Genie AWP IWP Service Manual 31758 – PDF DOWNLOAD

Description

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

S.S 04/24