Genie GR-20 Wheelchair User Manual
Contents
1. Ground Control Panel 7 amp breaker for electrical circuits Key switch for platform off ground selection Hour meter Platform up down toggle switch Red Emergency Stop button TRO DP A TEREX COMPANY PartNo 97779 GR 12 GR 15 GR 20 11 Operator s Manual Third Edition e Second Printing Pre operation Inspection Do Not Operate Unless M You learn and practice the principles of safe machine operation contained in this operator s manual 1 Avoid hazardous situations 2 Always perform apre 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 COMPANY 12 GR 12 GR 15 GR 20 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 v2. 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 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 1EX COMPANY 16 GR 12 GR 15 GR 20 PartNo 97779 Third Edition Second Printing Operator s Manual 1 Select a test area that is firm level and free of obstruction 2 Be sure the battery pack is connected At the Ground Controls 3 Pull out the platform and ground red Emergency Stop buttons to the on position 4 Turn the key switch to ground control 5 Observe the diagnostic LED readout on the platform controls Result The LED should look like the picture at right Test Emergency Stop 6 Pushin the ground red Emergency Stop button to the off position Result No functions should operate 7 Pull out the red Emergency Stop button to the on position Test t
3. 2 Raise the platform approximately 1 5 m 3 Open the battery cover Rest the cover against the chassis 4 Lower the platform until the mast just contacts the battery cover Crushing hazard Keep hands clear AWARNING of the battery cover when lowering the platform 5 Turn the key switch to the off position 6 Be sure that the battery cable connections are tight and free of corrosion Part No 97779 A TEREX CO GR 12 GR 15 GR 20 15 MPANY MAINTENANCE 7 Remove the battery vent caps 8 Check the battery acid level If needed replenish with distilled water to the bottom of the battery fill tube Do not overfill 9 Install the vent caps 10 Raise the platform and lower the cover 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 Operator s Manual Third Edition e Second Printing Function Tests Do Not Operate Unless M 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. Genie r i iti Operators Manual een with Maintenance Information Part No 97779 GR 12 GR 15 GR 20 CE Models Operator s Manual Third Edition e Second Printing eee Important Read understand and obey these safety rules and operating instructions before operating this machine Only trained and authorized personnel shall be permitted to operate this machine This manual should be considered a permanent part of your machine and should remain with the machine at all times If you have any questions call Genie Industries Contents Page Safety Rules cceceeeeeeeeeneeeeneeeeseneeeeeeeeeseeeeeseaaes 1 Pegon ecs vil dccuspesshaceneteieewaiaiceess 9 Controls uzyc aeaa a adaa 10 Pre operation Inspection sssseseserrressrrrersrrrnesrnnssees 12 Maintenance ua ru s zo ees ni a Eizo asd wik Raka A 14 Function Tests seesesaaaaaa aaa nana aaa aaa aaa aaa zzzaaaaazaaa 16 Workplace Inspection ee u eesesaaaaaaaasea 20 Operating Instructions sseeaesssaa aa sanacaeh 21 Transport and Lifting Instructions 11 11 26 Decals wassat 28 Specifications 0 ue eoesea aaa aaa aaa aaa inaa ach 32 Contact us Copyright 2000 by Genie Industries First Edition Sixth Printing October 2002 Internet http www genielift com m Pa R sat Second Edition First Printing August 2004 e mail techpu
5. Third Edition e Second Printing Operator s Manual DECALS Shading indicates decal is hidden from 97772 view i e under covers 97873 or 97898 n q 28235 BIGLE 8 8_ 40434 p FE a oo PN or 97813 97810 or 97811 52475 or 97812 82487 72086 Note Platform decals Feat may be in diffferent ai ane SL ee f locations on optional 7 28235 E AWP and fiberglass lt lt UDAR 97833 or 28174 DR aa SH ill or 82835 AE 97776 BL i p 72188 0487 44980 a RS i Gaaie i 72184 or 43658 F m 1 i om c iy Ley 3 97882 97810 97882 82836 82829 or 97883 or 97811 or 97883 52475 52475 or 97813 or 97812 or 97813 A TEREX COMPANY PartNo 97779 GR 12 GR 15 GR 20 29 Operator s Manual
6. 07 m Airborne noise emissions 70 dB Maximum sound level at normal operating workstations Height stowed maximum 1 98 m A weighted Height stowed maximum 1 60m Maximum slope rating stowed position 30 17 stock picker platform with bike racks Maximum side slope rating 30 17 Width 80 cm Note Slope rating is subject to ground conditions and Length stowed 1 42 m adequate traction Length with standard platform 1 92 m Stowed maximum 4 0 km h optional platform extension extended 12 2 m 10 9 sec Length with stock picker platform 1 94 m Platform raised maximum 0 8 km h including adjustable tray 12 5 m 55 sec Maximum capacity 159kg Floor Loading Information standard platform Tire Load maximum 553 kg Maximum capacity 159 kg AWP and fiberglass platform Tire Contact Pressure 13 kg cm2 1292 76 kPA Maximum capacity 159 kg stock picker platform Occupied Floor Pressure 1180 kg m 11 57 KPA Maximum wind speed 45 km h Turning radius inside Ocm Note Floor loading information is approximate and does not incorporate different option configurations Turning radius outside 78 7cm It should be used only with adequate safety factors Weight See Serial Label Machine weights vary with option configurations Power source 4 Batteries 6V 225AH Continuous improvement of our products is a Genie Controls Proportional policy Product specifications are subject to change without notice or obligation 34 GR 12 GR 15 GR 20
7. 12 GR 15 GR 20 31 Operator s Manual Third Edition Second Printing Specifications GR 12 Power source 4 Batteries 6V 225AH Height working maximum 5 31 m Controls Proportional Height platform maximum 3 48 m AC outlet in platform Standard Height stowed maximum 1 72m Tire size 25 4 x 7 6 x 2 5 cm Height stowed maximum 1 62 m Airborne noise emissions 70 dB standard platform with work station tray Maximum sound level at normal operating workstations A weighted Height stowed maximum 1 62 m stock picker platform with work station tray Maximum slope rating stowed position 30 17 Height stowed maximum 1 60 m Maximum side slope rating 30 17 stock picker platform with bike racks WE Note Slope rating is subject to ground conditions and Width 75 cm adequate traction Length stowed 1 35 m Drive speeds Length with standard platform 1 85 m Stowed maximum 4 0 km h optional platform extension extended 12 2 m 10 9 sec Length with stock picker platform 1 87 m Platform raised maximum 0 8 km h including adjustable tray 12 5 m 55 sec Length with stock picker platform 1 91 m Floor loading information including adjustable tray and work station tray Tire load maximum 464 kg Maximum capacity 227 kg standard platform Tire contact pressure 11 06 kg cm 1085 kPA Maximum capacity 159 kg Occupied floor pressure 936 kg m2 AWP and fiberglass
8. 15 GR 20 21 Operator s Manual Third Edition e Second Printing OPERATING INSTRUCTIONS Emergency Stop Push in the red Emergency Stop button to the off position at the ground or platform controls to stop all machine functions Repair any function that operates when either red Emergency Stop button is pushed in Auxiliary Lowering 1 Pull the auxiliary lowering knob Operation From Ground 1 Turn the key switch to ground control 2 Pullout both ground and platform red Emergency Stop buttons to the on position 3 Be sure the battery pack is connected before operating the machine To Position Platform 1 Move the up down toggle switch according to the markings on the control panel Drive and steer functions are not available from the ground controls Operation From Platform 1 Turn the key switch to platform control 2 Pullout the ground and platform red Emergency Stop buttons to the on position 3 Be sure the battery pack is connected before operating the machine A TEREX CO 22 GR 12 GR 15 GR 20 MPANY To Position Platform 1 Press the lift function select button 2 Press and hold the function enable switch on the control handle 3 Move the control handle according to the markings on the control panel To Steer 1 Press the drive function select button 2 Press and hold the function enable switch on the control handle 3 Turn the steer wheels with the thumb rocker switch locat
9. Do not drive the machine on or near uneven terrain unstable surfaces or other hazardous conditions with the platform raised Do not replace items critical to machine stability with items of different weight or specification Do not use the machine on a moving or mobile surface or vehicle Do not place or attach fixed or overhanging loads to any part of this machine YAR 7 M Do not place ladders or scaffolds in the platform or against any part of this machine Be sure all tires are in good condition castle nuts are properly tightened and cotter pins are properly installed PartNo 97779 Third Edition Second Printing Operator s Manual Do not use batteries that weigh less than the original equipment Batteries are used as counterweight and are critical to machine stability Each battery must weigh 28 kg Do not use the machine as a crane Do not push the machine or other objects with the platform Do not contact adjacent structures with the platform Do not tie the platform to adjacent structures Fall Hazards The guard rail system provides fall protection If occupants of the platform are required to wear personal fall protection equipment PFPE due to job site or employer rules PFPE equipment and its use shall be in accordance with the PFPE manufacturer s instructions and applicable governmental requirements Do not sit stand or climb on the platform guard rails Maintain a firm footing on the
10. Oil Level Maintaining the hydraulic oil at the proper level is essential to safe 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 Perform this procedure with the platform in the stowed position 1 Visually inspect the hydraulic oil level through the indicator at the back of the machine Result The hydraulic oil level should be visible 2 Add oil if necessary Do not overfill Hydraulic oil specifications Hydraulic oil type Chevron Rykon Premium MV equivalent Part No 97779 Third Edition Second Printing Operator s Manual Check the Batteries Proper battery condition is essential to good performance and operational safety Improper fluid levels or damaged cables and connections can result in component damage and hazardous conditions This procedure does not need to be performed on machines with sealed or maintenance free batteries AWARNING Electrocution hazard Contact with hot or live circuits could result in death or serious injury Remove all rings watches and other jewelry AWARNING 0dily injury hazard Batteries contain acid Avoid spilling or contacting battery acid Neutralize battery acid spills with baking soda and water Perform this test after fully charging the batteries 1 Put on protective clothing and eye wear
11. Third Edition e Second Printing EE DECALS Inspection for Decals with Symbols Stock Picker Platform Determine whether the decals on your machine have words or symbols Use the appropriate inspection to verify that all decals are legible and in place Part No Description Quantity Part No Description Quantity 28171 Label No Smoking 1 82836 Label Manual Lowering 1 28174 Label Power to Platform 230 V 2 97772 Overlay Platform Controls 1 28235 Label Power to Platform 115 V 2 97776 Ground Control Panel 1 40434 Label Lanyard Anchorage 1 97810 Cosmetic Genie GR 12 2 43658 Label Power to Charger 230 V 1 97811 Cosmetic Genie GR 15 2 44980 Label Power to Charger 115 V 1 97812 Cosmetic Genie GR 20 2 52475 Label Transport Tie down 3 97813 Label Wheel Load GR 20 4 72086 Label Lifting Eye 1 97834 Danger Max Capacity 227 kg 72143 Label Emergency Stop 1 GR 12 GR 15 i 72184 Cosmetic Genie Runabout 1 97835 Danger Max Capacity 159 kg GR 20 1 72188 Label Directional Arrows 2 97871 Danger Max Capacity Bike Rack GR 12 GR 15 1 82481 Danger Battery Safety 1 97872 Danger Max Capacity Bike Rack 82487 Label Read the Manual 2 GR 20 82495 Danger Brake Release Safety amp 97882 Label Wheel Load GR 12 Operating Instructions 1 97883 Label Wheel Load GR 15 82614 Danger Collision
12. and charger To Charge Batteries Maintenance free batteries 1 Connectthe battery charger to a grounded AC circuit 2 The charger will indicate when the battery is fully charged PartNo 97779 A TEREX COMI GR 12 GR 15 GR 20 25 PANY OPERATING INSTRUCTIONS Standard Batteries 1 Puton protective clothing and eye wear 2 Raise the platform approximately 1 5 m 3 Open the battery cover Rest the cover against the chassis 4 Lower the platform until the mast just contacts the battery cover Crushing hazard Keep hands clear AWARNING of the battery cover when lowering the platform 5 Turn the key switch to the off position 6 Be sure that the battery cable connections are tight and free of corrosion 7 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 8 Replace the battery vent caps 9 Connect the battery charger to a grounded AC circuit 10 The charger will indicate when the battery is fully charged 11 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 12 Raise the platform and lower the cover Operator s Manual Third Edition Second Printing Transport and Lifting Instructions Observe and Obey MI Common sense and planning must be applied to control the movem
13. platform 9 18 kPA Maximum capacity 227 kg stock picker platform Note Floor loading information is approximate and Maximum wind speed 12 5 m s does not incorporate different option configurations It should be used only with adequate safety factors Turning radius inside 0 cm Turning radius outside 78 7 cm Weight See Serial Label Machine weights vary with option configurations A TEREX COMI 32 GR 12 GR 15 GR 20 PANY Continuous improvement of our products is a Genie policy Product specifications are subject to change without notice or obligation Part No 97779 Third Edition Second Printing Operator s Manual SPECIFICATIONS GR 15 Power source 4 Batteries 6V 225AH Height working maximum 6 30 m Controls Proportional Height platform maximum 4 47 m AC outlet in platform Standard Height stowed maximum 1 72 m Tire size 25 4 x 7 6 x 2 5 cm Height stowed maximum 1 62 m Airborne noise emissions 70 dB standard platform with work station tray Maximum sound level at normal operating workstations A weighted Height stowed maximum 1 62 m stock picker platform with work station tray Maximum slope rating stowed position 30 17 Height stowed maximum 1 97 m Maximum side slope rating 30 17 stock picker platform with bike racks WE Note Slope rating is subject to ground conditions and Width 75 cm adequate t
14. 71 Label No Smoking 1 82836 Label Manual Lowering 1 28174 Label Power to Platform 230 V 2 97772 Overlay Platform Controls 1 28235 Label Power to Platform 115 V 2 97776 Ground Control Panel 1 40434 Label Lanyard Anchorage 1 97810 Cosmetic Genie GR 12 2 43658 Label Power to Charger 230 V 1 97811 Cosmetic Genie GR 15 2 44980 Label Power to Charger 115 V 1 97812 Cosmetic Genie GR 20 2 52475 Label Transport Tie down 3 97813 Label Wheel Load GR 20 4 72086 Label Lifting Eye 1 97815 Label Lower Midrail 72143 Label Emergency Stop 1 models with sliding midrail entry option 1 72184 Cosmetic Genie Runabout gt 97832 Danger Max Capacity 227 kg GR 12 GR 15 standard platform 1 72188 Label Directional Arrows 2 z 97833 Danger Max Capacity 159 kg GR 20 1 82481 Danger Battery Safety 1 z 97873 Danger Max Capacity Workstation Tray 82487 Label Read the Manual 2 22 kg GR 12 GR 15 82495 Danger Brake Release Safety amp 97882 Label Wheel Load GR 12 Operating Instructions 1 97883 Label Wheel Load GR 15 4 82614 Danger Collision Hazard 1 97898 Danger Max Capacity Parcel Tray 82666 Label Forklift Pocket 2 68 kg GR 12 GR 15 1 82829 Danger Electrocution Hazard 1 97899 Danger Safety Chock 1 82830 Danger Max Side Force 200 N 1 82835 Danger Max Capacity 159 kg models with AWP and fiberglass platform 1 Genie 28 A TERI GR 12 GR 15 GR 20 1EX COMPANY Part No 97779
15. Hazard 1 97898 Danger Max Capacity Parcel Tray 82666 Label Forklift Pocket 2 68 kg GR 12 GR 15 1 82829 Danger Electrocution Hazard 1 97899 Danger Safety Chock 1 82830 Danger Max Side Force 200 N 1 Genie A TEREX COMPANY 30 GR 12 GR 15 GR 20 Part No 97779 Third Edition e Second Printing Operator s Manual DECALS Safety Tape M Shading indicates 97898 decal is hidden from b view i e under covers 28235 or 28174 40434 72184 or 97812 or 97813 52475 CPAT B SALI Ll i JI ae gt IJ L A P 44980 a dE I r or 43658 z o a A 82666 rr a gt fm EG aa i NOT a 2 mO R ie Gi 97882 97810 97882 82836 82829 Safety or 97883 or 97811 or 97883 52475 52475 Tape or 97813 or 97812 or 97813 Genie A TEREX COMPANY PartNo 97779 GR
16. Maximum occupants GR 12 GR 15 GR 20 PartNo 97779 Third Edition Second Printing Operator s Manual SAFETY RULES Maximum capacity GR 20 Do not raise the platform unless the machine is on sa firm level surface Standard platform 159 kg Maximum occupants 1 Stock Picker platform 159 kg Adjustable work station tray 68 kg Bike rack option each 20 kg 4 w M Maximum occupants 1 AWP and fiberglass platform 159 kg Maximum occupants 1 Do not depend on the tilt alarm as a level indicator The tilt alarm sounds only when the machine is on a slope If the tilt alarm sounds Lower the platform immediately Move the machine to a firm level surface If the tilt alarm sounds when the platform is raised use extreme caution to lower the platform Do not alter or disable the limit switches Do not drive over 0 8 km h with the platform raised Use extreme care and slow speeds while driving the machine in the stowed position across uneven terrain debris unstable or slippery surfaces and near holes and drop offs Do not drive the machine on a slope that exceeds the slope and side slope rating of the machine Slope rating applies to machines in the stowed position Maximum slope rating stowed position 30 17 Maximum side slope rating stowed position 30 17 Note Slope rating is subject to ground conditions and adequate traction A TEREX COMPANY PartN
17. PartNo 97779 Third Edition Second Printing Operator s Manual Platform dimensions all models length x width Standard platform 88 x 75 cm Standard platform with extension 1 4mx 75 cm Stock picker platform 88 x 73 cm Stock picker platform including adjustable tray 1 4 m x 73 cm Standard AWP platform 69 x 51 cm Narrow AWP platform 66 cm x 51 cm Standard fiberglass platform Narrow fiberglass platform 74 x 67 cm 66 x 56 cm Genie Part No 97779 SPECIFICATIONS A TEREX COMPANY GR 12 GR 15 GR 20 35 Genie North America Phone 425 11 Toll Free 53 1 Fax 425 3345 Genie Australia Pty Ltd Phone 1 3351 Fax 1 3351 2 Genie Scandinavia Phone 315 51 Fax 4 315 2 Genie China Phone 2153 525 Fax 2153 525 Genie France Phone 33 23 2 Fax 33 23 2 Genie Malaysia Phone 5 4 5 Fax 5 533544 Genie Iberica Phone 34 35 5 42 Fax 34 35 55 Genie Germany Phone 4 422 52 Fax 4 422 522 Genie J apan Phone 133453 2 Fax 133453 3 Genie Korea Phone 2255 2 Fax 2255 3 1 Genie U K Phone 44 14 5 4333 Fax 44 14 5 4334 Genie Brasil Phone 4551141 5 55 Fax 551141 5 54 Genie Mexico City Phone 52555 5242 Fax 452555 3241 Genie Holland Phone 43113511 2 Fax 311 35 15
18. ariation 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 pre operation 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 PartNo 97779 Third Edition Second Printing Operator s Manual Pre operation Inspection Ii Be sure that the operator s safety and responsibilities manuals are complete legible and in the storage container located on the platform See Decals section See Maintenance section U 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 m cables m Hydraulic power unit tank hoses fittings cylinders and manifolds Battery pack and connections Drive motors Tires and wheels Limit switches and alarms Nuts bolts and other fasteners Platform entry mid rail bar or gate Sequencing cables and pulleys Platform extension if equipped Work trays and bike racks if equipped Mast co
19. b genieind com Third Edition Second Printing May 2005 Genie is a registered trademark of Genie Industries in the U S A and many other countries Runabout and GR are trademarks of Genie Industries Z Printed on recycled paper Printed in U S A Genie A TEREX COMPANY 2 GR 12 GR 15 GR 20 PartNo 97779 Third Edition Second Printing Operator s Manual Safety Rules Danger Failure to obey the instructions and safety rules in this manual will result in death or serious injury Do Not Operate Unless MT 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 M You read understand and obey the manufacturer s instructions and safety rules safety and operator s manuals and machine decals MI You read understand and obey employer s safety rules and worksite regulations MI You read understand and obey all applicable governmental regulations M You are properly trained to safely operate the machine A TEREX COMPANY PartNo 97779 GR 12 GR 15 GR 20 1 Operator s Manual SAFETY RULES Electrocution Hazards This machine is not electrically insulated and will n
20. c oil level indicator 10 Powerto platform battery charger connection for optional inverter 11 Work station tray if equipped 12 Brake release pump knob under covers 13 Mid rail entry bar 14 Adjustable work station tray 15 Platform controls 16 Dual entry gate 17 Lanyard anchorage 18 Parcel tray if equipped Part No 97779 Legend 19 Bike rack if equipped 20 Mast 21 GFCI outlet 22 Manual storage container 23 Battery compartment cover 24 Battery cover latch 25 Steer tire 26 Platform extension release pedal 27 Platform extension entry gate A TEREX COMPANY GR 12 GR 15 GR 20 Operator s Manual Third Edition e Second Printing Controls O Platform Controls 1 RedEmergency Stop button 5 Proportional control handle and function enable 2 LED diagnostic readout Platform overload switch for lift and drive functions indicator Battery charge indicator 6 Thumb rocker switch for steer functions 3 Lift function select button 7 Drive speed button 4 Hornbutton if equipped 8 Drive function select button Genie A TEREX COMPANY 10 GR 12 GR 15 GR 20 PartNo 97779 Third Edition Second Printing Operator s Manual CONTROLS A N 0 O H STOP SR
21. ed on the top of the control handle To Drive 1 Press the drive function select button 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 Part No 97779 Third Edition Second Printing Operator s Manual To Reduce 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 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 mf Note Slope rating is subject to ground conditions and adequate traction Press the drive speed button to the fast drive speed mode Part No 97779 A TEREX CO GR 12 GR 15 GR 20 23 MPANY OPERATING INSTRUCTIONS To determine the slope grade Measure the slope wit
22. ent ofthe machine when lifting it with a crane or forklift MI The transport vehicle must be parked on a level surface MI The transport vehicle must be secured to prevent rolling while the machine is being loaded MI Be sure the vehicle capacity loading surfaces and chains or straps are sufficient to withstand the machine weight See the serial plate for the machine weight MI The machine must be on a level surface or secured before releasing the brakes M Do not drive the machine on a slope that exceeds the slope or side slope rating See Driving on a Slope in the Operating Instructions section MI If the slope of the transport vehicle bed exceeds the maximum slope rating the machine must be loaded and unloaded using a winch as described A TEREX CO 26 GR 12 GR 15 GR 20 MPANY 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 Push in both ground and platform red Emergency Stop buttons to the off position 2 Turn the key switch to the off position 3 Chock the wheels to prevent the machine from rolling 4 Push the brake release switch closed to reset the brakes Brake Release Switch Part No 97779 T
23. ents must remain closed and secured during operation Part No 97779 Third Edition Second Printing Operator s Manual Battery Safety Burn Hazards Batteries contain acid Always wear protective clothing and eye wear when working with batteries Avoid spilling or contacting battery acid Neutralize battery acid spills with baking soda and water Do not expose the batteries or the charger to water or rain during charging Explosion Hazards Keep sparks flames and lighted tobacco away from batteries Batteries emit an explosive gas a PN il The battery tray should remain open during the entire charging cycle Do not contact the battery terminals or the cable clamps with tools that may cause sparks Part No 97779 A TEREX CO GR 12 GR 15 GR 20 MPANY SAFETY RULES Component Damage Hazard Do not use any battery charger greater than 24V to charge the batteries Electrocution Hazards w Avoid electrical shock from contact with battery terminals Remove all rings watches and other jewelry Connect the battery charger to a grounded AC 3 wire electrical outlet only Inspect daily for damaged cord cables and wires Replace damaged items before operating Tip over Hazard Do not use batteries that weigh less than the original equipment Batteries are used as counterweight and are critical to machine stability Each battery must weigh 28 kg Lifting Hazard Use the app
24. er a pothole guard Raise the platform Result Before the platform is raised 2 1 m from the ground an alarm should sound and the drive function should not work 48 Lower the platform and remove the 2x4 Operator s Manual Third Edition e Second Printing Workplace Inspection Do Not Operate Unless M 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 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 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 condi
25. h a digital inclinometer OR use the following procedure You will need carpenter s level straight piece of wood at least 1 m long tape measure Lay the piece of wood on the slope At 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 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 run Run 3 6 m Rise 0 3 m 0 3 m 3 6 m 0 083 x 100 8 3 If the slope exceeds the maximum slope or side slope rating the machine must be winched or transported up or down the slope See Transport and Lifting section Operator s Manual Third Edition e Second Printing OPERATING INSTRUCTIONS Error Indicator display To Extend and Retract Platform if equipped 1 Step on the platform extension release pedal If the LED diagnostic readout displays an error code such as LL push in and pull out the red Emergency Stop button to reset the system 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 Operation From Ground with Controller Maintain safe distances between the operator machine and fixed objects Be aware of the direction the machine w
26. he Up Down Functions 8 Activate the up function Result The platform should raise 9 Activate the down function Result The platform should lower The descent alarm should sound while the platform is lowering Test Manual Lowering 10 Activate the up function and raise the platform approximately 60 cm 11 Pull the manual lowering knob located at the base of the machine below the charger Result The platform should lower The descent alarm will not sound 12 Turn the key switch to platform control Part No 97779 A TEREX CO GR 12 GR 15 GR 20 17 MPANY FUNCTION TESTS At the Platform Controls Test Emergency Stop 13 Push in the platform red Emergency Stop button to the off position Result No functions should operate Test the Horn 14 Pull out the red Emergency Stop button to the on position 15 Push the horn button Result The horn should sound Test the Function Enable Switch 16 Do not press the function enable switch on the control handle 17 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 Up Down Functions 18 Press the lift function select button O 19 Press and hold the function enable switch on the control handle 20 Slowly move the control handle in the direction indicated by the blue arrow Result The platform should ra
27. hird Edition Second Printing Operator s Manual Loading the Machine With a Crane Use the lifting eye mounted on the rear mast column Make sure the mast is fully lowered Inspect the machine and remove any loose or unsecured items Always place the lifting hook through the lifting eye so that it points away from the machine Part No 97779 A TEREX COMPANY GR 12 GR 15 GR 20 27 TRANSPORT ANDLIFTINGINSTRUCTIONS Securing to Truck or Trailer for Transit Always chock the machine wheels in preparation fortransport Turn the key switch to the off position and remove the key before transporting Inspect the entire machine for loose or unsecured items Securingthe Chassis 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 4 chains Adjust the rigging to prevent damage to the chains Truck bed Operator s Manual Third Edition e Second Printing Decals Inspection for Decals with Symbols Standard and AWP Platforms Determine whether the decals on your machine have words or symbols Use the appropriate inspection to verify that all decals are legible and in place Part No Description Quantity Part No Description Quantity 281
28. ill travel when using the controller Platform Overload 1 Pushin the Red Emergency stop button to the off position Flashing OL in the LED diagnostic readout indicates the platform is overloaded and no functions will operate An alarm will sound Remove the weight from the platform 3 Pull out the Red Emergency stop button to the on position A TEREX CO 24 GR 12 GR 15 GR 20 Battery Level Indicator Full Low Use the LED diagnostic readout to determine the battery level 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 After Each Use 1 Select a safe parking location firm level surface clear of obstruction and traffic 2 Lowerthe platform 3 Turn the key switch to the off position and remove the key to secure from unauthorized use 4 Chock the wheels 5 Chargethebatteries PartNo 97779 Third Edition Second Printing Operator s Manual Battery and Charger Instructions Observe and Obey MT Do not use an external charger or booster battery MI Charge the battery in a well ventilated area M Use proper AC input voltage for charging as indicated on the machine MT Use only a Genie authorized battery
29. ion should not work in either direction 39 Lower the platform and drive the machine off both pieces of wood Test Limited Drive Speed 40 Press the lift function select button 41 Press and hold the function enable switch on the control handle Raise the platform approximately 60 cm from the ground 42 Press the drive function select button 43 Press and hold the function enable switch on the control handle Slowly move the control handle to the full drive position Result The maximum achievable drive speed with the platform raised should not exceed 20 cm per second If the drive speed with the platform raised exceeds 20 cm per second immediately tag and remove the machine from service Part No 97779 COMPANY GR 12 GR 15 GR 20 19 FUNCTION TESTS Test the Pothole Guards Note The pothole guards should automatically deploy when the platform is raised The pothole guards activate another limit switch which allows the machine to continue to function If the pothole guards do not deploy an alarm sounds and the machine will not drive 44 Raise the platform Result When the platform is raised 1 2 m from the ground the pothole guards should deploy 45 Press on the pothole guards on one side and then the other Result The pothole guards should not move 46 Lower the platform Result The pothole guards should return to the stowed position 47 Place a 2x4 or similar piece of wood und
30. ise 21 Release the control handle Result The platform should stop raising Operator s Manual Third Edition e Second Printing FUNCTION TESTS 22 Press and hold the function enable switch 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 Test the Steering Note When performing the steer and drive function tests stand in the platform facing the steer end of the machine 23 Press the drive function select switch 24 Press and hold the function enable switch on the control handle 25 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 that the blue triangle points on the control panel 26 Press the thumb rocker switch in the direction indicated by the yellow triangle on the control panel Result The steer wheels should turn in the direction that the yellow triangle points on the control panel A TEREX CO 18 GR 12 GR 15 GR 20 MPANY Test Drive and Braking 27 Press and hold the function enable switch on the control handle 28 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 handle to the center position Result The machine
31. lumns and counterweight Platform controls Uooouovoeeee oe ou Brake release components Part No 97779 LI Be sure that all decals are legible and in place Electrical components wiring and electrical GR 12 PRE OPERATIONINSPECTION Check the entire machine for U Cracks in welds or structural components LI Dents or damage to the machine 1 Be sure that all structural and other critical components are present and all associated fasteners and pins are in place and properly tightened U Check for hydraulic oil leaks and proper oil level A TEREX COMPANY GR 15 GR 20 13 Operator s Manual Third Edition e Second Printing Maintenance Observe and Obey MI Only routine maintenance items specified in this manual shall be performed by the operator M Scheduled maintenance inspections shall be completed by qualified service technicians according to the manufacturer s specifications and the requirements specified in the responsibilities manual 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 amaintenance 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 A TEREX COM 14 GR 12 GR 15 GR 20 Check the Hydraulic
32. o 97779 GR 12 GR 15 GR 20 3 Operator s Manual Third Edition e Second Printing SAFETY RULES Do not use the platform controls to free a platform that is caught snagged or otherwise prevented from normal motion by an adjacent structure All personnel must be removed from the platform before attempting to free the platform using the ground controls Do not push off or pull toward any object outside of the platform ny Maximum allowable manual force l M CE 200 N Do not transport tools and materials unless they are evenly distributed and can be safely handled by person s in the platform Do not alter or disable machine components that in any way affect safety and stability Do not modify or alter an aerial work platform without prior written permission from the manufacturer Mounting attachments for holding tools or other materials onto the platform toeboards or guard rail system can increase the weight in the platform and the surface area of the platform or the load Do not raise the mast when wind speeds may exceed 12 5 m s If wind speeds exceed 12 5 m s when the plaform is raised lower the platform and do not continue to operate the machine A TEREX CO 4 GR 12 GR 15 GR 20 MPANY 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 AU gt a 5_
33. ot provide protection from contact with or proximity to electrical current zd 2 POR Maintain safe distances from electrical power lines and apparatus in accordance with applicable governmental regulations and the following chart Voltage Minimum Safe Phase to Phase Approach Distance Meters 0 to 300V Avoid Contact 300V to 50KV 3 05 50KV to 200KV 4 60 200KV to 350KV 6 10 350KV to 500KV 7 62 500KV to 750KV 10 67 750KV to 1000KV 13 72 Allow for platform movement electrical line sway or sag and beware of strong or gusty winds Keep away from the machine if it contacts energized power lines Personnel on the ground or in the platform must not touch or operate the machine until energized power lines are shut off Do not operate the machine during lightning or storms Do not use the machine as a ground for welding A TEREX COMPANY Third Edition Second Printing el Tip over Hazards Occupants equipment and materials must not exceed the maximum platform capacity Weight in trays and in each bike rack is part of the total platform load Maximum capacity GR 12 and GR 15 Standard platform 227 kg Work station tray option 22 kg Parcel tray option 68 kg Maximum occupants 1 Stock Picker platform 227 kg Adjustable work station tray 68 kg Parcel tray option 68 kg Bike rack option each 20 kg Maximum occupants 1 AWP and fiberglass platform 159 kg
34. platform floor at all times Do not climb down from the platform when raised Keep the platform floor clear of debris Lower the platform mid rail bar or close the platform entry gate before operating Part No 97779 A TEREX CO GR 12 GR 15 GR 20 MPANY SAFETY RULES Collision Hazards Be aware of limited sight distance and blind spots when driving or operating L Be aware ofthe extended platform position when moving the machine Sw Operators must comply with employer job site and governmental rules regarding use of personal protective quipment Check the work area for overhead obstructions or other possible hazards Be aware of crushing hazards when grasping the platform guard rail Observe and use the color coded direction arrows on the platform controls and platform decal plate for drive and steer functions No stunt driving or horseplay while operating a machine Operator s Manual Third Edition e Second Printing SAFETY RULES Do not lower the platform unless the area below is clear of personnel and obstructions Limit travel speed according to the condition of the ground surface congestion slope location of personnel and any other factors which may cause collision Do not operate a machine in the path of any crane or moving overhead machinery unless the controls of the crane have been locked out and or precautions have been taken to prevent any poten
35. raction Length stowed 1 35 m Drive speeds Length with standard platform 1 85 m Stowed maximum 4 0 km h optional platform extension extended 12 2 m 10 9 sec Length with stock picker platform 1 87 m Platform raised maximum 0 8 km h including adjustable tray 12 5 m 55 sec Length with stock picker platform 1 91 m Floor loading information including adjustable tray and work station tray Tire load maximum 606 kg Maximum capacity 227 kg standard platform Tire contact pressure 14 4 kg cm 1418 kPA Maximum capacity 159 kg Occupied floor pressure 1210 kg m AWP and fiberglass platform 11 87 kPA Maximum capacity 227 kg stock picker platform Note Floor loading information is approximate and Maximum wind speed 12 5 m s does not incorporate different option configurations It should be used only with adequate safety factors Turning radius inside 0 cm Turning radius outside 78 7 cm Weight See Serial Label Machine weights vary with option configurations PartNo 97779 A TEREX CON GR 12 GR 15 GR 20 33 MPANY Continuous improvement of our products is a Genie policy Product specifications are subject to change without notice or obligation Operator s Manual Third Edition Second Printing SPECIFICATIONS GR 20 AC outlet in platform Standard Height working maximum 7 90 m Tire size 25 4 x 7 6 x 2 5 cm Height platform maximum 6
36. ropriate number ofpeople and proper lifting techniques when lifting batteries Operator s Manual Third Edition e Second Printing SAFETY RULES Decal Legend Genie product decals use symbols color coding and signal words to identify the following Safety alert symbol used to alert personnel to potential personal injury hazards Obey all safety messages that follow this symbol to avoid possible injury or death Red used to indicate the ADANGER presence of an imminently hazardous situation which if not avoided will result in death or serious injury gt AWARNING Orange used to indicate the presence of a potentially A hazardous situation which if not avoided could result in death or serious injury Yellow with safety alert symbol ACAUTION used to indicate the presence of a A potentially hazardous situation which if not avoided may cause minor or moderate injury Yellow without safety alert CAUTION symbol used to indicate the presence of a potentially hazardous situation which if not avoided may result in property damage Green used to indicate operation or maintenance information A TEREX COMPANY 8 GR 12 GR 15 GR 20 PartNo 97779 Third Edition Second Printing Operator s Manual Pothole guard Non steer tire Manual lowering valve Transporttie down Forklift pocket Battery charger display Covers Ground controls OAN O OI A ND Hydrauli
37. should move in the direction that the blue arrow points on the control panel then come to an abrupt stop 29 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 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 Note The brakes must be able to hold the machine on any slope it is able to climb Test the Tilt Sensor Operation Note Perform this test from the ground with the platform controller Do not stand in the platform 30 Press the lift function select button 31 Fully lower the platform 32 Place a 2x4 or similar piece of wood in front of each wheel on one side of the machine 33 Press the drive function select button 34 Drive the machine up onto both pieces of wood 35 Press the lift function select button Part No 97779 Third Edition Second Printing Operator s Manual 36 Raise the platform Result Before the platform is raised approximately 30 cm the lift function should stop an alarm should sound and the LED readout should display LL 37 Press the drive function select button 38 Press and hold the function enable switch and slowly move the control handle in the direction indicated by the blue arrow then in the direction indicated by the yellow arrow Result The drive funct
38. tial collision Crushing Hazard Use common sense and planning when operating the machine with the controller from the ground Maintain safe distances between the operator the machine and fixed objects Component Damage Hazard Do not use the machine as a ground for welding A TEREX CO 6 GR 12 GR 15 GR 20 MPANY Explosion and Fire Hazard Do not operate the machine or charge the battery in hazardous locations or locations where potentially flammable or explosive gases or particles may be present Damaged Machine Hazards Do not use a damaged or malfunctioning machine Conducta thorough pre operation inspection of the machine and test all functions before each work shift Immediately tag and remove from service a damaged or malfunctioning machine Be sure all maintenance has been performed as specified in this manual and the appropriate service manual Be sure all decals are in place and legible Be sure the operator s safety and responsibilities manuals are complete legible and in the storage container located on the platform Bodily Injury Hazard Do not operate the machine with a hydraulic oil or air leak An air leak or hydraulic leak can penetrate and or burn skin Improper contact with components under any cover will cause serious injury Only trained maintenance personnel should access compartments Access by the operator is only advised when performing a pre operation inspection All compartm
39. tions the presence of unauthorized personnel other possible unsafe conditions 20 GR 12 GR 15 GR 20 PartNo 97779 Third Edition Second Printing Operator s Manual Operating Instructions Do Not Operate Unless M You learn and practice the principles of safe machine operation contained in this operator s manual 1 Avoid hazardous situations 2 Alwaysperformapre operation inspection 3 Always perform function tests prior to use 4 Inspect the workplace 5 Only use the machine as it was intended COMPANY 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 pre operation inspection function tests and a workplace inspection before using the machine PartNo 97779 GR 12 GR
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