Operator’s Manual Fourth Edition • Third Printing 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. Contents Page Safety Rules .............................................................. 1 Controls .........
Fourth Edition • Third Printing Operator’s 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: 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.
Operator’s Manual Fourth Edition • Third 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. 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.
Fourth Edition • Third Printing Operator’s Manual SAFETY RULES 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 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 authorized replacement parts. Do not push the Genie AWP from the platform side of the machine.
Operator’s Manual Fourth Edition • Third Printing SAFETY RULES ANSI / CSA models: 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. CE/AUS standard base models with outdoor outriggers: Do not raise the platform when wind speeds may exceed 28 mph / 12.5 m/s. If wind speeds exceed 28 mph / 12.
Fourth Edition • Third Printing Operator’s Manual SAFETY RULES Do not exit the platform while raised. If a power failure occurs, have ground personnel activate the manual lowering valve. Keep the platform floor clear of debris. Lower the platform entry mid-rail or gate before operating. 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.
Operator’s Manual Fourth Edition • Third Printing SAFETY RULES Battery and Charger Safety - DC Models Electrocution Hazards Connect the charger to a grounded AC circuit only. Burn Hazards Do not expose the battery or charger to water or rain. Batteries contain acid. Always wear protective clothing and eye wear when working with batteries. Before each use, inspect for damage. Replace damaged components before operating. Lifting Hazard Avoid spilling or contacting battery acid.
Fourth Edition • Third Printing Operator’s Manual 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.
Operator’s Manual Fourth Edition • Third Printing Controls Ground Controls AC and DC Models Ground Controls Air Models 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 Power light 7 Auxiliary platform lowering button 8 Air pressure gauge 9 Control activate button 10 Up/Down switch 8 Genie AWP Super Series Part No.
Fourth Edition • Third Printing Operator’s Manual Legend 1 Lifting eye 2 AC models: Circuit breaker 3 Outrigger storage socket 4 Tilt-back frame retaining pin in strut socket 5 Tilt-back strut 6 Swivel lock 7 Tilt-back frame 8 Loading stop bracket Part No.
Operator’s Manual Fourth Edition • Third Printing 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.
Fourth Edition • Third Printing Operator’s Manual PRE-OPERATION INSPECTION Sequencing cables and pulleys Pre-operation Inspection Be sure that the operator’s, safety and responsibilities manuals are complete, legible and in the storage container located on the platform. Be sure that all decals are legible and in place. See Decals section. Check for battery fluid leaks and proper fluid level. Add distilled water if needed. See Maintenance section.
Operator’s Manual Fourth Edition • Third Printing Maintenance 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. Observe and Obey: Only routine maintenance items specified in this manual shall be performed by the operator. Electrocution hazard. Contact with hot or live circuits could result in death or serious injury.
Fourth Edition • Third Printing Operator’s Manual MAINTENANCE 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.
Operator’s Manual Fourth Edition • Third 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.
Fourth Edition • Third Printing Operator’s Manual 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. 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. A malfunctioning machine must never be used.
Operator’s Manual Fourth Edition • Third Printing FUNCTION TESTS Function Tests 8 Repeat this procedure for each of the remaining outriggers. Setup 9 Use the bubble level and adjust the leveling jacks until the machine base is level. 1 Position the machine on a firm surface directly below the desired work area. 2 Connect to 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.
Fourth Edition • Third Printing Operator’s Manual FUNCTION TESTS 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 23 Connect the power source to the machine. 24 Turn the key switch to platform control.
Operator’s Manual Fourth Edition • Third Printing Workplace Inspection Workplace Inspection Be aware of and avoid the following hazardous situations: Do Not Operate Unless: You learn and practice the principles of safe machine operation contained in this operator’s manual.
Fourth Edition • Third Printing Operator’s Manual Operating Instructions Setup 1 Position the machine on a firm surface directly below the desired work area. You learn and practice the principles of safe machine operation contained in this operator’s manual. 2 Connect to the appropriate power source: DC models: Connect the battery pack. AC models: Connect to a grounded 15A AC power supply. Use a 12 gauge / 3.3mm2 3-wire grounded extension cord no longer than 50 feet / 13 m.
Operator’s Manual Fourth Edition • Third Printing OPERATING INSTRUCTIONS 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.
Fourth Edition • Third Printing Operator’s Manual Battery Charging Instructions To Charge Battery 1 Open the battery pack lid to access the battery. Battery and Charger Instructions 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. 3 Replace the battery vent caps. Observe and Obey: Do not use an external charger or booster battery.
Operator’s Manual Fourth Edition • Third Printing Transport Instructions 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: · the physical condition, strength and disabilities or prior injuries of the people involved Transport Instructions Observe and Obey: Be sure the transport vehicle capacity and loading surfaces are sufficient to support the machine weight. See the serial label for the machine weight.
Fourth Edition • Third Printing Operator’s Manual TRANSPORT INSTRUCTIONS 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 Remove the outriggers from the base and place them in the storage sockets. 4 DC models: Disconnect 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.
Operator’s Manual Fourth Edition • Third Printing TRANSPORT INSTRUCTIONS Securing the Machine Use chains or straps of ample load capacity. Winching the Machine onto a Flatbed Truck Use a minimum of 2 chains. 1 Fully lower the platform. Adjust the rigging to prevent damage to the chains. 2 Push in the 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.
Fourth Edition • Third Printing Operator’s Manual Tilt-back Operation Instructions 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: Tilt-back Operation Instructions Observe and obey: The retaining pin must be inserted to prevent the spring-loaded tilt-back frame from dropping. Do not tilt the machine back unless the area is clear of personnel and obstructions.
Operator’s Manual Fourth Edition • Third Printing TILTBACK OPERATION INSTRUCTIONS Lowering the Tilt-back Assembly Tilting Back the Machine 1 Be sure the area behind the machine and under the tilt-back frame is clear of personnel and obstructions. 1 Slide out the Thandle until the lock pin snaps into place. 2 Fully lower the platform. 3 Remove the outriggers from the base and place them in the storage sockets.
Fourth Edition • Third Printing Operator’s Manual TILTBACK OPERATION INSTRUCTIONS Returning the Machine to Standing Position Stowing the Tilt-back Assembly 1 Remove the retaining pin. 1 Be sure the area below the machine base and T-handle is clear of personnel and obstructions. 2 Slide out the T-handle until the lock pin snaps into place. 3 Carefully pull down the T-handle until the machine rests at midtilt position.
Operator’s Manual Fourth Edition • Third 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.
Fourth Edition • Third Printing Operator’s Manual DECALS Note: Platform decals may be in different locations on optional fiberglass basket. Models with Tilt-back Frame Part No.
Operator’s Manual Fourth Edition • Third Printing 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 place. Part No. Description Quantity Part No.
Fourth Edition • Third Printing Operator’s Manual DECALS 82974 82780 or 82781 28174 or 28235 82987 82802 82913 or 82914 82913 or 114010 Note: Platform decals may be in different locations on optional fiberglass basket.
Operator’s Manual Fourth Edition • Third Printing Specifications Machine Specifications Height, working maximum AWP-20S AWP-25S AWP-30S AWP-36S AWP-40S 26 ft 1 in / 8.0 m 30 ft 9 in / 9.4 m 35 ft 6 in / 10.8 m 42 ft 5 in / 12.9 m 46 ft 3 in / 4.1 m Height, platform maximum AWP-20S AWP-25S AWP-30S AWP-36S AWP-40S 20 ft 1 in / 6.1 m 24 ft 9 in / 7.6 m 29 ft 6 in / 9.0 m 36 ft 6 in / 11.1 m 40 ft 3 in / 12.3 m 78 in / 2.0 m 1091/2 in / 2.8 m Width Standard base Narrow base Rough terrain base 29 in / 73.
Fourth Edition • Third Printing Operator’s Manual SPECIFICATIONS Outrigger Specifications Standard Base AWP-20S AWP-25S AWP-30S Outrigger footprint (l x w) ANSI / CSA 603/4 x 523/4 in 1.5 x 1.3 m 603/4 x 523/4 in 1.5 x 1.3 m 691/4 x 611/4 in 1.8 x 1.6 m Outrigger footprint (l x w) CE / AUS Indoor 603/4 x 523/4 in 1.5 x 1.3 m 691/4 x 611/4 in 1.8 x 1.6 m 751/2 x 671/2 in 1.9 x 1.7 m Outrigger footprint (l x w) CE / AUS Outdoor 831/4 x 751/4 in 2.1 x 1.9 m 89 x 81 in 2.3 x 2.
Operator’s Manual Fourth Edition • Third Printing SPECIFICATIONS Outrigger Specifications Narrow Base / Rough Terrain Base AWP-20S AWP-25S AWP-30S Outrigger footprint (l x w) ANSI / CSA 64 x 481/4 in 1.6 x 1.2 m 64 x 481/4 in 1.6 x 1.2 m 711/2 x 58 in 1.8 x 1.5 m Outrigger footprint (l x w) CE / AUS Indoor Use Only 711/4 x 58 in 1.8 x 1.5 m 711/4 x 58 in 1.8 x 1.5 m 741/2 x 651/2 in 1.9 x 1.6 m CE/AUS Narrow Base or Rough Terrain base machines are Indoor Use Only, even with longer outriggers.