Terex Genie IWP Series User manual

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

Operator's Manual Sixth Edition • First Printing
IWP®Super Series Part No. 1298036GT
Front Matter
Contents
Introduction ............................................................1
Symbol and Hazard Pictorials Definitions..............5
General Safety.......................................................7
Personal Safety................................................... 11
Work Area Safety................................................ 12
Legend................................................................ 18
Controls............................................................... 19
Inspections.......................................................... 20
Operating Instructions......................................... 32
Maintenance ....................................................... 35
Battery Charging Instructions ............................. 37
Transport and Lifting Instructions ....................... 39
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.
These machines comply with
ANSI/SAIA A92.20
CAN/CSA B354.6

Sixth Edition • First Printing Operator's Manual
Introduction
Part No. 1298036GT IWP®Super Series 1
Introduction
About this manual
Genie appreciates your choice of our machine for
your application. Our number one priority is user
safety, which is best achieved by our joint efforts.
This book is an operation and daily maintenance
manual for the user or operator of a Genie
machine.
This manual should be considered a permanent
part of your machine and should remain with the
machine at all times. If you have any questions,
contact Genie.
Product Identification
The machine serial number is located on the serial
label.
Serial number stamped
on chassis
Serial label
Intended Use and Familiarization
Guide
The intended use of this machine is to lift
personnel, including tools, and materials to an
aerial work site. Before operating the machine, it’s
the operator’s responsibility to read and
understand this familiarization guide.
Each person must be trained to operate a
Mobile Elevating Work Platform (MEWP).
Familiarization with the MEWP must be given
to each person who is authorized, competent
and trained.
Only trained and authorized personnel should
be permitted to operate the machine.
The operator is responsible to read,
understand, and obey the manufacturer’s
instructions and safety rules provided in the
Operator’s Manual.
The Operator’s Manual is located in the
manual storage container, at the platform.
For specific product applications, see
Contacting The Manufacturer.

Operator's Manual Sixth Edition • First Printing
Introduction
2 IWP®Super Series Part No. 1298036GT
Platform controls symbology and related
machine movement:
Platform up
Platform down
Ground controls symbology and related
machine movement:
Keyswitch - Off
Keyswitch - On
Ground controls
Platform controls
Emergency platform
lowering
Low battery indicator
Footpad interlock - Off
Footpad interlock - On
Level sensor interlock - Off
Level sensor interlock - On
Interlocked functions:
All platform and ground controls.
Limitations of use:
The intended use of this machine is to lift
personnel, including tools, and materials to an
aerial work site.
Do not elevate the platform unless the machine
is on firm level ground.

Sixth Edition • First Printing Operator's Manual
Introduction
Part No. 1298036GT IWP®Super Series 3
Bulletin Distribution and
Compliance
Safety of product users is of paramount
importance to Genie. Various bulletins are used by
Genie to communicate important safety and
product information to dealers and machine
owners.
The information contained in the bulletins is tied to
specific machines using the machine model and
serial number.
Distribution of bulletins is based on the most
current owner on record along with their
associated dealer, so it is important to register
your machine and keep your contact information
up to date.
To ensure safety of personnel and the reliable
continued operation of your machine, be sure to
comply with the action indicated in a respective
bulletin.
To view any open bulletins for your machine, visit
us on the web at www.genielift.com.
Contacting the Manufacturer
At times it may be necessary to contact Genie.
When you do, be ready to supply the model
number and serial number of your machine, along
with your name and contact information. At
minimum, Genie should be contacted for:
Accident reporting
Questions regarding product applications and
safety
Standards and regulatory compliance information
Current owner updates, such as changes in
machine ownership or changes in your contact
information. See Transfer of Ownership, below.
Transfer of Machine Ownership
Taking a few minutes to update owner information
will ensure that you receive important safety,
maintenance and operating information that
applies to your machine.
Please register your machine by visiting us on the
web at www.genielift.com or by calling us toll free
at 1-800-536-1800.

Operator's Manual Sixth Edition • First Printing
Introduction
4 IWP®Super Series Part No. 1298036GT
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 function tests prior to use.
4 Inspect the workplace.
5 Only use the machine as it was intended.
You read, understand and obey the
manufacturer’s instructions and safety rules—
safety and operator’s manuals and machine
decals.
You read, understand and obey employer’s
safety rules and worksite regulations.
You read, understand and obey all applicable
governmental regulations.
You are properly trained to safely operate the
machine.
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.
Hazard Classification
Decals on this machine use symbols, color coding,
and signal words to identify the following:
Safety alert symbol—used to alert
you to potential personal injury
hazards. Obey all safety
messages that follow this symbol
to avoid possible injury or death.
Indicates a hazardous situation
which, if not avoided, will result in
death or serious injury.
Indicates a hazardous situation
which, if not avoided, could result
in death or serious injury.
Indicates a hazardous situation
which, if not avoided, could result
in minor or moderate injury.
Indicates a property damage
message.

Sixth Edition • First Printing Operator's Manual
Symbol and Hazard Pictorials Definitions
Part No. 1298036GT IWP®Super Series 5
Symbol and Hazard Pict orials Definitions
Read the operator’s
manual
Read the service
manual
Crush hazard
No smoking
Collision hazard
Crush hazard
Tip-over hazard
Tip-over hazard
Electrocution hazard
Tip-over hazard
Maintain required
clearance
Tip-over hazard
Use common sense
and planning to
control the movement
of the machine on or
near inclines.
Collision hazard
Tiedown
Burn hazard
Explosion hazard
Fire hazard
Electrocution hazard
Transport diagram

Operator's Manual Sixth Edition • First Printing
Symbol and Hazard Pictorials Definitions
6 IWP®Super Series Part No. 1298036GT
Voltage rating for
power to platform
Pressure rating for air
line to platform
Lifting point
Release brakes
Grounded AC
3-wire only
Replace damaged
wires and cords
Wheel load
Lanyard anchorage
points
Side force
Manual force
Footpad load
Indoor
Maximum capacity
Emergency lowering
Wind speed
Maximum capacity including occupant, tools,
materials and options

Sixth Edition • First Printing Operator's Manual
General Safety
Part No. 1298036GT IWP®Super Series 7
General Safety

Operator's Manual Sixth Edition • First Printing
General Safety
8 IWP®Super Series Part No. 1298036GT

Sixth Edition • First Printing Operator's Manual
General Safety
Part No. 1298036GT IWP®Super Series 9

Operator's Manual Sixth Edition • First Printing
General Safety
10 IWP®Super Series Part No. 1298036GT

Sixth Edition • First Printing Operator's Manual
Personal Safety
Part No. 1298036GT IWP®Super Series 11
Personal Safet y
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
instructions.

Operator's Manual Sixth Edition • First Printing
Work Area Safety
12 IWP®Super Series Part No. 1298036GT
Work Area Saf ety
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
machine by raising or lowering a fixed or
overhanging load.
Do not transport tools and materials unless they
are evenly distributed and can be safely handled
by the person in the platform.
Do not place or attach fixed or 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 of
the platform.
Maximum allowable manual force
45 lbs / 200 N
Do not operate the machine near drop-offs, holes,
bumps, debris, unstable or slippery surfaces or
other possible hazardous conditions.
Do not alter or disable machine components that
in any way affect safety and stability.
Do not replace items critical to machine stability
with items of different weight or specification.
Do not tie the platform to adjacent structures.
Do not place loads outside the platform perimeter.
Use only Genie approved replacement parts.
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 use the machine on a moving or mobile
surface or vehicle.
Do not alter or modify a mobile elevating work
platform without prior written permission from the
manufacturer. Mounting attachments for holding
tools or other materials onto the platform,
toeboards, or guard rail system can increase the
weight in the platform and the surface area of the
platform or the load.

Sixth Edition • First Printing Operator's Manual
Work Area Safety
Part No. 1298036GT IWP®Super Series 13
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.
Occupants, equipment
and materials shall not
exceed the maximum
platform capacity.
ANSI, CSA, AUS & CE models
Maximum capacity
350 lbs
159 kg
Maximum occupants
1 person
ANSI, AUS & CE models
Maximum capacity
IWP-20S with outreach
option
300 lbs
136 kg
Maximum occupants
1 person
Do not install the outreach option on an IWP-25S
or an IWP-30S. The outreach option is for the
IWP-20S.
Fall Hazards
The guard rail system provides fall protection. If
occupant(s) of the platform are required to wear
personal fall protection equipment (PFPE) due to
job site or employer rules, PFPE and its use shall
be in accordance with the PFPE manufacturer’s
instructions and applicable governmental
requirements. Attach the lanyard to the anchor
provided in the platform.
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 ground personnel activate the
manual lowering valve.
Keep the platform floor clear of debris.
Lower the platform entry mid-rail or gate before
operating.

Operator's Manual Sixth Edition • First Printing
Work Area Safety
14 IWP®Super Series Part No. 1298036GT
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.
Obey all local and governmental regulations
regarding required clearance from electrical power
lines. At a minimum, the required clearance
contained in the chart below must be followed.
Voltage
Phase to Phase
Minimum Safe
Approach Distance
0 to 300V
Avoid Contact
300V to 50KV
10 ft
3.05 m
50KV to 200KV
15 ft
4.60 m
200KV to 350KV
20 ft
6.10 m
350KV to 500KV
25 ft
7.62 m
500KV to 750KV
35 ft
10.67 m
750KV to 1000KV
45 ft
13.72 m
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.
Collision Hazards
Operators must comply with employer, job site,
and governmental rules regarding use of personal
protective equipment.
Check the work area for overhead obstructions or
other possible hazards.
Be aware of crushing hazards when grasping the
platform guard rail.
Do not lower the platform unless the area below is
clear of personnel and obstructions.

Sixth Edition • First Printing Operator's Manual
Work Area Safety
Part No. 1298036GT IWP®Super Series 15
Use common sense and
planning to control the
movement of the
machine on or near
inclines.
Stay clear of descending platform.
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 appropriate Genie
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 platform.
Conduct a thorough pre-operation inspection of
the machine and test all functions before each
work shift. Immediately tag and remove from
service a damaged or malfunctioning machine.
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.
Crushing Hazard
Keep hands and limbs out of mast.
Use common sense and planning when operating
the machine with the controller from the ground.
Maintain safe distances between the operator, the
machine and fixed objects.
Explosion and Fire Hazards
Do not operate the machine or charge the battery
in hazardous locations or locations where
potentially flammable or explosive gases or
particles may be present.

Operator's Manual Sixth Edition • First Printing
Work Area Safety
16 IWP®Super Series Part No. 1298036GT
Outreach Option Safety
Bodily Injury Hazard
Keep hands and feet away from moving parts:
mounting plate, locking bracket and extension
arms.
Power Wheel Assist Option
Safety
Collision Hazard
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.
Battery Safety
Burn Hazards
Batteries contain acid.
Always wear protective
clothing and eye wear 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 the upright
position.
Do not expose the batteries or the charger to
water or rain during charging.

Sixth Edition • First Printing Operator's Manual
Work Area Safety
Part No. 1298036GT IWP®Super Series 17
Explosion Hazards
Keep sparks, flames, and
lighted tobacco away from
batteries. Batteries emit
explosive gas.
Charge the battery in a well
ventilated area.
Do not contact the battery
terminals or the cable
clamps with tools that may
cause sparks.
Do not disconnect charger
DC output wires from the
battery when the charger is
on.
Component Damage Hazard
Do not use any battery charger greater than 24V
to charge the batteries.
Electrocution/Burn Hazards
Connect the battery charger to a
grounded, AC 3-wire electrical
outlet only.
Inspect daily for damaged cords,
cables and wires. Replace
damaged items before operating.
Avoid electrical shock from contact with battery
terminals. Remove all rings, watches and other
jewelry.
Hazard
The battery pack weighs 90 lbs / 40.8 kg. Use the
appropriate number of people and proper lifting
techniques when lifting the battery pack.
Use the appropriate number of people and proper
lifting techniques when lifting batteries.
Lockout After Each Use
1Select a safe parking location—firm level
surface, clear of obstruction and traffic.
2Lower the platform.
3Turn the key switch to the off position and
remove the key to secure from unauthorized
use.
4Charge the batteries.

Operator's Manual Sixth Edition • First Printing
Legend
18 IWP®Super Series Part No. 1298036GT
Legend
1AC models: Power supply for
machine
DC models: Power to
platform
2Ground controls
3Circuit breaker
4Mast
5Platform
6Lanyard anchorage point
7Operator's manual storage
container
8Lifting eye
9Breather cap
10 Platform controls
11 Level sensor with bubble
level*
12 AC outlet
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 Forklift ring
19 Left side leveling jack
20 Winching point
21 Counterweight
22 Right side leveling jack
23 Forklift pocket
24 DC models: Battery charger
25 Level sensor with bubble
level*
26 Foot pedal
27 Power wheel assist option
28 Manual lowering valve
(located at the bottom of the
hydraulic cylinder)
29 Battery strap
30 Steer handle - power wheel
assist option
31 Base lowering handle
32 Function enable lever - power
wheel assist option
33 Steering handle
34 Direction-reversing safety
switch - power wheel assist
option
35 Thumb rocker switch - power
wheel assist option
*Two different styles of level sensor
were produced.