Terex Genie AWP Series User manual

Operator's Manual
Serial Number Range
AWP®Super
Series
from AWPP-100000
CE
with
Maintenance
Information
Original Instructions
Fifth Edition
First Printing
Part No. 1298034GT

Operator's Manual Fifth Edition • First Printing
AWP®Super Series Part No. 1298034GT
Front Matter
Manufacturer:
Terex South Dakota, Inc.
500 Oakwood Road
Watertown, SD 57201, USA
Authorized representative:
Genie Industries B. V.
Boekerman 5
4751 XK OUD GASTEL
The Netherlands
Contents
Introduction ............................................................1
Symbol and Hazard Pictorials Definitions..............5
General Safety.......................................................7
Personal Safety......................................................9
Work Area Safety................................................ 10
Legend................................................................ 16
Controls............................................................... 17
Inspections.......................................................... 18
Operating Instructions......................................... 26
Maintenance ....................................................... 29
Battery Charging Instructions ............................. 32
Transport Instructions......................................... 33
Tilt-back Operation Instructions.......................... 37
Specifications...................................................... 40
Copyright © 1996 Terex Corporation
Fifth Edition: First Printing, November 2020
"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.
Complies with EC Directive 2006/42/EC
See EC Declaration of Conformity

Fifth Edition • First Printing Operator's Manual
Introduction
Part No. 1298034GT AWP®Super Series 1
Introduction
About this manual
Genie appreciates your choice of our machine for
your application. Our number one priority is user
safety, which is best achieved by our joint efforts.
This book is an operation and daily maintenance
manual for the user or operator of a Genie
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,
contact Genie.
Product Identification
The machine serial number is located on the serial
label.
Serial label
Serial number
stamped on chassis
Intended Use and Familiarization
Guide
The intended use of this machine is to lift
personnel, including tools, and materials to an
aerial work site. Before operating the machine, it’s
the operator’s responsibility to read and
understand this familiarization guide.
Each person must be trained to operate a
Mobile Elevating Work Platform (MEWP).
Familiarization with the MEWP must be given
to each person who is authorized, competent
and trained.
Only trained and authorized personnel should
be permitted to operate the machine.
The operator is responsible to read,
understand, and obey the manufacturer’s
instructions and safety rules provided in the
Operator’s Manual.
The Operator’s Manual is located in the
manual storage container, at the platform.
For specific product applications, see
Contacting The Manufacturer.

Operator's Manual Fifth Edition • First Printing
Introduction
2 AWP®Super Series Part No. 1298034GT
Platform controls symbology and related
machine movement:
Platform up
Platform down
Ground controls symbology and related
machine movement:
Keyswitch - Off
Keyswitch - On
Ground controls
Platform controls
Emergency platform
lowering
Low battery indicator
Air pressure
Interlocked functions:
All platform and ground controls.
Limitations of use:
The intended use of this machine is to lift
personnel, including tools, and materials to an
aerial work site.
Do not elevate the platform unless the machine
is on firm level ground.

Fifth Edition • First Printing Operator's Manual
Introduction
Part No. 1298034GT AWP®Super Series 3
Bulletin Distribution and
Compliance
Safety of product users is of paramount
importance to Genie. Various bulletins are used by
Genie to communicate important safety and
product information to dealers and machine
owners.
The information contained in the bulletins is tied to
specific machines using the machine model and
serial number.
Distribution of bulletins is based on the most
current owner on record along with their
associated dealer, so it is important to register
your machine and keep your contact information
up to date.
To ensure safety of personnel and the reliable
continued operation of your machine, be sure to
comply with the action indicated in a respective
bulletin.
To view any open bulletins for your machine, visit
us on the web at www.genielift.com.
Contacting the Manufacturer
At times it may be necessary to contact Genie.
When you do, be ready to supply the model
number and serial number of your machine, along
with your name and contact information. At
minimum, Genie should be contacted for:
Accident reporting
Questions regarding product applications and
safety
Standards and regulatory compliance information
Current owner updates, such as changes in
machine ownership or changes in your contact
information. See Transfer of Ownership, below.
Transfer of Machine Ownership
Taking a few minutes to update owner information
will ensure that you receive important safety,
maintenance and operating information that
applies to your machine.
Please register your machine by visiting us on the
web at www.genielift.com or by calling us toll free
at 1-800-536-1800.

Operator's Manual Fifth Edition • First Printing
Introduction
4 AWP®Super Series Part No. 1298034GT
Danger
Failure to obey the instructions and
safety rules in this manual will 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.
Know and understand the safety rules
before going on to the next section.
2 Always perform a pre-operation inspection.
3 Always perform function tests prior to use.
4 Inspect the workplace.
5 Only use the machine as it was intended.
You read, understand and obey the
manufacturer’s instructions and safety rules—
safety and operator’s manuals and machine
decals.
You read, understand and obey employer’s
safety rules and worksite regulations.
You read, understand and obey all applicable
governmental regulations.
You are properly trained to safely operate the
machine.
The first time this machine is set up for use, a
breather cap is installed. See Pre-operation
Inspection section for breather cap
instructions.
Safety Sign Maintenance
Replace any missing or damaged safety signs.
Keep operator safety in mind at all times. Use mild
soap and water to clean safety signs. Do not use
solvent-based cleaners because they may
damage the safety sign material.
Hazard Classification
Decals on this machine use symbols, color coding,
and signal words to identify the following:
Safety alert symbol—used to alert
you to potential personal injury
hazards. Obey all safety
messages that follow this symbol
to avoid possible injury or death.
Indicates a hazardous situation
which, if not avoided, will result in
death or serious injury.
Indicates a hazardous situation
which, if not avoided, could result
in death or serious injury.
Indicates a hazardous situation
which, if not avoided, could result
in minor or moderate injury.
Indicates a property damage
message.

Fifth Edition • First Printing Operator's Manual
Symbol and Hazard Pictorials Definitions
Part No. 1298034GT AWP®Super Series 5
Symbol and Hazard Pict orials Definitions
Read the operator’s
manual
Read the service
manual
Crush hazard
No smoking
Collision hazard
Tip-over hazard
Tip-over hazard
Tip-over hazard
Electrocution hazard
Tip-over hazard
Burn hazard
Explosion hazard
Fire hazard
Refer to ourigger
decal
Electrocution hazard
Voltage rating for
power to platform
Pressure rating for
air line to platform
Crush hazard
Transport diagram
Tiedown

Operator's Manual Fifth Edition • First Printing
Symbol and Hazard Pictorials Definitions
6 AWP®Super Series Part No. 1298034GT
Maintain required
clearance
Outrigger load
Lifting point
Release brakes
Grounded AC
3-wire only
Replace damaged
wires and cords
Wheel load
Lanyard anchorage
points
Side force
Wind speed
Maximum capacity
Use common sense
and planning to
control the movement
of the machine on or
near inclines.
Indoor
Outdoor
Emergency lowering
Maximum capacity
including occupant,
tools, materials and
options

Fifth Edition • First Printing Operator's Manual
General Safety
Part No. 1298034GT AWP®Super Series 7
General Safety
* These decals are model, option or configuration specific.

Operator's Manual Fifth Edition • First Printing
General Safety
8 AWP®Super Series Part No. 1298034GT
* These decals are model, option or configuration specific.

Fifth Edition • First Printing Operator's Manual
Personal Safety
Part No. 1298034GT AWP®Super Series 9
Personal Safet y
Personal Fall Protection
Personal fall protection equipment (PFPE) is not
required when operating this machine. If PFPE is
required by job site or employer rules, the
following shall apply:
All PFPE must comply with applicable
governmental regulations and must be inspected
and used in accordance with the manufacturer’s
instructions.

Operator's Manual Fifth Edition • First Printing
Work Area Safety
10 AWP®Super Series Part No. 1298034GT
Work Area Saf ety
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.
Obey all local and
governmental regulations
regarding required
clearance from electrical
power lines. At a
minimum, the required
clearance contained in the
chart below must be
followed.
Voltage
Phase to Phase
Minimum Safe
Approach Distance
0 to 300V
Avoid Contact
300V to 50KV
10 ft
3.05 m
50KV to 200KV
15 ft
4.60 m
200KV to 350KV
20 ft
6.10 m
350KV to 500KV
25 ft
7.62 m
500KV to 750KV
35 ft
10.67 m
750KV to
1000KV
45 ft
13.72 m
Allow for platform movement, electrical line sway
or sag, and beware of 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 move the machine while the platform is
raised.
Do not adjust or remove
the outriggers while the
platform is occupied or
raised.
Do not place ladders or
scaffolds in the platform
or against any part of this
machine.

Fifth Edition • First Printing Operator's Manual
Work Area Safety
Part No. 1298034GT AWP®Super Series 11
Do not place or attach fixed or 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.
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 machine by
raising or lowering a
fixed or overhanging
load.
Do not push off or pull
toward any object
outside of the platform.
Maximum allowable side force
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 machine stability
with items of different weight or specification.
Do not tie the platform to adjacent structures.
Do not place loads outside the platform perimeter.
Use only Genie approved replacement parts.
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 alter or modify a mobile elevating work
platform without prior written permission from the
manufacturer. Mounting attachments for holding
tools or other materials onto the platform,
toeboards, or guard rail system can increase the
weight in the platform and the surface area of the
platform or the load.

Operator's Manual Fifth Edition • First Printing
Work Area Safety
12 AWP®Super Series Part No. 1298034GT
Standard base models with outdoor outriggers:
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 the platform is raised,
lower the platform and do not continue to operate
the machine.
Standard base models with indoor outriggers:
Indoor use only. Do not raise the platform when
wind speeds may exceed 0 mph / 0 m/s. If wind
speeds exceed 0 mph / 0 m/s when platform is
raised, lower the platform and do not continue to
operate the machine.
Narrow or RT base models: Indoor use only. Do
not raise the platform when wind speeds may
exceed 0 mph / 0 m/s. If wind speeds exceed
0 mph / 0 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 occupants
1 person
Crushing Hazard
Keep hands and limbs out of mast.
Use common sense and planning when operating
the machine with the controller from the ground.
Maintain safe distances between the operator, the
machine and fixed objects.

Fifth Edition • First Printing Operator's Manual
Work Area Safety
Part No. 1298034GT AWP®Super Series 13
Fall Hazards
The guard rail system
provides fall protection. If
occupant(s) of the
platform are required to
wear personal fall
protection equipment
(PFPE) due to job site or
employer rules, PFPE
and its use shall be in
accordance with the
PFPE manufacturer’s
instructions and
applicable governmental
requirements. Attach the
lanyard to the anchor
provided in the platform.
Do not sit, stand, or climb on the platform guard
rails. Maintain a firm footing on the platform floor at
all times.
Do not exit the platform while raised. If a power
failure occurs, have ground personnel activate the
manual lowering valve.
Keep the platform floor clear of debris.
Lower the platform entry mid-rail or gate before
operating.
Collision Hazards
Operators must comply with employer, job site,
and governmental rules regarding use of personal
protective equipment.
Use common sense and
planning to control the
movement of the
machine on or near
inclines.
Do not lower the platform
unless the area below is
clear of personnel and
obstructions.
Check the work area for
overhead obstructions or
other possible hazards.
Be aware of crushing
hazards when grasping
the platform guard rail.
Stay clear of descending platform.

Operator's Manual Fifth Edition • First Printing
Work Area Safety
14 AWP®Super Series Part No. 1298034GT
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 Hazards
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.
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.
Be sure all maintenance has been performed as
specified in this manual and the appropriate Genie
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 machine.
Battery Safety
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 the upright
position.
Do not expose the batteries or the charger to
water or rain during charging.

Fifth Edition • First Printing Operator's Manual
Work Area Safety
Part No. 1298034GT AWP®Super Series 15
Explosion Hazards
Keep sparks, flames, and
lighted tobacco away from
batteries. Batteries emit
explosive gas.
Charge the battery in a well
ventilated area.
Do not contact the battery
terminals or the cable
clamps with tools that may
cause sparks.
Do not disconnect charger
DC output wires from the
battery when the charger is
on.
Component Damage Hazard
Do not use any battery charger greater than 24V
to charge the batteries.
Electrocution/Burn Hazards
Connect the battery charger to a
grounded, AC 3-wire electrical
outlet only.
Inspect daily for damaged cords,
cables and wires. Replace
damaged items before operating.
Avoid electrical shock from contact with battery
terminals. Remove all rings, watches and other
jewelry.
Lifting Hazard
Use the appropriate number of people and proper
lifting techniques when lifting batteries.
Improper Use Hazard
Do not leave the machine unattended unless the
key is removed to secure from unauthorized use.
Lockout After Each Use
1Select a safe parking location—firm level
surface, clear of obstruction and traffic.
2Lower the platform.
3Turn the key switch to the off position and
remove the key to secure from unauthorized
use.
4Charge the batteries.

Operator's Manual Fifth Edition • First Printing
Legend
16 AWP®Super Series Part No. 1298034GT
Legend
1Lifting eye
2AC models: Circuit breaker
3Outrigger storage socket
4Tilt-back frame retaining pin
in strut socket
5Tilt-back strut
6Swivel lock
7Tilt-back frame
8Loading stop bracket
9Loading pivot bar
10 Forklift pocket
11 Airline lubricator adjustment
knob
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 Sliding T-handle
20 Lanyard anchorage point
21 AC outlet
22 Platform controls
23 Operator's manual storage
container
24 Manual lowering valve (under
machine)
25 Base outrigger socket
26 Outrigger with 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 Ground controls
32 Mast

Fifth Edition • First Printing Operator's Manual
Controls
Part No. 1298034GT AWP®Super Series 17
Controls
The ground control station can be used in the event of an emergency to rescue an incapacitated person in
the platform.
Ground controls - AC and DC Models
Ground controls - Air Models
Platform controls
1Red Emergency Stop button
2Key switch
3Outrigger interlock display lights (four)
4Low battery indicator light for auxiliary lowering
5DC models: Low battery indicator light
6Power light
7Emergency platform lowering button
8Air pressure gauge
9Control activate button
10 Up/Down switch

Operator's Manual Fifth Edition • First Printing
Inspections
18 AWP®Super Series Part No. 1298034GT
Inspections
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 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.
The first time this machine is
set up for use, the pipe plug
in the hydraulic reservoir must
be removed and permanently
replaced with a breather cap.
A breather cap is supplied
and can be found in the
manual storage box.
Pre-operation Inspection
Fundamentals
It is the responsibility of the operator to perform a
pre-operation inspection 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.