Terex Genie GR10-20000 User manual

Operator's Manual
Serial Number Range
GR-12 from GR10-20000
from GRR-101
AUS
Australia
GR-15
GR-20
with
Maintenance
Information
First Edition
Fourth Printing
Part No. T107913

Operator's Manual First Edition • Fourth Printing
GR-12 • GR-15 • GR-20 Part No. T107913
Front Matter
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, contact us.
Contact Us:
Internet: www.genielift.com
E-mail: [email protected]
Contents
Introduction ........................................................... 1
Symbol and Hazard Pictorials Definitions............. 3
General Safety ...................................................... 5
Personal Safety..................................................... 7
Work Area Safety.................................................. 8
Legend ................................................................ 14
Controls............................................................... 15
Inspections.......................................................... 18
Operating Instructions......................................... 30
Transport and Lifting Instructions ....................... 39
Maintenance ....................................................... 43
Specifications...................................................... 45
Copyright © 2000 Terex Corporation
First Edition: Fourth Printing, May 2014
Genie is a registered trademark of Terex South Dakota, Inc. in
the U.S.A. and many other countries. “GR” is a trademark of
Terex South Dakota, Inc.
These machines comply with
AS 1418.10

First Edition • Fourth Printing Operator's Manual
Introduction
Part No. T107913 GR-12 • GR-15 • GR-20 1
Introducti on
Owners, Users and Operators:
Thank you for choosing 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.
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 First Edition • Fourth Printing
Introduction
2 GR-12 • GR-15 • GR-20 Part No. T107913
Hazard Classification
Decals on this machine use 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
message.
Intended Use
This machine is intended to be used only to lift
personnel, along with their tools and materials to
an aerial work site.
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.
DANGER
WARNING
CAUTION
NOTICE

First Edition • Fourth Printing Operator's Manual
Symbol and Hazard Pictorials Definitions
Part No. T107913 GR-12 • GR-15 • GR-20 3
Symbol and Hazard Pic torials Definiti ons
Read the operator’s
manual
Read the service
manual
Crush hazard No smoking Collision hazard
Collision hazard Tip-over hazard Tip-over hazard Use a piece of
cardboard or paper to
search for leaks
Electrocution hazard
Electrocution hazard Explosion hazard Fire hazard Burn hazard Skin injection hazard
Transport diagram Tiedown Keep away from
moving parts
Move machine to
level ground
Batteries used as
counterweights

Operator's Manual First Edition • Fourth Printing
Symbol and Hazard Pictorials Definitions
4 GR-12 • GR-15 • GR-20 Part No. T107913
Maintain required
clearance
Only trained
maintenance
personnel should
access
compartments
Chock the wheels Release brakes Grounded AC
3-wire only
Replace damaged
wires and cords
Wheel load Lanyard anchorage
point
Side force Wind speed
Voltage rating for
power to platform
Pressure rating for
air line to platform
Maximum capacity Emergency lowering

First Edition • Fourth Printing Operator's Manual
General Safety
Part No. T107913 GR-12 • GR-15 • GR-20 5
General Safety

Operator's Manual First Edition • Fourth Printing
General Safety
6 GR-12 • GR-15 • GR-20 Part No. T107913

First Edition • Fourth Printing Operator's Manual
Personal Safety
Part No. T107913 GR-12 • GR-15 • GR-20 7
Personal Safety
Personal 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.

Operator's Manual First Edition • Fourth Printing
Work Area Safety
8 GR-12 • GR-15 • GR-20 Part No. T107913
WorkArea Safety
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 powe
r
lines and apparatus in
accordance with
applicable governmental
regulations and the
following chart.
Line Voltage Required Clearance
0 to 50KV 3.05 m
50 to 200KV 4.60 m
200 to 350KV 6.10 m
350 to 500KV 7.62 m
500 to 750KV 10.67 m
750 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.
Tip-over Hazards
Occupants, equipment and materials shall not
exceed the maximum platform capacity or the
maximum platform capacity of the platform
extension. Weight in trays 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 tray station (option) 50 lbs 22 kg
Maximum occupants 1
500 lbs / 227 kg Extension only
250 lbs/113 kg
Platform only
250 lbs/113 kg
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
Work tray station (option) 50 lbs 22 kg
Maximum occupants 1
350 lbs / 159 kg Extension only
250 lbs/113 kg
Platform only
100 lbs/45 kg

First Edition • Fourth Printing Operator's Manual
Work Area Safety
Part No. T107913 GR-12 • GR-15 • GR-20 9
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 the
ground controls when the
machine is on a severe
slope.
Do not drive over 0.8 km/h with the platform raised.
When raising the platform, follow ratings for
allowable manual force and number of occupants
on the next page.
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.
The machine is rated for
indoor use only. Do not
raise the platform when
wind speeds may exceed
0 m/s
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 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.
The 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.

Operator's Manual First Edition • Fourth Printing
Work Area Safety
10 GR-12 • GR-15 • GR-20 Part No. T107913
Do not push off or pull
toward any object outside
of the platform.
Model
Maximum allowable
manual force
Maximum number
of occupants
AUS 200 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 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
person(s) 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.

First Edition • Fourth Printing Operator's Manual
Work Area Safety
Part No. T107913 GR-12 • GR-15 • GR-20 11
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.
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
occupant(s) of the platform are 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.
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 extended platform position when
moving the machine.
The machine must be on a level surface or
secured before releasing the brakes.
Operators must comply with employer, job site and
governmental rules regarding use of personal
protective equipment.
Check the work area for
overhead obstructions or
other possible hazards.
Be aware of crushing
hazards when grasping
the platform guard rail.

Operator's Manual First Edition • Fourth Printing
Work Area Safety
12 GR-12 • GR-15 • GR-20 Part No. T107913
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.
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 Genie
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 machine.
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.

First Edition • Fourth Printing Operator's Manual
Work Area Safety
Part No. T107913 GR-12 • GR-15 • GR-20 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
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.
Do not use the machine as a ground for welding.
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 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
1Select a safe parking location—firm level
surface, clear of obstruction and traffic.
2Lower the platform.
3Turn the key switch to the off position and
remove the key to secure from unauthorized
use.
4Charge the batteries.

Operator's Manual First Edition • Fourth Printing
Legend
14 GR-12 • GR-15 • GR-20 Part No. T107913
Legend
1Pothole guard
2Non-steer tire
3Emergency lowering valve
4Transport tie-down
5Forklift pockets
6Battery charger display
7Covers
8Ground controls
9Hydraulic 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 Sliding mid-rail
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

First Edition • Fourth Printing Operator's Manual
Controls
Part No. T107913 GR-12 • GR-15 • GR-20 15
Controls
Ground Control Panel
17A breaker for electrical circuits
2Red 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.
3Menu down button
4Menu enter button
5Platform up button
6Platform down button
7Lift function enable button
Press and hold this button to activate the lift
function.
8Menu escape button
9Menu up button
10 LCD diagnostic readout
11 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 ground position
and the ground controls will operate.

Operator's Manual First Edition • Fourth Printing
Controls
16 GR-12 • GR-15 • GR-20 Part No. T107913
Platform Control Panel
1Low speed lift enable button
Press and hold this button to
activate the low speed platform
function.
2Red 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.
3High speed lift enable button
Press and hold this button to
activate the high speed platform
function.
4Horn button
Press the horn button and the horn
will sound. Release the horn button
and the horn will not sound.
5Drive speed select button
Press this button to activate the
slow drive function. The indicator
light will be on when slow drive is
selected.
6Proportional control handle and function
enable switch for drive function
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 control panel 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 control
panel and the machine will move in the
direction that the yellow arrow points.
+-
=
+-
=
STOP
137636
STOP
+-
=
2
10
1
6
4
7
5
3
9
8
2
12
4
7
5
11
14
13

First Edition • Fourth Printing Operator's Manual
Controls
Part No. T107913 GR-12 • GR-15 • GR-20 17
7Thumb rocker switch for steer function
Press the left side of the thumb
rocker and the machine will turn in
the direction the blue triangle
points on the platform control
panel.
Press the right side of the thumb
rocker and the machine will turn in
the direction the yellow triangle
points on the platform control
panel.
8LED diagnostic readout / battery charge
indicator
9Platform up button
Press and hold the platform up
button and the platform will raise.
10 Platform down button
Press and hold the platform down
button and the platform will lower.
11 Lift function button
Push this button to activate the lift
function.
12 Proportional control handle and function
enable switch for drive, steer, and lift 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 control panel 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 control
panel and the machine will move in the
direction that the yellow arrow points.
13 LED diagnostic readout, battery charge
indicator and lift/drive mode indicator
14 Drive function button
Push this button to activate the
drive function.

Operator's Manual First Edition • Fourth Printing
Inspections
18 GR-12 • GR-15 • GR-20 Part No. T107913
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.