Technical Publications
®
AWP IWP
®
TM
TM
Service Manual
First Edition, Second Printing Part No. 31758
Service Manual - First Edition
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.
Part No. 31758
Genie IWP & Genie AWP
111
Introduction
Service Manual - First Edition
SAFETY RULES
Personal Safety
Workplace 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.
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.
Read each procedure thoroughly. This manual and the decals on the machine use signal words to identify the following: Indicates the presence of
，南 IJ!'H t1~:事 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 it.
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.
IV
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.
Genie IWP & Genie AWP
Part No. 31758
Service Manual - First Edition
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 cod e-for example: 371119-111-1 9-are not covered in this service manual.
Part No. 31758
Genie IWP & Genie AWP
V
Service Manual - First Edition
Table of Contents Introduction Important Information .........….......…..…"……..........…….....................………….................ii Section One
Safety Rules General Safety Rules ......……….........……..................…"……·….........…......……............. iii nHHHnuns
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Section Three
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Section
Scheduled Maintenance Inspections
1ntroduction .... ....... ........ ..... ...... .... ........... ... ...... ... ... ... ...…...........................…….........3-1 TableA …..............................…......….........…….........….........…….............…...........… 3-2 Table B............ …….........…...............….......................................…......…..................3-2 TableC....... …..……........................….................................…............….........…"…….3-3 Maintenance Inspection Section Four
Scheduled
Repo此…..........................................……............…......… .....3-4
MaintenanωProcedures
Introduction ..............…… ...........................................................................................4-1
VI
A斗
Inspect the Operators and Responsibility Manualsincluding 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 Genie IWP & Genie AWP
Part No. 31758
Service Manual - First Edition
TA8LE OF CONTENTS
Section Four
Scheduled A-9
MaintenanωProcedures，
continued
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
Section Five
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
Part No. 31758
1
Power Li ght WiII Not Turn On - AC Models ……….......….........…… ...................5四3
2
Power Li ght W iII Not Turn On - DC Models ...............................……….............5-4
3
Interlock Li ghts WiII Not Turn On - AWP AC Models ........……..........................5-6
4
Interlock Li ghts W iII Not Turn On - AWP DC Models ....…........… .....................5-8
5
Interlock Li ghts W iII Not Turn On - IWP Models
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
.....................….........… ...........ι9
VII
Service Manual - First Edition
TABLE OF CONTENTS
Section Seven
Repair Procedures, continued Ground Control Box 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
Part No. 31758
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
Service Manual - First Edition
TABLE OF CONTENTS
This page intentionally left blank.
X
Genie IWP & Genie AWP
Part No. 31758
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
350lbs
159 kg
350lbs
159 kg
Lift
capacity
Power sources Machine weight DC AC
12V DC 110V AC or 220V AC 1111 Ibs 1050lbs
Li仕 capacity
Power sources
12V DC 110V AC or 220V AC
505 kg 477 kg
Machine weight DC AC
Height, stowed , base lowered Height, stowed , base fully raised
77in 79 in
195 cm 200 cm
1311 Ibs 1250lbs
596 kg 568 kg
Height , stowed , base lowered Height, stowed , base fully raised
77in 79in
195 cm 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
Platform width
26in
66cm
Platform railing height
43in
Platform height
43in
106 cm
c町1
106 cm
Corner access 6in 15 cm (corner of pla甘orm top rail to corner of wall with ability to rotate leveling jack handle)
Corner access 6in 15 cm (corner of pla甘Orm top rail to corner of wall with ability to rotate leveling jack handle)
Platform function speed, maximum
sp锦d ，
AC
DC
Platform function maximum
AC
DC
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
Section 2 - Specifications
Service Manual - First Edition
SPECIFICATIONS
AWP-19
AWP-24
Height, maximum working
25 筒 6in
7.8 m
Height, maximum working
30 仕
9.1 m
Height, maximum working
19 ft 6 in
5.9 m
Height, maximum working
24 ft
7.3 m
300lbs
136 kg
300lbs
136 kg
Li促 capacity
Power sources Machine weight DC AC
12V DC 115V AC or 220V AC
Lift capacity Power sources
6941bs 6231bs
315 kg 283 kg
Machine weight DC AC
Height, stowed
79in
200cm
Width (outriggers stored)
29in
74cm
47.5 in
120 cm
Length
Outrigger footprint width
58in
146 cm
Outrigger footprint length
65in
164 cm
Pla甘orm
26in
Platform width
12V DC 115V AC or 220V AC 7171bs 6391bs
325 kg 290 kg
Height, stowed
79in
200cm
Width (outriggers stored)
29in
74cm
47.5 in
120 cm
Outrigger footprint width
58in
146 cm
Outrigger footprint length
65in
164 cm
66 cm
Platform length
26in
66cm
26in
66cm
Platform width
26in
66
Platform railing height
43in
106 cm
Platform railing height
43in
106 cm
Outrigger length
22in
56cm
Outrigger length
22in
56cm
Length
length
cη1
21 in 53cm Corner a∞ess (corner of platform top rail to corner of wall with ability to rotate leveling jack handle)
Corner access 21 in 53cm (corner of platform top rail to corner of wall with ability to rotate leveling jack handle)
Platform function speed, maximum
sp锦d，
AC
DC
Platform function maximum
AC
DC
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 1600 psi
110 bar
Maximum hydraulic pressure 1800 psi
124 bar
2-2
Genie IWP
&Genie AWP
Part No. 31758
Section 2 - Specifications
Service Manual - First Edition
SPECIFICATIONS
AWP-36
AWP-30 Height, maximum working
36 ft
11 m
Height, maximum working
30 ft
9.1 m
300lbs
136 kg
Li仕 capacity
12V DC 115V AC or 220V AC
Power sources Machine weight DC AC
wo刷 ng
42 促
12.8 m
Height, maximum working
36 ft
11 m
250lbs
113 kg
Height, maximum
Li刊 capacity
Power sources
8661bs 788lbs
393 kg 357 kg
Machine weight DC AC
Height, stowed
93in
236cm
Height,
Height，回Ited
79in
200cm
29in
74cm
Width (outriggers
back
stor创)
Length
12V DC 115V AC or 220V AC 940lbs 8681bs
426 kg 394 kg
112 in
284cm
Height, tilted back
79in
200 cm
Width (outriggers
29in
74cπ1
51.5 in
131 cm
81 in
205cm
StOWI回
stor，回)
51.5 in
131 cm
Length
75in
191cm
Outrigger
Outrigger footprint length
73in
186 cm
Outrigger footprint length
81 in
205cm
Platform length
26in
66cm
Platform length
26in
66cm
Platform width
26in
66cm
Platform width
26in
66cm
43in
106 cm
Platform railing height
43in
106 cm
31 in
79cm
Outrigger length
36in
92cm
Outrigger
Platform
f，∞句:>rint
刚 ling
width
height
Outrigger length
foo协 rint
width
31 .75 in 81 cm Comer al∞ess (comer of platform top rail to comer of wall with ability to rotate leveling jack handle)
105 cm 41.5 in Comer access (comer of p剧orm top rail to comer of wall with ability to rotate leveling jack handle)
Platform function speed, maximum
Platform function speed, maximum
AC
DC
Platform up
50 sec
33s臼
Platform down
32 sec
32 sec
Maximum hydraulic pressure 2050 psi
141 bar
Part No. 31758
AC
DC
Platform up
60 sec
41 sec
Platform down
43sec
43
Maximum hydraulic
Genie IWP & Genie AWP
p陪ssure
1900 psi
SE虫。
131 bar
2-3
Section 2 - Specifications
SeNice Manual- First Edition
SPECIFICATIONS
Bolt Torque Specifications Size
Threads perinch
SAE Grade 5 Bolts Torque - Dry Torque - Dry inch币ounds
10
1/4
5116
3/8
7116
1/2
9116
5/8
3/4
7/8
Torque
footτ)()unds
。
Torque - Dry Newton meters
SAE Grade 8 Bolts Torque - Dry Torque - Dry inchτ)Ounds
foot-阳 unds
② Torque - Dry Newton meters
24
43
5
60
7
32
49
6
68
8
20
96
11
144
16
28
120
14
168
19
18
17
23
25
34
24
19
28
25
34
16
30
41
45
61
24
35
48
50
68
14
50
68
70
95
20
55
75
80
109
13
75
102
110
149
20
90
122
120
163
12
110
149
150
204
18
120
163
170
231
11
150
204
220
298
18
170
231
240
326
10
260
353
380
515
16
300
407
420
570
9
430
583
600
814
14
470
637
660
895
8
640
868
900
1221
12
700
949
1000
1356
sp臼 ifications
for lubricated bolts are 25% less than the dry torque specifications for each bolt size.
These bolt torque specifications are for general use only. Specification may vary depending on application of bolt.
2-4
Genie IWP
&Genie AWP
Part No. 31758
Service Manual - First Edition
Section 3 - Scheduled Maintenance Inspections
Scheduled Maintenance Inspections About This Section Schedule
。bserve
and Obey:
回 Maintenance
inspections shall be completed by a person trained and qualified on the maintenance of this machine.
回 Scheduled
maintenance inspections shall be completed daily , quarterly and annually as specified on the Maintenance Inspection Report.
There are three types of maintenance inspections that must be performed according to a schedul edaily, quarterly and annual. To account for repeated procedures , the Maintenance Tables and the Maintenance Inspection Report have been divided into three subsections-A , B and C. Use the following chart to determine which group(s) of procedures are required to perform a scheduled inspection. Insp臼tion
Table or Checklist
Daily
A
Quarterly (every 150 hours or three months) Failure to properly complete each inspection when required may result in death , serious injury or substantial machine damage.
Annual
A+B A+B+C
Maintenance Tables
回 Immediately
tag and remove from service a damaged or malfunctioning machine.
回 Repair
any machine damage or malfunction before operating machine.
回 Keep
records on all inspections for three years.
回 Machines
that have been out of service for a period longer than 3 months must complete the quarterly inspection.
The maintenance tables contained in this section provide summary information on the specific physical requirements for each inspection. Complete step-by-step instructions for each scheduled maintenance procedure are provided in section 4 , Scheduled Maintenance Procedures. Maintenance Inspection
Rep。同
The Maintenance Inspection Report contains checklists for each type of scheduled inspection. Make copies of the Maintenance Inspection Report to use for each inspection. Store completed forms for three years.
Part No. 31758
Genie IWP & Genie AWP
3-1
Service Manual - First Edition
Section 3 - Scheduled Maintenance Inspections
Maintenance Tables Table A
Toolsa用
N制问自
Dealer serv ce
r饲uirE到
明uirl创
Sl唱拥es恒d
A-1
Inspect the operator' s and responsibility manuals - including storage container
A-2
Insp田t
A-3
Inspect for Damage and Loose or Missing Parts
因
A-4
Check for Hydraulic Leaks
因
A-5
Check the Manual Lowering Operation
A-6
Inspect the Battery and Battery Charger - DC Models
A-7
Inspect the Columns for Damage
A-8
Check the Sequencing Cables
A-9
Check the Interlock System for Proper Operation
A-10
Test the Power and Function Controls
A-11
Inspect the Li fting Chains and Idler Wheels
A-12
Inspect the Breather Cap(s)
A-13
Test the Base Operation - IWP Models
,
the Decals and Placards
因
Table B Complete all procedures in Table A
B-1
Inspect the Electrical Wiring
8-2
Inspect AII Welds
3-2
因 Genie IWP
&Genie AWP
Part No. 31758
Section 3 - Scheduled Maintenance Inspections
Service Manual - First Edition
MAINTENANCE TABLES
Table B, continued
De副er Toolsa用
N制 parts
Set'VlC揭
r叫Ulr，创
raquir创
sugg酬ed
8 -3
Test the Tilt-back Operation AWP-3 0 and 36 Models
B-4
Check the Li fting Chain Adjustrnents
圈
8-5
Check the 8attery
因
8-6
Clean and Lubricate the Columns
圈
8-7
T臼，t
the Li fting Capacity
因
8 -8
T臼，t
the Power To Platform Operation
因
E凶
Adjust the Sequencing Cables
因
8-10
Inspect for Proper Outrigger Length -AWP Models
因
8-11
Test the Level Sensing Operation -IWP Models
回 因
回 回
Table C Complete all procedures in Table A and Table B
ι1
Inspect and Lubricate the Casters and Wheels
因
C-2
Insp臼t
因
C-3
Lubricate the Li fting Chains
因
因
c-4
Replace the Hydraulic Oil
因
因
Part No. 31758
the Mast Assembly for Wear
Genie IWP & Genie AWP
因
回 回
3-3
Section 3 - Scheduled Maintenance Inspections
Maintenance Inspection d 剧一-U
部一'阳
A-b hH-auVHH-0 Fu--RH
Model
Serial number
by (print)
削list叫(s) for . Select the appropr川iatecheck thetypeofi阳 nspection to be per叫foαrmed.
EE 日 『阳阳 Dail 刽副啕州 阳… ily 刷 Iyy圳l
Quar 眈terl 叫Iylnsp臼t 臼ion:A+B
Annuallnspect剖ion:A+B+C
. Place a check in the appropriate box after each inspection procedure is ∞mpleted.
. Use the maintenance tables in this section and the s怡p-by-step pr，∞edures in section 4 to learn how to perform these inspections.
Y N
Welds
A-2
Decals and plal臼 rds
B-3
Tilt-backoperation - AWP 30 , 36 models
A-3
Damage ， l∞seor
B-4
Liftingchain adjustments
8-5
Battery
B-6
Clean and lubricate columns
Lifting capacity
mi岱ingpa由
A-4
Hydraulic leaks
A-5
Manuallowering opera目on
A-6
Battery and charger - DCmodels
8-7
A-7
Columns
B-8
A-8
Sequencing cables
A-9
Interl∞ksystem 。因ration
A-10 Power and function controls
Power to platform 。因ra回on
8-9
Sequencing cables
8- 10 Proper outrigger le咱th
-AWPmodels
8-11 Level sensing
A-11 Lifting chai ns and idler wheels A-12
R
Refer to Table B
8-2
Inspector company
Instructions . Make ∞pies of this page to use for each inspection.
ChecklistB
Electrical wiring
Inspectorsignature Inspectortitle
Y N R
eA
8- 1
Machineowner Insp臼ted
Rep。同
Operator's and Responsibility manuals
A-1
Date
Service Manual- First Edition
。因ration
-IWPmodels
Br闺thercap(s)
A-13 Base operation -IWPmodels
Refer to Table C 时
. If any inspection receives an "N", remove the machine from use , repair and re-inspect it. After repair , place a check in the "R" box.
Y N R
ChecklistC
Ca:ster:sandwheels
G2MastassembIy C-3Liftingchains
c-4
L啕end
Hydraulic oil
Y=yes ， a∞eptable N=no， una∞:eptable R= 陀 paired
Comments
3-4
Genie IWP & Genie AWP
Part No. 31758
Service Manual - First Edition
Section 4 - Scheduled Maintenance Procedures
Scheduled Maintenance Procedures About This Section This section contains detailed procedures for each scheduled maintenance inspection. Each procedure includes a description , safety warnings and step-by-step instructions.
Observe and Obey:
Symbolsιegend
inspections shall be completed by a person trained and qualified on the maintenance of this machine.
回 Maintenance
Indicates the presence of a
rl可"J~'Hti~ :喜 hazard that will cause death or
senous InJury. Indicates the presence of a hazard that may cause death or serious inju叩.
回 Scheduled
maintenance inspections shall be completed daily, frequently (every 3 months) , and annually as specified on the maintenance report. Failure to properly complete each inspection when required may result in death , serious inju叩 or substantial machine damage. tag and remove from service a damaged or malfunctioning machine.
回 Immediately
any machine damage or malfunction before operating machine.
回 Repair
回 Keep
Indicates the presence of a hazard that will or may cause serious i时U叩 or damage to the machine. Indicates speci创
operation
噩 a*lH毒草噩 maintenance information.
or
<:> Indicates that a specific result is exp四ted a他r performing a series of steps.
records on all inspections for three years.
Part No. 31758
Genie IWP &Genie AWP
4-1
Service Manual- First Edition
Section 4 - Scheduled Maintenance Procedures
Table A Procedures A-1 Inspect the Operator's and Responsibility Manuals
A-2 Inspect the Decals and Placards
Maintaining the operator's and responsibility manuals in good condition is essential to safe machine operation. Manuals are included with each machine and should be stored in the container provided at the platform. An iII egible or missing manual will not provide safety and operational information necessaĺ?Š for a safe operating condition. Check to make sure that the operator's and responsibility manuals are present and complete in the storage container at the plaäť&#x201D;orm.
2 Examine the pages of each manual to be sure that they are legible and in good condition. 3 Always return the manuals to the storage box after use.
Maintaining all of the safety and instructional decals and placards in good condition is essential for safe machine operation. Decals alert operators and personnel to the many possible hazards associated with using a machine. They also provide users with operation and maintenance information. An iII egible decal will fail to alert personnel of a procedure or hazard and could result in unsafe operating conditions. 1 Refer to the Decals section in the Genie IWP Operator's Manual or the Genie A WP Operator's Manual and use the decal list and iII ustrations to determine that all decals and placards are in place. 2 Inspect all decals for legibility and damage. Replace any damaged or illegible decal immediately.
4 Be sure the storage container and lid are present and in good condition.
Contact your authorized Genie distributor or Genie Industries if replacement decals are needed.
Contact your authorized Genie distributor or Genie Industries if replacement manuals are needed.
4-2
Genie IWP & Genie AWP
Part No. 31758
Service Manual - First Edition
Section 4 - Scheduled Maintenance Procedures
TABLE
A-3 Inspect for Damage and Loose or Missing Parts Daily machine condition inspections are essential to safe machine operation and good machine performance. Failure to locate and repair damage , and discover loose or missing parts may result in an unsafe operating condition. 1 Inspect the entire machine for damage and improperly installed or missing parts including:
A
PROCEDURES
A-4 Check for Hydraulic Leaks Detecting hydraulic fluid leaks is essential to operational safety and good machine performance. Undiscovered leaks can develop into hazardous conditions , impair machine functions and damage machine components. 1 Inspect for hydraulic oil puddles , dripping or residue on or around the following areas: hydraulic power unit-tank, valves , fittings
electrical cables and wiring
hydraulic cylinder(s)
electrical cable anchors and pulleys
flow control valve
hydraulic power unit, hoses , fittings , cylinder(s)
ground area under the machine
sequencing cables and pulleys
all hydraulic hoses and fittings hydraulic manifolds and foot pump - IWP models
lifting chains and idler wheels mast columns and counterweight nuts , bolts and other fasteners platform
entĺ?Š mid-rail
breather cap(s) hydraulic manifolds and foot pump - IWP models contact point wear pads - IWP models outriggers , leveling jacks and foot pads -AWP models dents or damage to machine cracks in welds or structural components
Part No. 31758
Genie IWP
&Genie AWP
4-3
Section 4 - Scheduled Maintenance Procedures
TABLE
A
PROCEDURES
A-5 Check the Manual Lowering Operation Detection of manual lowering malfunction is essential for safe machine operation. An unsafe working condition exists if the manual lowering function does not operate in the event of a main power loss. Raise the platform slightly. 2 Pull out the manual lowering lever located on the hydraulic power unit.
o
Service Manual - First Edition
Result: Platform should lower.
5 Plug charger in and set timer to
position (if applicable). Confirm the charger is operating.
。 Result: The charger ammeter or lights should beON.
A-7 Inspect the Columns for Damage Detection of damage to columns is essential for safe machine operation. An unsafe working condition exists if the columns are damaged and do not operate smoothly , free of hesitation and binding. A daily check of the columns allows the inspector to identify changes in the operating condition of the column assembly that might indicate damage.
A-6 Check the Battery and Ba忧ery Charger - DC Models Proper battery and charger condition is essential to good machine performance and operational safety. Improper fluid levels or damaged cables and connections can result in component damage and hazardous conditions. Batteries contain acid. Avoid spilling or contacting battery acid. Neutralize battery acid spills with baking soda and water.
ON
Visually inspect the exterior of each column for the following: dents, gouges or abrasions bends or warping excesslve wear
2 Raise and lower the platform through a complete cycle.
o
Resul t: Platform should raise and lower smoothly , free of hesitation and binding.
Put on protective clothing and eye wear.
2 Be sure that the battery cable connections are tight and free of corrosion.
3 Check the battery acid leve l. If needed , replenish with water to the bottom of the ba忧ery fill tube. Do not overfil l.
4 Install the vent caps.
4-4
Genie IWP & Genie AWP
Part No. 31758
Service Manual - First Edition
Section 4 - Scheduled Maintenance Procedures
TABLE
A-8 Check the Sequencing Cables
A
PROCEDURES
A-9 Check the Interlock System for Proper Operation
Detection of damage to sequencing cables or components is essential for safe machine operation. An unsafe working condition exists if the sequencing components are damaged and do not operate smoothly. A daily check of the sequencing system allows the inspector to identify changes in the operating condition that might indicate damage.
3 Turn the key switch to the ON position.
1 Visually inspect the cables and components for
o
the following:
AWP Models 1 Select a test area free of obstructions. 2 Connect the appropriate power source.
Result: The power light should come on.
4 Pull out the red Emergency Stop button to the ON
frayed or broken wire strands kinks in the cable corroslon paint or foreign materials broken or damaged pulleys unusual or excessive pulley wear split or cracked threaded swage ends
position.
5 Select an outrigger and slide it into a base socket until the outrigger lock pin snaps into the locked position. Bring the outrigger leveling jack into firm contact with the ground. 6 Check the interlock display lights at the ground controls.
2 Check to be sure of the following: cables are on the pulleys lower cable ends are properly secured upper and lower mounting brackets are properly secured
。 Confirm that the
corresponding light is on.
7 Repeat steps 5 and 6 for each of the remaining outriggers.
Part No. 31758
Genie IWP
GclÎ C2..
Intarlack Displ啕
&Genie AWP
。
。
4-5
Section 4 - Scheduled Maintenance Procedures
Service Manual - First Edition
TABLE A PROCEDURES
12 Turn both the leveling jacks clockwise to the full down position.
IWP Models 1 Connect the appropriate power source.
2 Insert the key and turn to the ON position. 3 Pull out the red Emergency Stop button to the 。N position.
ø
13 Pull the base lowering handle to lower the base.
ø
Result: The power light should come on.
Result: The base willlower and all four interlock display lights should be 。何 and remain 0仔 because the base is not level. The lights may remain on for 2 to 3 seconds after lowering the base , then turn off.
4 Use the bubble level and adjust the leveling jacks until the machine is level and all four contact points are in firm contact with the ground.
14 Twist to release the red Emergency Stop bu忧on at the platform controls.
ø
15 Push in the control activate button and rotate t。 the Up position , then the DOWN position.
Result: Within 3 to 6 seconds , all four interlock display lights should turn on and remain on.
5 Pump the foot pedal to raise the base. 6 Turn the right hand leveling jack clockwise 3 full turns.
7 Pull the base lowering handle to lower the base.
ø
Result: The base willlower and the diagonal pair of lights corresponding t。 the extended leveling jack will remain on. The opposite pair of lights will turn off.
。"施
In阳10昧 Di咽l啕 、 1/
万余飞 1
飞 1/
3年c
/ lI:&:Ji]、 1/
泞C
工收
ø
A-10 Test the Power and Function Controls Testing the machine functions and the Emergency Stop buttons for malfunctions is essential for safe machine operation. An unsafe working condition exists if any function fails to operate properly or either Emergency Stop button fails to stop all the machine functions. Each function should activate, operate smoothly and be free of hesitation , jerking and unusual noise. Turn the key switch to the ON position and pull out red Emergency Stop button to the ON position.
8 Pump the foot pedal to raise the base. 9 Turn the right hand leveling jack counterclockwise 3 full turns. Then turn the left hand leveling jack clockwise 3 full turns. 10 Pull the base lowering handle to lower the base.
ø
Resul t: The base willlower and the diagonal pair of lights corresponding to the extended leveling jack will remain on. The opposite pair of lights will turn off.
Result: Platform up function should not operate.
ø
Result: The power light should be on.
2 Twist to release the red Emergency Stop button at the platform controls. 3 Push in the control activate button and rotate t。 the UP position , then the ∞WN position.
ø
Result: Platform up and down functions should operate smoothly.
11 Pump the foot pedal to raise the base.
4-6
Genie IWP & Genie AWP
Part No. 31758
Section 4 - Scheduled Maintenance Procedures
Service Manual - First Edition
TABLE
4 Push in the Emergency Stop button at the platform controls to the and down functions.
OFF
position and test up
。 Result: Up and down functions should not
PROCEDURES
3 Inspect the chain terminations near the bottom of each column to confirm that each termination has an adjustment nut and a lock nut.
4 Inspect the chain terminations near the bottom
operate.
5 Twist to release the red Emergency Stop button at the
A
pla仔orm
controls.
of each to confirm that each pair of termination rods has equal tension.
6 Push in the Emergency Stop button at the ground controls to the OFF position. Then test up and down functions. 。 Result: Up and down functions should not
operate.
A-11
Inspect the Li fting Chains and Idler Wheels Maintaining the lifting chains and idler wheels in good condition is essential to safe machine operation. Failure to find and replace damaged chains or idler wheels could result in unsafe operating conditions and may cause component damage.
a b c d
adjus怕lentnut lockn川
termination rod
rnast
Raise the platform approximately 3 feet (1 m) off the base.
2 Visually inspect the chains and idler wheels near the top of each column for the following: excesslve corroSlon broken or missing chain leafs tight or kinked joints in the chain idler wheel axle plates improperly secured idler wheels and related components missing ordamaged
Part No. 31758
Genie IWP
&Genie AWP
4-7
Section 4 - Scheduled Maintenance Procedures
Service Manual - First Edition
TABLE A PROCEOURES
A-12 Inspect the Breather Cap(s) The hydraulic reservoir is a breathing type reservoir. The breather cap has an internal air filter that can clog and allow the power unit to operate improperly. If the breather cap is not properly installed and checked daily, impurities can enter the hydraulic system and cause component damage. 1 Be sure the breather cap is installed on the hydraulic power unit reservoir and is not damaged. 00 not remove it. 2 IWP models: Be sure the breather cap is installed on the hydraulic manifold and is not damaged. 00 not remove it.
A-13 Test the Base Operation -IWP Models Testing the base for proper operation is essential for safe machine operation. An unsafe working condition exists if the base fails to operate properly. The base should operate smoothly and be free of hesitation , jerking and binding. 1 Pump the foot pedal ten complete strokes.
ø
Resul t: Base non-adjustable contact points should be 2 inches (5 cm) off the ground.
2 Pull the base lowering handle.
ø
Result: Base should lower putting all four contact points in firm contact with the ground.
4-8
Genie IWP &Genie AWP
Part No. 31758
Section 4 - Scheduled Maintenance Procedures
Service Manual - First Edition
Table B Procedures 8-1 Inspect the Electrical Wiring
8-2 Inspect AII Welds
Maintaining electrical wiring in good condition is essential to safe operation and good machine performance. Failure to find and replace burnt , chafed , corroded or pinched wires could result in unsafe operating conditions and may cause component damage.
Weld inspections are essential to safe machine operation and good machine performance. Failure to locate and repair damage may result in an unsafe operating condition.
Electrocution hazard. Contact with hot or live circuits may cause death or serious injury. Remove all rings , watches and other jewel叩.
1 lnspect the following areas for burnt , chafed , corroded and loose wires:
Visually inspect the welds in the following locations: platform base power pack mounting brackets mast brace mounting brackets AWP models only:
inside of the base junction box
loading pivot bar
inside of the ground control box
outrigger storage sockets
inside of the mast junction box
mast suppo叶
hydraulic power unit
tilt-back frame (30 and 36 models)
all external machine cables
tilt-back frame mounting brackets (30 and 36 models)
inside of the
pla仔orm
control box
angles
pack - DC models
IWP models only:
three-prong AC power supply cord
counterweight
ba忧ery
(30 and 36 models)
. base contact points
Part No. 31758
Genie lWP
&Genie AWP
4-9
Service Manual - First Edition
Section 4 - Scheduled Maintenance Procedures
TABLE
B PROCEDURES
8-3
Test the Tilt-back Operation AWP-30 and 36 Models The Genie AWP-30 and 36 models have a tiltback frame which allows the machine to be rolled through a standard doorway. Failure to detect improper tilt-back operation could result in unsafe operating conditions and may cause injury and component damage. 1 Fully lower the
plaç&#x201D;&#x2DC;orm.
5 Slide out the base T-handle until the lock pin snaps into the locked position. 6 Using two people , lift the machine with the T-handle to the mid-tilt position (tiltback frame casters contacting the floor and the machine suppoć°&#x2018;ed bythe extended tilt-back strut). Crushing hazard. The machine could fall if the T-handle lock pin is not locked into the base.
2 Remove the outriggers from the sockets base and place them in the outrigger storage sockets. 3 Maintain a firm grasp on the tilt-back frame and remove the retaining pin.
7 Continue lifting the T-handle until the tilt-back strut is completely compressed.
4 Lower the tilt-back frame and guide the tilt-back strut into the strut socket. Then insert the retainer pin into the strut socket.
Crushing hazard. The machine will fall if the retainer pin is not locked into the strut socket.
4 -10
Genie IWP & Genie AWP
Part No. 31758
Service Manual - First Edition
Section 4 - Scheduled Maintenance Procedures
TABLE B PROCEDURES
2 AWP models: Measure the distance between the base tube and the bottom of the platform.
8-4
Check the Li fting Chain Adjustments Maintaining proper adjustment of the lifting chains is essential to safe machine operation. Failure to maintain proper chain adjustment could result in unsafe operating conditions and may cause component damage.
IWP models: Measure the distance between the bottom of the platform to the top of the counterweigh t.
Fully lower the platform and measure the maximum height of the machine. IWP models: Turn the screw jacks counterclockwise to the full up position and then pull the base lowering handle to lower the base. <:)
Resul t: The machine should be no taller than specification. If measurement does not meet specification , adjust the chains. See Repair procedure 5-3 , How to Adjust the Lifting Cha的s.
。 Result:
The measurement should be no less than specification. If measurement does not meet specification , a吗 ust the chains. See Repair procedure 5-3, How to Adjust the LiftJ的'g Chains.
Specifications
Part No. 31758
Model
Height
Measurement (step 2)
IWP-19
77in 195 cm
2.5 in 6.35 cm
IWP-24
77in 195 cm
2.5 in 6.35 cm
AWP-19
79in 200cm
3in 7.6 cm
AWP-24
79in 200cm
3in 7.6cm
AWP-30
93in 236 cm
12in 30.5 cm
AWP-36
112 in 284 cm
12in 30.5 cm
Genie IWP & Genie AWP
4 - 11
Service Manual- First Edition
Section 4 - Scheduled Maintenance Procedures
TABLE
B
PROCEOURES
B-5
B-6
Check the Battery
Clean and Lubricate the Columns
Proper battery condition is essential to good machine pe时ormance and operational sa1ety. Improper 11uid levels or damaged cables and connections can result in component damage and hazardous conditions.
Clean and properly lubricated columns are essential to good machine performance and sa1e operation. Extremely dirty conditions may require that the columns be cleaned and lubricated more often.
Batteries contain acid. Avoid spilling or cont缸ting battery acid. Neutralize battery acid spills with baking soda and water. 1 Put on protective clothing and eye wear.
1 Raise the platform to the maximum height. 2 Visually inspect the inner and outer channels 01 the columns 10r debris or 10reign materia l. 11 necessary, use a mild cleaning solvent to clean the columns. This procedure will require the use 01 additional access equipmen t. 00 not place ladders or sca何old on or against any part 01 the machine. Performing this procedure without the proper skills and tools may result in death or serious injury. Oealer service is strongly recommended.
2 Remove the battery vent caps and check the speci1ic gravity with a hydrometer. 3 Check the battery acid leve l. 11 needed , replenish with water to co叩er the battery plates. 00 not overfil l. 4 Install the vent caps. 5 Plug charger in and set timer to the ON position (i1 applicable) and observe charger ammeter after one hour to confirm charging amperage has dropped. 11 amperage does not drop, the
3 11 needed , lubricate the inner and outer channels 01 the columns with a dry silicone spray (Genie part no. 90337) or silicone wax.
事露出噩 batte叩 is bad and needs to be replaced.
6 Remove the vent caps. Check the battery acid leve l. 11 needed , replenish with water to the bottom 01 the battery 1i11 tube. 00 not overfil l. 7 Install the vent caps.
4 -12
Genie IWP & Genie AWP
Part No. 31758
Service Manual - First Edition
Section 4 - Scheduled Maintenance Procedures
TABLE
B
PROCEDURES
8-7
8-8
Test the Li fting Capacity
Test the Power To Platform Operation
Proper lifting capacity is essential to safe machine operation. Improper lifting capacity adjustment could allow machine to be overloaded and may cause death or serious i时 ury. This procedure requires specific repair skills , lifting equipment and a suitable workshop. Attempting this procedure without these skills and tools may result in death or serious injury and significant component damage. Dealer service is strongly recommended.
AC power to the platform is intended to be an extension cord to the platform for using hand tools. 1 Connect a three-prong extension cord to the AC power supply cord at the base of the machine. 2 In the platform , plug a power drill (or similar tool) into the AC outlet.
o
Resul t: The tool should operate normally.
1 Load the pla甘orm with the maximum rated load. Secure the load to the pla仔orm.
Models equipped with a GFCI outlet may require that the outlet be reset with the reset button.
2 Raise the platform slightly.
o
Resul t: The hydraulic power unit should raise the platform.
3 Fully lower the
pla甘orm.
4 Add an additional 30 pounds (14 kg) to the platform. Secure the additional weigh t. 5 Raise the platform slightly.
o
Result: The hydraulic power unit should not be able to raise the pla仔orm. If the hydraulic power unit is unable to lift rated load or lifts more than rated load , see Repair procedure 3号 ， How to Adjust the Pressure Relief Valve.
Li fting capacity AWP-36
250lbs
113 kg
AWP-30
300lbs
136 kg
AWP-24
300lbs
136 kg
AWP-19
300lbs
136 kg
IWP-19
350lbs
159 kg
IWP-24
350lbs
159 kg
Part No. 31758
Genie IWP & Genie AWP
4 -13
Service Manual - First Edition
Section 4 - Scheduled Maintenance Procedures
TABLE B PROCEDURES
8-9 Adjust the Sequencing Cables Maintaining proper adjustment of the sequencing cables is essential for safe machine operation. An unsafe working condition exists if the sequencing cables are improperly adjusted. A frequent check of the sequencing system allows the inspector to identify changes in the operating condition that might indicate damage.
4 Re-check the tension on each sequencing cable.
5 Repeat adjustment for each cable. 6 Raise and lower the pla仔orm through three complete cycles and re-check cable tension.
specification Maximum Deflection
3.5 to 4.5 inches 8.9 to 11 .4 cm
1 Fully lower the platform.
2 Check the tension on each sequencing cable by grasping the cable half way down the column and pulling the cable from one side then to the other. Measure the total distance between the two points (this is the maximum de刊ection).
8-10 Inspect for Proper Outrigger Length -AWP Models Proper outrigger length is essential to safe machine operation. Operating a machine with outriggers different from those originally designed for the model , will result in death or serious inju叩. 1 Measure each outrigger and verify for proper length.
陪刨
nsn
巾 -oa
二
川阳m 、u
陌回回
则'Bq ω 阳炮
ahucEtE Eau
Length nHAU ee
3 Hold the threaded swage end of the cable from turning and adjust the tension nut to obtain correct tension. Turn the adjustment nut clockwise to increase the tension or counterclockwise to decrease the tension.
AWP Models (sold in North America only) A-A-A-A w-w-w-W 22inches
Component damage hazard. Do not exceed the recommended tension. 4 -14
Genie IWP & Genie AWP
55.9 cm
22 inches
55.9 cm
31 inches
78.7 cm
36 inches
91 .4 cm
Part No. 31758
Section 4 - Scheduled Maintenance Procedures
Service Manual - First Edition
TABLE
8-11 Test the Level Sensing Operation -IWP Models
B
PROCEDURES
display lights should turn off and remain off.
8 Repeat steps 3 through 7 to test the opposite side of the machine tested previously.
9 Pump the foot pedal to raise the base. Detection of level sensing malfunctions is essential for safe machine operation. An improperly functioning level sensing system will allow the machine to be operated in an unsafe condition.
1 Turn the key switch to the
position and pull out red Emergency Stop button to the ON position.
o
10 Place a 3/4 inch (19 mm) thick block under both adjustable contact points.
11 Pull the release handle to fully lower the base.
o
ON
Resul t: Within 3 to 5 seconds , all four interlock display lights should turn on and remain on.
12 Repeat steps 9 and 10 using an 11/2 inch (38.1 mm) spacer.
Result: Power Ii ght should be on. 13 Pull the release handle to fully lower the base.
2 Use the bubble level and adjust the leveling jacks until the machine is level and all four contact points are in firm contact with the ground. ă&#x20AC;&#x201A; Result:
Within 3 to 5 seconds , all four interlock display lights should turn on and remain on.
o
Resul t: After 2 to 3 seconds , all four interlock display lights should turn off and remain off.
14 Repeat steps 9 through 13 to test the non-adjustable contact points.
3 Pump the foot pedal to raise the base. 4 Place a
1/4 inch (6.35 mm) thick block under one adjustable and one non-adjustable contact point on the same side of the machine.
5 Pull the release handle to fully lower the base.
o
Result: Within 3 to 5 seconds , all four interlock display lights should turn on and remain on.
6 Repeat steps 3 and 4 using a 1/2 inch (12 .7 mm) spacĂŠr. 7 Pull the release handle to fully lower the base.
o
Resul t: After 2 to 3 seconds , all four interlock
Part No. 31758
Genie IWP & Genie AWP
4 -15
Section 4 - Scheduled Maintenance Procedures
Service Manual - First Edition
Table C Procedures C-1
C-2
Inspect and Lubricate the Casters andWheels
Inspect the Mast Assembly forWear
Extremely di即 conditions may require that the casters and wheels be inspected and lubricated more often.
Detection of excessive or unusual wear in the mast assembly is essential for safe machine operation. An unsafe working condition exists if the mast assembly has excessive wear and/or does not operate smoothly, free of hesitation and binding.
1 Visually inspect each caster and wheel for cuts , cracks or unusual wear. 2 Move the machine on a flat smooth surface and
check that the casters and wheels roll smoothly.
3 Pump grease into the caster or wheel until it can be seen coming out of the bearing seal
1 Check the side-to-side movement at the top of the column that the platform is mounted to (referred to as the carriage).
ø
gap. Grl铺揭 Type
Result: The carriage should not be able to touch either side of the adjacent column.
Lithium-based
a b c
∞lumn
carriage platform
2 Remove the mounting fasteners from the mast cover. Then remove the mast cover from the machine. 3 Visually inspect the top of each column for clearance between the roller wheels and the adjacent column surface.
ø
4 -16
Result: There should be a maximum gap of 0.020 inches (0.5 mm) between the roller wheel and the column.
Genie IWP & Genie AWP
Part No. 31758
Service Manual - First Edition
Section 4 - Scheduled Maintenance Procedures
TABLE
If mast inspection results in a measurement that is not within specification , refer to Repair procedure 5-2 , How to Assemble the Mas t.
C
PROCEDURES
Do not place the jack stand on the ground. AWP models will require blocks on the base to support the jack stand. 7 Lower the platform onto the jack stand.
4 Loosen but do not remove the adjustment nut on the sequencing cable located at the top of the first column.
Crushing hazard. Keep away from lowering platform. 8 Inspect each idler wheel for the following: excessive wear on the side flanges unusual wear movement side to side in excess of 0.040 inches (1 mm) any movement of wheel front to back
5 Raise the platform approximately 3 feet (1 m) above the top of the base.
①
6 Place a jack stand on the top of the base , centered under the pla甘orm. Adjust the jack stand to 24 inches (61 cm).
a b c
idlerwheel spacer liftingchain
If idler wheel inspection results in a measurement that is not within specification , refer to Repair procedure 5-2 , How to Assemble the Mas t.
a b
Part No. 31758
c
platform jackstand support block
d
base
9 Raise the platform and remove the jack stand and the suppo时 blocks. Then lower the platform. 10 Install the mast cover and adjust the sequencing cable. See B-9 , Adjust 的e Sequencing Cables.
Genie IWP & Genie AWP
4 - 17
Section 4 - Scheduled Maintenance Procedures
Service Manual - First Edition
TABLE C PROCEOURES
C-3 Lubricate the Li fting Chains Lubricated chains are essential to good machine performance and safe operation. Extremely di即 conditions may require that the chains be cleaned and lubricated more often. 1 Raise the pla町orm to the maximum height. 2 Lubricate each chain with a d叩 type spray lubricant. This procedure will require the use of additional access equipment. 00 not place ladders or sca何Old on or against any part of the machine. Performing this procedure without the proper skills and tools may result in death or serious i时 ury. Oealer service is strongly recommended.
6 Install the suction strainer, then the reservoir. 7 Apply pipe thread sealant to the drain plug and re-install it in the reservoir. 8 FiII the reservoir with hydraulic oil until the level is visible in the sight gauge on the side of the reservoir. 00 not overfil l. 9 Replace the breather cap with a new one. IWP Models: Replace the breather cap located on the hydraulic manifold. 10 Raise and lower the platform through three complete cycles. Add hydraulic oil if needed to allow platform to reach full height. Component Oamage Hazard. 00 not allow the hydraulic reservoir to completely empty when raising the platform. Pressurized air in the hydraulic system can damage hydraulic components. Hydraulic
Dexron 11 equivalent
Hydraulic fluid
C-4 Replace the Hydraulic Oil Replacement of the hydraulic oil is essential for good machine pe付:ormance and service life. Oirty oil and suction strainer may cause the machine to perform poorly and continued use may cause component damage. Extremely dirty conditions may require oil changes to be performed more 0饨en.
Fully lower the platform. 2 Remove the plastic cover from the power pack. 3 Remove the drain plug from the hydraulic reservoir and completely drain the reservoir into a container. Properly dis臼rd of oi l. 4 Remove the reservoir from the hydraulic power unit. 5 Remove the suction strainer, the reservoir and the magnet and clean them using a mild solvent.
4 -18
Sy剖:em
Hydraulic reservoir capacity AC models DC models Hydraulic
Sy:副em
4.5 quarts 3.3 quarts
C8pacity (includes
4.2liters 3.1 Iiters
re:饵rvoir)
AC models IWP -19 IWP-24
5.4 qua民s 5.4 quarts
5.1 Iiters 5.1 Iiters
AWP -19 AWP -24 AWP-30 AWP -36
5.4 5.4 5 5.1
quarts quarts quarts quarts
5.1 Iiters 5.1 liters 4.7 liters 4.8liters
IWP -19 IWP-24
4.2 4.2
qua内S qua此S
41iters 41iters
AWP -19 AWP -24 AWP-30 AWP -36
4.2 4.2 3.8 3.9
quarts quarts quarts quarts
4liters 4liters 3.6 Iiters 3.7 liters
DC models
Genie IWP & Genie AWP
Part No. 31758
Section 5 - Troubleshooting Flow Charts
Service Manual - First Edition
Troubleshooting Flow Charts Before Troubleshooting: 固 Read ，
understand and obey the safety rules and operating instructions printed in the Genie IWP Ope用归rs Manual and the Genie AWP Operators Manual.
。bserve
回 Be
sure that all necessa叩 tools and test equipment are available and ready for use.
and Obey:
回 Troubleshooting
团 Read
回 Immediately
回 Be
and repair procedures shall be completed by a person trained and qualified on the repair of this machine. tag and remove from service a damaged or malfunctioning machine.
回 Repair
any machine damage or malfunction before operating the machine.
each appropiate flow chart thoroughly. Attempting shortcuts may produce hazardous conditions. aware of the following hazards and follow generally accepted safe workshop practices.
曹南 IJ!H 【CJ~ :事
Electrocution hazard. Contact with electrically charged circuits may resu忧 in death or serious injury. Remove all rings , watches and other jewelry. Bodily injury hazard. Spraying hydraulic oil can penetrate and burn skin. Loosen hydraulic connections ve叩 slowly to allow the oil pressure to dissipate gradually. 00 not allow oil to squirt or spray. Perform all troubleshooting on a firm level surface. Two persons will be required to safely pe时orm some troubleshooting procedures.
Part No. 31758
Genie IWP
&Genie AWP
5-1
Section 5 - Troubleshooting Flow Charts
Service Manual - First Edition
TROUBLESHOOTING FLOW CHARTS
General Repair
About This Section
ProĎ&#x2030;55
When a malfunction is discovered , the flow charts in this section will help a service professional pinpoint the cause of the problem. To use this section , basic hand tools and certain pieces of test equipment are required-voltmeter, ohmmeter, pressure gauges. The location of terminals mentioned in this section can be found on the appropriate electrical or hydraulic schematics provided in section 6, Schematics. Since various degrees of a particular function loss may occur, selecting the appropriate flow chart may be troublesome. When a function will not operate with the same speed or power as a machine in good working condition , refer to the flow chart which most closely describes the problem.
5-2
Genie IWP & Genie AWP
Part No. 31758
Service Manual - First Edition
Section 5 - Troubleshooting Flow Charts
Chart 1 Power Light WiII Not Turn OnAC Models
同咱 i nto different power supply and r<创1础 voltage.
Replace 甘1e
power light.
Be sure the key switch is in the appropriate position. Be sure the Emergency Stop buttons are pulled up to the ON position. Be sure the ground control box fuses are not blown.
Check 伽e voltage at the center post on 伽e 『前tifier.
Check for damaged wire from theωnter poston the rectifier to the 仙se.
Replace 甘1e power light.
OVDC
Check 甘1e voltaae on the left a_nd righf posts of the rl臼tifier.
Replaωther田tifier.
Ch创巾e r<创 wir<臼 betw四nthe 甘ansformer andthe r，臼俑er.
Repair open in the rl创
Wl res.
Check 甘1ewiri咱 back
through the Emergency Stop buHon, key switch and power supply OR ∞nsult Genie Industries ServiωDepartment.
Part No. 31758
Genie IWP & Genie AWP
5-3
Service Manual - First Edition
Section 5 - Troubleshooting Flow Charts
Chart 2 Power Light WiII Not Turn OnDC Models
Cha咱e 甘le battery OR
check batterv ∞时恼。n
and r，句lace巾adba由ery.
Re网ropen in 阳 wire.
Be sure the key switch is in the appropriate position. Be sure the Emergency Stop buttons are pulled up to the ON position. Be sure the battery cables are connected.
12VDC
Re回ace the fuse.
Trace the black wire
怕 m terminal 3 back to theflωe and check for 由m啕e.
Repair 叩en in the wire.
Re阳四世lekey 刷刷1.
Trace the black wire
怕m terminal1 back to thekey 侧面chand check for 也mage.
R叩air open in the wire.
Replace the Emergency
stop button.
5-4
Genie IWP & Genie AWP
Part No. 31758
Service Manual- First Edition
Section 5 - Troubleshooting Flow Charts
CHART2
Continu创 from 甘1e
prevlous page.
Check the voltage at 甘1e input side of the 阳>wer light.
Check for damaaed r创 wire or damaged terminals.
R句air open in the red wire andlor replace 阳werlight.
Repair open in the black wire and/or replaω 阳wer Iight.
12VDC
Repla田间wer light.
Part No. 31758
Genie IWP
&Genie AWP
5-5
Section 5 - Troubleshooting Flow Charts
Service Manual - First Edition
Chart 3 Interlock Li ghts WiII Not Turn OnAWP AC Models Be sure the key switch is in the appropriate position.
Check 胁h。啕 e5川 A
OVDC
甘vo1eltaogrOe| to
fuse in ground ∞ntrol box.
Be sure the Emergency Stop buttons are pulled up to the ON position.
!;;tkc hl ReplmhereCHEer-
haM e rr创 ighmteterr-minals on
|tCoh甘e1detthraensifno川 rmer al唱|歧'
Be sure the power light Ison. Be sure the outriggers are the correct length. Be sure the leveling jacks are in firm contact with the ground.
vtCroah旭|emd40tehmoemf甘or1啕 aet hlJteleft
I
To何umaM hechmωwkehrseource l bad 12VDC
∞『n16tancuto-tyr ofeach
∞
Jt阳Rae『附阳商f伽oαrmmm『n『n1egr.h 4∞ ReM阳 actor刷-刷ve
onthe
gaEnrmoduehrngdee∞ nkcenyytS棚 otloitptmcbhxu.itntohne
Turn the 阪mer supply off and 仿制<the ∞ntinuity of each ∞ntactor in 甘1e platforrn ∞耐01 switch assembly.
5-6
Genie IWP
&Genie AWP
Part No. 31758
Service Manual - First Edition
Section 5 - Troubleshooting Flow Charts
CHART3
Continued from the preVlous page.
Traωthe wire from proximity 驯时1 to the ∞rrespondi咱 relay in
Repl~ce the proximity
刷itch.
the base junction box. Check the input voltage to the relay on terminal 85.
Replaωthe relay.
Trace the input wire back to the ground ∞ntrol box relay 卸1d check for cJamage.
Part No. 31758
Genie IWP
&Genie AWP
Rep剑r open
in the wire.
5-7
Service Manual - First Edition
Section 5 - Troubleshooting Flow Charts
Chart 4 Interlock Li ghts WiII Not Turn OnAWP DC Models Be sure the key switch is in the appropriate position.
|叫 bateasdu1re刨甘.e1e叩 magnetmisto Check 胁h 。leJP5uAt vhoel恒og「Oe| b hse in eground ∞附'01 box.
|m
OVDC
4tRueb阳 e. 阳 0剧由er
To何urannhdedp民 owke甘r1seoum ∞∞nnttanduiovr ofeach onthe
gaErn『oTdIt』er时伽uee∞nkec巾 yySs。twloibtcobh p xu-itntohne
Be sure the Emergency Stop buttons are pulled up to the ON position. Be sure the power light IS on.
I~础the阳mal刚 chinmewiruinm g
Be sure the outriggers are the correct length.
OR ∞n1actGenie I~叫 e阳dmdeM.Mce
Be sure the leveling jacks are in firm contact with the ground.
4俨R阳 ∞e邻切np网阳恒| 制 doαr.
|
Tu 川d 由lE!IC怵 阳阳… k町盯叫叫伽 r内s创 eu 刚叩 叫p 。何 and
∞∞I时16anduiovrionfheaecphlatform ∞巾。1
switch assembly. g∞d
Traωthe wire from|IOVDCJ'l SRWepItclahω~the pro刘mity
mu αh田xerM 回U国M归tymfeM咀拥l咱ndM剧m闹b顶闹o曲yMhmtEneP L
ttoemheinma|l8ay5.on
Replace the relay.
Trace the input wire back to the ground ∞ntrol OOx relay and check for damage.
5-8
Genie IWP
&Genie AWP
Repair open in 甘lewire.
Part No. 31758
Service Manual - First Edition
Section 5 - Troubleshooting Flow Charts
Chart 5 Interlock Li ghts WiII Not Turn OnIWP Models Be sure the key switch is in the appropriate position. Be sure the Emergency Stop buttons are pulled up to the ON position.
i自m回回句回的曲l回刨节n(国s，自B翩e也田国翩咱揣se 2阳 L严I且DC叫| mi 阳阳 酬 αetBeck1&2s 白 m画n白uHy h阳H 出~ 时nt;即向 ∞ennstai咱 ct aiy
Be sure the ground control box fuse(s) are not blown.
Gasesneiem|bnldyuOstRdes
I Service Department.
12VDC center 阳m晒 terminal the αleckthe nal恒bon国nad伽~~ 揭R"k回酣脚时国咽ld圈udk町a放'y随回m回缸阳国ke刨x)l 战l b2{刨黯m刨Mee础l曲钮阳'市回回阳g咱m岛国n]以anyEiXumg nthe 甘1e
Be sure the power light IS on. Be sure the unit is set up according to the operator's manual.
ll
a terminal on the level .sen.sing a.s.sembly.
I 12VDC Turn 世1ehmewmerascohiunrece 。何.Wi曲
S∞回阳S回l四hSn回田mu回Ih，vy 捕 dEdmm世时d畸伽自e 由
H位且 缸却MtEi晒h卡)Os回nt创Rm臼抽ume恒mct
t
jrudnadyoinn伽ebaS43 box. ↓∞耐nu
|
T国dr阳鸭ckd阻睛刨t阳oM世阳悟由xim，m用M回钮嘎，脚 国扣and
J Repair open in 甘阳ire.
Check for dama副 ground wire OR replace the interlock di.splay light(.s}.
Part No. 31758
Genie IWP & Genie AWP
5-9
Section 5 - Troubleshooting Flow Charts
Service Manual - First Edition
Chart 6 Machine WiII Not Li白， AC Models Be sure the key switch is in the appropriate position.
agα8m毡ea mM，g慧c'kBoE回g棚饱m回emm咽t国gM恒晴EMFU耐meKaprl也Bntew
臼n饱ctor - AC
Be sure all display lights are on.
OVDC
Chedth1Mewxiodn咱hienhe jmunodtoroOnRreplace he motor.
k曲回恒Ihe 由 che加 ckmgmte， 口 I些-些--」 -I Toaumzbued阴回阳来e伽f矶e'由 function aOO
wvoirlteaogen taetrhmeinoarla6啕atehe toerromuiMnd∞st巾 dp。ilntmhxe. grouOO control box.
下馆阳H<回m回。回抽s回row回α回u呻w剧卸eEkMsa目KmR刀2t创阳Sa1,eey
5 - 10
Models.
'---
Be sure the emergency stop buttons are pulled up to the ON position. Be sure the ground control box fuse(s) are good.
Re『p1t!aad四:or甘i1neAC 12VDC TestlheAC ∞刷刷『 in lL之h出'!In一-叫l ∞ 甘2抽 1·e3，gHRroeouw阳ndtor∞pTmengtto伽dlbueoreAxC-甘1egrouOO ∞巾。1 box.
4∞ Ren阳 tactor刷.刷ve
∞∞rnIH恒nduiowr ionfheaech
plaMom ∞ntrol switch
I assembly.
Rreelaphlaωdefective relay(s).
Genie IWP & Genie AWP
Part No. 31758
Service Manual - First Edition
Section 5 - Troubleshooting Flow Charts
Chart 7 Machine WiII Not Li ft, But Power Unit WiII OperateAC Models
Check 甘1e resistance of the normally 叩en valve ∞il on the power unit.
R~pair. o[l9n in ft.1e
wiringbetw，四 n 甘1e 回 me
delay relay to the valve
Be sure the key switch is in the appropriate position.
∞il.
Be sure the Emergency Stop buttons are pulled up to the ON position.
12VDC
Be sure the ground control box fuse(s) are not blown.
R~pair，。因n in the
wm咱 between 由etime
delay relay to terminal 8 on the terminal strip in
世1eground ∞ntrol
Be sure the power unit reservoir is full. the power unit manifold valves for
Ch创叫 I
∞ntamination.
box.
Clean valves and manifold and t臼t 由e
H制咱田间city. 也e Maintenance Droωdure B平， Test 甘1e Li甜咱
Capacity.
Part No. 31758
Genie IWP & Genie AWP
5 - 11
Service Manual - First Edition
Section 5 - Troubleshooting Flow Charts
Chart 8 Machine WiII Not Li ftDC Models
q回8ha事e瞄 eground 回mu幅·z画·刷回幅唰睬刷，耐恒由回 F回a回aKtpBh 回hι 1剧团 I 闸the motor蝴 control bOx. I !，ω阳臼。le由tmhdiuedr.eMSo3 倒b毡r，R阳SM刚i to |也lenoid.
Be sure the key switch is in the appropriate position.
rMh叫 e motorOR mMaceohn阳
Be sure the emergency stop buttons are pulled up to the ON position. Be sure the ground control box fuse is good. Be sure all display lights are on.
J蚓 ReMe『m 耐 the motor start
motor.
Advatet1e pdlaehckm由uep 仙nction and
ov ∞
T。而u卸m M胁:ict阳 1创:k叫 the 附Iy I bad
vWolmhgoentaerhmeinoarla6咱ate甘le
创∞n世tancubtyr deach|
tgemrmuinndal∞stri 怖p。ilnb由oxe-
Ma部 a阳 emmMy∞.睛。l 棚扭曲
~∞ Re『例阳翻 ctor白hedef，时ve
in 伽e
mRelapyla{sM).efedve
5 -12
Genie IWP & Genie AWP
Part No. 31758
Service Manual - First Edition
Section 5 - Troubleshooting Flow Charts
Chart 9 Machine WiII Not Lift, But Power Unit WiII OperateDC Models Be sure the key switch is in the àppropriate position. Be sure the Emergency Stop buttons are pulled up to the ON position.
Check 伽e resistance of the 阳mally 叩envalve coilon 甘le power unit.
Repla白白e 曲fective
valve ∞，il.
R部副rtheopen in wiring between 世le valve 创1 10 rnotor start solenoid and ground. CI臼nvalvesand manifold and t部1 uni1
OR ∞n恒.ctGenie
Ind出创es Servi曲
h阳tme瓜
Be sure the ground control box fuse not blown. Be sure the power unit reservoir is full.
Part No. 31758
Genie IWP & Genie AWP
5 -13
Section 5 - Troubleshooting Flow Charts
Service Manual - First Edition
Chart 10 Machine WiII Not LowerUp Function Operates
Check the pr，臼sure relief valve se俑咱·句e
~aintenanc:e p~。但dure B芋， Test Th e Li fting C叩acity.
A司ust the pr部su陀 relief valve. S回 Reoair
proωdure 3-5, How to Adjust 甘le Pressure
Relief Valve.
Repla四 theωIwn function ∞时actor in the up/down 棚it，矶
check the i~put vol恒ge 12V DCd侧n solenoid.
t。由 e
12VDC
Remove the inscection the down solenoid. Activate the platform d仰nfunction
∞，ver from
卸1d ch刨〈伽esolenoid fαoperation.
Replace the 12V DC solenoid.
由Iwn
works
Adjust the manual down
valve. 也e Repair prα:ecl ure 3-6, How to Adiust 阳Down 岛Ilenoid. Test platform
down function.
Ch创( the hydraulic system for ∞ntamination OR ∞nsult Genie Industries ServiωDepartment.
5 -14
Genie IWP & Genie AWP
Part No. 31758
Section 5 - Troubleshooting Flow Charts
Service Manual - First Edition
Chart 11 Base WiII Not Raise With Foot PumpIWP Models Be sure the pla仔'orm is fully lowered.
Check 甘1e base rdease ωblefor 时 p『.仰er
in∞W田t
Check the number 2
no
onto the mast valve.
MS5国筒如U32uα归s啕陆ftctCh阳t同GM也aromKm E咱suliM剧回由m u由s司M国阻'
eee
Be sure the base manifold is full of hydraulic fluid. Be sure to pump the foot pedal with slow , even strokes.
See 1R·3ep，HaiαrN
ApCrd曲 EjXu蛐 lset.t』1reeBase Reletoase
adjustme
∞lumn forfull ∞时act
A 但dbjules.t he base r创ease
Servi四 Department.
||SCVME怡cmk甘z1oerh|臼 yd挝ra咱uli·c
问叫 tzrmplaω ∞mponen怡.
+
kecmfuHg也wmemhkwd陆ma或黯eMomwaeogemawndkma饵o田，民dtc
怡55 甘1an
但M国pa晴l habnd叩ade恤a京M阳世M隔t T
pSI
16∞
prωsure.
Clean the system OR Industries
∞ntact Genie
ServiωDe阳此me时.
Primethe fl∞tpump.
S锦 Repair llI"∞回ure
1-3, HωtoPrimethe PumpOR ∞ntact Genie Irn::J ÍJstries Serviω Department. F∞，t
Part No. 31758
Genie IWP & Genie AWP
5 -15
Section 5 - Troubleshooting Flow Charts
Service Manual - First Edition
Chart 12 Base WiII Raise , ButWiII Not Hold In Up Position IWP Models
Check the base release cable for proper adjustment.
Adjust the base release
see Repair
ωble. prα宠dure
1-3, HαNtO
Adjust the Base Release Cable.
Dis∞nnect the hydraulic hosefrom rlωendpo此 of the base cylindei". Connecta Oto30∞ psiga啕eto
the hydraúlic hOS9.
Pumpthefl∞tpedaland
check the pr'部sure.
Prime the foot pump. Repair proωdure 1-3, H仰 to Prime 甘1e F∞，t Pump OR adjust the p!essure r，创 ief valve. 臼e Repair proc创ure1也e
3， H侧 to Adiust 甘1e Pr，ωsure Relief Valve.
OR Industries
Clean 甘1esystem
∞ntact Genie
ServiωDepa此ment.
Primethef，∞Itpump.
也e Repair~oωdure
1-3, HowtoPrimethe
F∞tPumpOR ∞ntact
Genie Industries Serviω De阳rtment.
5 -16
Genie IWP & Genie AWP
Part No. 31758
Section 5 - Troubleshooting Flow Charts
Service Manual- First Edition
Chart 13 Base WiII Not LowerIWP Models Be sure there are no obstructions under the base.
Check 甘le base release ωble for proper a咱u创ment.
Adjust the base release ωble.S回 Repair
procedure j .3, H9w to Adjust the Base Release Cable. Adjust the inner base fraine. see Repair proωdure 1.2, H仰 to Adjust the Inner Base Frame. Clean the system OR
∞ntact Genie Indus创es
Service Department.
Part No. 31758
Genie IWP & Genie AWP
5 - 17
Service Manual - First Edition
Section 5 - Troubleshooting Flow Charts
Chart 14 Platform WiII Not Hold In Up Position
R制ace 甘le 阳"咱 ∞mpo闲时(5).
Aclivate the 向阳m 叩 仙nclion 毗lile simul!aneously
aclivati咱甘le manual Ioweri咱 valve. Test 甘le
unit.
Clean valves and manifold and I臼t unit.
CI回nflow ∞附UI valve
andtest unit.
Remove and rebuild the hydraulic rlflcylinder OR
∞阳ctGe晦 Indus时es 臼rvice Depa阳e眈
5 -18
Genie IWP & Genie AWP
Part No. 31758
Service Manual - First Edition
Section 5 - Troubleshooting Flow Charts
Chart 15 Power Unit W iII Not Li ft Rated Load
Charge 1he battery OR
CheCI( ba'世erv ∞M胁n
and~邵阳ωibad ba'忧ery
OR use 1heaoorooriatë ~~ω时 O ∞nsuH
Ge时e Indus时es 如rvice D部artme眈
Part No. 31758
Genie IWP & Genie AWP
5 - 19
Service Manual - First Edition
Section 5 - Troubleshooting Flow Charts
This page intentionally left blank.
5-20
Genie IWP & Genie AWP
Part No. 31758
Service Manual - First Edition
Section 6 - Schematics
Schematics About This Section There are two groups of schematics in this section. Electrical Schematics
。bserve
Electrocution hazard. Contact with electrically charged circuits may result in death or serious injury. Remove all rings , watches and other jewelry.
and Obey:
回 Troubleshooting
and repair procedures shall be completed by a person trained and qualified on the repair of this machine.
Hydraulic Schematics
固 Immediately
tag and remove from service a damaged or malfunctioning machine.
Bodilyi时 u 叩 hazard. Spraying hydraulic oil can penetrate and burn skin. Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually. Do not allow oil to squirt or spray.
回 Repair
any machine damage or malfunction before operating the machine.
Before Troubleshooting: 回 Read ，
understand and obey the safety rules and operating instructions printed in the
General Repair Process
Genie IWP Operators Manual and the Genie A WP Operators Manual. 回 Be sure that all necessa叩 tools and test
equipment are available and ready for use.
Part No. 31758
Genie IWP & Genie AWP
6-1
Section 6 - Schematics
Service Manual - First Edition
Symbols Legend
Electrical Symbols
Wi re color
Ught
Terminal
with cable number
「一
十
T-circuits connect at terminal
T-circuits connect
Connection no terminal
十
哩三卡 Circuit breaker
皿斗四1
Circuits cr。由ing no connection
Solenoid or relay coil
z
lE| Diode
m
Emergency Stop
Ba'忧ery
bu忧on
normally closed
-e•
斗h Relay contact normally open
Resistor
Relay Contactor
Hydraulic Symbols
?
••| Cylinder
由L Relief valve
6-2
Pressure gauge
::::=‘=、二0.035
Ori自ce
with size
Relay Coil
Transformer
今
中
Filter
Fixed displacement pump
Check valve
中
①二
4 Solenoid roepcetiroanteadl 2lvpeos. , 3 way, directional va
Genie IWP &Genie AWP
dSuomlepnovidalvoepemted
---<>一
p{eu『Wmp Inepdme mover or motor)
Part No. 31758
Section 6 - Schematics
Service Manual - First Edition
Electrical Schematic AWP AC Models
BLK
BLK
WHT
1A
FOR 11 0V SR/DGE 1 TO 3 & TRANSFORMER
2 T04. (S阳湖1\1) FOR2却V BR/DGE 2
5A SB
RED 12VDC
+
\，气/
REO
1?2
TO 3 (ONI:η.
GRN厅且
BI..K
acn 空:?佣严。且石嗣同时俨
PEE-4Z寸14E
g g g
umm 刷
LOAD DOWNSOι
GRNlYEL
阴阳T
S1
筒~、"
RED
01 BιK
s2
REO D2
部
I BLK
RED
D3
s4
REO M
LEGENO:
CAS CR
CONTROιAC百VAlë SW/TCH
o
DIODE
ES KS
KEY SwrTCH
COHTROιRELAY
EMERGENCY STOP SWIl古H
ιUGHT (LED)
MC
MOτORCONTAC丁。同
NOV
NORMALLYOPENVALVE
PB
POWER TO BASKET (GRαJNO FAULTCIRCUIT INlëRRU阿7
S
S阳7四1-αJTI'!IGGER
SB
SLOW BLOW RJSE
s。ιSOιENαD
TOR
O
T1ME DELAY RELAY
削DlCAlëS CONlROL回IXC倒即1剧
Part No. 31758
Genie IWP & Genie AWP
6-3
Section 6 - Schematics
Service Manual - First Edition
Electrical Wiring Diagram AWP AC Models
i;
一一」
L 〉。""‘
辛。，， d‘ g
L/飞
6-4
Genie IWP & Genie AWP
Part No. 31758
Service Manual - First Edition
Section 6 - Schematics
Electrical Wiring Diagram AWP AC Models
E立一
z
自哥哥司制
L
Part No. 31758
一
Genie IWP & Genie AWP
~
一一一'1
11
6-5
Service Manual - First Edition
Section 6 - Schematics
Electrical SchematicAWP DC Models
GRN/YEl
BLK
5A SB \_/
BιK
E g g g
REO
型生旦旦尘己严少3 日|同时 t
BLK
BlUE 。R
YEl Sl
I
DO帆刷 s。ι
i
M排fT
17
REO
RE,
s2
GRN/YEL
\ /
筒。随
REO
D l:'nJDI ~
01 l唱
/\
GRN/YEL
i 02
s3
REO
03
s4
LEGENO: CAS CA o ES KS L MC NOV PB S SB SOL
o 6-6
REO
D4 CONTAOlACTIVATESW/TCH CONTROl AELAY O/OOE EMEAGENCY STOP SW/TCH KEYSW/TCH LlGHT (LEO) MOTOA CONTACTOR NORMAllY OPEN VAlVE POWER TO BASKET (GROUNO FAULT C/RCU汀 INTERRUPη SW/TCH - OUTR/GGER SLOW BlOW FUSE SOLENO/O
INO阳'ES ∞NTROL 回IX CONNECT/ON
Genie IWP &Genie AWP
Part No. 31758
Service Manual - First Edition
Section 6 - Schematics
This page intentionally leäť&#x2022; blank.
Part No. 31758
Genie IWP & Genie AWP
6-7
Section 6 - Schematics
Service Manual - First Edition
Electrical Wiring Diagram AWP DC Models
ç&#x201D;ťl
L
6-8
Genie IWP &Genie AWP
Part No. 31758
Service Manual - First Edition
Section 6 - Schematics
Electrical Wiring Diagram AWP DC Models
「τ
-P 且主建』KUUHM 386244 ‘Meg吨 a， -
白但 Z去呈阳 ezgE 〈U
z
剖面
h回回
回〉呈筐。
l
-4 司d M瑞町 hE 部 回到
叫晴圆圆同
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--.'" -.-.. --‘'.
一一一一一---…一一一'一申……--------一……--一-一---……-----一一一一…·一一一-------一一一一-一-…叶-，
Part No. 31758
Genie IWP & Genie AWP
6-9
Section 6 - Schematics
Service Manual - First Edition
Electrical SchematicIWP AC Models
BLK
帆刷T
1A
8
5A SB
I
FOR 110V BRIDGE 1 TO 3 晶 2 TO 4. (SHOWN) FOR 220V BRIDGE 2 TO 3 (ONLη.
RED
GRNlYEL
12VDC + RED
四-M
2FV EH-RH E』
-0
ω只川
RUL RS EP
BLK
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o 6 - 10
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INDICATE5 CONTROL BOX CONNECTION
Genie IWP & Genie AWP
Part No_ 31758
Service Manual - First Edition
Section 6 - Schematics
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Part No. 31758
Genie IWP & Genie AWP
6 - 11
Section 6 - Schematics
Service Manual - First Edition
Electrical Wiring Diagram IWP AC Models
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Part No. 31758
Service Manual - First Edition
Section 6 - Schematics
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Genie IWP & Genie AWP
6 - 13
Service Manual - First Edition
Section 6 - Schematics
Electrical Schematic IWP DC Models
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6 - 14
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Genie IWP & Genie AWP
Part No. 31758
Service Manual - First Edition
Section 6 - Schematics
This page intentionally left blank.
Part No. 31758
Genie IWP & Genie AWP
6 - 15
Section 6 - Schematics
Service Manual - First Edition
Electrical Wiring Diagram IWP DC Models
92
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6 -16
Genie IWP & Genie AWP
Part No. 31758
Service Manual - First Edition
Section 6 - Schematics
Electrical Wiring Diagram IWP DC Models
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Genie IWP & Genie AWP
11帝国 6 -17
Service Manual - First Edition
Section 6 - Schematics
Hydraulic Schematic AWP Models
ä¸&#x20AC;I CHECKVALVE
MANUAL
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HYDRAULlC
6 -18
POWER UNIT
Genie IWP & Genie AWP
Part No. 31758
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Section 6 - Schematics
Service Manual - First Edition
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6-20
Genie IWP & Genie AWP
Part No. 31758
Section 7 - Repair Procedures
Service Manual - First Edition
Repair Procedures About This Section Most of the procedures in this section should only be performed by a trained service professional in a suitably equipped workshop. Select the appropriate repair procedure after troubleshooting the problem.
。bserve
and Obey:
回 Repair
procedures shall be completed by a person trained and qualified on the repair of this machine.
回 Immediately
tag and remove from service a damaged or malfunctioning machine.
Perform disassembly procedures to the point where repairs can be completed. Then to re-assemble , perform the disassembly steps in reverse order. General Repair Process
回 Repair
any machine damage or malfunction before operating the machine.
Before Repairs Start: 回 Read ，
understand and obey the safety rules and operating instructions in the Genie IWP Operator's Manual and the
Genie AWP Operator's Manual. 回 Be
sure that all necessa叩 tools and parts are available and ready for use.
Symbols Legend
回 Read
each procedure completely and adhere to the instructions. Attempting shortcuts may produce hazardous conditions.
ri电吁!1 过司主:事
Indicates the presence of a hazard that will cause death or senous InJU 叩. Indicates the presence of a hazard that may cause death or senous InJU 叩. Indicates the presence of a hazard that will or may cause serious inju 叩 or damage to the machine. Indicates special operation or maintenance information.
o
Part No. 31758
Indicates that a specific result is expected after performing a series of steps.
Genie IWP & Genie AWP
7 -1
Section 7 - Repair Procedures
Service Manual - First Edition
Base Assembly 5 Loosen the squeeze connector and pull the wires out of the junction box.
1-1 Proximity Switches AWP models: The proximity switches indicate proper installation of the outriggers and allow the machine to operate only when the outriggers are installed and adjusted. IWP models: The proximity switches indicate that all four base contact points are in firm ∞ntact with the ground.
6 Follow the wires to the grommets where the wire enters and exits the base tube. Pull the grommets out of the base tube , then pull the wires through the grommets and base tube. 7 Grasp the proximity switch mounting bracket inside the base outrigger socket and pull it out with the wires. 事噩 ITill(撞撞 Proximity switches must be
adjusted when reassembled to be sure of proper operation.
How to Remove a Proximity Switch - AWP Models 1 Fully lower the pla甘'orm， turn the machine off and remove the key. Then store the outriggers in the storage sockets. 2 Remove the proximity switch mounting fasteners from the outrigger base socket.
How to Adjust a Proximity Switch -AWP Models 1 With the proximity switch installed and wired , install the outrigger into the base socket. 2 Turn the machine on and adjust the outrigger
screw jack clockwise until the foot pad is in firm contact with the ground.
3 Check the corresponding interlock display Iight. The Iight should be on. If the Iight comes on , proceed to step 5. 4 If the Ii ght does not come on , loosen the two mounting fasteners and slide the fasteners with the proximity switch bracket upward until the Ii ght comes on. Tighten the mounting fasteners.
a b c
junction box ∞，ver base proximity switch mounting f臼tener
3 Remove the base junction box cover.
5 Adjust the outrigger screw jack counterclockwise until the foot pad is 2 inches (5 cm) off the ground. 6 Check the corresponding interlock display Ii ght. The Ii ght should be off. If the Ii ght is off, the switch is adjusted correctly.
4 Trace the proximity switch wires into the junction box and locate the relay that the switch is connected to. Remove the red wire from the relay and cut the corresponding black wire. Then clip the connectors off the wires.
7-2
Genie IWP & Genie AWP
Part No. 31758
Section 7 - Repair Procedures
Service Manual - First Edition
BASE ASSEMBLY
7 If the light does not turn off, loosen the two mounting fasteners and slide the fasteners with the proximity switch bracket downward until the light is off. Tighten the mounting fasteners. 8Repeat steps 2 through 6. 噩 al)~[锋事 If proper adjustm朋t cannot be
obtained , contact Genie Industries Service Department.
5 Loosen the squeeze connector and pull the wires out of the junction box. 6 Remove the mounting bolts from the proximity switch mounting plate. Then remove the proximity switch assembly from the base tube. Access the switch from the hole located on the inside of the base tube. Note how many threads of the proximity switch are above the switch mounting plate. This will provide a starting point for proximity switch installation.
How to Remove a Proximity Switch - IWP Models Fully lower the platform , turn the machine 0何 and remove the key. 2 Pull the base release handle to fully lower the base.
How to Adjust a Proximity Switch -IWP Models Install the proximity switch into the mounting plate , and adjust to the starting point position noted in the removal procedure.
3 Remove the base manifold and base junction box covers.
2 Adjust the proximity switch to obtain a distance 。f 0.884 inches (22 .4 mm) between the top of the switch to the top of the mounting plate.
」
c
aJ a b
lb a b c d
junction box cover manifoldcover
4 Trace the proximity switch wires into the junction box and locate the relay that the switch is connected to. Remove the wires from the relay. Then clip the connectors off the wires.
Part No. 31758
d
sili∞neadhesive
proximity switch mounting plate proximity switch 0.884 inches (22.4 mm) distance
3 Apply silicone adhesive to the wire side of the mounting plate.
Genie IWP &Genie AWP
7-3
Section 7 - Repair Procedures
Service Manual - First Edition
BASE ASSEMBLY
4 Install the switch assembly into the base tube. Then route the wires from the switch to the junction box. Remove the excess slack from the wires and tighten the squeeze connector. 00 not allow the wires to twist. Proximity switch adjustment may change if the wires are twisted. 5 Connect the wires to the relay and replace the junction box cover. 6 Test the proximity switches. See Maintenance procedure B-11 , Test the Level Sensing Operation - IWP Models.
How to Adjust the Inner Base Frame 1 Pull the base release handle to fully lower the base. 2 Turn the machine on and raise the platform slightly. Then fully lower the platform. This will fully raise the inner base frame. 3 Check for side-to-side movement of the inner base frame. The inner base frame should have no side-to-side clearance and not be too tight to cause dragging or binding. When adjusting the inner base frame , it may be necessa叩 to allow minimal side-to-side clearance to obtain no dragging or binding.
1-2 Inner Base Frame - IWP Models How to Remove the Inner Base Frame This procedure requires specific repair skills , lifting equipment and a suitable workshop. Attempting this procedure without these skills and tools may result in death or serious i 时 ury and significant component damage. Oealer service is strongly recommended.
4 To adjust, loosen the lock nut on the roller wheel axle and turn the axle clockwise to decrease the clearance , or counterclockwise to increase the clearance. Hold the 拟le from turning and tighten the lock nut. 5 Measure the distance between the inner and outer base frames at both the front and back on one side. Make the proper adjustments to obtain equal distances. Maintain squareness between the inner and outer base frames. This will allow the machine to have even clearance on all four base contact points.
Pull the base release handle to fully lower the base. 2 Remove the mounting bolt from the base lift cylinder rod end. Li位 the rod end of the cylinder up and tie it to the base. 3 Using a forklift , carefully lift the machine off of the inner base frame. 00 not allow the inner base frame to fall when lifting the machine.
6 Raise and lower the inner base frame with the foot pump to check for dragging or binding. Re-adjust if necessa叩.
Crushing hazard. The machine may fall , if it is not properly supported by the forklift.
7-4
Genie IWP & Genie AWP
Part No. 31758
Service Manual - First Edition
Section 7 - Repair Procedures
BASE ASSEMBLY
1-3 Hydraulic Manifold Components - IWP Models Index No.
Schematic Item
Description
Function
Torque
Flow regulator valve …… ..................L ........… Base lowering
........…"…...............…8- 10 作 Ibs
1 11-1 4 Nm
..........… ........................10-12 仕-Ibs
2
Manual release valve ......…........…·… K ........... Lowers base
3
Relief valve , 1600 psi (110 bar) ........ J ............ Foot pump ............……………..… ......25-30 ft-Ibs 1 34-41 Nm
4
Foot pump …….......…........….............M....…... Outer base frame
.............................8户10 作 Ibs
114-16 Nm
111-14 Nm
2
Plug Torque Specifications Description
4
Part No. 31758
Hex Size
Torque
SAE No. 2
1/8
50 in-Ibs 1 6 Nm
SAE No. 4
3116
13 仕-Ibs
SAE No. 6
1μ
18 ft-Ibs 1 24 Nm
SAE No. 8
5116
50 ft-Ibs 1 68 Nm
SAE No. 10
9116
55 何-Ibs
SAE No. 12
5/8
118 Nm
175 Nm
75 ft-Ibs 1102 Nm
3
Genie IWP & Genie AWP
7-5
Section 7 - Repair Procedures
Service Manual - First Edition
BASE ASSEMBLY
How to Adjust the Pressure Relief Valve Component damage hazard. The work area and surfaces where this procedure will be performed must be clean and free of debris that could get into the hydraulic system and cause severe component damage. Oealer service is recommended.
How to Adjust the Base Release Cable Pull the base release handle to fully lower the base. 2 Remove the cover from the base manifold. 3 Loosen the set screw or the lock nuts on the base release cable.
1 Pull the base release handle to fully lower the base. 2 Oisconnect the hydraulic hose from the port on the rod end of the base cylinde r. Cap the cylinder port. Bodily injury hazard. Spraying hydraulic oil can penetrate and burn skin. Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually. 00 not allow oil to squirt or spray. 3 Connect a 0 to 3000 psi (0 to 206 bar) pressure gauge to the hydraulic hose. 4 Slowly pump the foot pedal and check the pressure.
o
Resul t: The pressure gauge should read 1600 psi :t 50 psi(11 0 bar :!: 3 .4 bar). Adjust if necessaĺ?Š.
a b c
base manifold set screw or lock nut base release cable
4 Push the base release handle fully in. Position the handle 5116 inch (7.9 mm) from the cable mounting nut. Then tighten the set screw or lock nuts.
5 Hold the relief valve and remove the hex cap (item 3). 6 Adjust the internal hex socket. Turn it clockwise to increase the pressure or counterclockwise to decrease the pressure. Then install the relief valve cap. Ti p-over hazard. 00 not adjust the relief valve higher than recommended. It is set to prevent a ti p-over or unsafe operation. 7 Pump the foot pedal and re-check the pressure. Re-adjust if necessary.
7-6
Genie IWP & Genie AWP
a b c
base release handle inch (7 .9 mm) clearance cable mounting nut
5116
Part No. 31758
Service Manual - First Edition
Section 7 - Repair Procedures
BASE ASSEMBLY
5 Pump the foot pedal to raise the base.
How to Prime the Foot Pump
<:> Result: The base should not lower.
1 Pull the base release handle to fully lower the
6 Pull the base release handle to be sure the base lowers. Re-adjust if necessaĺ?Š.
How to Remove the Foot Pump Component damage hazard. The work area and surfaces where this procedure will be performed must be clean and free of debris that could get into the hydraulic system and cause severe component damage. Dealer service is recommended.
1 Pull the base release handle to fully lower the base. 2 Pull and hold the base release handle. Then press and hold the foot pedal down.
3 While holding the foot pedal down , remove the nut from the linkage mounting fastener on the foot pump rod.
4 Release the foot pedal.
2 Pull and hold the base release handle. Then press and hold the foot pedal down.
3 While holding the foot pedal down , remove the nut from the linkage mounting fastener on the foot pump rod.
4 Release the foot pedal.
5 Hold the spring and remove the mounting bolt. Then release the spring.
6 Pull and hold the base release handle. Then push the foot pump rod in as far as it will go.
7 Release the base release handle and pull the foot pump rod out 2 inches (5 cm). Do not allow the rod to come completely out of the pump.
8 Repeat steps 6 and 7. 9 Check the hydraulic fluid leve l. The fluid level should be 3/8 inch (9.5 mm) below the breather cap
5 Hold the spring and remove the mounting bolt. Then release the spring.
6 Remove the foot pump from the manifold. Plug the manifold
base.
poćŻ&#x201D;
poĺ&#x2021;Ą
10 Re-assemble the foot pump linkage and check the foot pump operation. The base should reach full height after 8 to 10 pumps on the foot pedal.
The foot pump must be primed after installation.
Part No. 31758
Genie IWP
&Genie AWP
7-7
Section 7 - Repair Procedures
Service Manual - First Edition
Ground Control Box 2-2 How to Test the Transformer -AC Models
2-1 Ground Control Box
How to Test a Relay Label and then disconnect all the wiring from the relay to be tested.
2 Connect the leads from an ohmmeter or continuity tester to each terminal combination and check for continuity. Terminals 85 and 86 represent the coil and should not be tested in any other combination.
Fully lower the platform , turn the key switch off and disconnect the power supply.
2 Open the ground control box and locate the transformer. 3 Label and then disconnect all wiring from the transformer. 4 Connect the leads from an ohmmeter to the following terminal combinations and check the resistance.
abed terminal no. 30
terminal no. 86 terminal no. 87 terminal no. 85 Test
Desired result
terminal 85 to 86
85t095Q
terminal 87 to 30
no continuity (infinite Q)
3 Connect 12V DC to terminal 85 and a ground wire to terminal 86 , then test the following terminal combinations. Test terminal 87 to 30
7-8
Desired result continuity (zero Q)
Genie IWP & Genie AWP
abedefghij terminal no. 1
terminal no. 2 terminal no. 3 terminal no. 4 terminal no. 5 terminal no. 6 terminal no. 7 terminal no. 8 terminal no. 9 terminal no. 10
Part No. 31758
Section 7 - Repair Procedures
Service Manual - First Edition
GROUND CONTROL BOX
Desired result
Test
Test
Desired result
terminals 1 to 2
12t014n
terminal a to b
terminals 3 to 4
12t014n
terminal 7 to 4 , 9 , 6 and 3
terminals 6 to 7
0.4 to 1 n
no continuity (infinite n)
terminals 8 to 7
0.4 to 1 n
terminal 5 to 6 , 7 , 4 and 1
no continuity
95t0105n
terminal 7 to 1
continuity (zero n)
terminal 9 to 3
continuity
2-3
How to Test the AC Contactor -AC Models Fully lower the platform , turn the key switch off and disconnect the power supply.
2 Open the ground control box and locate the AC
5 Push and hold the blue button , then test the following terminal combinations. Test
Desired result
terminal 7 to 1
no continuity (infinite n)
terminal 9 to 3
no continuity
terminal 7 to 4
continuity
contactor.
3 Label and then disconnect all wiring from the contacto r.
(zero n)
4 Connect the leads from an ohmmeter to the following terminal combinations and check the continuity/resistance.
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G ă&#x20AC;&#x2039;h
Part No. 31758
terminal 9 to 6
continuity
terminal no. a terminal no. 7 terminal no. 4 terminal no. 1 terminal no. 3 terminal no. 6 terminal no. 9 terminal no. b Genie IWP
&Genie AWP
7-9
Section 7 - Repair Procedures
Service Manual - First Edition
GROUND CONTROL BOX
6 Connect the black lead (-) to the center terminal. Then connect the red lead (+) to the right terminal.
2-4
How to Test the Rectifier -AC Models
o
Fully lower the platform , turn the key switch off and disconnect the power supply.
7 Connect the black lead (-) to the right terminal. Then connect the red lead (+) to the center terminal.
2 Open the ground control box and locate the rectifier assembly.
3 Tag and then disconnect all wiring from the rectifier.
Resul t: Meter should indicate continuity (100 to 130 kQ).
o
Resul t: Meter should indicate no continuity (infinite Q).
4 Connect the black lead (-) from a multi-meter to the center termina l. Then connect the red lead (+) to the left terminal.
o
Resul t: Meter should indicate continuity (100 to 130 kQ).
a b c
leftterminal centerterminal rightterminal
5 Connect the black lead (-) to the
leä˝? terminal.
Then connect the red lead (+) to the center termina l.
o
Resul t: Meter should indicate no continuity (infinite Q).
7 -10
Genie IWP & Genie AWP
Part No. 31758
Service Manual - First Edition
Section 7 - Repair Procedures
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Part No. 31758
Genie IWP & Genie AWP
7 - 11
Section 7 - Repair Procedures
Service Manual - First Edition
Hydraulic Power Units 3- 1
Hydraulic Power Unit Components -AC Models Index No.
Description
2
Adaptor plate ..... ...…................…….........…..... Connects motor to manifold
3
Relief valve .....................................…............... Hydraulic relief valve adjustment
4
Relief valve cap ........................................…..... Locks and seals relief valve
Function
11 5-230V AC electric motor .......……"…......….. 2 horse power, single phase - 2850/3450 rpm , 50/60 Hz.
5
12V DC coil..............…...................................... Activates N.O. dump valve
6
Solenoid operated N.O. dump valve ................ Diverts pump output back to reservoir during motor start up
7
Check valve ...…................................................ One way valve for pump output
8
Coupler ..............................…..............……........ Connects motor to pump
9
O-ring....... ….......…............................................ Seals reservoir
10
Pump ....................….........…............................. 0.65 gallon per minute at 1600 psi 2.5 liters per minute at 110 bar
11
Suction cover ... .... ....…….........…....................… Connect suction line to pump
12
Reservoir ...........…..................….........…........... 5.5 quarts / 5.2 liters
13
Plug......................….........….............................. Reservoir drain
14
Sight gauge .................…...................……·…...... Hydraulic fluid level
15
Breather cap ..................................................... Reservoir vent
16
Suction strainer ..........................…................... Filters hydraulic fluid
17
12V DC solenoid ............................................... Activates lowering valve
18
Loweri ng valve.. ......…....................................... Releases hydraulic fluid from cylinder back to reservoir to lower platform
19
Manifold ….........……..….......….......…................. Connects pump to motor and controls hydraulic fluid flow
20
Capacitor ...........…..................….........…........... Motor start circuit
7 - 12
Genie IWP & Genie AWP
Part No. 31758
Service Manual - First Edition
Section 7 - Repair Procedures
HYDRAU Ll C POWER UNITS
① ①
①①①
20
19
9
10
11
@
12
@ 14
13
Part No. 31758
Genie IWP & Genie AWP
7 -13
Section 7 - Repair Procedures
Service Manual - First Edition
HYDRAU Ll C POWER UNITS
3-2
Hydraulic Power Unit Components - DC Models Index No.
Description
Function
12V DC electric motor ............. .....…………… 12V DC 130 amp standard duty 1 terminal permanent magnet
2
Coupler..……...........................…....................... Connects motor to pump
3
Relief valve ...........….........................…............. Hydraulic relief valve adjustment
4
Relief valve cap ...............….........….........…...... Locks and seals relief valve
5
Check valve .....................…................…........… One way valve for pump output
6
12V DC coil...........................…......................... Activates N.O. dump valve
7
Solenoid operated N.O. dump valve ................ Diverts pump output back to reservoir during motor start up
8
O-ring ................................................................ Seals reservoir
9
Pump ................................…............................. 1 gallon per minute at 1600 psi 3.8 liters per minute at 110 bar
10
Suction cover .......…….......…..............….........… Connect suction line to pump
11
日eservoir …….........…·……......….........………… 3
quarts / 2.8 liters
12
Plug ................................................................... Reservoir drain
13
Sight gauge ......................…......................….... Hydraulic fluid level
14
Breather cap ...........….........…...............…......... Reservoir vent
15
Suction strainer ..............…........….................… Filters hydraulic fluid
16
12V DC solenoid ............................................... Activates lowering valve
17
Lowering valve.. …............................................. Releases hydraulic fluid from cylinder back to reservoir to lower platform
18
Manifold ..….......…….....................……......…….. Connects pump to motor and controls hydraulic fluid flow
19
Motor start solenoid ...........…·…….......…........... Relay connecting power supply to electric motor
7 -14
Genie IWP & Genie AWP
Part No. 31758
Service Manual- First Edition
Section 7 - Repair Procedures
HYDRAU Ll C POWER UNITS
① 19
① ①
5
① ①
18
@ 8
9
10
@
14
11
@ 12
Part No. 31758
Genie IWP & Genie AWP
7 -15
Section 7 - Repair
Pr∞edures
Service Manual - First Edition
HYORAU Ll C POWER UNITS
3-3
3-4
How to Remove the Hydraulic Power Unit
How to Remove the Hydraulic Pump
1 Fully lower the platform , turn the machine off and remove the key.
1 Fully lower the platform, turn the machine off and remove the key.
2 IWP models: Pull the base release handle t。 fully lower the base.
2 IWP models: Pull the base release handle to fully lower the base.
3 Remove the plastic cover from the power unit.
3 Remove the plastic cover from the
4 Tag , disconnect and plug the hydraulic hoses. Cap the fittings on the power unit.
4 Support the hydraulic reservoir with a lifting device.
Bodily injury hazard. Spraying hydraulic oil can penetrate and burn skin. Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually. 00 not allow oil to squirt or spray. 5 Tag and disconnect the electrical wiring from the down solenoid and valve coi l. 6 DC models: Tag and disconnect the electrical wiring from the motor start solenoid. AC models: Remove the cover from the junction box on the motor. Then tag and disconnect the electrical wiring in the junction box. Loosen the squeeze connector on the junction box and pull the wiring out through the squeeze connector.
po响er
unit.
5 Remove the mounting fasteners from the reservoir. Then carefully remove the reservoir from the po叩ver unit. 00 not allow the hydraulic oilto spill. 噩重 nllH毒草草 It may be necessary to 恒pthe
side of the reservoir with a soft rubber mallet to loosen it. 6 Remove the mounting fastener from the suction cover assembly on the pump. Then remove the suction cover. 7 Remove the mounting fasteners from the pump. Then rem。叫le the pump from the power unit. 重噩 a.1H毒草噩 When installing the reservoir, be
ure not to damage the o-ring.
7 Support the hydraulic power unit with a lifting device. 8 Remove the mounting fasteners from the power unit, then remove the power unit from the machine. Crushing hazard. The power unit will fall unless it is properly supported. If a new power unit is installed , the pressure relief valve must be properly adjusted. See 3-5 , How 归 Adjust the Pressure Relief Valve.
7 -16
Genie IWP & Genie AWP
Part No. 31758
Service Manual - First Edition
Section 7 - Repair Procedures
HYDRAU Ll C POWER UNITS
3-5
How to Adjust the Pressure Relief Valve 1 Remove the motor cover if applicable. 2 Remove the white tag from the relief valve cap located on the right side of the motor (if applicable) . 3 Remove the relief valve cap. 4 Remove the pipe plug from the reservoir. 5 FiII the reservoir up to the sight glass with Oexron " ATF hydraulic oil equivalen t.
12 Add an additional30 pounds (14 kg) to the platform. Secure the additional weigh t. 13 Raise the platform slightly. 14 The power unit should not be able to lift the platform. If the power unit lifts the platform , turn the relief valve counterclockwise until the aĺ?Ť ustment is correct. 15 Bleed the hydraulic system by raising machine to full height. If pump cavitates or machine fails to reach full height , add hydraulic oil until pump is functioning correctly. 00 not overfill the reservolr. Component damage hazard. 00 not continue to operate machine if hydraulic pump is cavitating.
6 Install the breather cap elbow. 7 Follow the appropriate operator's manual to set up the machine. Be sure to properly install all four outriggers , if applicable.
16 Install the relief valve cap , breather cap and the motor cover.
8 Place maximum rated load into the plaç&#x201D;&#x2DC;orm. Secure the load to the platform. Model
Maximum Load
AWP-36
250lbs
113 kg
AWP-30
300lbs
136 kg
AWP-24
300lbs
136 kg
AWP-19
300lbs
136 kg
IWP-19
350lbs
159 kg
IWP-24
350lbs
159 kg
9 Raise the platform slightly. 10 Turn the relief valve screw clockwise , just until the machine begins to lift. 11 Fully lower the platform.
Part No. 31758
Genie IWP & Genie AWP
7 - 17
Section 7 - Repair Procedures
Service Manual - First Edition
HYDRAU Ll C POWER UNITS
。 Result:
3-6
How to Adjust the Down Solenoid Fully lower the platform.
The pla甘orm down speed should not increase when the manuallowering lever is pulled.
7 Raise the platform to maximum height.
2 Remove the inspection cover from the down solenoid.
8 Activate the pla甘orm down function from the platform controls.
<:> Result: The platform should lower. If the down solenoid does not operate as described , re-adjust the solenoid gap.
3-7
How to Check the Resistance 01 a Valve Coil Fully lower the platform , turn the machine off and remove the key.
2 Connect the leads from an ohmmeter to the valve coil terminals. abcdef
down solenoid solenoid pin valve rod adjustment bolt locknut
inspection cover manuallowering handle 3 Push the manual lowering handle and measure the gap between the solenoid pin and the valve rod adjustment bolt.
<:> Resul t: The gap should be 0.060 to 0.070 inches (1.5 to 1.7 mm). 4 To adjust the gap, loosen the lock nut on the
valve rod and turn the adjustment bolt clockwise to increase the gap or counterclockwise to decrease the gap. 5 Raise the
pla甘orm
10 feet (3 m).
6 Activate the down function in the pla仔Orm and have a second person pull the manual lowering lever. 7 - 18
Valve coil specifications Solenoid operated N.O. valve , 10V
70
Solenoid operated N.O. valve , 12V
100
Genie IWP & Genie AWP
Part No. 31758
Service Manual - First Edition
Section 7 - Repair Procedures
HYDRAU Ll C POWER UNITS
3-8
3 Connect 12V DC to one of the small posts and a ground wire to the other small post , then test the following terminal combinations.
How to Test the Motor Start Solenoid Electrocution hazard. Contact with electrically charged circuits may result in death or serious i叶 U叩Remove all rings , watches and other jewelry.
Test 2 large posts
Desired result continuity (zero n)
Electrocution hazard. Disconnect the ground cable from the battery before performing this procedure. Label and disconnect all the wiring from the motor start solenoid. 2 Connect the leads from an ohmmeter to each terminal combination and check for continuity. Desired result
Test 2 small posts
13 to 17 n
2 large posts
no continuity (infinite n)
Any small post to any large post
no continuity (infinite n)
a b
Part No. 31758
high amp power ∞ ntactterminal (Iarge post) solenoid activate coil terminal (small post)
Genie IWP & Genie AWP
7 -19
Service Manual - First Edition
Section 7 - Repair Procedures
Power Pack ç&#x2030;&#x203A;1
How to Change a Power Pack
10 Label , disconnect and plug the hydraulic hoses from the moto r. Bodily injury hazard. Spraying hydraulic oil can penetrate and burn skin. Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually. 00 not allow oil to squirt or spray.
Fully lower the platform and disconnect the machine from the power source. IWP models: Pull the base lowering handle to lower the base.
2 3 4 5
Remove the power unit cover. Separate both quick disconnect couplers. Unplug the quick disconnects.
11 Support the power pack and remove the power pack mounting bolts. Crushing hazard. When mounting bolts are removed , power pack will become unbalanced and may fall if not properly supported.
DC models: Oisconnect the battery cables from the motor.
6 Oisconnect the power cable tension spring. Then remove the spring bolt that attaches to the back of the power pack mounting plate. The spring bolt will be reused on the new power pack. (Note: spring bolt is not used on 19 foot mode l.)
7
AWP 19 and 24 models: Remove the loading wheel on the motor side.
12 Remove the power pack.
Installation Reassemble in the reverse order of disassemble procedure.
8 Remove the breather cap from the hydraulic power unit and install a pipe plug into the filler hole.
9 AWP 19 models: Remove the wire clamp on the back of the power pack mounting plate holding the power cable.
00 not install the motor cover until the relief valve adjustment is complete. Refer to 3-5 , How to Adjust the Pressure Relief Valve. Component damage hazard. 00 not overtighten the hydraulic fittings.
abede return Ji ne high pressure Ji ne pressure relief valve plug notused
7 - 20
Genie IWP & Genie AWP
Part No. 31758
Service Manual - First Edition
Section 7 - Repair Procedures
Mast Assembly MAST - 4 COLUMN
MAST - 5 COLUMN e
e
e
e
••
g
h
Mast Components - 4 Column a number 1 column b number2column c number 3 column d number 4 column
Mast Components - 5 Column a number 1 column b number2 ∞ lumn c number 3 column d number 4 column
e
carriage
e
9 h
number 2 column idler wheel assembly number 3 column idler wheel assembly number 4 column idler wheel assembly
9 h
Part No. 31758
Genie IWP & Genie AWP
臼 mage
number 5 column number 2 column idler wheel assembly number 3 column idler wheel assembly number 4 column idler wheel assembly number5 ∞lumn idlerwheel assembly
7 -21
Service Manual - First Edition
Section 7 - Repair Procedures
MAST ASSEMBLY
5 Remove the socket head retaining bolt from the clevis block on the lift cylinder rod end.
5-1 Lift Cylinder How to Remove the Li ft Cylinder This procedure requires specific repair skills , lifting equipment and a suitable workshop. Attempting this procedure without these skills and tools may result in death or serious injury and significant component damage. Oealer service is strongly recommended. 1 Fully lower the platform , turn the machine and remove the key.
⑤
@
0何
AWP models: Remo叫fe the outriggers from the outrigger storage socket. 2 Remove the breather cap from the hydraulic power unit and install a plug into the filler hole. 3 Attach an overhead crane to the back of the mast near the top.
a b c
top 01 no. 1 column retaining bolt clevis block
6 Oisconnect and plug the lift cylinder hydraulic hoses. Cap the fittings on the lift cylinder.
4 Li ft the machine slightly and then while lowering it , guide it over onto the platform. Before the pl甜orm reaches the ground , place a saw horse under the mast just above the platform. Lo响er the machine onto the saw horse. Be sure the saw horse is of ample capacity.
Bodily inju 叩 hazard. Spraying hydraulic oil can penetrate and burn skin. Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually. 00 not allow oil to squirt or spray.
Crushing hazard. The machine will fall unless it is properly supported with the overhead crane.
7 - 22
Genie IWP & Genie AWP
Part No. 31758
Service Manual- First Edition
Section 7 - Repair Procedures
MAST ASSEMBLY
7 AWP models: Remove the mounting fasteners from the cylinder mounting brackets.
8
Suppo此 the
cylinder and carefully slide it out of the bottom of the mast. Crushing hazard. The lift cylinder will fall unless it is properly supported.
5-2
How to Remove the Mast Assembly - AWP Models This procedure requires specific repair skills , lifting equipment and a suitable workshop. Attempting this procedure without these skills and tools may result in death or serious i时 ury and significant component damage. Dealer service is strongly recommended. a b c d
mounting fastener cylinder mounting bracket base liftcylinder
IWP models: Remove the mounting fasteners from the right side cylinder mounting bracket. Remove the fastener that attaches the valve mounting bracket to the right side cylinder mounting bracket. Remove the cotter pins from the cylinder barrel-e nd mounting pin and remove the pin.
飞过』
1 Fully lower the platform , turn the machine off and remove the key. 2 Remove the platform. See 7-1 , How to Remove
an Aluminum Platform. 3 Remove the power pack. See 4-1 , How to Change a Power Pack. 4 AWP 30 and 36 models: Remove the tilt-back frame. See 6-1, How to Remove the 百~t-back
Frame. 5 Attach an overhead crane to the back of the mast near the top. 6 Place a saw horse in front of the machine where the top of the mast will rest.
a b c d
Part No. 31758
bracket moun回ng fasteners cylinder mounting pin cylinder mounting bracket hydrauliccylinder
Genie IWP & Genie AWP
7-23
Section 7 - Repair Procedures
Service Manual - First Edition
MAST ASSEMBLY
7 Li ft the machine slightly and then while lowering it, guide it over onto the saw horse. Be sure the saw horse is of ample capacity.
AWP 30 and 36 models: Remove the rubber grommet from the access hole in the mast support angle. Carefully pull the hydraulic hoses down and out through the bottom of the mast. Then pull the electrical cables ou t. 15 Attach a Iifting device to the base. 16 Carefully lift and remove the base from the mast. 00 not damage the Iift cylinder hydraulic fittings when removing the base. Crushing hazard. The base will fall unless it is properly supported.
Crushing hazard. The machine will fall unless it is properly supported with the overhead crane.
How to Remove the Mast Assembly - IWP Models This procedure requires specific repair skills , lifting equipment and a suitable workshop. Attempting this procedure without these skills and tools may result in death or serious i 时 ury and significant component damage. Oealer service is strongly recommended.
8 Attach the overhead crane to the base. 9 Li ft the base slightly and place a second saw horse under the mast near the base. Lower the mast onto the saw horse. 10 Oisconnect and cap the lift cylinder hydraulic hoses. Remove the flow control valve from the cylinder. Plug the cylinder ports. Bodilyi时U叩 hazard. Spraying hydraulic oil can penetrate and burn skin. Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually. 00 not allow oil to squirt or spray.
11 Remove the cotter pins from the Ii ft cylinder barrel end mounting pin. Remove the pin. 12 Remove the fasteners that mount the strut bracket(s) to the mast.
1 Fully lower the platform , turn the machine off and remove the key. 2 Pull the base release handle to fully lower the base. 3 Remove the pla仔Orm. See 7-1 , How to Remove an Aluminum Platform. 4 Remove the power pack. See 4-1 , How to Change a Power Pack. 5 Oisconnect and cap the Iift cylinder hydraulic hoses. Remove the flow control valve from the cylinde r. Plug the cylinder ports.
13 Remove the four base mounting fasteners. 14 AWP 19 and 24 models: Remove the cable attachment brackets from the side of the mast.
7 - 24
Genie IWP & Genie AWP
Bodily inju 叩 hazard. Spraying hydraulic oil can penetrate and burn skin. Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually. 00 not allow oil to squirt or spray. Part No. 31758
Service Manual - First Edition
Section 7 - Repair Procedures
MAST ASSEMBLY
6 Remove the mounting fasteners from the mast valve mounting bracket. Do not remove the valve from the bracket or the hydraulic hoses from the valve. 7 Remove the fasteners that mount the level sensor assembly to the mast. 8 Remove the cable attachment brackets from the side of the mast.
1 Remove the mast. See the appropriate procedure above , How to Remove the Mast Assemb.äź&#x160;.
2 IWP models: Remove the mounting fasteners from the cylinder mounting brackets. 3 Remove the socket head retaining bolt from the clevis block on the lift cylinder rod end.
9 Disconnect the control cable tension spring. 10 Attach an overhead crane to the lifting eye located on the back of the mast. 11 Remove the fasteners that mount the strut bracket to the mast. 12 Remove the four base mounting fasteners. 13 Carefully lift the mast out of the base.
@
@
Crushing hazard. The mast will fall unless it is properly suppoć¤ed. 14 Place two saw horses under the mast. 15 Lower the bottom of the mast onto one saw horse and continue to lower the mast until the top is resting on the second saw horse. The mast should be resting on the platform side. The level sensing system will not operate correctly if the number 1 column does not maintain an 1.5 degree 壍 0.1 degree lean back (away from the platform) in relationship to the base. Consult Genie Industries Service Department.
How to Disassemble the Mast This procedure requires specific repair skills , lifting equipment and a suitable workshop. Attempting this procedure without these skills and tools may result in death or serious injury and significant component damage. Dealer service is strongly recommended. Part No. 31758
a b c
top of no. 1 column retaining bolt clevis block
4 Support the cylinder and carefully slide it out of the bottom of the mast. 5 Carefully rotate the mast until it is resting on the back of the number one column. 6 Remove the adjustment nuts from all the sequencing cables. Label and remove all the lower sequencing pulley brackets. 7 Remove the decal plate mounting fasteners and lay the decal plate aside with the platform control box attached. 8 Remove the screws that mount the lower junction box to the mast. Remove the control cable from the mast. 9 Remove the lock nuts and adjustment nuts from the chain terminals on the carriage. 10 Remove the carriage by sliding it out the bottom of the mast.
Genie IWP & Genie AWP
7-25
Section 7 - Repair Procedures
Service Manual- First Edition
MAST ASSEMBLY
11 Lay the chains out on the floor at the top of the mast. 00 not allow the chains to become
How to Assemble the Mast This procedure requires specific repair skills , lifting equipment and a suitable workshop. Attempting this procedure without these skills and tools may result in death or serious injury and significant component damage. Oealer service is strongly recommended.
twisted.
Remove all the shims from under the roller wheel buttons and clean all of the columns. 2 Secure the number 1 column to the saw horses and lay the chains out on the floor at the top.
3 Apply a generous amount of Boe-Iube wax (Genie pa同 number 90338) to the inside and outside channels of each column.
ahuede 百 rst column chain
4 Slide the number 2 column into the number 1 column until the top of the number 2 column reaches the top roller wheels on the number 1
second column topofmast second column chain firstcolumn
coluπln.
12 Slide the top column towards the top 1 foot (30 cm) to expose the idler wheel mounting bolts.
13 Remove the fasteners that mount the idler wheel axle plates to the top of the column. Remove the entire idler wheel assembly from the column. Be sure to keep the assembly together.
14 Remove the lock nuts and adjustment nuts from the chain terminals on the top column.
15 Remove the column by sliding it out of the bottom of the mast and set it aside. 16 Lay the chains that are in the column out on the floor at the top of the mast. Pick up the first set of chains and lay them in what is now the top column. 00 not allow the chains to become twisted.
5 Apply a dab of grease on the end of the roller bolt to hold the shims and the button in place.
6 Install one medium and one small shim in the top roller wheels. Install the roller wheel buttons. 00 not install the lower roller wheel buttons.
7 Slide the number 2 column into the number 1 column and move it through its entire length checking for tight spots or binding.
8 Use shims equally on each side to adjust the column so the tightest spot measures 15 to 20 pounds (6.8 to 9 kg) of resistance.
9 Install shims and buttons in the lower roller wheels to obtain an additional 15 to 20 pounds (6.8 to 9 kg) of resistance. Always install the shims equally on each side of a column to maintain squareness.
17 Repeat steps 12 through 16 for each remaining column. If the chains are removed , be sure to mark the location and label each chain before remova l. 7 晴 26
10 Repeat steps 3 through 8 to shim each remaining column.
Genie IWP & Genie AWP
Part No. 31758
Service Manual- First Edition
Section 7 - Repair Procedures
MAST ASSEMBLY
11 After all the columns have been shimmed , remove the columns and lay them out on the saw horses in sequence. 12 Install the chains into the columns and tighten the chain mounting fasteners (if they where removed during disassembly). 13 Lay the chains into each of the columns. 14 Lay the chains from the number 1 column out onto the floo r. 00 not allow the chains to become twisted or dirty. 15 Slide the number 2 column into the number 1 column until the top of the number 2 column is approximately 12 inches (30 cm) past the top of the number 1 column. 16 Install the idler wheel assembly into the top of the number 2 column. Tighten the mounting fasteners. Be sure the idler wheels rotate with no side to side movement in excess of 0.040 inches (1 mm). Replace worn shims if necessary. Be sure to maintain an equal amount of distance on the outside of the idler wheels.
20 Install the chain termination rods from the number 1 column chains into the termination bracket of the number 3 column by guiding the termination rods into the termination bracket while popping the number 3 column into the number 2 column. Tighten the adjustment nuts finger tight.
equal distance
17 Lay the chains from the number 2 column out onto the floor. 00 not allow the chains to become twisted or dirty.
a b
chaintermination rĎ&#x2030; termination bracket
21 Secure the number 2 column to the number 1 column using vise grips.
18 Take the chains from the number 1 column and place them inside the number 2 column. Route them up and over the idler wheels on the number 2 column. 00 not allow the chains to become twisted or dirty. 19 Tip the number 3 column up on one side (this will allow the column to clear the chains in the lower column) and slide it into the number 2 column untit the top of the number 3 column is approximately 12 inches (30 cm) before the top of the number 2 column. Part No. 31758
Genie IWP & Genie AWP
7 -27
Section 7 - Repair Procedures
Service Manual - First Edition
MAST ASSEMBLY
22 Slide number 3 column approximately 12 inches (30 cm) up past the top of the number 2 column.
28 Be sure all the termination rod adjustment nuts are finger tight and the chain termination rods have an equal amount of tension.
23 Install the idler wheel assembly into the top of the number 3 column. Tighten the mounting fasteners. Be sure the idler wheels rotate with no side to side movement in excess of 0.040 inches (1 mm). Replace worn shims if necessary. Be sure to maintain an equal amount of distance on the outside of the idler wheels.
29 Install the lock nuts on columns 4, 5 and the carnage. 30 Push the number 3 column forward 4 inches (5.08 cm). 31 Mark a reference line on the bottom of the number 2 column to specification. Measure up from the bottom of the column. Stagger Adjustment AWP-19 & 24 AWP-30 & 36 IWP-19 & 24
5/8 3/4 1/2
inch inch inch
15.9 m ç&#x203A;Ż1 19 mm 12.7 mm
32 Pull the carriage towards the bottom of the mast. This will close the mast.
equal distance 24 Lay the chains from the number 3 column out onto the floor. Do not allow the chains to become twisted or dirty. 25 Take the chains from the number 2 column and place them inside the number 3 column. Route them up and over the idler wheels on the number 3 column. Do not allow the chains to become twisted or di ĺ&#x2020;&#x2026;y. 26 Repeat steps 19 through 25 for the remaining column(s) and carriage. 27 With the number 2 column still secured to the number 1 column , pull all the columns toward the bottom until they are all even.
33 Adjust the number 3 column chain termination rods until the bottom of the number 3 column reaches the reference line on the bottom of the number 2 column. Be sure there is equal tension on the chain termination rods. 34 Install the lock nuts on the number 3 column. Be sure that the stagger of the columns does not change. 35 AWP-19 & IWP-19 models: Mark a reference line on the bottom of the number 4 column to specification. Measure up from the bottom of the column. Stagger Adjustment AWP-19 IWP-19
1 inch 1 5/8 inches
2.54 cm 4.1 cm
36 Adjust the carriage chain termination rods until the bottom of the carriage reaches the reference line on the bottom of the number 4 column. Be sure there is equal tension on the chain termination rods.
7 -28
Genie IWP & Genie AWP
Part No. 31758
Service Manual - First Edition
Section 7 - Repair Procedures
MAST ASSEMBLY
37 Install the lock nuts on the carriage. Be sure that the stagger of the columns does not change.
5-3
How to Adjust the Li fting Chains Fully lower the machine and measure the distance between the bottom of the number 2 column and the bottom of the number 3 column (referred to as the stagger). The chains are adjusted correctly if the measurement meets the specification. If the adjustment is correct proceed to step 5.
38 AWP-24 , 30, 36 & IWP-24 models: Mark a reference line on the bottom of the number 5 column to specification. Measure up from the bottom of the column. Stagger Adjustment
一&&U
·川一 46i
W刊 -GUOhh
A
39 Adjust the carriage chain termination rods until the bottom of the carriage reaches the reference line on the bottom of the number 5 column. Be sure there is equal tension on the chain termination rods.
d.-23MF M-WWMW e--men。--PPL
2.54 cm 4.1 cm
mv一斗刁恒
1 inch 1 5/8 inches
Cu--AHA阳 m川
AWP-24 , 30 & 36 IWP-24
inch inch 1/2 inch
5/8 3/4
15.9 mm 19 mm
12.7 mm
40 Install the lock nuts on the carriage. Be sure that the stagger of the columns does not change. 41 Push the number 3 column forward 6 inches (15.2 cm). This will open the mast. 42 Be sure all of the idler wheel axle plate mounting bolts are flush with the column. Component damage hazard. The roller wheels will become damaged if the idler wheel 缸le plate mounting bolts are not flush with the column. 43 Reassemble the machine. Then adjust the lifting chains. See 5-3, How to Adjust the Lífting
a b
Chains.
c
no. 3 column no. 2 column base
To adjust number 3 column chains: 2 Raise the
pla仔orm
6 feet (2 m).
3 Loosen the lock nuts on the number 3 column chain termination rods. 4 Turn the adjustment nuts on both chain terminals clockwise to increase the stagger or counterclockwise to decrease the stagge r. Then re-tighten the lock nuts. Part No. 31758
Genie IWP & Genie AWP
7 -29
Section 7 - Repair Procedures
Service Manual - First Edition
MAST ASSEMBLY
5 Fully lower the machine and measure the distance between the bottom of the number 3 column and the bottom of the number 4 column. The chains are adjusted correctly if the measurement meets specification. If the adjustment is correct proceed to step 9 or 13. S恒 gger
Adjustment
AWP-19 & 24 AWP-30 &36 IWP-19 & 24
13 AWP-19 & IWP-19 models: Fully lower the machine and measure the distance between the bottom of the number 4 column and the bottom of the carriage. The chains are adjusted correctly if the measurement meets specification. S恒gger
5/8 3/4 1/2
inch inch inch
15.9 mm 19 mm 12.7 mm
Adjustment
AWP-19 IWP-19
1 inch 1 5/8 inches
2.54 cm 4.1 cm
14 Raise the platform 6 feet (2 m). 6 Raise the platform 6 feet (2 m). 7 Loosen the lock nuts on the number 4 column chain termination rods. 8 Turn the adjustment nuts on both chain terminals clockwise to increase the stagger or counterclockwise to decrease the stagger. Then re-tighten the lock nuts. 9 AWP-24, 30, 36 & IWP-24 models: Fully lower the machine and measure the distance between the bottom of the number 4 column and the bottom of the number 5 column. The chains are adjusted correctly if the measurement meets specification. If the adjustment is correct proceed to step 18. Stagger Adjustment AWP-24 AWP-30 &36 IWP-24
10 Raise the
16 Turn the adjustment nuts on both chain terminals clockwise to increase the stager or counterclockwise to decrease the stager. Then re-tighten the lock nuts. 17 Be sure the chain terminals on each column have equal tension and the lock nuts are tigh t. 18 AWP-24 , 30, 36 & IWP-24 models: Fully lower the machine and measure the distance between the bottom of the number 5 column and the bottom of the carriage. The chains are adjusted correctly if the measurement meets specification. S恒gger
5/8 3/4 1/2
pla甘orm
15 Loosen the lock nuts on the carriage chain termination rods.
inch inch inch
15.9 mm 19 mm 12.7 mm.
Adjustment
AWP-.饵 .30
& 36
IWP-24
19 Raise the
6 feet (2 m).
pla甘Qrm
1 inch 1 5/8 inches
2.54 cm 4.1 cm
6 feet (2 m).
11 Loosen the lock nuts on the number 5 column chain termination rods.
20 Loosen the lock nuts on the carriage chain termination rods.
12 Turn the adjustment nuts on both chain terminals clockwise to increase the stager or counterclockwise to decrease the stager. Then re-tighten the lock nuts.
21 Turn the adjustment nuts on both chain terminals clockwise to increase the stager or counterclockwise to decrease the stager. Then re-tighten the lock nuts. 22 Be sure the chain terminals on each column have equal tension and the lock nuts are tigh t.
7 - 30
Genie IWP & Genie AWP
Part No. 31758
Section 7 - Repair Procedures
Service Manual - First Edition
MAST ASSEMBLY
5-4
How to Inspect the Lifting Chains Inspection
Procedure
Inspection Failure
Inspection Remedy
驯lear
Count out 16 chain links and measure pin to pin centerline dimension with a steel tape.
When the length of the 16 links (pin to pin) measure more than 8.25 inch臼 for 1/2 inch chain 。r 10.31 inches for 5/8 inch chain.
Replace both chains on that column s回tion. Replace entire chain. D。 not repair just the affec过:ed portion of the chain.
Visually inspect the chains for rust and corroslon.
Evidence of rust or corroslon.
Remove chain and inspect for cracked
Visually inspect the chains for lubrication.
When external surfaces are not protected with a layer of oi l.
Lubricate chain with motor oil (SAE 40).
Inspect chain link joints for easy movement.
Joints that do not flex freely or are bound up.
If rust and corrosion is found , refer to "Failure Remedy" for rust and corroslon.
Note: Be sure to measure a section of chain that moves over the idler wheels. Rust and Corrosion
Tight Joints
l plat臼 (s锦 inspection of cracked plates). If no cracks are found , lubricate chain with motor oil (SAE 40) and re-install chain.
If link plates or pins are bent or deformed , replace entire chain. Replace both chains on that column. Do not repair just the affected portion of the chain.
Part No. 31758
Genie IWP & Genie AWP
7 - 31
Service Manual - First Edition
Section 7 - Repair Procedures
MAST ASSEMBLY
Inspection
Inspection Failure
Procedure
i ;l eu--== -
茸茸寸 -zz-
Chain Side
a
RH ·lCUWZZZ nLE nv、、
Visually inspect for raised pms.
创土幸?
Raised or Turned Pins
Inspection Remedy Replace both chains on that column section. D。 not repair just the affected po时ion of the chain.
Visually inspect for turned pins by insuring all the flats on the "V" heads are aligned.
Misalignment of flats on all "V" heads.
Replace both chains on that column section. Do not repair just the affected portion of the chain.
Visually inspect for wear pa忧.erns on heads of link pins and outside link plates where they contact the idler whee l.
Wear on pin heads or noticeable wear in the profile of the outside link plate.
Replace both chains on that column section. Do not repair just the affected portion of the chain.
~ \-/
Check alignment of chain anchors and idler wheels.
link plate wear
啤
Visually insp田t chain anchors.
Chain Anchors
附副r \.~"
四
chain /南1 anchors LJν
/
Cracked Link Plates
7 -32
iI 且
Visually inspect chain link plates for cracks.
Replace chain anchor.
Twisted or misaligned chain anchor.
Re-align chain anchor to ensure even loading of chain.
Threaded rod not visible in inspection hole. MUW ha WH ewn enhbeave huaAUMY F-nH
Replace chain anchor and threaded rod.
」-
idler
wheel'
Visually inspect chain idler wheels.
8ent or damaged anchor.
』H
~丸
… …
Replace chain anchor.
en 出
Idler Wheels
hm aM.o OUW4A rE
8roken chain anchor fingers.
Replace idler wheel and check chain alignment.
Idler wheels have grooves worn into chain contact surface.
Replace idler whee l.
Cracks in any chain link plate.
Replace both chains on that column section. Replace entire chain. Do not repair just the a忏臼ted po此ion of the chain.
Genie IWP & Genie AWP
Part No. 31758
Service Manual- First Edition
Section 7 - Repair Procedures
Tilt-back Frame - AWP-30 and 36 6- 1
How to Remove the Tilt-back Frame 1 Fully lower the platform , turn the machine off and remove the key. 2 Maintain a firm grasp on the tilt-back frame and remove the retaining pin. Then lower the tilt-back frame to the ground. 3 Remove the fasteners that mount the tilt-back frame hinges to the base. 4Removethe frame from the machine. 蹦出如间串串
Note the amount of shims used between the hinges and the base.
6-2
How to Adjust the Pivot Slider or Stop Bracket 噩 J邵{仨抽曹喝 挝吕{悦暗串灌 3 疆
Check for side 令to-side movement the pivot slider or stop bracket. They should have no side-to-side clearance and not be too tight to cause dragging or binding. Adjust if necessa叩· 。f
1 Remove the tilt-back frame. See 6-1, How 的 Remove the Tilt-back Frame.
2 Remove the mounting fasteners and roll pins from the tilt-back frame hinges. 3 Remove the lower stop bolts from the frame. 4 Slide the pivot slider and the stop braβket out of the frame and add shims as necessary to obtain zero clearance and zero drag.
Part No. 31758
Genie IWP & Genie AWP
(AWP 36 shown) a loading stop bracket b shock absorber assembly c ti忧心ackframe d shocka胁。 rbermoun回ngbolt e loadi咱 pivotbar
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Service Manual - First Edition
Section 7 - Repair Procedures
TILT-BACK FRAME - AWP 30 AND 36
6-3
How to Disassemble the Shock Absorber Assembly Fully lower the pla甘Orm ， turn the machine and remove the key.
0仔
2 Maintain a firm grasp on the tilt-back frame and remove the retaining pin. Then lower the tilt-back frame to the ground.
3 Remove the fastener that mounts the shock absorber assembly to the frame.
4 Remove the shock absorber assembly from the frame and separate the lower tube from the assembly.
5 Remove the top decal plate mounting bolt. Then pull the shock absorber out of the upper tube.
6 Remove the metric nut from each end of the shock absorber and remove the mounting blocks. Bodily injury hazard. Contents of the shock absorber are under pressure. Use care during removal.
(AWP 36 Shown) a lower shock mounting block b lowertube c uppertube d upper shock mounting block decalp恼.te mounting bolt e metricnut 9 shock absorber h spring (AWP 36 models only)
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Genie IWP & Genie AWP
Part No. 31758
Section 7 - Repair Procedures
Service Manual - First Edition
Platform 7-1
7-3
How to Remove an Aluminum Platform
Platform Control Box
1 Place support blocks between the platform and base. Then lower the pla仔'orm onto the blocks. Crushing hazard. Keep away from descending pla甘orm. 2 Remove the lower mounting fasteners from the platform. 3 Remove the nuts from the U-bolts, then pull the platform away from the mast and remove it from the machine. Ifapla仔orm
is being replaced , be sure that all appropriate safety and instructional decals are applied to the new pla甘orm.
How to Test the Contactors 1 Fully lower the pla仔。rm， turn the key switch off and disconnect the power supply. 2 Loosen the platform control box lid fasteners and open the control box. 3 Observe the markings on the contactor to be checked. The N.O. marking designates the switch as normally open and N.C. designates the switch as normally closed. 4 Connect a continuity tester to the exposed screw terminals.
<:> Result: Normally open contactors should have no continuity. Normally closed contactors should have full continuity. 5 Push the small triangular button on the top of the contactor and check the continuity.
7-2
How to Install a Fiberglass Platform
<:> Resul t: Normally open contactors should have full continuity. Normally closed contactors should have no continuity.
1 Remove the aluminum pla恬orm. See 7-1 , How to Remove an Aluminum Platform. 2 Support the platform with a lifting device , then place the pla甘Orm against the mounting angles. 3 Install the mounting fasteners. 4 Remove all manuals from the carriage mounted storage container and place them in the storage container in the fiberglass platform. If a platform is being replaced , be sure that all appropriate safety and instructional decals are applied to the new platform.
Part No. 31758
Genie IWP & Genie AWP
7 - 35
Service Manual - First Edition
Section 7 - Repair Procedures
PLATFORM
How to Test Power-to-Platform GFloutlet Fully lower the platform , turn the key switch off. 2 AC and DC models: Be sure the AC power supply is properly connected.
3 Connect an AC voltage tester or a small hand tool to the platform GFI receptacle.
4 Test the voltage or test the hand tool operation.
o
Result: The voltage should be 115V AC nominal or the hand tool should operate normally.
5 Push the black TEST button on the GFI receptacle.
o
Result: The voltage should be OV or the hand tool should not operate.
6 Push the red RESET button on the GFI receptacle.
o
Resul t: The voltage should be 115V AC nominal or the hand tool should operate normally.
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Genie IWP & Genie AWP
Part No. 31758
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