Operator’s Manual Fifth Edition • Third 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. Contents Page Safety Rules .............................................................. 1 Controls .................
Fifth Edition • Third 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 Fifth Edition • Third 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 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.
Fifth Edition • Third 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 Fifth Edition • Third Printing SAFETY RULES Allow for platform 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.
Fifth Edition • Third 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 Fifth Edition • Third 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 eye wear 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.
Fifth Edition • Third Printing Operator’s Manual Controls Ground Controls Platform Controls 1 DC models: Low battery indicator light 7 Level sensor interlock display lights 2 Low battery indicator light for auxiliary lowering 8 Footpad interlock display lights 3 Power light 9 Control activate button 4 Auxiliary platform lowering button 10 Up/Down switch 5 Red Emergency Stop button 6 Key switch 9 10 Part No. 145358 Note: Two different interlock display decals were produced.
Operator’s Manual Fifth Edition • Third 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 Lanyard anchorage point 7 Operator’s manual storage container 8 Lifting eye 9 Breather cap 10 Platform controls 11 Level sensor with bubble level* 12 AC outlet 8 13 DC models: Battery quick disconnect 14 DC models: Battery pack 15 Footpad 16 Transport tie down 17 Platform entry mid-rail or gate 18 F
Fifth Edition • Third 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. 1 Avoid hazardous situations. 2 Always perform a pre-operation inspection. Know and understand the pre-operation inspection before going on to the next section.
Operator’s Manual Fifth Edition • Third Printing PRE-OPERATION INSPECTION If equipped: Power wheel assist option Pre-operation Inspection Be sure that the operator's, safety and responsibilities manuals are complete, legible and in the storage container located on the mast. Check for hydraulic oil leaks and proper oil level. Add oil if needed. See Maintenance section.
Fifth Edition • Third 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 component damage and hazardous conditions. Observe and Obey: Only routine maintenance items specified in this manual shall be performed by the operator. Electrocution hazard. Contact with hot or live circuits could result in death or serious injury.
Operator’s Manual Fifth Edition • Third 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.
Fifth Edition • Third 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. A malfunctioning machine must never be used.
Operator’s Manual Fifth Edition • Third Printing FUNCTION TESTS 8 Pull out the red Emergency Stop button at the platform controls to the on position. Function Tests 1 Select a firm, level test area free of obstructions. Result: The power light should come on. Within 1 to 4 seconds, the two level sensor interlock display lights and the two foot pad interlock display lights should turn on and remain on. 2 Pump the foot pedal to raise the base. Result: The wheels should contact the ground.
Fifth Edition • Third Printing Operator’s Manual FUNCTION TESTS 10 Pull the base lowering handle to lower the base. Result: The two footpad display lights should be on. 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. 11 Pump the foot pedal to raise the base.
Operator’s Manual Fifth Edition • Third Printing 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. 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.
Fifth Edition • Third Printing Operator’s Manual Workplace Inspection Be aware of and avoid the following hazardous situations: · drop-offs or holes · bumps and floor obstructions · debris Do Not Operate Unless: · sloped surfaces You learn and practice the principles of safe machine operation contained in this operator's manual. · unstable or slippery surfaces · overhead obstructions and high voltage conductors 1 Avoid hazardous situations.
Operator’s Manual Fifth Edition • Third Printing 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.
Fifth Edition • Third Printing Operator’s Manual OPERATING INSTRUCTIONS 8 Be sure that the two level sensor interlock display lights and the two footpad interlock display lights are on. 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.
Operator’s Manual Fifth Edition • Third Printing 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.
Fifth Edition • Third Printing Operator’s Manual OPERATING INSTRUCTIONS To Charge Battery 1 Open the battery pack lid to access the battery. Battery and Charger Instructions 2 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. 3 Replace the battery vent caps. Observe and Obey: Do not use an external charger or booster battery. Charge the battery in a well-ventilated area.
Operator’s Manual Fifth Edition • Third Printing Transport and Lifting Instructions Winching the Machine onto a Flatbed Truck 1 Lower the platform. 2 Push in the red Emergency Stop buttons, turn the key switch to the off position and remove the key. 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. The transport vehicle must be parked on a level surface.
Fifth Edition • Third Printing Operator’s Manual TRANSPORT AND LIFTING INSTRUCTIONS Loading the Machine With a Crane Securing the Machine Use the lifting eye mounted on the rear mast column. Use a minimum of 3 chains. Use chains or straps of ample load capacity. Adjust the rigging to prevent damage to the chains. 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.
Operator’s Manual Fifth Edition • Third 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. Part No.
Fifth Edition • Third Printing Operator’s Manual DECALS Outreach Option Note: Platform decals may be in different locations on optional fiberglass basket. Part No.
Operator’s Manual Fifth Edition • Third Printing 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 place. Part No.
Fifth Edition • Third Printing Operator’s Manual DECALS Outreach Option Note: Platform decals may be in different locations on optional fiberglass basket. Part No.
Operator’s Manual Fifth Edition • Third Printing Specifications Model 1 IWP-20S IWP-25S Height, working maximum 26.1 ft 8.0 m 30.9 ft 9.4 m 35.5 ft 10.8 m Height, platform maximum 20.1 ft 6.1 m 24.9 ft 7.6 m 29.5 ft 9.
Fifth Edition • Third Printing Operator’s Manual SPECIFICATIONS Airborne noise emissions Sound pressure level at ground workstation < 70 dBA Sound pressure level at platform workstation < 70 dBA Total vibration value to which the hand/arm system is subjected does not exceed 2.5 m/s2. Highest root mean square value of weighted acceleration to which the whole body is subjected does not exceed 0.5 m/s2.
