Operator`s Manual
Contents
1. 7 Repeat procedure for each of the remaining outriggers Test Emergency Stop 8 Use the bubble level and adjust leveling jacks until the machine base is level 9 Twist to release the red Emergency Stop button at the platform controls 10 Push in the red Emergency Stop button at the ground controls to the orr position PRE OPERATION INSPECTION amp FUNCTION TESTS 11 Push in the control activate button and rotate the up down switch in the direction of intended travel O Result Up Down functions should not operate 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 ow position 14 Push in the control activate button and rotate the up down switch in the direction of intended travel Result Up Down functions should not operate Test Outrigger Interlock 15 Twist to release the red Emergency Stop button at the platform controls 16 Pull out the red Emergency Stop button at the ground controls to the on position Result Up Down functions should operate 17 Unscrew one leveling jack until the corresponding interlock display light turns off Result Up Down functions should not operate 18 Return the leveling jack to previous setting and check the bubble level 19 Repeat procedure for each outrigger Test Manual Lowering 20 Raise platform slightly 21 Activ2. Insert key and turn to the on position 4 Pull out the red Emergency Stop button and be sure the power light is on After Each Use 5 Install outriggers and adjust to level the 1 Select a safe storage location firm level machine and raise base casters slightly off the surface weather protected clear of obstruction ground and traffic 2 Chock wheels to prevent machine from rolling Remove key to secure from unauthorized use DC models Disconnect battery pack and recharge battery 10 Genie AWP Part No 33424 Fourth Edition Operator s Manual Battery and Charger Instructions Observe and Obey MI Do not use external charger or booster battery M Charge battery in a well ventilated area MI Use proper AC input voltage for charging as indicated on charger MI Use only Genie authorized battery and charger CSA applicable model Manual Lester charger 06685 or 06670 Automatic Lester charger 15840 90 To Charge Battery 1 Manual charger models Disconnect the battery pack from the machine 2 Open battery pack lid to access battery 3 Remove the battery vent caps and check the battery acid level If necessary add only enough water to cover the plates Do not overfill prior to charging cycle 4 Replace the vent caps Style A models Battery pack lid must remain open during entire charging cycle Style B models Battery pack lid can remain open or closed during the charging cycle Style B
3. OPERATING INSTRUCTIONS 5 Connect the battery charger to grounded AC circuit 6 Automatic charger models Set the power switch to the auto position Charger will start after a short delay Manual Charger models Set the timer based on the amount of use Light use less than 15 lifting cycles Set to 7 hours Heavy use greater than 15 lifting cycles Set to oN position 7 All models The charger will automatically shut off at end of the set period Manual charger models If ampere meter drops to 3A or less within the first 15 minutes the battery is fully charged and the battery charger should be turned off Disconnect the AC supply 9 Check the battery acid level when the charging cycle is completed Replenish with water to the bottom of the fill tube Dry Battery Filling and Charging Instructions 1 Remove battery vent caps and permanently remove plastic seal from battery vent openings Fill each cell with battery acid electrolyte until level is sufficient to cover plates Do not fill to maximum level until battery charge cycle is complete Overfilling can cause the battery acid to overflow during charging Neutralize battery acid spills with baking soda and water Install the vent caps Charge the battery Check the battery acid level when the charging cycle is complete Replenish with water to the bottom of the fill tube Part No 33424 Genie AWP 11 Operator s Manual Fourth E
4. with a breather cap A breather cap is supplied and can be found in an envelope taped to the mast near the platform controls Pre operation Inspection Be sure that all decals are legible and in place Be sure that the operator s manual is legible and in the storage container located in the platform Check for damage and improperly installed or missing parts Electrical components wiring and electrical cables Hydraulic power unit hoses fittings and cylinder Platform entry mid rail Sequencing cables and pulleys Lifting chains and idler wheels Nuts bolts and other fasteners Weld or structural cracks Mast columns and counterweight Breather cap Outriggers leveling jacks and footpads Perform quarterly and annual machine inspections Keep records for three years See the Genie AWP service manual for details 8 Genie AWP Part No 33424 Fourth Edition Operator s Manual Function Tests 1 Select a test area free of obstructions Connect appropriate power source Turn the key switch to the ow position Result The power light should come on Roo mv Pull out the red Emergency Stop button to the on position o Select an outrigger and slide it into a base socket until the outrigger lock pin snaps into place Bring the outrigger leveling jack into firm contact with ground 6 Check the interlock display lights at the xl o ground controls Confirm that the corresponding light is on
5. U S A Patent No 5 105 913 Printed on recycled paper Printed in U S A Genie AWP Part No 33424 Fourth Edition 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 M You are trained to safely operate the machine M You read understand and obey manufacturer s instructions and safety rules operator s manual and machine decals employer s safety rules and worksite regulations applicable governmental regulations M You inspect the entire machine for possible damage and test all machine functions for proper operation MI The first time this machine is set up for use a breather cap is installed see Breather Cap page 8 Part No 33424 Genie AWP Operator s Manual Fourth Edition SAFETY RULES Tip over Hazards Do not raise platform unless base is level all four outriggers are properly installed and leveling jacks firmly contact floor Do not adjust or remove outriggers while platform is occupied or raised Do not move machine while the platform is raised Do not place or attach overhanging loads to any part of this machine Do not push off or pull toward any object outside the platform t Do not place ladders or scaffolds in platform or against any part of this machine Do not use machine to lift material or equipment Machine is intended for pers
6. optional fiberglass platform is not electrically insulated and will not provide protection from contact with or proximity to electrical current Le Keep away from machine if it contacts energized power lines or becomes electrically charged Personnel on ground or in platform must not touch or operate machine until energized power lines are shut off Ne R SAFETY RULES Maintain safe distances from electrical power lines and apparatus in accordance with applicable governmental regulations and the following chart Voltage Minimum Safe 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 Allow for platform movement electrical line sway or sag and movement due to strong or gusty winds Do not use machine as a ground for welding Do not operate AC powered machine or 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 Part No 33424 Genie AWP Operator s Manual Fourth Edition SAFETY RULES Collision Hazards Check 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 obs
7. 7 Battery Pack Automatic Charger Battery Pack Manual Charger This decal is visible when battery pack cover is raised 20 Genie AWP Part No 33424 Fourth Edition Operator s Manual Specifications Model AWP 19 AWP 24 AWP 30 AWP 36 Height working maximum 25 ft 6 in 30 ft 36 ft 42 ft 7 8m 9 1m 11 0m 12 8m Height platform maximum 19 ft 6 in 24 ft 30 ft 36 ft 5 9m 7 3m 9 1m 11 0m Lift capacity 300 Ibs 300 lbs 300 Ibs 250 lbs 136kg 136kg 136kg 113kg Power source DC model 12V 12V 12V 12V AC model 110V or 220V 110V or 220V 110V or 220V 110V or 220V Machine weight 694 623 Ibs 717 639 Ibs 866 788 Ibs 940 868 Ibs DC AC models 315 283kg 325 290kg 393 357kg 426 394kg Height stowed 79 in 79 in 93 in 112 in 200cm 200cm 236cm 284cm Width 29 in 29 in 29 in 29 in 74cm 74cm 74cm 74cm Length 47 5 in 47 5 in 51 5 in 51 5 in 120 6cm 120 6cm 130 8cm 130 8cm Platform length 26 in 26 in 26 in 26 in 66cm 66cm 66cm 66cm Platform width 26 in 26in 26 in 26 in 66cm 66cm 66cm 66cm Platform height 43 in 43 in 43 in 43 in 106cm 106cm 106cm 106cm Outrigger footprint 65 x 58 in 65 x 58 in 75 x 73 in 81 x 81 in 164 x 146 5cm 164 x 146 5cm 190 5 x 185 5cm 205 x 205cm Continuous improvement of our products is a Genie policy Product specifications are subject to change without notice or obligation Part No 33424 Genie AWP 21 a U S A 18340 NE 76th Street P O Box 69 Red
8. Genie AWP 36 and is representative of all AWP models Fuse s AC power supply cord Ground controls Hydraulic power unit Manual lowering valve Outrigger with leveling jack Base outrigger socket Bubble level ON O R UON W 2 9 3 O s Q9 2 b 3 J Wr 1 5 o JI ME O t9 9 Base 19 10 Transport tie down 11 Sliding T handle ay 12 Operator s manual Al storage container 22 13 Platform 23 14 Platform entry mid rail 24 15 AC outlet 16 Platform controls gt 17 Mast 26 18 Outrigger storage socket Legend 69 Battery charger DC models Forklift pocket Loading pivot bar Battery pack DC models Loading stop bracket Retaining pin Genie AWP 30 amp 36 Tilt back frame Genie AWP 30 amp 36 Tilt back strut Genie AWP 30 8 36 Part No 33424 Genie AWP Operator s Manual Fourth Edition Pre operation Inspection amp Function Tests Observe and Obey M Conduct a thorough pre operation inspection and function test before each work shift M Immediately tag and remove from service a damaged or malfunctioning machine M Repair any machine damage or malfunctions before operating machine Breather Cap Component damage will occur if the machine is operated without a breather cap The first time this machine is set up for use the pipe plug in the hydraulic reservoir should be removed and permanently replaced
9. Technical Publications Genie AWP Operator s Manual Fourth Edition First Printing E Part No 33424 Operator s Manual Fourth Edition Genie AW 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 If you have any questions call Genie Industries Genie North America Telephone 206 881 1800 Toll Free 800 536 1800 in U S A Toll Free 800 426 8089 in Canada Fax 206 883 3475 Genie Europe Telephone 44 0636 813943 Fax 44 0636 815270 Contents Page Safety Rules sese 1 Coritiols secs e NNNM 6 E rem 7 Pre operation Inspection amp Function Tests 8 Operating Instructions ssessssseees 10 Battery and Charger Instructions 11 Transport Instructions seses 12 Tilt back Operation Instructions 14 Maintenance Inspection eseesess 16 BI c 18 M a Specifications eooee aaa aaa aaa aaa a 21 Genie Industries Copyright 1993 by Genie Industries Third Edition First Printing March 1993 Second Printing June 1994 Fourth Edition First Printing July 1994 Genie is a registered trademark of Genie Industries Registered 2009987 U S A Patent No 5 121 816
10. ate the manual lowering valve located on the hydraulic power unit Result Platform should descend Part No 33424 Genie AWP 9 Operator s Manual Fourth Edition Operating Instructions 6 Check the interlock display Be sure that all four interlock display lights are on Emergency Stop Before Each Use Push in the red Emergency Stop button at platform controls or at ground M Conduct a thorough pre operation inspection of Controls to stop all Emergency Stop M Read understand and obey all safety rules see Safety Rules page 1 Control Activate Up Down Switch the machine see Pre operation Inspection functions page 8 MI Test all machine functions for proper operation see Function Tests page 9 Manual Lowering M Repair any machine damage or malfunctions 1 Activated from ground only before operating the machine 2 Activate manual lowering valve located on hydraulic power unit to lower platform Platform Raise and Lower Setup 1 Follow Setup procedure 1 Position machine on a firm level surface 2 Twist to release the directly below desired work area red Emergency Stop 2 Connect to appropriate power source button DC models Connect battery pack 3 Push in control AC models Connect to a grounded 15A AC activate button and power supply Use a 12 gauge 3 3mm 3 wire rotate the up down grounded extension cord no longer than switch in the desired 50 feet 13m direction of travel
11. dition OPERATING INSTRUCTIONS Transport Instructions Observe and Obey MI Be sure vehicle capacity and loading surfaces are sufficient to support machine weight see Specifications page 21 Some pick up truck tailgates are not strong enough to support the weight of the machine and may require reinforcement MI Do not load machine onto a vehicle unless it is parked on a level surface MI Transport vehicle must be secured to prevent rolling while machine is being loaded M Lifting force needed to tilt machine onto transport vehicle requires two people M Machine must be securely fastened to transport vehicle MI Be sure to lock both swivel casters on tilt back frame Genie AWP 30 amp 36 MI Do not transport with the tilt back frame in the lowered position Loading for Transport 1 Fully lower platform 2 Pushin red Emergency Stop buttons turn key switch to the orr position and remove key 3 Remove outriggers from base and place in storage sockets 4 DC models Disconnect battery cable and remove battery pack 5 Inspect entire machine for loose or unsecured items 6 Slide the stop bracket to the top lock position Genie AWP 30 and 36 12 Genie AWP Part No 33424 Fourth Edition Operator s Manual OPERATING INSTRUCTIONS 6 Hook loading pivot to stop bracket 7 Position machine flush against loading surface Lower and lock stop bracket to the lowest lock pin position above loadin
12. g surface 11 Carefully push machine into transport position 12 Return sliding T handle to stowed position 13 Secure the machine base and mast to the transport vehicle Use chains or straps of 8 AWP 30 and 36 models ample load capacity Be sure both stop bracket lock pins are fully 14 Reverse procedure to unload engaged Be sure both tilt back frame swivel casters are locked 9 Slide out T handle until lock pin snaps into place 10 Two people should lift T handle to tilt machine onto loading surface Part No 33424 Genie AWP 13 Operator s Manual Fourth Edition OPERATING INSTRUCTIONS Lowering Tilt back Assembly 1 Be sure area behind machine and under tilt back frame is clear of personnel and obstructions 2 Remove outriggers from base and place in storage sockets Tilt back Operation Instructions Tilt back frame is spring loaded and will immediately fall outward when retaining pin is Observe and obey removed Maintain firm grasp on tilt back frame and remove retaining pin M Retaining pin must be inserted to prevent spring loaded tilt back frame from dropping M Do not tilt the machine back unless area is clear of personnel and obstructions MI Do not stand behind or under tilt back frame when raising or lowering it M Lifting force necessary requires two people 3 Lower tilt back frame and guide the tilt back strut i
13. ith batteries Avoid spilling or contacting battery acid Neutralize battery acid spills with baking soda and water Sei Battery pack must remain in upright position Explosion Hazards a aN Batteries emit explosive gas Keep sparks flames and lighted tobacco away from battery Charge batteries in a well ventilated area Do not disconnect charger DC output wires from battery when charger is on SAFETY RULES Electrocution Hazards Connect charger to a grounded AC circuit only Do not expose battery or charger to water and or rain Before each use inspect for damage Replace damaged items before operating w Lifting Hazard Battery pack weighs 80 Ibs 36kg Two people should lift it together Part No 33424 Genie AWP Operator s Manual Fourth Edition Controls Ground Controls Interlock Display The power light and all four interlock display lights must be illuminated before attempting to operate the machine See operator s manual 9 Platform Controls 1 Outrigger interlock display lights four Key switch Emergency stop button Power light Control activate button O oa R I Up Down switch 6 Genie AWP Part No 33424 Fourth Edition Operators Manual K a amp G G G0 W T a EES OO OWOGWOG Model shown is a
14. ivel Lock Caution Pipe Plug 26 27873 13 1699 Notice Maintain firm grasp on Safety Tape 27 27844 14 27865 1 Label Strut Socket Label Bubble Level 28 27840 15 27863 3 Label Retaining Pin Caution Component Damage Hazard 29 27843 16 27839 1 Label Tilt back Strut Label Sliding T handle 18 Genie AWP Part No 33424 Fourth Edition Operator s Manual DECALS Part No Quantiy Fiberglass Platform Option Decal Description 30 27838 1 Warning Tilt back Hazards Notice Tilt back Instructions 31 27874 1 Label Insert retaining pin into 32 31070 1 Danger Tip over Hazard moving machine 33 31068 1 Danger Battery Safety Notice Battery Charger Instructions 34 28372 1 Caution Quick Disconnect 35 28398 1 Danger Battery Safety manual charger 36 27856 1 Caution Component Damage manual charger 37 27853 1 Notice Battery Charger Instructions AWP 19 amp 24 R i gt yt ees EMO OJJ ord L4 jj 46 2 8 Q Q A a p za wv SS i CQG 90 Part No 33424 Genie AWP 19 Operator s Manual Fourth Edition DECALS AWP 30 amp 36 o 6 9 G6 O 6 l 63 68 za gt ij Segall wa amp wa 16 Sao 69 0 14 1
15. ls Inspected By Date Serial No Model AC 19 30 DC 24 36 Part No 33424 Genie AWP 17 Operator s Manual Decals Fourth Edition amp PartNo Quantity x Part No Decal Description Decal Description 1 31237 1 17 31311 Notice Before Each Work Shift Label AWP 19 or 2 31243 1 31312 Danger General Safety Label AWP 24 3 31071 1 or Warning Failure to Read Obey Manual 31452 Label AWP 30 4 31072 1 or Label Operator s Manual Storage Container 31453 5 33597 1 Label AWP 36 Label Fuses AC models only 18 31067 6 31074 1 Notice Operating Instructions Label ANSI Patents 19 27870 Genie AWP 19 24 amp 30 only 7 33598 1 d Maximum Capacity 300 Ibs Label Interlock Display 27869 Genie AWP 36 only 8 27845 1 Notice Maximum Capacity 250 Ibs Notice Manual Lowering Lever i 20 27872 2 Collision Hazard descending platform Danger Tip over Hazard outriggers 32986 1 21 27841 Notice Manual Lowering Knob Label Stop Bracket Caution Collision Hazard descending platform 22 27842 9 31245 1 Label Loading Pivot Warning Collision Hazard runaway lift 23 27864 10 31076 1 Notice Lower Stop Bracket before Caution 8A Maximum 115V AC 24 27868 11 28157 1 Danger Relief Valve Notice Dexron 25 27867 12 27857 1 Label Sw
16. mond Washington 98073 0069 E Europe Market Place Southwell Nottinghamshire NG25 OHE England
17. ned and qualified on the maintenance of this machine M Immediately tag and remove from service a damaged or malfunctioning machine M Repair any machine damage or malfunctions before operating machine 16 Genie AWP Part No 33424 Fourth Edition Operator s Manual TEE MAINTENANCE INSPECTION Daily Check List Make copies of this checklist to use for each inspection Index Index No No Inspect decals and placards for 7 Check that all structural and other damage and legibility see critical components are present and Decals page 18 all fasteners and pins are in place 1 Inspect and test outrigger interlock and properly tightened system 8 Inspect lifting chains for proper 2 Check operation of all power and acjusunent function controls 9 Inspect lifting chains and idler 3 Inspect for damaged loose or wheels Toren agde proper operation missing parts 10 Inspect sequencing cables for damage and proper operation 4 Inspect hydraulic components for leaks and damages 11 Inspect and clean battery terminals and all battery cable connections Check hydraulic oil level Check cables and wiring for frays abrasion or physical damage Notes Perform quarterly or every 150 hours and annual machine inspections Keep records for three years See the Genie AWP service manual for detai
18. nto the strut socket Tilt back Frame The Genie AWP 30 amp 36 have a tilt back frame which allow the machine to roll through a standard doorway 4 Insert retaining pin into strut socket 14 Genie AWP Part No 33424 Fourth Edition Operator s Manual OPERATING INSTRUCTIONS Tilting back Stowing Tilt back Assembly Machine 1 Slide out T handle until lock pin snaps into place 1 Remove retaining pin 2 Two people should lift the machine with the T handle to mid tilt position casters on tilt back frame contact floor and machine supported by extended tilt back strut 2 Firmly grasp tilt back frame and remove tilt back strut from strut socket 3 Lift tilt back frame n hold in upright e position against spring and secure with retaining pin 3 Continue lifting until telescoping tilt back strut is completely compressed Returning Machine To Standing Position 1 Be sure area below machine base and T handle is clear of personnel and obstructions 2 Carefully pull down T handle until machine rests at mid tilt position 3 Two people should lower the machine with the T handle until base casters are in contact with ground 4 Return sliding T handle to stowed position Part No 33424 Genie AWP 15 Operator s Manual Fourth Edition Maintenance Inspection MI The Maintenance Inspection shall be completed daily by a person trai
19. onnel access only Do not raise platform unless machine is on firm level surface Do not use machine on a moving or mobile surface or vehicle Do not raise platform in strong or gusty winds Do not exceed rated platform load capacity Maximum capacity AWP 19 300 Ibs 136kg AWP 24 300 Ibs 136kg AWP 30 300 Ibs 136kg AWP 36 250 Ibs 113kg Maximum occupancy 1 person Do not operate machine near drop offs holes bumps debris unstable or slippery surface or other possible hazardous conditions Do not alter or disable machine components that in any way affects safety and stability Do not replace items critical to stability with items of different weight or specification Use only Genie authorized replacement parts When moving the machine with a forklift or other transport vehicle platform should be fully lowered machine should be turned off and no personnel shall remain in platform Do not push the Genie AWP from the platform side of the machine 2 Genie AWP Part No 33424 Fourth Edition Operator s Manual Fall Hazards Do not sit stand or climb on platform guard rails Maintain a firm footing on the platform floor at all times Do not exit platform while raised If a power failure occurs have ground personnel activate manual lowering valve Keep platform floor clear of debris Lower platform entry mid rail before operating Electrocution Hazards This machine even with an
20. tructions Be careful when transporting on incline Stay clear of descending platform Improper Use Hazards Do not leave machine unattended unless key is removed to secure from unauthorized use Damaged Machine Hazards Do not use a damaged or malfunctioning machine Conduct a thorough pre operation inspection of 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 Genie AWP service manual Be sure all decals are in place and legible Be sure operator s manual is legible complete and in the operator s manual storage container located in the platform Decal Legend Genie product decals use color coding and signal words to identify the following j Red used to indicate the 33 presence of a hazard that will cause death or serious injury AWARNING Orange used to indicate the presence of a hazard that may cause death or serious injury ACAUTION Yellow used to indicate the presence of a hazard that will or may cause serious personal injury or damage to the machine Green used to indicate operation or maintenance information 4 Genie AWP Part No 33424 Fourth Edition Operator s Manual Battery and Charger Safety DC Models Burn Hazards Batteries contain acid Always wear protective clothing and eyewear when working w
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