Terex Genie IWP Series, Operator'S Manual

Page 1: ...tor 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 1298...

Page 2: ...ols 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 F...

Page 3: ...ped 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 machi...

Page 4: ...f 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 Inter...

Page 5: ...e 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 Gen...

Page 6: ...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...

Page 7: ...nual 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...

Page 8: ...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 Manu...

Page 9: ...Sixth Edition First Printing Operator s Manual General Safety Part No 1298036GT IWP Super Series 7 Gener al Safety...

Page 10: ...Operator s Manual Sixth Edition First Printing General Safety 8 IWP Super Series Part No 1298036GT...

Page 11: ...Sixth Edition First Printing Operator s Manual General Safety Part No 1298036GT IWP Super Series 9...

Page 12: ...Operator s Manual Sixth Edition First Printing General Safety 10 IWP Super Series Part No 1298036GT...

Page 13: ...al 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...

Page 14: ...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 D...

Page 15: ...reach 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...

Page 16: ...hase 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 75...

Page 17: ...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...

Page 18: ...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 t...

Page 19: ...ds 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 contac...

Page 20: ...t 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...

Page 21: ...ecals were produced The symbols on them are different but they both operate the same way Both are illustrated here and in the text throughout this manual Platform controls 1 DC models Low battery indi...

Page 22: ...tion 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...

Page 23: ...ylinders Hydraulic manifolds and foot pump Platform entry mid rail or gate Sequencing cables and pulleys Lifting chains and idler wheels Mast columns and counterweight Nuts bolts and other fasteners B...

Page 24: ...use the machine as it was intended 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...

Page 25: ...pads are in firm contact with the ground 6 Insert the key and turn to platform control 7 Pull out the red Emergency Stop button at the ground controls to the on position 8 Pull out the platform red E...

Page 26: ...to the up position then the down position Result The platform up down function should not operate Test Emergency Stop 15 Use the bubble level and adjust the leveling jacks until the machine base is le...

Page 27: ...orm controls to the on position Confirm that the interlock display lights and the power light are on 32 Push in the control activate button and rotate the up down switch to the up position to raise th...

Page 28: ...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 Ins...

Page 29: ...to read and remember the workplace hazards then watch for and avoid them while moving setting up and operating the machine Workplace Inspection Checklist Be aware of and avoid the following hazardous...

Page 30: ...n 1 48645 Danger Power Wheel Assist Option Safety 1 52475 Label Transport Tie down 3 72086 Label Lifting Point 1 72844 Danger General Safety 1 82366 Label Chevron Rando 1 82802 Label Function Enable 1...

Page 31: ...Sixth Edition First Printing Operator s Manual Inspections Part No 1298036GT IWP Super Series 29...

Page 32: ...Read the Manual 1 82802 Label Function Enable 1 82915 Label Manual Lowering Valve 1 82974 Warning Collision Hazard 1 82987 Danger Electrocution Hazard 1 97538 Label Function Enable Power Wheel Assist...

Page 33: ...Sixth Edition First Printing Operator s Manual Inspections Part No 1298036GT IWP Super Series 31...

Page 34: ...and dangerous 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...

Page 35: ...Lower 1 Pull out the platform red Emergency Stop button to the on position 2 Push in the control activate button and rotate the up down switch in the direction of intended travel Manual Lowering 1 Ac...

Page 36: ...e rocker switch is released 5 Release the function enable lever to stop the machine and set the brake Note The brake will hold the machine on inclines of less than 3 To Move The Machine Without Power...

Page 37: ...ates that tools will be required to perform this procedure Indicates that new parts will be required to perform this procedure Check the Batteries DC Models Proper battery condition is essential to go...

Page 38: ...lowered 2 Check the sight gauge on the side of the hydraulic reservoir Result The hydraulic oil level should be visible in the middle of the sight gauge Do not overfill Hydraulic oil specifications Hy...

Page 39: ...hen the charge cycle is complete Replenish with distilled water to the bottom of the fill tube Do not overfill To Charge Secondary Battery if equipped 1 Disconnect the primary battery from the machine...

Page 40: ...ll with battery acid electrolyte until the level is sufficient to cover the plates Do not fill to maximum level until the battery charge cycle is complete Overfilling can cause the battery acid to ove...

Page 41: ...ine must be securely fastened to the transport vehicle Use chains or straps of ample load capacity Winching the Machine onto a Flatbed Truck 1 Fully lower the platform 2 Push in the red Emergency Stop...

Page 42: ...be removed before lifting the machine with a crane Disconnect the battery plug before removing the battery pack Inspect the entire machine and remove any loose or unsecured items Always place the lif...

Page 43: ...operating temperature 20 F to 135 F 29 C to 57 C Airborne noise emissions Sound pressure level at ground workstation 70 dBA Sound pressure level at platform workstation 70 dBA Total vibration value to...

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