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

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.

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Introduction

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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.

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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.

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Introduction

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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

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Symbol and Hazard Pictorials Definitions

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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

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General Safety

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General Safety

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Sixth Edition • First Printing Operator's Manual

General Safety

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Operator's Manual Sixth Edition • First Printing

General Safety

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Sixth Edition • First Printing Operator's Manual

General Safety

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General Safety

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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.

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Work Area Safety

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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.

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Work Area Safety

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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.

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