Genie GR -12, GR -15, GR -20 Operator's Manual

Download

Operator's Manual

Serial Number Range

GR™-12

from GRP-60000 from GRR-10001

ANSI/CSA North America South America Asia

GR™-15

GR™-20

with Maintenance Information

Original Instructions Sixth Edition First Printing Part No. 1297723GT

Operator's Manual Sixth Edition • First Printing

GR™-12 • GR™-15 • GR™-20 Part No. 1297723GT

Front Matter

Contents

Introduction ............................................................1

Symbol and Hazard Pictorials Definitions ..............5

General Safety .......................................................7

Personal Safety ................................................... 13

Work Area Safety ................................................ 14

Legend ................................................................ 21

Controls ............................................................... 22

Inspections .......................................................... 25

Operating Instructions ......................................... 39

Transport and Lifting Instructions ....................... 48

Maintenance ....................................................... 53

Specifications ...................................................... 55

the U.S.A. and many other countries. “GR” is a trademark of Terex South Dakota, Inc. These machines comply with

ANSI/SIA A92.20 CAN/CSA B354.6

Sixth Edition • First Printing Operator's Manual

Introduction

Part No. 1297723GT GR™-12 • GR™-15 • GR™-20 1

Introduction

About this manual

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. This book is an operation and daily maintenance manual for the user or operator of a Genie 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, contact Genie.

Product Identification

The machine serial number is located on 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

Mobile Elevating Work Platform (MEWP).

 Familiarization with the MEWP must be given

to each person who is authorized, competent and trained.

 Only trained and authorized personnel should

be permitted to operate the machine.

 The operator is responsible to read,

understand, and obey the manufacturer’s

instructions and safety rules provided in the Operator’s Manual.

 The Operator’s Manual is located in the

manual storage container, at the platform.

 For specific product applications, see

Contacting The Manufacturer.

Operator's Manual Sixth Edition • First Printing

Introduction

2 GR™-12 • GR™-15 • GR™-20 Part No. 1297723GT

Platform controls symbology and related machine movement:

Lift function enable button

Drive function enable button

Platform up/down (when lift function selected)

Drive forward/reverse (when drive function selected)

Steer right/left (when drive function selected)

Area of operation, indoor use button

Area of operation, outdoor use button

Ground controls symbology 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 platform unless the machine

is on firm level ground.

Sixth Edition • First Printing Operator's Manual

Introduction

Part No. 1297723GT GR™-12 • GR™-15 • GR™-20 3

Bulletin Distribution and Compliance

Safety of product users is of paramount importance to Genie. Various bulletins are used by Genie to communicate important safety and product information to dealers and machine owners.

The information contained in the bulletins is tied to specific machines using the machine model and serial number.

Distribution of bulletins is based on the most current owner on record along with their associated dealer, so it is important to register your machine and keep your contact information up to date.

To ensure safety of personnel and the reliable continued operation of your machine, be sure to comply with the action 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 regarding product applications and

safety Standards and regulatory compliance information Current owner updates, such as changes in

machine ownership or changes in your contact information. See Transfer of Ownership, below.

Transfer of Machine Ownership

Taking a few minutes to update owner information will ensure that you receive important safety, maintenance and operating information that applies to your machine.

Please register your machine by visiting us on the web at www.genielift.com or by calling us toll free at 1-800-536-1800.

Operator's Manual Sixth Edition • First Printing

Introduction

4 GR™-12 • GR™-15 • GR™-20 Part No. 1297723GT

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.

Safety Sign Maintenance

Replace any missing or damaged safety signs. Keep operator safety in mind at all times. Use mild soap and water to clean safety signs. Do not use solvent-based cleaners because they may damage the safety sign material.

Hazard Classification

Decals on this machine 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 serious injury.

Indicates a hazardous situation which, if not avoided, could result in minor or moderate injury.

Indicates a property damage message.

Sixth Edition • First Printing Operator's Manual

Symbol and Hazard Pictorials Definitions

Part No. 1297723GT GR™-12 • GR™-15 • GR™-20 5

Symbol and Hazard Pictorials Definitions

Read the operator’s

manual

Read the service manual

Crush hazard

No smoking

Collision hazard Collision hazard

Tip-over hazard

Electrocution hazard

Burn hazard

Explosion hazard

Fire hazard

Batteries used as counterweights

Tiedown

Voltage rating for power to platform

Pressure rating for air line to platform

Keep away from moving parts

Move machine to level ground

Lifting & tie down instructions

Operator's Manual Sixth Edition • First Printing

Symbol and Hazard Pictorials Definitions

6 GR™-12 • GR™-15 • GR™-20 Part No. 1297723GT

Maintain required clearance

Access by trained and authorized personnel only

Chock the wheels

Release brakes

Grounded AC 3-wire only

Replace damaged wires and cords

Wheel load

Lanyard anchorage points

Side force

Manual force Lifting point

Indoor

Outdoor

Auxiliary lowering

Wind speed

Maximum capacity

Maximum capacity including occupant, tools, materials and options

Platform overloaded

Sixth Edition • First Printing Operator's Manual

General Safety

Part No. 1297723GT GR™-12 • GR™-15 • GR™-20 7

General Safety

Operator's Manual Sixth Edition • First Printing

General Safety

8 GR™-12 • GR™-15 • GR™-20 Part No. 1297723GT

Sixth Edition • First Printing Operator's Manual

General Safety

Part No. 1297723GT GR™-12 • GR™-15 • GR™-20 9

Operator's Manual Sixth Edition • First Printing

General Safety

10 GR™-12 • GR™-15 • GR™-20 Part No. 1297723GT

Sixth Edition • First Printing Operator's Manual

General Safety

Part No. 1297723GT GR™-12 • GR™-15 • GR™-20 11

Operator's Manual Sixth Edition • First Printing

General Safety

12 GR™-12 • GR™-15 • GR™-20 Part No. 1297723GT

Sixth Edition • First Printing Operator's Manual

Personal Safety

Part No. 1297723GT GR™-12 • GR™-15 • GR™-20 13

Personal Safety

Personal 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.

Operator's Manual Sixth Edition • First Printing

Work Area Safety

14 GR™-12 • GR™-15 • GR™-20 Part No. 1297723GT

Work Area Safety

Electrocution Hazards

This machine is not electrically insulated and will not provide protection from contact with or proximity to electrical current.

Obey all local and governmental regulations regarding required clearance from electrical power lines. At a minimum, the required clearance contained in the chart below must be followed.

Line Voltage

Required Clearance

0 to 50KV

10 ft

3.05 m

50 to 200KV

15 ft

4.60 m

200 to 350KV

20 ft

6.10 m

350 to 500KV

25 ft

7.62 m

500 to 750KV

35 ft

10.67 m

750 to 1000KV

45 ft

13.72 m

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.

Tip-over Hazards

Occupants, equipment and materials shall not exceed the maximum platform capacity or the maximum platform capacity of the platform extension. Weight in trays is part of the total platform load.

Maximum capacity - GR-12 and GR-15

Standard platform

Platform without extension

500 lbs

227 kg

Platform retracted

500 lbs

227 kg

Platform extended – Platform only

250 lbs

113 kg

Platform extended – Extension only

250 lbs

113 kg

Work tray station (option)

50 lbs

22 kg

Maximum occupants

500 lbs / 227 kg

Extension only 250 lbs/113 kg

Platform only

250 lbs/113 kg

Sixth Edition • First Printing Operator's Manual

Work Area Safety

Part No. 1297723GT GR™-12 • GR™-15 • GR™-20 15

Maximum capacity - GR-20

Standard platform

Platform without extension

350 lbs

159kg

Platform retracted

350 lbs

159 kg

Platform extended – Platform only

100 lbs

45 kg

Platform extended – Extension only

250 lbs

113 kg

Work tray station (option)

50 lbs

22 kg

Maximum occupants

350 lbs/159 kg

Extension only 250 lbs/113 kg

Platform only 100 lbs/45 kg

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 at the platform controls and the ground controls when the machine is on a severe slope.

If the tilt alarm sounds: Lower the platform. 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 drive over 0.5 mph / 0.8 km/h with the platform raised.

Do not raise the platform 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.

Follow ratings for allowable side force and number of occupants shown below.

Outdoor use: Do not operate the machine outdoors with the indoor use button selected.

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.

Operator's Manual Sixth Edition • First Printing

Work Area Safety

16 GR™-12 • GR™-15 • GR™-20 Part No. 1297723GT

Do not drive the machine on or near uneven terrain, unstable surfaces or other hazardous conditions with the platform raised.

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. Do not place loads outside the platform perimeter.

The work station tray is considered part of the platform.

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

side force

Maximum occupants

45 lbs / 200 N

Do not alter or disable the limit switches. Do not alter or disable machine components that

in any way affect safety and stability. Do not replace items critical to machine stability

with items of different weight or specification. 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 62 lbs/28 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 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 person(s) in the platform.

Sixth Edition • First Printing Operator's Manual

Work Area Safety

Part No. 1297723GT GR™-12 • GR™-15 • GR™-20 17

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

Be sure all tires are in good condition, castle nuts are properly tightened and cotter pins are properly installed.

Crushing Hazard

Keep hands and limbs out of mast. Do not work under the platform or mast without the

battery cover raised. 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.

Operation on Slopes Hazards

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% (16.7°)

Maximum side slope rating, stowed position

30% (16.7°)

Note: Slope rating is subject to ground conditions with one person 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 manufacturer’s instructions and applicable governmental requirements. Use approved lanyard attachment point provided.

Keep the platform floor clear of debris. Close the entry gate before operating.

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 raised.

Do not enter or exit the platform unless the machine is in the stowed position.

Operator's Manual Sixth Edition • First Printing

Work Area Safety

18 GR™-12 • GR™-15 • GR™-20 Part No. 1297723GT

Collision Hazards

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

Be aware of extended platform position when moving the machine.

The machine must be on a level surface and wheels chocked or secured before releasing the brakes.

Operators must comply with employer, job site, and governmental rules regarding use of personal protective equipment.

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

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

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.

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

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.

No stunt driving or horseplay while operating a machine.

Sixth Edition • First Printing Operator's Manual

Work Area Safety

Part No. 1297723GT GR™-12 • GR™-15 • GR™-20 19

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.

Explosion and Fire Hazards

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 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 not use any battery charger greater than 24V to charge the batteries.

Do not use the machine as a ground for welding.

Operator's Manual Sixth Edition • First Printing

Work Area Safety

20 GR™-12 • GR™-15 • GR™-20 Part No. 1297723GT

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 explosive gas.

The battery tray may remain open during the entire charging cycle.

Do not contact the battery terminals or the 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/Burn Hazards

Connect the battery charger to a grounded, AC 3-wire electrical outlet only.

Inspect daily for damaged cords, 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 a minimum of 62 lbs/28 kg.

Lifting Hazard

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

Lockout After Each Use

1 Select a safe parking location—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 Charge the batteries.

Sixth Edition • First Printing Operator's Manual

Legend

Part No. 1297723GT GR™-12 • GR™-15 • GR™-20 21

Legend

1 Pothole guard 2 Non-steer tire 3 Auxiliary lowering valve 4 Transport tie-down 5 Forklift pockets 6 Battery charger display 7 Covers 8 Hydraulic oil level indicator

9 Ground controls 10 Mast 11 Brake release pump knob

(under covers) 12 Platform controls 13 Manual storage container 14 Lanyard anchorage point

15 Tool Tray 16 GFCI outlet 17 Battery compartment cover 18 Battery cover latch 19 Steer tire 20 Platform extension release

pedal

21 Platform extension entry gate

Operator's Manual Sixth Edition • First Printing

Controls

22 GR™-12 • GR™-15 • GR™-20 Part No. 1297723GT

Controls

The ground control station is to be used as a means to raise the platform for function tests and for storage purposes. The ground control station can be used in the event of an emergency to rescue an incapacitated person in the platform.

Ground Control Panel

1 7A breaker for electrical 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 7 Lift function enable button

Press and hold this button to activate the lift

function.

8 Menu escape button 9 Menu up button 10 LCD diagnostic readout 11 Key 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.

12 Tech Pro Link Connector

Sixth Edition • First Printing Operator's Manual

Controls

Part No. 1297723GT GR™-12 • GR™-15 • GR™-20 23

Platform Control Panel

1 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.

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.

5 Proportional control handle and function

enable switch for drive, steer, and lift functions Lift function: Press and hold the function

enable switch to enable the lift function on the platform control handle. Move the control handle in the direction indicated by the blue arrow and the platform will raise. Move the control handle in the direction indicated by the yellow arrow and the platform will lower. The descent alarm should sound while the platform is lowering.

Drive function: Press and hold the function enable switch to enable the drive function 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.

Operator's Manual Sixth Edition • First Printing

Controls

24 GR™-12 • GR™-15 • GR™-20 Part No. 1297723GT

6 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.

Press the right side of the thumb rocker and the machine will turn in the direction the yellow triangle points on the platform control panel.

7 LED diagnostic readout, battery charge

indicator and lift/drive mode indicator 8 Drive function button

Push this button to activate the drive function.

9 Indoor use button

Press this button for indoor use Note: Selecting indoor use permits

elevating to maximum indoor platform height. Refer to specification pages.

10 Outdoor use button

Press this button for outdoor use Note: Selecting outdoor use

permits elevating to maximum outdoor platform height. Refer to specification pages.

Sixth Edition • First Printing Operator's Manual

Inspections

Part No. 1297723GT GR™-12 • GR™-15 • GR™-20 25

Inspections

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.

3 Always perform function tests prior to use. 4 Inspect the workplace. 5 Only use the machine as it was intended.

Pre-operation Inspection Fundamentals

It is the responsibility of the operator to perform a pre-operation inspection and routine maintenance.

The pre-operation inspection is a visual inspection performed by the operator prior to each work shift. The inspection 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 unauthorized variation from factory delivered condition is discovered, the machine must be tagged and removed from service.

Repairs to the machine may only be made by a qualified service technician, according to the

manufacturer’s specifications. After repairs are

completed, the operator must perform a preoperation inspection again before going on to the function tests.

Scheduled maintenance inspections shall be performed by qualified service technicians,

according to the manufacturer’s specifications and

the requirements listed in the responsibilities manual.

Operator's Manual Sixth Edition • First Printing

Inspections

26 GR™-12 • GR™-15 • GR™-20 Part No. 1297723GT

Pre-operation Inspection

 Be sure that the operator’s, safety, and

responsibilities manuals are complete, legible

and in the storage container located in the

platform.  Be sure that all decals are legible and in place.

See Inspections section.  Check for hydraulic oil leaks and proper oil

level. Add oil if needed. See Maintenance

section.  Check for battery fluid leaks and proper fluid

level. Add distilled water if needed. See

Maintenance section. Check the following components or areas for

damage, improperly installed, or missing parts and unauthorized modifications:

 Electrical components, wiring, and

electrical cables

 Hydraulic power unit, reservoir, hoses,

fittings, cylinders and manifolds

 Battery pack and connections

 Drive motors

 Tires and wheels

 Ground strap

 Limit switches, alarms and horn

 Beacons (if equipped)

 Nuts, bolts and other fasteners

 Platform entry mid-rail or gate

 Sequencing cables and pulleys

 Wear pads

 Pothole guards  Lanyard anchorage points  Platform extension (if equipped)  Work trays (if equipped)  Brake release components  Battery cover  Mast columns and counterweight  Platform control joystick  Platform overload components

Check entire machine for:

 Cracks in welds or structural components  Dents or damage to machine  Excessive rust, corrosion or oxidation

 Verify that all structural and other critical

components are present and all associated fasteners and pins are in place and properly tightened.

Note: If the platform must be raised to inspect the machine, make sure that the battery cover is in place to prevent the mast sections and platform from coming down. See Operating Instructions section.

Sixth Edition • First Printing Operator's Manual

Inspections

Part No. 1297723GT GR™-12 • GR™-15 • GR™-20 27

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.

Know and understand the function tests before going on to the next section.

4 Inspect the workplace. 5 Only use 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 only be made by a qualified service

technician, according to the manufacturer’s

specifications. After repairs are completed, the operator must

perform a pre-operation inspection and function tests again before putting the machine into service.

Operator's Manual Sixth Edition • First Printing

Inspections

28 GR™-12 • GR™-15 • GR™-20 Part No. 1297723GT

At the Ground Controls

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

hazards. 2 Be sure the batteries are connected. 3 Pull out the platform and ground red

Emergency Stop button to the on position. 4 Turn the key switch to ground control. 5 Observe the diagnostic LED readout on the

platform controls.

Result: The LED should look like the picture

below.

6 Observe the diagnostic LCD readout on the

ground controls.

Result: The LCD should look like the picture

below.

Test Emergency Stop

7 Push in the ground red Emergency Stop

button to the off position.

Result: No functions should operate.

8 Pull out the red Emergency Stop button to the

on position.

Test the Up/Down Functions

The audible warnings on this machine and the standard horn all come from the same central alarm. The horn is a constant tone. The descent alarm sounds at 60 beeps per minute. The alarm sounds at 180 beeps per minute when the pothole guards have not deployed and when the machine is not level. An optional automotive-style horn is also available.

9 Do not press the lift function enable button. 10 Press the platform up or platform down button.

Result: The lift function should not operate.

11 Do not press the platform up or platform down

buttons.

12 Press the lift function enable button.

Result: The lift function should not operate.

13 Press and hold the lift function enable button,

and press the platform up button.

Result: The lift function should not operate.

14 Press the Enter button to cycle between indoor

and outdoor area of operation. 15 Select the outdoor area of operation. 16 Press and hold the lift function enable button,

and press the platform up button.

Result: The platform should raise.

17 Press and hold the lift function enable button,

and press the platform down button.

Result: The platform should lower.The descent

alarm should sound while the platform is

lowering.

Sixth Edition • First Printing Operator's Manual

Inspections

Part No. 1297723GT GR™-12 • GR™-15 • GR™-20 29

Test Auxiliary Lowering

18 Activate the up function by pressing the lift

enable button and platform up button, and raise the platform approximately 2 ft. / 60 cm.

19 Pull the auxiliary lowering knob located at the

base of the machine below the mast.

Result: The platform should lower. The

descent alarm will not sound.

Test the Tilt Sensor Operation

20 Press the ground control down button

(button 3)

Result: The ground control LCD screen will

display the status of the tilt sensor. The X and Y values (pitch and roll) will be displayed.

21 Turn the key switch to platform control.

At the Platform Controls

Test Emergency Stop

22 Push in the platform red Emergency Stop

button to the off position.

Result: No functions should operate.

Test the Horn

23 Pull out the red Emergency Stop button to the

on position.

24 Press the horn button.

Result: The platform alarm, chassis alarm, and

automotive horn (if equipped) should sound.

Test the Function Enable Switch and the Up/Down Functions

25 Press the outdoor use button.

Result: The outdoor use button should

illuminate.

26 Do not hold the function enable switch on the

control handle.

27 Slowly move the control handle in the direction

indicated by the blue arrow, then in the direction indicated by the yellow arrow.

Result: No functions should operate. 28 Press the lift function button. 29 Wait seven seconds for the lift function to time

out.

30 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. 31 Press the lift function button. 32 Press and hold the function enable switch on

the control handle. Slowly move the control handle in the direction indicated by the blue arrow.

Result: The platform should raise. The pothole

guards should deploy.

33 Release the control handle.

Result: The platform should stop raising. 34 Press and hold the function enable switch on

the control handle. 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.

Operator's Manual Sixth Edition • First Printing

Inspections

30 GR™-12 • GR™-15 • GR™-20 Part No. 1297723GT

Test the Outdoor Use Button

35 Do not press and hold the function enable

switch on control handle.

36 Press the outdoor use button.

Result: The LED under the outdoor button will

illuminate. 37 Press the lift function enable button. 38 Press and hold the function enable switch on

the control handle. Slowly move the control

handle in the direction indicated by the blue

arrow.

GR-12: Result: The platform should raise to

9 ft 1 in/2.76 m and stop. The alarm should

sound. The platform controls LED readout

should display OHL.

GR-15: Result: The platform should raise to

11 ft 1 in/3.37 m and stop. The alarm should

sound. The platform controls LED readout

should display OHL.

GR-20: Result: The platform should raise to

15 ft 6 in/4.72 m and stop. The alarm should

sound. The platform controls LED readout

should display OHL.

Test the Drive Function Button

39 Press the drive function button.

40 Wait seven seconds for the drive function to

time out. Slowly move the control handle in the direction indicated by the blue arrow, then in the direction indicated by the yellow arrow.

Result: No functions should operate.

Test the Steering

Note: When performing the steer and drive function tests, stand in the platform facing the steer end of the machine.

41 Press the drive function button.

42 Press and hold the function enable switch on

the control handle.

43 Press the thumb rocker switch on top of the

control handle in the direction indicated by the blue triangle on the control panel.

Result: The steer wheels should turn in the

direction indicated by the blue triangle.

44 Press the thumb rocker switch 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.

Sixth Edition • First Printing Operator's Manual

Inspections

Part No. 1297723GT GR™-12 • GR™-15 • GR™-20 31

Test Drive and Braking

45 Press the drive function button.

46 Press and hold the function enable switch on

the control handle.

47 Slowly move the control handle in the direction

indicated by the blue arrow on the control panel until the machine begins to move, then return the control handle to the center position.

Result: The machine should move in the

direction that the blue arrow points on the control panel, then come to an abrupt stop when the control handle is returned to the center position.

48 Slowly move the control handle in the direction

indicated by the yellow arrow on the control panel until the machine begins to move, then return the control handle to the center position.

Result: The machine should move in the

direction that the yellow arrow points on the control panel, then come to an abrupt stop when the control handle is returned to the center position.

Note: The brakes must be able to hold the machine on any slope it is able to climb.

Test Drive Tilt Cutout

Note: Perform this test from the ground with the platform controller. Do not stand in the platform.

49 Fully lower the platform. 50 Drive the machine onto a slope where the

chassis angle is greater than 1.5° side to side.

51 Raise the platform to approximately

7 ft/2.13 m.

Result: The platform should stop and the tilt

alarm will sound at 180 beeps per minute. The platform controls LED readout should display LL and the ground controls LCD should

display LL: Machine Tilted. 52 Press the drive function button. 53 Press and hold the function enable switch on

the control handle. 54 Move the control handle 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. 55 Fully lower the platform. 56 Drive the machine.

Result: The machine should drive.

57 Return to level ground and raise the platform

in excess of approximately 7 ft/2.13 m.

Operator's Manual Sixth Edition • First Printing

Inspections

32 GR™-12 • GR™-15 • GR™-20 Part No. 1297723GT

58 Drive the machine onto a slope where the

pitch angle is greater than 1.5° side to side.

Result: The machine should stop once the

machine reaches 1.5° of chassis tilt and the tilt alarm will sound at 180 beeps per minute. The platform controls LED readout should display LL and the ground controls LCD should display LL: Machine Tilted

59 Return to level ground and fully lower the

platform.

60 Drive the machine onto a slope where the

chassis angle is greater than 3° front to back.

61 Raise the platform to approximately

7 ft/2.13 m.

Result: The platform should stop and the tilt

alarm will sound at 180 beeps per minute. The platform controls LED readout should display LL and the ground controls LCD should

display LL: Machine Tilted. 62 Press the drive function button. 63 Press and hold the function enable switch on

the control handle. 64 Move the control handle 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.

65 Fully lower the platform. 66 Drive the machine.

Result: The machine should drive.

67 Return to level ground and raise the platform

in excess of approximately 7 ft/2.13 m.

68 Drive the machine onto a slope where the

pitch angle is greater than 3° front to back.

Result: The machine should stop once the

machine reaches 3° of chassis tilt and the tilt alarm will sound at 180 beeps per minute. The platform controls LED readout should display LL and the ground controls LCD should display LL: Machine Tilted

69 Fully lower the platform and return to level

ground.

Test Elevated Drive Speed

70 Raise the platform approximately 4 ft / 1.2 m

from the ground.

71 Press the drive function button.

72 Press and hold the function enable switch on

the control handle.Slowly move the control handle to full drive position.

Result: The maximum achievable drive speed

with the platform raised should not exceed

0.72 ft / 22 cm per second.

If the drive speed with the platform raised exceeds

0.72 ft / 22 cm per second, immediately tag and remove the machine from service.

Sixth Edition • First Printing Operator's Manual

Inspections

Part No. 1297723GT GR™-12 • GR™-15 • GR™-20 33

Test the Pothole Guards

Note: The pothole guards should automatically deploy when the platform is raised. The pothole guards activate limit switches that allow the machine to continue to function. If the pothole guards do not deploy, an alarm sounds and the machine will not drive or steer.

73 Raise the platform.

Result: When the platform is raised

approximately 4 ft / 1.2 m from the ground, the pothole guards should deploy.

74 Press on the pothole guards on one side, and

then the other.

Result: The pothole guards should not move.

75 Lower the platform.

Result: The pothole guards should return to

the stowed position.

76 Place a 2x4 or similar piece of wood under a

pothole guard.

77 Raise the platform.

Result: Before the platform is raised

approximately 7 ft / 2.1 m from the ground, an alarm should sound. The platform controls LED readout should display PHS and the ground controls LCD should display PHS: Pothole Guard Stuck.

78 Press the drive function button.

79 Press and hold the function enable switch on

the control handle.

80 Slowly move the control handle in the direction

indicated by the blue arrow, then in the direction indicated by the yellow arrow.

Result: The machine should not move forward

or backward.

81 Press the drive function button.

82 Press and hold the function enable switch on

the control handle.

83 Press the thumb rocker switch on top of the

control handle in the direction indicated by the blue and yellow triangles on the control panel.

Result: The steer wheels should not turn left or

right. 84 Fully lower the platform. 85 Remove the 2x4 or similar piece of wood.

Operator's Manual Sixth Edition • First Printing

Inspections

34 GR™-12 • GR™-15 • GR™-20 Part No. 1297723GT

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.

5 Only use the machine as it was intended.

Workplace Inspection Fundamentals

The workplace inspection helps the operator 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 situations:

 drop-offs or holes  bumps, floor obstructions, or debris  sloped surfaces  unstable or slippery surfaces  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

Sixth Edition • First Printing Operator's Manual

Inspections

Part No. 1297723GT GR™-12 • GR™-15 • GR™-20 35

Inspection for Decals with Words

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. Decal Description

Qty

28174 Label – Power to Platform, 230V*

28235 Label – Power to Platform, 115V*

28236 Warning – Improper Operation

28373 Label – Forklift Pocket

31508 Danger – Electrocution Hazard

31788 Danger – Explosion/Burn Hazard

38122 Label – Manual Storage

38149 Label – Patents

43658 Label – Power to Charger, 230V*

44736 Danger – Tip-over Hazard, Tilt Alarm

44980 Label – Power to Charger, 115V*

52475 Label – Transport Tie-down

52865 Warning – Annual Inspection Record

72086 Label – Lifting Point

72159 Danger – Tip-over Hazard, Batteries

72188 Label – Directional Arrows

72832 Danger – Do Not Alter Limit Switch

72970 Instructions – Battery Charger

Operation

82366 Label – Chevron Rando*

82836 Label – Auxiliary Lowering

82975 Warning – Collision Hazard

97815 Label – Lower Mid-rail*

114325 Instructions – Battery Connection

Diagram

133013 Danger – Electrocution Hazard

133092 Danger – Crushing Hazard, Use Safety

Chock

133586 Instructions – Operation, Ground

Control

137605 Label – Emergency Stop, Platform

Control

137656 Label – Drive/Steer Direction,

Platform Control

220283 Warning – Unauthorized Use Hazard*

1263543 Warning – Compartment Access

Part No. Decal Description

Qty

1270489 Label – Wheel Load, GR, GRC

1272242 Label – Machine Registration/Owner

Transfer

1280819 Label – Warning, Prop 65

1281175 Label – Lanyard Anchorage Point, Fall

Restrained

1283228 Label – GCON, GR, Tech Pro

1283810 Label – Platform Control Panel

1283878 Label – Tech Pro Link

1293165 Danger – Tip-over, Crush Hazard

1293324 Label – ICES-2/CAN-2 Compliance

1294398 Label – ANSI/CSA Compliant

1294635 Label – Platform Overload LED

Indicator Light

1296034 Label – Smartlink Dual Zone

1296295 Label – Fault Codes

1296619 Label – Maximum Capacity, 350 lbs,

Side Force 45 lbs*

1296621 Label – Maximum Capacity, 500 lbs,

Side Force 45 lbs*

1296821 Decal – Warning, Tool Box

1297735 Label – Transport Diagram

T107029 Danger/Instructions – Brake Release

Safety and Operation

T107894 Label – Tire Specifications

* These decals are model, option or configuration specific.

Operator's Manual Sixth Edition • First Printing

Inspections

36 GR™-12 • GR™-15 • GR™-20 Part No. 1297723GT

Sixth Edition • First Printing Operator's Manual

Inspections

Part No. 1297723GT GR™-12 • GR™-15 • GR™-20 37

Inspection for Decals with Symbols

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. Decal Description

Qty

28174 Label – Power to Platform, 230V*

28235 Label – Power to Platform, 115V*

43658 Label – Power to Charger, 230V*

44980 Label – Power to Charger, 115V*

52475 Label – Transport Tie-down

72086 Label – Lifting Point

72188 Label – Directional Arrows

82481 Label – Battery/Charger Safety

82487 Label – Read the Manual

82495 Label – Brake Release Safety and

Operating Instructions

82614 Warning – Collision Hazard

82666 Label – Forklift Pocket

82836 Label – Auxiliary Lowering

97815 Label – Lower Mid-rail*

97899 Label – Use Safety Chock

114334 Label – Electrocution Hazard, Plug

114338 Label – Tip-over Hazard, Tilt Alarm

133015 Danger – Electrocution hazard

133146 Danger – Tip-over Hazard, Batteries

133147 Label – Tip-over Hazard, Limit Switch

137605 Label – Emergency Stop, Platform

Control

137656 Label – Drive/Steer Direction,

Platform Control

1263542 Label – Compartment Access

1270489 Label – Wheel Load, GR, GRC

1272242 Label – Machine Registration/Owner

Transfer

1281175 Label – Lanyard Anchorage Point, Fall

Restrained

1283228 Label – GCON, GR, Tech Pro

1283810 Label – Platform Control Panel

1283878 Label – Tech Pro Link

Part No. Decal Description

Qty

1293166 Danger, Warning – Tip-over, Crush

Hazard

1294398 Label – ANSI/CSA Compliant

1294688 Label – Platform Overload LED

Indicator Light

1296034 Label – Smartlink Dual Zone

1296620 Danger – Max. Capacity, Side Force,

GR*

1296622 Danger – Max. Capacity, Side Force,

GR*

1297735 Label – Transport Diagram

1298467 Label – Read the Manual

* These decals are model, option or configuration specific.

Operator's Manual Sixth Edition • First Printing

Inspections

38 GR™-12 • GR™-15 • GR™-20 Part No. 1297723GT

Sixth Edition • First Printing Operator's Manual

Operating Instructions

Part No. 1297723GT GR™-12 • GR™-15 • GR™-20 39

Operating Instructions

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.

5 Only use the machine as it was

intended.

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.

Only trained and authorized personnel should be permitted to operate a machine. If more than one operator is expected to use a machine at different times in the same work shift, they must all be qualified operators and are all expected to follow

all safety rules and instructions in the operator’s,

safety, and responsibilities manuals. That means every new operator should perform a preoperation inspection, function tests, and a workplace inspection before using the machine.

Operator's Manual Sixth Edition • First Printing

Operating Instructions

40 GR™-12 • GR™-15 • GR™-20 Part No. 1297723GT

Emergency Stop

Push in the red Emergency Stop button to the off position at the ground controls or the platform controls to stop all functions.

Repair any function that operates when either red Emergency Stop button is pushed in.

Auxiliary Lowering

Pull the auxiliary lowering knob to lower the platform.

Operation from Ground

1 Be sure the battery pack is connected before

operating the machine. 2 Turn the key switch to ground control. 3 Pull out both ground and platform red

Emergency Stop buttons to the on position.

To Position Platform

1 At the control panel, press Enter button to

cycle between indoor and outdoor area of

operations. Note: Area of operation can only be changed when

the machine is in the stowed position. 2 Press and hold the lift function enable. 3 Press the platform up or down button.

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 Indoor or

Outdoor use button.

Note: Area of operation can only be changed when the machine is in the stowed position.

2 Press the lift function button. On the

LED screen, a circle below the lift function symbol will turn on.

If the control handle is not moved within seven seconds of pushing the lift function button, the circle below the lift function symbol will turn off and lift function will not operate. Press the lift function button again.

3 Press and hold the function enable switch on

the control handle. 4 Move the control handle in the direction

indicated by the markings on the control panel.

Sixth Edition • First Printing Operator's Manual

Operating Instructions

Part No. 1297723GT GR™-12 • GR™-15 • GR™-20 41

To Steer

1 Press the drive function button. On the LED

screen, a circle below the drive function symbol will turn on.

If the control handle is not moved within seven seconds of pushing the drive function button, the circle below the drive function symbol will turn off and drive function will not operate. Press the drive function button again.

2 Turn the steer wheels with the

thumb rocker switch located on the top of the control handle.

To Drive

1 Press the drive function button. On the LED

screen, a circle below the drive function symbol will turn on.

2 Press and hold the function enable switch on

the control handle.

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 arrows on the platform controls and on the platform to identify the direction the machine will travel.

Machine travel speed is restricted when the platform is raised.

Battery condition will affect machine performance. Machine drive speed and function speed will drop when the battery level indicator is flashing.

To select drive speed

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.

Press the drive speed button to select the desired drive speed.

Note: When the platform is elevated, the drive speed button light is always on, indicating elevated drive speed.

Operator's Manual Sixth Edition • First Printing

Operating Instructions

42 GR™-12 • GR™-15 • GR™-20 Part No. 1297723GT

Driving on a slope

Determine the slope and side slope ratings for the machine and determine the slope grade.

Maximum slope rating, stowed position:

30% (17°)

Maximum side slope rating, stowed position:

30% (17°)

Note: Slope rating is subject to ground conditions with one person in the platform and adequate traction. Additional platform weight may reduce slope rating.

To determine the slope grade:

Measure the slope with a digital inclinometer OR use the following procedure.

You will need:

 carpenter’s level  straight piece of wood, at least 3 feet/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 of wood to the ground.

Divide the tape measure distance (rise) by the length of the piece of wood (run) and multiply by

100. Example:

Piece of wood = 144 inches (3.6 m) Run = 144 inches (3.6 m) Rise = 12 inches (0.3 m) 12 in ÷ 144 in = 0.083 x 100 = 8.3% grade

0.3 m ÷ 3.6 m = 0.083 x 100 = 8.3% grade If the slope exceeds the maximum slope or side

slope rating, then the machine must be winched or transported up or down the slope. See Transport and Lifting section.

Sixth Edition • First Printing Operator's Manual

Operating Instructions

Part No. 1297723GT GR™-12 • GR™-15 • GR™-20 43

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.

LED Readout

LCD Readout

Operational Indicator Codes

Code

Condition

Off-Level

Platform Overloaded

Chassis Mode Operation

PHS

Pothole Guard Stuck

No Drive (option)

OHL

Outdoor Height Limit

For further information, please consult the appropriate Genie Service Manual. A code and a description of a code can also be viewed at 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 Stop button to the

on position.

LED Readout

LCD Readout

When the platform is being raised or lowered, a self-check function will be performed near maximum height. The machine may stop and an alarm may sound. If the machine is not overloaded, normal operation will resume.

Overload Recovery

If the ground controls LCD diagnostic readout displays Overload Recovery, the auxiliary lowering system has been used while the platform was overloaded. For information on how to reset the message, please consult the appropriate Genie Service Manual.

Operator's Manual Sixth Edition • First Printing

Operating Instructions

44 GR™-12 • GR™-15 • GR™-20 Part No. 1297723GT

Tilt Sensor Activation Settings

Chassis Angle (side to side)

1.5°

Chassis Angle (front to back)

3°

If the tilt alarm sounds while raising the platform, lower the platform and 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.

When the platform controls LED readout displays LL, the ground controls LCD displays LL: Machine Tilted, and the tilt alarm sounds at 180 beeps per minute, the following functions are affected: drive, steer, and elevate functions are disabled.

Return the machine to level ground to restore lift functions.

Operation from Ground with Controller

Maintain safe distances between the operator, machine and fixed objects.

Be aware of the direction the machine will travel when using the controller.

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 display, the machine must be taken out of service and charged, otherwise all machine functions will be disabled.

Full Charge

Half Charge

Low Charge

LO Flashing

Sixth Edition • First Printing Operator's Manual

Operating Instructions

Part No. 1297723GT GR™-12 • GR™-15 • GR™-20 45

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.

3 Step on the platform extension release pedal

and pull the guard rails to retract the platform.

Lift Tools Work Tray Instructions

The Lift Tools Work Tray assembly consists of one tray and a mounting bracket with hardware.

1 lift tool work tray 2 washer, flat, 3/8" 3 bolt, 3/8-16 x 2" 4 nut, nylock, 3/8-16 5 bolt, #10-24 x 0.50" 6 tool tray bracket 7 decal, warning

Operator's Manual Sixth Edition • First Printing

Operating Instructions

46 GR™-12 • GR™-15 • GR™-20 Part No. 1297723GT

Observe and Obey: Lift Tools Work Tray Installation

 Lift Tools Work Tray must be installed on the

inside of the platform.

 Only one Lift Tools Work Tray can be used per

machine.

 Mount Lift Tools Work Tray on the top of the

Platform Support near the mast only.

 Be sure the Lift Tools Work Tray is secured to

the Platform Support.

 Lift Tools Work Tray lanyard is for tools only.

Do not attach personal safety lanyard.

Lift Tools Work Tray Operation

1 Place the load so that it rests inside the Lift

Tools Work Tray.

The Lift Tools Work Tray assembly weighs 4 lbs / 1.8 kg.

Maximum capacity of Lift Tools Work Tray is 50 lbs / 23 kg.

Tip-over hazard. The weight of Lift Tools Work

Tray assembly and the load in the Lift Tools Work Tray assembly will reduce the rated platform capacity of the machine and must be factored into the total platform load.

After Each Use

1 Select a safe parking location—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 Charge the batteries.

Sixth Edition • First Printing Operator's Manual

Operating Instructions

Part No. 1297723GT GR™-12 • GR™-15 • GR™-20 47

Battery and Charger Instructions Observe and Obey:

 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 a Genie authorized battery and

charger.

To Charge Battery

1 Be sure the batteries are connected before

charging the batteries.

2 The compartment may remain closed for the

entire charging cycle.

Maintenance-free batteries

1 Connect the battery charger to a grounded AC

circuit.

2 The charger will indicate when the battery is

fully charged.

Standard Batteries

1 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. 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.

Operator's Manual Sixth Edition • First Printing

Transport and Lifting Instructions

48 GR™-12 • GR™-15 • GR™-20 Part No. 1297723GT

Transport and Lifting Instructions

Observe and Obey:

 Genie provides this securement information as

a recommendation. Drivers are solely responsible for making sure machines are properly secured and the correct trailer is selected pursuant to US Department of Transportation regulations, other localized regulations, and their company policy.

 Genie customers needing to containerize any

lift or Genie product should source a qualified freight forwarder with expertise in preparing, loading and securing construction and lifting equipment for international shipment.

 Only qualified mobile elevating work platform

operators 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. See the inspections section for the serial label location.

 The machine must be on a level surface or

secured before releasing the brakes.

 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.

 If the slope of the transport vehicle bed

exceeds the uphill or downhill maximum slope rating, the machine must be loaded and unloaded using a winch or forklift as described in the brake release operation. See the Specifications section for the slope ratings.

Sixth Edition • First Printing Operator's Manual

Transport and Lifting Instructions

Part No. 1297723GT GR™-12 • GR™-15 • GR™-20 49

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 Push in the black brake

release knob to open the brake valve.

4 Pump the red brake release pump knob.

After the machine is loaded:

1 Chock the wheels to prevent the machine from

rolling. 2 Pull out the red Emergency Stop button at

both the ground and platform controls to the

on position, and turn the key switch to the

platform position.

3 Press the drive function button.

4 Press and hold the function enable switch on

the control handle. Move the control handle off

center and immediately release it to reset the

brakes. 5 Push the red Emergency stop button at both

the ground and platform controls to the off

position. Towing the GR-12, the GR-15, and the GR-20 is

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

Operator's Manual Sixth Edition • First Printing

Transport and Lifting Instructions

50 GR™-12 • GR™-15 • GR™-20 Part No. 1297723GT

Securing to Truck or Trailer for 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 the tie-down points on the chassis for anchoring down to the transport surface.

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.

Sixth Edition • First Printing Operator's Manual

Transport and Lifting Instructions

Part No. 1297723GT GR™-12 • GR™-15 • GR™-20 51

Observe and Obey:

 Only qualified riggers should rig and lift the

machine.

 Only qualified forklift operators should lift the

machine with a forklift.

 Be sure the crane capacity, loading surfaces

and straps or lines are sufficient to withstand the machine weight. See the serial label for the machine weight.

Lifting 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 chassis, below the covers.

Position the forklift forks in position with the forklift pockets.

Drive forward to the full extent of the forks. Raise the machine 6 in / 15 cm and then tilt the

forks back slightly to keep the machine secure. Be sure the machine is level when lowering the

forks.

Lifting the machine from the side can result in component damage.

Operator's Manual Sixth Edition • First Printing

Transport and Lifting Instructions

52 GR™-12 • GR™-15 • GR™-20 Part No. 1297723GT

Loading the Machine With a Crane

Fully lower the platform. Be sure the extension deck, controls and component trays are secure. Remove all loose items on the machine.

Use the lifting eye mounted on the rear mast column.

Make sure the mast is fully lowered. Inspect the entire machine and remove any loose

or unsecured items. Adjust the rigging to prevent damage to the

machine and to keep the machine level.

Sixth Edition • First Printing Operator's Manual

Maintenance

Part No. 1297723GT GR™-12 • GR™-15 • GR™-20 53

Maintenance

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.

 Dispose of material in accordance with

governmental regulations.

 Use only Genie approved replacement parts.

Maintenance Symbols Legend

The following symbols have been used in this manual to help communicate the intent of the instructions. When one or more of the symbols appear 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 the inspector to identify changes in oil level that might indicate the presence of hydraulic system problems.

1 Be sure that the machine is on a firm, level

surface, free of obstructions, with the platform

in the stowed position. 2 Visually inspect the oil level in the hydraulic oil

tank.

Result: The hydraulic oil level should be

between the ADD and FULL marks on the tank. 3 Add oil as needed. Do not overfill.

Hydraulic oil specifications

Hydraulic oil type

Chevron Rando HD equivalent

Operator's Manual Sixth Edition • First Printing

Maintenance

54 GR™-12 • GR™-15 • GR™-20 Part No. 1297723GT

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.

Electrocution hazard. Contact with hot or live

circuits may result in death or serious injury. Remove all rings, watches and other jewelry.

Bodily injury hazard. Batteries contain acid.

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

Scheduled Maintenance

Maintenance performed quarterly, annually and every two years must be completed by a person trained and qualified to perform maintenance on this machine according to the procedures found in the service manual for this machine.

Machines that have been out of service for more than three months must receive the quarterly inspection before they are put back into service.

Sixth Edition • First Printing Operator's Manual

Specifications

Part No. 1297723GT GR™-12 • GR™-15 • GR™-20 55

Specifications

Model

GR-12

Height, working maximum indoor

17 ft 4 in

5.3 m

Height, working maximum outdoor

15 ft 1 in

4.60 m

Height, platform maximum indoor

11 ft 4 in

3.5 m

Height, platform maximum outdoor

9 ft 1 in

2.8 m

Height, stowed maximum

70 in

177.8 cm

Width

29.5 in

74.9 cm

Length, stowed

53 in

134.6 cm

Length, platform extended (option)

73.3 in

1.85 m

Platform dimensions, all models (length x width)

Standard platform

35 x

29.5 in

88.9 x

74.9 cm

Standard platform with extension extended

55 x

29.5 in

139.7 x

74.9 cm

Maximum capacity, standard platform

500 lbs

227 kg

Maximum wind speed, outdoors

28 mph

12.5 m/s

Maximum wind speed, indoors

0 mph

0 m/s

Turning radius (inside)

0 in

0 cm

Turning radius (outside)

52 in

132.1 cm

Ground clearance

2.5 in

6.5 cm

Weight

1681 lbs

763 kg

(Machine weights vary with option configurations. See serial label for specific machine weight.)

Power source

4 Batteries, 6V 225AH

AC outlet in platform

Standard

Maximum hydraulic pressure (functions)

3500 psi

241 bar

Tire size

10 x 3 x 1 in

25.4 x 7.6 x 2.5 cm

Airborne noise emissions

Sound pressure level at ground workstation

<70 dBA

Sound pressure level at platform workstation

<70 dBA

Vibration value does not exceed

2.5 m/s2

Maximum slope rating, stowed position

30% (16.7°)

Maximum side slope rating, stowed position

30% (16.7°)

Note: Slope rating is subject to ground conditions with one person in the platform and adequate traction. Additional platform weight may reduce slope rating.

Maximum allowable chassis inclination

Parallel to lift structure

3.0°

Perpendicular to lift structure

1.5°

Drive speeds

Stowed, maximum

2.5 mph

40 ft/10.9 sec

4.0 km/h

12.2 m/10.9 sec

Platform raised, maximum

0.5 mph

40 ft/55 sec

0.8 km/h

12.2 m/55 sec

Floor loading information

Tire load maximum

680 lbs

308 kg

Tire contact pressure

104.62 psi

7.36 kg / cm2

721.3 kPa

Occupied floor pressure

200.87 psf

980.7 kg / m2

9.62 kPa

Note: Floor loading information is approximate and does not incorporate different option configurations. It should be used only with adequate safety factors.

Continuous improvement of our products is a Genie policy. Product specifications are subject to change without notice or obligation.

Operator's Manual Sixth Edition • First Printing

Specifications

56 GR™-12 • GR™-15 • GR™-20 Part No. 1297723GT

Model

GR-15

Height, working maximum indoor

20 ft 8 in

6.3 m

Height, working maximum outdoor

17 ft 1 in

5.2 m

Height, platform maximum indoor

14 ft 8 in

4.5 m

Height, platform maximum outdoor

11 ft1 in

3.4 m

Height, stowed maximum

70 in

177.8 cm

Width

29.5 in

74.9 cm

Length, stowed

53 in

1.35 m

Length, platform extended (option)

73.3 in

1.85 m

Platform dimensions, all models (length x width)

Standard platform

35 x

29.5 in

88.9 x

74.9 cm

Standard platform with extension extended

55 x

29.5 in

139.7 x

74.9 cm

Maximum capacity, standard platform

500 lbs

227 kg

Maximum wind speed, outdoors

28 mph

12.5 m/s

Maximum wind speed, indoors

0 mph

0 m/s

Turning radius (inside)

0 in

0 cm

Turning radius (outside)

52 in

132.1 cm

Ground clearance

2.5 in

6.5 cm

Weight

2178 lbs

988 kg

(Machine weights vary with option configurations. See serial label for specific machine weight.)

Power source

4 Batteries, 6V 225AH

AC outlet in platform

Standard

Maximum hydraulic pressure (functions)

3500 psi

241 bar

Tire size

10 x 3 x 1 in

25.4 x 7.6 x 2.5 cm

Airborne noise emissions

Sound pressure level at ground workstation

<70 dBA

Sound pressure level at platform workstation

<70 dBA

Vibration value does not exceed

2.5 m/s2

Maximum slope rating, stowed position

30% (16.7°)

Maximum side slope rating, stowed position

30% (16.7°)

Note: Slope rating is subject to ground conditions with one person in the platform and adequate traction. Additional platform weight may reduce slope rating.

Maximum allowable chassis inclination

Parallel to lift structure

3.0°

Perpendicular to lift structure

1.5°

Drive speeds

Stowed, maximum

2.5 mph

40 ft/10.9 sec

4.0 km/h

12.2 m/10.9 sec

Platform raised, maximum

0.5 mph

40 ft/55 sec

0.8 km/h

12.2 m/55 sec

Floor loading information

Tire load maximum

720 lbs

327 kg

Tire contact pressure

110.77 psi

7.79 kg / cm2

763.7 kPa

Occupied floor pressure

251.99 psf psf

1230 kg/m2

12.07 kPa

Note: Floor loading information is approximate and does not incorporate different option configurations. It should be used only with adequate safety factors.

Continuous improvement of our products is a Genie policy. Product specifications are subject to change without notice or obligation.

Sixth Edition • First Printing Operator's Manual

Specifications

Part No. 1297723GT GR™-12 • GR™-15 • GR™-20 57

Model

GR-20

Height, working maximum indoor

25 ft 9 in

7.9 m

Height, working maximum outdoor

21 ft 6 in

6.6 m

Height, platform maximum indoor

19 ft 9 in

6.0 m

Height, platform maximum outdoor

15 ft 6 in

4.7 m

Height, stowed maximum

78 in

198.1 cm

Width

31.5 in

80 cm

Length, stowed

53 in

1.35 cm

Length, platform extended (option)

73.3 in

1.86 m

Platform dimensions, all models (length x width)

Standard platform

35 x

29.5 in

89.9 x

74.9 cm

Standard platform with extension extended

55 x

29.5 in

139.7 x

74.9 cm

Maximum capacity, standard platform

350 lbs

159 kg

Maximum wind speed, outdoors

28 mph

12.5 m/s

Maximum wind speed, indoors

0 mph

0 m/s

Turning radius (inside)

0 in

0 cm

Turning radius (outside)

53 in

134.6 cm

Ground clearance

2.5 in

6.5 cm

Weight

2513 lbs

1140 kg

(Machine weights vary with option configurations. See serial label for specific machine weight.)

Power source

4 Batteries, 6V 225AH

AC outlet in platform

Standard

Maximum hydraulic pressure (functions)

3500 psi

241 bar

Tire size

10 x 3 x 1 in

25.4 x 7.6 x 2.5 cm

Airborne noise emissions

Sound pressure level at ground workstation

<70 dBA

Sound pressure level at platform workstation

<70 dBA

Vibration value does not exceed 2.5 m/s2

Maximum slope rating, stowed position

30%

(16.7°)

Maximum side slope rating, stowed position

30%

(16.7°)

Note: Slope rating is subject to ground conditions with one person in the platform and adequate traction. Additional platform weight may reduce slope rating.

Maximum allowable chassis inclination

Parallel to lift structure

3.0°

Perpendicular to lift structure

1.5°

Drive speeds

Stowed, maximum

2.5 mph

40 ft/10.9 sec

4.0 km/h

12.2 m/10.9 sec

Platform raised, maximum

0.5 mph

40 ft/55 sec

0.8 km/h

12.2 m/55 sec

Floor loading information

Tire load maximum

870 lbs

395 kg

Tire contact pressure

133.85 psi

9.41 kg / cm2

922.84 kPa

Occupied floor pressure

250.39 psf

1223 kg/m2

11.99 kPa

Note: Floor loading information is approximate and does not incorporate different option configurations. It should be used only with adequate safety factors.

Continuous improvement of our products is a Genie policy. Product specifications are subject to change without notice or obligation.

GR™-12 • GR™-

15 • GR™-20

Part No.

1297723GT

Operator's

Manual

Sixth Edition •

First Printing

Genie GR -12, GR -15, GR -20 Operator's Manual

Specifications and Main Features

Frequently Asked Questions

User Manual