Genie Load Lifter 5.5 User manual

Third Edition
Second Printing
Part No. 82299
Operator’s Manual

GenieLoadLifter PartNo.82299
Third Edition • Second PrintingOperator'sManual
Copyright © 1995 by Genie Industries
First Edition: Second Printing, July 1995
Second Edition: Third Printing, December 2001
Third Edition: Second Printing, January 2004
"Genie" is a registered trademark of
Genie Industries in the U.S.A. and many other
countries. "Load Lifter" is a trademark of Genie
Industries.
Printed on recycled paper
Printed in U.S.A.
Important
Read,understandandobeythesesafetyrulesand
operatinginstructionsbeforeoperatingthismachine.
Onlytrainedandauthorizedpersonnelshallbe
permitted to operate this machine. If you have any
questions, call Genie Industries.
Contents
Page
Safety ......................................................................... 1
Legend ........................................................................ 5
Pre-operationInspection ............................................. 6
Function Tests............................................................ 8
WorkplaceInspection................................................ 10
OperatingInstructions............................................... 11
Decals ...................................................................... 13
Specifications ........................................................... 15
Contact us:
Internet:http://www.genielift.com
e-mail:[email protected]

PartNo.82299 GenieLoadLifter 1
Operator's ManualThird Edition • Second Printing
Safety Rules
Warning
Failure to obey the instructions and
safety rules in this manual may
result in 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.
Knowandunderstandthesafetyrulesbefore
going on to the next section.
2 Alwaysperformapre-operation
inspection.
3 Always perform the function tests prior to
use.
4 Inspect the workplace.
5 Only use the machine as it was intended.
Youread,understandandobeythe
manufacturer'sinstructionsandsafetyrules—
safetyandoperator'smanualsandmachine
decals.
Youread,understandandobeyemployer's
safety rules and worksite regulations.
Youread,understandandobeyallapplicable
governmentalregulations.
Youareproperlytrainedtosafelyoperate the
machine.

2 GenieLoadLifter PartNo.82299
Operator's Manual Third Edition • Second Printing
Fall Hazards
Do not use as a personnel
lifting platform or step.
Do not stand or sit on the
loadplatform.
Do not climb on the
machine.
Tip-over Hazards
Do not exceed the rated load capacity. The
maximum capacity is 200 lbs / 91 kg.
Do not raise the load unless the legs have been
fullyloweredandlocked.
Do not raise the load unless the machine is on a
firm, level surface.
Do not move the machine with a raised load,
exceptfor minor positioning.
Do not tilt the machine back with a raised load.
Donotoperatethemachineunlessthewheel/leg
configurationisproperlyinstalled.
Do not use blocks to level the machine.
Do not operate the machine in strong or gusty
winds. Increasing the load surface area will
decrease machine stability in windy conditions.
SAFETY RULES
Do not place ladders or scaffolding against any part
of the machine.
Prior to use, check the work area for drop-offs,
holes, bumps, debris, unstable or slippery surfaces
orotherpossiblehazardousconditions.
Avoid debris and uneven surfaces while rolling a
machine with the legs folded up.
Do not replace machine parts critical to stability or
structure with items of different weight or
specification.
Do not cause a horizontal force or side load to the
machine by raising or lowering a fixed or
overhangingload.
Do not use the machine on a moving or mobile
surface or vehicle.
Collision Hazards
Do not raise if the load is not properly centered on
theloadplatform.
Checkthe work area for
overheadobstructionsor
otherpossiblehazards.
Donotstandunderorallow
personnelunderthe
machine when the load is
raised.
Donotlowertheload
unless the area below is clear of personnel and
obstructions.
Usecommonsenseandplanningwhentransporting
the machine on an incline, slope or stairs.

PartNo.82299 GenieLoadLifter 3
Operator's ManualThird Edition • Second Printing
SAFETY RULES
Lifting Hazard
Use proper lifting techniques to load or tip the
machine, or to move the machine on stairs.
Electrocution Hazards
This machine is not electrically insulated and will
not provide protection from contact with or
proximity to electrical current.
Maintain safe distances away from electrical power
linesandapparatusinaccordancewith applicable
governmentalregulationsandthefollowingchart.
Allow for mast movement and electrical line sway
or sag, and beware of strong or gusty winds.
Keep away from the machine if it contacts
energizedpowerlines.Personnelmustnottouchor
operate the machine until power lines are shut off.
Do not use the machine as a ground for welding.
Improper Use Hazard
Neverleaveamachineunattendedwithaload.
Unauthorizedpersonnelmayattempttooperatethe
machinewithoutproperinstruction,creatingan
unsafecondition.
Voltage Minimum Safe
Approach Distance
Phase to Phase Feet Meters
0 to 300V Avoid Contact
300V to 50KV 10 3.1
50KV to 200KV 15 4.6
200KV to 350KV 20 6.1
350KV to 500KV 25 7.6
500KV to 750KV 35 10.7
750KV to 1000KV 45 13.7
Bodily Injury Hazards
Do not grasp the cable.
Do not allow the platform to drop during setup.
Keep hands and fingers away from folding legs,
pulleys,thecarriageandotherpotentialpinch
points.
Do not place arms, hands or fingers through the
frame.
Damaged Machine Hazards
Donotuseadamagedormalfunctioningmachine.
Do not use a machine with a
worn,frayed,kinkedordamaged
cable.
Do not use a machine with less
than 4 wraps of cable on the
winchdrumwhenthecarriageis
fullylowered.
Conductathoroughpre-
operationinspectionpriorto
each use.
Be sure all decals are in place
andlegible.
Maintainproperlubricationonthewinch. Do not
allow oil or grease on braking surfaces.
Do not use any type of lubrication on the channel
surfaces.
Crushing Hazard
Maintain a firm grasp on the winch handle until the
brake is locked. The brake is locked when the load
will not cause the winch handle to turn.

4 GenieLoadLifter PartNo.82299
Operator's Manual Third Edition • Second Printing
SAFETY RULES
Decal Legend
Genie product decals use symbols, color coding
and signal words to identify the following:
Safety alert symbol—used to alert
personneltopotentialpersonal
injury hazards. Obey all safety
messages that follow this symbol
to avoid possible injury or death.
Red—usedtoindicatethe
presence of an imminently
hazardous situation which, if not
avoided, will result in death or
seriousinjury.
Orange—usedtoindicatethe
presence of a potentially
hazardous situation which, if not
avoided, could result in death or
seriousinjury.
Yellow with safety alert symbol—
used to indicate the presence of a
potentiallyhazardoussituation
which, if not avoided, may cause
minorormoderateinjury.
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—usedtoindicateoperation
ormaintenanceinformation.

PartNo.82299 GenieLoadLifter 5
Operator's ManualThird Edition • Second Printing
Legend
1 Outer frame glide button
2 Handle
3 Inner frame pulley
4 Cabletermination
5 Outer frame pulley
6 Inner frame
7 Outer frame
8 Cable
9 Roller wheel
10 Carriage
11 Carriage pulley
12 Loadplatform
13 Foldingleg
14 Footpad
15 Innerframeglidebutton
16 Front leg caster (option)
17 Leg lock bolt
18 Legspring
19 Baseplate
20 Rear wheel
21 Stair glide (option)
22 Brake (option)
23 Winch handle
24 Winch (under plate)
25 Winch mounting plate
21
14
23
22
18
19
24
25
20
16
17
8
9
7
3
3
4
5
13
13
10
6
12
11
15
2
1

6 GenieLoadLifter PartNo.82299
Operator's Manual Third Edition • Second Printing
Pre-operation Inspection
Do Not Operate Unless:
You learn and practice the principles of safe
machineoperationcontainedinthisoperator's
manual.
1 Avoidhazardous situations.
2 Alwaysperformapre-operation
inspection.
Knowandunderstandthepre-operation
inspection before going on to the next
section.
3 Always perform function tests prior to use.
4 Inspect the workplace.
5 Only use the machine as it was intended.
Fundamentals
Thepre-operationinspection is a visual inspection
performed by the operator prior to each work shift.
This inspection is designed to discover if anything
isapparently wrong with a machine beforethe
operator tests it.
Refer to the list on the next page and check each
of the items.
Ifdamage oranyunauthorized variationfrom
factory delivered condition is discovered, the
machinemust 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.

PartNo.82299 GenieLoadLifter 7
Operator's ManualThird Edition • Second Printing
PRE-OPERATION INSPECTION
Pre-operation Inspection
oBe sure that the operator’s manual is complete,
legibleandavailableforreference.
oBe sure that all decals are legible and in place.
See Decals section.
Checkthe following components or areas for
damage,improperly installed ormissingpartsand
unauthorizedmodifications:
oWinchandrelatedcomponents
oBasecomponents
oLegs
oGlidebuttonsandrollerwheels
oInnerandouterframes
oCableanchor
oCableandpulleys
oWheels
oCasters(ifequipped)
oLoadplatform
oNuts, bolts and other fasteners
oCable (kinks, frays, abrasions)
Check the entire machine for:
oDentsordamage
oCorrosionoroxidation
oCracks in welds or structural components
oBe sure that all structural and other critical
componentsare present andallassociated
fastenersand pins are in place and properly
tightened.
oBe sure there is a minimum of 4 wraps of cable
around the winch drum when the carriage is fully
lowered.

8 GenieLoadLifter PartNo.82299
Operator's Manual Third Edition • Second Printing
Do Not Operate Unless:
You learn and practice the principles of safe
machineoperationcontainedinthisoperator's
manual.
1 Avoidhazardous situations.
2 Alwaysperformapre-operation
inspection.
3 Alwaysperform functiontestspriorto
use.
Knowandunderstandthefunctiontests
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 manufacturer's
specifications.
After repairs are completed, the operator must
perform a pre-operation inspection and function
tests again before putting the machine into service.
FunctionTests

PartNo.82299 GenieLoadLifter 9
Operator's ManualThird Edition • Second Printing
FUNCTION TESTS
1 Select a test area that is firm, level and free of
obstructions.
Setup
2 Tilt the machine back.
3 Lift the folding legs up to unlock them.
4 Lower the folding legs and push in to lock them.
5 Lower the platform. Do not drop it.
6 Removetheknobonthewinchhandle,reverse
the winch handle and replace the knob. The
handle grip should face the operator.
Test the Spring Tension of
the Legs
7 Pull the legs out and release.
Result: The legs should snap back into locked
position.
Test the Winch Operation
8 Rotate the winch handle clockwise to raise the
platform.
Result: The carriage should raise to the top of
the inner frame and then the inner frame should
raise. The carriage and inner frame should
move smoothly, free of hesitation and binding.
9 Rotatethe winch handle counterclockwise to
lower the platform.
Result: The inner frame and the carriage should
lower into the outer frame. The carriage and
inner frame should move smoothly, free of
hesitation and binding.

10 GenieLoadLifter PartNo.82299
Operator's Manual Third Edition • Second Printing
Workplace Inspection
Fundamentals
Theworkplaceinspectionhelpstheoperator
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
remembertheworkplacehazards, thenwatchfor
and avoid them while moving, setting up and
operating the machine.
Do Not Operate Unless:
You learn and practice the principles of safe
machineoperationcontainedinthisoperator's
manual.
1 Avoidhazardous situations.
2 Alwaysperformapre-operation
inspection.
3 Always perform function tests prior to use.
4 Inspecttheworkplace.
Knowandunderstandtheworkplace
inspection before going on to the next
section.
5 Only use the machine as it was intended.
Be aware of and avoid the following hazardous
situations:
· drop-offsorholes
· bumpsand floorobstructions
· debris
· overheadobstructionsandhighvoltage
conductors
· hazardouslocations
· slopedsurfaces
· unstableor slippery surfaces
· inadequatesurface supportto withstandall
load forces imposed by the machine
· windandweatherconditions
· all other possible unsafe conditions

PartNo.82299 GenieLoadLifter 11
Operator's ManualThird Edition • Second Printing
Operating Instructions
Do Not Operate Unless:
You learn and practice the principles of safe
machineoperationcontainedinthisoperator's
manual.
1 Avoidhazardous situations.
2 Alwaysperformapre-operation
inspection.
3 Always perform function tests prior to use.
4 Inspect the workplace.
5 Only use the machine as it was intended.
Fundamentals
TheOperating Instructions sectionprovides
instructions for each aspect of machine operation.
It is the operator's responsibility to follow all the
safety rules and instructions in the operator's
manual.
Using the machine for anything other than lifting
material is unsafe.
If more than one operator is expected to use a
machine at different times in the same work shift,
each operator is expected to follow all safety rules
and instructions in the operator's manual. That
means every new operator should perform a pre-
operation inspection, function tests and a
workplaceinspectionbefore usingthemachine.
Setup
Select an area that is firm, level and free of
obstructions.
Follow the Setup procedures in the Function Tests
section.
Raising and Lowering Load
1 Center the load on the load platform.
2 Raise the load by firmly grasping the winch
handle and rotating it clockwise. Do not allow
the cable to wind unevenly onto the drum.
3 Lower the load by firmly grasping the winch
handle and rotating it counterclockwise. After
lowering to the desired position, turn the winch
handle clockwise (raise the load) 1/4turn to set
the brake.

12 GenieLoadLifter PartNo.82299
Operator's Manual Third Edition • Second Printing
Moving Machine with a Load
It is best to move the machine on the worksite with
no load. Moving a raised load should be restricted
to positioning for loading and unloading. If it is
necessary to move the machine with a raised load,
understandandobeythefollowing safety rules:
· Make sure the area is level and clear of
obstructions.
· Make sure the load is centered on the load
platform.
· Avoid sudden starts and stops.
· Travel with the load in the lowest possible
position.
· Keeppersonnelaway fromthe machineand
load.
· Do not tilt the machine back with a raised
load.
Moving Machine on Stairs
· Fully lower the load.
· Ease the machine over each stair. Maintain a
firmgrasp on the handle.
· Do not allow the machine to become
unbalanced.
· Continue carefully up or down the stairs.
· Usetheappropriatenumberofpeopleand
properlifting techniques with heavy loads.
After Each Use
To prepare the machine for storage, follow the
Setup procedure in reverse order. The platform
must be fully lowered to store the legs.
Select a safe storage location - firm level surface,
weather protected, clear of obstructions and traffic.
OPERATINGINSTRUCTIONS

PartNo.82299 GenieLoadLifter 13
Operator's ManualThird Edition • Second Printing
Decals
Inspection for Decals with Words
Determinewhetherthedecalsonyourmachine
havewords or symbols. Use the appropriate
inspection to verify that all decals are legible and in
place.
Part No. Description Quantity
33468 Warning - No Riders 1
35546 Warning - Machine Safety 1
35547 Notice - Machine Setup 1
35552 Warning - Tip-over 2
35555 Notice - Maximum Capacity, 200 lbs / 91 kg1
Part No. Description Quantity
35567 Warning - Bodily Injury Hazard 1
52981 Cosmetic - Genie Load Lifter 1
44754 Label - Raise / Lower 1
97529 Caution - Bodily Injury Hazard 1
35547
97529
35555
33567
52981
35546
Serial Plate
33468
35552
44754

14 GenieLoadLifter PartNo.82299
Operator's Manual Third Edition • Second Printing
DECALS
Inspection for Decals with
Symbols
Determinewhetherthedecalsonyourmachine
havewords or symbols. Use the appropriate
inspection to verify that all decals are legible and in
place.
Part No. Description Quantity
52981 Cosmetic - Genie Load Lifter 1
82487 Label - Read the Manual 1
82961 Label - Raise / Lower 1
82962 Warning - No Riders 1
Part No. Description Quantity
97514 Notice - Maximum Capacity, 91 kg 1
97532 Warning - Bodily Injury Hazard 1
97536 Warning - Do Not Reach 1
82487
97532
97514
52981
98536
Serial Plate
82962
82961

PartNo.82299 GenieLoadLifter 15
Operator's ManualThird Edition • Second Printing
Height, maximum platform 5 ft 7 in 1.70 m
Lift capacity 200 lbs 91 kg
Machine weight 441/2 lbs 20 kg
Height, stowed 45 in 1.14 m
Width 201/2 in 52 cm
Airborne Noise Emissions 78 dB
by Machinery
Maximum sound level at normal
operating workstations (A-weighted)
Specifications
Length - Stowed 15 in 38 cm
Length - Operating 283/4 in 73 cm
Load Platform
Length 17 in 43.2 cm
Width 163/4 in 43 cm
Load Height 2 in 5 cm
Component Mounting Locations

Genie North America
Phone [phone]
Toll Free USA and Canada
800.536.1800
Fax [phone]
Genie Australia Pty Ltd.
Phone [phone]
Fax [phone]
Genie China
Phone [phone]
Fax [phone]
Genie Malaysia
Phone [phone]
Fax [phone]
Genie Japan
Phone [phone]
Fax [phone]
Genie Korea
Phone [phone]
Fax [phone]
Genie Brasil
Phone [phone]
Fax [phone]
Genie Holland
Phone [phone]
Fax [phone]
Genie Scandinavia
Phone [phone]
Fax [phone]
Genie France
Phone [phone]
Fax [phone]
Genie Iberica
Phone [phone]
Fax [phone]
Genie Germany
Phone [phone]
Fax [phone]
Genie U.K.
Phone [phone]
Fax [phone]
Genie Mexico City
Phone [phone]
Fax [phone]
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