Genie GR-15, GR-12, GR-20 User Manual

Operator's Manual	Fifth Edition • First Printing

Important

Read, understand and obey these safety rules and operating instructions before operating this machine. Only trained and authorized personnel shall be permitted to operate this machine. This manual should be considered a permanent part of your machine and should remain with the machine at all times. If you have any questions, call Genie Industries.

Contents
	Page
Introduction ................................................................	1
Symbol and Hazard Pictorials Definitions ..................	3
General Safety ..........................................................	5
Personal Safety .........................................................	9
Work Area Safety .....................................................	10
Legend .....................................................................	18
Controls ....................................................................	19
Inspections ...............................................................	22
Operating Instructions ..............................................	35
Transport and Lifting Instructions ..............................	40
Maintenance .............................................................	43
Specifications ...........................................................	45
Contact us:
Internet: http://www.genielift.com
e-mail: [e-mail]

Copyright © 2000 by Genie Industries

Fifth Edition:

First Printing, May 2010

"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.

These machines comply with

ANSI/SIA 92.6

CSA B.354.2

Printed on recycled paper

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Owners, Users and Operators:

Genie appreciates your choice of our machine for your application. Our number one priority is user safety, which is best achieved by our joint efforts. We feel that you make a major contribution to safety if you, as the equipment users and operators:

1Comply with employer, job site and governmental rules.

2Read, understand and follow the instructions in this and other manuals supplied with this machine.

3Use good safe work practices in a commonsense way.

4Only have trained/certified operators, directed by informed and knowledgeable supervision, running the machine.

If there is anything in this manual that is not clear or which you believe should be added, please contact us.

Internet: www.genielift.com

E-mail: [e-mail]

Introduction

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 work site regulations.

You read, understand and obey all applicable governmental regulations.

You are properly trained to safely operate the machine.

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Introduction

Hazard Classification

Genie uses 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
Red	death or serious injury.

Indicates a hazardous situation

which, if not avoided, could result Orange in death or serious injury.

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

Indicates a hazardous situation which, if not avoided, could result

Blue in property damage.

Intended Use

This machine is intended to be used only to lift personnel, along with their tools and materials to an aerial work site.

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.

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Symbol and Hazard Pictorials Definitions

	Read the	Read the
	operator’s manual	service
		manual	Crush hazard	No smoking	Collision hazard
				Use a piece of
				cardboard or
				paper to search	Electrocution
	Collision hazard	Tip-over hazard	Tip-over hazard	for leaks
					hazard
	Electrocution				Skin injection
	hazard	Explosion hazard	Fire hazard	Burn hazard	hazard
			Keep away from	Move machine to	Batteries used as
	Transport diagram	Tiedown			counterweights
			moving parts	level ground
		Only trained
		maintenance	Chock the wheels	Release brakes	Grounded AC
		personnel should
					3-wire only
		access
	Maintain required
		compartments
	clearance
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Symbol and Hazard Pictorials Definitions

Replace damaged				Lanyard				Voltage rating for
wires and cords	Wheel load		Side force	attachment point				power to platform

Pressure rating for

air line to platform Wind speed

		+
		+
		+
		22 kg
	Maximum capacity including occupant	Maximum capacity including occupant,
		tools and tray

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General Safety

Safety signs and locations

Decals with words

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Decals with words

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General Safety

Safety signs and locations

Decals with symbols

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Decals with symbols

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Personal Safety

Fall Protection

Personal fall protection equipment (PFPE) is not required when operating this machine. If PFPE is required by job site or employer rules, the following shall apply:

All PFPE must comply with applicable governmental regulations, and must be inspected and used in accordance with the PFPE manufacturer’s instructions.

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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.

Maintain safe distances from electrical power lines and apparatus in accordance with applicable governmental regulations and the following chart.

Line Voltage			Required Clearance
0 to 50KV			10 ft	3.05 m
50KV to 200KV			15 ft	4.60 m
200KV to 350KV			20 ft	6.10 m
350KV to 500KV			25 ft	7.62 m
500KV to 750KV			35 ft	10.67 m
750KV 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 must not exceed the maximum platform capacity or the maximum capacity of the platform extension.

Weight in trays are part of the total platform load.

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 station tray (option)		50 lbs	22 kg
Maximum occupants			1
500 lbs / 227 kg	Extension only	Platform only
	250 lbs / 113 kg	250 lbs / 113 kg

AWP platform		350 lbs			159 kg
Maximum occupants			1

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Maximum capacity - GR-20

Standard platform

Platform without extension		350 lbs	159 kg
Platform retracted		350 lbs	159 kg
Platform extended - Platform only		100 lbs	45 kg
Platform extended - Extension only		250 lbs	113 kg
Maximum occupants			1
350 lbs / 159 kg	Extension only	Platform only
	250 lbs / 113 kg	100 lbs / 45 kg

AWP platform		350 lbs			159 kg
Maximum occupants			1

Work Safety

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 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.

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Work Area Safety

Do not raise the mast when wind speeds may exceed 28 mph / 12.5 m/s.If wind speeds exceed 28 mph / 12.5 m/s when the platform is raised, lower the platform and do not continue to operate the machine.

Do not operate the machine in strong or gusty winds. Do not increase the surface area of the platform or the load. Increasing the area exposed to the wind will decrease machine stability.

Use extreme care and slow speeds while driving the machine in a stowed position across uneven terrain, debris, unstable or slippery surfaces and near holes and drop-offs.

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. 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	Maximum
	allowable	number of
Model	side force	occupants
ANSI/CSA	100 lbs / 445 N	1

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 62 pounds / 28 kg.

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.

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Do not place or attach fixed or overhanging loads to any part of this machine.

Do not place ladders or scaffolds in the platform or against any part of this machine

Do not transport tools and materials unless they are evenly distributed and can be safely handled by the person in the platform.

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

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

Work Area Safety

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 only.

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.

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Work Area Safety

Fall Hazards

Collision Hazards

The guard rail system provides fall protection. If the occupant of the platform is required to wear personal fall protection equipment (PFPE) due to job site or employer rules, PFPE and its use shall be in accordance with the PFPE manufacturer’s instructions and applicable governmental requirements. Use approved lanyard attachment point provided.

Keep the platform floor clear of debris.

Lower the platform mid-rail bar or 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.

Lower the platform mid-rail bar or close the platform entry gate before operating.

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

Be aware of the extended platform position when moving the machine.

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

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

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

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