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Genie AWP Super Series IWP Super Series Service Manual 38139 – PDF
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Description
Genie AWP Super Series IWP Super Series Service Manual 38139 – PDF DOWNLOAD
Language : English
Pages : 213
Downloadable : Yes
File Type : PDF
Table of Contents:
Genie AWP Super Series IWP Super Series Service Manual 38139 – PDF DOWNLOAD
Front Cover............................................................................................................................. 1 Important Information................................................................................................................... 2 Find a Manual for this Model............................................................................................................ 2 Revision History........................................................................................................................ 3 Serial Number Legend.................................................................................................................... 5 General Safety Rules.................................................................................................................... 6 Table of Contents....................................................................................................................... 8 Specifications.......................................................................................................................... 17 AWP-15S, 20S and 25S Specifications................................................................................................. 17 AWP30S, 36S and 40S Specifications.................................................................................................. 18 AWP Narrow Base Specifications...................................................................................................... 19 AWP Rough Terrain Base Specifications............................................................................................... 20 IWP Specifications.................................................................................................................. 21 AWP/IWP Performance and Hydraulic Specifications.................................................................................... 22 Hydraulic Hose and Fitting Torque Specifications.................................................................................... 23 Torque Procedure.................................................................................................................... 24 SAE and Metric Fasteners Torque Charts.............................................................................................. 26 Scheduled Maintenance Procedures........................................................................................................ 27 Introduction........................................................................................................................ 27 Pre-Delivery Preparation Report..................................................................................................... 31 Maintenance Inspection Report....................................................................................................... 33 Checklist A Procedures.............................................................................................................. 35 A-1 Inspect the Manuals and Decals.............................................................................................. 35 A-2 Perform Pre-operation Inspection............................................................................................ 36 A-3 Perform Function Tests...................................................................................................... 36 A-4 Inspect for Damage and Loose or Missing Parts............................................................................... 37 A-5 Check for Hydraulic Leaks................................................................................................... 38 A-6 Check the Hydraulic Oil Level............................................................................................... 38 A-7 Test the Base Operation - IWPS Models....................................................................................... 39 A-8 Test the Auxiliary Platform Lowering Operation.............................................................................. 39 A-9 Test the Manual Platform Lowering Operation................................................................................. 40 A-10 Inspect the Columns for Damage............................................................................................. 40 A-11 Check the Sequencing Cables................................................................................................ 41 A-12 Check the Interlock System for Proper Operation............................................................................ 41 A-13 Test the Power and Function Controls....................................................................................... 43 A-14 Inspect the Lifting Chains and Idler Wheels................................................................................ 44 A-15 Inspect the Breather Cap................................................................................................... 44 A-16 Check the Tire Pressure - AWPS Models with Rough Terrain Base Option....................................................... 45 A-17 Check the Air Supply Lubricator Oil Level - Air Models..................................................................... 45 A-18 Check the Air Supply Lubricator Drip Rate - Air Models..................................................................... 46 A-19 Check the Air Filter/Regulator Canister - Air Models....................................................................... 46 Checklist B Procedures.............................................................................................................. 47 B-1 Inspect the Battery......................................................................................................... 47 B-2 Inspect the Electrical Wiring............................................................................................... 48 B-3 Inspect All Welds........................................................................................................... 48 B-4 Test the Tilt-back Operation (if equipped).................................................................................. 49 B-5 Check the Lifting Chain Adjustment.......................................................................................... 50 B-6 Clean and Lubricate the Columns............................................................................................. 51 B-7 Test the Lifting Capacity................................................................................................... 52 B-8 Adjust the Sequencing Cables................................................................................................ 52 B-9 Inspect for Proper Outrigger Length - AWPS Models........................................................................... 54 B-10 Inspect and Lubricate the Outrigger Leveling Jack Footpads - AWPS Models................................................... 55 B-11 Test the Level Sensing Operation - IWPS Models............................................................................. 55 B-12 Check the Chain Adjustment, IWP-20S Models with Outreach Option............................................................ 56 Checklist C Procedures.............................................................................................................. 57 C-1 Inspect and Lubricate the Casters and Wheels................................................................................ 57 C-2 Inspect the Mast Assembly for Wear.......................................................................................... 57 C-3 Inspect and Lubricate the Lifting Chains.................................................................................... 59 C-4 Replace the Hydraulic Oil................................................................................................... 59 C-5 Replace the Auxiliary Platform Lowering Batteries........................................................................... 61 Repair Procedures....................................................................................................................... 63 Introduction........................................................................................................................ 63 Base Assembly....................................................................................................................... 65 1-1 Interlocks.................................................................................................................. 65 1-2 Base Components IWPS Models................................................................................................. 66 1-3 Foot Pump Manifold Components - IWPS Models (to SN IWP09-8269).............................................................. 70 1-4 Foot Pump Manifold Components - IWPS Models (from SN IWP09-8270)............................................................ 71 1-5 Power Wheel Assist Manifold Components - IWPS Models (to SN 4097-990)....................................................... 72 1-6 Power Wheel Assist Manifold Components - IWPS Models (from SN 4097-997 to 4099-2532)........................................ 73 1-7 Power Wheel Assist Manifold Components - IWPS Models (from SN 4099-2533).................................................... 74 Ground Controls..................................................................................................................... 75 2-1 How to Test the Transformer - AC Models..................................................................................... 75 2-2 How to Test the AC Contactor - AC Models.................................................................................... 76 Hydraulic Power Unit................................................................................................................ 77 3-1 Hydraulic Power Unit - AC Models (to SN AWP03-27389 and IWP03-5150)......................................................... 77 3-2 Hydraulic Power Unit - AC Models (from SN AWP03-27390 to AWP08-60145, IWP03-5151 to IWP08-7708)............................. 79 3-3 Hydraulic Power Unit - AC Models (from SN AWP08-60146, IWP08-7709).......................................................... 81 3-4 Hydraulic Power Unit - DC Models (to SN AWP08-60547 and IWP08-7754)......................................................... 83 3-5 Hydraulic Power Unit - DC Models (from SN AWP08-60548 and IWP08-7755)....................................................... 85 3-6 Hydraulic Power Unit Components - Air Powered Models (to SN AWP04-27779).................................................... 87 3-7 Hydraulic Power Unit Components - Air Powered Models (from SN AWP04-27780).................................................. 89 3-8 Hydraulic Power Unit........................................................................................................ 91 3-9 Hydraulic Pump.............................................................................................................. 93 3-10 Valve Adjustment........................................................................................................... 93 3-11 How to Test the Motor Start Solenoid - DC Models........................................................................... 94 Power Pack.......................................................................................................................... 95 4-1 Power Pack.................................................................................................................. 95 Mast Components..................................................................................................................... 96 Mast Components................................................................................................................. 96 5-1 Lift Cylinder............................................................................................................... 97 5-2 Mast Assembly............................................................................................................... 98 5-3 Glide Pads..................................................................................................................103 5-4 Lifting Chains..............................................................................................................103 Tilt-back Frame, AWP-36S and 40S Models.............................................................................................106 6-1 Tilt-back Frame.............................................................................................................106 Platform............................................................................................................................108 7-1 Platforms...................................................................................................................108 7-2 Platform Control Box........................................................................................................109 7-3 Platform Outreach Chain.....................................................................................................110 Schematics..............................................................................................................................112 Introduction........................................................................................................................112 Electrical Component and Wire Color Legends.........................................................................................113 Electrical Symbol Legend............................................................................................................115 Hydraulic Symbols Legend............................................................................................................116 Electrical Schematics - AWP Models..................................................................................................117 Electrical Schematic - AWP Super Series DC Models (from SN 3896-101 to 3896-300)................................................118 Electrical Schematic - AWP Super Series DC Models (from SN 3896-301 to 3896-430)................................................119 Electrical Schematic - AWP Super Series DC Models (from SN 3896-431 to AWP07-54898).............................................122 Electrical Schematic - AWP Super Series DC Models with Standard Base (from SN AWP07-54899)......................................123 Electrical Schematic - AWP Super Series DC Models with Narrow Base (from SN AWP07-54899)........................................126 Electrical Schematic - AWP Super Series DC CE Models (from SN 3896-432 to AWP07-54898)..........................................127 Electrical Schematic - AWP Super Series DC CE Models with Standard Base (from SN AWP07-54899)...................................130 Electrical Schematic - AWP Super Series DC CE Models with Narrow Base (from SN AWP07-54899).....................................131 Electrical Schematic - AWP Super Series DC TUV Models (from SN 3896-431)........................................................134 Electrical Schematic - AWP Super Series AC Models (from SN 3896-103 to 3896-303)................................................135 Electrical Schematic - AWP Super Series AC Models (from SN 3896-304 to 3896-450)................................................138 Electrical Schematic - AWP Super Series AC Models (from SN 3896-451 to AWP07-54898).............................................139 Electrical Schematic - AWP Super Series AC Models with Standard Base (from SN AWP07-54899 to AWP07-57594).......................142 Electrical Schematic - AWP Super Series AC Models with Narrow Base (from SN AWP07-54899 to AWP-57594)...........................143 Electrical Schematic - AWP Super Series AC Models with Standard Base (from SN AWP07-57595)......................................146 Electrical Schematic - AWP Super Series AC Models with Narrow Base (from SN AWP07-57595)........................................147 Electrical Schematic - AWP Super Series AC CE Models (from SN 3896-451 to AWP07-54898)..........................................150 Electrical Schematic - AWP Super Series AC CE Models with Standard Base (from SN AWP07-54899 to AWP07-57594)....................151 Electrical Schematic - AWP Super Series AC CE Models with Narrow Base (from SN AWP07-54899 to AWP07-57594)......................154 Electrical Schematic - AWP Super Series AC CE Models with Standard Base (from SN AWP-57595).....................................155 Electrical Schematic - AWP Super Series AC CE Models with Narrow Base (from SN AWP07-57595).....................................158 Electrical Schematic - AWP Super Series AC TUV Models (from SN 3896-461)........................................................159 Electrical Schematics - IWP Models..................................................................................................161 Electrical Schematic - IWP Super Series DC Models (from SN 4096-101 to 4096-287)................................................162 Electrical Schematic - IWP Super Series DC Models (from SN 4096-288 to 4096-341)................................................163 Electrical Schematic - IWP Super Series DC Models (from SN 4096-342 to IWP07-7065)..............................................166 Electrical Schematic - IWP Super Series DC Models (from SN IWP07-7066 to IWP15-9621)............................................167 Electrical Schematic - IWP Super Series DC Models (from SN IWP15-9622 to IWPP-12398)............................................170 Electrical Schematic - IWP Super Series DC Models (from SN IWPP-12399)..........................................................171 Electrical Schematic - IWP Super Series DC Models with Power Assist.............................................................174 Electrical Schematic - IWP Super Series DC Models with Power Assist (Directional Valve Coils Powering Function Manifold)........175 Electrical Schematic - IWP Super Series DC TUV Models...........................................................................178 Electrical Schematic - IWP Super Series DC TUV Models with Outreach.............................................................179 Electrical Schematic - IWP Super Series DC TUV Models with Power Assist.........................................................182 Electrical Schematic - IWP Super Series DC TUV Models with Power Assist and Outreach............................................183 Electrical Schematic - IWP Super Series DC TUV Models with Power Assist (Directional Valve Coils Powering Function Manifold)....186 Electrical Schematic - IWP Super Series AC Models (from SN 4096-105 to 4096-285)................................................187 Electrical Schematic - IWP Super Series AC Models (from SN 4096-286 to 4096-355)................................................190 Electrical Schematic - IWP Super Series AC Models (from SN 4096-356 to IWP07-7065)..............................................191 Electrical Schematic - IWP Super Series AC Models (from SN IWP07-7066 to IWP07-57594)...........................................194 Electrical Schematic - IWP Super Series AC Models (from SN IWP07-57595).........................................................195 Electrical Schematic - IWP Super Series AC TUV Models (With Base Mounted Junction Box)..........................................198 Electrical Schematic - IWP Super Series AC TUV Models (Without Base Mounted Junction Box).......................................199 Electrical Schematic - IWP Super Series AC TUV Models with Outreach.............................................................202 Hydraulic Schematics................................................................................................................203 Hydraulic Schematic - AWP Super Series Models...................................................................................203 Hydraulic/Pneumatic Schematic - AWP Super Series Models.........................................................................206 Hydraulic Schematic - IWP Super Series Models without Power Assist..............................................................207 Hydraulic Schematic - IWP Super Series Models with Power Assist.................................................................210 Hydraulic Schematic - IWP Super Series Models with Power Assist and Brake.......................................................211 Back Cover..............................................................................................................................213
S.S 04/24
