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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
Safe Operation in Hazardous Locations ..................... 1
Safety Rules .............................................................. 2
Controls .................................................................... 10
Pre-operation Inspection ........................................... 13
Maintenance ............................................................. 15
Function Tests .......................................................... 17
Workplace Inspection ................................................ 22
Operating Instructions ............................................... 23
Transport and Lifting Instructions .............................. 31
Decals ...................................................................... 34
Specifications ........................................................... 36
Printed in U.S.A.
Failure to obey the instructions and Do not operate the engine while the machine is in
hazardous locations.
safety rules in this manual will result
in death or serious injury. Do not charge the batteries in hazardous locations.
Areas Not Cut Off or Ventilated. The entire area of 1 If the engine is running, turn off the engine.
the hangar, including any adjacent and 2 Allow the engine to cool down until the
communicating areas not suitably cut off from the thermometer reads below 348°F.
hangar, shall be classified as a Class I, Division 2
or Zone 2 location up to a level 450 mm (18 in) 3 Locate the engine and charger switches.
above the floor. 4 Move the switches to the off position and lock.
Vicinity of Aircraft. The area within 1.5 m (5 ft) 5 Lock all 3 AC plug covers.
horizontally from aircraft power plants or aircraft
fuel tanks shall be classified as a Class I, Division 6 Be sure the lanyards on the battery disconnect
2 or Zone 2 location that shall extend upward from plugs are in place and secured.
the floor to a level 1.5 m (5 ft) above the upper 7 Be sure the engine side chassis cover is latched
surface of wings and of engine enclosures. and locked.
8 Be sure the plate in the back of the battery box
is in place to prevent battery movement.
Safety Rules
Danger
Failure to obey the instructions and
safety rules in this manual will result
in death or serious injury.
SAFETY RULES
Maximum capacity
Do not operate the machine during lightning or Do not depend on the tilt alarm as a level indicator.
storms. The tilt alarm sounds in the platform only when the
machine is on a severe slope.
Do not use the machine as a ground for welding.
SAFETY RULES
If the tilt alarm sounds: Do not use air-filled tires. These machines are
Do not extend, rotate or raise the boom above equipped with foam-filled tires. Wheel weight and
horizontal. Move the machine to a firm, level proper counterweight configuration are critical to
surface before raising the platform. If the tilt alarm stability.
sounds when the platform is raised, use extreme
caution to retract the boom and lower the platform. Do not drive the machine on or near uneven terrain,
Do not rotate the boom while lowering. Move the unstable surfaces or other hazardous conditions
machine to a firm, level surface before raising the with the boom raised or extended.
platform. Do not drive the machine on a slope that exceeds
Do not use the platform controls to free a platform the maximum uphill, downhill or side slope rating of
that is caught, snagged or otherwise prevented the machine. Slope rating applies only to machines
from normal motion by an adjacent structure. All in the stowed position.
personnel must be removed from the platform
before attempting to free the platform using the Maximum slope rating, stowed position
ground controls. Platform downhill 30% (17°)
Do not raise the boom when wind speeds may Platform uphill 20% (11°)
exceed 28 mph / 12.5 m/s. If wind speeds exceed
28 mph / 12.5 m/s when the boom is raised, lower Side slope 25% (14°)
the boom and do not continue to operate the
Note: Slope rating is subject to ground conditions
machine.
and adequate traction.
Do not operate the machine in strong or gusty
Do not push off or pull
winds. Do not increase the surface area of the
toward any object
platform or the load. Increasing the area exposed to
outside of the platform.
the wind will decrease machine stability.
Maximum allowable
side force - ANSI & CSA
150 lbs / 667 N
Use extreme care and slow speeds while driving Do not modify or alter an aerial work platform
the machine in the stowed position across uneven without prior written permission from the
terrain, debris, unstable or slippery surfaces and manufacturer. Mounting attachments for holding
near holes and drop-offs. tools or other materials onto the platform, toeboards
or guard rail system can increase the weight in the
Do not alter or disable the limit switches. platform and the surface area of the platform or the
load.
SAFETY RULES
SAFETY RULES
SAFETY RULES
Do not spray ether into engines equipped with glow Do not operate any of the
plugs. machine controls when the
auxiliary platform is
Damaged Machine Hazards occupied.
SAFETY RULES
Electrocution Hazards
Connect the battery charger to a
grounded, AC 3-wire electrical
outlet only.
SAFETY RULES
Decal Legend
Genie product decals use symbols, color coding
and signal words to identify the following:
Controls
1 2 3 4 5 6 7
22 21 20 19 18
CONTROLS
8 9 10 11 12 13 14
17 16 15
· Rabbit & Foot Switch: foot switch activated 16 Boom function speed controller
high idle
17 Primary boom extend/retract switch
· Turtle: low idle
· Rabbit: high idle and quickest battery charging 18 Primary boom up/down switch
12 Drive lights switch 19 Secondary boom up/down switch
13 Machine not level indicator light 20 Turntable rotate left/right switch
14 Red Emergency Stop button 21 Beacons switch
15 Proportional control handle for drive function and 22 Battery charge indicator
thumb rocker for steer function
CONTROLS
7 9
5
10
4
2 11
1
12
17 16 15 14 13
Pre-operation Inspection
Fundamentals
It is the responsibility of the operator to perform a
pre-operation inspection and routine maintenance.
PRE-OPERATION INSPECTION
Pre-operation Inspection
R Platform entry mid-rail
R Be sure that the operator's, safety and
responsibilities manuals are complete, legible R Beacon and alarms
and in the storage container located on the
R Auxiliary platform components
platform.
R Aircraft protection package components
R Be sure that all decals are legible and in place.
See Decals section. Check entire machine for:
R Check for engine oil leaks and proper fluid level. R Cracks in welds or structural components
Add oil if needed. See Maintenance section.
R Dents or damage to machine
R Check for engine coolant leaks and proper fluid
R Be sure that all structural and other critical
level. Add coolant if needed. See Maintenance
section. components are present and all associated
fasteners and pins are in place and properly
R Check for hydraulic oil leaks and proper oil tightened.
level. Add oil if needed. See Maintenance
R After you complete your inspection, be sure that
section.
all compartment covers are in place and
R Check for battery fluid leaks and proper fluid secured.
level. Add distilled water if needed. See
Maintenance section.
Check the following components or areas for
damage, improperly installed or missing parts and
unauthorized modifications:
Maintenance
MAINTENANCE
Check the Engine Oil Level Check the Hydraulic Oil Level
Maintaining the proper engine oil level is essential Maintaining the hydraulic oil at the proper level is
to good engine performance and service life. essential to machine operation. Improper hydraulic
Operating the machine with an improper oil level oil levels can damage hydraulic components. Daily
can damage engine components. checks allow the inspector to identify changes in oil
level that might indicate the presence of hydraulic
Check the oil level with the
system problems.
engine off.
1 Be sure the boom is in the stowed position, then
1 Check the oil level dipstick. Add oil as needed.
visually inspect the oil level in the hydraulic
Result: The oil level should be at the FULL mark tank.
on the dipstick.
Result: The hydraulic oil level should be within
Kubota Engine Z482-E the FULL and ADD marks on the hydraulic tank.
Engine oil should have properties of API classification Hydraulic oil type Mil-5606H
CC/SE, CD/SE, CC/SF or CD/SF grades. Units ship Mil-83282D
with 10W-40 SG/CC
Function Tests
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.
FUNCTION TESTS
1 Select a test area that is firm, level and free of 14 Hold the function enable switch to either side
obstruction. and activate each boom and platform function
toggle switch.
At the Ground Controls
Result: All boom and platform functions should
2 Turn the key switch to ground control. operate through a full cycle. The alarm should
sound while any function is operating.
3 Pull out the red Emergency Stop button to
the on position. Test the Tilt Sensor
4 Start the engine. See Operating Instructions 15 Turn the key switch to platform control. Pull out
section. the platform red Emergency Stop button to the
Test Emergency Stop on position.
16 Open the engine side
5 Push in the red Emergency Stop button to the
turntable cover and locate
off position.
the tilt sensor to the right of
Result: The engine should turn off and all the engine.
functions should not operate.
17 Press down one side of the
6 Pull out the red Emergency Stop button to tilt sensor and hold for 5
the on position. seconds.
Test Thermometer Result: The alarm, located
in the platform, should
7 Start the engine. sound.
8 Check the thermometer on the control panel. Test Auxiliary Controls
Result: The temperature should rise.
18 Turn the key switch to ground control.
9 Push in the red Emergency Stop button to turn
19 Pull out the red Emergency Stop button to the
off the engine.
on position.
Test the Engine Lock-out Switch
20 Simultaneously hold the auxiliary
10 Move the engine lock-out switch to the off power switch on and activate
position. each boom function toggle
switch.
11 Push the engine start button.
Note: To conserve battery power, test each
Result: The engine should not start. function through a partial cycle.
12 Move the engine lock-out switch to the on Result: All boom functions should operate.
position.
Test the Machine Functions
13 Do not hold the function enable
switch to either side. Attempt to
activate each boom and platform
function toggle switch.
Result: All boom and platform functions should
not operate.
FUNCTION TESTS
21 Push in the platform red Emergency Stop button 33 Activate each machine function control handle
to the off position. or toggle switch.
22 Activate each machine function control handle Result: All boom/platform functions should
or toggle switch. operate through a full cycle.
Result: No functions should operate. Note: Control the speed of boom functions by
adjusting the boom function speed controller. Drive
23 Pull out the red Emergency Stop button to the and steer functions are not affected by the boom
on position. function speed controller.
Test the Horn Test the Steering
24 Push the horn button. 34 Press down the foot switch.
Result: The horn should sound. 35 Depress the thumb rocker switch on top of the
Test the Beacon drive control handle in the direction identified by
the blue triangle on the control panel.
25 Move the beacon toggle switch to the on
Result: The steer wheels should turn in the
position.
direction that the blue triangles point on the
Result: The beacon should flash. drive chassis.
26 Move the beacon toggle switch to the foot 36 Depress the thumb rocker switch in the direction
switch activated on position. Do not step on the identified by the yellow triangle on the control
foot switch. panel.
Result: The beacon should not flash. Result: The steer wheels should turn in the
direction that the yellow triangles point on the
27 Press down the foot switch.
drive chassis.
Result: The beacon should flash.
Test the Foot Switch
FUNCTION TESTS
FUNCTION TESTS
Result: The drive function should operate. 58 Extend the primary boom 2 ft / 60 cm.
Note: When the drive enable system is in use, the 59 Move the gray bumper at the bottom of the
machine may drive in the opposite direction that the platform 2 inches / 5 cm in any direction.
drive and steer control handle is moved. 60 Activate each function control handle or toggle
Use the color-coded direction switch.
arrows on the platform Blue
Result: All boom and steer functions should not
controls and the drive operate.
chassis to identify the
direction of travel. 61 Move the function override switch to either side.
Yellow
62 Activate each function control handle or toggle
switch.
Result: All boom and steer functions should
operate.
Workplace Inspection
Workplace Inspection
Be aware of and avoid the following hazardous
situations:
· drop-offs or holes
· bumps, floor obstructions or debris
Do Not Operate Unless: · sloped surfaces
You learn and practice the principles of safe · unstable or slippery surfaces
machine operation contained in this operator's
manual. · overhead obstructions and high voltage
conductors
1 Avoid hazardous situations.
· hazardous locations
2 Always perform a pre-operation
inspection. · inadequate surface support to withstand all load
forces imposed by the machine
3 Always perform function tests prior to use.
· wind and weather conditions
4 Inspect the workplace.
· the presence of unauthorized personnel
Know and understand the workplace
inspection before going on to the next · other possible unsafe conditions
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
operating the machine.
Operating Instructions
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.
Do Not Operate Unless: Using the machine for anything other than lifting
personnel, along with their tools and materials, to
You learn and practice the principles of safe
an aerial work site is unsafe and dangerous.
machine operation contained in this operator's
manual. Only trained and authorized personnel should be
1 Avoid hazardous situations. permitted to operate a machine. If more than one
operator is expected to use a machine at different
2 Always perform a pre-operation times in the same work shift, they must all be
inspection. qualified operators and are all expected to follow all
3 Always perform function tests prior to use. safety rules and instructions in the operator's,
safety and responsibilities manuals. That means
4 Inspect the workplace. every new operator should perform a pre-operation
inspection, function tests, and a workplace
5 Only use the machine as it was intended.
inspection before using the machine.
OPERATING INSTRUCTIONS
OPERATING INSTRUCTIONS
OPERATING INSTRUCTIONS
Driving on a slope While holding the piece of wood level, measure the
vertical distance from the bottom of the piece of
Determine the uphill, downhill and side slope ratings
wood to the ground.
for the machine and determine the slope grade.
Divide the tape measure distance (rise) by the
Maximum slope rating,
length of the piece of wood (run) and multiply by
platform downhill (gradeability):
100.
30% (17°)
Example:
Maximum slope rating,
platform uphill: run
20% (11°)
Be sure the boom is below horizontal and the Run = 144 inches (3.6 m)
platform is between the non-steer wheels.
Rise = 12 inches (0.3 m)
Move the drive speed select switch to
12 in ÷ 144 in = 0.083 x 100 = 8.3% grade
machine on incline symbol.
0.3 m ÷ 3.6 m = 0.083 x 100 = 8.3% grade
To determine the slope grade:
If the slope exceeds the maximum uphill, downhill
Measure the slope with a digital inclinometer OR
or side slope rating, then the machine must be
use the following procedure.
winched or transported up or down the slope. See
You will need: Transport and Lifting section.
carpenter’s level
straight piece of wood, at least 3 feet / 1 m long
tape measure
Lay the piece of wood on the slope.
At downhill end, lay the level on the top edge of the
piece of wood and lift the end until the piece of
wood is level.
OPERATING INSTRUCTIONS
OPERATING INSTRUCTIONS
8 Unfold the auxiliary platform to the fully upright Machine Not Level Indicator
position.
Light
9 Secure the four pins at the toeboard.
Light on indicates the machine is not
10 Secure the four pins at the mid-rail. level. The tilt alarm will be sounding
when this light is on. Move the
machine to a firm level surface.
Work Lights
The on/off switch for each light is on the back of
the light.
The light can be removed from the clamp for use.
OPERATING INSTRUCTIONS
OPERATING INSTRUCTIONS
Be sure the vehicle capacity, loading surfaces 1 Chock the wheels to prevent the machine from
and chains or straps are sufficient to withstand rolling.
the machine weight. See the serial plate for the 2 Apply the non-steer wheel brakes by turning
machine weight. over the drive hub disconnect caps.
The machine must be on a level surface or
secured before releasing the brakes. Towing Instructions
Be sure the turntable is secured with the Before towing:
turntable rotation lock before transporting. Be 1 Chock the wheels to prevent the machine from
sure to unlock the turntable for operation. rolling.
Be sure the traction ramps are removed from the 2 Attach the towing bar securely to the towing
drive chassis and stowed in the platform before vehicle and to the machine.
using the tie-down points. Disengage
3 Disengage the rear Position
Do not drive the machine on a slope that wheel brakes by
exceeds the slope or side slope rating. See turning over the drive
Driving on a Slope in the Operating Instructions hub disconnect caps.
Engage
section. Position
4 Turn the steering
If the slope of the transport vehicle bed exceeds bypass valve counterclockwise to hydraulically
the uphill or downhill maximum slope rating, the release the steering.
machine must be loaded and unloaded using a After the machine is towed:
winch as described.
1 Chock the wheels to prevent the machine from
rolling.
2 Disconnect the towing bar.
3 Turn the steering bypass valve clockwise to
restore the steering.
4 Engage the rear wheel brakes by turning over
the drive hub disconnect caps.
Lifting Instructions
Fully lower and retract the boom. Fully lower the jib.
Remove all loose items from the machine.
Decals
Part No. Decal Description Quantity 52787 Notice - Charger Operating Instructions 2
72867 Label - Driving Lights 1
27204 Arrow - Blue 1
27205 Arrow - Yellow 1 82279 Platform Control Panel 1
28162 Warning - Bodily Injury Hazard 1 97594 Warning - Explosion Hazards, Battery 2
28165 Notice - Foot Switch 1 97596 Warning - Explosion Hazard, Battery Box 2
97597 Warning - Explosion Hazard, Switches 1
28171 Label - No Smoking 1
97598 Label - Ramp Storage 1
28175 Caution - Compartment Access 1
97599 Warning - Explosion Hazard, Temp 1
28176 Notice - Missing Manuals 1
97610 Caution - Collision Hazard 1
28177 Warning - Platform Rotate 2
97612 Warning, Explosion Hazards, Plugs 1
28181 Warning - No Step or Ride 1
97615 Notice - Remove Ramps 2
28235 Label - Power to Platform, 115V 1
97633 Ground Control Panel 1
28236 Warning - Failure To Read . . . 1
97634 Label - Auxiliary Platform ID Numbers 1
28372 Caution - Quick Disconnect 2
97644 Label - Machine ID Numbers 1
29104 Danger - Towing Safety/Instructions 1
97679 Label - CG 2
30080 Notice - Maximum Load, 500 lbs / 227 kg 1
97680 Warning - Explosion Hazard, Inclines 1
31060 Danger - Tip-over Hazard, Interlock 3
97691 Label - Traction Ramp ID Numbers 2
31508 Notice - Power to Charger 1
97887 Notice - Max Side Force, 150 lbs / 667N 1
31786 Notice - Connection Diagram 2
97890 Danger - General Safety 2
31787 Danger - Tip-over Hazard 2
106334 UID Plate, Auxiliary Platform 1
31788 Danger - Battery Safety 2
106336 UID Plate 1
33952 Danger - Tilt-Alarm 1
110282 Notice - Kubota Engine Spec 1
35526 Caution - Towing Speed 1
114061 Label - Wheel Load 4
40434 Label - Lanyard Anchorage 4
133278 Label - Ultra Low Sulfur Diesel 1
43595 Danger - Tip-over Hazard, Tires 4
139306 Instructions - Kubota Engine Spec 1
44980 Label - Power to Charger, 115V 1
1000027 Notice - Operating Instructions 2
44981 Label - Air Line to Platform 2
46468 Label - Function Override 1
DECALS
Platform
Drive
Chassis
Engine
Side
SPECIFICATIONS
Maximum drive speed, 0.6 mph 1 km/h Localized pressure per tire 100 psi 7.03 kg/cm2
booms raised 40 ft/45 sec 12.2 m/45 sec 690 kPa
Airborne noise emissions 100 dB Occupied pressure 325 psf 15.87 kPa
Maximum sound level at normal operating workstations Note: Floor loading information is approximate and
(A-weighted) does not incorporate different option configurations. It
Machine weight 17,500 lbs 7938 kg should be used only with adequate safety factors.