Genie AWP 114002 User's Manual
Contents
1. Genie Operators Manual with Maintenance Information Part No 114002 AWP Super Series Operator s Manual Third Edition First Printing gt ZG Z ZYZ MLmNM 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 eeeee eee aaa aaa aaa cana cana 1 GOntOlS E iv divesiect ht A dosyc 8 LOGON sist ita Sinton AA SC 9 Pre operation Inspection ee sssaeaaeaaaaanacaa 10 Maintenance sssese saa iiaia aa eni aeaa Ea 12 Function Tests eeeeee eee aaa aaa aaa aaa aaa 15 Workplace Inspection ee e eeasaaaaaaaaca 18 Operating Instructions se esessaaaaassaaaaeie 19 Battery Charging Instructions 211 211 21 Transportlnstructions se eeeeaaaa aa aaaaaaaania 22 Tilt back Operation Instructions 2 2 2 211122 25 Decals zaba a RO O WALNE et as Ak 28 Specifications 0euuooo uazie cana 32 Contact us Copyright 1996 by Genie Industries First Edition Eighth Printing Oct2. 2 Alwaysperform apre operation inspection 3 Always perform function tests prior to use 4 Inspect the workplace 5 Only use the machine as it was intended Fundamentals The Operating Instructions section provides instructions for each aspect of machine operation It is the operator s responsibility to follow all the safety rules and instructions in the operator s safety and responsibilities manuals Using the machine for anything other than lifting personnel along with their tools and materials to an aerial work site is unsafe and dangerous If more than one operator is expected to use a machine at different times in the same work shift each operator is expected to follow all safety rules and instructions in the operator s manual That Setup 1 Position the machine on a firm surface directly below the desired work area Connectto the appropriate power source DC models Connect the battery pack AC models Connect to a grounded 15A AC power supply Use a 12 gauge 3 3mm 3 wire grounded extension cord no longerthan 50 feet 13 m Air models Connect the air line Insert the key and turn to platform control Pull out the red Emergency Stop button at the ground controls and twist to release the red Emergency Stop at the platform controls Be sure the power light is on or the air pressure gauge reads 80 110 psi 5 5 7 8 bar Install the outriggers and adjust to level the machine and raise the base ca
3. Avoid hazardous situations 2 Always perform a pre operation inspection 3 Always perform funciion tests prior to use 4 Inspectthe workplace Know and understand the work place inspection before going on to the next section 5 Only use the machine as it was intended Fundamentals The workplace inspection helps the operator determine if the workplace is suitable for safe machine operation It should be performed by the operator prior to moving the machine to the workplace It is the operator s responsibility to read and remember the workplace hazards then watch for and avoid them while moving setting up and operating the machine A TEREX CON 18 Genie AWP Super Series Workplace Inspection Be aware of and avoid the following hazardous situations drop offs or holes bumps floor obstructions or debris slopes that exceed the machine s leveling capability unstable or slippery surfaces overhead obstructions and high voltage conductors hazardous locations inadequate surface support to withstand all load forces imposed by the machine wind and weather conditions the presence of unauthorized personnel other possible unsafe conditions Part No 114002 Third Edition First Printing Operators Manual Operating Instructions Do Not Operate Unless M You learn and practice the principles of safe machine operation contained in this operator s manual 1 Avoid hazardous situations
4. IE N j 2 mig i ha gt i p SZT M M jk SLL U 97523 82915 97523 97523 82915 97523 A TEREX COMPANY Part No 114002 Genie AWP Super Series 31 Operator s Manual Third Edition First Printing Specifications Machine Specifications Height working maximum AWP 20S AWP 25S AWP 30S AWP 36S AWP 40S 26 ft 1 in 8 0m 30 ft 9 in 9 4 m 35 ft 6 in 10 8 m 42 ft5in 12 9m 46 ft 3 in 4 1 m Height platform maximum AWP 20S AWP 25S AWP 30S AWP 36S AWP 40S 20 ft 1 in 6 1m 24 ft 9 in 7 6m 29 ft6in 9 0m 36 ft6in 11 1 m 40 ft 3 in 12 3 m Height stowed AWP 208S 25S 30S AWP 368 40S 78 in 2 0m 1091 2 in 2 8m Width Standard base Narrow base Rough terrain base 29 in 73 6 m 22 in 55 8 cm 291 2 in 75cm Length AWP 20S 25S 30S Standard base 46 in 1 2 m Narrow base 291 2 in 75 cm Rough terrain base 58 in 1 5m Length AWP 36S 40S Standard base 55 in 1 4m Weight See Serial Label Lift capacity AWP 208 25S 305 36S 350 Ibs 159 kg AWP 40S 300 Ibs 136 kg Power source DC model 12V AC model 110V or 220V Air motor 100 psi 6 9 bar 80 cfm 37760 cc sec 20 F to 135 F 29 C to 57 C Airborne noise emissions 80 dB Maximum sound level at normal operating workstations A weighted Platform dimensions length x width x height 27 x 26 x 443 4 in 69 cm x 66 cm x 1 1 m 22 x 18 x 443 4 in 56 cm x 46 cm x 1 1 m 26 x 20
5. Manual DECALS Inspection for Decals with Symbols Determine whether the decals on your machine have words or symbols Use the appropriate inspection to verify that all decals are legible and in Third Edition First Printing P gt gt gt M CE 000 place Part No Description Quantity Part No Description Quantity 28174 Label Power to Platform 230V 2 82973 Warning Insert Pin 1 28235 Label Power to Platform 115V 2 82974 Warning Collision Hazard 1 52996 Cosmetic Genie Logo 1 82976 Danger Wind Speed 51 cm Outrigger 4 52999 Cosmetic AWP 20S 2 82977 Danger Wind Speed 66 cm Outrigger 4 62992 Cosmetic AWP 25S 2 82978 Danger Wind Speed 77 cm Outrigger 4 62993 Cosmetic AWP 30S 2 82979 Danger Wind Speed 91 cm Outrigger 4 62994 Cosmetic AWP 36S 2 82980 Danger Wind Speed 1 02 m Outrigger 4 62995 Cosmetic AWP 40S 2 82981 Danger Wind Speed 1 17 m Outrigger 4 82481 Danger Battery Charger Safety 1 82982 Danger Wind Speed 1 52 m Outrigger 4 82487 Label Read the Manual 1 82983 Danger Wind Speed 1 91 m Outrigger 4 82614 Caution Collision Hazard 1 82984 Danger Wind Speed 2 16 m Outrigger 4 82780 Label Interlock Display 1 82987 Danger Electrocution Hazard 1 82781 Label Interlock Display 1 82988 Label Read the Manual Tilt back Frame 1 82802 Label Function Enable 1 97522 L
6. charger to a grounded AC circuit only Do not expose the battery or charger to water or rain Before each use inspect fordamage Replace damaged components before operating The battery pack weighs 90 Ibs 40 8 kg Use the appropriate number of people and proper lifting techniques when lifting the battery pack Genie AWP Super Series Part No 114002 Third Edition First Printing Operators Manual E 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 AWARNING Orange used to indicate the presence of a potentially A hazardous situation which if not avoided could result in death or serious injury Yellow with safety alert symbol ACAUTION used to indicate the presence of a A potentially hazardous situation which if not avoided may cause minor or moderate injury Yellow without safety alert CAUTION 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 A TEREX COMPANY Part
7. cm 33 15 2 cm 47 18 4 cm Corner access wall access 21 121 4 in 191 2 93 4 in 22 9 in CE AUS Indoor 53 3 31 1 cm 49 5 24 7cm 55 8 22 8 cm Corner access wall access 76 2 44 4 cm 98 4 53 3 cm 1 3 m 67 3 cm Corner of platform top rail to corner of wall with ability to rotate leveling jack Continuous improvement of our products is a Genie policy Product specifications are subject to change without notice or obligation Part No 114002 A TEREX COMPANY Genie AWP Super Series 33 Genie North America Phone 425 881 1800 Toll Free USA and Canada 800 536 1800 Fax 425 883 3475 Genie Australia Pty Ltd Phone 61 7 3375 1660 Fax 617 3375 1002 Genie Scandinavia Phone 46 31575100 Fax 446 31579020 Genie China Phone 86 21 53852570 Fax 86 21 53852569 Genie France Phone 33 0 2 37 26 09 99 Fax 33 0 2 37 26 09 98 Genie Malaysia Phone 65 98 480 775 Fax 65 67 533 544 Genie Iberica Phone 34 93 579 5042 Fax 34 93579 5059 Genie Germany Phone 49 0 4202 88520 Fax 49 0 4202 8852 20 Genie J apan Phone 81 3 3453 6082 Fax 81 3 3453 6083 Genie Korea Phone 82 25 587 267 Fax 82 25 583 910 Genie U K Phone 44 0 1476 584333 Fax 44 0 1476 584334 Genie Brasil Phone 455 11 41 665 755 Fax 55 11 41 665 754 Genie Mexico City Phone 52 55 5666 5242 Fax 52 55 5666 3241 Genie Holland Phone 31 183 581 102 Fax 31 183 581 56
8. in place See Decals section U Check for battery fluid leaks and proper fluid level Add distilled water if needed See Maintenance section PRE OPERATION INSPECTION Sequencing cables and pulleys Lifting chains and idler wheels Nuts bolts and other fasteners Mast columns and counterweight Breather cap Outriggers leveling jacks and footpads LCL LL LI Adjustable glide pads M AC 8 DC models Check for hydraulic oil leaks Check entire machine for and proper oil level Add oil if needed See Maintenance section i RT base models Check for proper tire pressure Add air to tires if needed See Maintenance section 0 T Air models Check the oil level of the airline lubricator See Maintenance section m Air models Check the oil lubricator canister drip rate Adjust as needed See Maintenance section Ii Air models Check the air filter regulator canister Drain water as needed See Maintenance section Check the following components or areas for damage improperly installed or missing parts and unauthorized modifications M Electrical components wiring and electrical cables M AC amp DC models Hydraulic power unit hoses fittings and cylinder Ly Air models Air power unit air lines fittings and cylinder Ly Platform entry mid rail or gate A TEREX COMPANY U Dents ordamage W Corrosion or oxidation U Cracks in welds or structural components Inspect and clean battery
9. terminals and all battery cable connections Be sure that all structural and other critical components are present and all associated fasteners and pins are in place and properly tightened Part No 114002 Genie AWP Super Series 11 Operator s Manual Third Edition First Printing Maintenance Observe and Obey MI Only routine maintenance items specified in this manual shall be performed by the operator MI Scheduled maintenance inspections shall be completed by qualified service technicians according to the manufacturer s specifications and the requirements specified in the responsibilities manual 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 amaintenance 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 A TEREX COMI 12 Genie AWP Super Series Check the Battery DC Models Proper battery condition is essential to good machine performance and safe operation Improper fluid levels or damaged cables and connections can result in component damage and hazardous conditions Electrocution hazard Contact with AWARNING hot or live circuits could result in death or serious injury Remove all rings watches and other jewelry B
10. the platform is raised R Voltage Approach Distance Phase to Phase Feet Meters 0 to 300V Avoid Contact 300V to 50KV 10 3 05 Do not place ladders or scaffolds in the platform or 50KV to 200KV 15 4 60 against any part of this machine 200KV to S50KV 20 6 10 Do not place or attach overhanging loads to any 350KV to 500KV 25 7 62 part of this machine 500KV to 750KV 35 10 67 Do not transport tools and materials unless they are 750KV to 1000KV 45 13 72 evenly distributed and can be safely handled by the person in the platform Genie 2 Genie AWP Super Series A TEREX COMI Part No 114002 Third Edition First Printing Operators Manual Do not raise the platform unless the machine is level Do not set the machine up on a surface where it cannot be leveled using only the leveling jacks Do not cause a horizontal force or side load to the machine by raising or lowering a fixed or overhanging load Do not push off or pull toward any object outside the platform Maximum allowable side force ANSI CSA 50 Ibs 222 N Maximum allowable I manual force CE AUS 45 Ibs 200 N Do not operate the machine near drop offs holes bumps debris unstable or slippery surfaces or other possible hazardous conditions Do not alter or disable machine components that in any way affect safety and stability Do not replace items critical to stability with items of different weight or specification Use only Genie aut
11. x 443 4 in 66cmx51cmx1 1m 29 x 261 2 x 431 2 in 74cmx67cmx1 1m 26 x 22 x 431 2 in 66 cm x 56 cm x 1 1 m 20 x 26 x 443 4 in 51cm x 66cm x 1 1m Ambient operating temperature Standard platform gated or sliding mid rail Gated ultra narrow platform Gated narrow platform Standard fiberglass platform Narrow fiberglass platform Front entry gated narrow platform Wheel load maximum 509 Ibs 231 kg Outrigger load maximum 400 Ibs 181 kg Outrigger Specifications Extra large front and side entry platform 30 x 28 x 443 4 in 76cm x 71cmx 1 1m Standard Base AWP 20S AWP 25S AWP 30S Outrigger footprint 603 4 x 523 4 in 603 4 x 523 4 in 691 4 x 611 4 in x w ANSI CSA 1 5 x1 3m 1 5 x1 3m 1 8x1 6m Outrigger footprint 603 4 x 523 4 in 691 4 x 611 4 in 751 2 x 671 2 in x w CE AUS Indoor 1 5 x1 3m 1 8x1 6m 1 9x1 7m Outrigger footprint 831 4 x 751 4 in 89 x 81 in 1171 4 x 1091 2 in I x w CE AUS Outdoor 2 1 x1 9m 2 3x2 1m 3 0 x 2 8 m Corner access wall access 141 2 51 2 in 14 3in 181 2 43 4 in ANSI CSA 36 9 7 4 cm 35 1 7 4 cm 46 6 11 9 cm Corner access wall access 141 2 51 2 in 191 4 71 4 in 221 4 8 in CE AUS Indoor 36 9 7 4 cm 48 6 18 2 cm 56 5 20 3 cm Corner access wall access 30 163 4 in 321 2 17 in 503 4 283 4 in CE AUS Outdoor 76 42 4 cm 82 5 43 4 cm 1 3 m 73 cm Corner of platform top rail to corn
12. 114009 Notice Max Manual Force 45 Ibs 200N AUS 1 37144 Notice Max Capacity 300 Ibs 159 kg AWP 40S 1 114011 Danger General Safety 1 Genie 28 Genie AWP Super Series A TEREX COMPANY Part No 114002 Third Edition First Printing Operators Manual DECALS 31071 27857 28174 82780 31245 _ 82366 Note Platform or 28235 or gt 82986 28372 decals may be 38122 37141 or in diffferent 82802 or 41268 locations on optional 37144 fiberglass or 37143 basket 11400 or 114009 27867 non De PA 37142 il 27865 L T 28174 EH 52999 or 28235 s or 62992 52996 or 62993 ae Ba or 62994 or 62995 97523 97522 27839 27863 97523 97522 Models with Tilt back Frame Models without Tilt back Frame 72086 27873 72086 38142 _ 82907 38142 i ons erasa 27874 lk 31070 ua o7g43 31070 s _ 27868 27844 27868 27872 27840 27864 27872 27864 27841 Serial Serial Label has Label 27842 27842 ui J T f at li g L JL A 97523 37145 27863 97523 97523 37145 27863 97523 Genie PartNo 114002 A TEREX COMPANY Genie AWP Super Series 29 Operator s
13. 6
14. No 114002 Genie AWP Super Series 7 Operators Manual Third Edition First Printing Controls Ground Controls Ground Controls AC and DC Models Air Models Interlock Display Platform Controls 1 Red Emergency Stop button 2 Key switch 3 Outrigger interlock display lights four 4 Low battery indicator light for auxiliary lowering 5 DC models Low battery indicator light 6 Powerlight 7 Auxiliary platform lowering button 8 Airpressure gauge 9 Control activate button 10 Up Down switch A TEREX COMPANY 8 Genie AWP Super Series Part No 114002 Third Edition First Printing Operators Manual Legend 1 Lifting eye 9 Loading pivot bar 25 Outrigger with 2 AC models Circuit 10 Forklift pocket leveling jack breaker 11 Airline lubricator 18 Base 26 Outrigger lock pin 3 Outrigger storage adjustmentknob 19 Sliding T handle 27 Platform socket 12 Air supply for 20 AC outlet 28 Platform entry mid 4 Tilt back frame machine 21 Platform controls rail or gate retaining pin in strut 13 Airline lubricator 22 Operator s manual 29 AC models Power socket 14 DC models Battery storage container supply for ma
15. Super Series 25 Operators Manual Third Edition First Printing TILTBACK OPERATION INSTRUCTIONS Lowering the Tilt back Tilting Back the Machine Assembly 1 Slide out the T 1 Be sure the area behind the machine and under handle until the lock the tilt back frame is clear of personnel and pin snaps into obstructions place 2 Fully lower the platform 2 Lift the machine with the T handle to 3 Remove the outriggers from the base and place mid tilt position them in the storage sockets casters on the tilt back frame are in contact with the floor and the machine is supported by the extended tilt back strut Use the appropriate number of people and proper lifting techniques The tilt back frame is spring loaded and will immediately fall outward when the retaining pin is removed Maintain a firm grasp on the tilt back frame and remove the retaining pin 3 Continue lifting until the telescoping tilt back strut is completely compressed 4 Lower the tilt back frame and guide the tilt back strut into the strut socket 4 Return the sliding T handle to the stowed position 5 Insert the retaining pin into the strut socket A TEREX COMPANY 26 Genie AWP Super Series Part No 114002 Third Edition First Printing Operators Manual TILTBACK OPERATION INSTRUCTIONS Returning the Machine to Stowing the Tilt back Assembly Standing Position 1 Remove the retaining pin 1 Be sure the are
16. a below the machine base and T handle is clear of personnel and obstructions 2 Slide out the T handle untl the lock pin snaps into place 3 Carefully pull down the T handle until the machine rests at mid tilt position 2 Firmly grasp the tilt back frame and remove the tilt back strut from the strut socket 3 Lift the tilt back frame hold in an upright position against the spring and secure with the retaining pin 4 Lower the machine with the T handle until the base casters are in contact with the ground Use the appropriate number of people and proper lifting techniques 5 Return the sliding T handle to the stowed position A TEREX COMPANY Part No 114002 Genie AWP Super Series 27 Operator s Manual Third Edition First Printing Decals Inspection for Decals with Words Determine whether the decals on your machine have words or symbols Use the appropriate inspection to verify that all decals are legible and in place Part No Description Quantity Part No Description Quantity 27838 Warning Tilt back Hazards Instructions 1 37145 Label Manual Lowering Valve 1 27839 Label Sliding T handle 1 38122 Label Manual Storage Container 1 27840 Label Retaining Pin 1 38142 Label Circuit Breaker AC models 1 27841 Label Stop B
17. abel Wheel Load 4 82913 Danger Max Capacity 159 kg 97523 Label Outrigger Load 4 AMISEOS ene SAD 208 1 97815 Label Lower Mid rail 1 82914 Danger Max Capacity 136 kg 114010 Danger Maximum Side Force 222N AWP 40S 1 ANSI 1 82915 Label Manual Lowering Valve 1 82916 Danger Maximum Manual Force 200N CE 1 30 Genie AWP Super Series Part No 114002 Third Edition First Printing Operators Manual DECALS 28174 82780 82974 82987 Note Platform decals or 28235 or 82781 may be in diffferent locations on optional fiberglass basket 82802 82913 or 82914 82913 97815 or 114010 ma 52999 3 20336 or 62992 or 62993 or 62994 52996 or 62995 97523 97522 97522 82976 or 82977 or82978 or 82979 or 82980 or 82981 or 82982 or 82983 or 82984 97523 Models with Tilt back Frame Models without Tilt back Frame AH iT Z a 82481 5 82481 WERE Serial II Label Serial Label z
18. chine 5 Tilt back strut pack with charger 23 Manual lowering DC models Power 6 Swivel lock 15 Hydraulic power unit valve under to platform 7 Tilt back frame 16 Winching tie down machine 30 Ground controls 8 Loading stop point 24 Base outrigger 31 Mast bracket 17 Bubble level socket A TEREX COMPANY Part No 114002 Genie AWP Super Series 9 Operator s Manual Third Edition First Printing Pre operation Inspection Do Not Operate Unless M 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 the function tests prior to use 4 Inspect the workplace 5 Only use the machine as it was intended Breather Cap AC amp DC Models Component damage will occur if the machine is operated without a breather cap Check to make sure the breather cap is in place in the hydraulic reservoir AWP 36 amp AWP 40 The first time these machines are set up for use the pipe plug in the hydraulic reservoir should be removed and permanently replaced with abreather Ill cap A breather cap is supplied and can be found in an envelope taped to the mast near the platform controls A TEREX CON 10 Genie AWP Super Series MPANY Fundamentals It is the responsibili
19. e rigging to prevent damage to the chains oo A TEREX CO 24 Genie AWP Super Series Winching the Machine onto a Flatbed Truck 1 Fully lower the platform 2 Push inthe red Emergency Stop buttons turn the key switch to the off position and remove the key 3 Remove the outriggers from the base and place them in the storage sockets 4 Inspect the entire machine for loose or unsecured items 5 Connect the cable to the winching point located at the rear of the base 6 Carefully winch the machine onto the truck 7 Secure the machine base to the transport vehicle See Securing the Machine Loading the Machine With a Crane Use the lifting eye mounted on the rear mast column The battery pack must be removed before lifting the machine with a crane Disconnect the battery plug before removing the battery pack Be sure to inspect the machine and remove any loose or unsecured items Always place the lifting hook through the lifting eye so that it points away from the machine Part No 114002 Third Edition First Printing Operators Manual Tilt back Operation Instr
20. er of wall with ability to rotate leveling jack 32 A TEREX COMI Genie AWP Super Series Part No 114002 Third Edition First Printing Operators Manual Outrigger Specifications SPECIFICATIONS Standard Base AWP 36S AWP 40S Outrigger footprint 831 4 x 751 4 in 89 x 81 in x w ANSI CSA 2 1x1 9m 2 3 xX 2 0m Outrigger footprint 831 4 x 751 4 in 89 x 81 in I x w CE AUS Indoor 2 1x1 9m 2 3x2 0m Outrigger footprint 139 x 131 in 153 x 145 in x w CE AUS Outdoor 3 5x3 3 m 3 9x 3 7 m Corner access wall access 281 2 141 4 in 311 4 141 2 in ANSI CSA 72 7 36 2 cm 79 4 37 1 cm Corner access wall access 281 2 141 4 in 311 4 141 2 in CE AUS Indoor 72 7 36 2 cm 79 4 37 1 cm Corner access wall access 52 311 4 in 503 4 283 4 in CE AUS Outdoor 1 3 m 79 3 cm 1 3 m 73 cm Corner of platform top rail to corner of wall with ability to rotate leveling jack Outrigger Specifications Narrow Base Rough Terrain Base AWP 20S AWP 25S AWP 30S Outrigger footprint 64 x 481 4 in 64 x 481 4 in 711 2 x 58 in x w ANSI CSA 1 6x1 2m 1 6x1 2m 1 8x1 5m Outrigger footprint 711 4 x 58 in 711 4 x 58 in 741 2 x 651 2 in x w CE AUS Indoor 1 8x 1 5m 1 8x 1 5m 1 9x 1 6m Outrigger footprint 831 4 x 74 in 951 4 x 893 4 in 112 x 112 in I x w CE AUS Outdoor 2 1x1 9m 2 4x2 2m 2 8 x 2 8m Corner access wall access 141 4 81 2 in 13 6in 181 2 71 4 in ANSI ANSI 36 2 21 6
21. ew one leveling jack until the corresponding interlock display light turns off Result The up down function should not operate 17 Return the leveling jack to the previous setting and check the bubble level 18 Repeat this procedure for each outrigger Test Auxiliary Platform Lowering AC amp DC Models 19 Raise the platform slightly 20 Disconnect the power source from the machine 21 Turn the key switch to ground control 22 Push in the auxiliary platform lowering button at the ground controls Result The platform should lower Part No 114002 A TEREX CON Genie AWP Super Series 17 MPANY FUNCTION TESTS 23 Connect the power source to the machine 24 Turn the key switch to platform control 25 Raise the platform slightly 26 Disconnect the power source from the machine 27 Push in the control activate button and rotate the up down switch in the down direction Result The platform should lower 28 Connect the power source to the machine Test Manual Lowering 29 Raise the platform slightly 30 Activate the manual lowering valve located at the bottom of the hydraulic cylinder Result The platform should lower Operator s Manual Third Edition First Printing Workplace Inspection Do Not Operate Unless You learn and practice the principles of safe machine operation contained in this operator s manual 1
22. hine as it was intended COMPANY Part No 114002 Genie AWP Super Series Function Tests 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 manufacturers specifications After repairs are completed the operator must perform a pre operation inspection and function tests before putting the machine into service 15 Operator s Manual Third Edition First Printing FUNCTION TESTS Function Tests Setup 1 Position the machine on a firm surface directly below the desired work area Connectto the appropriate power source DC models Connect the battery pack AC models Connect to a grounded 15A AC power supply Use a 12 gauge 3 3mm 3 wire grounded extension cord no longer than 50 feet 13 m Air models Connect the air line Insert the key and turn to platform control Pull out the red Emergency Stop button to the on position at the ground controls Twist to release the red Emergency Stop butto at the platform controls Result AC amp DC models The power light shou come on Repeat this procedure for each ofthe remaining ou
23. horized replacement parts Do not push the Genie AWP from the platform side Part No 114002 A TEREX CON Genie AWP Super Series 3 MPANY SAFETY RULES of the machine When moving the machine with a forklift or other transport vehicle the platform should be fully lowered the machine should be turned off and no personnel shall remain in the platform Do not use the machine on a moving or mobile surface or vehicle Do not raise the platform when wind speeds may exceed 28 mph 12 5 m s If wind speeds exceed 28 mph 12 5 m s when 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 Occupants equipment and materials shall not exceed the maximum platform capacity Maximum capacity AWP 20S 350 Ibs 159 kg AWP 25S 350 Ibs 159 kg AWP 30S 350 Ibs 159 kg AWP 36S 350 Ibs 159 kg AWP 40S 300 Ibs 136 kg Maximum occupancy 1 person Operator s Manual Third Edition First Printing SAFETY RULES 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 gove
24. machine is set up for use a breather cap is installed See Pre operation Inspection section A TEREX COMPANY Part No 114002 Genie AWP Super Series 1 Operator s Manual Third Edition First Printing SAFETY RULES Electrocution Hazards This machine even with an optional fiberglass platform is not electrically insulated and will not provide protection from contact with or proximity to electrical current Le Keep away from the machine if it contacts energized power lines or becomes electrically charged Personnel on the ground or in the platform must not touch or operate the machine until energized power lines are shut off Maintain safe distances from electrical power lines and apparatus in accordance with applicable governmental regulations and the following chart Minimum Safe Allow for platform movement electrical line sway or sag and movement due to strong or gusty winds Do not use the machine as a ground for welding Do not operate an AC powered machine or a DC battery charger unless using a 3 wire grounded extension cord connected to a grounded AC circuit Do not alter or disable 3 wire grounded plugs Tip over Hazards Do not raise the platform unless the base is level all four outriggers are properly installed and the leveling jacks firmly contact the floor Do not adjust or remove the outriggers while the platform is occupied or raised Do not move the machine while
25. may be present Part No 114002 A TEREX CON Genie AWP Super Series MPANY SAFETY RULES Damaged Machine Hazards Do not use a damaged or malfunctioning machine Be sure all maintenance has been performed as specified in this manual and the Genie AWP Super Series 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 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 Do not use the machine as a ground for welding Operator s Manual Third Edition First Printing SAFETY RULES Battery and Charger Safety DC Models Burn Hazards Batteries contain acid Always wear protective clothing and eye wear when working with batteries ip Avoid spilling or contacting battery acid Neutralize battery acid spills with baking soda and water The battery pack must remain in an upright position Explosion Hazards a Batteries emit explosive gas Keep sparks flames and lighted tobacco away from the battery Charge the battery in a well ventilated area Do not disconnect charger DC output wires from the battery when the charger is on A TEREX COMI Electrocution Hazards w Lifting Hazard Connect the
26. n 2 Activate the auxiliary platform lowering button at the ground controls 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 After Each Use 1 Select a safe storage location firm level surface weather protected clear of obstruction and traffic 2 Chock the wheels to prevent the machine from rolling 3 Remove the key to secure from unauthorized use 4 DC models Recharge the battery Part No 114002 Third Edition First Printing Operators Manual Battery Charging Instructions To Charge Battery 1 Open the battery pack lid to access the battery 2 Remove the battery vent caps and check the battery acid level If necessary add only enough distilled water to cover the plates Do not overfill prior to the charge cycle Battery and Charger Instructions 3 Replace the battery vent caps 2 2 4 Be sure that the DC output cord is properly Observe and Obey connected to the battery Black to negative red to positive MI Do notuse an external charger or booster 5 Connectthe battery charger to agrounded AC battery circuit MI Charge the battery in a well ventilated area 6 The charger will turn off automatically when the MI Use p
27. nent damage 1 Be sure the platform is fully lowered 2 Inspect the lubricator canister for the proper oil level Result The oil level must be within 1 2 inch 12 7 mm from the top of the lubricator canister 3 To add oil remove the oil lubricator canister from the lubricator base and fill with oil Install the canister back onto the lubricator base Oil Specifications Oil Type 10W automotive engine oil Check the Tire Pressure RT Base Models It is essential to maintain proper pressure in all air filled tires Improperly inflated tires can affect machine handling 1 Check each tire with an air pressure gauge Add air as needed The proper air pressure is stamped on the tire Genie Part No 114002 A TEREX COMI Genie AWP Super Series 13 Operator s Manual Third Edition First Printing MAINTENANCE Check the Oil Lubricator Canister Drip Rate Air Models Maintaining the proper oil drip rate into the lubricator canister is essential to safe operation and good machine performance Failure to maintain the proper drip rate could result in machine component damage 1 While raising the platform visually inspect the oil lubricator sight gauge Result There should be a maximum of 1 to 2 drops of oil visible in the sight gauge 2 To adjust the drip rate turn the oil flow control valve clockwise to decrease the flow or counterclockwise to increase the flow 3 Repeat this procedure
28. ober 2001 Internet http www genielift com e mail techpub genieind com Second Edition Second Printing April 2004 Third Edition First Printing August 2005 Genie and AWP are registered trademarks of Genie Industries in the U S A and many other countries Super Series is a trademark of Genie Industries This machine complies with ANSI SIA 92 3 1990 Printed on recycled paper Printed in U S A Genie A TEREX COMPANY 2 Genie AWP Super Series Part No 114002 Third Edition First Printing Operators Manual Safety Rules Danger Failure to obey the instructions and safety rules in this manual will cause death or serious injury Do Not Operate Unless M 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 M You read understand and obey the manufacturer s instructions and safety rules safety and operator s manuals and machine decals M You read understand and obey employer s safety rules and worksite regulations M You read understand and obey all applicable governmentalregulations M You are properly trained to safely operate the machine MI The first time this
29. odily injury hazard Batteries AWARNING contain acid Avoid spilling or contacting battery acid Neutralize battery acid spills with baking soda and water Perform this test after fully charging the battery 1 Puton protective clothing and eye wear 2 Remove the battery vent caps 3 Check the battery acid level If needed replenish with distilled water to the bottom of the battery fill tube Do not overfill 4 Install the vent caps Part No 114002 Third Edition First Printing Operator s Manual Check the Hydraulic Oil Level Maintaining the hydraulic oil at the proper level is essential to 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 1 Be sure the platform is fully lowered 2 Check the sight gauge on the side of the hydraulic reservoir Result The hydraulic oil level should be visible in the middle of the sight gauge Do not overfill Hydraulic oil specifications Hydraulic oil type Chevron Rykon Premium MV equivalent MAINTENANCE Check the Air Line Lubricator Oil Level Air Models Maintaining the proper oil level in the lubricator canister is essential to safe operation and good machine performance Failure to keep the lubricator canister at the proper oil level could result in unsafe operating conditions and possible compo
30. onnect the battery cable and remove the battery pack 5 Inspect the entire machine for loose or unsecured items 6 Slide the stop bracket to the top lock position a stop bracket b loading pivot All models without tilt back frame a stop bracket b loading pivot All models with tilt back frame 7 Hook the loading pivot to the stop bracket Part No 114002 A TEREX CON Genie AWP Super Series 23 TRANSPORT INSTRUCTIONS 8 Position the machine flush against the loading surface Lower and lock the stop bracket to the lowest lock pin position above the loading surface 9 All models with tilt back frame Be sure both stop bracket lock pins are fully locked Be sure both tilt back frame swivel casters are locked 10 Slide out the T handle until the lock pin snaps into place 11 Lift the T handle to tilt the machine onto the loading surface Use the appropriate number of people and proper lifting techniques 12 Carefully push the machine into the transport position 13 Return the sliding T handle to the stowed position 14 Secure the machine base and mast to the transport vehicle See Securing the Machine on the next page 15 Reverse this procedure to unload the machine Operators Manual Third Edition First Printing TRANSPORT INSTRUCTIONS Securing the Machine Use chains or straps of ample load capacity Use a minimum of 2 chains Adjust th
31. ort vehicle unless it is parked on a level surface MI The transport vehicle must be secured to prevent rolling while the machine is being loaded M The machine must be securely fastened to the transport vehicle Use chains or straps of ample load capacity M Be sure to lock both swivel casters on the tilt back frame MI Do not transport with the machine resting on the tilt back frame A TEREX COMI 22 Genie AWP Super Series Lifting Instructions The number of people required to load and unloada machine is dependent on a number of factors including but not limited to the physical condition strength and disabilities or prior injuries of the people involved the vertical and horizontal distances the machine has to be moved the number of times the machine will be loaded or unloaded the stance posture and grip used by the people involved the lifting techniques used the site conditions and weather in which the activity is being performed i e slippery icy raining The appropriate number of people and proper lifting techniques must be used to prevent physical injury Part No 114002 Third Edition First Printing Operators Manual Loading for Transport 1 Fully lower the platform 2 Push in the red Emergency Stop buttons turn the key switch to the off position and remove the key 3 Removethe outriggers from the base and place them in the storage sockets 4 DC models Disc
32. racket 1 41266 Label Interlock Display Air Models 27842 Label Loading Pivot 1 Stee Beer EK 41268 Label Interlock Display Air Models ates tabel Tiltiback Strut i Narrow Base and Rough Terrain Base 1 2383 ADO Soe 1 52996 Cosmetic Genie Logo 1 e A 52999 Cosmetic AWP 20S 2 27863 Warning Collision Hazard 3 62992 _ Cosmetic AWP 25S 2 27864 Notice Lower Stop Bracket Before 1 62993 Cosmetic AWP 30S 2 27865 Label Bubble Level 1 62994 Cosmetic AWP 36S 2 27867 Label Swivel Lock 1 62995 Cosmetic AWP 40S 2 27868 Danger Relief Valve 1 72086 Label Lifting Eye 1 27872 Danger Tip over Hazard Outriggers 1 82366 Label Chevron Rykon 1 27873 Notice Maintain Firm Grasp 1 82780 Label Interlock Display 1 27874 Label Insert Retaining Pin 1 82781 Label Interlock Display 1 28174 Label Power to Platform 230V 2 82802 Label F nction Enable 1 28235 Label Power to Platform 115V 2 82907 Danger Battery Charger Safety 1 28372 Caution Quick Disconnect 1 82975 Danger Collision Hazard 1 31070 Danger Tip over Hazard Moving 1 f 82986 Danger Electrocution Hazard 1 31071 Warning Failure to Read 1 97522 Label Wheel Load 4 31245 Warning Collision Hazard 1 752 Label i L 37141 Notice Manual Lowering Instructions 1 R ebel Cumlgger ORA i 5 i 114008 Notice Max Side Force 50 Ibs 222 N 37142 Notice Operating Instructions 1 ANSI CSA 1 37143 Notice Max Capacity 350 Ibs 136 kg AWP 208 25S 30S 36S 1
33. rnmental requirements Do not sit stand or climb onthe platform guard rails Maintain a firm footing on the platform x floor at all times Do not exit the platform while raised If a power failure occurs have ground personnel activate the manuallowering valve Keep the platform floor clear of debris Lower the platform entry mid rail or gate before operating A TEREX CON 4 Genie AWP Super Series Collision Hazards Operators must comply with employer job site and governmental rules regarding the use of personal protective equipment Check the work area for overhead obstructions or other possible hazards Be aware of crushing hazard when grasping the platform guardrail Do not lower the platform unless the area below is clear of personnel and obstructions Use common sense and planning to control the movement of the machine on or near inclines Stay clear of descending platform MPANY Part No 114002 Third Edition First Printing Operators Manual Improper Use Hazard Do not leave the machine unattended unless the key is removed to secure from unauthorized use 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 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
34. roper AC input voltage for charging as parten is Iu changed indicated on the charger 7 Check the battery acid level when the charge cycle is complete Replenish with distilled water MI Use only Genie authorized battery and charger to the bottom of the fill tube Do not overfill Dry Battery Filling and Charging Instructions 1 Remove the battery vent caps and permanently remove the plastic seal from the battery vent openings 2 Fill each cell with battery acid electrolyte until the level is sufficient to cover the plates Do not fill to maximum level until the battery charge cycle is complete Overfilling can cause the battery acid to overflow during charging Neutralize battery acid spills with baking soda and water 3 Install the battery vent caps 4 Charge the battery 5 Check the battery acid level when the charging cycle is complete Replenish with distilled water to the bottom of the fill tube Do not overfill A TEREX COMPANY Part No 114002 Genie AWP Super Series 21 Operator s Manual Third Edition First Printing Transport Instructions Transport Instructions Observe and Obey MI Be sure the transport vehicle capacity and loading surfaces are sufficient to support the machine weight See the serial label for the machine weight Some pick up truck tailgates are not strong enough to support the weight of the machine and may require reinforcement MI Do not load the machine onto a transp
35. sters slightly off the ground Be sure all four interlock display lights at the ground controls are on and all four outriggers are in firm contact with the ground Use the bubble level to make sure the machine is level Note If adjustment is necessary check the bubble level and interlock display again to make sure the machine is level and all four interlock display lights means every new operator should perform a pre are on operation inspection function tests and a work place inspection before using the machine Genie PartNo 114002 A TEREX CON Genie AWP Super Series 19 Operator s Manual Third Edition First Printing OPERATINGINSTRUCTIONS Emergency Stop Push in the red Emergency Stop button at the platform controls or at the ground controls to stop the up function Platform Raise and Lower 1 Pull out the red Emergency Stop button to the on position at the ground controls Twist to release the red Emergency Stop button at the platform controls 2 Push in the control activate button and rotate the up down switch in the desired direction of travel Manual Lowering 1 Activate the manual lowering valve located at the bottom of the hydraulic cylinder 20 Genie AWP Super Series Auxiliary Platform Lowering AC 8 DC Models 1 Turn the key switch to ground control Pull out the red Emergency Stop button to the on positio
36. triggers Use the bubble level and adjust the leveling jacks until the machine base is level Test Emergency Stop 10 Push in the red Emergency Stop button at the ground controls to the off position 11 Push in the control activate button and rotate the up down switch in the direction of intended n travel Result The up down function should not Id operate Air models The air pressure gauge should read 80 110 psi 5 5 7 8 bar Select an outrigger and slide it into a base socket until the outrigger lock pin snaps into place Adjust the outrigger to level the machine and raise the base casters slightly off the ground Level the machine using only the outriggers Check the interlock display lights at the ground controls Confirm that the corresponding light is on Genie AWP Super Series A TEREX COMPANY Part No 114002 Third Edition First Printing Operator s Manual 12 Push in the red Emergency Stop button at the platform controls to the off position 13 Pull out the red Emergency Stop button at the ground controls to the on position 14 Push in the control activate button and rotate the up down switch in the direction of intended travel Result The up down function should not operate Test Outrigger Interlock 15 Twist to release the red Emergency Stop button at the platform controls Result The up down functions should operate 16 Unscr
37. ty 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 Part No 114002 Third Edition First Printing Operator s Manual Pre operation Inspection Ii Be sure that the operator s safety and responsibilities manuals are complete legible and in the storage container located on the platform U Be sure that all decals are legible and
38. uctions Lifting Instructions The number of people required to load and unload a machine is dependent on a number of factors including but not limited to A r the physical condition strength and Tilt back Operation Instructions disabilities or prior injuries of the people ea a a a a involved Observe and obey the vertical and horizontal distances the M The retaining pin must be inserted to prevent the machine has to be moved spring loaded tilt oack frame from dropping the number of times the machine will be MI Do not tilt the machine back unless the area is loagederunloaded clear of personnel and obstructions the stance posture and grip used by the people involved MI Do not stand behind or under the tilt back frame when raising or lowering it the lifting techniques used the site conditions and weather in which the activity is being performed i e slippery icy raining The appropriate number of people and proper lifting Tilt back Frame techniques must be used to prevent physical injury The Genie AWP Super Series has a tilt back frame which allows the machine to roll through a standard doorway The tilt back frame is standard equipment on standard base AWP 36S and 40S models and optional on standard base AWP 15S 20S 25S and 30S models The tilt back frame is not available on narrow base machines or rough terrain base machines A TEREX COMPANY Part No 114002 Genie AWP
39. until the proper oil drip rate is achieved Check the Air Filter Regulator Canister Air Models It is essential to drain the air filter regulator canister of water to ensure good air motor performance and service life A water filled canister could cause the air motor to perform poorly and continued use could cause component damage 1 Check the air filter regulator canister for any water accumulation 2 If water is visible loosen the drain plug at the bottom of the canister and allow the water to drain out 3 Tighten the drain plug A TEREX COMI 14 Genie AWP Super Series 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 Part No 114002 Third Edition First Printing Operators Manual Do Not Operate Unless M You learn and practice the principles of safe machine operation contained in this operator s manual 1 Avoid hazardous situations 2 Always perform apre operation inspection 3 Always perform the 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 mac
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