Genie Lift Guard GRC-12 User manual

Operator's Manual First Edition • First Printing
GRC-12 PartNo.133136
Copyright © 2008 by Genie Industries
First Edition: First Printing, August 2008
"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
Printed on recycled paper
Printed in U.S.A.
Contact us:
Internet:http://www.genielift.com
E-mail:[email protected]
Important
Read,understandandobeythesesafetyrulesand
operating instructions before operating this machine.
Only trained and authorized personnel shall be
permitted to operate this machine. This manual
should be considered a permanent part of your
machine and should remain with the machine at all
times. If you have any questions, call Genie Industries.
Contents
Page
Introduction ................................................................ 1
Symboland Hazard Pictorials Definitions................... 3
GeneralSafety........................................................... 5
PersonalSafety ......................................................... 7
Work Area Safety....................................................... 8
Legend ...................................................................... 14
Controls .................................................................... 15
Inspections ............................................................... 18
OperatingInstructions............................................... 28
Transportand LiftingInstructions .............................. 33
Maintenance ............................................................. 36
Specifications ........................................................... 38

Operator's Manual
First Edition • First Printing
Part No.133136 GRC-12 1
Danger
Failure to obey the instructions and
safety rules in this manual will result
in death or serious injury.
Do Not Operate Unless:
You learn and practice the principles of safe
machine operation contained in this operator's
manual.
1 Avoid hazardous situations.
Know and understand the safety rules
before going on to the next section.
2 Always perform a pre-operation inspection.
3 Always perform function tests prior to use.
4 Inspect the workplace.
5 Only use the machine as it was intended.
You read, understand and obey the
manufacturer's instructions and safety rules—
safety and operator's manuals and machine
decals.
You read, understand and obey employer's
safety rules and work site regulations.
You read, understand and obey all applicable
governmentalregulations.
You are properly trained to safely operate the
machine.
Introduction
Owners, Users and Operators:
Genie appreciates your choice of our machine for
your application. Our number one priority is user
safety, which is best achieved by our joint efforts.
We feel that you make a major contribution to
safety if you, as the equipment users and
operators:
1 Comply with employer, job site and
governmental rules.
2 Read, understand and follow the instructions
in this and other manuals supplied with this
machine.
3 Use good safe work practices in a
commonsense way.
4 Only have trained/certified operators,
directed by informed and knowledgeable
supervision, running the machine.
If there is anything in this manual that is not clear
or which you believe should be added, please
contact us.
Internet:www.genielift.com
E-mail:[email protected]

Operator's Manual First Edition • First Printing
2 GRC-12 Part No.133136
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-based cleaners because they may damage
the safety sign material.
Hazard Classification
Genie uses symbols, color coding and signal
words to identify the following:
Safety alert symbol—used to alert
you to potential personal injury
hazards. Obey all safety
messages that follow this symbol
to avoid possible injury or death.
Indicates a hazardous situation
which, if not avoided, will result in
death or serious injury.
Indicates a hazardous situation
which, if not avoided, could result
in death or serious injury.
Indicates a hazardous situation
which, if not avoided, could result
in minor or moderate injury.
Indicates a property damage
notice.
Red
Orange
Yellow
Blue

Operator's Manual
First Edition • First Printing
Part No.133136 GRC-12 3
Symbol and Hazard Pictorials Definitions
Read the
operator’s manual Read the service
manual Crush hazard Collision hazard
Tip-over hazard Tip-over hazard Electrocution
hazard
Electrocution
hazard Explosion hazard Fire hazard Burn hazard Skin injection
hazard
Keep away from
moving parts Move machine to level ground
Maintainrequired
clearance
Only trained
maintenance
personnel should
access
compartments
Use a piece of
cardboard or
paper to search
for leaksCollision hazard
Batteries used as
counterweights
Chock the wheels Release brakes Grounded AC
3-wire only
No smoking
Transport diagram Tiedown
= 28 kg x 4

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4 GRC-12 Part No.133136
Voltage rating for
power to platform
Pressure rating for
air line to platform
Replace damaged
wires and cords Lanyard
attachmentpoint
Wind speed
Side force
Maximum capacity including occupant
+
Maximum capacity including occupant,
tools and tray
22 kg
+
+
Wheel load
Symbol and Hazard Pictorials Definitions
Indoor

Operator's Manual
First Edition • First Printing
Part No.133136 GRC-12 5
Safety signs and locations
Decals with symbols
General Safety
82495
82614
82481
82481 B
82495 B
133015
82487
82487 C
82487
82487 C
Battery Charger Side
114334
114338
114338 A
1
2
82473
133146
97899B
x
97899
82614B
82472
133015A
0 to 50KV 3.05 m
50KV to 200KV 4.60 m
200KV to 350KV 6.10 m
350KV to 500KV 7.62 m
500KV to 750KV 10.67 m
750KV to 1000KV 13.72 m
114334 A
82473 C
133147

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6 GRC-12 Part No.133136
Safety signs and locations
Decals with symbols
General Safety
82487 C
Decal Plate
114338
82487
133274
133198
227 kg
227 kg
133198 B GRC-12
+
=
114338 A
1
2
445 N

Operator's Manual
First Edition • First Printing
Part No.133136 GRC-12 7
Personal Safety
Fall Protection
Personal fall protection equipment (PFPE) is not
required when operating this machine. If PFPE is
required by job site or employer rules, the following
shall apply:
All PFPE must comply with applicable
governmental regulations, and must be inspected
and used in accordance with the PFPE
manufacturer’sinstructions.

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8 GRC-12 Part No.133136
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 is part of the total platform load.
Maximum capacity - GRC-12
Platform retracted 227 kg
Work station tray (each) 11 kg
Maximum occupants 2
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 inside the battery
charger tray only when the
machine is on a severe
slope.
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
governmentalregulations
and the following chart.
Line Voltage Required Clearance
0 to 50KV 3.05 m
50KV to 200KV 4.60 m
200KV to 350KV 6.10 m
350KV to 500KV 7.62 m
500KV to 750KV 10.67 m
750KV to 1000KV 13.72 m
Allow for platform movement, electrical line sway
or sag and beware of strong or gusty winds.
Keep away from the machine if it contacts
energized power lines. Personnel on the ground or
in the platform must not touch or operate the
machine until energized power lines are shut off.
Do not operate the machine during lightning or
storms.
Do not use the machine as a ground for welding.
Work Area Safety

Operator's Manual
First Edition • First Printing
Part No.133136 GRC-12 9
Work Area Safety
If the tilt alarm sounds:
Lower the platform. Move the machine to a firm,
level surface. If the tilt alarm sounds when the
platform is raised, use extreme caution to lower the
platform.
Do not drive over 0.8 km/h with the platform raised.
When raising the platform, follow rating for
allowable manual force and number of occupants
in the next column.
Do not operate the
machine in strong or gusty
winds. Do not increase the
surface area of the
platform or the load.
Increasing the area
exposed to the wind will
decrease machine stability.
Use extreme care and slow speeds while driving
the machine in a stowed position across uneven
terrain, debris, unstable or slippery surfaces and
near holes and drop-offs.
Do not drive the machine
on or near uneven terrain,
unstable surfaces or other
hazardous conditions with
the platform raised.
Do not use the machine as a crane.
Do not push the machine or other objects with the
platform.
Do not contact adjacent structures with the
platform.
Do not tie the platform to adjacent structures.
Do not place loads outside the platform perimeter.
Do not use the platform controls to free a platform
that is caught, snagged or otherwise prevented
from normal motion by an adjacent structure. All
personnel must be removed from the platform
before attempting to free the platform using the
ground controls.
Do not push off or pull
toward any object outside
of the platform.
Maximum Maximum
allowable number of
Model manual force occupants
CE 445 N Indoor only - 2
Do not alter or disable the limit switches.
Do not alter or disable machine components that in
any way affect safety and stability.
Do not replace items critical to machine stability
with items of different weight or specification.

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10 GRC-12 Part No.133136
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 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 place or attach fixed
or overhanging loads to
any part of this machine.
Do not place ladders or
scaffolds in the platform or
against any part of this
machine.
Do not transport tools and
materials unless they are
evenly distributed and can
be safely handled by the
person in the platform.
Do not use the machine on
a moving or mobile surface
or vehicle.
Be sure all tires are in good
condition, castle nuts are
properly tightened and
cotter pins are properly
installed.
Crushing Hazard
Keep hands and limbs out of mast.
Do not work under the platform or mast without the
battery cover raised.
Use common sense and planning when operating
the machine with the controller from the ground.
Maintain safe distances between the operator, the
machine and fixed objects.
Operation on Slopes Hazards
Do not drive the machine on a slope that exceeds
the slope and side slope rating of the machine.
Slope rating applies to machines in the stowed
position only.
Maximum slope rating,
stowed position 30% (17°)
Maximum side slope rating,
stowed position 30% (17°)
Note: Slope rating is subject to ground conditions
and adequate traction.
Fall Hazards
The guard rail system provides fall protection. If the
occupant of the platform is required to wear
personal fall protection equipment (PFPE) due to
job site or employer rules, PFPE and its use shall
be in accordance with the PFPE manufacturer’s
instructions and applicable governmental
requirements. Use approved lanyard attachment
point provided.
Work Area Safety

Operator's Manual
First Edition • First Printing
Part No.133136 GRC-12 11
Keep the platform floor clear of debris.
Close the entry gate before operating.
Do not sit, stand or climb
on the platform guard rails.
Maintain a firm footing on
the platform floor at all
times.
Do not climb down from the
platform when raised.
Do not enter or exit the
platform unless the
machine is in the stowed
position.
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.
The machine must be on a level surface or
secured before releasing the brakes.
Check the work area for
overhead obstructions or
other possible hazards.
Be aware of crushing
hazards when grasping the
platform guard rail.
Operators must comply
with employer, job site and
governmental rules
regarding use of personal
protectiveequipment.
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
potentialcollision.
No stunt driving or horseplay while operating a
machine.
Work Area Safety

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12 GRC-12 Part No.133136
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.
Explosion and Fire Hazards
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.
Component Damage Hazards
Do not use any battery charger greater than 24V to
charge the batteries.
Do not use the machine as a ground for welding.
Work Area Safety

Operator's Manual
First Edition • First Printing
Part No.133136 GRC-12 13
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/Burn Hazards
Connect the battery
charger to a grounded, AC
3-wire electrical outlet only.
Inspect daily for damaged
cords, cables and wires.
Replace damaged items
beforeoperating.
Avoid electrical shock/
burns 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 28 kg.
Lifting Hazard
Use the appropriate number of people and proper
lifting techniques when lifting batteries.
Lockout After Each Use
1 Select a safe parking location—firm level
surface, clear of obstruction and traffic.
2 Lower the platform.
3 Turn the key switch to the off position and
remove the key to secure from unauthorized
use.
4 Chock the wheels.
5 Charge the batteries.
Work Area Safety

Operator's Manual First Edition • First Printing
14 GRC-12 Part No.133136
1 Pothole guard
2 Non-steer tire
3 Forklift pocket
4 Transport tie-down
5 Emergency lowering valve
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 GFCI outlet
12 Work station tray
13 Brake release pump knob
(under covers)
14 Platform controls
15 Platform extension release lever
16 Mast
17 Platform extension entry gate
18 Battery compartment cover
19 Battery cover latch
20 Steer tire
21 Manual storage container
22 Lanyard anchorage point
Legend
1312 15 16
4
3
2
1
5
2
4
3
6
7
8
9
10
11
17
19
18
4
20
21
14
22

Operator's Manual
First Edition • First Printing
Part No.133136 GRC-12 15
Ground Control Panel
1 7 amp breaker for electric circuits
2 Key switch for platform/off/ground selection
Turn the key switch to the platform position and
the platform controls will operate. Turn the key
switch to the off position and the machine will
be off. Turn the key switch to the base position
and the ground controls will operate.
3 Hour meter
Indicates the number of hours the machine has
been put into use.
4 Platform up/down toggle switch
Move the switch up and the
platform will raise. Move the switch
down and the platform will lower.
5 Red Emergency Stop button
Push in the red Emergency Stop button to the
off position to stop all functions. Pull out the red
Emergency Stop button to the on position to
operate the machine.
Controls
STOP
00009.9
2
3
4
5
1

Operator's Manual First Edition • First Printing
16 GRC-12 Part No.133136
Controls
Platform Control Panel
1 Thumb rocker switch for steer functions
2 Drive speed button
3 Drive function select button
4 Red Emergency Stop button
5 LED diagnostic readout / Platform overload
indicator / Battery charge indicator
6 Lift function select button
7 Horn button
8 Proportional control handle and function enable
switch for lift and drive functions

Operator's Manual
First Edition • First Printing
Part No.133136 GRC-12 17
Controls
Platform Control Panel
1 Thumb rocker switch for steer functions
Press the thumb rocker switch in either
direction to activate the steer function.
2 Drive speed button
Press this button to activate slow drive function.
The indicator light will be on when slow drive is
selected.
3 Drive function select button
Press this button to activate the
drive function.
4 Red Emergency Stop button
Push in the red Emergency Stop button to the
off position to stop all functions. Pull out the red
Emergency Stop button to the on position to
operate the machine.
5 LED
Diagnostic read out, platform overload indicator,
battery charge indicator.
6 Lift function select button
Press this button to activate the
lift function.
7 Horn Button
Push the horn button and the horn will sound.
Release the horn button and the horn will stop.
8 Proportional control handle and function enable
switch for lift and drive functions
Lift function: Press and hold the function enable
switch to enable the lift function on the platform
control handle. Move the control handle in the
direction indicated by the blue arrow and the
platform will raise. Move the control handle in
the direction indicated by the yellow arrow and
the platform will lower. The descent alarm
should sound while the platform is lowering.
Drive function: Press and hold the function
enable switch to enable the drive function on
the platform control handle. Move the control
handle in the direction indicated by the blue
arrow on the platform entry gate and the
machine will move in the direction that the blue
arrow points. Move the control handle in the
direction indicated by the yellow arrow on the
platform entry gate and the machine will move
in the direction that the yellow arrow points.

Operator's Manual First Edition • First Printing
18 GRC-12 Part No.133136
Inspections
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.
Pre-operation Inspection
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.