Terex Genie AWP Super Series Operator's Manual
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Terex Genie AWP Super Series Operator's Manual

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

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  • Page 1 Operator's Manual Serial Number Range Super ® from AWPP-100000 Series with Maintenance Information Original Instructions Fifth Edition First Printing Part No. 1298034GT...

  • Page 2: Table Of Contents

    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.

  • Page 3: Introduction

    Fifth Edition • First Printing Operator's Manual Introduction Intr oducti on About this manual Intended Use and Familiarization Guide Genie appreciates your choice of our machine for your application. Our number one priority is user The intended use of this machine is to lift safety, which is best achieved by our joint efforts.
  • Page 4 Fifth Edition • First Printing Operator's Manual Introduction Platform controls symbology and related Ground controls symbology and related machine movement: machine movement: Platform up Keyswitch - Off Keyswitch - On Platform down Ground controls Platform controls Emergency platform lowering Low battery indicator Air pressure Interlocked functions: ...
  • Page 5 Fifth Edition • First Printing Operator's Manual Introduction Bulletin Distribution and Contacting the Manufacturer Compliance At times it may be necessary to contact Genie. When you do, be ready to supply the model Safety of product users is of paramount number and serial number of your machine, along importance to Genie.
  • Page 6 Fifth Edition • First Printing Operator's Manual Introduction 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.

  • Page 7: Symbol And Hazard Pictorials Definitions

    Fifth Edition • First Printing Operator's Manual Symbol and Hazard Pictorials Definitions Symbol and H az ard Pictorials Definiti ons Read the operator’s Read the service Crush hazard No smoking Collision hazard manual manual Tip-over hazard Tip-over hazard Tip-over hazard Electrocution hazard Tip-over hazard Burn hazard...
  • Page 8 Fifth Edition • First Printing Operator's Manual Symbol and Hazard Pictorials Definitions Maintain required Outrigger load Lifting point Release brakes Grounded AC clearance 3-wire only Replace damaged Wheel load Lanyard anchorage Side force Wind speed wires and cords points Maximum capacity Use common sense Indoor Outdoor...

  • Page 9: General Safety

    Fifth Edition • First Printing Operator's Manual General Safety Gener al Safety These decals are model, option or configuration specific. ® Part No. 1298034GT Super Series...
  • Page 10 Fifth Edition • First Printing Operator's Manual General Safety These decals are model, option or configuration specific. ® Super Series Part No. 1298034GT...

  • Page 11: Personal Safety

    Fifth Edition • First Printing Operator's Manual Personal Safety Pers onal Safety 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...

  • Page 12: Work Area Safety

    Fifth Edition • First Printing Operator's Manual Work Area Safety Wor k Ar ea Safety Electrocution Hazards Allow for platform movement, electrical line sway or sag, and beware of strong or gusty winds. This machine, even with an optional fiberglass platform, is not electrically insulated and will not Do not use the machine as a ground for welding.
  • Page 13 Fifth Edition • First Printing Operator's Manual Work Area Safety Do not place or attach fixed or overhanging loads Do not operate the machine near drop-offs, holes, to any part of this machine. bumps, debris, unstable or slippery surfaces or other possible hazardous conditions.
  • Page 14 Fifth Edition • First Printing Operator's Manual Work Area Safety Standard base models with outdoor outriggers: Maximum capacity Do not raise the platform when wind speeds may AWP-20S 350 lbs 159 kg exceed 28 mph / 12.5 m/s. If wind speeds exceed AWP-25S 350 lbs 159 kg...
  • Page 15 Fifth Edition • First Printing Operator's Manual Work Area Safety Fall Hazards Collision Hazards Operators must comply with employer, job site, The guard rail system and governmental rules regarding use of personal provides fall protection. If protective equipment. occupant(s) of the platform are required to Use common sense and wear personal fall...
  • Page 16 Fifth Edition • First Printing Operator's Manual Work Area Safety Bodily Injury Hazard Battery Safety Do not operate the machine with a hydraulic oil or Burn Hazards air leak. An air leak or hydraulic leak can penetrate Batteries contain acid. and/or burn skin.
  • Page 17 Fifth Edition • First Printing Operator's Manual Work Area Safety Explosion Hazards Electrocution/Burn Hazards Keep sparks, flames, and Connect the battery charger to a lighted tobacco away from grounded, AC 3-wire electrical batteries. Batteries emit outlet only. explosive gas. Inspect daily for damaged cords, Charge the battery in a well cables and wires.

  • Page 18: Legend

    Fifth Edition • First Printing Operator's Manual Legend Leg end Lifting eye 12 Air supply for machine 24 Manual lowering valve (under machine) AC models: Circuit breaker 13 Airline lubricator 25 Base outrigger socket Outrigger storage socket 14 DC models: Battery pack with charger 26 Outrigger with leveling jack Tilt-back frame retaining pin...

  • Page 19: Controls

    Fifth Edition • First Printing Operator's Manual Controls 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 Red Emergency Stop button Key switch...

  • Page 20: Inspections

    Fifth Edition • First Printing Operator's Manual Inspections Ins pections 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. Do Not Operate Unless: The inspection is designed to discover if anything is apparently wrong with a machine before the...
  • Page 21 Fifth Edition • First Printing Operator's Manual Inspections Pre-operation Inspection  Sequencing cables and pulleys  Lifting chains and idler wheels  Be sure that the operator’s, safety and  Nuts, bolts and other fasteners responsibilities manuals are complete, legible and in the storage container located in the ...
  • Page 22 Fifth Edition • First Printing Operator's Manual Inspections Function Test 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 Do Not Operate Unless: tagged and removed from service.
  • Page 23 Fifth Edition • First Printing Operator's Manual Inspections Function Tests Select an outrigger and slide it into a base Setup socket until the outrigger lock pin Position the machine on a firm surface directly snaps into place. below the desired work area. Adjust the outrigger to Connect to the appropriate power source.
  • Page 24 Fifth Edition • First Printing Operator's Manual Inspections Test Emergency Stop Test Auxiliary Platform Lowering - AC & DC Models 10 Push in the ground red Emergency Stop button to the off position. 19 Raise the platform slightly. 11 Push in the control activate button and rotate 20 Disconnect the power source from the the up/down switch in the direction of intended machine.
  • Page 25 Fifth Edition • First Printing Operator's Manual Inspections Workplace Inspection Checklist Be aware of and avoid the following hazardous situations:  drop-offs or holes  bumps, floor obstructions, or debris  sloped surfaces Do Not Operate Unless:  unstable or slippery surfaces ...
  • Page 26 Fifth Edition • First Printing Operator's Manual Inspections Inspection for Decals with Part No. Decal Description Symbols 1257853 Danger - Wind Speed, 75 in/191 cm Outrigger* Use the inspection to verify that all decals are 1257854 Danger - Wind Speed, 60 in/152 cm legible and in place.
  • Page 27 Fifth Edition • First Printing Operator's Manual Inspections ® Part No. 1298034GT Super Series...

  • Page 28: Operating Instructions

    Fifth Edition • First Printing Operator's Manual Operating Instructions Operati ng Instr ucti ons Fundamentals The Operating Instructions section provides 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, safety and responsibilities manuals.
  • Page 29 Fifth Edition • First Printing Operator's Manual Operating Instructions Setup Emergency Stop Position the machine on a firm surface directly Push in the red Emergency Stop button at the below the desired work area. platform controls or at the ground controls to stop the up function.
  • Page 30 Fifth Edition • First Printing Operator's Manual Operating Instructions Auxiliary Platform Lowering - AC & DC Models Turn the key switch to ground control. Pull out the red Emergency Stop button to the on position. Activate the auxiliary platform lowering button at the ground controls.

  • Page 31: Maintenance

    Fifth Edition • First Printing Operator's Manual Maintenance Maintenanc e Check the Batteries - DC Models Proper battery condition is essential to good machine performance and operational safety. Improper fluid levels or damaged cables and Observe and Obey: connections can result in component damage and hazardous conditions.
  • Page 32 Fifth Edition • First Printing Operator's Manual Maintenance Check the Hydraulic Oil Level Check the Air Line Lubricator Oil Level - Air Models Maintaining the hydraulic oil at the proper level is essential to machine operation. Improper hydraulic Maintaining the proper oil level in the lubricator oil levels can damage hydraulic components.
  • Page 33 Fifth Edition • First Printing Operator's Manual Maintenance Check the Oil Lubricator Canister Scheduled Maintenance Drip Rate - Air Models Maintenance performed 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 Maintaining the proper oil drip rate into the the service manual for this machine.

  • Page 34: Battery Charging Instructions

    Fifth Edition • First Printing Operator's Manual Battery Charging Instructions Batter y Charging Instr ucti ons Dry Battery Filling and Charging Instructions Remove the battery vent caps and permanently remove the plastic seal from the battery vent openings. Fill each cell with battery acid (electrolyte) until Battery and Charger Instructions the level is sufficient to cover the plates.

  • Page 35: Transport Instructions

    Fifth Edition • First Printing Operator's Manual Transport Instructions Trans port Instr ucti ons Lifting Instructions The number of people required to load and unload a machine is dependent on a number of factors, including but not limited to:  the physical condition, strength and disabilities or prior injuries of the people involved Transport Instructions...
  • Page 36 Fifth Edition • First Printing Operator's Manual Transport Instructions Loading for Transport Hook the loading pivot to the stop bracket. Fully lower the platform. Position the machine flush against the loading Push in the red Emergency Stop buttons, turn surface. Lower and lock the key switch to the off position and remove the stop bracket to the the key.
  • Page 37 Fifth Edition • First Printing Operator's Manual Transport Instructions Winching the Machine onto a Lifting the Machine with a Forklift Flatbed Truck Inspect the entire machine and remove any loose or unsecured items. Fully lower the platform. Fully lower the platform. The platform must remain Push in the red Emergency Stop buttons, turn lowered during all loading and transport the key switch to the off position and remove...
  • Page 38 Fifth Edition • First Printing Operator's Manual Transport Instructions Loading the Machine With a Securing the Machine Crane Use chains or straps of ample load capacity. Use the lifting eye mounted on the rear mast Use a minimum of 2 chains or straps. column.

  • Page 39: Tilt-Back Operation Instructions

    The appropriate number of people and proper lifting techniques must be used to prevent physical injury. Tilt-back Frame The Genie AWP Super Series has a tilt-back frame which allows the machine to roll through a standard doorway. The tilt-back frame is standard...
  • Page 40 Fifth Edition • First Printing Operator's Manual Tilt-back Operation Instructions Lowering the Tilt-back Assembly Tilting Back the Machine Be sure the area behind the machine and Slide out the T-handle under the tilt-back frame is clear of personnel until the lock pin snaps and obstructions.
  • Page 41 Fifth Edition • First Printing Operator's Manual Tilt-back Operation Instructions Returning the Machine to Stowing the Tilt-back Assembly Standing Position Remove the retaining pin. Be sure the area below the machine base and T-handle is clear of personnel and obstructions. Slide out the T-handle until the lock pin snaps into place.

  • Page 42: Specifications

    Fifth Edition • First Printing Operator's Manual Specifications Specific ati ons Machine Specifications Lift capacity Height, working maximum AWP-20S, 25S, 30S, 36S 350 lbs/159 kg AWP-20S 26 ft 1 in/8.0 m AWP-40S 300 lbs/136 kg AWP-25S 30 ft 9 in/9.4 m Power source AWP-30S 35 ft 6 in/10.8 m...
  • Page 43 Fifth Edition • First Printing Operator's Manual Specifications Outrigger Specifications - Standard AWP-20S AWP-25S AWP-30S base Outrigger footprint (l x w) 60.75 x 52.75 in 69.25 x 61.25 in 75.50 x 67.50 in Indoor 1.5 x 1.3 m 1.8 x 1.6 m 1.9 x 1.7 m Outrigger footprint (l x w) 97 x 89 in...
  • Page 44 Fifth Edition • First Printing Operator's Manual Specifications Contents of EC Declaration of Conformity <Manufacturer’s name> hereby declares that the machinery described below complies with the provisions of the following Directives: 1. EC Directive 2006/42/EC, Machinery Directive, under consideration of harmonized European standard EN280 as described in EC type-examination certificate <variable field>...

This manual is also suitable for:

Genie awp-20sGenie awp-25sGenie awp-30sGenie awp-36sGenie awp-40s

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