Genie IWP Super Series User manual

Operator’s Manual Second Edition
Fourth Printing
Part No. 48643
with Maintenance Information

Genie IWP Super Series Part No. 48643
Operator’s Manual Second Edition • Fourth Printing
Copyright © 1996 by Genie Industries.
First Edition: Fifth Printing, November 1997
Second Edition: Fourth Printing, January 2002
"Genie" and "IWP" are registered trademarks of
Genie Industries in the U.S.A. and many other
countries. "Super Series" is a trademark of Genie
Industries.
This machine complies with
ANSI/SIAA92.3-1990.
Printed on recycled paper.
Printed in U.S.A.
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 ..................................................................... 7
Legend ...................................................................... 8
Pre-operation Inspection ........................................... 9
Maintenance ............................................................. 11
Function Tests.......................................................... 13
Workplace Inspection ............................................... 16
Operating Instructions .............................................. 17
Battery and Charger Instructions.............................. 20
Transport Instructions .............................................. 21
Decals ...................................................................... 22
Specifications ........................................................... 24
Contact us:
Internet: http://www.genielift.com
e-mail: [email protected]

Part No.48643 Genie IWP Super Series 1
Operator’s ManualSecond Edition • Fourth Printing
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.
4 Inspect the workplace.
5 Only use the machine as it was intended.
You read, understand and obey:
manufacturer's instructions and safety
rules—operator's manual and machine
decals
employer's safety rules and worksite
regulations
applicable governmental regulations

2 Genie IWP Super Series Part No.48643
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 cause a horizontal force or side load to the
machine by raising or lowering a fixed or
overhangingload.
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.
Do not push off or pull toward any object outside
the platform.
Maximum allowable 45 lbs
manual force 200 N
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.
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.
Do not exceed the rated platform load capacity.
Maximum capacity -
ANSI & CE 350 lbs 159 kg
Maximum capacity -
CSA 300 lbs 136 kg
Maximum capacity 300 lbs 136 kg
IWP-20Swith outreachoption
Maximum occupancy 1 person

Part No.48643 Genie IWP Super Series 3
Operator’s ManualSecond Edition • Fourth Printing
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 until
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
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.
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
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
groundpersonnel activate
the manual lowering valve.
Keep the platform floor clear of debris.
Lower the platform entry mid-rail before operating.

4 Genie IWP Super Series Part No.48643
Operator’s Manual Second Edition • Fourth Printing
Allow for platform movement, electrical line
sway or sag and movement due to 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
Check the work area for overhead obstructions or
other possible hazards.
Be aware of crushing hazard 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.
SAFETY RULES
Damaged Machine Hazards
Do not use a damaged 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.

Part No.48643 Genie IWP Super Series 5
Operator’s ManualSecond Edition • Fourth Printing
Outreach Option Safety
Bodily Injury Hazard
Keep hands and feet away from moving parts:
mounting plate, locking bracket and extension
arms.
PowerWheel 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 machine on an
incline.
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
presence of an imminently
hazardous situation which, if not
avoided, will result in death or
serious injury.
Orange—used to indicate the
presence of a potentially
hazardous situation which, if not
avoided, could result in death or
serious injury.
Yellow with safety alert symbol—
used to indicate the presence of 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.
Green—used to indicate operation
or maintenance information.
SAFETY RULES

6 Genie IWP Super Series Part No.48643
Operator’s Manual Second Edition • Fourth Printing
SAFETY RULES
Battery and Charger Safety -
DC Models
Burn Hazards
Batteries contain acid. Always wear protective
clothing and eyewear when working with batteries.
Avoid spilling or contacting battery acid. Neutralize
battery acid spills with baking soda and water.
The battery pack must
remain in an upright
position.
Explosion Hazards
Batteries emit explosive
gas. Keep sparks, flames
and lighted tobacco away
from batteries.
Charge the battery in a
well-ventilated area.
Do not disconnect
charger DC output
wires from the battery
when the charger is on.
ElectrocutionHazards
Connect the charger to a grounded AC circuit only.
Do not expose the battery or
charger to water and/or rain.
Before each use, inspect for
damage. Replace damaged
components before
operating.
Lifting Hazard
The battery pack weighs 90 lbs / 40.8 kg. Use the
appropriate number of people and proper lifting
techniques.

Part No.48643 Genie IWP Super Series 7
Operator’s ManualSecond Edition • Fourth Printing
Controls
Ground Controls
3 8
Platform Controls -
ANSI & CSA
1 Interlock display lights (four)
2 Key switch
3 Red Emergency Stop button
4 Auxiliary platform lowering
button
5 Powerlight
6 Low battery indicator light for
auxiliarylowering
7 DC models: Low battery
indicator light
8 Control activate button
9 Up/Downswitch
Platform Controls -
CE
9 8 93
3
4
7
6
1
5
2

8 Genie IWP Super Series Part No.48643
Operator’s Manual Second Edition • Fourth Printing
Legend
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 leveling jack
19 Counterweight
20 Right side leveling jack
21 Forklift pocket
22 DC models: Battery charger
23 Foot pedal
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
24 Power wheel assist option
25 Manual lowering valve
(*located at the bottom of the
hydraulic cylinder)
26 Battery strap
27 Steer handle - power wheel
assist option
28 Base lowering handle
29 Function enable lever -
power wheel assist option
30 Steering handle
31 Direction-reversing safety
switch - power wheel assist
option
32 Thumb rocker switch - power
wheel assist option

Part No.48643 Genie IWP Super Series 9
Operator’s ManualSecond Edition • Fourth Printing
Pre-operation Inspection
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.
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 and locations for modifications,
damage or loose or missing parts.
A damaged or modified machine must never be
used. If damage or any 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
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.

10 Genie IWP Super Series PartNo.48643
Operator’s Manual Second Edition • Fourth Printing
Pre-operation Inspection
oBe sure that the operator's, safety and
responsibilities manuals are complete, legible
and in the storage container located on the
mast.
oBe sure that all decals are legible and in place.
See Decals section.
oAC & DC models: Check for hydraulic oil leaks
and proper oil level. Add oil if needed. See
Maintenancesection.
oDC 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, modifications and improperly installed or
missing parts:
oElectrical components, wiring and
electrical cables
oHydraulic power unit, hoses, fittings and
cylinders
oHydraulic manifolds and foot pump
oPlatform entry mid-rail or gate
oSequencing cables and pulleys
oLifting chains and idler wheels
oMast columns and counterweight
oNuts, bolts and other fasteners
oBreathercap
oFoot pads
oAdjustable glide pads
If equipped: Power wheel assist option
oSteerhandle
oHydraulic motor and hoses
If equipped: IWP-20S with Outreach option
oLocking bracket
oHandle and handle lock
oExtension arms
oConfirmpropercounterweight
configuration (part number is stamped on
top of counterweight)
ANSI & CE Indoor Front P/N Rear P/N
IWP-20S Standard Base 37354 37355
IWP-20S Wide Base 40990 40991
CSA Front P/N Rear P/N
IWP-20S Wide Base 40988 40989
Check entire machine for:
oDents or damage
oCorrosionor oxidation
oCracks in welds or structural components
oInspect and clean battery terminals and all
battery cable connections
oBe sure that all structural and other critical
components are present and all associated
fasteners and pins are in place and properly
tightened.
PRE-OPERATION INSPECTION

Part No.48643 Genie IWP Super Series 11
Operator’s ManualSecond Edition • Fourth Printing
Maintenance
Observe and Obey:
Only routine maintenance items specified in
this manual shall be performed by the operator.
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 a maintenance
procedure, it conveys the meaning
below.
Indicates that tools will be required to
perform this procedure.
Indicates that new parts will be
required to perform this procedure.
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.
Electrocution hazard. Contact with
hot or live circuits could result in
death or serious injury. Remove
all rings, watches and other
jewelry.
Bodily injury hazard. Batteries
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 Put on 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.

12 Genie IWP Super Series PartNo.48643
Operator’s Manual Second Edition • Fourth Printing
MAINTENANCE
Scheduled Maintenance
Maintenanceperformed quarterly,annuallyand
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.
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 sure the platform is fully lowered.
2 Check the 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 Dexron equivalent

Part No.48643 Genie IWP Super Series 13
Operator’s ManualSecond Edition • Fourth Printing
FunctionTests
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.
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.
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
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.

14 Genie IWP Super Series PartNo.48643
Operator’s Manual Second Edition • Fourth Printing
TestInterlockSystem
9 Pump the foot pedal to raise the base.
Result: The two foot pad display lights should be
off.
10 Pull the base lowering handle to lower the base.
Result: The two foot pad 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.
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.
TestEmergencyStop
15 Use the bubble level and adjust the leveling
jacks until the machine base is level. Be sure
all four display lights 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.
Result: The platform up/down function should
notoperate.
18 Push in the red 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.
Result: The platform up/down function should
notoperate.
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 Connectthe appropriate powersource.
5 Use the bubble level and adjust the leveling
jacks until the machine is level and all four foot
pads are in firm contact with the ground.
6 Insert the key and turn to the ON position OR
turn to platform controls.
7 Pull out the red Emergency Stop button at the
ground controls to the ON position.
8 Twist to release the red Emergency Stop button
at the platform controls.
Result: The power light
should come on. Within
1 to 4 seconds, all four
display lights should turn on
and remain on.

Part No.48643 Genie IWP Super Series 15
Operator’s ManualSecond Edition • Fourth Printing
a b a b
TestAuxiliaryPlatformLowering
20 Raise the platform slightly.
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
(ifequipped).
23 Push in the auxiliary platform lowering button at
the ground controls.
Result: The platform should lower.
24 Connect the power source to the machine.
25 Turn the key switch to platform control
(ifequipped).
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.
TestManualLowering
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 the manual
lowering valve located
at the bottom of the
hydraulic cylinder.
Result: The platform
shouldlower.
TestPlatformRaise andLower
33 Push in the control activate button and rotate
the up/down switch to the UP position.
ANSI & CSA CE
a control activate button
b up/down switch
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.
Test the Direction-reversing Safety Switch
(modelswithPowerWheelAssistOptiononly)
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.
37 Press the direction-reversing safety switch on
the end of the steer handle.
Result: The machine should travel in the
forward direction.
FUNCTION TESTS

16 Genie IWP Super Series PartNo.48643
Operator’s Manual Second Edition • Fourth Printing
Workplace Inspection
Fundamentals
The Workplace 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
operatingthe 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 Inspecttheworkplace.
Knowandunderstandtheworkplace
inspection before going on to the next
section.
5 Only use the machine as it was intended.
Be aware of and avoid the following hazardous
situations:
· Drop-offs or holes
· Bumps and floor obstructions
· Debris
· 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.48643 Genie IWP Super Series 17
Operator’s ManualSecond Edition • Fourth Printing
Operating Instructions
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.
5 Only use the machine as it was intended.
Fundamentals
Using the machine for anything other than lifting
personnel and tools to an aerial work site is
unsafe.
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.
2 Use the steering handle
to push the machine.
3 Position the machine on a firm, level surface
directly below the work area.
4 Pull the base lowering
handle to lower the base
until all four foot pads are
in firm contact with the
ground.
5 Connect to an appropriate power source:
DC models: Connect battery pack.
AC models: Connect to a grounded
15A AC power supply. Use a 12 gauge / 3.3mm2
3-wire grounded extension cord no longer than
50 feet / 13 m.
6 Insert the key and turn to the ON position OR to
platform control.
7 Pull out the red Emergency Stop button at the
ground controls and be sure the power light is
on.
8 Check the interlock display. Be sure that all four
display lights are on.

18 Genie IWP Super Series PartNo.48643
Operator’s Manual Second Edition • Fourth Printing
OPERATING INSTRUCTIONS
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 & Lower
1 Twist to release the red Emergency Stop button
at the platform controls.
2 Push in the control activate button and rotate
the up/down switch in the desired direction of
travel.
ANSI & CSA CE
a control activate button
b up/down switch
Manual Lowering
1 Activate the manual
lowering valve located
at the bottom of the
hydraulic cylinder.
Auxiliary Platform Lowering
1 Turn the key switch to ground control
(ifequipped).
2 Activate the auxiliary platform lowering button at
the ground controls.
After Each Use
1 Select a safe storage location—firm, level
surface, weather protected, clear of obstruction
and traffic.
2 Pull the base lowering handle to lower the base
until all four foot pads are in firm contact with
the ground.
3 Remove the key to secure from unauthorized
use.
4 DC models: Recharge battery.
a b a b