Genie AWP IWP Service Manual 31758 – PDF DOWNLOAD
Language : English
Pages : 112
Downloadable : Yes
File Type : PDF
Table of Contents:
Genie AWP IWP Service Manual 31758 – PDF DOWNLOAD
Table of Contents................................................................ 5 Section 1 • Safety Rules......................................................... 2 Section 2 • Specifications....................................................... 10 IWP-19....................................................................... 10 IWP-24....................................................................... 10 AWP-19....................................................................... 11 AWP-24....................................................................... 11 AWP-30....................................................................... 12 AWP-36....................................................................... 12 Bolt Torque Specification.................................................... 13 Section 3 • Scheduled Maintentance Inspections................................... 14 Maintenance Tables........................................................... 15 Maintenance Inspection Report................................................ 17 Section 4 • Schedule Maintenance Procedures...................................... 18 Introduction................................................................. 19 Table A Procedures........................................................... 19 A-1 Inspect the Operator's and Responsibility Manuals................... 19 A-2 Inspect the Decals and Placards..................................... 19 A-3 Inspect for Damage and Loose or Missing Parts....................... 20 A-4 Check for Hydraulic Leaks........................................... 20 A-5 Check the Manual Lowering Operation................................. 21 A-6 Check the Battery and Battery Charger - DC Models................... 21 A-7 Inspect the Columns for Damage...................................... 21 A-8 Check the Sequencing Cables......................................... 22 A-9 Check the Interlock System for Proper Operation..................... 22 A-10 Test the Power and Function Controls................................ 23 A-11 Inspect the Lifting Chains and Idler Wheels......................... 24 A-12 Inspect the Breather Cap(s)......................................... 25 A-13 Text the Base Operation - IWP Models................................ 25 Table B Procedures........................................................... 26 B-1 Inspect the Electrical Wiring....................................... 26 B-2 Inspect All Welds................................................... 26 B-3 Test the Tilt-back Operation - AWP-30 and 36 Models................. 27 B-4 Check the Lifting Chain Adjustments................................. 28 B-5 Check the Battery................................................... 29 B-6 Clean the Lubricate the Columns..................................... 29 B-7 Test the Lifting Capacity........................................... 30 B-8 Test the Power To Platform Operation................................ 30 B-9 Adjust the Sequencing Cables........................................ 31 B-10 Inspect for Proper Outrigger Length - AWP Models.................... 31 B-11 Test the Level Sensing Operation - IWP Models....................... 32 Table C Procedures........................................................... 33 C-1 Inspect and Lubricate the Casters and Wheels........................ 33 C-2 Inspect the Mast Assembly for Wear.................................. 33 C-3 Lubricate the Lifting Chains........................................ 35 C-4 Replace the Hydraulic Oil........................................... 35 Section 5 • Troubleshooting Flow Charts.......................................... 36 Introduction................................................................. 36 Chart 1 - Power Light Will Not Turn On - AC Models........................... 38 Chart 2 - Power Light Will Not Turn On - DC Models........................... 39 Chart 3 - Interlock Lights Will Not Turn On - AWP AC Models.................. 41 Chart 4 - Interlock Lights Will Not Turn On - AWP DC Models................. 43 Chart 5 - Interlock Lights Will Not Turn On - IWP Models..................... 44 Chart 6 - Machine Will Not Lift - AC Models.................................. 45 Chart 7 - Machine Will Not Lift, But Power Unit Will Operate - AC Models..... 46 Chart 8 - Machine Will Not Lift - DC Models.................................. 47 Chart 9 - Machine Will Not Lift, But Power Unit Will Operate - DC Models..... 48 Chart 10 - Machine Will Not Lower - Up Function Operates..................... 49 Chart 11 - Base Will Not Raise With Foot Pump - IWP Models................... 50 Chart 12 - Base Will Raise, But WIll Not Hold in Up Position - IWP Models.... 51 Chart 13 - Base Will Not Lower - IWP Models.................................. 52 Chart 14 - Platform Will Not Hold in Up Position............................. 53 Chart 15 - Power Unit Will Not Lift Rated Load............................... 54 Section 6 • Schematics........................................................... 56 Introduction................................................................. 56 Symbols Legend............................................................... 57 Electrical Schematics........................................................ 58 AWP AC Models............................................................ 58 AWP DC Models............................................................ 61 IWP AC Models............................................................ 65 IWP DC Models............................................................ 69 Electrical Wiring Diagrams................................................... 59 AWP AC Models............................................................ 59 AWP DC Models............................................................ 63 IWP AC Models............................................................ 67 IWP DC Models............................................................ 71 Hydraulic Schematics......................................................... 73 AWP Models............................................................... 73 IWP Models............................................................... 74 Section 7 • Repair Procedures.................................................... 76 Introduction................................................................. 76 Base Assembly................................................................ 77 1-1 Proximity Switches.................................................. 77 1-2 Inner Base Frame - IWP Models....................................... 79 1-3 Hydraulic Manifold Components - IWP Models.......................... 80 Ground Control Box........................................................... 83 2-1 Ground Control Box.................................................. 83 2-2 How to Test the Transformer - AC Models............................. 83 2-3 How to Test the AC Contactor - AC Models............................ 84 2-4 How to Test the Rectifier - AC Models............................... 85 Hydraulic Power Units........................................................ 87 3-1 Hydraulic Power Unit Components - AC Models......................... 87 3-2 Hydraulic Power Unit Components - DC Models......................... 89 3-3 How to Remove the Hydraulic Power Unit.............................. 91 3-4 How to Remove the Hydraulic Pump.................................... 91 3-5 How to Adjust the Pressure Relief Valve............................. 92 3-6 How to Adjust the Down Solenoid..................................... 93 3-7 How to Check the Resistance of a Valve Coil......................... 93 3-8 How to Test the Motor Start Solenoid................................ 94 Power Pack................................................................... 95 4-1 How to Change a Power Pack.......................................... 95 Mast Assembly................................................................ 96 5-1 Lift Cylinder....................................................... 97 5-2 How to Remove the MAst Assembly - AWP Models........................ 98 5-3 How to Adjust the Lifting Chains....................................104 5-4 How to Inspect the Lifting Chains...................................106 Tilt-back Frame - AWP-30 and 36..............................................108 6-1 How to Remove the Tilt-back Frame...................................108 6-2 How to Adjust the Pivot Slider or Stop Bracket......................108 6-3 How to Disassemble the Shock Absorber Assembly......................109 Platform.....................................................................110 7-1 How to Remove an Aluminum Platform..................................110 7-2 How to Install a Fiberglass Platform................................110 7-3 Platform Control Box................................................110
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