Operatr s Manual with Maintenance Infrmatin Secnd Editin Furth Printing Part N. 48643
Operatr s Manual Secnd Editin Furth Printing Imprtant Read, understand and bey these safety rules and perating instructins befre perating this machine. Only trained and authrized persnnel shall be permitted t perate this machine. This manual is cnsidered a permanent part f yur machine and shuld remain with the machine at all times. If yu have any questins, call Genie Industries. Cntents Page Safety Rules... 1 Cntrls... 7 Legend... 8 Pre-peratin Inspectin... 9 Maintenance... 11 Functin Tests... 13 Wrkplace Inspectin... 16 Operating Instructins... 17 Battery and Charger Instructins... 20 Transprt Instructins... 21 Decals... 22 Specificatins... 24 Cntact us: Internet: http://www.genielift.cm e-mail: techpub@genieind.cm Cpyright 1996 by Genie Industries. First Editin: Fifth Printing, Nvember 1997 Secnd Editin: Furth Printing, January 2002 "Genie" and "IWP" are registered trademarks f Genie Industries in the U.S.A. and many ther cuntries. "Super Series" is a trademark f Genie Industries. This machine cmplies with ANSI/SIA A92.3-1990. Printed n recycled paper. Printed in U.S.A. Genie IWP Super Series Part N. 48643
Secnd Editin Furth Printing Operatr s Manual Safety Rules Danger Failure t bey the instructins and safety rules in this manual will result in death r serius injury. D Nt Operate Unless: Yu learn and practice the principles f safe machine peratin cntained in this peratr's manual. 1 Avid hazardus situatins. Knw and understand the safety rules befre ging n t the next sectin. 2 Always perfrm a pre-peratin inspectin. 3 Always perfrm the functin tests prir t use. 4 Inspect the wrkplace. 5 Only use the machine as it was intended. Yu read, understand and bey: manufacturer's instructins and safety rules peratr's manual and machine decals emplyer's safety rules and wrksite regulatins applicable gvernmental regulatins Part N. 48643 Genie IWP Super Series 1
Operatr s Manual Secnd Editin Furth Printing SAFETY RULES Tip-ver Hazards D nt raise the platfrm unless the machine is n a firm, level surface. D nt mve the machine while the platfrm is raised. D nt use the machine t lift material r equipment. The machine is intended t lift persnnel and tls t an aerial wrk site. D nt perate the machine near drp-ffs, hles, bumps, debris, unstable r slippery surfaces r ther pssible hazardus cnditins. D nt use the machine n a mving r mbile surface r vehicle. D nt alter r disable machine cmpnents that in any way affect safety and stability. D nt perate the machine in strng r gusty winds. D nt increase the surface area f the platfrm r the lad. Increasing the area expsed t the wind will decrease machine stability. D nt cause a hrizntal frce r side lad t the machine by raising r lwering a fixed r verhanging lad. D nt place r attach verhanging lads t any part f this machine. D nt place ladders r scafflds in the platfrm r against any part f this machine. D nt exceed the rated platfrm lad capacity. Maximum capacity - ANSI & CE 350 lbs 159 kg Maximum capacity - CSA 300 lbs 136 kg D nt push ff r pull tward any bject utside the platfrm. Maximum capacity 300 lbs 136 kg IWP-20S with utreach ptin Maximum allwable manual frce 45 lbs 200 N Maximum ccupancy 1 persn 2 Genie IWP Super Series Part N. 48643
Secnd Editin Furth Printing Operatr s Manual SAFETY RULES D nt replace items critical t stability with items f different weight r specificatin. When mving the machine with a frklift r ther transprt vehicle, the platfrm shuld be fully lwered, the machine shuld be turned ff and n persnnel shall remain in the platfrm. Electrcutin Hazards This machine, even with an ptinal fiberglass platfrm, is nt electrically insulated and will nt prvide prtectin frm cntact with r prximity t electrical current. D nt install the utreach ptin n an IWP-25S r an IWP-30S. The utreach ptin is fr the IWP- 20S with the prper cunterweight cnfiguratin. Fall Hazards D nt sit, stand r climb n the platfrm guard rails. Maintain a firm fting n the platfrm flr at all times. D nt exit the platfrm while raised. If a pwer failure ccurs, have grund persnnel activate the manual lwering valve. Keep the platfrm flr clear f debris. Keep away frm the machine if it cntacts energized pwer lines r becmes electrically charged. Persnnel n the grund r in the platfrm must nt tuch r perate the machine until energized pwer lines are shut ff. Maintain safe distances frm electrical pwer lines and apparatus in accrdance with applicable gvernmental regulatins and the fllwing chart. Lwer the platfrm entry mid-rail befre perating. Vltage Minimum Safe Apprach Distance Phase t Phase Feet Meters 0 t 300V Avid Cntact 300V t 50KV 10 3.05 50KV t 200KV 15 4.60 200KV t 350KV 20 6.10 350KV t 500KV 25 7.62 500KV t 750KV 35 10.67 750KV t 1000KV 45 13.72 Part N. 48643 Genie IWP Super Series 3
Operatr s Manual Secnd Editin Furth Printing SAFETY RULES Allw fr platfrm mvement, electrical line sway r sag and mvement due t strng r gusty winds. D nt use the machine as a grund fr welding. D nt perate an AC pwered machine r a DC battery charger unless using a 3-wire grunded extensin crd cnnected t a grunded AC circuit. D nt alter r disable 3-wire grunded plugs. Cllisin Hazards Check the wrk area fr verhead bstructins r ther pssible hazards. Be aware f crushing hazard when grasping the platfrm guard rail. D nt lwer the platfrm unless the area belw is clear f persnnel and bstructins. Damaged Machine Hazards D nt use a damaged r malfunctining machine. Be sure all maintenance has been perfrmed 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 peratr s, safety and respnsibilities manuals are cmplete, legible and in the strage cntainer lcated n the mast. Cnduct a thrugh pre-peratin inspectin f the machine and test all functins befre each wrk shift. D nt use the machine as a grund fr welding. Imprper Use Hazard D nt leave the machine unattended unless the key is remved t secure frm unauthrized use. Bdily Injury Hazard D nt perate the machine with a hydraulic il r air leak. An air leak r hydraulic leak can penetrate and/r burn skin. Use cmmn sense and planning t cntrl the mvement f the machine n r near inclines. Stay clear f descending platfrm. 4 Genie IWP Super Series Part N. 48643
Secnd Editin Furth Printing Operatr s Manual SAFETY RULES Outreach Optin Safety Bdily Injury Hazard Keep hands and feet away frm mving parts: munting plate, lcking bracket and extensin arms. Pwer Wheel Assist Optin Safety Cllisin Hazards Limit travel speed accrding t the cnditin f the grund surface, cngestin, slpe, lcatin f persnnel and any ther factrs which may cause cllisin. Be aware f limited sight distance when mving the machine. D nt mve the machine with the platfrm raised. When mving the machine n an incline, perate frm the uphill side f the machine. D nt rely n the brake t hld the machine n an incline. Decal Legend Genie prduct decals use symbls, clr cding and signal wrds t identify the fllwing: Safety alert symbl used t alert persnnel t ptential persnal injury hazards. Obey all safety messages that fllw this symbl t avid pssible injury r death. Red used t indicate the presence f an imminently hazardus situatin which, if nt avided, will result in death r serius injury. Orange used t indicate the presence f a ptentially hazardus situatin which, if nt avided, culd result in death r serius injury. Yellw with safety alert symbl used t indicate the presence f a ptentially hazardus situatin which, if nt avided, may cause minr r mderate injury. Yellw withut safety alert symbl used t indicate the presence f a ptentially hazardus situatin which, if nt avided, may result in prperty damage. Green used t indicate peratin r maintenance infrmatin. Part N. 48643 Genie IWP Super Series 5
Operatr s Manual Secnd Editin Furth Printing SAFETY RULES Battery and Charger Safety - DC Mdels Burn Hazards Batteries cntain acid. Always wear prtective clthing and eyewear when wrking with batteries. Avid spilling r cntacting battery acid. Neutralize battery acid spills with baking sda and water. The battery pack must remain in an upright psitin. Explsin Hazards Electrcutin Hazards Batteries emit explsive gas. Keep sparks, flames and lighted tbacc away frm batteries. Charge the battery in a well-ventilated area. D nt discnnect charger DC utput wires frm the battery when the charger is n. Cnnect the charger t a grunded AC circuit nly. Lifting Hazard D nt expse the battery r charger t water and/r rain. Befre each use, inspect fr damage. Replace damaged cmpnents befre perating. The battery pack weighs 90 lbs / 40.8 kg. Use the apprpriate number f peple and prper lifting techniques. 6 Genie IWP Super Series Part N. 48643
Secnd Editin Furth Printing Operatr s Manual Cntrls Grund Cntrls 2 3 1 4 5 6 7 Platfrm Cntrls - ANSI & CSA Platfrm Cntrls - CE 3 9 8 8 3 9 1 Interlck display lights (fur) 2 Key switch 3 Red Emergency Stp buttn 4 Auxiliary platfrm lwering buttn 5 Pwer light 6 Lw battery indicatr light fr auxiliary lwering 7 DC mdels: Lw battery indicatr light 8 Cntrl activate buttn 9 Up/Dwn switch Part N. 48643 Genie IWP Super Series 7
Operatr s Manual Secnd Editin Furth Printing Legend 1 AC mdels: AC pwer supply line fr machine DC mdels: pwer t platfrm 2 Grund cntrls (interlck display) 3 Circuit breaker 4 Mast 5 Platfrm 6 Operatr s manual strage cntainer 7 Lifting eye 8 Breather cap 9 Platfrm cntrls 10 Bubble level/level sensr 11 AC utlet 12 DC mdels: Battery quick discnnect 13 DC mdels: Battery pack 14 Ftpad 15 Transprt tie dwn 16 Platfrm entry mid-rail r gate 17 Frklift ring 18 Left side leveling jack 19 Cunterweight 20 Right side leveling jack 21 Frklift pcket 22 DC mdels: Battery charger 23 Ft pedal 24 Pwer wheel assist ptin 25 Manual lwering valve (*lcated at the bttm f the hydraulic cylinder) 26 Battery strap 27 Steer handle - pwer wheel assist ptin 28 Base lwering handle 29 Functin enable lever - pwer wheel assist ptin 30 Steering handle 31 Directin-reversing safety switch - pwer wheel assist ptin 32 Thumb rcker switch - pwer wheel assist ptin 8 Genie IWP Super Series Part N. 48643
Secnd Editin Furth Printing Operatr s Manual Pre-peratin Inspectin Fundamentals It is the respnsibility f the peratr t perfrm a Pre-peratin Inspectin and rutine maintenance. D Nt Operate Unless: Yu learn and practice the principles f safe machine peratin cntained in this peratr's manual. 1 Avid hazardus situatins. 2 Always perfrm a pre-peratin inspectin. Knw and understand the pre-peratin inspectin befre ging n t the next sectin. 3 Always perfrm functin tests prir t use. 4 Inspect the wrkplace. 5 Only use the machine as it was intended. The Pre-peratin Inspectin is a visual inspectin perfrmed by the peratr prir t each wrk shift. The inspectin is designed t discver if anything is apparently wrng with a machine befre the peratr perfrms the functin tests. The Pre-peratin inspectin als serves t determine if rutine maintenance prcedures are required. Only rutine maintenance items specified in this manual may be perfrmed by the peratr. Refer t the list n the next page and check each f the items and lcatins fr mdificatins, damage r lse r missing parts. A damaged r mdified machine must never be used. If damage r any variatin frm factry delivered cnditin is discvered, the machine must be tagged and remved frm service. Repairs t the machine may nly be made by a qualified service technician, accrding t the manufacturer's specificatins. After repairs are cmpleted, the peratr must perfrm a pre-peratin inspectin again befre ging n t the functin tests. Scheduled maintenance inspectins shall be perfrmed by qualified service technicians, accrding t the manufacturer's specificatins and the requirements listed in the respnsibilities manual. Part N. 48643 Genie IWP Super Series 9
Operatr s Manual Secnd Editin Furth Printing PRE-OPERATION INSPECTION Pre-peratin Inspectin Be sure that the peratr's, safety and respnsibilities manuals are cmplete, legible and in the strage cntainer lcated n the mast. Be sure that all decals are legible and in place. See Decals sectin. AC & DC mdels: Check fr hydraulic il leaks and prper il level. Add il if needed. See Maintenance sectin. DC mdels: Check fr battery fluid leaks and prper fluid level. Add distilled water if needed. See Maintenance sectin. Check the fllwing cmpnents r areas fr damage, mdificatins and imprperly installed r missing parts: Electrical cmpnents, wiring and electrical cables Hydraulic pwer unit, hses, fittings and cylinders Hydraulic maniflds and ft pump Platfrm entry mid-rail r gate Sequencing cables and pulleys Lifting chains and idler wheels Mast clumns and cunterweight Nuts, blts and ther fasteners Breather cap Ft pads Adjustable glide pads If equipped: Pwer wheel assist ptin Steer handle Hydraulic mtr and hses If equipped: IWP-20S with Outreach ptin Lcking bracket Handle and handle lck Extensin arms Cnfirm prper cunterweight cnfiguratin (part number is stamped n tp f cunterweight) ANSI & CE Indr Frnt P/N Rear P/N IWP-20S Standard Base 37354 37355 IWP-20S Wide Base 40990 40991 CSA Frnt P/N Rear P/N IWP-20S Wide Base 40988 40989 Check entire machine fr: Dents r damage Crrsin r xidatin Cracks in welds r structural cmpnents Inspect and clean battery terminals and all battery cable cnnectins Be sure that all structural and ther critical cmpnents are present and all assciated fasteners and pins are in place and prperly tightened. 10 Genie IWP Super Series Part N. 48643
Secnd Editin Furth Printing Operatr s Manual Maintenance Check the Battery - DC Mdels Observe and Obey: Only rutine maintenance items specified in this manual shall be perfrmed by the peratr. Scheduled maintenance inspectins shall be cmpleted by qualified service technicians, accrding t the manufacturer's specificatins and the requirements specified in the respnsibilities manual. Maintenance Symbls Legend The fllwing symbls have been used in this manual t help cmmunicate the intent f the instructins. When ne r mre f the symbls appear at the beginning f a maintenance prcedure, it cnveys the meaning belw. Prper battery cnditin is essential t gd machine perfrmance and peratinal safety. Imprper fluid levels r damaged cables and cnnectins can result in engine cmpnent damage and hazardus cnditins. Electrcutin hazard. Cntact with ht r live circuits culd result in death r serius injury. Remve all rings, watches and ther jewelry. Bdily injury hazard. Batteries cntain acid. Avid spilling r cntacting battery acid. Neutralize battery acid spills with baking sda and water. Perfrm this test after fully charging the batteries. 1 Put n prtective clthing and eye wear. 2 Remve the battery vent caps. 3 Check the battery acid level. If needed, replenish with distilled water t the bttm f the battery fill tube. D nt verfill. 4 Install the vent caps. Indicates that tls will be required t perfrm this prcedure. Indicates that new parts will be required t perfrm this prcedure. Part N. 48643 Genie IWP Super Series 11
Operatr s Manual Secnd Editin Furth Printing MAINTENANCE Check the Hydraulic Oil Level Maintaining the hydraulic il at the prper level is essential t machine peratin. Imprper hydraulic il levels can damage hydraulic cmpnents. Daily checks allw the inspectr t identify changes in il level that might indicate the presence f hydraulic system prblems. Scheduled Maintenance Maintenance perfrmed quarterly, annually and every tw years must be cmpleted by a persn trained and qualified t perfrm maintenance n this machine accrding t the prcedures fund in the service manual fr this machine. Machines that have been ut f service fr mre than three mnths must receive the quarterly inspectin befre they are put back int service. 1 Be sure the platfrm is fully lwered. 2 Check the sight gauge n the side f the hydraulic tank. Result: The hydraulic il level shuld be visible in the middle f the sight gauge. D nt verfill. Hydraulic il specificatins Hydraulic il type Dexrn equivalent 12 Genie IWP Super Series Part N. 48643
Secnd Editin Furth Printing Operatr s Manual Functin Tests Fundamentals The Functin Tests are designed t discver any malfunctins befre the machine is put int service. The peratr must fllw the step-by-step instructins t test all machine functins. D Nt Operate Unless: Yu learn and practice the principles f safe machine peratin cntained in this peratr's manual. 1 Avid hazardus situatins. 2 Always perfrm a pre-peratin inspectin. 3 Always perfrm functin tests prir t use. Knw and understand the functin tests befre ging n t the next sectin. 4 Inspect the wrkplace. 5 Only use the machine as it was intended. A malfunctining machine must never be used. If malfunctins are discvered, the machine must be tagged and remved frm service. Repairs t the machine may nly be made by a qualified service technician, accrding t the manufacturer's specificatins. After repairs are cmpleted, the peratr must perfrm a pre-peratin inspectin and functin tests again befre putting the machine int service. Part N. 48643 Genie IWP Super Series 13
Operatr s Manual Secnd Editin Furth Printing FUNCTION TESTS Functin Tests 1 Select a level test area free f bstructins. 2 Pump the ft pedal t raise the base. Result: The wheels shuld cntact the grund. 3 Pull the base lwering handle t fully lwer the base. Result: All fur ft pads shuld cme in firm cntact with the grund. 4 Cnnect the apprpriate pwer surce. 5 Use the bubble level and adjust the leveling jacks until the machine is level and all fur ft pads are in firm cntact with the grund. 6 Insert the key and turn t the ON psitin OR turn t platfrm cntrls. 7 Pull ut the red Emergency Stp buttn at the grund cntrls t the ON psitin. 8 Twist t release the red Emergency Stp buttn at the platfrm cntrls. Result: The pwer light shuld cme n. Within 1 t 4 secnds, all fur display lights shuld turn n and remain n. Test Interlck System 9 Pump the ft pedal t raise the base. Result: The tw ft pad display lights shuld be ff. 10 Pull the base lwering handle t lwer the base. Result: The tw ft pad display lights shuld be n. 11 Pump the ft pedal t raise the base. 12 Turn bth the leveling jacks clckwise t the full dwn psitin. 13 Pull the base lwering handle t lwer the base. Result: The base will lwer and the tw level sensr display lights shuld be ff and remain ff because the base is nt level. 14 At the platfrm cntrls, push in the cntrl activate buttn and rtate the up/dwn switch t the UP psitin, then the DOWN psitin. Result: The platfrm up/dwn functin shuld nt perate. Test Emergency Stp 15 Use the bubble level and adjust the leveling jacks until the machine base is level. Be sure all fur display lights are n. 16 Push in the red Emergency Stp buttn at the grund cntrls. 17 At the platfrm cntrls, push in the cntrl activate buttn and rtate the up/dwn switch in each directin. Result: The platfrm up/dwn functin shuld nt perate. 18 Push in the red Emergency Stp buttn at the platfrm cntrls and pull ut the red Emergency Stp buttn at the grund cntrls. 19 At the platfrm cntrls, push in the cntrl activate buttn and rtate the up/dwn switch in each directin. Result: The platfrm up/dwn functin shuld nt perate. 14 Genie IWP Super Series Part N. 48643
Secnd Editin Furth Printing Operatr s Manual FUNCTION TESTS Test Auxiliary Platfrm Lwering 20 Raise the platfrm slightly. Result: The inner frame wheels shuld lift ff the grund. 21 Discnnect the pwer surce frm the machine. 22 Turn the key switch t grund cntrl (if equipped). 23 Push in the auxiliary platfrm lwering buttn at the grund cntrls. Result: The platfrm shuld lwer. 24 Cnnect the pwer surce t the machine. 25 Turn the key switch t platfrm cntrl (if equipped). 26 Raise the platfrm slightly. 27 Discnnect the pwer surce frm the machine. 28 At the platfrm cntrls, push in the cntrl activate buttn and rtate the up/dwn switch in the dwn directin. Result: The platfrm shuld lwer. 29 Cnnect the pwer surce t the machine. Test Manual Lwering 30 Twist t release the red Emergency Stp buttn at the platfrm cntrls. Cnfirm that the interlck display lights and the pwer light are n. 31 Push in the cntrl activate buttn and rtate the up/dwn switch t the UP psitin t raise the platfrm apprximately 6 inches / 15 cm. 32 Activate the manual lwering valve lcated at the bttm f the hydraulic cylinder. Result: The platfrm shuld lwer. Test Platfrm Raise and Lwer 33 Push in the cntrl activate buttn and rtate the up/dwn switch t the UP psitin. ANSI & CSA CE a b a b a b cntrl activate buttn up/dwn switch Result: The platfrm shuld raise smthly, free f hesitatin. 34 Push in the cntrl activate buttn and rtate the up/dwn switch t the DOWN psitin. Result: The platfrm shuld lwer. Test the Directin-reversing Safety Switch (mdels with Pwer Wheel Assist Optin nly) 35 Pull and hld the functin enable lever n either side. 36 Press the thumb rcker switch and drive the machine in the reverse directin. 37 Press the directin-reversing safety switch n the end f the steer handle. Result: The machine shuld travel in the frward directin. Part N. 48643 Genie IWP Super Series 15
Operatr s Manual Secnd Editin Furth Printing Wrkplace Inspectin Be aware f and avid the fllwing hazardus situatins: Drp-ffs r hles Bumps and flr bstructins D Nt Operate Unless: Yu learn and practice the principles f safe machine peratin cntained in this peratr's manual. 1 Avid hazardus situatins. 2 Always perfrm a pre-peratin inspectin. 3 Always perfrm functin tests prir t use. 4 Inspect the wrkplace. Knw and understand the wrkplace inspectin befre ging n t the next sectin. 5 Only use the machine as it was intended. Debris Overhead bstructins and high vltage cnductrs Hazardus lcatins Inadequate surface supprt t withstand all lad frces impsed by the machine Wind and weather cnditins All ther pssible unsafe cnditins Fundamentals The Wrkplace Inspectin helps the peratr determine if the wrkplace is suitable fr safe machine peratin. It shuld be perfrmed by the peratr prir t mving the machine t the wrkplace. It is the peratr's respnsibility t read and remember the wrkplace hazards, then watch fr and avid them while mving, setting up and perating the machine. 16 Genie IWP Super Series Part N. 48643
Secnd Editin Furth Printing Operatr s Manual Operating Instructins Setup 1 Pump the ft pedal t raise the base until the wheels cntact the grund. D Nt Operate Unless: Yu learn and practice the principles f safe machine peratin cntained in this peratr's manual. 1 Avid hazardus situatins. 2 Always perfrm a pre-peratin inspectin. 3 Always perfrm functin tests prir t use. 4 Inspect the wrk place. 5 Only use the machine as it was intended. Fundamentals Using the machine fr anything ther than lifting persnnel and tls t an aerial wrk site is unsafe. If mre than ne peratr is expected t use a machine at different times in the same wrk shift, each peratr is expected t fllw all safety rules and instructins in the peratr's manual. That means every new peratr shuld perfrm a preperatin inspectin, functin tests and a wrk place inspectin befre using the machine. 2 Use the steering handle t push the machine. 3 Psitin the machine n a firm, level surface directly belw the wrk area. 4 Pull the base lwering handle t lwer the base until all fur ft pads are in firm cntact with the grund. 5 Cnnect t an apprpriate pwer surce: DC mdels: Cnnect battery pack. AC mdels: Cnnect t a grunded 15A AC pwer supply. Use a 12 gauge / 3.3mm 2 3-wire grunded extensin crd n lnger than 50 feet / 13 m. 6 Insert the key and turn t the ON psitin OR t platfrm cntrl. 7 Pull ut the red Emergency Stp buttn at the grund cntrls and be sure the pwer light is n. 8 Check the interlck display. Be sure that all fur display lights are n. Part N. 48643 Genie IWP Super Series 17
Operatr s Manual Secnd Editin Furth Printing OPERATING INSTRUCTIONS Emergency Stp 1 Push in the red Emergency Stp buttn at the platfrm cntrls r at the grund cntrls t stp the up functin. Platfrm Raise & Lwer 1 Twist t release the red Emergency Stp buttn at the platfrm cntrls. 2 Push in the cntrl activate buttn and rtate the up/dwn switch in the desired directin f travel. ANSI & CSA CE Auxiliary Platfrm Lwering 1 Turn the key switch t grund cntrl (if equipped). 2 Activate the auxiliary platfrm lwering buttn at the grund cntrls. After Each Use 1 Select a safe strage lcatin firm, level surface, weather prtected, clear f bstructin and traffic. 2 Pull the base lwering handle t lwer the base until all fur ft pads are in firm cntact with the grund. 3 Remve the key t secure frm unauthrized use. 4 DC mdels: Recharge battery. a b a b a b cntrl activate buttn up/dwn switch Manual Lwering 1 Activate the manual lwering valve lcated at the bttm f the hydraulic cylinder. 18 Genie IWP Super Series Part N. 48643
Secnd Editin Furth Printing Operatr s Manual OPERATING INSTRUCTIONS Outreach Optin Operating Instructins 1 Lift up n the lcking bracket. 2 Rtate the handle clckwise t extend the platfrm. Rtate the handle cunterclckwise t retract the platfrm. 3 Be sure t lck the handle. CE mdels: When the utreach is extended, the up/dwn functin will nt perate. Retract the utreach and repsitin the platfrm. Pwer Wheel Assist Optin Operating Instructins 1 Lwer the steer handle. 2 Pull and hld the functin enable lever n either side. 3 Activate the thumb rcker switch in the desired directin f travel. 4 Release the thumb rcker switch. The machine will cntinue t rll when the rcker switch is released. 5 Release the functin enable lever t stp the machine and set the brake. Nte: The brake will hld the machine n inclines f less than 3. T Mve The Machine Withut Pwer Wheel Assist: Pull and hld the functin enable lever t release the brake. Part N. 48643 Genie IWP Super Series 19
Operatr s Manual Secnd Editin Furth Printing OPERATING INSTRUCTIONS 8 Mnitr the ampere meter fr the crrect charge rate. The initial charge rate shuld be apprximately 10A. The charge rate will decrease as the battery reaches full charge. Battery and Charger Instructins Observe and Obey: D nt use an external charger r bster battery. 9 The charger will turn ff autmatically when the battery is fully charged. Set the pwer switch t the OFF psitin, then discnnect frm the AC supply. 10 Check the battery acid level when the charge cycle is cmplete. Replenish with distilled water t the bttm f the fill tube. D nt verfill. Charge the battery in a well-ventilated area. Use prper AC input vltage fr charging as indicated n the charger. Use nly Genie authrized battery and charger. T Charge Battery 1 Open the battery pack lid t access the battery. 2 Remve the battery vent caps and check the battery acid level. If necessary, add nly enugh distilled water t cver the plates. D nt verfill prir t the charge cycle. 3 Replace the battery vent caps. 4 Set the pwer switch t the OFF psitin. Be sure that the DC utput crd is prperly cnnected t the battery. Black t negative, red t psitive. 5 Cnnect the battery charger t a grunded AC circuit. 6 If equipped: Set the AC Selectr switch t the prper vltage. 7 Set the pwer switch t the AUTO psitin. Dry Battery Filling and Charging Instructins 1 Remve battery vent caps and permanently remve plastic seal frm battery vent penings. 2 Fill each cell with battery acid (electrlyte) until the level is sufficient t cver the plates. D nt fill t maximum level until battery charge cycle is cmplete. Overfilling can cause the battery acid t verflw during charging. Neutralize battery acid spills with baking sda and water. 3 Install the battery vent caps. 4 Charge the battery. 5 Check the battery acid level when the charging cycle is cmplete. Replenish with distilled water t the bttm f the fill tube. D nt verfill. 20 Genie IWP Super Series Part N. 48643
Secnd Editin Furth Printing Operatr s Manual Transprt Instructins Lading the Machine With a Frklift Observe and Obey: Cmmn sense and planning must be applied t cntrl the mvement f the machine when lifting it with a crane r frklift. The transprt vehicle must be parked n a level surface. The transprt vehicle must be secured t prevent rlling while the machine is being laded. Vehicle capacity, lading equipment and surfaces must be capable f supprting the machine weight. See Specificatins sectin. The base f the machine must remain lwered during all lading and transprt prcedures. The machine must be secured t the transprt vehicle with chains r straps f ample lad capacity. Winching the Machine nt a Flatbed Truck 1 Lwer the platfrm. 2 Push in the red Emergency Stp buttns, turn the key switch t the OFF psitin and remve the key. 3 Inspect the entire machine fr lse r unsecured items. 4 Cnnect the cable t the winching pint lcated n the frnt f the base. 5 Carefully winch the machine nt the truck. 6 Secure the machine base and mast t the transprt vehicle. Use chains r straps f ample lad capacity. Use the frklift pckets lcated n the sides f the machine r the frklift rings lcated behind the cunterweight under the platfrm. Be sure t inspect the machine and remve any lse r unsecured items. T use the frklift rings: 1 Raise the platfrm 3 inches / 7.5 cm. 2 Psitin the frklift rings in the up psitin. Lading the Machine With a Crane Use the lifting eye munted n the rear mast clumn. The battery pack must be remved befre lifting the machine with a crane. Be sure t inspect the machine and remve any lse r unsecured items. Always place the lifting hk thrugh the lifting eye s that it pints away frm the machine. Part N. 48643 Genie IWP Super Series 21
Operatr s Manual Secnd Editin Furth Printing Decals Decal Inspectin Use the pictures n the next page t verify that all decals are legible and in place. Belw is a numerical list with quantities and descriptins. Part N. Descriptin Quantity 27857 Cautin - Pipe Plug 1 27865 Label - Bubble Level 1 27868 Danger - Relief Valve 1 28157 Label - Dexrn 1 28372 Cautin - Quick Discnnect 1 31068 Danger - Battery Charger Safety 1 31070 Danger - Tip-ver Hazard, Mving 1 31071 Warning - Failure t Read 1 31073 Label - Ft Pedal 1 31075 Cautin - Crushing Hazard 4 31076 Cautin - 8A Maximum, 115V AC 1 31077 Cautin - Cllisin Hazard 1 31245 Warning - Cllisin Hazard 1 33550 Safety Tape, CE --- 37134 Label - Interlck Display 1 Part N. Descriptin Quantity 38142 Label - Circuit Breaker (AC mdels) 1 38149 Label - Patents 1 43657 Danger - Tip-ver Hazard, Outreach Optin 1 46212 Ntice - Max Side Frce 45 lbs / 200 N 1 44813 Label - Interlck Display 1 44999 Label - Cntrl Activate 1 48644 Label - Functin Enable Lever 1 48645 Danger - Pwer Wheel Assist Optin Safety 1 52996 Csmetic - Genie Lg 2 62045 Csmetic - IWP-25S 2 62046 Csmetic - IWP-30S 2 62996 Csmetic - IWP-20S 2 72844 Danger - General Safety 1 37141 Manual Lwering Instructins 1 37143 Ntice - Max Capacity 300 lbs / 136 kg 1 37144 Ntice - Max Capacity 350 lbs / 159 kg 1 37145 Label - Manual Lwering Valve 1 38116 Danger - Outreach Optin Safety & Instructins 1 38117 Ntice - Pwer Wheel Assist Optin Operating Instructins 1 38119 Ntice - Operating Instructins 1 38122 Label - Manual Strage Cntainer 1 22 Genie IWP Super Series Part N. 48643
Secnd Editin Furth Printing Operatr s Manual DECALS Outreach Optin Nte: Platfrm decals may be in diffferent lcatins n ptinal fiberglass basket. Part N. 48643 Genie IWP Super Series 23
Operatr s Manual Secnd Editin Furth Printing Specificatins Mdel IWP-20S IWP-25S 1 IWP-30S Height, wrking maximum 26 ft 5 in 30 ft 5 in 35 ft 6 in 8.1 m 9.3 m 10.8 m Height, platfrm maximum 20 ft 5 in 24 ft 5 in 29 ft 6 in 6.2 m 7.4 m 9.0 m Lift capacity - ANSI & CE 350 lbs 350 lbs 350 lbs 159 kg 159 kg 159 kg Lift capacity - CSA 300 lbs 300 lbs 300 lbs 136 kg 136 kg 136 kg Lift capacity 300 lbs with utreach ptin 136 kg Pwer surce DC mdel 12V 12V 12V AC mdel 110V r 220V 110V r 220V 110V r 220V Machine weight See Serial Plate See Serial Plate See Serial Plate (Machine weights vary with ptin cnfiguratins) Height, stwed 76 in / 78 in 76 in / 78 in 76 in / 78 in base fully lwered/base raised 1.9 m / 2.0 m 1.9 m / 2.0 m 1.9 m / 2.0 m Width - Standard base 32 in 32 in 81 cm 81 cm Length - Standard base 60 in 60 in 1.5 m 1.5 m Width - Wide base 40 in 40 in 40 in 1 m 1 m 1 m Length - Wide base 60 in 60 in 60 in 1.5 m 1.5 m 1.5 m Optinal Outreach, extended 26 in 66 cm Crner access 2 6 in 6 in 7 in 15 cm 15 cm 18 cm 1 IWP-30S is nly available with a wide base. 2 Crner f platfrm tp rail t crner f wall with ability t rtate leveling jack handle. Cntinuus imprvement f ur prducts is a Genie plicy. Prduct specificatins are subject t change withut ntice r bligatin. 24 Genie IWP Super Series Part N. 48643
Secnd Editin Furth Printing Operatr s Manual SPECIFICATIONS Ambient perating -20 F t 135 F temperature -29 C t 57 C Airbrne nise emissins 80 db Maximum sund level at nrmal perating wrkstatins (A-weighted) Platfrm Dimensins (length x width x height) Standard platfrm 27 x 26 x 44 3 /4 in gated r sliding mid-rail 69 cm x 66 cm x 1.1m Gated ultra-narrw platfrm Gated narrw platfrm Standard fiber platfrm Narrw fiber platfrm 22 x 18 x 44 3 /4 in 56 cm x 46 cm x 1.1 m 26 x 20 x 44 3 /4 in 66 cm x 51 cm x 1.1 m 29 x 26 1 /2 x 43 1 /2 in 74 cm x 67 cm x 1.1 m 26 x 22 x 43 1 /2 in 66 cm x 56 cm x 1.1 m Frnt entry gated narrw platfrm 20 x 26 x 44 3 /4 in 51cm x 66 cm x 1.1 m Extra large frnt and side entry platfrm 30 x 28 x 44 3 /4 in 76 cm x 71 cm x 1.1 m Part N. 48643 Genie IWP Super Series 25
Genie Hlland Phne + 31 70 51 78836 Fax + 31 70 51 13993 Genie Scandinavia Phne + 46 31 3409612 Fax + 46 31 3409613 Genie France Phne + 33 (0)2 37 26 09 99 Fax + 33 (0)2 37 26 09 98 Genie Iberica Phne + 34 93 579 5042 Fax + 34 93 579 5059 Genie Germany Phne + 49 (0)4202 88520 Fax + 49 (0)4202 8852-20 Genie U.K. Phne + 44 (0)1476 584333 Fax + 44 (0)1476 584334 Genie Mexic City Phne + 52 5 653 03 84 Fax + 52 5 664 40 16 Genie Nrth America Phne 425.881.1800 Tll Free USA and Canada 800.536.1800 Fax 425.883.3475 Genie Australia Pty Ltd. Phne + 61 7 3375 1660 Fax + 61 7 3375 1002 Genie China Phne + 86 21 53852570 Fax + 86 21 53852569 Genie Malaysia Phne + 60 4 228 1235 Fax + 60 4 226 6872 Genie Japan Phne + 81 3 3453 6082 Fax + 81 3 3453 6083 Genie Krea Phne + 82 2 558 7267 Fax + 82 2 558 3910 Genie Africa Phne + 27 11 455 0373 Fax + 27 11 455 0355 Genie Latin America Phne + 55 11 4055 2499 Fax + 55 11 4043 1661 Distributed By: