Genie Lift Guard GR-12 Setup guide

Operator’s Manual Third Edition
Second Printing
Part No. 97773
with Maintenance Information

Operator's Manual Third Edition • Second Printing
2 GR-12 • GR-15 • GR-20 PartNo.97773
Copyright © 2000 by Genie Industries
First Edition: Sixth Printing, October 2002
Second Edition: Second Printing, August 2004
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.
These machines comply with
ANSI/SIA92.6-1999.
Printed on recycled paper
Printed in U.S.A.
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 .............................................................. 1
Legend ....................................................................... 9
Controls .................................................................... 10
Pre-operationInspection ........................................... 12
Maintenance ............................................................. 14
Function Tests .......................................................... 16
WorkplaceInspection ................................................ 20
OperatingInstructions ............................................... 21
Transport and Lifting Instructions .............................. 26
Decals ...................................................................... 28
Specifications ........................................................... 36
Contact us:
Internet: http://www.genielift.com
e-mail: [email protected]

Operator's Manual
Third Edition • Second Printing
Part No. 97773 GR-12 • GR-15 • GR-20 1
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:
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.

Operator's Manual Third Edition • Second Printing
2 GR-12 • GR-15 • GR-20 Part No. 97773
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 and in each bike rack 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 station tray (option) 50 lbs 22 kg
Parcel tray (option) 150 lbs 68 kg
Maximum occupants 1
Stock Picker platform
Platform capacity 500 lbs 227 kg
Adjustable work station tray 150 lbs 45 kg
Parcel tray (option) 150 lbs 68 kg
Bike rack (option) (each) 45 lbs 20 kg
Maximum occupants 1
AWP and fiberglass platform 350 lbs 159 kg
Maximum occupants 1
SAFETY RULES
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.
Voltage Minimum Safe
Phase to Phase Approach Distance
Feet Meters
0 to 300V Avoid Contact
300V to 50KV 10 3.05
50KV to 200KV 15 4.60
200KV to 350KV 20 6.10
350KV to 500KV 25 7.62
500KV to 750KV 35 10.67
750KV to 1000KV 45 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.
500 lbs / 227 kg Extension only
250 lbs / 113 kg
Platform only
250 lbs / 113 kg

Operator's Manual
Third Edition • Second Printing
Part No. 97773 GR-12 • GR-15 • GR-20 3
SAFETY RULES
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 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 0.5 mph / 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.
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
Stock Picker platform
Platform capacity 350 lbs 159 kg
Adjustable work station tray 150 lbs 45 kg
Bike rack (option) (each) 45 lbs 20 kg
Maximum occupants 1
AWP and fiberglass platform 350 lbs 159 kg
Maximum occupants 1
350 lbs / 159 kg Extension only
250 lbs / 113 kg
Platform only
100 lbs / 45 kg

Operator's Manual Third Edition • Second Printing
4 GR-12 • GR-15 • GR-20 Part No. 97773
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.
Maximum allowable
side force
ANSI/CSA
100 lbs / 445 N
Maximum allowable
manual force
AUS
45 lbs / 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 28 mph / 12.5 m/s. If wind speeds exceed
28 mph / 12.5 m/s when the plaform 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.
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.
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.

Operator's Manual
Third Edition • Second Printing
Part No. 97773 GR-12 • GR-15 • GR-20 5
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 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 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.
Collision Hazards
Be aware of limited sight
distance and blind spots
when driving or
operating.
Be aware of the extended platform position when
moving the machine.
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.
SAFETY RULES

Operator's Manual Third Edition • Second Printing
6 GR-12 • GR-15 • GR-20 Part No. 97773
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
potential 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.
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.
Conduct a thorough pre-operation inspection of the
machine and test all functions before each work
shift. Immediately tag and remove from service a
damaged or malfunctioning machine.
Be sure all maintenance has been performed as
specified in this manual and the appropriate 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 compartments must
remain closed and secured during operation.

Operator's Manual
Third Edition • Second Printing
Part No. 97773 GR-12 • GR-15 • GR-20 7
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.
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.
Component Damage Hazard
Do not use any battery charger greater than 24V to
charge the batteries.
Electrocution Hazards
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.
Avoid electrical shock from contact with battery
terminals. Remove all rings, watches and other
jewelry.
Tip-over Hazard
Do not use batteries that weigh less than the
original equipment. Batteries are used as
counterweight and are critical to machine stability.
Each battery must weigh 62 pounds / 28 kg.
Lifting Hazard
Use the appropriate number of people and proper
lifting techniques when lifting batteries.
SAFETY RULES

Operator's Manual Third Edition • Second Printing
8 GR-12 • GR-15 • GR-20 Part No. 97773
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
presence of an imminently
hazardous situation which, if not
avoided, will result in death or
serious injury.
Orange—used to indicate the
presence of a potentially
hazardous situation which, if not
avoided, could result in death or
serious injury.
Yellow with safety alert symbol—
used to indicate the presence of a
potentially hazardous situation
which, if not avoided, may cause
minor or moderate injury.
Yellow without safety alert
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.

Operator's Manual
Third Edition • Second Printing
Part No. 97773 GR-12 • GR-15 • GR-20 9
Legend
1 Pothole guard
2 Non-steer tire
3 Manual lowering valve
4 Transport tie-down
5 Forklift pocket
6 Battery charger display
7 Covers
8 Ground controls
9 Hydraulic oil level indicator
10 Power to 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)
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

Operator's Manual Third Edition • Second Printing
10 GR-12 • GR-15 • GR-20 Part No. 97773
Controls
Platform Controls
1 Red Emergency Stop button
2 LED diagnostic readout / Battery charge
indicator
3 Lift function select button
4 Horn button (if equipped)
5 Proportional control handle and function enable
switch for lift and drive functions
6 Thumb rocker switch for steer functions
7 Drive speed button
8 Drive function select button

Operator's Manual
Third Edition • Second Printing
Part No. 97773 GR-12 • GR-15 • GR-20 11
CONTROLS
Ground Control Panel
1 7 amp breaker for electrical circuits
2 Key switch for platform/off/ground selection
3 Hour meter
4 Platform up/down toggle switch
5 Red Emergency Stop button
00009.9
STOP
3
2
1
4
5

Operator's Manual Third Edition • Second Printing
12 GR-12 • GR-15 • GR-20 Part No. 97773
Pre-operation Inspection
Do Not Operate Unless:
You learn and practice the principles of safe
machine operation contained in this operator's
manual.
1 Avoid hazardous situations.
2 Always perform a pre-operation
inspection.
Know and understand the pre-operation
inspection before going on to the next
section.
3 Always perform function tests prior to use.
4 Inspect the workplace.
5 Only use the machine as it was intended.
Fundamentals
It is the responsibility of the operator to perform a
pre-operation inspection and routine maintenance.
The pre-operation inspection is a visual inspection
performed by the operator prior to each work shift.
The inspection is designed to discover if anything
is apparently wrong with a machine before the
operator performs the function tests.
The pre-operation inspection also serves to
determine if routine maintenance procedures are
required. Only routine maintenance items specified
in this manual may be performed by the operator.
Refer to the list on the next page and check each
of the items.
If damage or any unauthorized variation from
factory delivered condition is discovered, the
machine must be tagged and removed from
service.
Repairs to the machine may only be made by a
qualified service technician, according to the
manufacturer's specifications. After repairs are
completed, the operator must perform a
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.

Operator's Manual
Third Edition • Second Printing
Part No. 97773 GR-12 • GR-15 • GR-20 13
PRE-OPERATION INSPECTION
Pre-operation Inspection
oBe sure that the operator's, safety and
responsibilities manuals are complete, legible
and in the storage container located on the
platform.
oBe sure that all decals are legible and in place.
See Decals section.
oCheck for hydraulic oil leaks and proper oil level.
See Maintenance section.
oCheck 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:
oElectrical components, wiring and electrical
cables
oHydraulic power unit, tank, hoses,
fittings, cylinders and manifolds
oBattery pack and connections
oDrive motors
oTires and wheels
oLimit switches and alarms
oNuts, bolts and other fasteners
oPlatform entry mid-rail bar or gate
oSequencing cables and pulleys
oPlatform extension (if equipped)
oWork trays and bike racks (if equipped)
oMast columns and counterweight
oPlatform controls
oBrake release components
Check the entire machine for:
oCracks in welds or structural components
oDents or damage to the machine
oBe sure that all structural and other critical
components are present and all associated
fasteners and pins are in place and properly
tightened.

Operator's Manual Third Edition • Second Printing
14 GR-12 • GR-15 • GR-20 Part No. 97773
Maintenance
Observe and Obey:
Only routine maintenance items specified in this
manual shall be performed by the operator.
Scheduled maintenance inspections shall be
completed by qualified service technicians,
according to the manufacturer's specifications
and the requirements specified in the
responsibilities manual.
Check the Hydraulic 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
Maintenance Symbols Legend
The following symbols have been
used in this manual to help
communicate the intent of the
instructions. When one or more of
the symbols appear at the
beginning of a maintenance
procedure, it conveys the meaning
below.
Indicates that tools will be required to
perform this procedure.
Indicates that new parts will be
required to perform this procedure.

Operator's Manual
Third Edition • Second Printing
Part No. 97773 GR-12 • GR-15 • GR-20 15
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.
Electrocution hazard. Contact with
hot or live circuits could result in
death or serious injury. Remove all
rings, watches and other jewelry.
Bodily injury hazard. Batteries
contain acid. Avoid spilling or
contacting battery acid. Neutralize
battery acid spills with baking soda
and water.
Perform this test after fully
charging the batteries.
1 Put on protective clothing and eye wear.
2 Raise the platform approximately 5 feet / 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
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.
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 • Second Printing
16 GR-12 • GR-15 • GR-20 Part No. 97773
Function Tests
Do Not Operate Unless:
You learn and practice the principles of safe
machine operation contained in this operator's
manual.
1 Avoid hazardous situations.
2 Always perform a pre-operation
inspection.
3 Always perform function tests prior to
use.
Know and understand the function tests
before going on to the next section.
4 Inspect the workplace.
5 Only use the machine as it was intended.
Fundamentals
The function tests are designed to discover any
malfunctions before the machine is put into service.
The operator must follow the step-by-step
instructions to test all machine functions.
A malfunctioning machine must never be used. If
malfunctions are discovered, the machine must be
tagged and removed from service. Repairs to the
machine may only be made by a qualified service
technician, according to the manufacturer's
specifications.
After repairs are completed, the operator must
perform a pre-operation inspection and function
tests again before putting the machine into service.

Operator's Manual
Third Edition • Second Printing
Part No. 97773 GR-12 • GR-15 • GR-20 17
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 Push in 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 the 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 2 feet / 60 cm.
11 Pull the manual lowering knob located at the
base of the machine below the mast.
Result: The platform should lower. The descent
alarm will not sound.
12 Turn the key switch to platform control.
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.
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 raise.
21 Release the control handle.
Result: The platform should stop raising.

Operator's Manual Third Edition • Second Printing
18 GR-12 • GR-15 • GR-20 Part No. 97773
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.
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 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.