyard anchorage
18 Parcel tray
(if equipped)
19 Bike rack (if equipped)
20 Mast
21 GFCI outlet
22 Manual storage container
23 Battery compartment cover
24 Battery cover latch
25 Steer tire
26 Platform extension release
pedal
27 Platform extension entry gate
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
3 Lift function select button
4 Horn button (if equipped)
10 GR-12 • GR-15 • GR-20 Part No. 97779
5 Proportional control handle and function enable
switch for lift and drive functions
6 Thumb rocker switch for steer functions
7 Drive speed button
8 Drive function select button
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