Genie AWP Super Series 114002 User manual

Operator’s Manual
with Maintenance Information
Third Edition
Fourth Printing
Part No. 114002

Operator’s Manual Third Edition • Fourth Printing
Genie AWP Super Series PartNo.114002
Copyright © 1996 by Genie Industries
Third Edition: Fourth Printing, April 2012
"Genie" and "AWP" are registered trademarks
of Terex South Dakota in the U.S.A. and many
other countries. "Super Series" is a trademark
of Terex South Dakota.
This machine complies with
ANSI/SIA 92.3
CAN/CSA B354.1
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. 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-operationInspection ........................................... 10
Maintenance ............................................................. 12
Function Tests .......................................................... 15
Workplace Inspection ................................................ 18
OperatingInstructions ............................................... 19
Battery Charging Instructions .................................... 21
TransportInstructions ............................................... 22
Tilt-back Operation Instructions ................................ 25
Decals ...................................................................... 28
Specifications ........................................................... 32
Contact us:
Internet:www.genielift.com
e-mail:[email protected]

Operator’s ManualThird Edition • Fourth Printing
PartNo.114002 Genie AWP Super Series 1
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
governmentalregulations.
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.

Operator’s Manual Third Edition • Fourth Printing
2 Genie AWP Super Series PartNo.114002
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.
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
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.
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.

Operator’s ManualThird Edition • Fourth Printing
PartNo.114002 Genie AWP Super Series 3
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
overhangingload.
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
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
authorizedreplacementparts.
Do not push the Genie AWP from the platform side
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 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

Operator’s Manual Third Edition • Fourth Printing
4 Genie AWP Super Series PartNo.114002
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
governmentalrequirements.
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
groundpersonnel activate
themanual 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
protectiveequipment.
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.

Operator’s ManualThird Edition • Fourth Printing
PartNo.114002 Genie AWP Super Series 5
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.

Operator’s Manual Third Edition • Fourth Printing
6 Genie AWP Super Series PartNo.114002
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
Batteries emit explosive
gas. Keep sparks, flames
and lighted tobacco away
from the battery.
Charge the battery in a well-
ventilatedarea.
Do not disconnect charger DC output wires from the
battery when the charger is on.
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
fordamage. Replace
damagedcomponents
beforeoperating.
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.
SAFETY RULES

Operator’s ManualThird Edition • Fourth Printing
PartNo.114002 Genie AWP Super Series 7
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.
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—usedto indicateoperation
ormaintenance information.

Operator’s Manual Third Edition • Fourth Printing
8 Genie AWP Super Series PartNo.114002
Controls
1 Red Emergency Stop button
2 Key switch
3 Outrigger interlock display
lights (four)
4 Low battery indicator light for
auxiliarylowering
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
Ground Controls -
Air Models
Platform Controls
Ground Controls -
AC and DC Models

Operator’s ManualThird Edition • Fourth Printing
PartNo.114002 Genie AWP Super Series 9
Legend
9 Loading pivot bar
10 Forklift pocket
11 Airline lubricator
adjustmentknob
12 Air supply for
machine
13 Airline lubricator
14 DC models: Battery
pack with charger
15 Hydraulic power unit
16 Winching/tie-down
point
17 Bubble level
18 Base
19 SlidingT-handle
20 Lanyardanchorage
point
21 AC outlet
22 Platform controls
23 Operator'smanual
storagecontainer
24 Manuallowering
valve(under
machine)
1 Lifting eye
2 AC models: Circuit
breaker
3 Outriggerstorage
socket
4 Tilt-back frame
retaining pin in strut
socket
5 Tilt-back strut
6 Swivel lock
7 Tilt-back frame
8 Loadingstop
bracket
25 Base outrigger
socket
26 Outriggerwith
leveling jack
27 Outrigger lock pin
28 Platform
29 Platform entry mid-
rail or gate
30 AC models: Power
supply for machine
DC models: Power
to platform
31 Groundcontrols
32 Mast

Operator’s Manual Third Edition • Fourth Printing
10 Genie AWP Super Series PartNo.114002
Pre-operation Inspection
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.
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 & 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&AWP-40:The
first time these machines
are set up for use, the pipe
plug in the hydraulic
reservoir should be
removedand 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.
Fundamentals
It is the responsibility of the operator to perform a
pre-operationinspection 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.

Operator’s ManualThird Edition • Fourth Printing
PartNo.114002 Genie AWP Super Series 11
PRE-OPERATIONINSPECTION
Pre-operation Inspection
RBe sure that the operator’s, safety and
responsibilities manuals are complete, legible
and in the storage container located on the
platform.
RBe sure that all decals are legible and in place.
See Decals section.
RCheck for battery fluid leaks and proper fluid
level. Add distilled water if needed. See
Maintenancesection.
RAC & DC models: Check for hydraulic oil leaks
and proper oil level. Add oil if needed. See
Maintenancesection.
RRT base models: Check for proper tire pressure.
Add air to tires if needed. See Maintenance
section.
RAir models: Check the oil level of the airline
lubricator. See Maintenance section.
RAir models: Check the oil lubricator canister drip
rate. Adjust as needed. See Maintenance
section.
RAir models: Check the air filter/regulator
canister. Drain water as needed. See
Maintenancesection.
Check the following components or areas for
damage, improperly installed or missing parts and
unauthorizedmodifications:
RElectrical components, wiring and
electrical cables
RAC & DC models: Hydraulic power unit,
hoses, fittings and cylinder
RAir models: Air power unit, air lines, fittings
andcylinder
RPlatform entry mid-rail or gate
RSequencing cables and pulleys
RLifting chains and idler wheels
RNuts, bolts and other fasteners
RMast columns and counterweight
RBreathercap
ROutriggers, leveling jacks and footpads
RAdjustable glide pads
Check entire machine for:
RDents or damage
RCorrosionor oxidation
RCracks in welds or structural components
RInspect and clean battery terminals and all
battery cable connections.
RBe sure that all structural and other critical
components are present and all associated
fasteners and pins are in place and properly
tightened.

Operator’s Manual Third Edition • Fourth Printing
12 Genie AWP Super Series PartNo.114002
Maintenance
Observe and Obey:
Only routine maintenance items specified in this
manual shall be performed by the operator.
Scheduled maintenance inspections shall be
completed by qualified service technicians,
according to the manufacturer's specifications
and the requirements specified in the
responsibilitiesmanual.
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 a maintenance
procedure, it conveys the meaning
below.
Indicates that tools will be required to
performthis procedure.
Indicates that new parts will be required
to perform this procedure.
Check the Battery - DC Models
Proper battery condition is essential to good
machineperformance and safe operation. Improper
fluid levels or damaged cables and connections can
result in component damage and hazardous
conditions.
Electrocution hazard. Contact with
hot or live circuits could result in
death or serious injury. Remove all
rings, watches and other jewelry.
Bodily injury hazard. Batteries
contain acid. Avoid spilling or
contacting battery acid. Neutralize
battery acid spills with baking soda
andwater.
Perform this test after fully
charging the battery.
1 Put on 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.

Operator’s ManualThird Edition • Fourth Printing
PartNo.114002 Genie AWP Super Series 13
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
hydraulicreservoir.
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
Check the Tire Pressure - RT
Base Models
It is essential to maintain proper pressure in all air-
filled tires. Improperly inflated tires can affect
machinehandling.
1 Check each tire with an air pressure gauge. Add
air as needed. The proper air pressure is
stamped on the tire.
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 component
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 1/2inch /
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.
OilSpecifications
Oil Type 10W automotive engine oil

Operator’s Manual Third Edition • Fourth Printing
14 Genie AWP Super Series PartNo.114002
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 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
causecomponent damage.
1 Check the air filter/regulator canister for any
wateraccumulation.
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.
Scheduled Maintenance
Maintenanceperformed 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.

Operator’s ManualThird Edition • Fourth Printing
PartNo.114002 Genie AWP Super Series 15
Function Tests
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.
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 machine as it was intended.
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.

Operator’s Manual Third Edition • Fourth Printing
16 Genie AWP Super Series PartNo.114002
FUNCTIONTESTS
Function Tests
Setup
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 / 3.3mm23-wire
grounded extension cord no longer than
50 feet / 13 m.
Air models: Connect the air line.
3 Insert the key and turn to platform control.
4 Pull out the red Emergency Stop button to the
on position at the ground controls.
5 Twist to release the red Emergency Stop button
at the platform controls.
Result: AC & DC models: The power light should
come on.
Air models: The air pressure gauge should read
80-110 psi /5.5 - 7.8 bar.
6 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.
7 Check the interlock display
lights at the ground
controls. Confirm that the
corresponding light is on.
8 Repeat this procedure for each of the remaining
outriggers.
9 Use the bubble level and adjust the leveling
jacks until the machine base is level.
TestEmergencyStop
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
travel.
Result: The up/down function should not
operate.

Operator’s ManualThird Edition • Fourth Printing
PartNo.114002 Genie AWP Super Series 17
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.
TestOutriggerInterlock
15 Twist to release the red Emergency Stop button
at the platform controls.
Result: The up/down functions should operate.
16 Unscrew one leveling jack until the
corresponding interlock display light turns off.
Result: The up 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.
TestAuxiliaryPlatformLowering
- AC & 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.
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.
TestManualLowering
29 Raise the platform slightly.
30 Activate the manual
lowering valve located
at the bottom of the
hydraulic cylinder.
Result: The
platformshould
lower.

Operator’s Manual Third Edition • Fourth Printing
18 Genie AWP Super Series PartNo.114002
Workplace Inspection
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.
3 Always perform function tests prior to use.
4 Inspecttheworkplace.
Knowandunderstandthe workplace
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
operatingthe machine.
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
· hazardouslocations
· 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