Genie AWP IWP Work Platform Service Repair Manual

Technical Publications First Edition, Second Printing Part No. 31758 Service Manual ® AWP TM ® IWP TM

Service Manual - First Edition Part No. 31758 Section 1 - Safety Rules Safety Rules Oanger Failure to obey the instructions and safety rules in this manual and the Genie IWP Operator's Manual and the Genie AWP Operator's Manual will cause death or serious inju叩· Many of the hazards identified in the operator's manuals are also safety hazards when maintenance and repair procedures are pertormed. 00 Not Peñorm Maintenance Unless: 团 You are trained and qualified to perform maintenance on this machine. 回 You read , understand and obey: - manufacturer's instructions and safety rules - employer's safety rules and worksite regulations - applicable governmental regulations 固 You have the appropriate tools, lifting equipment and a suitable workshop. Genie IWP & Genie AWP 111

Introduction SAFETY RULES Personal Safety Any person working on or around a machine must be aware of all known safety hazards. Personal safety and the continued safe operation of the machine should be your number one priority. Read each procedure thoroughly. This manual and the decals on the machine use signal words to identify the following: ，南 IJ!'Ht1~:事 Indicates the presence of a hazard that will cause death or serious injury. Indicates the presence of a hazard that may cause death or serious i时U叩· Indicates the presence of a hazard that will or may cause senous InJu叩 or damage to the machine. Indicates special operation or maintenance information. Be sure to wear protective eye wear and other protective clothing if the situation warrants i t. Be aware of potential crushing hazards such as moving parts , free-swinging or unsecured components when lifting or placing loads. Always wear approved steel-toed shoes. Service Manual - First Edition Workplace Safety Be sure to keep sparks , flames and lighted tobacco away from flammable and combustible materials like battery gases. Always have an approved fire extinguisher within easy reach. Be sure that all tools and working areas are properly maintained and ready for use. Keep work surfaces clean and free of debris that could get into machine components and cause damage. Be sure that your workshop or work area is well ventilated and safely and adequately iII uminated. Be sure any forklift , overhead crane or other lifting or supporting device is fully capable of supporting and stabilizing the weight to be lifted. Use only chains or straps that are in good condition and of ample load capacity. Be sure that fasteners intended for one-time use (i. e. , cotter pins and self-Iocking nuts) are not reused. These components may fail if they are used a second time. Be sure to properly dispose of old oil or other fluids. Use an approved container. Please be mindful of the environment. IV Genie IWP & Genie AWP Part No. 31758

Service Manual - First Edition Part No. 31758 Section 1 - Safety Rules Important This service manual covers Genie IWP and Genie AWP models with the following five-digit product code: Product code Model 27476........ ………………........AWP-19 27477 …................. …………....AWP-24 27478 ….............. ……...……......AWP-30 27479............ ……………..........AWP-36 29814........…·….........................IWP-19 29815 …..……………......... …… IWP-24 The product code is found on the lower right corner of the serial plate. Machines with a twelve digit product code- for example: 371119-111-1 9-are not covered in this service manual. Genie IWP & Genie AWP V

Service Manual - First Edition Table of Contents Introduction Important Information ......... …....... …..…"…….......... ……..................... …………................. ii Section One Safety Rules General Safety Rules ...... ………......... …….................. …"……·…......... …...... ……............. iii Section Tw，。 4E4tnJ-ntquqUA斗吨'』nζ町'』呵'』n，』呵，』呵'』 HHnH -unu --·‘ a ·"·户UW户UV Hah- s … HHHHHp nHHHnuns 。 av da………………阳 c .. 9406n n9叫1233。·唱唱4IFd····FI C--PPPP.-l 伽…WW刷刷刷刷刷 Sect ion Three Scheduled Maintenance Inspections 1 ntroduction .... ....... ........ ..... ...... .... ........... ... ...... ... ... ... ...…........................... ……......... 3-1 TableA ….............................. …...... …......... ……......... …......... ……............. …........... … 3-2 Table B............ ……......... …............... …....................................... …...... ….................. 3-2 TableC....... …..……........................ …................................. …............ …......... …"…….3-3 Maintenance Inspection Repo此…..........................................……............…......….....3-4 Section Four Scheduled MaintenanωProcedures Introduction .............. ……...........................................................................................4-1 A斗 Inspect the Operators and Responsibility Manuals- including storage container ............... …..................... ……................................ 4-2 A-2 Inspect the Decals and Placards ............ ….............. …........................... …...... 4-2 A-3 Inspect for Damage, Loose or Missing Parts ...………...... …...... …………........... 4-3 A-4 Check for Hydraulic Leaks ................ …......................... ….......... ……............... 4-3 A-5 Check the Manual Lowering Operation ……....... …....... ….......................... ….............. 4-4 A-6 Inspect the Ba忧e叩 and Ba忧ery Charger - DC Models ...... ……………........ …·… 4-4 A-7 Inspect the Columns for Damage ….................... ……........ …......... ………................ 4-4 A-8 Check the Sequencing Cables …........... …................................. …....... …………… 4-5 VI Genie IWP & Genie AWP Part No. 31758

Service Manual - First Edition TA8LE OF CONTENTS Section Four Scheduled MaintenanωProcedures， continued Section Five Part No. 31758 A-9 Check the Interlock System for Proper Operation ……….................. …………… 4-5 A-1 0 Test the Power and Function Controls ......... ........ ….......... …........ …............... 4-6 A-11 Inspect the Li fting Chains and Idler Wheels ......... …................. …......... …......... 4-7 A-12 Inspect the 8reather Cap(s) …"…......... ……........ …........... …............................4 - 8 A-13 Test the 8ase Operation -IWP Models ………....................... …......... …...........4 - 8 8-1 Inspect the Electrical Wiring …..…..…………....... …………………..….......4 - 9 8-2 Inspect AII Welds ……....... …….. .•. .•. ..... …………………………...................4 - 9 8-3 Test the Tilt-back Operation - AWP 30 and 36 Models ................. …............ 4-10 8-4 Check the Li fting Chain Adjustments ......... …........ …·…................. …·…......... 4- 11 8-5 Check the 8a忧e叩…………………........…..........……………........…·…...........…...4-12 8 -6 Clean and Lubricate the Columns .................... ...…..................... …............... 4- 12 8-7 Test the Li fting Capacity ……….................... …·……………......... …................... 4-13 8-8 Test the Power-To-Platform Operation ......... ………............................... …..… 4 - 13 8-9 Adjust the Sequencing Cables ... .... ……................. ……..................................4-14 8-10 Inspect for Proper Outrigger Length - AWP Models .....................................4 - 14 8-11 Test the Level Sensing Operation -IWP Models .... ……................................4- 15 C-1 Inspect and Lubricate the Casters and Wheels ……..………......... …............. 4- 16 C-2 Inspect the Mast Assembly for Wear ......................................... …......... …… 4 - 16 C-3 Lubricate the Li fting Chains ........... …........ …........... …....... …........ ……........... 4-18 C-4 Replace the Hydraulic Oil ............ ... ........ ...…..................... …........................4- 18 Troubleshooting Flow Charts Introduction ........... …......... …................. …......... …...................... …·………........ ……......5-1 1 Power Li ght WiII Not Turn On - AC Models ……….......….........…… ...................5四3 2 Power Li ght WiII Not Turn On - DC Models ............................... ………............. 5-4 3 Interlock Li ghts WiII Not Turn On - AWP AC Models ........ …….......................... 5- 6 4 Interlock Li ghts WiII Not Turn On - AWP DC Models .... …........ ….....................5-8 5 Interlock Li ghts WiII Not Turn On - IWP Models .....................….........… ...........ι9 6 Machine WiII Not Li ft - AC Models ..................... …………................ …......... …..5-10 7 Machine WiII Not Li ft , 8ut Power Unit WiII Operate - AC Models ………..........5-11 8 Machine WiII Not Li ft - DC Models ... ... ... ... ...…............................... ……........... 5- 12 Genie IWP & Genie AWP VII

Service Manual - First Edition TABLE OF CONTENTS Section Seven Repair Procedures, continued Ground Control Box Part No. 31758 2-1 How to Test a Relay ........... ….................................. …......... …...........................7-8 2-2 How to Test the Transformer - AC Models ……................. …...... ……....... …....... 7-8 2-3 How to Test the AC Contactor - AC Models ...... ............ …………......... …...........7-9 2-4 How to Test the Rectifier - AC Models ...... …........ …......... …....... …………........ 7-10 Hydraulic Power Uni恒 3-1 Hydraulic Power Unit Components - AC Models ...……....... ….........................7-12 3-2 Hydraulic Power Unit Components - DC Models ........................ ….................7-14 3-3 How to Remove the Hydraulic Power Unit ................. …................... …......... …. 7-16 3-4 How to Remove the Hydraulic Pump …….............. …....... …............................. 7-16 3-5 How to Adjust the Pressure Relief Valve …............... …………..........................7-17 3-6 How to Adjust the Down Solenoid ......................... …........ ……………................ 7-18 3-7 How to Check the Resistance of a Valve Coil........ …........................ …...........7-18 3-8 How to Test the Motor Start Solenoid …..................................... ….................. 7-19 Power Pack 4-1 How to Change a Power Pack ...... ... ... ... ......... ......... ................. ...... ……..........7-20 Mast Assembly Mast IlI ustrations ....................... …·….................. …......... …........................... … 7-21 5-1 How to Remove the Li ft Cylinder ...... .............. ... ................... ... ........ …............7-22 5-2 How to Remove the Mast Assembly .......... …..……....... …......... …....................7-23 5-3 How to Adjust the Li fting Chains ............ …................. …·…...... ……..................7-29 5-4 How to Inspect the Li fting Chains ........ …·…........... ……·…"…·……........ …·…….7-31 Tilt-back Frame - AWP-30 and 36 6-1 How to Remove the Tilt-back Frame ................................…...... ...…...............7-33 6-2 How to Adjust the Pivot Slider or Stop Bracket............................................... 7-33 6-3 How to Disassemble the Shock Absorber Assembly …....... …....... …...............7-34 Platform 7-1 How to Remove an Aluminum Platform ......................................... …..............7-35 7-2 How to Install a Fiberglass Platform ..........................…..................................7-35 7-3 How to Test the Contactors ................. …......... …............................................7-35 Genie IWP & Genie AWP IX

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Service Manual - First Edition Section 2 - Specifications Specifications IWP-19 IWP-24 Height, maximum working 25 ft 4 in 7.7 m Height, maximum working 29 仕 10 in 9.1 m Height, maximum platform 19 仕 4in 5.8 m Height, maximum pla甘orm 23 仕 10 in 7.2 m Lift capacity 350lbs 159 kg Li仕 capacity 350lbs 159 kg Power sources 12V DC Power sources 12V DC 110V AC or 220V AC 110V AC or 220V AC Machine weight Machine weight DC 1111 Ibs 505 kg DC 1311 Ibs 596 kg AC 1050lbs 477 kg AC 1250lbs 568 kg Height, stowed , base lowered 77in 195 cm Height, stowed , base lowered 77in 195 cm Height, stowed, base fully raised 79in 200 cm Height, stowed, base fully raised 79 in 200 cm Width 32 in 81 cm Width 32 in 81 cm Length 60 in 152 cm Length 60 in 152 cm Platform length 26in 66cm Platform length 26in 66cm Platform width 26in 66 c町1 Platform width 26in 66cm Platform railing height 43in 106 cm Platform height 43in 106 cm Corner access 6in 15 cm Corner access 6in 15 cm (corner of pla甘orm top rail to corner of wall with ability (corner of pla甘Orm top rail to corner of wall with ability to rotate leveling jack handle) to rotate leveling jack handle) Platform function AC DC Platform function AC DC speed, maximum sp锦d， maximum Platform up 40 sec 27 sec Platform up 40 sec 27 sec Platform down 27 sec 27 sec Platform down 27 sec 27 sec Maximum hydraulic pressure 1800 psi 124 bar Maximum hydraulic pressure 2000 psi 138 bar Part No. 31758 Genie IWP & Genie AWP 2 -1

Genie AWP IWP Work Platform Service Repair Manual

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