Genie IWP 25S (APK)
Contents
1. Part No Description Quantity Part No Description Quantity 27857 Caution Pipe Plug 1 43657 Danger Tip over Hazard Outreach 27868 Danger Relief Valve 1 A 28174 Label Power ta Platform 230V 2 48644 Label Function Enable Lever 1 28235 Label Power to Platform 115V 2 RE a APOS 1 28372 Caution Quick Disconnect 1 52996 Cosmetic Genie Logo 2 31070 Danger Tip over Hazard Moving 1 62045 Cosmetic IWP 25S 2 31071 Warning Failure to Read 1 62046 _ Cosmetic IWP 30S 2 31073 Label Foot Pedal 1 62996 Cosmetic IWP 20S 2 31075 Caution Crushing Hazard 4 72086 Label Lifting Eye 1 31245 Warning Collision Hazard 1 72844 Danger General Safety 1 37141 Notice Manual Lowering Instructions 1 82366 Label Chevron Rykon 1 37143 Notice Max Capacity 300 Ibs 136 kg 1 82782 Label Interlock Display 1 37144 Notice Max Capacity 350 Ibs 159 kg 1 82802 Label Control Activate 1 37145 Label Manual Lowering Valve 1 82907 Danger Battery Charger Safety 1 38116 Danger Outreach Option Safety 82975 Caution Collision Hazard 1 and Instructions 1 38117 Notice Power Wheel Assist Option iat SRO GCTOGHTORURIA AGO 1 Operating Instructions 1 97519 Notice Max Side Force 45 Ibs 200 N 1 38119 Notice Operating Instructions 1 97526 Label Footpad Load 4 38122 Label Manual Storage Container 1 97527 Label Wheel Load 2 382. Third Edition Fourth Printing place Part No Description Quantity 28174 Label Power to Platform 230V 2 28235 Label Power to Platform 115V 2 52996 Cosmetic Genie Logo 2 62045 Cosmetic IWP 25S 2 62046 Cosmetic IWP 30S 2 62996 Cosmetic IWP 20S 2 82475 Caution Foot Crush 4 82481 Danger Battery Charger Safety 1 82487 Label Read the Manual 2 82614 Danger Collision Hazard 1 82782 Label Interlock Display 1 82802 Label Control Activate 1 82913 Danger Max Capacity 159 kg 1 82914 Danger Max Capacity 136 kg 1 82915 Label Manual Lowering Valve 1 82974 Warning Collision Hazard 1 82987 Danger Electrocution Hazard 1 97526 Label Footpad Load 4 97527 Label Wheel Load 2 97537 Danger Maximum Manual Force 200N 1 97538 Label Function Enable Power Wheel Assist 1 97775 Label Interlock Display 1 26 Genie IWP Super Series Part No 82909 Third Edition Fourth Printing Operators Manual DECALS 82782 52996 82475 82487 or 97775 97526 82914 2 UE 82802 H 28174 j or 28235 97538 82987 Outreach Option 82481 82915 Serial Plate 28174 or 28235 82475 Soen 82974 62
3. Geni Operators Manual with Maintenance Information Third Edition Fourth Printing Part No 82909 IWP Super Series Operator s Manual Third Edition Fourth Printing 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 is 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 essent 1 Daga 7 E e opee UEM 8 Pre operation Inspection seseeeeessess 9 Malritenarioe oiii EE M dnt paz KA 11 Function Tests iiiter recen nnne is 13 Workplace Inspection sees 17 Operating Instructions sesesseeeees 18 Battery and Charger Instructions 21 Transport and Lifting Instructions 22 Decals ana TUN 24 Specificatloris cei ienien 28 Co ntact us Copyright 1996 by Genie Industries Internet http www genielift com First Edition Fifth Printing November 1997 e mail techpub genieind com Second Edition Fourth Printing January 2002 Third Edition Fourth Printing July 2008 Genie and IWP are registered trademarks of Genie Industries in the U S A and ma
4. MI Use only a Genie authorized battery and charger OPERATING INSTRUCTIONS To Charge Battery 1 2 Open the battery pack lid to access the battery Remove the battery vent caps and check the battery acid level If necessary add only enough distilled water to cover the plates Do not overfill prior to the charge cycle Replace the battery vent caps Be sure that the DC output cord is properly connected to the battery black to negative red to positive Connectthe battery charger to a grounded AC circuit The charger will turn off automatically when the battery is fully charged Check the battery acid level when the charge cycle is complete Replenish with distilled water to the bottom of the fill tube Do not overfill Dry Battery Filling and Charging Instructions 1 Remove the battery vent caps and permanently remove the plastic seal from the battery vent openings Fill each cell with battery acid electrolyte until the level is sufficient to cover the plates Do not fill to the maximum level until the battery charge cycle is complete Overfilling can cause the battery acid to overflow during charging Neutralize battery acid spills with baking soda and water 3 4 5 Install the battery vent caps Chargethe battery Check the battery acid level when the charging cycle is complete Replenish with distilled water to the bottom of the fill tube Do not overfill Part No 82909 Genie IWP Super
5. 7 O O ly Q Note Two different interlock display decals were produced The symbols on them are different but they both operate the same way Both are illustrated in this text Emergency Stop 1 Push in the red Emergency Stop button at the platform controls or at the ground controls to stop the up function Platform Raise and Lower 1 Twist to release the red Emergency Stop button at the platform controls 2 Pushin the control activate button and rotate the up down switch in the desired direction of travel Manual Lowering 1 Activate the manual lowering valve located at the bottom of the hydraulic cylinder OPERATING INSTRUCTIONS Auxiliary Platform Lowering 1 Turn the key switch to ground control 2 Activate the auxiliary platform lowering button at the ground controls 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 After Each Use 1 Select a safe storage location firm level surface weather protected clear of obstructions and traffic 2 Pullthe base lowering handle to lower the base until all four footpads are in firm contact with the ground Remove the key to secure from
6. 18 in e 2 CSA 46 cm E Corner access 6 in 6 in 7 in 15 cm 15 cm 18 cm IWP 30S is only available with a wide base Continuous improvement of our products is a Genie policy Product specifications are subject to change without notice or obligation Corner of platform top rail to corner of wall with ability to rotate leveling jack handle 28 Genie IWP Super Series Part No 82909 Third Edition Fourth Printing Operator s Manual Airborne noise emissions 80 dB Maximum sound level at normal operating workstations A weighted Platform Dimensions length x width x height Standard platform 27 x 26 x 443 4 in gated or sliding mid rail 69 cm x 66 cm x 1 1m Gated ultra narrow platform 22 x 18 x 443 4 in 56 cm x 46cm x 1 1m Gated narrow platform 26 x 20 x 443 4 in 66 cm x 51 cm x 1 1 m Standard fiber platform 29 x 261 2 x 431 2 in 74 cm x 67 cem x 1 1 m Narrow fiber platform 26 x 22 x 431 2 in 66 cm x 56 cm x 1 1 m Front entry gated narrow platform 20 x 26 x 443 4 in 51cm x 66cmx 1 1 m Extra large front and side entry 30 x 28 x 443 4 in platform 76 cm x 71 cm x 1 1 m SPECIFICATIONS Part No 82909 Genie IWP Super Series 29 Genie North America Phone 425 881 1800 Toll Free USA and Canada 800 536 1800 Fax 425 883 3475 Genie Australia Pty Ltd Phone 61 7 3375 1660 Fax 4617 3375 1002 Genie Scandinavia Phone 46 31575100 Fax 446 31579020 Geni
7. Series 21 Operator s Manual Third Edition Fourth Printing Transport and Lifting Instructions Observe and Obey MI Common sense and planning must be applied to control the movement of the machine when lifting it with a crane or forklift MI The transport vehicle must be parked on a level surface MI The transport vehicle must be secured to prevent rolling while the machine is being loaded M Vehicle capacity loading equipment and surfaces must be capable of supporting the machine weight See the serial plate for the machine weight MI The base of the machine must remain lowered during allloading and transport procedures M The machine must be secured to the transport vehicle with chains or straps of ample load capacity Winching the Machine onto a FlatbedTruck 1 Lowerthe platform 2 Pushin the red Emergency Stop buttons turn the key switch to the off position and remove the key 3 Inspect the entire machine for loose or unsecured items 4 Connect the cable to the winching point located on the front of the base 5 Carefully winch the machine onto the truck 6 Secure the machine base and mast to the transport vehicle Use chains or straps of ample load capacity Loading the Machine With a Forklift Use the forklift pockets located on the sides of the machine or the forklift rings located behind the counterweight under the platform Be sure to inspect the machine and remove any loose or
8. in this text Insert the key and turn to platform control TestlInterlock System 7 Pull out the red Emergency Stop button at the 9 Pump the foot pedal to raise the base groundeontrois toha OR DOSIDIOR Result The two footpad display lights should be off O O 14 Genie IWP Super Series Part No 82909 Third Edition Fourth Printing Operator s Manual 10 Pull the base lowering handle to lower the base Result The two footpad display lights should be on 11 Pump the foot pedal to raise the base 12 Turn both the leveling jacks clockwise to the full down position 13 Pull the base lowering handle to lower the base Result The base will lower and the two level sensor display lights should be off and remain off because the base is not level O O 9 9 14 At the platform controls push in the control activate button and rotate the up down switch to the up position then the down position Result The platform up down function should not operate FUNCTION TESTS Test Emergency Stop 15 Use the bubble level and adjust the leveling jacks until the machine base is level Be sure all four display lights at the ground controls are on 16 Push in the red Emergency Stop button at the ground controls 17 At the platform controls push in the control activate button and rotate the up down switch in each direction O Result The platform up down function should notoperate 18 Push in the r
9. 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 Part No 82909 Genie IWP Super Series 9 Operator s Manual Third Edition Fourth Printing PRE OPERATION INSPECTION Pre operation Inspection Ii Be sure that the operator s safety and responsibilities manuals are complete legible and in the storage container located on the mast I Be sure that all decals are legible and in place See Decals section Add oil if needed See Maintenance section Li DC models Check for battery fluid leaks and proper fluid 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 1 Electrical components wiring and electrical cables LI Hydraulic power unit hoses fittings and cylinders Hydraulic manifolds and foot pump Platform entry mid rail or gate Sequencing cables and pulleys Lifting chains and idler wheels Mast columns and counterweight Nuts bolts and other fasteners Breather cap Foot pads L Loc oe LL LI Adjustable glide pads U
10. 142 Label Circuit Breaker AC models 1 97775 Label Interlock Display 1 24 Genie IWP Super Series Part No 82909 Third Edition Fourth Printing Operators Manual DECALS 82782 38142 72086 52996 31075 38119 or 97775 97526 N USE B 82802 GB 28174 I CEH or 28235 AJl 38116 31245 A 43657 38117 LEN 48644 E AA 2 PE J a M 3 gt Outreach Option 31070 fl LH BR p 27868 gt AIR 82907 4 K AN ML w Z u 37145 E a Em eZ ZA 28174 Serial ROR i oF 28235 Plate R Sy 31071 48645 bk et 27857 31073 31075 d 37141 97526 62996 or 62045 or i 208 62046 T 38122 97527 97519 dios 72844 api 37144 c or 28235 or 37143 37 31075 me f 97526 or 62045 or 62046 Note Platform decals may be in diffferent locations on optional fiberglass basket 52996 82975 31075 97526 97527 Part No 82909 Genie IWP Super Series 25 Operator s Manual e DECALS Inspection for Decals with Symbols Determine whether the decals on your machine have words or symbols Use the appropriate inspection to verify that all decals are legible and in
11. 996 or 62045 or 62046 97527 28174 or 28235 97537 82913 2 or 82914 45 uv 4 gt 82475 y P T 82802 L ion iud Ln 62996 I or 62045 ii or 62046 ej Note Platform decals may SZ be in diffferent locations on optional fiberglass basket 52996 82614 82475 97526 97527 PartNo 82909 Genie IWP Super Series 27 Operator s Manual Specifications Third Edition Fourth Printing Model IWP 20S IWP 25S IWP 30S Height working maximum 26 ft 5 in 30 ft 5 in 35 ft 6 in 8 1m 9 3m 10 8 m Height platform maximum 20 ft5 in 24 ft5 in 29 ft 6 in 6 2m 7 4m 9 0 m Lift capacity ANSI amp CE 350 Ibs 350 Ibs 350 Ibs 159 kg 159 kg 159 kg Lift capacity CSA 300 Ibs 300 Ibs 136 kg 136 kg Lift capacity 300 Ibs mE with outreach option 136 kg Power source DC model 12V 12V 12V AC model 110V or 220V 110V or 220V 110V or 220V Machine weight See Serial Plate Machine weights vary with option configurations See Serial Plate See Serial Plate Height stowed 76 in 78 in 76 in 78 in 76 in 78 in base fully lowered base raised 1 9m 2 0m 1 9m 2 0m 1 9m 2 0m Width Standard base 32 in 32 in 81 cm 81 cm Length Standard base 60 in 60 in 1 5m 1 5m Width Wide base 40 in 40 in 40 in 1m 1m 1m Length Wide base 60 in 60 in 60 in 1 5 m 1 5 m 1 5m Optional Outreach extended 26 in sz m ANSI and CE 66 cm m IM Optional Outreach extended
12. Check for hydraulic oil leaks and proper oil level If equipped Power wheel assist option Q Steerhandle U Hydraulic motor and hoses If equipped IWP 20S with Outreach option QJ Locking bracket Handle and handle lock m d Extension arms d Confirm proper counterweight configuration part number is stamped on top of counterweight ANSI amp CE Indoor Front P N Rear P N IWP 20S Standard Base 37354 37355 IWP 20S Wide Base 40990 40991 Check entire machine for 11 Dentsordamage 1 Corrosion or oxidation Q Cracks in welds or structural components Inspect and clean battery terminals and all battery cable connections Be sure that all structural and other critical components are present and all associated fasteners and pins are in place and properly tightened 10 Genie IWP Super Series Part No 82909 Third Edition Fourth Printing Operator s Manual Observe and Obey M Only routine maintenance items specified in this manual shall be performed by the operator M Scheduled maintenance inspections shall be completed by qualified service technicians according to the manufacturer s specifications and the requirements specified in the responsibilities manual 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 amaintenance procedure it convey
13. aged or malfunctioning machine Be sure all maintenance has been performed as specified in this manual and the Genie IWP 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 mast Conduct a thorough pre operation inspection of the machine and test all functions before each work shift Do not use the machine as a ground for welding 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 4 Genie IWP Super Series Part No 82909 Third Edition Fourth Printing Operator s Manual Outreach Option Safety Bodily Injury Hazard Keep hands and feet away from moving parts mounting plate locking bracket and extension arms Power Wheel Assist Option Safety Collision Hazards Limit travel speed according to the condition of the ground surface congestion slope location of personnel and any other factors which may cause collision Be aware of limited sight distance when moving the machine Do not move the machine with the platform raised When moving the machine on an incline operate from the uphill side of the machine Do not rely on the brake to hold the mac
14. e China Phone 86 21 53852570 Fax 86 21 53852569 Genie France Phone 433 0 2 37 26 09 99 Fax 433 0 2 37 26 09 98 Genie Malaysia Phone 65 98 480 775 Fax 65 67 533 544 Genie Iberica Phone 34 93 579 5042 Fax 34 93 579 5059 Genie Germany Phone 449 0 4202 88520 Fax 449 0 4202 8852 20 Genie J apan Phone 4813 3453 6082 Fax 81 3 3453 6083 Genie Korea Phone 82 25 587 267 Fax 82 25 583 910 Genie U K Phone 44 0 1476 584333 Fax 444 0 1476 584334 Genie Brasil Phone 455 11 41 665 755 Fax 55 11 41 665 754 Genie Mexico City Phone 52 55 5666 5242 Fax 52 55 5666 3241 Genie Holland Phone 31 183 581 102 Fax 31 183 581 566
15. e manual lowering valve located at the bottom of the hydraulic cylinder O Result The platform DI should lower VENT R 2 BN s L A AR 3 B Weed Test Platform Raise and Lower 33 Push in the control activate button and rotate the up down switch to the up position O Result The platform should raise smoothly free of hesitation 34 Push in the control activate button and rotate the up down switch to the down position Result The platform should lower Testthe Direction reversing Safety Switch models with Power Wheel Assist Option only 35 Pull and hold the function enable lever on either side 36 Press the thumb rocker switch and drive the machine in the reverse direction 3 Press the direction reversing safety switch on the end of the steer handle Result The machine should travel in the forward direction 16 Genie IWP Super Series Part No 82909 Third Edition Fourth Printing Operator s Manual Workplace Inspection Be aware of and avoid the following hazardous situations Do Not Operate Unless M You learn and practice the principles of safe machine operation contained in this operator s manual 1 Avoid hazardous situations Always perform a pre operation inspection Always perform function tests prior to use R Im Inspectthe workplace Know and understand the workplace inspection before going on to the next section 5 Only use the machi
16. ed Emergency Stop button at the platform controls and pull out the red Emergency Stop button at the ground controls 19 At the platform controls push in the control activate button and rotate the up down switch in each direction O Result The platform up down function should notoperate Part No 82909 Genie IWP Super Series 15 Operator s Manual Third Edition Fourth Printing FUNCTION TESTS Test Auxiliary Platform Lowering 20 Raise the platform slightly O Result The inner frame wheels should lift off the ground 21 Disconnect the power source from the machine 22 Turn the key switch to ground control 23 Push in the auxiliary platform lowering button at the ground controls O Result The platform should lower 24 Connect the power source to the machine 25 Turn the key switch to platform control 26 Raise the platform slightly 27 Disconnect the power source from the machine 28 At the platform controls push in the control activate button and rotate the up down switch in the down direction Result The platform should lower 29 Connect the power source to the machine Test Manual Lowering 30 Twist to release the red Emergency Stop button at the platform controls Confirm that the interlock display lights and the power light are on 31 Push in the control activate button and rotate the up down switch to the up position to raise the platform approximately 6 inches 15 cm 32 Activate th
17. hine on an incline 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 ADANGER presence of an imminently hazardous situation which if not avoided will result in death or serious injury AWARNING Orange used to indicate the presence of a potentially A hazardous situation which if not avoided could result in death or serious injury gt Yellow with safety alert symbol ACAUTION used to indicate the presence ofa 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 CAUTION Green used to indicate operation or maintenance information Part No 82909 Genie IWP Super Series 5 Operator s Manual Third Edition Fourth Printing SAFETY RULES Battery and Charger Safety DC Models Burn Hazards Batteries contain acid Always wear protective clothing and eye wear when working with batteries i Avoid spilling or contacting battery acid Neutralize battery acid spills with baking soda and water The battery pack must rema
18. in in an upright SY position Explosion Hazards a EA Batteries emit explosive gas Keep sparks flames and lighted tobacco away from batteries Charge the battery ina well ventilated area 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 w Lifting Hazard The battery pack weighs 90 Ibs 40 8 kg Use the appropriate number of people and proper lifting techniques Do not expose the battery or charger to water or rain Before each use inspect for damage Replace damaged components before operating 6 Genie IWP Super Series Part No 82909 Third Edition Fourth Printing Operator s Manual Controls Ground Controls 066 D SDE 2 o 9 3 1 DC models Low battery 7 Levelsensor interlock display Platform Controls indicator light lights e la 2 Low battery indicator lightfor 8 Footpad interlock display auxiliary lowering lights f 3 Powerlight 9 Controlactivate button du 4 Auxiliary platform lowering 10 Up Down switch button O f I DC Red Emergency Stop button Key switch Note Two different interlock display decals were produced o The symbols on them are different but they both operate the same way Both are illustrated here and in the text 9 10 5 throughout this manual PartNo 82909 Genie IWP Super Se
19. ities manuals Using the machine for anything other than lifting personnel along with their tools and materials to an aerial work site is unsafe and dangerous 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 work place inspection before using the machine Setup 1 Pump the foot pedal to raise the base until the wheels contact the ground Use the steering handle to push the machine Position the machine on a firm level surface directly below the work area Pull the base lowering handle to lower the base until all four footpads are in firm contact with the ground Connectto an appropriate power source DC models Connect the battery pack AC models Connect to a grounded 15A AC power supply Use a 12 gauge 3 3mm 3 wire grounded extension cord no longer than 50 feet 13 m Insert the key and turn to platform control Pull out the red Emergency Stop button at the ground controls and be sure the power light is on 18 Genie IWP Super Series Part No 82909 Third Edition Fourth Printing Operator s Manual 8 Be sure that the two level sensor interlock display lights and the two footpad interlock display lights are on O 0
20. l 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 Voltage Minimum Safe 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 Part No 82909 Genie IWP Super Series 3 Operator s Manual Third Edition Fourth Printing SAFETY RULES Allow for plattorm 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 Collision Hazards Operators must comply with employer job site and governmental rules regarding the use of personal protective equipment Check the work area for overhead obstructions or other possible hazards Be aware of crushing hazards 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 Damaged Machine Hazards Do not use a dam
21. mb rocker switch power wheel assist option Two different styles of level sensor were produced Genie IWP Super Series Part No 82909 Third Edition Fourth Printing Operator s Manual Pre operation Inspection Do Not Operate Unless M You learn and practice the principles of safe machine operation contained in this operator s manual 1 Avoid hazardous situations 2 Alwaysperforma 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 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
22. ne as it was intended Fundamentals The wworkplace 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 drop offs or holes bumps and floor obstructions debris sloped surfaces unstable or slippery surfaces overhead obstructions and high voltage conductors hazardous locations inadequate surface support to withstand all load forces imposed by the machine wind and weather conditions all other possible unsafe conditions Part No 82909 Genie IWP Super Series 17 Operator s Manual Third Edition Fourth Printing Operating Instructions Do Not Operate Unless M You learn and practice the principles of safe machine operation contained in this operator s manual 1 Avoid hazardous situations Always perform a pre operation inspection Always perform function tests prior to use Inspect the work place a AR I Only use the machine as it was intended 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 responsibil
23. ny other countries Super Series is a trademark of Genie Industries This machine complies with ANSI SIA A92 3 Printed on recycled paper Printed in U S A Genie IWP Super Series Part No 82909 Third Edition Fourth Printing Operator s Manual Safety Rules Danger Failure to obey the instructions and safety rules in this manual will result in death or serious injury Do Not Operate Unless MI 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 the function tests prior to use 4 Inspect the workplace 5 Only use the machine as it was intended M You read understand and obey the manufacturer s instructions and safety rules safety and operator s manuals and machine decals M You read understand and obey employer s safety rules and worksite regulations M You read understand and obey all applicable governmental regulations M You are properly trained to safely operate the machine Part No 82909 Genie IWP Super Series 1 Operator s Manual Third Edition Fourth Printing SAFETY RULES Tip over Hazards Do not raise the platform unless the machine is on a firm level surface Do not move the machine while the platform is raised Do not cause a ho
24. r 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 Part No 82909 Genie IWP Super Series 13 Operator s Manual See FUNCTION TESTS Function Tests 1 Select a firm level test area free of obstructions Third Edition Fourth Printing 8 Twistto release the red Emergency Stop button at the platform controls Result The power light should come on Within 1 to 4 seconds the two level sensor interlock 2 Pump the foot pedal to display lights and the two foot pad interlock raise the base display lights should turn on and remain on O Result The wheels VA VARY should contact the O Q O ground 3 Pull the base lowering l handle to fully lower the O base l l Result All four foot Bad pads should come in O firm contact with the ground O 4 Connectthe appropriate power source Note Two different interlock display decals were 5 Use the bubble level and adjust the leveling produced The symbols on them are different but jacks until the machine is level and all four foot they both operate the same way Both are pads are in firm contact with the ground illustrated
25. ries 7 Operator s Manual Third Edition Fourth Printing Legend amp amp OO O 2O 9 4 62 G 23 62 CD CD CD GD t9 18 1 AC models AC power supply line for machine DC models power to platform 2 Groundcontrols interlock display 3 Circuitbreaker 4 Mast 5 Platform 6 Operator s manual storage container 7 Lifting eye 8 Breathercap 9 Platform controls 10 Level sensor with bubble level 11 AC outlet 12 DC models Battery quick disconnect 18 DC models Battery pack 14 Footpad 15 Transporttie down 16 Platform entry mid rail or gate 17 Forklift ring 18 Left side leveling jack 19 Winching point 20 Counterweight 21 Right side leveling jack 22 Forklift pocket 23 DC models Battery charger 24 Level sensor with bubble level 25 Foot pedal 26 Power wheel assist option 27 Manuallowering valve located at the bottom of the hydraulic cylinder TND d QGGO CO O 8 28 Battery strap 29 Steer handle power wheel assist option 30 Base lowering handle 31 Function enable lever power wheel assist option 32 Steering handle 33 Direction reversing safety switch power wheel assist option 34 Thu
26. rizontal force or side load to the machine by raising or lowering a fixed or overhanging load Do not transport tools and materials unless they are evenly distributed and can be safely handled by the person in the platform Do not place or attach overhanging loads to any part of this machine Do not place ladders or scaffolds in the platform or against any part of this machine t f S a ll T Do not push off or pull toward any object outside the platform 45 lbs 200 N Maximum allowable side force Do not operate the machine near drop offs holes bumps debris unstable or slippery surfaces or other possible hazardous conditions Do not use the machine on a moving or mobile surface or vehicle Do not alter or disable machine components that in any way affect safety and stability 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 material shall not exceed the maximum platform capacity ANSI amp CE models Maximum capacity 350 Ibs 159 kg Maximum capacity 300 Ibs 136 kg IWP 20S with outreach option Maximum occupancy 1 person CSA models Maximum capacity 300 Ibs 136 kg Maximum occupancy 1 person 2 Genie IWP Super Series Part No 82909 Third Edition Fourth Printing Operator s Manual Do not replace items critical to stability
27. s the meaning below Indicates that tools will be required to perform this procedure Indicates that new parts will be required to perform this procedure Maintenance Check the Battery DC Models Proper battery condition is essential to good machine performance and operational safety Improper fluid levels or damaged cables and connections can result in component damage and hazardous conditions Electrocution hazard Contact with AWARNING hot or live circuits could result in death or serious injury Remove all rings watches and other jewelry Bodily injury hazard Batteries AWARNING contain acid Avoid spilling or contacting battery acid Neutralize battery acid spills with baking soda and water Perform this test after fully charging the batteries 1 Puton 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 Part No 82909 Genie IWP Super Series 11 Operator s Manual Third Edition Fourth Printing 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 s
28. unauthorized use R DC models Recharge the battery PartNo 82909 Genie IWP Super Series 19 Operator s Manual Third Edition Fourth Printing OPERATING INSTRUCTIONS Outreach Option Operating Instructions 1 Liftup on the locking bracket 2 Rotate the handle clockwise to extend the platform Rotate the handle counterclockwise to retract the platform 3 Be sure to lock the handle CE models When the outreach is extended the up down function will not operate Retract the outreach and reposition the platform Power Wheel Assist Option Operating Instructions 1 Lowerthe steer handle 2 Pulland hold the function enable lever on either side 3 Activate the thumb rocker switch in the desired direction of travel 4 Release the thumb rocker switch The machine will continue to roll when the rocker switch is released 5 Release the function enable lever to stop the machine and set the brake Note The brake will hold the machine on inclines of less than 3 To Move The Machine Without Power Wheel Assist Pull and hold the function enable lever to release the brake 20 Genie IWP Super Series Part No 82909 Third Edition Fourth Printing Operator s Manual Battery and Charger Instructions Observe and Obey M Do not use an external charger or booster battery M Charge the battery in a well ventilated area MI Use proper AC input voltage for charging as indicated on the charger
29. unsecured items To use the forklift rings 1 Raisethe platform 3 inches 7 5 cm 2 Position the forklift rings in the up position 22 Genie IWP Super Series Part No 82909 Third Edition Fourth Printing Operator s Manual Loading the Machine With a Crane Use the lifting eye mounted on the rear mast column The battery pack must be removed before lifting the machine with a crane Be sure to inspect the machine and remove any loose or unsecured items Always place the lifting hook through the lifting eye so that it points away from the machine TRANSPORT AND LIFTING INSTRUCTIONS Securing the Machine Use chains or straps of ample load capacity Use a minimum of 3 chains Adjust the rigging to prevent damage to the chains ol PartNo 82909 Genie IWP Super Series 23 Operator s Manual Third Edition Fourth Printing Decals Inspection for Decals with Words Determine whether the decals on your machine have words or symbols Use the appropriate inspection to verify that all decals are legible and in place
30. ure the platform is fully lowered 2 Checkthe sight gauge on the side of the hydraulic tank 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 Scheduled Maintenance 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 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 12 Genie IWP Super Series Part No 82909 Third Edition Fourth Printing Operators Manual Do Not Operate Unless M 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 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 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 A malfunctioning machine must neve
31. with items of different weight or specification 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 install the outreach option on an IWP 25S or an IWP 30S The outreach option is for the IWP 20S with the proper counterweight configuration 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 governmental requirements 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 before operating 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 unti
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