Genie AWP 114002 User Manual

Operator’s Manual

with Maintenance Information

Third Edition

First Printing

Part No. 114002

Operator’s Manual Third Edition • First 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 Industries.

Contents

Page

Safety Rules .............................................................. 1

Controls ..................................................................... 8

Legend ....................................................................... 9

Pre-operation Inspection ........................................... 10

Maintenance ............................................................. 12

Function Tests .......................................................... 15

Workplace Inspection ................................................ 18

Operating Instructions ............................................... 19

Battery Charging Instructions .................................... 21

Transport Instructions ............................................... 22

Tilt-back Operation Instructions ................................ 25

Decals ...................................................................... 28

Specifications ........................................................... 32

Contact us:

Internet: http://www.genielift.com
e-mail: [e-mail]

Copyright © 1996 by Genie Industries

First Edition: Eighth Printing, October 2001

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.

2 Genie AWP Super Series Part No. 114002

Operator’s ManualThird Edition • First Printing

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.
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.

The first time this machine is set up for use, a

breather cap is installed. See Pre-operation
Inspection section.

Part No. 1 14002 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.

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.

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 the platform is
raised.

Minimum Safe
Voltage Approach Distance
Phase to Phase Feet Meters

0 to 300V Avoid Contact
300V to 50KV 10 3.05
50KV to 200KV 15 4.60
200KV to 350KV 20 6.10
350KV to 500KV 25 7.62
500KV to 750KV 35 10.67
750KV to 1000KV 45 13.72

Do not place ladders or scaffolds in the platform or
against any part of this machine.

Do not place or attach overhanging loads to 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.

2 Genie A WP Super Series Part No. 1 14002

Operator’s ManualThird Edition • First Printing

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 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 lbs / 222 N

Maximum allowable
manual force

CE / AUS
45 lbs / 200 N

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.

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
authorized replacement parts.

Do not push the Genie AWP from the platform side

Occupants, equipment and materials shall not
exceed the maximum platform capacity.

Maximum capacity

AWP-20S 350 lbs 159 kg
AWP-25S 350 lbs 159 kg
AWP-30S 350 lbs 159 kg
AWP-36S 350 lbs 159 kg
AWP-40S 300 lbs 136 kg

Maximum occupancy 1 person

Part No. 1 14002 Genie AWP Super Series 3

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
governmental requirements.

Do not sit, stand or climb
on the platform guard
rails. Maintain a firm
footing on the platform
floor at all times.

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.

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 guard rail.

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.

4 Genie A WP Super Series Part No. 1 14002

Operator’s ManualThird Edition • First Printing

SAFETY RULES

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 may be
present.

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.

Part No. 1 14002 Genie AWP Super Series 5

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.

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

Electrocution Hazards

Connect the charger to a
grounded AC circuit only.

Do not expose the battery
or charger to water or rain.

Before each use, inspect
for damage. Replace
damaged components
before operating.

Lifting Hazard

The battery pack weighs 90 lbs / 40.8 kg. Use the
appropriate number of people and proper lifting
techniques when lifting the battery pack.

Batteries emit explosive
gas. Keep sparks, flames
and lighted tobacco away
from the battery.

Charge the battery in a well­ventilated area.

Do not disconnect charger DC output wires from the
battery when the charger is on.

6 Genie A WP Super Series Part No. 1 14002

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 ManualThird Edition • First Printing

SAFETY RULES

Orange—used to indicate the
presence of a potentially
hazardous situation which, if not
avoided, could result in death or
serious injury.

Yellow with safety alert symbol—
used to indicate the presence of a
potentially hazardous situation
which, if not avoided, may cause
minor or moderate injury.

Yellow without safety alert
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.

Part No. 1 14002 Genie AWP Super Series 7

Operator’s Manual Third Edition • First 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 A WP Super Series Part No. 1 14002

Operator’s ManualThird Edition • First Printing

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. 1 14002 Genie AWP Super Series 9

9 Loading pivot bar
10 Forklift pocket
11 Airline lubricator

adjustment knob

1 2 Air supply for

machine
13 Airline lubricator
1 4 DC models: Battery

pack with charger
15 Hydraulic power unit
16 Winching/tie-down

point
1 7 Bubble level

18 Base
19 Sliding T-handle
2 0 AC outlet
2 1 Platform controls
22 Operator's manual

storage container

23 Manual lowering

valve (under
machine)

24 Base outrigger

socket

25 Outrigger with

leveling jack
2 6 Outrigger lock pin
27 Platform
2 8 Platform entry mid-

rail or gate
2 9 AC models: Power

supply for machine

DC models: Power

to platform
30 Ground controls
31 Mast