Genie 48643 User Manual
Operator’s Manual
with Maintenance Information
Second Edition
Fourth Printing
Part No. 48643
Operator’s Manual Second Edition • Fourth 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 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: techpub@genieind.com
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"
Industries.
This machine complies with
ANSI/SIA A92.3-1990.
Printed on recycled paper.
Printed in U.S.A.
is a trademark of Genie
Genie IWP Super Series Part No. 48643
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
Part No. 48643 Genie IWP Super Series 1
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
overhanging load.
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 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
Do not push off or pull toward any object outside
the platform.
Maximum allowable 45 lbs
manual force 200 N
Maximum capacity 300 lbs 136 kg
IWP-20S with outreach option
Maximum occupancy 1 person
2 Genie IWP Super Series Part No. 48643
Operator’s ManualSecond Edition • Fourth Printing
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.
Do not install the outreach option on an IWP-25S or
an IWP-30S. The outreach option is for the IWP20S 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
ground personnel activate
the manual lowering valve.
Keep the platform floor clear of debris.
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.
Lower the platform entry mid-rail before operating.
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
Part No. 48643 Genie IWP Super Series 3
Operator’s Manual Second Edition • Fourth Printing
SAFETY RULES
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.
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
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.
Do not operate the machine with a hydraulic oil or
air leak. An air leak or hydraulic leak can penetrate
and/or burn skin.
4 Genie IWP Super Series Part No. 48643
Operator’s ManualSecond Edition • Fourth Printing
SAFETY RULES
Outreach Option Safety
Bodily Injury Hazard
Keep hands and feet away from moving parts:
mounting plate, locking bracket and extension
arms.
Po wer Wheel 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.
Part No. 48643 Genie IWP Super Series 5
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.
Electrocution Hazards
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.
6 Genie IWP Super Series Part No. 48643
Ground Controls
2
3
Operator’s ManualSecond Edition • Fourth Printing
Controls
1
4
Platform Controls ANSI & CSA
5
6
Platform Controls CE
7
1 Interlock display lights (four)
2 Key switch
3 Red Emergency Stop button
4 Auxiliary platform lowering
button
5 Power light
6 Low battery indicator light for
auxiliary lowering
7 DC models: Low battery
indicator light
3 8
Part No. 48643 Genie IWP Super Series 7
9 8 93
8 Control activate button
9 Up/Down switch
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