Terex Genie IWP Super Series Operator's Manual
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Terex Genie IWP Super Series Operator's Manual

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Operator's Manual
IWP
Super
®
Series
Serial Number Range
from IWPP-13000
ANSI/CSA
North America
South America
Asia
with
Maintenance
Information
Original Instructions
Sixth Edition
First Printing
Part No. 1298036GT

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Summary of Contents for Terex Genie IWP Super Series

  • Page 1 Operator's Manual Serial Number Range Super ® from IWPP-13000 ANSI/CSA North America Series South America Asia with Maintenance Information Original Instructions Sixth Edition First Printing Part No. 1298036GT...

  • Page 2: Table Of Contents

    Specifications ............41 Copyright © 1996 Terex Corporation Sixth Edition: First Printing, March 2020 "Genie" and "IWP" are registered trademarks of Terex South Dakota in the U.S.A. and many other countries. "Super Series" is a trademark of Terex South Dakota.

  • Page 3: Introduction

    Sixth Edition • First Printing Operator's Manual Introduction Intr oducti on About this manual Intended Use and Familiarization Guide Genie appreciates your choice of our machine for your application. Our number one priority is user The intended use of this machine is to lift safety, which is best achieved by our joint efforts.
  • Page 4 Sixth Edition • First Printing Operator's Manual Introduction Platform controls symbology and related Footpad interlock - Off machine movement: Platform up Footpad interlock - On Platform down Level sensor interlock - Off Level sensor interlock - On Ground controls symbology and related machine movement: Keyswitch - Off Interlocked functions:...
  • Page 5 Sixth Edition • First Printing Operator's Manual Introduction Bulletin Distribution and Contacting the Manufacturer Compliance At times it may be necessary to contact Genie. When you do, be ready to supply the model Safety of product users is of paramount number and serial number of your machine, along importance to Genie.
  • Page 6 Sixth Edition • First Printing Operator's Manual Introduction Safety Sign Maintenance Replace any missing or damaged safety signs. Keep operator safety in mind at all times. Use mild soap and water to clean safety signs. Do not use solvent-based cleaners because they may damage the safety sign material.

  • Page 7: Symbol And Hazard Pictorials Definitions

    Sixth Edition • First Printing Operator's Manual Symbol and Hazard Pictorials Definitions Symbol and H az ard Pict orials Definiti ons Read the operator’s Read the service Crush hazard No smoking Collision hazard manual manual Crush hazard Tip-over hazard Tip-over hazard Electrocution hazard Tip-over hazard Maintain required...
  • Page 8 Sixth Edition • First Printing Operator's Manual Symbol and Hazard Pictorials Definitions Voltage rating for Pressure rating for air Lifting point Release brakes Grounded AC power to platform line to platform 3-wire only Replace damaged Wheel load Lanyard anchorage Side force Manual force wires and cords points...

  • Page 9: General Safety

    Sixth Edition • First Printing Operator's Manual General Safety Gener al Safety ® Part No. 1298036GT Super Series...
  • Page 10 Sixth Edition • First Printing Operator's Manual General Safety ® Super Series Part No. 1298036GT...
  • Page 11 Sixth Edition • First Printing Operator's Manual General Safety ® Part No. 1298036GT Super Series...
  • Page 12 Sixth Edition • First Printing Operator's Manual General Safety ® Super Series Part No. 1298036GT...

  • Page 13: Personal Safety

    Sixth Edition • First Printing Operator's Manual Personal Safety Pers onal Safety Personal 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...

  • Page 14: Work Area Safety

    Sixth Edition • First Printing Operator's Manual Work Area Safety Wor k Ar ea Safety Tip-over Hazards Maximum allowable manual force 45 lbs / 200 N Do not operate the machine near drop-offs, holes, Do not raise the platform unless the machine is on bumps, debris, unstable or slippery surfaces or a firm, level surface.
  • Page 15 Sixth Edition • First Printing Operator's Manual Work Area Safety Fall Hazards Do not operate the machine in strong or gusty The guard rail system provides fall protection. If winds. Do not increase the occupant(s) of the platform are required to wear surface area of the personal fall protection equipment (PFPE) due to platform or the load.
  • Page 16 Sixth Edition • First Printing Operator's Manual Work Area Safety Allow for platform movement, electrical line sway Electrocution Hazards or sag, and beware of strong or gusty winds. This machine, even with an optional fiberglass Do not use the machine as a ground for welding. platform, is not electrically insulated and will not provide protection from contact with or proximity to Do not operate an AC powered machine or a DC...
  • Page 17 Sixth Edition • First Printing Operator's Manual Work Area Safety Improper Use Hazard Use common sense and planning to control the Do not leave the machine unattended unless the movement of the key is removed to secure from unauthorized use. machine on or near inclines.
  • Page 18 Sixth Edition • First Printing Operator's Manual Work Area Safety Outreach Option Safety Battery Safety Burn Hazards Bodily Injury Hazard Batteries contain acid. Keep hands and feet away from moving parts: Always wear protective mounting plate, locking bracket and extension clothing and eye wear when arms.
  • Page 19 Sixth Edition • First Printing Operator's Manual Work Area Safety Explosion Hazards Hazard The battery pack weighs 90 lbs / 40.8 kg. Use the Keep sparks, flames, and appropriate number of people and proper lifting lighted tobacco away from techniques when lifting the battery pack. batteries.

  • Page 20: Legend

    Sixth Edition • First Printing Operator's Manual Legend Leg end AC models: Power supply for 14 DC models: Battery pack 28 Manual lowering valve machine (located at the bottom of the 15 Footpad hydraulic cylinder) DC models: Power to 16 Transport tie-down platform 29 Battery strap 17 Platform entry mid-rail or gate...

  • Page 21: Controls

    Sixth Edition • First Printing Operator's Manual Controls Controls Ground controls The ground control station can be used in Note: Two different interlock display the event of an emergency to rescue an decals were produced. The symbols incapacitated person in the platform. on them are different but they both operate the same way.

  • Page 22: Inspections

    Sixth Edition • First Printing Operator's Manual Inspections Ins pections Pre-operation Inspection 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. Do Not Operate Unless: The inspection is designed to discover if anything is apparently wrong with a machine before the...
  • Page 23 Sixth Edition • First Printing Operator's Manual Inspections Pre-operation Inspection If equipped: Power wheel assist option  Steer handle  Be sure that the operator’s, safety and  Hydraulic motor and hoses responsibilities manuals are complete, legible and in the storage container located in the If equipped: IWP-20S with Outreach option platform.
  • Page 24 Sixth Edition • First Printing Operator's Manual Inspections Function Test 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 never be used. If malfunctions are discovered, the machine must be Do Not Operate Unless: tagged and removed from service.
  • Page 25 Sixth Edition • First Printing Operator's Manual Inspections Function Tests Pull out the platform red Emergency Stop button to the on position. Setup Result: The power light should come on. Select a test area that is firm, level and free of Within 1 to 4 seconds, the two level sensor hazards.
  • Page 26 Sixth Edition • First Printing Operator's Manual Inspections Test Emergency Stop 10 Pull the base lowering handle to fully lower the base. 15 Use the bubble level and adjust the leveling jacks until the machine base is level. Be sure Result: The two footpad display lights should all four display lights at the ground controls are be on.
  • Page 27 Sixth Edition • First Printing Operator's Manual Inspections Test Auxiliary Platform Lowering Test Platform Raise and Lower 21 Raise the platform slightly. 34 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.
  • Page 28 Sixth Edition • First Printing Operator's Manual Inspections 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 workplace.
  • Page 29 Sixth Edition • First Printing Operator's Manual Inspections Workplace Inspection Workplace Inspection Checklist Fundamentals Be aware of and avoid the following hazardous situations: The workplace inspection helps the operator determine if the workplace is suitable for safe  drop-offs or holes machine operation.
  • Page 30 Sixth Edition • First Printing Operator's Manual Inspections Inspection for Decals with Words Part No. Decal Description 1281175 Label – Lanyard Anchorage Point, Fall Determine whether the decals on your machine Restrained have words or symbols. Use the appropriate 1294398 Label – ANSI/CSA Compliant inspection to verify that all decals are legible and 1294685 Instructions –...
  • Page 31 Sixth Edition • First Printing Operator's Manual Inspections ® Part No. 1298036GT Super Series...
  • Page 32 Sixth Edition • First Printing Operator's Manual Inspections 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. Decal Description Label –...
  • Page 33 Sixth Edition • First Printing Operator's Manual Inspections ® Part No. 1298036GT Super Series...

  • Page 34: Operating Instructions

    Sixth Edition • First Printing Operator's Manual Operating Instructions Operati ng Instr ucti ons Setup Pump the foot pedal to raise the base until the wheels contact the ground. Do Not Operate Unless: Use the steering handle to push the machine. ...
  • Page 35 Sixth Edition • First Printing Operator's Manual Operating Instructions Manual Lowering Be sure that the two level sensor interlock display lights and the two footpad interlock Activate the display lights are on. manual lowering valve located at the bottom of the hydraulic cylinder.
  • Page 36 Sixth Edition • First Printing Operator's Manual Operating Instructions Power Wheel Assist Option After Each Use Operating Instructions Select a safe storage location—firm, level surface, weather protected, clear of Lower the steer handle. obstruction and traffic. Pull and hold the function enable lever on Pull the base lowering handle to lower the eitherside.

  • Page 37: Maintenance

    Sixth Edition • First Printing Operator's Manual Maintenance Maintenanc e Check the Batteries - DC Models Proper battery condition is essential to good machine performance and operational safety. Improper fluid levels or damaged cables and Observe and Obey: connections can result in component damage and hazardous conditions.
  • Page 38 Sixth Edition • First Printing Operator's Manual Maintenance Check the Hydraulic Oil Level Scheduled Maintenance Maintenance performed quarterly, annually and every two years must be completed by a person trained and qualified to perform maintenance on Maintaining the hydraulic oil at the proper level is this machine according to the procedures found in essential to machine operation.

  • Page 39: Battery Charging Instructions

    Sixth Edition • First Printing Operator's Manual Battery Charging Instructions Batter y Charging Instr ucti ons To Charge Secondary Battery (if equipped) Disconnect the primary battery from the machine by unplugging the Anderson connector located at the rear of the primary battery box.
  • Page 40 Sixth Edition • First Printing Operator's Manual Battery Charging Instructions Dry Battery Filling and Charging Instructions 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.

  • Page 41: Transport And Lifting Instructions

    Sixth Edition • First Printing Operator's Manual Transport and Lifting Instructions Trans port and Lifti ng Instr ucti ons Winching the Machine onto a Flatbed Truck Fully lower the platform. Push in the red Emergency Stop buttons, turn the key switch to the off position and remove the key.
  • Page 42 Sixth Edition • First Printing Operator's Manual Transport and Lifting Instructions Loading the Machine With a Securing the Machine Crane Use chains or straps of ample load capacity. Use the lifting eye mounted on the rear mast Use a minimum of 3 chains or straps. column.

  • Page 43: Specifications

    Sixth Edition • First Printing Operator's Manual Specifications Specific ati ons Specifications Airborne noise emissions Height, working maximum Sound pressure level at ground <70 dBA workstation IWP-20S 26 ft 3 in/8.0 m Sound pressure level at platform <70 dBA IWP-25S 30 ft 11 in/9.4 m workstation IWP-30S...

This manual is also suitable for:

Genie iwp-20sGenie iwp-25sGenie iwp-30s

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