Genie AWP-19 User manual

Technical
Publications
AWP
®
Operator's
Manual
Fourth Edition, First Printing
Part No. 33424

GenieAWP Part No. 33424
Operator’s Manual Fourth Edition
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
U.S.A. Patent No. 5,105,913
Printed on recycled paper
Printed in U.S.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. If you have any
questions, call Genie Industries.
Contents
Page
Safety Rules .............................................................. 1
Controls..................................................................... 6
Legend ...................................................................... 7
Pre-operation Inspection & Function Tests ............... 8
Operating Instructions .............................................. 10
Battery and Charger Instructions.............................. 11
Transport Instructions............................................... 12
Tilt-back Operation Instructions................................ 14
Maintenance Inspection ........................................... 16
Decals ...................................................................... 18
Specifications ........................................................... 21
Genie North America
Telephone [phone]
Toll Free 800 536-1800 in U.S.A.
Toll Free 800 426-8089 in Canada
Fax [phone]
Genie Europe
Telephone [phone]
Fax [phone]
®

Part No. 33424 GenieAWP 1
Operator’s ManualFourth Edition
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 are trained to safely operate the machine.
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
You inspect the entire machine for possible
damage and test all machine functions for
proper operation.
The first time this machine is set up for use, a
breather cap is installed (see Breather Cap ,
page 8).

2 GenieAWP Part No. 33424
Operator’s Manual Fourth Edition
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.
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 personnel 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 lbs 136kg
AWP-24 300 lbs 136kg
AWP-30 300 lbs 136kg
AWP-36 250 lbs 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.
SAFETY RULES

Part No. 33424 GenieAWP 3
Operator’s ManualFourth Edition
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 optional fiberglass
platform, is not electrically insulated and will not
provide protection from contact with or proximity to
electrical current.
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.
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.

4 GenieAWP Part No. 33424
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
obstructions.
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:
Red—used to indicate the
presence of a hazard that will
cause death or serious injury.
Orange—used to indicate the
presence of a hazard that may
cause death or serious injury.
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.

Part No. 33424 GenieAWP 5
Operator’s ManualFourth Edition
Battery and Charger Safety
- DC Models
Burn Hazards
Batteries contain acid. Always wear protective
clothing and eyewear when working with batteries.
Avoid spilling or contacting battery acid. Neutralize
battery acid spills with baking soda and water.
Battery pack must remain
in upright position.
Explosion Hazards
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.
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.
Lifting Hazard
Battery pack weighs 80 lbs (36kg). Two people
should lift it together.
SAFETY RULES

6 GenieAWP Part No. 33424
Operator’s Manual Fourth Edition
®
1 Outrigger interlock display
lights (four)
2 Key switch
3 Emergency stop button
4 Power light
5 Control activate button
6 Up/Down switch
Controls
Ground Controls
Platform Controls
3
5
6
3
2
1
4

Part No. 33424 GenieAWP 7
Operator’s ManualFourth Edition
Legend
611 6 9 8 7 67 10
16
13
3
4
1
2
5
7 66 10720 106
24
22
21
23
25
17
26
7
Model shown is a
Genie AWP-36 and is
representative of all AWP
models.
1 Fuse(s)
2 AC power supply cord
3 Ground controls
4 Hydraulic power unit
5 Manual lowering valve
6 Outrigger with leveling jack
7 Base outrigger socket
8 Bubble level
9 Base
10 Transport tie down
11 Sliding T-handle
12 Operator's manual
storage container
13 Platform
14 Platform entry mid-rail
15 AC outlet
16 Platform controls
17 Mast
18 Outrigger storage socket
19 Battery charger (DC
models)
20 Forklift pocket
21 Loading pivot bar
22 Battery pack (DC models)
23 Loading stop bracket
24 Retaining pin
(Genie AWP 30 & 36)
25 Tilt-back frame
(Genie AWP 30 & 36)
26 Tilt-back strut
(Genie AWP 30 & 36)
15
14
12
6
9
13
18
19
17

8 GenieAWP Part No. 33424
Operator’s Manual Fourth Edition
Pre-operationInspection&Function Tests
Observe and Obey:
Conduct a thorough pre-operation inspection
and function test before each work shift.
Immediately tag and remove from service a
damaged or malfunctioning machine.
Repair any machine damage or malfunctions
before operating machine.
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.
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
with a breather cap.
A breather cap is supplied and can be found
in an envelope taped to the mast near the
platform controls.

Part No. 33424 GenieAWP 9
Operator’s ManualFourth Edition
Function Tests
1 Select a test area free of obstructions.
2 Connect appropriate power source.
3 Turn the key switch to the ON position.
Result: The power light should come on.
4 Pull out the red Emergency Stop button to
the ON position.
5 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
ground controls.
Confirm that the
corresponding light
is on.
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 OFF position.
PRE-OPERATION INSPECTION & FUNCTION TESTS
11 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.
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: 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 Activate the manual lowering valve located on
the hydraulic power unit.
Result: Platform should descend.

10 GenieAWP Part No. 33424
Operator’s Manual Fourth Edition
Operating Instructions
Before Each Use:
Read, understand and obey all safety rules
(see Safety Rules , page 1).
Conduct a thorough pre-operation inspection of
the machine (see Pre-operation Inspection ,
page 8).
Test all machine functions for proper operation
(see Function Tests , page 9).
Repair any machine damage or malfunctions
before operating the machine.
6 Check the interlock display. Be sure that all four
interlock display lights are on.
Emergency Stop
Setup
1 Position machine on a firm, level surface
directly below desired work area.
2 Connect to appropriate power source:
DC models: Connect 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 (13m).
3 Insert key and turn to the ON position.
4 Pull out the red Emergency Stop button and be
sure the power light is on.
5 Install outriggers and adjust to level the
machine and raise base casters slightly off the
ground.
Push in the red
Emergency Stop
button at platform
controls or at ground
controls to stop all
functions.
Emergency Stop
Control Activate
Up/Down Switch
Manual Lowering
1 Activated from ground only.
2 Activate manual lowering valve located on
hydraulic power unit to lower platform.
Platform Raise and Lower
1 Follow Setup procedure.
2 Twist to release the
red Emergency Stop
button.
3 Push in control
activate button and
rotate the up/down
switch in the desired
direction of travel.
After Each Use
1 Select a safe storage location—firm, level
surface, weather protected, clear of obstruction
and traffic.
2 Chock wheels to prevent machine from rolling.
3 Remove key to secure from unauthorized use.
4 DC models: Disconnect battery pack and
recharge battery.

Part No. 33424 GenieAWP 11
Operator’s ManualFourth Edition
OPERATING INSTRUCTIONS
Battery and Charger Instructions
Observe and Obey:
Do not use external charger or booster battery.
Charge battery in a well-ventilated area.
Use proper AC input voltage for charging as
indicated on charger.
Use only Genie authorized battery and charger.
CSA applicable model:
Manual Lester charger 06685 or 06670
Automatic Lester charger 15840-90
5 Connect the battery charger to grounded
AC circuit.
6Automatic 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.
7All 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.
8 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.
2 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.
3 Install the vent caps.
4 Charge the battery.
5 Check the battery acid level when the charging
cycle is complete. Replenish with water to the
bottom of the fill tube.
Style A Style B
To Charge Battery
1Manual 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.

12 GenieAWP Part No. 33424
Operator’s Manual Fourth Edition
OPERATING INSTRUCTIONS
Transport Instructions
Observe and Obey:
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.
Do not load machine onto a vehicle unless it is
parked on a level surface.
Transport vehicle must be secured to prevent
rolling while machine is being loaded.
Lifting force needed to tilt machine onto
transport vehicle requires two people.
Machine must be securely fastened to transport
vehicle.
Be sure to lock both swivel casters on tilt-back
frame (Genie AWP-30 & 36).
Do not transport with the tilt-back frame in the
lowered position.
Loading for Transport
1 Fully lower platform.
2 Push in red Emergency Stop buttons, turn key
switch to the OFF 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-19 & 24
Genie AWP-30 and 36

Part No. 33424 GenieAWP 13
Operator’s ManualFourth Edition
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 loading surface.
8 AWP 30 and 36 models:
Be sure both stop bracket lock pins are fully
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.
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
ample load capacity.
14 Reverse procedure to unload.

14 GenieAWP Part No. 33424
Operator’s Manual Fourth Edition
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 frame is spring loaded and will
immediately fall outward when retaining pin is
removed. Maintain firm grasp on tilt-back frame
and remove retaining pin.
3 Lower tilt-back frame and guide the tilt-back
strut into the strut socket.
4 Insert retaining pin into strut socket.
Tilt-back Operation Instructions
Observe and obey:
Retaining pin must be inserted to prevent
spring loaded tilt-back frame from dropping.
Do not tilt the machine back unless area is
clear of personnel and obstructions.
Do not stand behind or under tilt-back frame
when raising or lowering it.
Lifting force necessary requires two people.
OPERATING INSTRUCTIONS
Tilt-back Frame
The Genie AWP-30 & 36
have a tilt-back frame
which allow the machine
to roll through a standard
doorway.

Part No. 33424 GenieAWP 15
Operator’s ManualFourth Edition
Tilting back
Machine
1 Slide out T-handle
until lock pin snaps
into place.
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.
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.
Stowing Tilt-back Assembly
1 Remove retaining pin.
2 Firmly grasp tilt-back frame and remove
tilt-back strut from strut socket.
3 Lift tilt-back frame,
hold in upright
position against
spring and secure
with retaining pin.
OPERATING INSTRUCTIONS

16 GenieAWP Part No. 33424
Operator’s Manual Fourth Edition
Maintenance Inspection
The Maintenance Inspection shall be
completed daily by a person trained and
qualified on the maintenance of this machine.
Immediately tag and remove from service a
damaged or malfunctioning machine.
Repair any machine damage or malfunctions
before operating machine.
7
31
67 3
1 4 3
71 1
10
3 7
3 7
611
9
632
1326
54
1132
73
7
3
61
7
3
1
7
3
78 3
7 3
3
3
7
3
73 7

Part No. 33424 GenieAWP 17
Operator’s ManualFourth Edition
MAINTENANCE INSPECTION
Index
No.
Make copies of this checklist to use for each inspection.
Index
No.
Inspect decals and placards for
damage and legibility (see
Decals, page 18).
1 Inspect and test outrigger interlock
system.
2 Check operation of all power and
function controls.
3 Inspect for damaged, loose or
missing parts.
4 Inspect hydraulic components for
leaks and damages.
5 Check hydraulic oil level.
6 Check cables and wiring for frays,
abrasion or physical damage.
Daily Check List
Inspected By
Date
Serial No.
Model AC 19 30
DC 24 36
7 Check that all structural and other
critical components are present and
all fasteners and pins are in place
and properly tightened.
8 Inspect lifting chains for proper
adjustment.
9 Inspect lifting chains and idler
wheels for damage and proper
operation.
10 Inspect sequencing cables for
damage and proper operation.
11 Inspect and clean battery terminals
and all battery cable connections.
Notes: Perform quarterly (or every 150 hours) and
annual machine inspections. Keep records for
three years. See the Genie AWP service manual
for details.

18 GenieAWP Part No. 33424
Operator’s Manual Fourth Edition
Decals
Index
Part No. Quantity
Decal Description
1 31237 1
Notice - Before Each Work Shift
2 31243 1
Danger - General Safety
3 31071 1
Warning - Failure to Read/Obey Manual
4 31072 1
Label - Operator's Manual Storage Container
5 33597 1
Label - Fuses (AC models only)
6 31074 1
Label - ANSI/Patents
7 33598 1
Label - Interlock Display
8 27845 1
Notice - Manual Lowering Lever
Caution - Collision Hazard (descending platform)
or
32986 1
Notice - Manual Lowering Knob
Caution - Collision Hazard (descending platform)
9 31245 1
Warning - Collision Hazard (runaway lift)
10 31076 1
Caution - 8A Maximum, 115V AC
11 28157 1
Notice - Dexron
12 27857 1
Caution - Pipe Plug
13 1699 —
Safety Tape
14 27865 1
Label - Bubble Level
15 27863 3
Caution - Component Damage Hazard
16 27839 1
Label - Sliding T-handle
Index
Part No. Quantity
Decal Description
17 31311 2
Label - AWP-19
or
31312 2
Label - AWP-24
or
31452 2
Label - AWP-30
or
31453 2
Label - AWP-36
18 31067 1
Notice - Operating Instructions
19 27870 - Genie AWP-19, 24 & 30 only 1
Notice - Maximum Capacity, 300 lbs.
or
27869 - Genie AWP-36 only 1
Notice - Maximum Capacity, 250 lbs.
20 27872 1
Danger - Tip-over Hazard (outriggers)
21 27841 1
Label - Stop Bracket
22 27842 1
Label - Loading Pivot
23 27864 1
Notice - Lower Stop Bracket before ...
24 27868 1
Danger - Relief Valve
25 27867 2
Label - Swivel Lock
26 27873 1
Notice - Maintain firm grasp on ...
27 27844 1
Label - Strut Socket
28 27840 1
Label - Retaining Pin
29 27843 1
Label - Tilt-back Strut