Terex Genie GR-12 User manual

Operator's Manual Fifth Edition • First Printing
GR-12 • GR-15 • GR-20 Part No. 133571
Copyright © 2000 by Genie Industries
Fifth Edition: First Printing, May 2010
"Genie" is a registered trademark of
Genie Industries in the U.S.A. and many other
countries. "Runabout" and "GR" are trademarks
of Genie Industries.
These machines comply with
ANSI/SIA 92.6
CSA B.354.2
Printed on recycled paper
Contact us:
Internet: http://www.genielift.com
e-mail: [email protected]
Important
Read, understand and obey these safety rules and
operating instructions before operating this machine.
Only trained and authorized personnel shall be
permitted to operate this machine. This manual should
be considered a permanent part of your machine and
should remain with the machine at all times. If you
have any questions, call Genie Industries.
Contents
Page
Introduction ................................................................ 1
Symbol and Hazard Pictorials Definitions .................. 3
General Safety .......................................................... 5
Personal Safety ......................................................... 9
Work Area Safety ..................................................... 10
Legend ..................................................................... 18
Controls .................................................................... 19
Inspections ............................................................... 22
Operating Instructions .............................................. 35
Transport and Lifting Instructions.............................. 40
Maintenance ............................................................. 43
Specifications ........................................................... 45

Operator's ManualFifth Edition • First Printing
Part No. 133571 GR-12 • GR-15 • GR-20 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
governmental regulations.
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]

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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 hazardous situation
which, if not avoided, could result
in property damage.
Intended Use
This machine is intended to be used only to lift
personnel, along with their tools and materials to
an aerial work site.
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.
Red
Orange
Yellow
Blue
Red

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Part No. 133571 GR-12 • GR-15 • GR-20 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
Maintain required
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

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Voltage rating for
power to platform
Pressure rating for
air line to platform
Replace damaged
wires and cords
Lanyard
attachment point
Wind speed
Side force
Maximum capacity including occupant
+
Maximum capacity including occupant,
tools and tray
22 kg
+
+
Wheel load
Symbol and Hazard Pictorials Definitions

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Part No. 133571 GR-12 • GR-15 • GR-20 5
General Safety
Safety signs and locations
Decals with words

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General Safety
Safety signs and locations
Decals with words

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Part No. 133571 GR-12 • GR-15 • GR-20 7
Safety signs and locations
Decals with symbols
General Safety

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Safety signs and locations
Decals with symbols
General Safety

Operator's ManualFifth Edition • First Printing
Part No. 133571 GR-12 • GR-15 • GR-20 9
Fall Protection
Personal fall protection equipment (PFPE) is not
required when operating this machine. If PFPE is
required by job site or employer rules, the following
shall apply:
All PFPE must comply with applicable
governmental regulations, and must be inspected
and used in accordance with the PFPE
manufacturer’s instructions.
Personal Safety

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Tip-over Hazards
Occupants, equipment and materials must not
exceed the maximum platform capacity or the
maximum capacity of the platform extension.
Weight in trays are part of the total platform load.
Maximum capacity - GR-12 and GR-15
Standard platform
Platform without extension 500 lbs 227 kg
Platform retracted 500 lbs 227 kg
Platform extended - Platform only 250 lbs 113 kg
Platform extended - Extension only 250 lbs 113 kg
Work station tray (option) 50 lbs 22 kg
Maximum occupants 1
500 lbs / 227 kg Extension only Platform only
250 lbs / 113 kg 250 lbs / 113 kg
Electrocution Hazards
This machine is not
electrically insulated and
will not provide protection
from contact with or
proximity to electrical
current.
Maintain safe distances
from electrical power lines
and apparatus in
accordance with applicable
governmental regulations
and the following chart.
Line Voltage Required Clearance
0 to 50KV 10 ft 3.05 m
50KV to 200KV 15 ft 4.60 m
200KV to 350KV 20 ft 6.10 m
350KV to 500KV 25 ft 7.62 m
500KV to 750KV 35 ft 10.67 m
750KV to 1000KV 45 ft 13.72 m
Allow for platform movement, electrical line sway
or sag and beware of strong or gusty winds.
Keep away from the machine if it contacts
energized power lines. Personnel on the ground or
in the platform must not touch or operate the
machine until energized power lines are shut off.
Do not operate the machine during lightning or
storms.
Do not use the machine as a ground for welding.
Work Area Safety
AWP platform 350 lbs 159 kg
Maximum occupants 1

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Work Safety
Maximum capacity - GR-20
Standard platform
Platform without extension 350 lbs 159 kg
Platform retracted 350 lbs 159 kg
Platform extended - Platform only 100 lbs 45 kg
Platform extended - Extension only 250 lbs 113 kg
Maximum occupants 1
350 lbs / 159 kg Extension only Platform only
250 lbs / 113 kg 100 lbs / 45 kg
AWP platform 350 lbs 159 kg
Maximum occupants 1
Do not raise the platform
unless the machine is on a
firm, level surface.
Do not depend on the tilt
alarm as a level indicator.
The tilt alarm sounds at the
platform controls and
ground controls when the
machine is on a severe
slope.
If the tilt alarm sounds:
Lower the platform. Move the machine to a firm,
level surface. If the tilt alarm sounds when the
platform is raised, use extreme caution to lower the
platform.
Do not drive over 0.5 mph / 0.8 km/h with the
platform raised.

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Work Area Safety
Do not push off or pull
toward any object outside
of the platform.
Maximum Maximum
allowable number of
Model side force occupants
ANSI/CSA 100 lbs / 445 N 1
Do not alter or disable the limit switches.
Do not alter or disable machine components that in
any way affect safety and stability.
Do not replace items critical to machine stability
with items of different weight or specification.
Do not use batteries that weigh less than the
original equipment. Batteries are used as
counterweight and are critical to machine stability.
Each battery must weigh 62 pounds / 28 kg.
Do not modify or alter an aerial work platform
without prior written permission from the
manufacturer. Mounting attachments for holding
tools or other materials onto the platform,
toeboards or guard rail system can increase the
weight in the platform and the surface area of the
platform or the load.
Do not raise the mast when wind speeds may
exceed 28 mph / 12.5 m/s.If wind speeds exceed
28 mph / 12.5 m/s when the platform is raised,
lower the platform and do not continue to operate
the machine.
Do not operate the
machine in strong or gusty
winds. Do not increase the
surface area of the platform
or the load. Increasing the
area exposed to the wind
will decrease machine
stability.
Use extreme care and slow
speeds while driving the
machine in a stowed
position across uneven
terrain, debris, unstable or
slippery surfaces and near
holes and drop-offs.
Do not drive the machine on or near uneven
terrain, unstable surfaces or other hazardous
conditions with the platform raised.
Do not use the machine as a crane.
Do not push the machine or other objects with the
platform.
Do not contact adjacent structures with the
platform.
Do not tie the platform to adjacent structures.
Do not place loads outside the platform perimeter.
Work station tray is considered part of the platform.
Do not use the platform controls to free a platform
that is caught, snagged or otherwise prevented
from normal motion by an adjacent structure. All
personnel must be removed from the platform
before attempting to free the platform using the
ground controls.

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Part No. 133571 GR-12 • GR-15 • GR-20 13
Do not place or attach fixed
or overhanging loads to
any part of this machine.
Do not place ladders or
scaffolds in the platform or
against any part of this
machine
Do not transport tools and
materials unless they are
evenly distributed and can
be safely handled by the
person in the platform.
Do not use the machine on
a moving or mobile surface
or vehicle.
Be sure all tires are in good
condition, castle nuts are
properly tightened and
cotter pins are properly
installed.
Work Area Safety
Crushing Hazard
Keep hands and limbs out of mast.
Do not work under the platform or mast without the
battery cover raised.
Use common sense and planning when operating
the machine with the controller from the ground.
Maintain safe distances between the operator, the
machine and fixed objects.
Operation on Slopes Hazards
Do not drive the machine on a slope that exceeds
the slope and side slope rating of the machine.
Slope rating applies to machines in the stowed
position only.
Maximum slope rating, stowed position 30% (17°)
Maximum side slope rating,
stowed position 30% (17°)
Note: Slope rating is subject to ground conditions
and adequate traction.

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Work Area Safety
Fall Hazards
The guard rail system provides fall protection. If the
occupant of the platform is required to wear
personal fall protection equipment (PFPE) due to
job site or employer rules, PFPE and its use shall
be in accordance with the PFPE manufacturer’s
instructions and applicable governmental
requirements. Use approved lanyard attachment
point provided.
Keep the platform floor clear of debris.
Lower the platform mid-rail bar or close the entry
gate before operating.
Do not sit, stand or climb
on the platform guard rails.
Maintain a firm footing on
the platform floor at all
times.
Do not climb down from the
platform when raised.
Do not enter or exit the
platform unless the
machine is in the stowed
position.
Lower the platform mid-rail bar or close the
platform entry gate before operating.
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.

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Part No. 133571 GR-12 • GR-15 • GR-20 15
Operators must comply with employer, job site and
governmental rules regarding use of personal
protective equipment.
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.
No stunt driving or horseplay while operating a
machine.
Work Area Safety

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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/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.

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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
before operating.
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 62 pounds / 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

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1 Pothole guard
2 Non-steer tire
3 Emergency 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 Platform controls
15 Lanyard anchorage point
16 Mast
17 GFCI outlet
18 Manual storage container
19 Battery compartment cover
20 Battery cover latch
21 Steer tire
22 Platform extension release
pedal
23 Platform extension entry gate
Legend