Genie GR-20J User manual

Operator's Manual
Serial Number Range
GR-
2
0J from GRJ13
-
523 to GRJ16
-
1151
(includes GRJ13-519)
from SN GRJ16L-1152 to GRJ16L-1999
CE
GR-
2
6J from SN GRJL
-
2000
with
Maintenance
Information
Original Instructions
Second Edition
First Printing
Part No. 216596

Operator's Manual Second Edition • First Printing
GR-20J•GR-26J PartNo.216596
Copyright © 2010 by Genie Industries
Second Edition: First Printing, August 2013
"Genie" is a registered trademarks of
Genie Industries in the USA and many other
countries.
Complies with EC Directive 2006/42/EC
See EC Declaration of Conformity
Printed on recycled paper
Printed in U.S.A.
Important
Read,understandand obey thesesafetyrules 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.
Contents
Page
Introduction ................................................................ 1
Symboland HazardPictorials Definitions................... 3
GeneralSafety........................................................... 5
PersonalSafety ......................................................... 7
Work Area Safety....................................................... 8
Legend ...................................................................... 15
Controls .................................................................... 16
Inspections ............................................................... 20
OperatingInstructions............................................... 32
TransportandLiftingInstructions .............................. 41
Maintenance ............................................................. 44
Specifications ........................................................... 46
Contact us:
Internet:http://www.genielift.com
e-mail:[email protected]

PartNo.216596 GR-20J•GR-26J 1
Operator'sManual
Second Edition • First Printing
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
machineoperationcontainedinthisoperator's
manual.
1 Avoidhazardoussituations.
Knowandunderstandthesafetyrulesbefore
going on to the next section.
2 Alwaysperformapre-operationinspection.
3 Always perform function tests prior to use.
4 Inspect the workplace.
5 Only use the machine as it was intended.
Youread,understandandobeythe
manufacturer'sinstructionsandsafetyrules—
safetyandoperator'smanualsandmachine
decals.
Youread,understandandobeyemployer's
safety rules and worksite regulations.
Youread,understandandobeyallapplicable
governmentalregulations.
Youare properly trainedto safely operate the
machine.
Owners, Users and Operators:
Genieappreciates your choice of our machine for
yourapplication. Our numberone 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:
1 Comply with employer, job site and
governmentalrules.
2 Read, understand and follow the instructions
in this and other manuals supplied with this
machine.
3 Use goodsafe work practices ina
commonsenseway.
4 Onlyhavetrained/certifiedoperators,directed
byinformedandknowledgeablesupervision,
runningthemachine.
If there is anything in this manual that is not clear
orwhich you believe should beadded, please
contact us.
Internet:www.genielift.com
Email:[email protected]

Operator'sManual Second Edition • First Printing
2 GR-20J•GR-26J PartNo.216596
Intended Use
This machine is intended to be used only to lift
personnel, along with their tools and materials to an
aerial work site.
Introduction
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-basedcleaners becausetheymaydamage
the safety sign material.
Hazard Classification
Genie uses symbols, color coding and signal words
to identify the following:
Safety alert symbol—used to alert
youto potential personal injury
hazards. Obey all safety
messages that follow this symbol
to avoid possible injury or death.
Indicatesa hazardous situation
which, if not avoided, will result in
deathor serious injury.
Indicatesa hazardous situation
which, if not avoided, could result
in death or serious injury.
Indicatesa hazardous situation
which, if not avoided, could result
inminorormoderateinjury.
Indicatesa hazardous situation
which, if not avoided, could result
inpropertydamage.
Red
Orange
Yellow
Blue

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Operator'sManual
Second Edition • First Printing
CrushHazard FireHazard
Electrocution
Hazard
FallHazard
Symbol and Hazard Pictorials Definitions
Tip-overHazard
Electrocution
Hazard Maintainrequired
clearance
CollisionHazard
Voltageratingfor
powertoplatform
NoSmoking
ExplosionHazard BurnHazard
NoOpenFlames
Batteries used as
counterweight
Nosmoking
Noflame.
Stopengine
Keepaway from
movingparts
Keep off this
surface
Readthe
operator’smanual
Onlytrained
maintenance
personnelshould
access
compartments
Chockwheels
beforereleasing
brakes.
x
CrushHazard Keep awayfrom
elevated
componentswhile
servicingmachine
CollisionHazard Do not stand
underraised
platform

Operator'sManual Second Edition • First Printing
4 GR-20J•GR-26J PartNo.216596
Lanyard
attachmentpoint Wheel load
GroundedAC
3-wireoutletonly Replacedamaged wiresand cords
Symbol and Hazard Pictorials Definitions
Burnhazard Maximum
platform capacity
MaximumManual
Force
MaximumWind
Speed
1
2
Tip-overHazard
Whentilt alarm
sounds,lower
platform

PartNo.216596 GR-20J•GR-26J 5
Operator'sManual
Second Edition • First Printing
Personal Safety
Fall Protection
Personal fall protection equipment (PFPE) is
requiredwhenoperatingthismachine.
Occupants must wear a safety belt or harness in
accordancewithgovernmentalregulations.Attach
the lanyard to the anchor provided in the platform.
Operators must comply with employer, job site and
governmentalrulesregardingtheuseofpersonal
protectiveequipment.
All PFPE must comply with applicable
governmentalregulations,andmustbeinspected
and used in accordance with the PFPE
manufacturer’sinstructions.

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6 GR-20J•GR-26J PartNo.216596
Work Area Safety
Electrocution Hazards
This machine is not
electricallyinsulatedand
willnotprovide protection
from contact with or
proximity to electrical
current.
Maintainrequired
clearancesfromelectrical
powerlinesandapparatus
inaccordance with
applicablegovernmental
regulationsandthe
followingchart.
LineVoltage Required Clearance
0 to 50KV 3.0 m
50 to 200KV 4.6 m
200 to 350KV 6.1 m
350 to 500KV 7.6 m
500 to 750KV 10.6 m
750 to 1000KV 13.7 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
energizedpowerlines.Personnelonthegroundor
in the platform must not touch or operate the
machine until energized power lines are shut off.
Donot operatethemachineduringlightningor
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.
Maximum platform capacity 200 kg
The weight of options and accessories, such as
pipecradles and panel cradles, will reduce therated
platform capacity and must be factored into the
total platform load. See the decals on the options
andaccessories.
If using accessories, read, understand and obey
the decals and instructions with the accessory.
Do not alter or disable the limit switches.
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 in the platform
onlywhenthemachine
is on a severe slope.
If the tilt alarm sounds:
Lower the mast, then
lower the jib boom. Move
the machine to a firm,
level surface. Use
extremecautiontolower
the mast.

PartNo.216596 GR-20J•GR-26J 7
Operator'sManual
Second Edition • First Printing
Whenraising theplatform, follow ratings for
allowablemanualforceandnumberofoccupants
below.
Donotoperate themachine
in strong or gusty winds. Do
notincrease the surface area
of the platform or the load.
Increasingtheareaexposed
to the wind will decrease
machine stability.
Useextreme care and slow
speedswhiledrivingthe
machine in the stowed
positionacrossuneven
terrain,debris,unstableor
slipperysurfacesand near
holesanddrop-offs.
Do not drive the machine on
ornearuneventerrain,
unstablesurfacesorother
hazardousconditions withthe
boomraisedorextended.
Do not push off or pull
toward any object outside of
theplatform.
Maximum Maximum
Manual Force Occupants
400 N Indoor Use Only 2
200 N Outdoor 1
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 modify or alter an aerial work platform
withoutpriorwrittenpermissionfromthe
manufacturer.Mountingattachmentsforholding
toolsor 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.
Work Area Safety

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8 GR-20J•GR-26J PartNo.216596
Work Area Safety
Do not use batteries that weigh less than the
originalequipment.Batteriesareusedas
counterweight and are critical to machine stability.
The battery box, including batteries, must weigh a
minimum of 212 kg.
Do not use the machine as a crane.
Do not push the machine or other objects with the
boom.
Do not contact adjacent structures with the boom.
Do not tie the boom or platform to adjacent
structures.
Do not place loads outside the platform perimeter.
Operation on Slopes Hazards
Do not drive the machine on a slope that exceeds
the maximum uphill, downhill or side slope rating of
the machine. Slope rating applies only to machines
in the stowed position.
Maximum slope rating, stowed position 25% (14°)
Maximum side slope rating,
stowedposition 15%
(9°)
Note: Slope rating is subject to ground conditions
and adequate traction. See Driving on a Slope in
the Operating Instructions section.
Do not place or attach
overhangingloadstoany
part of this machine.
Donot place laddersor
scaffolds in the platform or
against any part of this
machine.
Do not transport tools and
materials unless they are
evenlydistributed and can
be safely handled by
person(s)intheplatform.
Do not use the machine on
a moving or mobile
surface or vehicle.
Be sure all tires are in
goodconditionandlug
nutsareproperly
tightened.
Do not use the platform controls to free a platform
thatiscaught,snaggedor otherwise prevented
from normal motion by an adjacent structure. All
personnelmustbe removed fromthe platform
before attempting to free the platform using the
groundcontrols.

PartNo.216596 GR-20J•GR-26J 9
Operator'sManual
Second Edition • First Printing
Collision Hazards
Be aware of limited sight
distance and blind spots
whendrivingoroperating.
Be aware of the platform
positionandtailswingwhen
rotatingtheturntable.
Checkthe workarea for
overheadobstructionsor
otherpossiblehazards.
Beawareofcrushing
hazardswhengraspingthe
platformguardrail.
Operators must comply with
employer, job site and
governmentalrulesregarding
the use of personal
protectiveequipment.
Observeand use the color-
codeddirectionarrowson
theplatform controls and
drive chassis for drive and
steer functions.
Fall Hazards
Occupants must wear a
safety belt or harness in
accordancewith
governmentalregulations.
Attach the lanyard to the
anchorprovidedinthe
platform.
Do not sit, stand or climb on
theplatformguardrails.
Maintain a firm footing on
the platform floor at all
times.
Do not climb down from the
platformwhenraised.
Keepthe platform floor clear
of debris.
Lowertheplatform entrymid-
rail or close the entry gate
beforeoperating.
Do not enter or exit the
platformunless the machine
is in the stowed position and
the platform is at ground
level.
Work Area Safety

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10 GR-20J•GR-26J PartNo.216596
Work Area Safety
Bodily Injury Hazard
Do not operate the machine with a hydraulic oil or
air leak. An air leak or hydraulic leak can penetrate
and/orburn skin.
Impropercontactwithcomponentsunder any cover
will cause serious injury. Only trained maintenance
personnel should access compartments. Access
by the operator is only advised when performing a
pre-operationinspection.Allcompartmentsmust
remainclosedandsecuredduringoperation.
Damaged Machine Hazards
Donotuse a damagedor malfunctioning machine.
Conductathoroughpre-operationinspectionofthe
machine and test all functions before each work
shift. Immediately tag and remove from service a
damagedormalfunctioningmachine.
Besure all maintenance hasbeen 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
manualsare complete, legible and in the storage
containerlocatedon the platform.
Component Damage Hazard
Do not use the machine as a ground for welding.
Donotlowertheboom
unless the area below is
clearofpersonneland
obstructions.
Limittravelspeed according
to the condition of the
groundsurface,congestion,
slope,locationof personnel,
and any other factors which
may cause collision.
Donot operate a boom in
the path of any crane unless
the controls of the crane
havebeenlockedoutand/or
precautionshavebeentaken
to prevent any potential
collision.
Nostuntdriving or horseplay while operatinga
machine.
The machine must be on a level surface or secured
beforereleasingthebrakes.
Explosion and Fire Hazards
Chargethebatteryonlyinanopen,well-ventilated
area away from sparks, flames and lighted tobacco.
Donot operate the machine or charge thebatteries
inhazardouslocationsorlocationswhere
potentially flammable or explosive gases or
particles may be present.

PartNo.216596 GR-20J•GR-26J 11
Operator'sManual
Second Edition • First Printing
Work Area Safety
Battery Safety
Burn Hazards
Batteries contain acid. Always
wearprotectiveclothingand
eyewearwhenworkingwith
batteries.
Avoid spilling or contacting
batteryacid. Neutralize
battery acid spills with baking
sodaandwater.
The battery pack must remain
in the upright position.
Do not expose the batteries or
thechargerto water orrain.
Explosion Hazards
Keep sparks, flames and
lightedtobacco away from
batteries. Batteries emit an
explosive gas.
The battery pack cover must
remainoffduringtheentire
charging cycle.
Do not contact the battery
terminals or the cable clamps
with tools that may cause
sparks.
Component Damage Hazards
Do not use any battery charger greater than 48V to
chargethebatteries.
Electrocution Hazards
Connect the battery charger to a
grounded,AC
3-wireelectrical outlet only.
Inspect daily for damaged cord,
cablesand wires.Replace
damageditemsbefore
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
originalequipment.Batteriesareusedas
counterweight and are critical to machine stability.
The battery box, including batteries, must weigh a
minimum of 212 kg.
Lifting Hazard
Use a suitable lifting device to remove or install the
batteries.

Operator'sManual Second Edition • First Printing
12 GR-20J•GR-26J PartNo.216596
Work Area Safety
Lockout After Each Use
1 Select a safe parking location—firm level
surface, clear of obstruction and traffic.
2 Lower the Jib boom and the mast to the stowed
position.
3 Rotate the turntable so that the platform is
betweenthenon-steerwheels.
4 Turn the key switch to the off position and
remove the key to secure from unauthorized
use.
5 Chockthe wheels.

PartNo.216596 GR-20J•GR-26J 13
Operator'sManual
Second Edition • First Printing
1 Steertire
2 Emergencyloweringcontrols(alsoundercover
onoppositeside)
3 Groundcontrols
4 Batteries(undercover)
5 Mast
6 Jibboom
7 Emergencylowering valve for jibboom
8 Platformcontrols
9 Platform
10 Slidingmid-rail
11 Lanyardanchoragepoint
12 Manualstoragecontainer
13 RedEmergencyStop button
14 Powertocharger
15 Non-steertire
Legend

Operator'sManual Second Edition • First Printing
14 GR-20J•GR-26J PartNo.216596
PlatformControl Panel
1 Jib boom function button with indicator light
2 Mast function and turntable rotate function
buttonwith indicator light
3 Drive function button with indicator light
4 RedEmergency Stopbutton
5 Driveenableindicatorlight
6 Platformoverloadindicatorlight
7 Driveenablebutton
8 Machine not level indicator light
9 Hornbutton
10 Function enable switch for drive and boom
functions
11 Proportionalcontrolhandlefordriveandboom
functions
12 Thumb rocker switch for steer functions
Controls

PartNo.216596 GR-20J•GR-26J 15
Operator'sManual
Second Edition • First Printing
Controls
PlatformControl Panel
1 Jib boom function button with indicator light
Push the jib boom function button to select the
jib boom function. The indicator light will be on.
2 Mast function and turntable rotate function
buttonwith indicator light
Push the mast function and turntable rotate
function button to select the mast and turntable
rotate functions. The indicator light will be on.
3 Drive function button with indicator light
Push the drive function button to select the drive
and steer function. The indicator light will be on.
4 RedEmergency Stopbutton
Push in the red Emergency Stop button to the
off position to stop all functions. Twist the red
Emergency Stop button to the on position to
operatethemachine.
5 Driveenableindicatorlight
Light on indicates that the boom has moved just
pasteithernon-steer wheel anddrivefunction
hasbeeninterrupted.
6 Platformoverloadindicatorlight
Light on indicates the platform
is overloaded and no functions will operate. An
alarm will be sounding when this light is on.
Remove weight from the platform until the light
goes off and the alarm stops sounding.
7 Driveenablebutton
To drive when the drive enable light is on, push
thedrive enable button and the drive button and
slowly move the drive control handle off center.
Be aware that the machine may move in the
opposite direction that the drive and steer
controlsaremoved.
8 Machine not level indicator light
The machine not level indicator light will come
on when the tilt alarm sounds.
9 Hornbutton
Push the horn button and the horn will sound.
Release the horn button and the horn will stop.
10 Function enable switch for drive and boom
functions
Press and hold the function enable switch on the
control handle to enable the functions.
11 Proportionalcontrolhandlefordriveandboom
functions
Move the control handle in the direction
indicatedby the blue arrow andthe machine
functions will operate in the direction indicated
by the blue arrow. Move the control handle in
thedirection indicatedby theyellow arrowand
the machine functions will operate in the
direction indicated by the yellow arrow. Move
the control handle to the left and the turntable
will rotate to the left. Move the control handle to
the right and the turntable will rotate to the right.
12 Thumb rocker switch for steer functions
Press the left side of the thumb rocker and the
machine will steer to the left. Press the right
side of the thumb rocker and the machine will
steer to the right.

Operator'sManual Second Edition • First Printing
16 GR-20J•GR-26J PartNo.216596
Controls
5 Keyswitchforplatform/off/groundoperation
6 Jibboomup/downbutton
7 Function enable button for mast up, jib boom up
and turntable rotate left functions
8 Function enable button for mast down, jib boom
downandturntablerotaterightfunctions
GroundControl Panel
1 Mastup/downbutton
2 Turntablerotateleft/rightbutton
3 Machine not level indicator light
4 Platformoverloadindicatorlight

PartNo.216596 GR-20J•GR-26J 17
Operator'sManual
Second Edition • First Printing
Controls
GroundControl Panel
1 Mastup/downbutton
Push and hold the mast up/down button to
select the mast up/down function.
2 Turntablerotateleft/rightbutton
Push and hold the turntable rotate left/right
button to select the turntable rotate left/right
function.
3 Machine not level indicator light
The machine not level indicator light will come
on when the tilt alarm sounds.
4 Platformoverloadindicatorlight
Light on indicates platform is overloaded and no
functionswilloperate.
Removeweight from the platform to resume
machineoperationorhavea person on the
ground turn the key switch to ground control and
proceedtolower the platform.
Note: An alarm will sound at the platform when an
overloadcondition occurs and willstop sounding
whenweight is removed from the platform.
5 Keyswitchforplatform/off/groundoperation
Turn the key switch to the platform position and
the platform controls will operate. Turn the key
switch to the center position and the machine
will be off. Turn the key switch to the ground
positionandthegroundcontrolswilloperate.
6 Jibboomup/downbutton
Push and hold the jib boom up/down button to
select the jib boom up/down function.
7 Function enable button for mast up, jib boom up
and turntable rotate left functions
Press and hold this function enable button to
enable the mast up, jib boom up and turntable
rotate left functions
8 Function enable button for mast down, jib boom
downandturntablerotaterightfunctions
Press and hold this function enable button to
enablethe mast down,jib boom downand
turntablerotate rightfunctions

Operator'sManual Second Edition • First Printing
18 GR-20J•GR-26J PartNo.216596
Inspections
Do Not Operate Unless:
You learn and practice the principles of safe
machineoperationcontainedinthisoperator's
manual.
1 Avoidhazardous situations.
2 Alwaysperformapre-operation
inspection.
Knowandunderstandthepre-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-operationinspectionandroutinemaintenance.
Thepre-operation inspection is a visual inspection
performed by the operator prior to each work shift.
The inspection is designed to discover if anything
isapparentlywrong with amachinebefore the
operator performs the function tests.
Thepre-operationinspection also servesto
determineifroutinemaintenanceproceduresare
required.Onlyroutinemaintenanceitemsspecified
in this manual may be performed by the operator.
Refer to the list on the next page and check each
of the items.
Ifdamageoranyunauthorizedvariationfrom
factory delivered condition is discovered, the
machinemustbe tagged and removedfrom
service.
Repairs to the machine may only be made by a
qualified service technician, according to the
manufacturer'sspecifications. Afterrepairsare
completed,theoperatormustperforma
pre-operationinspectionagainbeforegoingonto
the function tests.
Scheduledmaintenanceinspectionsshallbe
performedby qualified service technicians,
accordingtothe manufacturer's specifications and
the requirements listed in the responsibilities
manual.