Operator’s Manual with Maintenance Information Second Edition Fourth Printing Part No.
Operator’s Manual Second 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 .............................................................. 1 Controls ....
Second 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: 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.
Operator’s Manual Second 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 use the machine to lift material or equipment. The machine is intended to lift personnel and tools to an aerial work site. Do not operate the machine near drop-offs, holes, bumps, debris, unstable or slippery surfaces or other possible hazardous conditions.
Second Edition • Fourth Printing Operator’s Manual SAFETY RULES Do not replace items critical to stability 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.
Operator’s Manual Second Edition • Fourth Printing SAFETY RULES Allow for platform movement, electrical line sway or sag and movement due to strong or gusty winds. Damaged Machine Hazards Do not use the machine as a ground for welding. Be sure all maintenance has been performed as specified in this manual and the Genie IWP Super Series service manual. 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.
Second Edition • Fourth Printing Operator’s Manual SAFETY RULES Outreach Option Safety Decal Legend Bodily Injury Hazard Genie product decals use symbols, color coding and signal words to identify the following: Keep hands and feet away from moving parts: mounting plate, locking bracket and extension arms.
Operator’s Manual Second Edition • Fourth Printing SAFETY RULES Battery and Charger Safety DC Models Explosion Hazards Batteries emit explosive gas. Keep sparks, flames and lighted tobacco away from batteries. Burn Hazards Batteries contain acid. Always wear protective clothing and eyewear when working with batteries. Charge the battery in a well-ventilated area. Do not disconnect charger DC output wires from the battery when the charger is on.
Second Edition • Fourth Printing Operator’s Manual Controls Ground Controls 2 3 1 4 Platform Controls ANSI & CSA 7 6 5 Platform Controls CE 1 Interlock display lights (four) 2 Key switch 3 Red Emergency Stop button 4 Auxiliary platform lowering button 5 Power light 6 Low battery indicator light for auxiliary lowering 7 DC models: Low battery indicator light 3 9 8 8 3 9 8 Control activate button 9 Up/Down switch Part No.
Operator’s Manual Second Edition • Fourth Printing Legend 1 AC models: AC power supply line for machine DC models: power to platform 2 Ground controls (interlock display) 3 Circuit breaker 4 Mast 5 Platform 6 Operator’s manual storage container 7 Lifting eye 8 Breather cap 9 Platform controls 10 Bubble level/level sensor 8 11 AC outlet 12 DC models: Battery quick disconnect 13 DC models: Battery pack 14 Footpad 15 Transport tie down 16 Platform entry mid-rail or gate 17 Forklift ring 18 Left side leveli
Second Edition • Fourth Printing Operator’s Manual Pre-operation Inspection Fundamentals It is the responsibility of the operator to perform a Pre-operation Inspection and routine maintenance. Do Not Operate Unless: You learn and practice the principles of safe machine operation contained in this operator's manual. The Pre-operation Inspection is a visual inspection performed by the operator prior to each work shift.
Operator’s Manual Second Edition • Fourth Printing PRE-OPERATION INSPECTION Pre-operation Inspection o Be sure that the operator's, safety and responsibilities manuals are complete, legible and in the storage container located on the mast. If equipped: Power wheel assist option o Be sure that all decals are legible and in place. See Decals section. If equipped: IWP-20S with Outreach option o Locking bracket o AC & DC models: Check for hydraulic oil leaks and proper oil level. Add oil if needed.
Second Edition • Fourth Printing Operator’s Manual 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 engine component damage and hazardous conditions. Observe and Obey: Electrocution hazard. Contact with hot or live circuits could result in death or serious injury. Remove all rings, watches and other jewelry.
Operator’s Manual Second 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.
Second Edition • Fourth Printing Operator’s Manual 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. Do Not Operate Unless: You learn and practice the principles of safe machine operation contained in this operator's manual. 1 Avoid hazardous situations. 2 Always perform a pre-operation inspection.
Operator’s Manual Second Edition • Fourth Printing FUNCTION TESTS Function Tests 1 Select a level test area free of obstructions. 2 Pump the foot pedal to raise the base. Result: The wheels should contact the ground. 3 Pull the base lowering handle to fully lower the base. Result: All four foot pads should come in firm contact with the ground. 4 Connect the appropriate power source.
Second Edition • Fourth Printing Operator’s Manual FUNCTION TESTS Test Auxiliary Platform Lowering Test Platform Raise and Lower 20 Raise the platform slightly. 33 Push in the control activate button and rotate the up/down switch to the UP position. Result: The inner frame wheels should lift off the ground. ANSI & CSA CE 21 Disconnect the power source from the machine. 22 Turn the key switch to ground control (if equipped). 23 Push in the auxiliary platform lowering button at the ground controls.
Operator’s Manual Second Edition • Fourth Printing Workplace Inspection Be aware of and avoid the following hazardous situations: · Drop-offs or holes · Bumps and floor obstructions · Debris Do Not Operate Unless: · Overhead obstructions and high voltage conductors 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.
Second Edition • Fourth Printing Operator’s Manual Operating Instructions Setup 1 Pump the foot pedal to raise the base until the wheels contact the ground. 2 Use the steering handle to push the machine. Do Not Operate Unless: You learn and practice the principles of safe machine operation contained in this operator's manual. 1 Avoid hazardous situations. 2 Always perform a pre-operation inspection. 3 Always perform function tests prior to use. 4 Inspect the work place.
Operator’s Manual Second Edition • Fourth Printing OPERATING INSTRUCTIONS Emergency Stop Auxiliary Platform Lowering 1 Push in the red Emergency Stop button at the platform controls or at the ground controls to stop the up function. 1 Turn the key switch to ground control (if equipped). Platform Raise & Lower 2 Activate the auxiliary platform lowering button at the ground controls. 1 Twist to release the red Emergency Stop button at the platform controls.
Second Edition • Fourth Printing Operator’s Manual OPERATING INSTRUCTIONS Outreach Option Operating Instructions 1 Lift up 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 Lower the steer handle.
Operator’s Manual Second Edition • Fourth Printing OPERATING INSTRUCTIONS 8 Monitor the ampere meter for the correct charge rate. The initial charge rate should be approximately 10A. The charge rate will decrease as the battery reaches full charge. Battery and Charger Instructions Observe and Obey: Do not use an external charger or booster battery. 9 The charger will turn off automatically when the battery is fully charged. Set the power switch to the OFF position, then disconnect from the AC supply.
Second Edition • Fourth Printing Operator’s Manual Transport Instructions 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. Observe and Obey: Common sense and planning must be applied to control the movement of the machine when lifting it with a crane or forklift. Be sure to inspect the machine and remove any loose or unsecured items.
Operator’s Manual Second Edition • Fourth Printing Decals Decal Inspection Use the pictures on the next page to verify that all decals are legible and in place. Below is a numerical list with quantities and descriptions. Part No. Description Quantity Part No.
Second Edition • Fourth Printing Operator’s Manual DECALS Outreach Option Note: Platform decals may be in diffferent locations on optional fiberglass basket. Part No.
Operator’s Manual Second Edition • Fourth Printing Specifications 1 Model IWP-20S IWP-25S Height, working maximum 26 ft 5 in 8.1 m 30 ft 5 in 9.3 m 35 ft 6 in 10.8 m Height, platform maximum 20 ft 5 in 6.2 m 24 ft 5 in 7.4 m 29 ft 6 in 9.
Second Edition • Fourth Printing Operator’s Manual SPECIFICATIONS Ambient operating temperature -20°F to 135°F -29°C to 57°C Airborne noise emissions 80 dB Maximum sound level at normal operating workstations (A-weighted) Platform Dimensions (length x width x height) Standard platform gated or sliding mid-rail 27 x 26 x 443/4 in 69 cm x 66 cm x 1.1m Gated ultra-narrow platform 22 x 18 x 443/4 in 56 cm x 46 cm x 1.1 m Gated narrow platform 26 x 20 x 443/4 in 66 cm x 51 cm x 1.
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