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AWP SS from SN 3896-101 to 3801

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1. D E F G H J K L eee oe 1 P1 CONTROLS MANIFOLD BK BK T BL BK EMERGENCY swei T vs Nc 2 BK DRIVE 21 w3 1 T ak FORWARD m WH L 12V DC POWER INPUT 2 KS1 L NEGATIVE 12V DC INPUT Y32 2 GROUND LED 14 12V DG INPUT 4 WH BK INDICATORS _ LED 12 12V DC INPUT 5 ac PLATFORM AD MU BD L5 LED 18 12V DC INPUT 5 5 INDICATOR x aK LED 15 12V DC INPUT 7 me e E 446 12 DC OUTPUT 8 io 4 a 12 OUTPUT 9 b BK 5 113 AUXILIARY COWERING 12 00 OUTPUT 9A B4 12V D
2. 1 a 5 f ATUM POWER WHEEL CONTROL ASSIST OPTION 1 STOP RD wa 16 0V DC INPUT wu 12 DC POWER INPUT CENTER TAP INPUT STEER SW22 PLATFORM NC L NEGATIVE 12V AUX INPUT 160 DC INPUT HANDLE FORWARD L POSITIVE 12V DC AUX INPUT 66 LEVEL INTERLOCK WH REVERSE a CONTROLS SWITCH 2 CONTROL LED 66 LEVEL INTERLOCK BOX 1 amp LED 67 FOOTPAD INTERLOCK BL fa B BN a ax L6 LED 67 FOOTPAD INTERLOCK z BK Le SW8 INDICATORFOR IV DCOUTPUT ud z flp CONTROL AUXILIARY LOWERING 12V DC OUTPUT ACTIVATE 12V DC OUTPUT 50 41 L7 WHT DRIVE BATTERIES DC MODEL UP SIGNAL OUTPUT RD ENABLE LOW BATTERY A SWITCH Swit INDICATOR UP SIGNAL OUTPUT DELAYED A 3 UP SIGNAL INPUT A PLATFORM BK U1 0 T DOMI POWER INDICATOR EMERG
3. M L K J H G F E D ee P1 RD 1 EMERGENCY TOP BK BK e BK Toe SS ee ro KS1 DC POWER INPUT 2 NEGATIVE 12V DC INPUT 8 ee LED 1 12V DC INPUT 4 m 2 INDICATORS _ LED212VDCINPUT 5 Iz BK BK L5 LED 3 12VDCINPUT 8 EL a a IPOWER INDICATOR RD 1 LED 4 12V DC INPUT 7 1 _ 14 L12 4416 12V pc OUTPUT 8 a INDICATOR FOR oc outeur e 80 BK BK IL L AUXILIARY LOWERING 12V DC OUTPUT 9A BLL RD 4 5 1713 GROUND 10 9 pes BAA 12V DC MOTOR SOLENOID OUTPUT 11 BATTERIES e 1 TIME DELAY 12V DC OUTPUT 12 3 swi2 DG MODEL 12V DC UP SIGNAL INPUT 13 AUXILIARY U10 7 e wit ______ __ ____
4. M L K J H G F E D C B A IERI RI TATE wm ruse gt m ne FRONT RIGHT 1 KS1 lt PLATFORM _____ L RD INTERLOCK S KEY BK REAR RIGHT EE aa a BK Y m m INTERLOCK ar at A x x SWi5 EMERGENCY PG a I a SW16 EN1 STOP BASEY 4 RD 11213 W3 16 0V DC INPUT 1 o QT d POWER INPUT CENTER TAP INPUT 2 ___5 4 mit L NEGATIVE 12V DC AUX INPUT 16 0V DC INPUT 3 F PLATFORM L POSITIVE 12V DC AUX INPUT Le 12 FRONTLEET 4 WH m 2 CONTROL EMERGENCY INDICATORS E INDICATORS LED 8 FRONTRIGHT 5 W6 NC ne ae INPUTS LED 15 REAR RIGHT 6 TERMINAL s m T RD LED 14 1 7 gt ene Y7 OWN w8 112 113 12V DC OUTPUT
5. UFRONRGH RD INTER FRONT LEFT 1 RD INTERLOCK REAR RIGHT OR RD INTERLOCK REAR LEFT BL RD x 15 re 11215 W3 18 0 DC INPUT 1 5 16 L42VDCPOWER INPUT CENTER TAP INPUT 2 x _ 5 13 L NEGATIVE 12V DC AUX INPUT 16 0V DC L POSITIVE 12V AUX INPUT Ten 13 FRONT 4 WH SW14 _ 2 8 LEVELING LONE T L6 RD PLATFORM ILOW BATTERY LED 12 FRONTLEFT 7 B Y7 DONN LASNE tvoccumUT 12V DC OUTPUT a RD LK 12V OUTPUT Li 4 MODEL GROUND 10 gt WHT ILOW BATTERY RD E occ UP SIGNAL OUTPUT 11 INDICATOR 15 UP SIGNAL OUTPUT DELAYED 12 STANDARD 3 OR powernpicator J10 UP SIGNAL INPUT PC BOARD wa 4 GND GROUND STUD 004 _ 88 EN2 7 5 7 1 4 ws mreo erm BN 5 gt 5 FYL gt
6. ___ _________ _ _____ ee es 2 RD NTERLOCK 1 RD FRONT RIGHT KS1 porns WH RD INTERLOCK 8 kv BK REAR SWITCH Th ABK REAR LEFT X BD INTERL P2 a BK SW15 EMERGENCY 07 094 enei e STOP EN 0 RD 160V 1 1 SW16 WH T RD cee 2 POWERINPUT CENTER TAP INPUT 2 x SW14 PLATFORM lot L NEGATIVE 12V DG AUX INPUT 180V DC INPUT SW13 2 1 POSITIVE 12V DC AUX INPUT Len 12 FRONTLEET 4 WH BK g LEVELING OR CONTROL INDICATORS _ eee LED 13 FRONTRIGHT 5 5 446 INPUTS LED 15 REAR RIGHT 8 D MI ii T RD E LOW BATTERY LED 14 LEFT 7 7 Sc DOWN Swe L12 LAS LOWERING 2 71 AD BLK te CONTROL 1 12V DC OUTPUT 9 ACTIVATE 4 I a e 12V DC OUTPUT BK 21
7. M L K J D C B A ee cce E CONTROLS MANIFOLD EMERGENCY doe m ee EMERGENCY DIRECTION REVERSING 0 B ee option SAFETYSWITCH pave i BD W3 1 EE FORWARD Hie KS1 42V DC POWER INPUT 2 c MN gt ien 50 22 di 2 Bk BK gt S L5 LED 3 12V DC INPUT 6 MD iJ 5 AD ou Gr qf INDICATOR LeD 412V DC INPUT 7 ss SWITCH RD 19 pave Y6 KS1 m iL14 L12 646 12V OUTPUT 8 3 221 REVERSE H GROUND ooo 1 pL RD B4 115 GROUND 10 le ee DNE no sa 12V DC MOTOR SOLENOID OUTPUT 11 ECCE BATTERIES gir an umm jie U10 waj NO ECT e 66550 E m GND WH T BD
8. A B C D E F G H K L 1 1 EMERGENCY 5 STOP EK 415 RD BK BK 0 RD NG a HE KS1 L NEGATIVE 1V DC INPUT GROUND POSITIVE 12V DGINPUT LED1412V DC INPUT 4 2 PLATFORM mu DG INPUT on BK ee US n 15 LEDIS 12V DC INPUT 6 gt BL IPOWER INDICATOR RD BK se BK LED15 12V INPUT 7 NO 114 L12 6 16 12V DC OUTPUT s 19 115 113 GROUND 10 HAH B4 TUS 12V DC MOTOR SOLENOID OUTPUT 11 AD 3 BATTERIES a 1 SECOND TIME DELAY 12V DC OUTPUT 12 SW12 DO MODEL 12V DC UP SIGNAL INPUT 13 ra U10 Wi E 05 L PCBOARD _ ____ E T P2 W6 TERMINAL STOP WH LT GROUND BK EN1 GND WH x 5 e e WH AEX Y7 PLATE OR PLATFORM IL I 21 EH 1 5 CONTROL swe GND 2 CONTROL
9. EE a FOR 240 V OPERATION JUMPER BROWN WHITE FRONT RIGHT 1 Soa THROUGH TERMINAL STRIP AND LEAVE v RD INTERLOCK KS1 mew WH BLACK UNGONNEGTED AS SHOWN REAR RIGHT KEY B LT m 2 ws eed FOR BROWN TO in REAR LEFT SSS SS SWITCH 1 Ug BLACK AND BLUE TO WHITE 8 ED INTEBLOCK B1 1 7 P2 BK J 3 2 as GROUND CONTROL BOX TRANSFORMER Sea AN WTA DAEN DNES Ws SW15 xs a SS CELE BK Sa 1 Ze lp H BK 11213 wa 16 0 DC INPUT i RD 3 BN 1 6 16 T EE DG POWER INPUT CENTER TAP INPUT 2 3 BL 1 se SW14 _ PLATFORM Me 4 cum NEGATIVE 12V DC AUX INPUT 16 0 DC INPUT WH SW13 POSITIVE 12V DG AUX INPUT __ _ __ poo BK s 1 LED 13 FRONT LEFT 4 F 2 LEVELIN CONTROL EMERGENCY oS INDICATORS _ LEVELING gt LED 15 REAR RIGHT 5 m 1 INPUTS LED 14 REAR LEFT 6 NC BOX L6 RD 1 Y7 PLATFORM QT AD BA Icy a ILOW BATTERY LED 12 FRONTLEFT 7 i DOWN Sw8
10. A B D E F G H 1 LN PRESSURE Q POWER WHEEL dE ASSIST MOTOR pol UR 3 x P vi _ POWER WHEEL ASSIST MANIFOLD 557 _ mr 4 y BASE LIFT SS ce CYLINDER HYDRAULIC POWER UNIT enn eee E ee B lex Le 99 1 12 EU TO par PLATFORM LIFT CYLINDER FOOTPUMP MANIFOLD 8 _____________________ 186 AWP Super Series IWP Super Series Part No 38139 2015 Service Manual Hydraulic Schematic Super Series Models with Power Assist and Brake J D C B A 1 1 PRESSURE e AO a Q 2 1600 i
11. A B C D E F G H J K L nee ee BK QT BK BK i Bo ee kst ER 2 GROUND M DIM SE LED 112VDOINPUT 4 PLATFORM i5 INDICATORS L5 LED 212VDCINPUT 5 POWER INDICATOR LEDS 12VDCINPUT 6 L2 jr n Dar eun FOR TY Dy OUTRUT o BK 45 15 ene sat 4 12V DC MOTOR SOLENOID OUTPUT 11 BD BATTERIES 17 1 SECOND TIME DELAY 12V DG OUTPUT 12 SW12 DG MODEL 12V DC UP SIGNAL INPUT 13 45 5 athe ______ __ ___ A ERN P2 We 6 EMERGENCY TERMINAL ws us GND WH RD 004 616 STUD vs STO GND WH WH 7 PLATFORM PLATFORM Ex E CONTROL sws wi 1 CONTROL GROUND 4 8 4 STUD EN2 OR 3 a OR swig GROUND re EIN CONTROL NEL swi7 e WH 9111 BOX swen POW PLATFORM LL LL lid 8 ja OU
12. Eu x KS1 Ui2 THERMAL E BD RD TRANSFORMER i NO YL BK US NO 806 1 Ee BD WH pi E 22 16 0V DC INPUT 1 ium EU EMERGENCY DC POWER INPUT GENTER TAP INPUT 2 m 3 a STOP m NEGATIVE 12V DG AUX INPUT 16 0V DO INPUT 3 j C NA D L POSITIVE 12V DC AUX INPUT LED 14 FRONTLEFT WH 2 T NG LEVELING LED 12FRONTRIGHT 5 OR BK Qi YL u INPULS LED13REARRIGHT 6 BL B1 LED 1S REAR LEFT 7 P iL14 12 power npicaTor 12V DC OUTPUT BK BATTERIES e a 64 12V DC OUTPUT 9 AD Swi2 WLG 12V DC OUTPUT 9 DOWN 4115 113 moicaronron aroun hoe H ES AUXILIARY LOWERING UP SIGNAL OUTPUT 49 7 fus e UP SIGNAL OUTPUT DELAYED 12 3 U1 0 UP SIGNAL INPUT i3e OR TTERY um BOARD W4 220V TERMINAL STRIP 4 15A CIRCUIT BREAKER DETAIL CB4 Quee MODELS CIRGUIT BREAKER 220V AC MODELS PLATFORM GND I STOP GROUND Rec aia ae CONTROL w 7 STUD a N7 x x5 5 NC BK
13. Checklist A YNR Checklist B YNR A 1 Inspect the manuals B 1 Batteries Serial number and decals 2 Electrical wiring A 2 Pre operation Date inspection B 3 Welds 3 Function tests B 4 X Tilt back operation Hour meter 4 Damage loose or B 5 Lifting chain missing parts adjustment Machine owner A 5 Hydraulic Leaks B 6 Clean and lubricate columns A 6 Check Hydraulic Oil m Inspected by print Level B 7 Lifting capacity Inspector signature 7 Test base operation B 8 Sequencing cables A IWP onl Inspector title 9 Proper outrigger Inspector company 8 X Auxiliary lowering length A 9 Manual lowering B 10 Outrigger footpads A 10 Columns B 11 Level sensing Instructions models 11 Sequencing cables Eds Make copies of this report to use for 7 each inspection A 12 Interlock system 205 with outreach e Select the appropriate checklist s for A 13 Power and function the type of inspection s to perform controls Checklist C R Daily or every 8 hours A 14 Lifting chains and C 1 Caster and wheels G arteri A B idler wheels C 2 Mast assembly 250 hours A 15 Breather cap Annually or every A B C 3 Lifting chains 1000 hours C 4 Hydraulic oil e Place a check in the appropriate box e ns d after each inspection procedure is OWe
14. A B C D E F G H L M eee RDB 07 FRONT RIGHT 240 OPERATION N m INTERLOCK JUMPER BROWN TO WHITE N FRONT LEFT 1 ports THROUGH TERMINAL STRIP AND LEAVE V RD AD INTERLOCK KS m zr ott EEN EN2 TI Teea erat Bi o gt p _ 44 GROUND CONTROL BOX x SWIS BK ____ LI 1 P SEE 112121 W3 md 3f BN x SWIG _ WH I RD x BASE LE 42 DC POWER INPUT CENTER TAP INPUT 2 pe 3 BL 513 PLATFORM NO Ss gt NEGATIVE 12V DC AUX INPUT 16 0V DC INPUT 3 WH swi4 2 nid mE L POSITIVE 12V DC AUX INPUT Len 13 FRONTLEFT 4 wHo 11 pere K lt 5 CONTROL sempe PME Ducit TERMINAL BOX 416 INPUTS em RD YT PLATFORM BD OW BATTERY LED 12 FRONT LEFT 7 En T sme DOWN swe SAR 1113 115 Fon 12V DG OUTPUT YL tit CONTROL YL BATTERIES 12V DG OUTPUT ACTIVATE e 817 12V DC OUTPUT 9 BL BK 1 12 1145 GROUND 10 WHT NAM UP SIGNAL OUTPUT 11 3 15 UP SIGNAL OUTPUT DELAYED 12
15. e 8 TILT SENSOR GNYL ES0073 171 Service Manual May 2015 Electrical Schematic IWP Super Series AC Models from SN IWP07 57595 172 2015 Service Manual Electrical Schematic IWP Super Series AC Models With Base Mounted Junction Box 173 Service Manual May 2015 Electrical Schematic Super Series Models With Base Mounted Junction Box A B C D E F G H J K L oe ee ee ee ee ey eens ee ee ee eee ee ee oe ee ee oe 1 1 STOP 09 TRANSFORMER ef s B Ne E 71818 16V INPUT CENTER TAP INPUT 1 NEGATIVE 12V DC INPUT 16V AG INPUT GROUND _ POSITIVE 12V DG LED14 12V DC INPUT 2
16. N M L K J D C B A 771 m 1 J KEY a1 L SRD 22 E t 2 y FOR 20 V OPERATION JUMPER BROWN WHITE m 5 _ x GROUND CONTROL BOX U9 THROUGH TERMINAL STRIP FRONTRIGHT 1 TRANSFORMER AND LEAVE BLACK UNCONNECTED INTERLOCK 2 2 ee i AS SHOWN gt ms z BK 1 amp ovpc eur hi AD ee INTERLOCK EN1 e N Moe m TT CENTER TAP INPUT 2 BL 17 INTERLOCK wi AD SO LA S 12V DC POWER INPUT pm i INTERL PLATFORM NC EL L NEGATIVE 12V DC AUX INPUT 16 0V DCINPUT 3 2 SEE T REAR LEFT POSITIVE 12V DC AUX INPUT WH INTERL 1 LED 13 FRONT AIGHT 4 SW15 2 n px c CONTROL EMERGENCY T INDICATORS LEVELING gt LED I REARRIGHT 5 Bi SW16 uis RE T LED 14 REARLEFT 6 t i ae INPUTS gt BOX B QT RD Low BATTERY LED 12 FRONTLEFT 7 SW13 Swe ml x NT 113 L AS AUXILIARY LOWERING ADEQUATE vs SW14 NC a Gn 12V DC OUTPUT BK WH GROUND 10
17. es es a Ss a a Ss ag RD PLATFORM ON WH 1 4 KS MEY KEY 9 389 A mL 4BK X EN2 pe i LS 240 V OPERATION Ce JUMPER BROWN WHITE pre amp GROUND CONTROL BOX U9 P2 3 TRANSFORMER AND LEAVE BLACK UNCONNECTED EMERGENCY 7 pele cu IE Ec lap i T um 16 0V DC INPUT 1 BN X 1 STOP N mo 8 12 3 W3 _ 36 4 22 T RD MODE eg AB 142 POWERINPUT CENTER TAP INPUT 2 PLATFORM NC m NEGATIVE 12V DC AUX INPUT 16 0V DC INPUT 3 R 5 2 P1 E POSITIVE 12V DC AUX INPUT ep FRONT LEFT 4 CONTROL EMERGENCY soem o 516 INPUTS LED14REAR LEFT 8 B RD RD B4 Ic e ILOW BATTERY LED 12 FRONT LEFT 7 AD swe Er a d CONTROL BK YL BATTERIES 12V DC OUTPUT ACTIVATE NO ar et 12V DC OUTPUT 1 wH iL15 L1 GROUND 106 x pce rer ij l UP SIGNAL OUTPUT 11 s 3 Sw 615 UP SIGNAL OUTPUT DELAYED 12 s POWER INDICATOR U10 UP SIGNALINPUT 134 Pe UP
18. OR WIRES a p _ 5585 161 4 88 00312 34 57 8 PLATFORM AG quickpisconnecTA Ef WE EXTENTION PINE PRU 4 Penne 7 TO PLATFORM BK 1284587 RD t CHARGE ecd ee NN BK y E WH WH QUICK DISCONNECTA QD POWER TO GND TO PLATFORM PLATFORM GROUND I STUD CUM VALVE ___ recepracte Cge SI mE 8 110V AC 220V BRAND 38139 Super Series IWP Super Series 143 Service Manual May 2015 Electrical Schematic IWP Super Series DC Models from SN 4096 288 to 4096 341 144 2015 Service Manual Electrical Schematic IWP Super Series DC Models from SN 4096 342 to IWP07 7065 145 Service Manual May 2015 ese Electrical Schematic IWP Super Series DC Models from SN 4096 342 to 07 7065
19. Li L ld 5 1 carriage 7 number 4 column idler wheel assembly 2 number 3 column 8 number 4 column 3 number 2 column 9 number 5 column 4 number 1 column 10 number 5 column idler wheel assembly 5 number 3 column idler wheel assembly 11 number 6 column idler wheel assembly 6 number 2 column idler wheel assembly 12 number 6 column Genie 74 AWP Super Series IWP Super Series Part No 38139 2015 Service Manual 5 1 Lift Cylinder How to Remove the Lift Cylinder AWARNING Bodily injury hazard This procedure requires specific repair skills lifting equipment and a suitable workshop Attempting this procedure without these skills and tools could result in death or serious injury and significant component damage Dealer service is strongly recommended Note When removing a hose assembly or fitting the O ring if equipped on the fitting and or hose end must be replaced All connections must be torqued to specification during installation Refer to Specifications Hydraulic Hose and Fitting Torque Specifications 1 Fully lowe
20. N M L K J G F E D FOR240VOPRERATION INTERLOCK JUMPER BROWN WHITE FRONT LEFT Oa S THROUGH TERMINAL STRIP AND LEAVE INTERLOCK 1 KS1 27 PLATFORM _ WH BLACK UNCONNECTED AS SHOWN REAR RIGHT Bil MODE 2 1 INTERLOCK C SES t Uo FOR 120V OPERATION JUMPER BROWN TO REAR LEFT mic 50 oe al BLACK AND BLUE WHITEAS m BK 2 SHOWN WITH DASHED 2 P2 l EN GROUND CONTROL BOX TRANSFORMER YL _ 4 15 CBO 64 _ SWi5 BK 1 RBLK 5241 wa 180V DC INPUT 1 AD i 1 50 16 WH 8 ok DC POWER INPUT CENTER TAP INPUT 24 3 BL SW13 NC MEE z ER L NEGATIVE 12V DC AUX INPUT 1 amp 0V DC INPUT 3 WH i SW14 1 Eid z gt L POSITIVE 12V DC AUX INPUT Len 13 FRONTLET 4 puse LEVELING F OR 2 CONTROL LED 15 REAR RIGHT 5 STOP LED 14 REAR LEFT 6 N C BOX 2 Lo INPUTS RD Y7 PLATFORM BD T kow sarreny LED 12 FRONTLEFT 7 aro Swe 1113 15 FOR 12V DC OUTPUT YL i
21. 4 e GND WH H on GROUND 05 0 STUD B L M _ EN4 provas vones 91 QD4 rowRTO EE ST ed TERE PLATFORM c E PIED RECEPTACLE prep pec Rb 6 2 6 Rb BN 5 5 YL wr DA a N27 110V AC OR 3 2 3 0R 3 7 2 2 2 8 Hi WH AND BK WIRES wl REPLACE BL AND BN WIRES SUN 55 NS 8 a 1 15 3 a NT I iol G T 45 6 7l TGPLUG EE 6 ADIA AAAA Al 128 4567 GND supply Ex 5 GROUND 5 E STUD 5 Eran neuer NENNEN MOTOR c 7 ur Y30 Y30 E MNT o Br E g xg 42 DUMP 22 pump 52 BOX VALVE VALVE OPTIONAL WARNING LIGHT BL 4 5 1 a ME er uda 1 2 110V 220 V AG In 4 DETAIL x a MOTOR DETAIL GND 8 pgs T ES0071_F po eset N eee E Genie 122 AWP Super Series IWP Super Series Part No 38139 PLATFORM CONTROL BOX SW11 UPDOWN N17 NARROW PLATFORM UNITS WH AND BK WIRES AND OR 3 WIRES
22. LS RD Tu 4 112 wig s 19 ER ma reme ce BK 115 113 GROUND 10 12V DG MOTOR SOLENOID OUTPUT 11 BD BATTERIES 1 SECOND TIME DELAY 12V DC OUTPUT 129 3 SW12 Ge MODEL 12N DC UP SIGNAL INPUT 13 E AUXILIARY lie WH BOARD e 9 4 poU 2 we EMERGENCY GND a 1 WH T RD i E STUD GND GNNL rele WHBK 49 PLATFORM PLATFORM 154 m EM 5 5 1 CONTROL swe GND iz 5 9 5 CONTROL GROUND 4 8 o STUD a OF i 2 e SWITCH 5 E 2 51 p GROUND j CONTROL 5 11 epa BOX PLATFORM BK UP DOWN DOWN 6 PLATFORM i E SEDE 4 N17 QD7 OPTION NARROW PLATFORM UNITS I WHANDBKWIRES REPLACE Ln TMOTOR fe BLAND OR WIRES t RD ee te E 2515 151 POWER 12 34 67 a 98 ae wi BRENTON 7 i t poene 12 84 7 4 QD1 4 3 Hur cto A Nn Sen BATTERY SABE 12V DC T PLATFORM
23. 79 EN6 22 J BOX J BOX VALVE OPTIONAL WARNING LIGHT BL 1 M5 1 M5 DESCENT ALARM 3 OR 3 N10 eens a 110V AC 2 220 4 DETAIL lw a MOTOR DETAIL 8 4 5 GND os ee a ES0071_F Genie BRAND Part No 38139 Super Series IWP Super Series 131 Service Manual May 2015 Electrical Schematic AWP Super Series AC CE Models with Standard Base from SN AWP07 54899 to AWP07 57594 132 2015 Service Manual Electrical Schematic AWP Super Series AC CE Models with Narrow Base from SN AWP07 54899 to AWP07 57594 133 Service Manual May 2015 Electrical Schematic AWP Super Series AC CE Models with Narrow Base from SN AWP07 54899 to AWP07 57594
24. STUD EN a OR e SWis p 2 101 2 BL ite i Tt GROUND 817 swit CONTROL W17 PLATFORM 6 LIR d d ____________ _ PLATFORM 82 sal OUTREACH TO 2 Nir roa QD7 STRAIN RELEF _ OPTION PLATFORM WH AND WIRES HEPLADE TI POWER UNIT BLAND OR WIRES EE ex DS ia 715 e 161 658 aps EE 7 __ avoxocomecra EIE AD QD1 2 nim ms CHARGE BL Bo E B WH BATTERY P0 wH QUICK DISCONNECTA opg POWER GND 05 PLATFORM 8 rar GN YL La e ci SSS DOO _ E Genie A TEREX BRAND 146 AWP Super Series IWP Super Series Part No 38139 2015 Electrical Schematic IWP Super Series DC Models from SN IWP07 7066
25. sequence code serial label serial number stamped on chassis ah Genie __________________ BRAND 38139 Super Series IWP Super Series V Service Manual May 2015 Safety Rules Danger Failure to obey the instructions and safety rules in this manual and the appropriate Operator s Manual on your machine will result in death or serious injury Many of the hazards identified in the operator s manual are also safety hazards when maintenance and repair procedures are performed Do Not Perform Maintenance Unless MI You are trained and qualified to perform maintenance on this machine M You read understand and obey e manufacturer s instructions and safety rules e employer s safety rules and worksite regulations applicable governmental regulations MI You have the appropriate tools lifting equipment and a suitable workshop a Super Series IWP Super Series Part No 38139 2015 Service Manual Personal Safety Any person working on or around a machine must be aware of all known safety hazards Personal safety and the continued safe operation of the machine should be your top priority A ADANGER Read each procedure thoroughly This manual and the decals on the machine use signal words to identify the following Safety alert symbol used to alert personnel to
26. O1 N 2 2 A 9 gt 1 9 kn gt 44 B i 2 lt c 2 lt 2 lt 4 lt NS iol N ole n B N 2 214 Genie BRAND 10 AWP Super Series IWP Super Series Part No 38139 2015 Service Manual Scheduled Maintenance Procedures Observe and Obey AWARNING 44 WN 5 Part No 38139 Maintenance inspections shall be completed by a person trained and qualified on the maintenance of this machine Scheduled maintenance inspections shall be completed daily quarterly and annually as specified on the Maintenance inspection Report The frequency and extent of periodic examinations and tests may also depend on national regulations Failure to perform each procedure as presented and scheduled may cause death serious injury or substantial damage Immediately tag and remove from service a damaged or malfunctioning machine Repair any machine damage or malfunction before operating the machine Use only Genie approved replacement parts Machines tha
27. pele NR 7 1284 67 WH 1 RD E SaaS a Lm ram TOBASE H WH QUICK DISCONNECT A zs Y30 E POWER TO GND 8 PEATTORM AROUND GROUND DUMP VALVE gewn c 110V AC 220V n OO 1 2 Genie BRAND 174 AWP Super Series IWP Super Series Part No 38139 2015 Service Manual Electrical Schematic Super Series AC TUV Models Without Base Mounted Junction Box L K J D C B A ee cca dnd f 7 CU 1 l EMERGENCY STOP sie RD els BL RD TRANSFORMER SR weinen NC IRD
28. 2015 Service Manual Electrical Schematic Super Series DC Models with Power Assist Directional Valve Coils Powering Function Manifold L K J F E D o owe Ee SSS STEER HANDLE 1 EB BK P3 sw21 ERE r eae DIRECTION REVERSING BK RD OPTION SAFETY SWITCH pave Y5 LI 1212 1 a FORWARD A wa L42v DC POWER INPUT 2 KS1 L NEGATIVE 12V DC INPUT 2 pave Y32 AROUND E sena LED 14 12V DC INPUT 4 FU
29. A B D E F G H L lc EcL ee eye ee ee E c 1 1 EMERGENCY TOP BK T AD TRANSFORMER _ 16V AG INPUT KS1 CENTER TAP INPUT PLATFORM _ NEGATIVE 12V DC INPUT 16V AG INPUT 2 ge BK 14 BK Iw x L5 12V DC INPUT POWER INDICATOR 1 LED15 12V DC INPUT GROUND 114 L12 a 12V DC OUTPUT L6 e a INDICATOR FOR 12V DG OUTPUT er 5 Bk 45 L13 AUXILIARY LOWERING 12VDC 12V DC MOTOR RELAY OUTPUT 3 17 1 SECOND TIME DELAY 12V DC OUTPUT 512 MODEL 12V DC SIGNAL INPUT DOWN INDICATOR U 1 0 BOARD x 0 0000 E EMERGENCY TERMINAL STOP STRIP N WH T RD aun ENI 204 BK I O PLATFORM GND GN YL RD RD x EX CONTROL STUD B MTM 19 BOX Hee 5 OM EN2 zx swe BK GROUND WH 1 1 WH mE SW17 SW11 Yt 1 5 BK 6 MESE SWITCH Li 2 BEN PLATFORM T 17 x 8 ax OUTREACH TO
30. al t WH 2 Nonm CIRCUIT BREAKER 1 240V MODELS i EN4 1 POWER TO LL Lo d _ _____ QD4 PENE STM sale 2 7J 5k RECEPTACLE BN H 5 5 YL 5 TOE 15A CIRCUIT BREAKER WH 4 4 GNNL x Tg 2095 0 5 LLLI on s 52 34 08 num ax E Ej I oe y i 4 poem E 8 zd 5 tI NS0 DENOTES ANEUTRAD LI E m S amp E gt ac 220v 55 2 55 TERMINAL STRIP WITH SLEEVE 5205 A 36 DETAIL 1 STRAIN RELIEF ibo NN ie ES 6 1 zi on 00311231587 LA ch ch ch ch cl J D5 wo 1234567 x 5 65 25 ONYC 55 5 4 TRAIN RELIEF DESCENT ALARM N27 UNITS WITHOUT PLUG 7 WH AND BK WIRES REPLACE um gt p See ines GROUND GROUND x Y30 amp SCREW SCREW 0 FB2 4 4 6 pump pump 2
31. ee a eK OY o Xp ce Yee S 1 4 KS EEN Y a 5 owon 2 es LL 71 aK T GROUND CONTROL BOX THROUGH TERMINAL STRIP P2 d TRANSFORMER ND LEAVE BLADKLINGORNECTEI 141 0 p 1 ws 16v ve Pur 1 Sa WH T RD ee Ul 2 POWERINPUT CENTER TAP INPUT 2 iua PLATFORM Ne NEGATIVE 12V DC AUX NPUT 16 0V DC INPUT 3 gt 2 LA P1 m L POSITIVE 12V DC AUX INPUT FRONTRIGET 4 2 CONTROL EMERGENCY em LEVELING s LEVELING LED 15 REAR RIGHT 5 STOP y 416 INPUTS LED 14REAR LEFT 6 Bb T RD P a ILOWBATTERY LED 12 FRONT LEFT 7 1 1 SW8 BAA 166 LGGINDICATOR FOR 12V DC OUTPUT e CONTROL BK YL BATTERIES AUXILIARY LOWERING 12V DC OUTPUT ADIBLK NC ay 6617 12V DC OUTPUT sA BK WH 1 GROUND WHT 1 67 UP SIGNAL OUTPUT si INDIGATOR m a s UP SIGNAL OUTPUT DELAYED 12 3 UP POWER INDIGATOR 010 UP DOWN DOWN em mp L swa BOARD WA ELLE 6 ve Lu 1 _ 1 17 BN NARROW PLATFOR
32. c __ connector AD RD 00 0 BL B2 go BL RD ics BK BK RD EN4 WH WH RD PLATFORM Qa 8 RECEPTACLE P GROUND PLATFORM STD BK GN YL DOWN Genie BRAND Part No 38139 Super Series IWP Super Series 99 Service Manual May 2015 Electrical Schematic AWP Super Series DC Models from SN 3896 301 to 3896 430 100 2015 Service Manual Electrical Schematic AWP Super Series DC Models from SN 3896 431 to AWP07 54898 101 Service Manual May 2015 lt my Electrical Schematic AWP Super Series DC Models from SN 3896 431 to AWP07 54898 A B D E F G H L 1 KS1 GROUND PLATFORM BD BD Bn i K m
33. VALVE OPTIONAL WARNING LIGHT BL 4 M5 408 3 8 10 detti Mri 110V 220 8 4 MOTOR DETAIL MOTOR DETAIL GND ee ES0071_J 71_ Genie A TEREX BRAND 138 AWP Super Series IWP Super Series Part No 38139 2015 Service Manual Electrical Schematic AWP Super Series AC TUV Models from SN 3896 461 M L J G F E KS1 112 GROUND THERMAL PLATFORM RD 09 DEVICE RD TRANSFORMER BK m mt 7 pos P1 2 1212 160VDC INPUT 1 EMERGENGY DC POWER INPUT CENTER TAP INPUT 2 J PIOR LNEGATIVE 12V DC AUX INPUT 160 3 BD 9 jm RD BL POSITIVE 12V DO AUX INPUT LED 14 FRONTLEFT 4 WH
34. BL ub M WH 8 POWER GND TO PLATFORM rcu UD GROUND D M VAVE aera PE Y BK LM L L Genie 166 AWP Super Series IWP Super Series Part No 38139 2015 Service Manual Electrical Schematic Super Series AC Models from SN 4096 356 to 07 7065 M L K J D C B A 1 TO EMERGENCY 1 STOP BL BK PR NEN 1 YL B 16V AC INPUT 1 N C 12 IRDYL 1 NEGATIVE 12V DG INPUT ae 0 H GHOUND
35. SML els GND m m Y7 PLATFORM I Po CONTROL Swe GND 5 STUD EN2 Flao SWITCH a 5 es SW18 PE GROUND 4 28 tele wi CONTROL SWIT SW e BOX w ax eo BK Lec usc PLATFORM 8 ais Spy ee ee OUTREACH ueram 1 POWER 2l cl EE mee POWER UNIT B i BL OR WIRES 1 0 als ale RD 05 5 a LS1 98 gray QUICK DISCONNECT 21 WH LL 7 PLATFORM _ 1 WH 82 5 woe woe 5 _ BL POWER GN YL CHARGE h TO BASE EN4 WH E Wh s wo QUICK DISCONNECT GND 05 Y30 TO PLATFORM PLATFORM GROUND POWER SUPPLY 8 necemracie C SN 5 Genie BRAND Part No 38139 Super Series IWP Super Series 159 Service Manual May 2015 Electrical Schematic IWP Super Series DC Models with Power Assist and Outreach 160 2015 Service Manual Electrical Schematic Super Series DC Mode
36. 11215 160V DC INPUT 1 AD 3 ant PE E SWi6 wH BD _ BSE amp L 42V CENTER TAP INPUT 2 SW14 __ NC MIS Lr L NEGATIVE 12V DC AUX 16 0 DC INPUT WH W13 2 1 any POSITIVE 12V DC AUX INPUT Len ig FRONTLEFT 4 A 1 z CONTROL FT INDEATORS _ EMG LED 15 REAR RIGHT 5 Lo LED 14REARLEFT 8 Sw Ts RD RD of LOW BATTERY LED 12 FRONT LEFT 7 em 8 BAA 112 L13 12V DGSQUTEUT Rim XE CONTROL uu YL BATTERIES AUXILIARY LOWERING 12V DC OUTPUT o ADIBLIC NC I4 e 12V DC OUTPUT oA BL BK WH 114 EE GROUND 1 Saal UP SIGNAL OUTPUT 11 INDICATOR 3 Swit 15 UP SIGNAL OUTPUT DELAYED 12 BK mc UPL SW12 POWER INDICATOR U10 UP SIGNAL INPUT 13 I UP DOWN DOWN f AUXILIARY ab m PC BOARD WA L fo oe Pe EE dallo i CEP 5 75 52 d BN 4 GND WH NARROW PLATFORM UNITS WH AND WIRES REPLACE E GROUND wu 1 BL 2 AND OR 3 WIRES 4 STUD PR4 Bk ___________ 4 c
37. 7 POSITIVE 12V DC AUX INPUT 13 FRONTLEFT 4 2 tev LEVELING LED 15 REAR RIGHT 5 SWi5 EMERGENCY pnm INDICATORS INDICATOR i PE NEN ee INPUTS LED 14 REARLEFT BL SW16 RD RD Low BATTERY LED 12 FRONT LEFT 7 m SW14 RAR L 113 1145 12V DC OUTPUT BATTERIES 12V DC OUTPUT o SWIS __ od e a 12V DC OUTPUT 94 WHT 15 16 GROUND 1091 JLOW BATTERY UP SIGNALOUTPUT 1 Y7 PLATFORM INDICATOR ET d DOW 15 UP SIGNAL OUTPUT DELAYED 12 s 3 rowenoceon 11 UR SIGNAL INPUT 187 tf WA swie BOARD 0 DOWN 1 NARROW BN BASE WH SS TET es fs hs H OR 4 r BK Bc T 1 1 1 15 CIRCUIT BREAKER CIRCUIT BREAKER 1 1 4 TOV AC MODELS 220V AC MODELS E QD4 pepe 4 4 4 1 4 4 L BK 7 2 7 BK TIE nb e 2 s nb ee 4 e T BRE BN 5 2 5 YL 28 WH 4 2 4 GNNL 5 N27 TOV AG oR a 2 s oR TERMINAL STRIP 2 2 2 BL ynrrswitHour Lug DETAIL 1 15 wa REPLACE BLAND BN WIRES E ni
38. w3 150v pc INPUT 1 Cav DC POWERINPUT CENTER TAP INPUT 2 L NEGATIVE 12V DC AUX INPUT 1 amp 0V DG INPUT a 2 1 POSITIVE 12V DC AUX INPUT Len 14 FRONTLEFT 4 WH LEVELING LEVELING EMERGENCY INDIG ATORS E INDICATOR LED 12 FRONT RIGHT 5 BE INPUTS LED 13 REAR RIGHT 6 BD QT BD 15 REAR LEFT 7 114 L1 gFOWER INDICATOR 12V DC OUTPUT 8 BK BK 1 RD BK Qi BK Se 12V DC OUTPUT e d B4 ILOW BATTERY tavocoutpur me 1115 L413 npicator FOR GROUND hoe BATTERIES JAUXILIARY LOWERING Up siGNALOUTPUT 114 RD G7 UP SIGNAL OUTPUT DELAYED 12 3 SW12 DG MODEL 10 UP SIGNAL INPUT ust m AUXILIARY LOW BATTERY WA INDICATOR PC BOARD BN Qu RD z 8 2 EMERGENCY ENI WH als RD PLATFORM CONTROL l own y 1 eee EN2 f p ws GROUND CONTROL STUD TERMINAL 171 STRIP CONTROL dl TECE BOX 8 5 11 PLATFORM BK UP DOWN DOWN 6 ae E 17 QD7 RELEF NARROW PLATFORM UNITS I ja WHANDBKWIRESREPLACE if i MOTOR E kx Sx rx Ex BL
39. 123 4 5 6 7 QN aos dB BUD uz Xe sg lx jq 1 825 gaz ENS DAE EX BUMP RD rae 0 PCM ee BL 5 VALVE YANG BL ete 1 5 oh 3 POWER 8 N10 PLATFORM GN YL 110V 220V GFA MOTORDETAIL MOTOR DETAIL Y7 8 RECEPTACLE aa 8 GND WHBK Su ak N ou ae PLATFORM M E Genie BRAND 118 AWP Super Series IWP Super Series Part No 38139 2015 Service Manual Electrical Schematic AWP Super Series AC Models from SN 3896 451 to AWP07 54898 G F E D n
40. 12 L QIINDICATOR FOR 12V OUTPUT ES CONTROL om parrenics ALLY LOWERING 32v OUTPUT AD BLK NG e e 17 12V DC OUTPUT 9 BL BK 1 WH 114 115 6 GROUND 10 BATTERY UP SIGNAL OUTPUT Swit 15 UP SIGNAL OUTPUT DELAYED 12 BK NARROW 3 OR 1 UPL SW12 POWER INDICATOR U1 0 UPDOWN DOWN f AUXILIARY __ _ __ pe m PC BOARD Wa ia lc a 5 Mo NU BN BN a 7 N17 GND NARROW PLATFORM UNITS x WH WIRES REPLACE ml m GROUND 1 SELO AND WIRES L STUD ES 4 x M eat 4 a S 2 CIRCUIT BREAKER 240V MODELS i TOS EELS RTOS ara 7 gt 7 RECEPTACLE 5 5 15A CIRCUIT BREAKER WH H 4 2 44 GNYL 0 120V AC MODELS ons 38 1 0 5 CB4 CIRCUIT BREAKER alu E w5 BL 2 2 240V AC MODELS 55 2 TERMINAL STRIP A j 1 ote o e 6 y
41. 85 6 1 Tilt back 85 87 eV 87 7 2 Platform Control BOX cdit creed eta 88 7 3 Platform Outreach nnn 89 Genie xii Super Series IWP Super Series Part No 38139 2015 Table of Contents Section 5 a A in 91 RETI TETTE 91 Electrical Component and Wire Color 92 Electrical Symbol begend m coating ce tt solace ca 94 Hydraulic Symbols 95 Electrical Schematics AWP Models 0 2 97 Electrical Schematic AWP Super Series DC Models from SN 3896 101 to 3896 300 4 4 4 98 Electrical Schematic AWP Super Series DC Models from SN 3896 301 to 3896 430 2 4 1 99 Electrical Schematic AWP Super Series DC Models from SN 3896 431 to 7 54898 102 Electrical Schematic AWP Super Series DC Models with Standard Base from SN 07 54899 00 103 Electrical Schematic AWP Super Series DC
42. RD BK ILOW BATTERY GNYL B4 IL15 1 FOR GROUND 10 nv Mc alia AUXILIARY LOWERING SIGNAL OUTPUT 114 RD BATTERIES 447 UP SIGNAL OUTPUT DELAYED 12 3 SW12 UP SIGNAL INPUT 13 AUXILIARY LOW BATTERY U 1 0 DOWN INDICATOR W4 ____ __ _____ 4 a 2 EMERGENCY 1 WH RD PLATFORM CONTROL GND GROUND 5 M EN2 ND ue 2 ama OM TERMINAL 5 CONTROL E 52 BOX 8 5 11 PLATFORM UP DOWN DOWN 6 55 ARM NE EE 1 17 QD7 STRAIN RELIEF NARROW PLATFORM UNITS IN WH AND BK WIRES REPLACE a is 56 m BL AND WIRES 4 Be 05 515 58 es gal 68 B9 ES 59 ad Emm POWER OB xi g a ot say 003 12 34 71 1 titi x xx Ez we QUICK DISCONNECT QUICK DISCONNECT 1240404 EE eee 7 PLATFORM Luo vL I er te lee al 5 12 34 4 F QD1 12 84 5 6 7 2 BATTERY __ RD BD Ho Hn Bi Ro BD BL AD
43. E 52 OUTREACH TO 17 QD7 STRAIN RELIEF SS SSS i OPTION PLATFORM NARROW PLATFORM UNITS M WH BK WIRES REPLACE 2 MOTOR POWER UNIT BLAND OR WIRES tL 2 E i 05 2 518 amp m 151 d 5 8 POWER QD3 234 6 7 PLATFORM SUPPLY EXTENTION AC DISCONNECT A i 4 TO PLATFORM po WH 7 i 12 34 7 2 BATTERY BATTERY 5 12V DC 128 DC 5 1 _ cance mU TOBASE WH EN4 WH WH QUICK DISCONNECTA a POWER TO 05 Y30 TO PLATFORM PLATFORM GND POWER SUPPLY EN STUD AC DUMP VALVE SIM a ee 8 110V 220V AC _ BK ATEREX BRAND Part No 38139 AWP Super Series IWP Super Series 151 Service Manual May 2015 Electrical Schematic IWP Super Series DC Models with Power Assist Directional Valve Coils Powering Function Manifold 152 153 2015 Service Manual fit Electrical Schematic IWP Super Series DC TUV Models Service Manual n Electrical Schematic Super Series DC Models 154 May 2015
44. ES LEVELING LED 12 FRONT RIGHT 5 oR oe L Nog LED 13 REAR RIGHT 6 LED 15 REAR LEFT 7 POWER INDICATOR Et L14 112 12V DC OUTPUT 8 16 12V OUTPUT 9 1 SW12 LOW BATTERY 12V DC OUTPUT 15 13 Fon GROUND 10 WH PE xcM AUXILIARY LOWERING ens BL BL U10 UP SIGNAL OUTPUT DELAYED 12 BK dg UP SIGNALINPUT 196 i PC BOARD WA REMOTE BOX CONTROL RE BBs sw P2 CONTROL EMERGENCY ACTIVATE STOP pte wis GND GROUND 2 STUD E E N9 1 220V 4 W5 TERMINAL STRIP TERMINAL STRIP swn avr GND PLATFORM GROUND UP DOWN oD BK up DOWN f 8 TS EN2 _ NARROW GROUND WIRES REPLACE Sx px Ex e BLAND OR WIRES 5 Eg DE al x CONTROL 58 88 a Wedel ee ee pown QD3 4 7 QD7 BOX 25 8 ae id 904 mm YOPLATFORM NR n Y 1 1311424 T e EX P gt gt gt oR BD 0 1 BL BE gen E POWER TO 1 PLATFORM WH WH 5 N10 GFCI 4 RECEPTACLE m 4 7 MOTOR DETAIL 110V 220
45. GND TO PLATFORM PLATFORM GROUND GND 8 RECEPTACLE GN YL UD DUMP VALVE 110V 220 AC _ Genie Part No 38139 Super Series IWP Super Series 167 Service Manual May 2015 Electrical Schematic IWP Super Series AC Models from SN 4096 356 to 07 7065 168 2015 Service Manual Electrical Schematic Super Series AC Models from SN IWP07 7066 to 07 57594 169 Service Manual May 2015 ese Electrical Schematic Super Series AC Models from SN IWP07 7066 to IWP07 57594 A B D E F G H J K L M N eur 20520540
46. Part No 38139 Genie AWP Super Series IWP Super Series 182 2015 Service Manual Hydraulic Schematic Super Series Models without Power Assist J H G F E D BASE LIFT CYLINDER PLATFORM LIFT CYLINDER ___1 CYL _ OR B ao S es 0 760 030 0 760 5 i 7 2 t Offs mW owe 140 bar D 2 FO y P FOOTPUMP MANIFOLD ASSY X TAM E TANK PRESSURE 4 5 ___ TANK _________ __ M FF H QoO 7 mw MO POWER UNIT ASSEMBLY Genie Part No 38139 BRAND Super Series IWP Super Series 183 Service Manual May 2015 Hydraulic Schematic Super Series Models without Power Assist 184 185 2015 Service Manual Hydraulic Schematic IWP Super Series Models with Power Assist Service Manual May 2015 Hydraulic Schematic IWP Super Series Models with Power Assist
47. tight and free of corrosion Note Adding terminal protectors and a corrosion preventative sealant will help eliminate corrosion on the battery terminals and cables 3 Remove the battery vent caps and check the specific gravity of each battery cell with a hydrometer Result If any battery cell displays a specific gravity of less than 1 026 the battery must be replaced 4 Check the battery acid level If needed replenish with distilled water to the bottom of the battery fill tube Do not overfill 5 Install the battery vent caps 6 If equipped Set the battery charger AC Selector switch to the proper voltage 7 Setthe power switch to the AUTO position 8 Result The charger ammeter should be on Checklist B Procedures B 2 Inspect the Electrical Wiring Genie requires that this procedure be performed every 250 hours or quarterly whichever comes first 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 A WARNING Electrocution burn hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry 1 Inspect the following areas for burnt chafed corroded pinched and loose wires e All base wiring Inside ground control box
48. 5 PLATFORM GROUND a POWER SUPPLY 4 ag ______ L_e _ Genie 142 AWP Super Series IWP Super Series Part No 38139 2015 Service Manual _________________________________________________________________ __________ Electrical Schematic IWP Super Series DC Models from SN 4096 288 to 4096 341 ee ud DE LM E Lands TUM NITET 1 BK STOP o BK ae AE E RD 12V DC POWER INPUT z L NEGATIVE 12V DG INPUT ae POSITIVE 12V DC INPUT WH KSI LED 142VDCINPUT 4 ps 2 INDICATORS _ LED 2 127 5 PLATFORM 15 LED312VDCINPUT 6 e IPOWER IN
49. DENOTES WIRE TO BE TAGGED _ 5 2806 amp A 5 5 5 fs es STRANRELEF _ ___ Lo LUIS 0 PELO TO PLUG SENE _ sii 8 QD3 1234567 Inana Ah anl 4 05 1234567 c TI LU P somiy Mii z cuir B 58 2 H4 STRAIN RELIEF _ UUU DESCENT _ eS eS SS ALARM TO MOTOR N PLUG N eS WH AND BK WIRES REPLACE 1 1 7 BL AND BN WIRES GROUND GROUND van m FB2 SCREW 30 SCREW Y30 WARNING Iz x z Nal 529 duh lz X z 42X DUMP A VALVE 22 J BOX VALVE WARNING LIGHT 1 5 4m 1 M5 i DESCENT ALARM im 2 2 WH 2 4 1 DETAIL DETAIL 8 GND GND ESO071 J BRAND 38139 Super Series IWP Super Series 135 Service Manual May 2015 Electrical Schematic AWP Super Series AC CE Models with Standard Base from SN AWP07 57595 136 137 2015 Service Manual Electrical Schematic AWP Super Series AC CE Models with Narrow Base from SN AWP07 57595 Service Manual May 2015 lt Electrical Schematic AWP Super Series CE Models with Narrow Base
50. E POWER TO PLATFORM arci 69 x Hi GROUND STUD we PLATFORM May 2015 Service Manual Electrical Schematic Super Series AC Models with Narrow Base from SN AWP07 54899 to AWP07 57594 J H G F E D RD BLK BD 5 P Lin EN2 poo 2 FOR 240 V OPERATION i JUMPER BROWN TO WHITE x GROUND CONTROL BOX US THROUGH TERMINAL STRIP FRONT LEFT TRANSFORMER LEAVE BLACK UNGONNECTE y INTERLOCK E EN 112151 W3 DG INPUT po BN id REAR RIGHT L L12VDCPOWERINPUT CENTER TAP INPUT 2 n i 1 INTERLOGK L NEGATIVE 12V DC AUX INPUT 160 DC INPUT 3 o 6 wi REAR LEFT
51. d 15 5 5 LS 6 885 d 28 P m STRAIN RELIEF oo TT rma ______ 0031122456 ET ds POWER We E DESCENT PME D 7 e POWER UNIT BK FB2 MOTOR WARNING Bic B2 TEN _ M5 AND MOTOR WH DESGENT ALARM Yao EX Ma we Genie BRAND 110 AWP Super Series IWP Super Series Part No 38139 GN YL STANDARD WH RD INTERLOCK FRONT LEFT RD RD INTERLOCK REAR RIGHT OR RD INTERLOCK REAR LEFT BL RD __ 16 _ SW13 _ SW14 _ NC Y7 PLATFORM DOWN ES0070_G 2015 Electrical Schematic Super Series DC CE Models with Narrow from SN AWP07 54899
52. m 2 5 _ RO 2 1 B Ms POWER ASSIST MANIFOLD ASSY iene m HYDRAULIC POWER UNIT BASE LIFT 2 CYLINDER zm 030 in 0 760 VENERE 6 0 O _ NEN 0 wk 7 LJ O CYLINDER 1600 psi 4 110 FOOTPUMP MANIFOLD B BRAND 38139 Super Series IWP Super Series 187 Service Manual May 2015 Hydraulic Schematic Super Series Models with Power Assist and Brake Genie A TEREX BRAND 188 AWP Super Series IWP Super Series Part No 38139 Genie Scandinavia Phone 0046 3157 5154 Fax 0046 3157 5104 Genie France Phone 0033 237 260 986 Fax 0033 237 260 998 Genie Iberica Phone 0034 935 725 090 Fax 0034 935 725 080 Genie Germany Phone 0800 180 9017 Phone 0049 4221 491 821 Fax 0049 4221 491 820 Genie U K Phone 0044 1476 584 333 Fax 0044 1476 584 330 Genie Mexico City Phone 452 55 5666 5242 Fax 52 55 5666 3241 Genie North America Phone 425 881 1800 Toll Free USA and Canada 800 536 1800 Fax 425 883 3475 Genie Australia Pty Ltd Phone 61 7 3456 4444 Fax 61 7 3375 1002 Genie China Phone 86 21 53853768 Fax 86 21 53852569 Genie Sinapore Phone 65 675335
53. 114 115 06 mone GROUND io BATTERIES ____ __ LOW BATTERY UP SIGNAL OUTPUT n BB INDICATOR NARROW 3 SW 415 UP SIGNAL OUTPUT DELAYED 12 pLatronm POWER INDICATOR U1 0 UPSIGNALINEUT 13 UP DOWN DOWN 2 WA L ITI u uu AUXILIARY PC BOARD 1 DOWN LO 7 17 lt NARROW PLATFORM UNITS x WIRES REPLACE BK 4 BL AND ORG WIRES L 502 42 a 58 GND WH GROUND STUD 4 GND POWER GROUND 004 PLATFORM D 8 7 71 ES _____ RECEPTACLE PE P WS 2 gt ps 1 BN 5 2 5 v 5 0 NR TERMNAL GROUND aun T T STRIP OR H 2 3 5 5 ane a CONTROL BL PERIE Hj WH AND BK WIRES 3 BOX wif 5 4 WH A REPLACE BL 1 AND BN 7 WIRES 86 Ld p Liege ___________ 28565 e ___ __STRAIN RELIEF 6 qatto TO MOTOR 7 00311254567 1399994 D5 123456 7 EH SUPPLY ag z AG 000 DESCENT L ALARM l EWNWIEDUOENETO on POWER UNIT 7 l ws BK 2 Ro MOTOR sic AD CONTACTOR LIGHT BATTERY OPTIONAL 12V DC 1 WARNING LIGHT ES QD1 M5 ug
54. AWP Super Series Super Series 77 Service Manual ssi Mast Components How to Remove the Mast 10 Assembly IWPS Models AWARNING AWARNING 78 11 Bodily injury hazard This procedure requires specific repair skills lifting equipment and a suitable workshop Attempting 12 this procedure without these skills and tools could result in death or serious injury and significant component damage Dealer service is strongly recommended 13 14 Fully lower the platform Turn the key switch off and remove the key Pull the base lowering handle to fully lower the base Remove the platform Refer to Repair Procedure How to Remove an Aluminum Platform Remove the power pack Refer to Repair Procedure How to Change a Power Pack Tag disconnect and plug the lift cylinder hydraulic hoses Remove the flow control valve from the cylinder Cap the cylinder ports Bodily injury 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 Remove the level sensor assembly mounting fasteners Remove the base lowering cable mounting fasteners from the side of the mast Disconnect the control cable tension spring Genie AWP Super Series IWP Super Series CAUTION May 2015 Attach an overhead crane to the lifting eye at the top of the mast Remove the four m
55. 9 6 24 1 me 2 a BK 4 4 4 s N30 he N29 4 gi ok DENOTES ANEUTRAD 5 X EE nov Ac 220V ac WIRE TO BE TAGGED 28685 UL TERMINAL STRIP MOHAN SLEEVE p _ _ _ 59 ita eal T fits 6 QD3 AA LIA 112 4 56 7 E ae SUPPLY GNAL x 2 a H4 STRAIN RELIEF _ 000 DESCENT _ ALARM TO MOTOR N27 N e WH AND WIRES REPLACE N BLAND EN WIRES Z 7 Se 8 Y30 WARNING N C l UGHT 8 5 DUMP VALVE BOX VALVE OPTIONAL WARNING LIGHT BL 1 5 5 IDESCENT ALARM 223 N10 110 AC 220 lta 47 MOTOR DETAIL B MOTOR DETAIL E SND GND 8 Accs ea er ers P es 50071_ BRAND 38139 Super Series IWP Super Series 127 Service Manual May 2015 Electrical Schematic Super Series AC Models with Narrow Base from SN AWP07 57595 128 2015 Service Manual El
56. BL AND BN hs GS 5 FB2 SCREW 5 30 30 ENS E X DUMP 42X DUMP FS BOX VALVE VALVE OPTIONAL wannie aa a 1 5 DESCENT ALARM 08 3 8 10 pce MIA 110V AC 220 V AC DETAIL MOTOR DETAIL t 1 ES0071_J Du a eee Genie 126 AWP Super Series IWP Super Series Part No 38139 2015 Service Manual Electrical Schematic AWP Super Series AC Models with Narrow Base from SN AWP07 57595
57. ae ee SS eee eee 112 1 THERMAL P1 KS1 09 DEVICE EMERGENCY GROUND n TRANSFORMER STOP PLATFORM BK YL 0 emt e _ EEEERS 1 1212 160v DCINPUT e lm i ra t i DC POWER INPUT CENTER TAP INPUT 2 ftom BN 4 L NEGATIVE 12V DG AUX INPUT teov DCINPUT a e PP FERRUM POSITIVE 12V AUX INPUT LED 14 FRONT LEFT 4 H WH swi2 D MEME out j AUXILIARY B1 T INPUTS LED 13 REAR RIGHT 6 H i 1 RD DOWN ie 161 5 LED 15 REAR LEFT 7 V L14 L12 12V DCOUTPUT e BK e amp 416 12V DC OUTPUT 9 PD 1 RD BATTERY 12V DG OUTPUT _ 115 113 INDICATOR GROUND 1oe 7 GNYL AUXILIARY LOWERING he PP 17 UP SIGNAL OUTPUT DELAYED 12 BG MODEL U10 UP SIGNAL INPUT 3 Ew POBOARD E S wa BK WIRE DISCONNECTED K IP FPR 15A CIRCUIT BREAKER 4 iov ac moneLs CIRGUIT BREAKER Leg re 220V AC MODELS PLATFORM P2 F EMERGENCY GND SS CONTROL se GROUND 4 aaax 8 8 BOX m ER nn STUD o N7 5 NG 7 4 4 110V bi W5 TERMINAL STRIP TERMINAL DETAIL B
58. e LED 15 REAR LEFT 7 put POWER INDICATOR BK 114 112 IVDC OUTPUT PA Gis 12V DC OUTPUT o NG ws 12V DC OUTPUT ONNYL B4 115 FOR GROUND 10 LOWERING SIGNAL OUTPUT e PP 8 BATTERIES UP SIGNAL OUTPUT DELAYED 12 3 SW12 mone U10 UP SIGNALINPUT 13 on AUXILIARY W4 Es BOARD EMERGENCY PLATFORM NC CONTROL E BOX GROUND E a STUD EN2 5 GND Ge ave crow GROUND TERMINAL ACTIVATE STRIP CONTROL x g BOX swit 4 puarorm UP UP DOWN DOWN 9 mos ae N E 17 STRANREIUEF NARROW UNTS 2 WH WIRES REPLACE d J 1 2 TO MOTOR ox M BLAND OR WIRES b al S a J cl 58 2 Z 5 52 2 JEN UN EB 58 E Lu 4 88 ops is ttt 7 5 TFFRETT QUICK DISCONNECT 1 L QUICK DISCONNECT B ECG GO qe TO PLATFORM TO eae 7 12 34 67 Pak 5 12 34 5 7 12846567
59. p STANDARD UPL SW12 POWER INDIGATOR U UP SIGNAL INPUT 13 DOWN 1 AUXILIARY NR re PC BOARD Ws BN BN 1 i NARROW PLATFORM UNITS D WH AND BK WIRES B GROUND wal gi new d w 4 5 it 2 9 CIRCUIT BREAKER 240V MODELS EN POWER NN Marl 7 1 RECEPTAGLE ro UN 55 15A CIRCUIT BREAKER T 4 2 4 GNIYL 5 5 120V AC MODELS AD 09 W5 eI EUN 5 7 POV AG MODELS E S 8 TERMINAL STRIP BL pp 2 2 2 BL Hii 1 14 WH 3 B a N30 LL A 110V 220 WIRE TAGGED a5 5 es 5 5 TERMINAL STRIP WITH AN SLEEVE meme ____ LA Em 6 Mc mee ADIA A A AA A Al Ds 1283456 7 Fl SUPPLY 5 5 _ 9 000 SS SS lt 7 7 ee oc peut temm T S 7
60. 0031275 07 QUICK DISCONNECT J EXTENTION 7 0 ped wh 125107 wi WH RD 1 OR 5 aL Tm ru BASE WH WH ih gt QUICK DISCONNECT GND 3 Y30 TO PLATFORM QD3 PLATFORM GROUND NO GFCI STUD GNNL GROUND DUMP VALVE cea GE NER UAE lee Genie Part No 38139 Super Series IWP Super Series 175 Service Manual May 2015 Electrical Schematic IWP Super Series AC Models Without Base Mounted Junction Box 176 177 2015 Service Manual Dn ______E Electrical Schematic IWP Super Series AC TUV Models with Outreach Service Manual May 2015 Electrical Schematic Super Series Models with Outreach
61. 1 Besure the platform is fully lowered 2 Inspectthe lubricator canister for proper oil level Result The oil level must be within inch 12 7 mm from the top of the lubricator canister 3 Toaddoil remove the oil lubricator canister from the lubricator base and fill with oil Install the canister back onto the lubricator base 1 oil lubricator base 2 oil lubricator canister Specification Oil Type 10W automotive engine oil Genie BRAND Super Series IWP Super Series 29 Part No 38139 Service Manual May 2015 Checklist A Procedures A 18 Check the Air Supply Lubricator Drip Rate Air Models Genie specifications require that this procedure be performed every 8 hours or daily whichever comes first Maintaining the proper oil drip rate into the air supply is essential to safe operation and good machine performance Failure to maintain the proper drip rate could result in machine component damage 1 While raising the platform visually inspect the oil lubricator sight gauge Result There should be a maximum of 1 to 2 drops of oil visible in the sight gauge 2 To adjust the drip rate turn the oil flow control valve clockwise to decrease the flow or counterclockwise to increase the flow 3 Repeat this procedure until the proper oil drip rate is achieved 1 oil lubricator flow control valve 2 oil lubricator sight gauge A 1
62. 110V WH 2 220 VAG 8 Du MOTOR DETAIL 1 MOTOR DETAIL GND GND _____________________ ES0073_G 2 Genie BRAND 170 AWP Super Series IWP Super Series Part No 38139 EMERGENCY EN 7 el PLATFORM CONTROL ACTIVATE 21 SW8 DOWN f NARROW PLATFORMUNITS cr S WH AND BK WIRES REPLACE m BL 2 AND OR 3 WIRES N ROUND STUD L May 2015 ___________________________________________ ____ Service Manual Electrical Schematic Super Series AC Models FOR 240 V OPERATION JUMPER BROWN WHITE N son THROUGH TERMINAL STRIP AND LEAVE Y KS1 lt PLATFORM l BLACK UN
63. 157 2015 Service Manual Electrical Schematic Super Series DC Models with Power Assist Service Manual May 2015 Electrical Schematic Super Series DC Models with Power Assist A B STEER HANDLE DRIVE P1 CONTROLS MANIFOLD EMERGENCY E P3 SW21 H1 BK EMERGENCY DIRECTION REVERSING 1 Y BK BK a es OPTION SAT ETYSWITCH DRIVE 5 E 2 1 lI 4 1 KS A 2 PLATFORM DIE LEVELING 9 SW22 WH FUNCTION
64. 3 Remove the socket head retaining bolt from the clevis block on the lift cylinder rod end 14 Remove the adjustment nuts from the chain tension rocker on the carriage 15 Slide the carriage out the bottom of the mast assembly 16 Lay the chains out on the floor at the top of the mast Do not allow the chains to become twisted or dirty 17 Remove the adjustment nuts from the chain tension rocker on the column 1 top of no 1 column 2 retaining fastener 18 Slide the column out the bottom of the mast 3 clevis block 19 Push the next column toward the top of the mast to access the idler wheel assembly 4 Supportthe cylinder and carefully slide it out of mounting fasteners the bottom of the mast 20 Hold the idler wheel axle from turning by 5 Carefully rotate the mast until the carriage is placing a screwdriver in the hole of the axle facing Up Remove the axle mounting fasteners and 6 Remove the mast covers remove the idler wheel assembly 7 Remove the cover from the platform control 21 Remove the adjustment nuts from the chain box Remove the control box mounting tension rocker on the column 22 Slide column out bottom of the mast 8 Remove the control box and control cable and 23 aside Repeat steps 19 through 22 for each remaining column 9 IWPS models Remove the base lowering Note If the chains are removed mark the location cable bracket from the mast and label each chai
65. C3 ae vi NN BK BK GNAL Part No 38139 Super Series IWP Super Series Service Manual May 2015 Electrical Schematic AWP Super Series AC TUV Models from SN 3896 461 140 2015 Service Manual Electrical Schematic Super SeriesDC Models from SN 4096 101 to 4096 287 141 Service Manual May 2015 Electrical Schematic IWP Super Series DC Models from SN 4096 101 to 4096 287 A B C D E F G H J K L et a P 1 1 EMERGENCY BK STOP T BK BK BD ee 12 DC POWER INPUT gt NEGATIVE 12V DC INPUT ae m 5 KS1 ED AANDE NEUT GROUND INDICATORS 5 Bi e POWER INDICATOR
66. Corner access wall 5 31 1 20 in 30 17 38 34 21 in 51 26 CE Outdoor 80 50 8 cm 76 2 44 4 cm 98 4 53 3 129 5 67 3 of platform top rail to corner of wall with ability to rotate the leveling jack Platform Dimensions Gated ultra narrow platform Lx Wx H 22x 18x 44 56 x 46 x 114 cm Narrow fiber platform Lx W x H 26 x 22 x 43 66 x 56 x 110 cm Gated narrow platform Lx Wx H 26 x 20 x 44 66 x 51 x 14 Part No 38139 Genie BRAND Super Series IWP Super Series Service Manual May 2015 Specifications Model AWP 15S AWP 20S AWP 25S AWP 30S Rough Terrain Base Machine weight 715 625 165 750 660 Ibs 784 694 Ibs 819 729 Ibs AC and Air models 324 5 283 7 kg 339 7 298 9 kg 355 3 314 6 kg 371 330 2 kg Height stowed 79 in 79 in 79 in 79 in 201 cm 201 cm 201 cm 201 cm Width 29 Yin 29 in 29 29 75 75 75 cm 75 Length 58 in 58 in 58 in 58 in 147 cm 147 cm 147 cm 147 cm Outrigger footprint 64 x 48 in 64 x 48 in 64 x 48 in 71 72x58 I x w Domestic 162 5 x 122 5 cm 162 5 x 122 5 cm 162 5 x 122 5 cm 181 6 x 147 3 cm Outrigger footprint 71 72x58 in 74 2 65 in 83 x 74 in 95 x 89 in Ix CSA 181 6 x 147 3 cm 189 2 x 166 3 cm 211 4 x 187 9 cm 241 9 x 227 9 cm Outrigger footprint 64 x 48 in 71 x 58
67. 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 1 Visually inspect each column for the following Dents gouges or abrasions e Bends or warping e Excessive wear 2 Raise and lower the platform through a complete cycle Result The platform should raise and lower smoothly free of hesitation and binding Genie 24 Super Series Super Series Part No 38139 2015 Service Manual A 11 Check the Sequencing Cables Genie specifications require that this procedure be performed every 8 hours or daily whichever comes first 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 1 Visually inspect the cables and components for the following e Frayed or broken wire strands e Kinks in the cable Corrosion e Paint or foreign materials e Broken or damaged pulleys e Unusual or excessive pulley wear e Split or crack
68. El RD INTERLOCK EMERGENCY pipe pA ea a INTERLOCK EN1 ___ 112138 W3 160 1 1 Imm B r REAR RIGHT wH AD Pd 12 POWER INPUT CENTER TAP INPUT 2 a pee RD INTERLOCK PLATFORM NE L NEGATIVE 12V DG AUX INPUT 1 amp 0V DC INPUT 3 aes MH REAR LEFT 1 L POSITIVE 12V DG AUX INPUT i3 RONTRIGHT 4 BD cde 2 CONTROL EMERGENCY LEVELING gt LED 15 REAR RIGHT 5 SW ct e 446 INPUTS iunc EE T BK 16 RD RD RD LOW BATTERY LED 12 FRONT LEFT 7 5 13 Sws ED EE L 15 LOWERING 2 AD BLK SW14 16 817 OUTPUT BK LL gm L14oc wena GROUND 10 WHT 5 LLLI LON BATTERY UP SIGNAL OUTPUT 141 OR Y7 PLATFORM INDICATOR m DOWN SW OL 15 UP SIGNAL OUTPUT DELAYED 12 3 POWER INDICATOR U10 UP SIGNAL INPUT 134 nm UP DOWN DOWN T m PC BOARD w DOWN n MEME STANDARD 17 BN NARROW PLATFORM UNITS BL WH AND WIRES
69. INDIGATORS LED 2 12V DG INPUT s ina BK a PD 5 BL FORWARD GNYL E POWER INDICATOR 20312000 8 4 1 116 BK LED412V DG INPUT 7 2 SWITCH g RD DRIVE m 114 12 Gs 12v pc ouTPUT 8 E 21 a BATTERY 12V DC OUTPUT AD E INDICATOR FOR 12V DG ouTPuT i Ld B4 115 GROUND 10 BAA 12V DC MOTOR SOLENOID OUTPUT 11 RO BATTERIES 1 SECOND TIME DELAY 12V DC OUTPUT 12 3 SW12 ei 12V DC UP SIANAL INPUT 13 mL AU AY a U10 MI a L PRCBOARD 2 4 a T 1 ME P2 W6 EMERGENCY TERMINAL RR j BK PLATFORM GND WH 5 ee Y7 CONTROL STUD 8 F Layt 9 e SW8 ND 15 5 m T6 ol CONTROL GROUND 8 5 STUD EN2 on B SWITCH BL 5 BL e SW18 GROUND 2181 He rele ic BK J CONTROL SW17 m BK SW11 m PLATFORM 6 cor eg J UU PLATFORM pw OUTREACH TO
70. IWPS 23 A 8 Test the Auxiliary Platform Lowering Operation 23 A 9 Test the Manual Platform Lowering Operation 24 A 10 Inspect the Columns for Damage sse 24 A 11 Check the Sequencing Cables sssssseeee emen 25 A 12 Check the Interlock System for Proper 25 A 13 Test the Power and Function Controls 4 27 A 14 Inspect the Lifting Chains and Idler Wheels 27 15 Inspect the Breather eene 28 A 16 Check the Tire Pressure AWPS Models with Rough Terrain Base 29 A 17 Check the Air Supply Lubricator Oil Level Air 29 A 18 Check the Air Supply Lubricator Rate Air Models 30 A 19 Check the Air Filter Regulator Canister Air 30 Genie BRAND Part No 38139 Super Series IWP Super Series ix 2015 c __ _ ______ ___ Table of Contents Checklist 31 B 1 Inspect Battery 31 B 2 Inspect th
71. Leya 12V DC INPUT INV DO INPUT 7 8 1 PLATFORM e INDICATORS _ 15 12V DC INPUT 5 _ 2 POWER INDIGATOR LED S 12VDGINPUT e ipm BK BK LED15 12V DC INPUT 7 H4 112 6 12V DC OUTPUT 8 2 INDICATOR FOR TEV DS OUTPUT B BK li 15 12V DC OUTPUT 9A e s BA 12V DG MOTOR Bu i n BATTERIES gwe m ra AN INDICATOR U10 WH DOWN phe aa 4 2 W6 Ll CH fm su guo am LETS n m vr ndi PLATFORM INL I ES Tet gt STUD 518 Tele CONTROL SWS8 GND WH 4 5 amp oN 5 CONTROL STUD on 2 2 er smon CB1 EN2 x n SW18 BK GROUND wi wet Fond ME CONTROL swit ec BOX a ae eer eee 6 SWITCH Er z PLATFORM 4 amp gu OUTREACH TO rower QD7 PLATFORM UU TO MOTOR m SS ee a sg POWER 0312 3 67 PLATFORM SUPPLY EXTENTION AS _ 7 PLATFORM 1 3467 gt RD N on 5 eee eee no WH WH ne QUICK DISCONNECT A
72. Remove the weight from the platform Bleed the hydraulic system by raising the platform to full height If the pump cavitates or the platform fails to reach full height add hydraulic oil until the pump is functioning correctly Do not overfill the hydraulic tank Component damage hazard Do not continue to operate the machine if the hydraulic pump is cavitating Install the breather cap and the power unit cover May 2015 3 8 How to Test the Motor Start Solenoid DC Models Electrocution burn hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry AWARNING Electrocution hazard Disconnect the ground cable from the battery before performing this procedure AWARNING 1 Tag and disconnect the electrical wiring from the motor start solenoid 2 Connect the leads from an ohmmeter to the following terminal combinations and check the continuity resistance Test Small post to ground Desired result 13 to 170 no continuity infinite 2 large posts 1 high amp power terminal large posts 2 solenoid coil terminal small post 3 Connect 12V DC to the small post and a ground wire to the case of the solenoid then test the following terminal combinations Test Desired result 2 large posts continuity zero Genie AWP Super Series IWP Super Series Part No 38139 2015 Service Manual
73. a m TO PLATFORM IT TO MOTOR sk LL MET Yoy x T E T T T GROUND Y30 Z 1234 5 6 iE zd pd DUMP EX 2 E ENS VALVE DUMP RD VALVE RD 1 5 1 N8 N10 AD ow 3 27 lt 220V AC 8 am MOTOR DETAIL MOTOR DETAIL 110V 220V AG GNYL GROUND e PLATFORM BK P y _ DOWN 130 AWP Super Series IWP Super Series Genie A TEREX BRAND Part No 38139 2015 Service Manual _ Electrical Schematic AWP Super Series AC CE Models with Standard Base from SN AWP07 54899 to AWP07 57594
74. lt MOTOR DESCENT ALARM m RD AD F11 inem n CHARGER BKEK 175 AMP FUSE Y30 8 E je 05 PLUGS ES0070_G VALVE INPUT Genie BRAND 106 AWP Super Series IWP Super Series Part No 38139 2015 Service Manual Electrical Schematic AWP Super Series DC CE Models from SN 3896 432 to AWP07 54898 M L K J D C B A KS1 1 BK RD RD RD BK BK BK cae De ER SEKSI T 13 16 0 DC INPUT 1 SE L42V DC POWER INPUT CENTER TAP INPUT 2 RD FD Rb L NEGATIVE 12 AUX INPUT 18 0 DG INPUT 3 POSITIVE 12V DC AUX INPUT TED 14 FRONTLEFT 4 WH 1 LEVELING LING LED 12 FRONT RIGHT 2 EMERGENCY JNDICATORS _ INDICATOR LED i R
75. 17 STRAIN RELIEF SSS OPTION PLATFORM NARROW PLATFORM UNITS R WH AND BK WIRES TO MOTOR BLAND on WIRES 4 E iE 05 2158 x x fee EL UM mem 7 ___ L oocosconneora __ _ M PLATFORM 4 1234 67 3223 5 5 o 12VDC 12 56 8 5 co POWERIGN YL CHARGE mL zd its pu QD3 POWER TO GND ES Y30 TO PLATFORM 8 o in d s RECEPTACLE gem p 220 BK SS SS A Genie 158 AWP Super Series IWP Super Series Part No 38139 2015 Service Manual __________________________________________________________________________________________________________ Electrical Schematic Super Series Models with Power Assist and Outreach
76. 20S 25S AC DC Hydraulic fluid Chevron Rando HD equivalant 305 Hydraulic tank capacity 3 quarts Platform up 40 seconds 30 seconds all models 2 8 liters Platform down 28 seconds 28 seconds Hydraulic System Pressure 7 AWP 36S AC DC All models 1600 psi Platform up 40 seconds 52 seconds 110 bar Platform down 42 seconds 42 seconds Hydraulic system capacity includes tank AWP 40S AC DC IWP 20S 3 7 quarts 3 5 liters Platform up 65 seconds 48 seconds _ 255 3 7 quarts 3 5 liters Platform down 38 seconds 38 seconds _ 305 3 7 quarts 3 5 liters IWP All models AC DC AWP 15S 3 7 quarts 3 5 liters Platform up 40 seconds 30 seconds AWP 20S 3 7 quarts 3 5 liters Platform down 28 seconds 28 seconds AWP 25S 3 7 quarts 3 5 liters Power Source AWP Models AWP 30S 3 7 quarts 3 5 liters DC models 12V AWP 36S 4 0 quarts 3 8 liters AC model 110V or 220V AWP 40S 3 9 quarts 3 7 liters Air model 100 psi 6 9 bar Power Source IWP Models DC models 12V AC model 110V or 220V Ambient Operating Temperature 20 F to 135 F 29 C to 57 C Genie 6 AWP Super Series IWP Super Series Part No 38139 2015 Service Manual Specifications Hydraulic Hose and Fitting Torque Specifications Your machine is equipped with Parker Seal Lok ORFS or 37 JIC fittings and hose ends Genie specifications require that fittings and hose ends be torqued to specification when they are removed SAE O ring Boss Port tube fitting installed i
77. 51 NEGATIVE 12 DC INPUT 5 LBD GROUND L ANG DC INPUT LED14 12V DC INPUT 4 P PLATFORM INDIGATORS LED1212V DC INPUT 5 2 RD 2 5 RD IP LED13 12V DC INFUT 6 BK em LED18 12V DC INPUT 7 NON gk 14 L12 6 16 12 DC OUTPUT 8 2 a INDICATOR FOR tavocourrur 80 BK AUXILIARY LOWERING 12V DC OUTPUT 9A LIS L13 cro fot 12V DC MOTOR RELAY OUTPUT 119 BATTERIES 1 SECOND TIME DELAY 12V DC OUTPUT 12 7 SW12 DC MODEL 12V DC UP SIGNAL INPUT 13 ak 3 redd INDICATOR U10 W4 LTT ______ _______ d i P2 W6 TERMINAL el GO 88 QD4 1 T K 7 H 7 BE NO ND WH wH FAX Y7 PLATFORM GROUND JL e Bk DOWN CONTROL Swe GND 5 5 Tofo 5 CONTROL GROUND H ST CB1 on G F ape EN2 n M 9 e SW18 es GROUND 0 MM 5 SW17 CONTROL wH SW11 BOX PLATFORM DOWN 6 Were wom 2 me Q3 OUTREACH am QD7 STRAIN RELIEF 1 OPTION PLATFORM 4 UT an 1 LE 5458 POWER UNIT a 4 mw
78. 71 4x58 in 74 2 x 65 1 x w CE Indoor 162 5 x 122 5 cm 181 6 x 147 3 cm 181 6 x 147 3 cm 189 2 x 166 3 cm Outrigger footprint 83 x 74 in 83 x 74 in 95 x 89 in 112 x 112 in CE Outdoor 211 4 x 187 9 211 4 187 9 241 9 x 227 9cm 284 4 x 284 4 Corner access wall access 16 11 in 14 418 13 6 18 7517 Ain Domestic 40 6 27 9 cm 36 2 7 4 cm 33 15 2 cm 47 118 4 cm Corner access wall access 22 1 14 24 1 1 14 in 2874 15 37 15118 CSA 57 1 37 5 cm 62 2 35 5 73 38 1 95 2 47 Corner access wall access 16 11 in 21 12 Y 19 9 in 22 9 CE Indoor 40 6 27 9 53 3 31 1 49 5 24 7 55 8 22 8 Corner access wall access 31 74 1 20 in 30 17 38 34 21 in 51 26 CE Outdoor 80 50 8 cm 76 2 44 4 cm 98 4 53 3 129 5 67 3 of platform top to corner of wall with ability to rotate the leveling jack Platform Dimensions Standard platform L x W x gated or sliding mid rail 27 x 26 x 44 in 69 x 66 x 114 cm Narrow fiber platform LxWxH 26 x 22 x 43 in 66 x 56 x 110 cm Gated ultra narrow platform LxWxH 22 x 18 x 44 in 56 x 46 x 114 cm Front and side entry platform LxWxH 30 x 28 x 44 in 76 x 71x 114 cm Gated narrow platform 26 x 20 x 44 7A in Extra large platform 30 x 28 44 in L x W x H 66 51 14 LxWxH 76 x 71 x 114 cm Sta
79. CONTROL BK BATTERIES AUXILIARY LOWERING 12V DC OUTPUT a RD BLK pm ACTIVATE e 6617 a ouTPUT LE 12 crane cur Wee ete UP SIGNAL OUTPUT 116 INDICATOR Swit UP SIGNAL OUTPUT DELAYED 126 STANDARD 3 OR 1 UP SIGNAL INPUT 13 PLATFORM BK UP 512 U 1 0 UP DOWN DOWN f AUXILIARY WA Lm BOARD ee ot eee 1 8 p UT NARROW PLATFORM UNITS 5 GND WH AND WIRES REPLACE E GROUND Wi BL AND ONG WIRES ty STUD T PR4I 202 4 a 5 2 5 CB9 WH 4 BREAKER 1 MINE 240V AG MODELS 004 PLATFORM adl 77 RD 6 gt 6 Rp mission 35 15A CIRCUIT BREAKER 1 Ee 4 4 GNYL 5 ly mre W5 5 4 MODELS Z sz a 8 BL 2 2 2 BL one 2a 25 5 d BK L 5 1 MES 2 7 A i d bi i N30
80. Electrical Schematic AWP Super Series AC Models from SN 3896 451 to AWP07 54898 120 2015 Service Manual Electrical Schematic AWP Super Series AC Models with Standard Base from SN AWP07 54899 to AWP07 57594 121 Service Manual Electrical Schematic AWP Super Series AC Models with Standard Base from SN AWP07 54899 to AWP07 57594 May 2015 lt O OU C D E F G H J L M AD ee 1 4 ksi ER KEY rlen poe f 7144 BK EN2 SSS 2 Fon sio v OPERATOR JUMPER BROWN TO WHITE NE _ _ q BK n GROUND CONTROL BOX U9 THROUGH TERMINAL STRIP 41 E FRONT RIGHT P2 TRANSFORMER AND LEAVE
81. Failure to detect an improperly adjusted platform outreach chain could result in unsafe operating conditions and may cause injury and component damage 1 Fully lower the platform 2 Lower the base and turn the key switch off 3 Fully extend the outreach and lock the handle 4 Locate the chain between the lower sprocket and the lower brace 5 Grasp the two chain sections and lightly pinch them together Result There should be a minimum of a inch 6 4 mm gap between the chain sections Note If measurement does not meet specification adjust the chains Refer to Repair Procedure How to Adjust the Platform Outreach Chain Genie AWP Super Series IWP Super Series Part No 38139 2015 Service Manual C 1 Inspect and Lubricate the Casters and Wheels Genie specifications require that this procedure be performed every 1000 hours or annually whichever comes first Extremely dirty conditions may require that the casters and wheels be inspected and lubricated more often 1 Visually inspect each caster and wheel for cuts cracks or unusual wear 2 Push the machine on a flat smooth surface and check that the casters and wheels roll smoothly 3 Pump grease into the zerk fitting on each caster and wheel until it can be seen coming out of the bearing seal gap Grease Type Lithium based Checklist C Procedures C 2 Inspect the Mast Assembly for Wear Genie specifications require tha
82. Lay the number 3 column chains on the floor Do not allow the chains to become twisted or dirty Lay the number 2 column chains inside the number 3 column Follow steps 4 through 11 for each remaining column and the carriage After all the columns are assembled the idler wheel assemblies can be installed Remove the tension from the lifting chains on the number 2 column by pushing the number 3 column towards the top of the mast Install the idler wheel assembly into the top of the number 2 column Securely tighten the mounting fasteners Do not over tighten Note Confirm that all idler wheels rotate with no excessive side movement Confirm that they do not rub on the inside of the column Replace worn spacers if necessary Refer to Maintenance Procedure nspect the Mast Assembly for Wear Specification Side movement Maximum 0 079 inch 2cm Genie AWP Super Series IWP Super Series Part No 38139 2015 Service Manual 16 Repeat steps 14 and 15 for each remaining idler wheel assembly 17 Confirm that all of the idler wheel axle mounting fasteners are flush with the column A CAUTION Component damage hazard The roller wheels may be damaged if the idler wheel axle mounting fasteners are not flush with the column 18 Install the mast assembly on the base 19 Adjust the lifting chains Refer to Repair Procedure How Adjust the Lifting Chains Note IWPS Models Adjust the base re
83. N8 N10 110V 220 VAC 8 MOTOR DETAIL MOTOR DETAIL GND Genie 134 BRAND AWP Super Series IWP Super Series Part No 38139 L M N ee FRONTLEFT INTERLOCK FRONT RIGHT on mb INTERLOCK REAR RIGHT a INTERLOCK REAR LEFT RD AD SW15 smie 95 14 swis W6 omer Y7 PAON DOWN YL d NARROW ES0071_F 2015 Service Manual Electrical Schematic AWP Super Series AC CE Models with Standard Base from SN AWP07 57595
84. Outrigger footprint 97 72 x 89 2 in 117 4 x 109 in 117 1 4 x 109 in Ix w CSA 247 5 x 227 2 cm 297 8 x 278 cm 297 8 x 278 cm Outrigger footprint 75 2x 67 in 83 4x 75 in 89 x 81 in I x w CE Indoor 192 x 171 4 211 5 x 191 2 225 9 x 205 6 Outrigger footprint 117 x 109 7 in 117 x 109 in 117 x 109 in CE Outdoor 297 8 x 278 cm 297 8 x 278 cm 297 8 x 278 cm Corner access wall access 18 721 4 in 28 75114 in 31 74114 Domestic 46 6 11 9 cm 72 7 36 2 cm 79 4 37 1 Corner access wall access 37 18 34 in 52131 50 34 28 in CSA 94 1 47 8 cm 132 5 79 3 128 8 73 Corner access wall access 2274 8 in 28 16 1 14 in 31 14 5 in CE Indoor 56 6 20 3 cm 72 7 36 2 cm 79 4 37 1 cm Corner access wall access 50 34 28 in 52 31 Ain 50 34 28 in 128 8 73 132 5 79 3 128 8 73 Corner of platform top to corner of wall with ability to rotate the leveling jack Platform Dimensions all models Narrow fiber platform 26 x 22 x 43 in Extra large platform 30 x 28 x 44 in LxWxH 66 56 LxWxH 76 71 114 Front and side entry platform 30 x 28 x 44 in LxWxH 76 71 114 Genie AWP Super Series IWP Super Series Part No 38139 2015 Service Manual Specifications Model
85. RD 4l F11 ay 8 ME AC a 2 50070 G Genie BRAND Part No 38139 Super Series IWP Super Series 111 Service Manual May 2015 Electrical Schematic AWP Super Series DC CE Models with Narrow Base from SN AWP07 54899 112 113 2015 Service Manual Electrical Schematic AWP Super Series DC TUV Models from 3896 431 Service Manual May 2015 ese Electrical Schematic AWP Super Series DC TUV Models from SN 3896 431 A B L i 7 1 KS1 GROUND PLATFORM BK RD pr RD 80 BK ra BK BK er 1213 36 0V DC INPUT 1 12 DC POWERINPUT CENTER TAP INPUT 2 NEGATIVE 12V DC AUX INPUT 16 0V DC INPUT 1 POSITIVE 12V DC AUX INPUT Le ia FRONT LEFT 4 OR 2 EMER
86. from SN AWP07 57595 A B D E F G H L M N gt ee ee ee ee cn ee ee es en ee ieee heen ee ee amm SS SS SS a 577 N28 E FRONT LEFT 1 7 FOR 240 V OPERATION 1 JUMPER BROWN TO WHITE N FRONT RIGHT Pos THROUGH TERMINAL STRIP AND LEAVE INTERLOCK KS1 ow NE BLACK UNCONNECTED AS SHOWN REAR RIGHT MODE RD EN2 9 3A INTERLOCK J FOR 120V OPERATION JUMPER BROWN TO Rib OT Y BLACK AND BLUE TO WHITE AS sk Bi 2 SHOWN WITH DASHED LINES _ 4 GROUND CONTROL BOX SERIES 1 METR
87. squirt or spray Genie BRAND Part No 38139 Super Series IWP Super Series 91 2015 Electrical Component and Wire Color Legends Item Description Item Description B Battery L Led or light cont B2 12V DC 115 Outrigger rear right ground B4 8 AA batteries L66 Level sensor interlock CB Circuit Breaker L67 Footpad interlock IWP CB4 15 AMP 120V 8 AMP 240V AC M5 Hydraulic power unit CB9 6 AMP 120V 3 240V N C Normally closed CR96 Power wheel IWP N O Normally open 05 Power supply N Note with description EN Enclosure N8 110V AC motor detail EN1 Platform control box N9 220V AC terminal strip detail EN2 Ground control box N10 220V AC motor detail EN3 Remote box ce option N17 Narrow platform units WH and BK wires 4 Power to platform GFCI receptacle replace BL and OR wires 5 Power unit 110 N27 Units without plug WH and BK wires replace BL and BN wires EN6 Power unit 220V AC N28 For 240V operation jumper brown to white F Fuse through terminal strip and leave black F1 15 Amp unconnected as shown CB4 8A CB9 FM 175 Amp o whites shown ith cien FB2 Warning light lines CB4 15A CB9 6A GND Ground N29 N Denotes a neutral wire to be tagged with H4 Descent alarm an N sleeve KS1 Key switch ground platform N3
88. z lt ji 58 85 amp 8 5 1 p GROUND 1234567 STUD 6 QD3 1A LATI 1234567 re 343 Ob oo amp STUD 5 STRAIN RELIEF DESCENT ALARM MOTOR GROUND Gan 7 FB2 SCREW 8 30 WARNING E vl No N O LIGHT 5 ENS DUMP EZX DUMP 5 E VALVE VALVE 5 N10 on 3 DESCENT ALARM 2 110V AC 220 V AC YL 4 MOTOR DETAIL MOTOR DETAIL GND 8 aS E eer se ee es el ES0071_F Genie BRAND Part No 38139 Super Series IWP Super Series 123 Service Manual May 2015 Electrical Schematic Super Series AC Models with Narrow Base from SN AWP07 54899 to AWP07 57594 124 125 2015 Service Manual Electrical Schematic AWP Super Series AC Models with Standard Base from SN AWP07 57595 Service Manual May 2015 Electrical Schematic AWP Super Series AC Models with Standard Base from SN AWP07 57595
89. 10 9 3 Class 12 9 23 D e 711 37 57 64 gt e 14 20 LB _ 20 e 12 18 110 18 1 130 10 200 16 220 9 ___14 ___12 12 7 320 350 530 7 670 7 840 1 1 4 12 19 vn ES 1460 12 1640 2 i lt r c m i di 3 lt dm c lt Qo 4 Ins le le o C2 le o gt Nilo c ry ole o a ual 9 a I o oo INS IND Nm 32 6 7 81 110 108 147 202 274 269 365 610 525 3 715 970 210 285 420 570 562 762 583 791 778 1055 909 1233 a T D gt a N e o 2 e gt _ so a N N 4 J gt j a eo Cn Ico 45 45 5 2 gt gt 6 5 e 1 1 gt oo o gt gt lt gt SSIs iel hed oa gt
90. 110V AC 717 t 5 TERMINAL STRIP TERMINAL DETAIL BK STRIP GNYL a 1 swe CONTROL gk GROUND lt PLATFORM UP DOWN DOWN 7 2 _ e at GROUND N17 NARROW PLATFORM UNITS l Ex E GND CONTROL Ex WH AND BK WIRES REPLACE 5 5 5 BL AND OR WIRES 1 D5 85 E STUD BOX 2 E z 5 Egl Ed WER amp hare qu d suriy 00312 34 67 QD7 4 41 1 W6 Be gE ub a 58 AC QUICK DISCONNECT A STRAIN RELIEF QUICK DISCONNECT B 7 TO PLATFORM MOTOR aoe I TT TT TT T T T T T T T w 12 34 87 GROUN vao amp 1224 56 7 1 m 40 m Y30 vo eis ax coe cae een n c aaan BL 5 VALVE BL BD E itu ps PLATFORM 8 N10 se aD GFCI GNYL GNYL 1 2 110 M RECEPTAOLE MOTOR DETAIL MOTOR DETAIL Y7 8 110V AC 220V AC GROUND amp YL 5700 BK PLATFORM Part No 38139 Super Series IWP Super Series 119 Service Manual May 2015 ___ _ _ __ _______________________ ___
91. 4 1 Power Pack How to Change a Power Pack 1 Fully lower the platform 2 Turn the key switch off and disconnect the power supply IWP models Pull the base lowering handle to fully lower the base Remove the power unit cover 4 AC and DC models Separate both control cable quick disconnect couplers from the ground control box Air models Disconnect the air lines from the air valve container filter regulator and air lubricator 5 AC and DC models Separate the battery quick disconnects 6 DC models Disconnect the battery cables from the motor start solenoid 7 AWPS models with Narrow Base or Rough Terrain Base Remove the loading wheels Power Pack 8 Remove the breather cap from the hydraulic power unit and install a pipe plug in the filler hole 9 Tag disconnect and plug the hydraulic hoses from the power unit AWARNING Bodily injury 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 10 Support the power pack and remove the power pack mounting bolts A WARNING Crushing hazard The power pack will fall if not properly supported when removed from the machine 11 Remove the power pack Installation A DANGER Tip over hazard On Narrow Base and Rough Terrain Base models the counterweights must be installed on the new power pack Component damage
92. 5 10V DC coil Activates N O dump valve 6 Hydraulic tank 3 quarts 2 8 liters 7 Drain plug Drains hydraulic tank 8 Sight gauge Hydraulic fluid level 9 Breather cap Hydraulic tank vent filler 10 Suction strainer Filters hydraulic fluid 11 O ring Seals tank 12 Pump 0 5 to 0 6 gallons per minute at 2000 psi 1 89 to 2 27 liters per minute at 138 bar 13 Check valve Pump output 14 Motor seal Seals motor from contaminants 15 Motor bearing Aligns motor shaft into pump Part No 38139 Genie BRAND Super Series IWP Super Series 61 2015 Hydraulic Power Unit Service Manual 9 38139 AZ m 1 E X LN Orel o eh jo 4 4 E S 4 lt 4 A AWP Super Series IWP Super Series 62 2015 Service Manual 3 2 Hydraulic Power Unit Hydraulic Power Unit AC Models from SN AWP03 27390 to AWP08 60145 Index No Description Function 1 115 230V AC electric motor Single phase 2850 3450 rpm 50 60 Hz 2 Capacitor Motor start circuit 3 Motor bearing Aligns motor shaft into pump 4 Motor seal Seals motor from contaminants 5 Relief valve Lift relief 6 Pump 0 5 to 0 6 gallons per mi
93. 5 to 1 50 red yellow wire to red wire 2 0 5 to 1 50 red wire 1 to red wire 2 0 5 to 1 50 yellow wire to black wire 0 5 to 1 50 all other wire combinations no continuity infinite Genie BRAND Part No 38139 AWP Super Series Super Series 59 2015 Ground Controls 2 2 How to Test the AC Contactor AC Models 1 Fully lower the platform 2 Turn the key switch off and disconnect the power supply 3 Open the ground control box and locate the AC contactor 4 Tag and disconnect all wiring from the contactor 5 Connect the leads from an ohmmeter to the following terminal combinations and check the continuity resistance Test Oar terminal no terminal no terminal no terminal no terminal no terminal no OF ND gt Desired result terminal 0 to 1 80 to 850 all other terminal combinations continuity infinite Genie 60 AWP Super Series IWP Super Series Part No 38139 2015 Service Manual Hydraulic Power Unit 3 1 Hydraulic Power Unit AC Models to SN AWP03 27389 and IWP03 5150 Index No Description Function 1 115 230V AC electric motor Single phase 2850 3450 rpm 50 60 Hz 2 Capacitor Motor start circuit 3 Relief valve Lift relief 4 Solenoid operated N O dump valve Diverts pump output back to tank during motor start up
94. C D E F G H 2050076500000 72255 1 1 P1 EMERGENCY RD RR 21212 16V AG INPUT RD CENTER TAP INPUT 1 L NEGATIVE 12V DG INPUT 16 AG INPUT L POSITIVE 12 DG INPUT 2 PLATFORM EE _ iene iN eh a 0 HV DOINPUT E 114 L1 ae 12V DG OUTPUT 115 L13 GROUND E A MUS 12V DC MOTOR RELAY OUTPUT 3 BATTERIES 617 1 SECOND TIME DELAY 12V DG OUTPUT SW12 DC MODEL 12V DC UP SIGNAL INPUT eae AUXILIARY LOW BATTERY DOWN INoicaroR U10 e _______ _ __ _____ 55 4 552 cw d EMERGENCY rein EN1 i x T GND tote us Y7 ro PLATFORM oom JB p em 2 Be PLATFORM 5 CONTROL swe GND aw Bid cw totol BOX CONTROL OR 4 5 408 EN2 BL 2 15 2 Gh M A GN GROUND mi fom cele SW17 7 CONTROL SW11 Pe 6 11121 a a Birch g E PLATFORM tH d 24 ROWER QD7 __STRAINAELEF OPTION PLATFORM 0 gg power unit 7 r o 8 12 21 a 2 8 151 7 a a el Ol gr E Ec p 5
95. IWPS Models Genie requires that this procedure be performed every 250 hours or quarterly whichever comes first Detection of level sensing malfunctions is essential for safe machine operation An improperly functioning level sensing system could result in unsafe operating conditions 1 Position the machine on a firm level surface 2 Turnthe key switch to ground control and pull out the red Emergency Stop button to the ON position Twist to release the red Emergency Stop button at the platform controls Result The power light should be on 3 Adjust the leveling jacks until the bubble is in the center ring of the bubble level and all four foot pads are in firm contact with the ground Result Within 1 to 4 seconds all four interlock display lights should turn on and remain on 4 Pump the foot pedal to raise the base 5 Place a inch 6 35 mm thick spacer under one adjustable and one non adjustable foot pad on the same side of the machine 6 Pull the base lowering handle to fully lower the base Result Within 1 to 4 seconds all four interlock display lights should turn on and remain on Genie BRAND Super Series IWP Super Series 39 Part No 38139 Service Manual May 2015 Checklist B Procedures 10 11 12 13 14 15 16 17 18 19 20 40 Repeat steps 4 and 5 using 75 inch 12 7 mm spacer Pull the base lowering handle to fully lower
96. MHT De OUTRUT Y7 645 UP SIGNAL OUTPUT DELAYED 12 BK DOWN 3 Swit YPI POWER INDICATOR U10 UP SIGNAL INPUT 139 tit UP DOWN DOWN WA swi m DN m 2 STANDARD E N17 S BASE NARROW PLATFORM UNITS x B WH AND BK WIRES REPLACE 8 L BL 2 AND OR 3 WIRES m 4 r a 88 GND GROUND x HF PR4 TUD N e E PLATFORM k xL NY RECEPTACLE M 2 2 mo 7 2 5 110V 1 x i 27 x TERMINAL STRIP 35 2 INITS WITHOUT PLUG Hii DETAR 1 1 WH a REPLACE BL AND BN WIRES wa 2a 7 5 N E D i NN 104 moo GROUND Eee EE m 6 1244441 D5 1234567 ra GND Spy 4 3 x GNIYL GROUND ag 5 25 zi o STUD H4 TRAIN RELIEF DESCENT S dies ALARM TO MOTOR SS SS 2 LIII O 1 7 GROUND GROUND 57 FB2 SCREW 30 SCREW 30 WARNING NO NI
97. Models with Narrow Base from SN 7 54899 nnne nnne 106 Electrical Schematic AWP Super Series DC CE Models from SN 3896 432 to AWPO7 54898 107 Electrical Schematic AWP Super Series DC CE Models with Standard Base from SN 07 54899 110 Electrical Schematic AWP Super Series DC CE Models with Narrow Base from SN 07 54899 111 Electrical Schematic AWP Super Series DC TUV Models from SN 3896 431 iocos eei rer een e a add 114 Electrical Schematic AWP Super Series AC Models from SN 3894 103 to 3896 303 115 Electrical Schematic AWP Super Series AC Models from SN 3896 304 to 3896 450 118 Electrical Schematic AWP Super Series AC Models from SN 3896 451 to 07 54898 4 4 2 000 119 Electrical Schematic AWP Super Series AC Models with Standard Base from SN AWP07 54899 to 07 57594 122 Genie BRAND Part No 38139 Super Series IWP Super Series xiii 2015 Table of Contents Electrical Schematic AWP Super Series AC Mode
98. Nm 10 Foot pump L Base lift cylinder 8 10 ft Ibs 11 14 Nm 11 Orifice 0 3 inch 0 76 mm M Foot Pump Genie BRAND Part No 38139 Super Series IWP Super Series 55 2015 Base Assembly 1 5 Power Wheel Assist Manifold Components IWPS Models to SN 4097 990 Index No Description Schematic Item Function Torque 1 Check valve AA System pressure 25 35 ft lbs 34 41 Nm 2 Solenoid valve 2 position AB Reverse 25 35 ft lbs 34 41 Nm 3 way 3 Solenoid valve 2 position AC Forward 25 35 ft lbs 34 41 Nm 3 way 4 Solenoid valve 2 position AD All functions 25 35 ft lbs 34 41 Nm 3 way oS 56 AWP Super Series Super Series Part No 38139 2015 Service Manual 1 6 Base Assembly Power Wheel Assist Manifold Components IWPS Models from SN 4097 991 to 4099 2532 Index No Description Schematic Item Function Torque 1 Check valve BA System pressure 25 35 ft lbs 34 41 Nm 2 Solenoid Valve 2 position BB Functions 25 35 ft lbs 34 41 Nm 2 way 3 Solenoid Valve 3 position BC Forward Reverse 25 35 ft lbs 34 41 Nm 4 way 4 Relief Valve 1600 psi 110 bar BD System relief 25 35 ft lbs 34 41 Nm BA o 9 Q S EZ BC BD Genie BRAND Part No 38139 AWP Super Series Super Series 57 Servi
99. Super Series IWP Super Series Part No 38139 2015 Table of Contents Section 4 Repair Procedur s iie csiccsteciccstensastecdeddeevexsascenbenedetvenstuacuaecsdievensaunctbesecersensanaanee 47 IMLFODUCUION 47 Base 2 Pega ne c E banno 49 ees 49 1 2 Base Components IWPS 50 1 3 Foot Pump Manifold Components IWPS Models to SN 09 8269 54 1 4 Foot Pump Manifold Components IWPS Models from SN IWP09 8270 55 1 5 Power Wheel Assist Manifold Components IWPS Models to SN 4097 990 sse 56 1 6 Power Wheel Assist Manifold Components IWPS Models from SN 4097 997 to 4099 2532 57 1 7 Power Wheel Assist Manifold Components IWPS Models from SN 4099 2533 2 022 58 Ground GControls rores rhe en 59 2 1 How to Test Transformer AC Models 59 2 2 How to Test the AC Contactor AC Models 60 Hydraulic Power 61 3 1 Hydraulic Power Unit AC Models to SN AWP03 27389 and 5
100. Type 1 as defined by ISO 16368 Machine Design Life Unrestricted with proper operation inspection and scheduled maintenance Find a Manual for this Model Go to www genielift com Use the links to locate Operator s Parts or Service Manuals Copyright 1996 by Terex Corporation 38139 Rev B December 2001 First Edition Seocnd Printing Genie and AWP are registered trademarks of Terex South Dakota in the U S A and many other countries Super Series is a trademark of Terex South Dakota Genie ii AWP Super Series IWP Super Series Part No 38139 2015 Service Manual OOOO Gh ____ Introduction Revision History Revision Date Section Procedure Page Description B8 5 2015 Maintenance Removed C 6 Reference Examples Section Maintenance B 3 Section Repair Procedure 4 2 Electronic Version Section Fault Codes All charts Click on any content or procedure in the Table of Contents to view the update Section Schematics Legends and schematics Genie BRAND Part No 38139 Super Series IWP Super Series Service Manual May 2015 Introduction Revision History continued Revision Date Section Procedure Page Description Reference Examples Section Maintenance B 3 Section Repair Procedure 4 2 S
101. YL CONTROL BK AUXILIARY LOWERING RD BLK B4 7 12V DC OUTPUT oA BK 1 GROUND 10 NET BATTERIES UP SIGNAL OUTPUT swit L5 INDICATOR Up SIGNAL OUTPUT DELAYED 12 NARROW 3 OR PLATO sk wl ___ 0 UP SIGNALINEUT 13 DOWN 7 Enc uM swi2 PC BOARD oe p sun _ LOG GUESS 2 N NARROW PLATFORM UNITS OWE i 4 ag z GND F WH GROUND mL GND POWER TO GROUND QD4 88 2 2 L Pye RECEPTACLE on 4 5 GROUND L ap 22 b BN H 5 5 v D TERMINAL oo E JE 27 ame Lu CONTROL mcm 2 2 2 238235 BOX wo 12 14 wH m REPLACE BL 1 AND BN 7 WIRES T7 58 LS 2 lL 5 ERE PEO LAN _ STRAIN RELIEF TEC END e edis _STRAIN RI RELIEF 6 TO PLUG eee TOMOTOR 1 45 7 D5 p nu TOES E F 5 DESCENT ALARM POWER UNIT 7 WH FB2 ap MOTOR WARNING Bk RD CONTACTOR 1 1 B2 WARNING LIGHT QD1 DESCENT ALARM U9
102. bracket 2 Check the deflection on each sequencing cable by grasping the cable halfway down the column and pulling the cable to one side then the other Measure the total distance between the two points this is the maximum deflection 1 adjustment tension nut 2 threaded swage end 3 sequencing cable nylock nut spring upper sequencing bracket sequencing cable 3 If needed adjust the sequencing cable deflection 1 1 1 1 36 AWP Super Series IWP Super Series Part No 38139 2015 3 Compress the spring to 15 16 2 4 cm turning the nylock nut clockwise to increase the spring compression or counterclockwise to decrease the spring compression Component damage hazard Do not exceed the recommended spring compression 4 Confirm the spring measurement on each sequencing cable 5 Raise and lower the platform through three complete cycles and confirm the spring compression 6 Repeat adjustment for each cable as required Checklist B Procedures B 9 Inspect for Proper Outrigger Length AWPS Models Genie specifications require that this procedure be performed every 250 hours or quarterly whichever comes first Proper outrigger length is essential to safe m
103. cap schematic item J 7 Adjust the internal hex socket Turn it clockwise to increase the pressure or counterclockwise to decrease the pressure 8 Install the relief valve cap ADANGER Tip over hazard Do not adjust the relief valve higher than specified 9 Repeat step 4 to confirm the relief valve setting Re adjust if necessary _________________ AWP Super Series IWP Super Series Part No 38139 2015 Service Manual 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 1 Pull the base lowering handle to fully lower the base 2 Remove the linkage mounting fasteners from the foot pump 3 Remove the foot pump from the manifold Plug the port in the manifold Note The foot pump must be bled after installation How to Bleed the Foot Pump 1 Pull the base lowering handle to fully lower the base 2 Place a container under the base lowering cylinder and remove the bleed screw from the barrel end of the base lowering cylinder 3 Pump the foot pedal until air stops coming out of the bleed screw hole 4 While holding the foot pedal down install the bleed screw Release the foot pedal 6 Check the sight gauge on the side of the hydraulic tank 7 Add oil if needed Do not overfill 8 Clean up any oil that may have spilled Properly disc
104. cap to SN 3897 4544 Hydraulic tank vent filler 14 Check valve Pump output 15 Pump 0 7 to 1 gpm at 2000 psi 2 6 to 3 76 L min at 138 bar 16 Pump Motor Adaptor Housing Protects coupling components 17 Pump adaptor Connects pump to spider coupler 18 Spider coupler Connects motor to pump 19 Motor adaptor Connects motor to spider coupler Part No 38139 Genie BRAND Super Series IWP Super Series 67 Service Manual May 2015 Hydraulic Power Unit dX 1 2 9 9 0 G9 OOG Gri S 68 AWP Super Series IWP Super Series Part No 38139 2015 Service Manual 3 5 Hydraulic Power Unit How to Remove the Hydraulic Power Unit AC Models 1 2 Fully lower the platform Turn the key switch off and disconnect the power supply IWPS models Pull the base lowering handle to fully lower the base Remove the power unit cover Tag disconnect and plug the hydraulic hoses Cap the fittings on the power unit AWARNING Bodily injury 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 6 Tag and disconnect the electrical wiring from the valve coil Hydraulic Power Unit Remove the cover from the junction box on the motor Tag and disconne
105. load or lifts more than rated load refer to Repair Procedure Valve Adjustment Genie BRAND Super Series IWP Super Series 35 Part No 38139 Service Manual May 2015 Checklist B Procedures B 8 4 Hold the threaded swage end of the cable from turning and adjust the tension to Adjust the Sequencing Cables obtain correct deflection Turn the adjustment nut clockwise to decrease the deflection or counterclockwise to increase the deflection Genie requires that this procedure be performed Component damage hazard Do every 250 hours or quarterly whichever comes not exceed the recommended first deflection 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 daily check of 6 Repeat adjustment for each cable as required the sequencing cables allows the inspector to identify changes in the operating condition that might indicate damage To serial number 3899 11843 Raise and lower the platform through three complete cycles and confirm deflection Deflection Maximum 1 to 2 inches 3 8 to 6 4 cm After serial number 3899 11843 1 Full 1 Fully lower the platform 2 Check for proper deflection of each sequencing cable by inspecting the spring compression The spring is located between the nylock nut and the upper sequencing
106. manufacturer s specifications and the requirements listed in the responsibilities manual Genie A TEREX BRAND Terex South Dakota Inc USA 500 Oak Wood Road PO Box 1150 Watertown SD 57201 6150 605 882 4000 Genie UK The Maltings Wharf Road Grantham Lincolnshire NG31 6BH England 44 1476 584333 Instructions Use the operator s manual on your machine The Pre delivery Preparation consists of completing the Pre operation Inspection the Maintenance items and the Function Tests Use this form to record the results Place a check in the appropriate box after each part is completed Follow the instructions in the operator s manual If any inspection receives an N remove the machine from service repair and re inspect it After repair place a check in the R box Legend Y yes acceptable no remove from service R repaired Comments Pre delivery Preparation Y N R Pre operation inspection completed Maintenance items completed Function tests completed Model Serial number Date Machine owner Inspected by print Inspector signature Inspector title Inspector company Service Manual May 2015 sees This page intentionally left blank _ _____________________ 16 AWP Super Series IWP Super Series Part No 38139 2015 Service Manual Maintenance Inspection Report Model
107. operate improperly If the breather cap is not properly installed and checked daily impurities can enter the hydraulic system and may cause component damage 1 Besure the breather cap is installed on the hydraulic power unit tank and is not damaged Do not remove it Genie 28 Super Series Super Series Part No 38139 2015 Service Manual A 16 Check the Tire Pressure AWPS Models with Rough Terrain Base Option Genie specifications require that this procedure be performed every 8 hours or daily whichever comes first It is essential to maintain proper pressure in all air filled tires Improperly inflated tires can affect machine handling 1 Check each tire with an air pressure gauge Add air as needed Models before serial number 3899 11837 Tire pressure should be 30 psi 2 bar in the front and rear tires Models after serial number 3899 11836 Tire pressure should be 50 psi 3 4 bar in the front and rear tires Checklist A Procedures A 17 Check the Air Supply Lubricator Cil Level Air Models Genie specifications require that this procedure be performed every 8 hours or daily whichever comes first Maintaining the proper oil level in the lubricator canister is essential to safe operation and good machine performance Failure to keep the lubricator canister at the proper oil level could result in unsafe operating conditions and may cause component damage
108. pad until 31 Install the lower sprocket housing fasteners paie dad son 2 32 Adjust the chain Refer to Repair Procedure pas How to Adjust the Platform Outreach Chain Install the two allen head screws Install the roller wheel 33 Install the outreach assembly onto the carriage Genie AWP Super Series IWP Super Series Part No 38139 2015 Service Manual Observe and Obey V Troubleshooting and repair procedures shall Schematics About This Section There are two groups of schematics in this section Electrical Schematics A WARNING Electrocution burn hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry be completed by a person trained and qualified on the repair of this machine before operating the machine Before Troubleshooting Read understand and obey the safety rules and operating instructions in the appropriate operator s manual on your machine Be sure that all necessary tools and test equipment are available and ready for use V Immediately tag and remove from service a damaged or malfunctioning machine V Repair any machine damage or malfunction Hydraulic Schematics A WARNING Bodily injury 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
109. potential personal injury hazards Obey all safety messages that follow this symbol to avoid possible injury or death Indicates a imminently hazardous situation which if not avoided will result in death or serious injury AWARNING Indicates a potentially hazardous situation which if not avoided could result in death or serious injury ACAUTION Indicates a potentially hazardous situation which if not avoided may cause minor or moderate injury Indicates a potentially hazardous situation which if not avoided may result in property damage Be sure to wear protective eye wear and other protective clothing if the situation warrants it gt 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 Safety Rules 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 top priority Be sure to keep sparks flames and lighted tobacco away from flammable and combustible materials like battery gases and engine fuels Always have an approved fire extinguisher within easy reach Be sure that all tools and working areas are properly maintained and ready for use Keep work surfaces clean and free of debris that could get into machine components and cause damage AN Be su
110. ui c NOTUM wi EN4 WH WH POWER TO 7 8 Sew GNNL WH BK NC RECEPTACLE l aRoUND PLATFORM BUB BK DOWN Genie A TEREX BRAND 98 AWP Super Series IWP Super Series Part No 38139 2015 Service Manual _________________________________________________________________________ Electrical Schematic AWP Super Series DC Models from SN 3896 301 to 3896 430 x 1 1 GROUND PLATFORM RD r BD BD BK e BK BK NO eS RD 1213 16 0V DCINPUT 1 CENTER TAP INPUT 2 L NEGATIVE 12V DC AUX INPUT 180V DC INPUT 3 1 L POSITIVE 12V DC AUX INPUT 14 4 2 EMERGENCY Bi LEVELING LEVELING LED 12 FRONT RIGHT 5 oR STOP INDICATOR BL INPUTS LED 18 REAR RIGHT 6 RD 21
111. 0 110V 220V AC terminal strip detail LS1 Limit switch platform extension IWP option Power switch L Led or light P1 Emergency Stop button at ground controls L5 Power indicator ground P2 Emergency Stop button at platform controls L6 Low battery indicator for auxiliary ground P3 putton at sieer handig L7 Low battery indicator main ground PR Power relay L12 Outrigger front left ground PR4 Function pump M5 L13 Outrigger front right ground L14 Outrigger rear left ground Ganie 92 AWP Super Series IWP Super Series Part No 38139 2015 Service Manual Electrical Component and Wire Color Legends Item Description Color QD Quick disconnect BK QD1 Battery quick disconnect BK RD QD3 Control cable to platform control box BL QD4 Control cable to base BL BK QD7 Control cable to motor BL OR S7 Tilt sensor BL WH SW Switch BR SW8 Control activate GN SW11 Platform up down GN BK SW12 Auxiliary down GN WH SW13 Outrigger interlock front left AWP GR YL SW14 Outrigger interlock front right AWP LB SW15 Outrigger interlock rear left OR SW16 Outrigger interlock rear right AWP OR BK SW17 Foot pad left side IWP OR RD SW18 Foot pad right side IWP OR WH SW21 Power assist Direction reversing safety RD Switch IWP RD BK SW22 Power assist Forward Reverse switch IWP RD WH SW24 Power assist Lift enable IWP WH U Electronic componen
112. 1 1 141 1 f2 Ez aC QUICK DISCONNECT A E QUICK DISCONNECT 4014 7 TO PLATFORM BASE TT T T 1234 67 CONTACTOR mk gt gt qj BATTERY 1 2158 ai RD ai B2 BD RD FUSE T w saen 5 Y30 a B 12V DC N O PR WH WH DUMP VALVE Y7 8 Eam own SSS 7 m PLATFORM RECEPTACLE stun BK BK a a SS RR D E Genie BRAND 114 AWP Super Series IWP Super Series Part No 38139 2015 Service Manual Electrical Schematic AWP Super Series AC Models from SN 3894 103 to 3896 303
113. 150 61 3 2 Hydraulic Power Unit AC Models from SN AWP03 27390 to 08 60145 62 3 3 Hydraulic Power Unit DC Models to SN AWP03 27401 and 5122 64 3 4 Hydraulic Power Unit Components Air Powered Models 2 etre etia te e t Rd e ad RO Rud ER Red n 66 3 5 Hydraulic Power Unit artc ce Der tao eet aab ee 69 3 6 Hydraulic PUMP A iiti renti temere ise 71 3 7 Valve Adjustment Irt me en ec La a it tre 71 3 8 How to Test the Motor Start Solenoid DC 5 72 Genie BRAND Part No 38139 Super Series IWP Super Series xi 2015 c I o 9c ___ ___ __ __ Table of Contents Power Pack esee is sene ere iai i A EH AH LH I 4 73 4 1 73 Mast Components bn REA 74 Mast 74 SUME Ke 75 5 2 Mast Assembly i ipe dere e esae te 76 5 3 Glide Pads 81 5 4 Lifting CHAINS Een dte eet ee ee b erg eerie 82 Tilt back Frame AWP 36S 405
114. 2 d 4 C ae STOP STRIP GND aps BK so t eel z ERv PLATFORM coe Las CONTROL swe GND 5 CONTROL GROUND HE STUD EN2 Fl a OR 2 SW18 T o GROUND BL BL WH WH CONTROL a SW17 SW Sur 1 s JN switcH DOWN 6 ____ ____________ _ PLATFORM 58 M UN rowan QD7 straw RELIEF LI ee OPTION PLATFORM WHANDBKWIRES REPLACE 5 if T POWER UNIT OCA OR MORS L 5 aly x AD _ ____ 05 a 515 835 oR LS1 489 mw 00312 67 QUICK DISCONNECT me OR 4 EXTENTION 7 T Tvmxwrn 1 WH T 12311 i RD QD1 4 F1 oo SSS B2 oe BK ac wa ru m EIE ET 2 PLATFORM GROUND POWER SUPPLY DUMP VALVE 8 RECEPTACLE 23 GHYL 2 0 52 055 110V AG 220V AG aic ll Bk Genie BRAND Part No 38139 Super Series IWP Super Series 155 Service Manual May 2015 Electrical Schematic Super Series DC TUV Models with Outreach 156
115. 2VDC 12VbC 5 F1 5 15 AMP gt gt Ed _ WH QUICK DISCONNECT A d GND D5 30 TO PLATFORM 8 PLATFORM FEWER SUPPLY e GNAL BK mm T Genie 162 AWP Super Series IWP Super Series Part No 38139 2015 Service Manual Electrical Schematic Super Series AC Models from SN 4096 105 to 4096 285 L K J H G F E D C B A 1 EN i 0 P1 Y EMERGENCY STOP m lue m BK sws NEGATIVE 12V DC INPUT 16V ACINPUT 3 22 L POSITIVE 12V DC INPUT 4 KS 858 2 ow L 12V DC
116. 3 14 15 16 17 18 19 20 21 22 23 90 Remove the lower sprocket housing mounting fasteners Do not allow the chain to become twisted Remove the upper sprocket housing mounting fasteners Do not allow the chain to become twisted Remove the fasteners from the outreach locking bracket Slide the platform mount off the inner frame extension arms and set it aside Locate the two allen head screws in the platform mount slide pad Remove the roller from the same side of the slide pad Remove the two allen head screws Remove the master link from the chain 24 25 26 27 28 29 May 2015 Thread the chain through the upper sprocket housing over the sprocket then back through the housing Thread the chain through the lower sprocket housing over the sprocket then back through the housing Don t allow the chain to become twisted Do not re use the old master link Install a new master link Slide the platform mount onto the extension arms Install the outreach locking bracket on the platform mount Install the upper sprocket housing to the platform mount Note When fasteners are installed be sure the center bolt is in between the two chains inside the Pull the chain out of the slide pad and both housing nOusinge 30 the slack out of the chain by pushing Install the new chain through the slidepad down on the lower sprocket housing Push the chain through the slide
117. 3896 303 116 117 2015 Service Manual Electrical Schematic AWP Super Series AC Models from SN 3896 304 to 3896 450 Service Manual May 2015 ese Electrical Schematic AWP Super Series AC Models from SN 3896 304 to 3896 450 A B C D E F G H J K L M jeu en 1 KS1 112 GROUND U9 Eee PLATFORM vr BD Eb TRANSFORMER 1 NO BK yL BK BK 220020 0001 Iud 1512 wa 160v 1 1 4 CENTER TAP INPUT 2 p BN EMERGENCY 12V DC POWER INPUT STOP L NEGATIVE 12V DC AUX INPUT 16 0 DC INPUT 8 m __36 Ta BL BK BD SPOSITIVE 12V BEAUX INPUT LED 14 1 4 wH 2 T NG TENPIN LEVELING LED 12 FRONTRIGHT 5 INDIGATORS _ i INDICATOR EL BK YL INPUTS LED 18 REAR RIGHT 6 1 LED 15 REAR LEFT 7 BK BAERS 114 112 powen inpicator 12v DC OUTPUT 8 SW12 Ge 12V 0 OUTPUT 9 RD 12V DC OUTPUT AUXILIARY LOW BATTERY DOWN 4115 L13 oicator ror GROUND 1 GNAL EET TT AUXILIARY LOWERING SIGNAL OUTPUT 19 17 U1 0 UP SIGNAL OUTPUT DELAYED 12 3 MOD
118. 39 3 Nm 8 Adj Non adj 60 ft lbs 81 3 Nm 37 Adj Non adj 52 ftlbs 70 5 Nm 10 ORFS Adj Non adj 100 ft lbs 135 6 Nm 37 Adj Non adj 85 ft lbs 115 3 Nm 12 All types 135 ft lbs 183 Nm 16 All types 200 ft lbs 271 2 Nm 20 All types 250 ft lbs 339 Nm 24 All types 305 ft lbs 413 5 Nm Service Manual May 2015 eee Specifications Torque Procedure JIC 37 fittings 1 Align the tube flare hex nut against the nose Seal Lok fittings of the fitting body body hex fitting and tighten the hex nut to the body hex fitting to hand tight 1 Replace the O ring The O ring must be approximately 30 in Ibs 3 4 Nm replaced anytime the seal has been broken The O ring cannot be re used if the fitting or 2 Using a permanent ink marker make hose end has been tightened beyond finger reference mark on one the flats of the hex nut tight and continue the mark onto the body of the Note The O ring in Parker Seal Lok fittings and hose end custom size O rings They not standard size O rings They available the L O ring field service kit Genie part number 49612 em 2 Lubricate the O ring before installation aN 1 3 the O ring face seal is seated and 3 retained properly 7 2 4 Position the tube and nut squarely on the face seal end of the fitting and tighten the nut finger tight Illustration 1 5 Tigh
119. 44 Fax 65 67533544 Genie Japan Phone 81 3 6436 2020 Fax 81 3 5445 1231 Genie Korea Phone 82 2 558 7267 Fax 82 2 558 3910 Genie Brasil Phone 55 11 4082 5600 Fax 55 22 4082 5630 Genie Holland Phone 31 183 581 102 Fax 31 183 581 566
120. 6 42 4 82 5 43 4 Corner of platform top to corner of wall with ability to rotate the leveling jack Platform Dimensions all models Standard platform L x W x H gated or sliding mid rail 27 x 26 x 44 in 69 x 66 x 114 Gated narrow platform LxWxH 26 x 20x 44 24 in 66 x 51x 114 cm Gated ultra narrow platform LxWxH 22x 18x 44 in 56 x 46x 114 cm Standard fiber platform LxWxH 29 x 26 2 x 43 2 in 74 x 67 x 110 cm Part No 38139 Genie BRAND Super Series IWP Super Series Service Manual May 2015 Specifications Model AWP 30S AWP 36S AWP 40S Standard Base Height working maximum 35 ft 6 in 42 ft 5 in 46 ft 3 in 10 8 12 9 m 14 1m Height platform maximum 29 ft 6 in 36 ft 6 in 40 ft 3 in 9 0 m 6 1m 12 3m Lift capacity 350 165 350 Ibs 300 165 all models except Canada 159 kg 159 kg 136 kg Lift capacity 300 Ibs 300 Ibs 300 Ibs models sold in Canada only 136 kg 136 kg 136 kg Machine weight 831 741 Ibs 1107 1017 Ibs 1130 1040 Ibs DC AC and Air models 377 1 336 kg 502 461 kg 513 472 kg Height stowed 78 in 109 109 198 cm 278 278 Width 29 in 29 in 29 in 73 6 cm 73 6 cm 73 6 cm Length 46 in 55 in 55 in 117 140 140 Outrigger footprint 69 x 61 83 4x 75 in 89 x 81 in x w Domestic 175 6 x 155 3 cm 211 5 x 191 2 cm 225 9 x 205 6 cm
121. 9 Check the Air Filter Regulator Canister Air Models Genie specifications require that this procedure be performed every 8 hours or daily whichever comes first It is essential to drain the air filter regulator canister of water to ensure good air motor performance and service life A water filled canister could cause the air motor to perform poorly and continued use may cause component damage 1 Check the air filter regulator canister for any water accumulation 2 If water is visible loosen the drain plug at the bottom of the canister and allow the water to drain out 3 Tighten the drain plug 1 air filter regulator 2 air filter regulator canister 3 air filter regulator canister drain plug Genie 30 AWP Super Series Super Series Part No 38139 2015 1 Inspect the Battery Genie specifications require that this procedure be performed every 250 hours or quarterly whichever comes first Proper battery 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 AWARNING Electrocution burn hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry 1 Put on protective clothing and eye wear 2 Be sure that the battery cable connections
122. A CIRCUIT BREAKER r CU C4 20769092 1 W5 1 1 PAV AC MODELS E EE 8 oe 4 y e e 8 z 4 EK N29 a S E J E i 1 1 z f 7 1 M M 1 N30 hs DENOTES A NEUTRAN WIRE BE TAGGED 5 2 Sow E05 5 5 MOV ARL PROVA NQWITHAN SLEEVE doo cm 8 5 5 m ____ STRAIN RELIEF ER i Dos NS LA E PEERS PLUG OA 0031124867 L lama po D5 1234567 POWER 5 SUPPLY P NE cage AG 85 5 4 STRAIN RELIEF UU DESCENT M be ALARM MOTOR A N27 UNITS WITHOUT PLUG Want WH AND WIRES 1 1 EL AND BN WIRES ROUND GROUND cao SCREW 30 5 amp 0 F 7 1 SE gag eR qut 2 pax z VALVE OPTIONAL 5 5 WARNING LIGHT BL 1 BE AND DESCENT ALARM sons 8 ice N10 rabia __2 1 wa 2 fi 220 40 MOTOR DETAIL I MOTOR DETAIL GND GND 38139 BRAND Super Series IWP Super Series from SN IWP07 57595 B A
123. AND OR WIRES T D5 zar 5 al x 2 ze 48 58 POWER QD3 12 34 67 4234 5 6 7 on lt au a 111101 904 1 1111 1 E dux Ez 2 we QUICK DISCONNECT QUICK DISCONNECT B de de 7 1131144 z 2 e RD 1 gt gt BATTERY on 0 9 u CONNECTOR RD BL B2 BL BD BATTERY BC 12V DI WH WH Pe POWER TO PLATFORM GNIYL 2 RECEPTACLE n PLATFORM STUD BK GN YL Di Genie ATEREX BRAND 102 AWP Super Series IWP Super Series Part No 38139 P2 EMERGENCY ENI gt 2015 Service Manual Electrical Schematic AWP Super Series DC Models with Standard Base from SN AWP07 54899 RD BLK PLATFORM 3 CONTROL BOX swe CONTROL ACTIVATE BK l5 WH SW11 PLATFORM Bk UP DOWN DOWN m cm Pd N17 NARROW PLATFORM UNITS x WH AND BK WIRES REPLACE m 812 AND WIRES R1 ee EN4 POWER TO PLATFORM GFCI RECEPTACLE E GROUND STUD L
124. ATFORM me om ___ jm RD 5 ar B a mm TO BASE Ur WH WH QUICK DISCONNECT QD3 POWER TO GND 30 PLATFORM PLATFORM GROUND GND 8 RECEPTACLE SYD ROUN DUMP a 22 Tok BE es SS Genie Part No 38139 AWP Super Series IWP Super Series A TEREX BRAND 163 Service Manual May 2015 Electrical Schematic IWP Super Series AC Models from SN 4096 105 to 4096 285 164 2015 Service Manual Electrical Schematic Super Series AC Models from SN 4096 286 to 4096 355 165 Service Manual May 2015 ese Electrical Schematic Super Series AC Models from SN 4096 286 to 4096 355 A B
125. AWP 15S AWP 20S AWP 25S AWP 30S Narrow Base Machine weight 711 621 Ibs 745 655 Ibs 780 690 Ibs 814 724 Ibs DC AC and Air models 322 282 kg 338 297 kg 353 313 kg 369 328 kg Height stowed 78 in 78 in 78 in 78 in 198 cm 198 cm 198 cm 198 cm Width 22 in 22 in 22 in 22 in 55 8 cm 55 8 cm 55 8 cm 55 8 cm Length 49 49 49 49 75 in 125 7 cm 125 7 cm 125 7 cm 125 7 cm Outrigger footprint 64 x 48 in 64 x 48 in 64 x 48 in 71 72x58 x w Domestic 162 5 x 122 5 cm 162 5 x 122 5 cm 162 5 x 122 5 cm 181 6 x 147 3 cm Outrigger footprint 71 x 58 74 x 65 in 83 x 74 in 95 1 4 x 89 in Ix w CSA 181 6 x 147 3 cm 189 2 x 166 3 cm 211 4 x 187 9 cm 241 9 x 227 9 cm Outrigger footprint 64 x 48 in 71 4 x 58 714x958 74 65 I x w CE Indoor 162 5 x 122 5 cm 181 6 x 147 3 cm 181 6 x 147 3 cm 189 2 x 166 3 cm Outrigger footprint 83 Ax 74 in 83 x 74 in 95 x 89 in 112x 112 in I x w CE Outdoor 211 4 x 187 9 211 4 x 187 9 241 9x227 9cm 284 4 x 284 4 Corner access wall access 16 11 in 14 418 13 6 in 18 751 7 A Domestic 40 6 27 9 cm 36 2 7 4 cm 33 15 2 cm 47 118 4 cm Corner access wall access 22 1 1 14 in 24 1 14 in 28 34 1 15 37 15118 CSA 57 1 37 5 cm 62 2 35 5 73 38 1 95 2 47 Corner access wall access 16 11 in 21 12 Y in 19 9 in 22 9 in CE Indoor 40 6 27 9 53 3 31 1 49 5 24 7 55 8 22 8
126. C Models from SN 4096 288 to 4096 341 idt eae esate an ee 143 Electrical Schematic IWP Super Series DC Models from SN 4096 342 to 07 7065 146 Electrical Schematic IWP Super Series DC Models from SN 7 7066 147 Electrical Schematic Super Series DC Models with Power Assist 150 Electrical Schematic IWP Super Series DC Models with Power Assist Directional Valve Coils Powering Function Manifold 151 Electrical Schematic Super Series DC Models 154 Electrical Schematic IWP Super Series DC TUV Models with Outreach 155 Electrical Schematic IWP Super Series DC TUV Models with Power Assist 158 Electrical Schematic IWP Super Series DC TUV Models with Power Assist and 2220 000 1 0 0 00000 159 Electrical Schematic IWP Super Series DC Models with Power Assist Directional Valve Coils Powering Function Manifold 162 Electrical Schematic Super Series AC Models from SN 4096 105 to LUI 163 Electrical Schematic Super Series AC Models from SN 4096 286 to 40962355 M 166 Electrical Schematic IWP Super Series AC Models from SN 4096 356 to lr cpm 167 Electrical Schematic IWP Super Series AC Models from
127. CONNECTED AS SHOWN BL DE s EN2 9 71 5 Ug FOR 120V OPERATION JUMPER BROWN TO BLACK AND BLUE WHITE ar GROUNDCONTROL BOA y e E OANT DASE BK X 1 wa 16 0 DC INPUT 1 BN 15 12 POWER INPUT CENTER INPUT 2 ADL 5 SE cmm L NEGATIVE 12 DG AUX INPUT 160V DG INPUT 3 imum WH P1 POSITIVE 12V DC AUX INPUT Len ig FRONT LEFT 4 wH P ms E LED 15 RIGHT 5 STOP n E 2 21 646 INDICATOR LED 14 REAR LEFT 6 B RD RD at ILOW BATTERY LED 12 FRONT LEFT 7 i IL66 L66 NDicATOR For 12V DC OUTPUT 8 T ae NS i BATTERIES AUXILIARY LOWERING 42 DC OUTPUT RD BLK NG 12V DC OUTPUT aa L67 167 DC AA GROUND 10 WHT ce E UP SIGNAL OUTPUT 1 2P 645 UP SIGNAL OUTPUT DELAYED 12 BK OR 2 POWER U 1 0 UP SIGNAL INPUT 13 AUXILIARY DOWN RO RD PC BOARD W4 BN EN a GND WH on a GROUND wal mE sb CIRCUIT BREAKER TAN AC MODELS m 1 WH 2 CB9 CIRCUIT BREAKER 240V AC MODELS i M 1 15
128. DICATOR E BK ate RD LED 4 12V DC INPUT 7 Bk 114 112 6 12V DC OUTPUT B N 12V DC OUTPUT 9 gt a IINDIGATOR FOR AD BK AUXILIARY LOWERING 12V DG OUTPUT 9 B4 115 L13 GROUND 10 BAA 12V DG MOTOR SOLENOID OUTPUT 11 _1 AD BATTERIES 617 1 SECOND TIME DELAY 12V DG OUTPUT 12 3 SW12 DEMODEL 12V DC UP SIGNAL INPUT 13 slo Para DOWN INDICATOR U1 0 e WH gt pem Ee ie 4 67 4 2 W6 TERMINAL N STOP GROUND 1 Ne QD4 6161 STUD c BK 7 7 O O NO 1 ap RD Le e WHIBK ey Y TPLATFORM PLATFORM I a NE 15121 wi m s WHBK rele CONTROL sws 2 9 CONTROL GROUND 8 STUD on A 4 OR He F SWITCH 5 SW18 BK i 2 8 ES 6 GROUND WH _________ SW17 5 1 CONTROL W 5 PLATFORM UP IDONN K SWITCH DOWN CM PEE _ PLATFORM 6 m N17 OUTREACH TO QD7 straw RELIEF OPTION PLATFORM NARROW PLATFORM UNITS r BKWIRES REPLACE 2 i TO MOTOR
129. DOWN DOWN w4 el swe 2 PC BOARD AUXILIARY lt 7 NARROW PLATFORMUNITS OR WH BK WIRES REPLACE 3 BL 2 AND OR 3 WIRES A E E WH 4 x al 5 GND eee 4 a 1 n CIRCUIT BREAKER POWER Ree ee i 004 Spee a 7 PLATFORM E s 25 RECEPTACLE RD 6 2 6 RD T CH 1 BN 5 gt 5 YL 5 Gs B af 44 lx M N27 17 110V AC oR 2 8 0R 5 E lt Vid TERMINAL STRIP 59 0 a 5 UNITS WITHOUT PLUG 17711 W5 DETAIL wi 1 1 WH WH AND WIRE rit REPLACE BL AND BN WIRES TEDMINAL 22 5 eolele WH EE 59 5 a 2l L amp 5 1 858 28 CE HN 6 L 4 E 90311234567 suo Qus POWER UIT IL SUPPLY OND 8 5 STUD TT BERN mE eu an P PLU To MOTOR r T eee ee 7 GROUND aon SCREW Y30 Y30 WARNING 42X LIGHT HHE Es 3 DUMP DUMP 5 VALVE OPTIONAL 5 WARNING LIGHT BL 1 DESCENT ALARM moror
130. EAR RIGHT BL STOP 645 INPUTS LED 15 REARLEFT 7 AD i IL 14 L1 INDICATOR 12V DC OUTPUT a BK e amp 19V DC OUTPUT e BD BK l e a av 12V DC OUTPUT 9 si BK L15 1 iINpIcATOR FoR GROUND 10 1 AUXILIARY LOWERING siaNAL OUTPUT tie B4 UP SIGNAL OUTPUT DELAYED 12 8AA L7 SW12 BATTERIES DG MODEL UP SIGNAL INPUT 13 3 AUXILIARY LOW BATTERY U 1 0 W4 DOWN INDICATOR PC BOARD NO BN p AD 2 4 PLATFORM 2 E CONTROL BOX BOX swe 2 CONTROL EMERGENCY STOP GND GNAL WH RD GROUND M LO STUD 4 x GND m 2 5 GROUND J ws GROUND TERMINAL 1 CONTROL M sw11 i 8 2252 DOWN 6 ves hy ate E N17 N 907 STRAINRELIEF MD pi BLAND OR WIRES 5 FERRITE POWER UNIT E 86 55 3 Med MN D5 B8 9x SS 5 2 E ER za 4 se 122497 6 8 xxx dE Ez QUICK DISCONNECT E _ __ __ QUICKPISCONNECTB n k i 7 __
131. EL UP SIGNAL INPUT 13 OR PC BOARD 9 220V TERMINAL STRIP DETAIL 15A CIRCUIT BREAKER CB4 p TOV AC MODELS CIRCUIT BREAKER 220V AG MODELS EN1 PLATFORM _ 2 EMERGENCY GND STOP GROUND CONTROL STUD 5 N7 5 NC t BK ttt 141 110V AC W5 TERMINAL STRIP ooo TERMINAL 1 ele elele d cud 8 3 GROUND CONTROL oS SS 5100 SW11 6 PLATFORM x 5 UP DOWN DOWN 5 ulin ENS NARROW PLATFORM UNITS JT 1 Ex 5 GND GROUND S 55 ES 55 A 0 D5 6 8 els 59 CONTROL Sasae oe Lor MN suy QDS 12 34 7 QD7 BOX QD4 W6 WE d QUICK DISCONNECT STRAIN RELIEF QUICK DISCONNECT B i TT TT gt T T T T T T T 1234 67 GROUND
132. ENCY 9 ae eee PC BOARD STOP et OPTION N17 T NARROW PLATFORM UNITS WH BK WIRES REPLACE BK BL AND OR WIRES Y5 m P eer DRIVE DRIVE FUNCTION py 4 FORWARD REVERSE m z 4 GND ch ca GROUND 1 STUD 1 A 1 EN4 GND WH WH POWER TO BROUNBD ess PLATFORM STUD 29 x DRIVE 1 Og tae LO PESE S 85 86 RECEPTACLE zs gps praca cum MANIFOLD N 5 0 Lem T i g 4 fy z 27 5 UNITS WITHOUT PLUG E 2 Hi WH AND BK WIRES Y7 a REPLAGE BL 1 AND BN 7 WIRES za NC PLATFORM 87 DOWN _ STRAIN RELIEF TOMOTOR 6 z SW17 7 T ti 57 SENSOR B2 Rn GN YL Th CHARGER BK 8 BK ear Se E ES0072_H Genie Part No 38139 BRAND Super Series IWP Super Series 147 Service Manual May 2015 Electrical Schematic IWP Super Series DC Models from SN 07 7066 148 149 2015 Service Manual Electrical Schematic IWP Super Series DC Models with Power Assist Service Manual Electrical Schematic Super Series DC Models with Power Assist May 2015 lt _______________ ___ ___ ___
133. G MOTOR d m 1 3 BATTERIES 17 1 SECOND TIME DELAY 12V DC OUTPUT 12 SW12 DC MODEL 12V DC UP SIGNAL INPUT epar cu AUXILIARY LOW BATTERY w4 DOWN INDICATOR U1 0 BOARD ar uu ae 48 Boo 6 MN GND RD T inn Em EN 1 CINES i M T p pm wede pem cel v ER Y7 nd NTR L a BL 5 2 5 YL ele j BOX e STUD EN2 38 OR e SW18 GROUND x am v dps CONTROL AA SW17 no BOX 6 Zi JAMES _ PLATFORM et ae 4 TO 2 NARROW NN sma reuer OPTION PLATFORM HAND BK WIRES REPLACE 8 E BL OR WIRES e 5 BD L D5 Ea 58 amp im 151 E EE cower QD3 3187 error SUPPLY SUE MAT 1 p RD 1171 1 BATTERY 82 5 c OR 12V DC 12V DC m POWER CES a o o O E x mL ac BATTERY 1 _ oe TO esu 30 TO PLATFORM QD3 8 PLATFORM GROUND POWER SUPPLY o mae avi EN cu x l Genie 150 AWP Super Series IWP Super Series Part No 38139
134. GENCY LEVELING Len mca 1 08 STOP m OD INPUTS LED 13 REAR RIGHT 6 e BD QT RD 4 e L LED 15 REAR LEFT 7 m o POWER INDICATOR IAV DG OUTPUT 1 BK RD __ BK 16 12V DC OUTPUT 9 Ne i dw B4 ILOW BATTERY 12V DC OUTPUT BATTERIES 15 LA 3iINDICATOR FOR GROUND 10 DNI AUXILIARY LOWERING UP SIGNAL OUTPUT 146 RD 17 UP SIGNAL OUTPUT DELAYED 12 3 512 DG MODEL U10 UP SIGNAL INPUT 136 on AUXILIARY LOW BATTERY WA DOWN No PC BOARD IL BD sau 2 4 2 EMERGENCY PLATFORM i GND GN YL CONTROL GROUND all EN2 5 GND les c m GROUND L TERMINAL 4 4 STRIP CONTROL 88e BOX SW PLATFORM UP DOWN DOWN l 4 85 N17 N 007 4 STRAIN RELIEF NARROWPLATFORMUNTS x coo WHANDEKWIESREPLACE 5 8 TO MOTOR Sx px BL AND oR WIRES Le u 25 55 m D5 a 552 S m c m EZ dz aa m zo POWER QD3 12 3 67 1234 5 6 7 SF q2 Be a SUPPLY LT 3 pop d QDA 1
135. Genie A TEREX BRAND Serial Number Range from 3896 101 AWP Super Series IWP Super Series from 4096 101 Part No 38139 Rev 8 May 2015 Service Manual May 2015 Introduction Important Read understand and obey the safety rules and operating instructions in the appropriate Operator s Manual on your machine before attempting any maintenance procedure This manual provides detailed scheduled maintenance information for the machine owner and user It also provides troubleshooting and repair procedures for qualified service professionals Basic mechanical hydraulic and electrical skills are required to perform most procedures However several procedures require specialized skills tools lifting equipment and a suitable workshop In these instances we strongly recommend that maintenance and repair be performed at an authorized Genie dealer service center Technical Publications Genie has endeavored to deliver the highest degree of accuracy possible However continuous improvement of our products is a Genie policy Therefore product specifications are subject to change without notice Readers are encouraged to notify Genie of errors and send in suggestions for improvement All communications will be carefully considered for future printings of this and all other manuals Contact Us Internet www genielift com E mail awp techpub terex com Compliance Machine Classification Group A
136. INPUT 6 ORM POWER INDICATOR 7 BK L1 4 112 LED15 12V DG INPUT NON EE 6416 12V DC OUTPUT 8 od ex INDICATOR FOR BK AUXILIARY LOWERING 12V DC OUTPUT se B4 iL15 13 GROUND 10 12V DG MOTOR RELAY OUTPUT 11 4 BD BATTERIES 617 1 SECOND TIME DELAY 12V DO OUTPUT 12 3 SW12 DC MODEL 12v nc uP sienaLinpur 18 OR mur Aqu DEAS UO PC BOARD m J P TES 4 P2 W6 EMERGENCY TERMINAL STOP STRIP WH QT RD 4 SUD N C a 1 1 ra 74 L 7 a e EX Y7 EE PLATFORM sdg Fe 12 21 Down gup WH 5 5 WHBK tele CONTROL swe GND l 5 GROUND eee ACTIVATE 8T CBI oR 8 e gt SWITCH asamp EN2 BL 5 3 2 GN e o GN GROUND 1 MH SWi7 CONTROL Swit BOX _ _ p d _ PLATFORM eee eec di Ele yx cup OUTREACH TO QD7 STRAIN RELIEF J OPTION PLATFORM EN T me ee ee as 488 mw 0031 21107 plo 7 PL
137. K STRIP GRAL SWS m B SW11 platform 0 5 z 6 UP DOWN DOWN 85 puo om n 2 4 NARROW PLATFORM UNITS x y gt 5 GND Sx px Ex X WHAND BK WIRES REPLACE 5 05 r Sl aly 8 GROUND Eas z8 58 BLAND OR WIRES n OE 2x STUD a al 8 s a bz Ed D REM E SUPPLY 12 7 QD7 QD4 7 11 W6 E PE i d 22 QUICK DISCONNECT A STRAIN RELIEF QUICK DISCONNECT B Mano TO PLATFORM MOTOR T m TO BASE 7 T T T T T T T T T T 123467 GROUND Y30 5 vao 12 34 567 5852 SCREW T x mile DUMP NO BK zzz gag ENS VALVE DUMP BD 0 9 9 v X Bi 5 J BOX VALVE 115 ws WH WH S Nu N10 2 PLATFORM GNAL GNAL 277 110V 220V 1 27 72 voaba Y7 RECEPTACLE z _ GROUND B GND mE 8 110V AG 220 STD Be CC IL E PLATFORM ee T E pe u M iem Genie 38139 Super Series IWP Super Series 115 Service Manual May 2015 _ __ ___ _____________ ____ _ ___ Electrical Schematic AWP Super Series AC Models from SN 3894 103 to
138. LED 15 REARLEFT 7 1 Bi L14 12 POWER INDICATOR cocum rr ii EMERGENCY BATTERIES 4 RD DCOUTPUT 9 STOP e i 12V DG OUTPUT sAe 415 L1 S INDICATOR FoR GROUND 10 WH 1 AUAIDARY LOWERING UP SIGNAL OUTPUT 11 3 en U1 0 UP SIGNAL OUTPUT DELAVED 12 SW12 DC MODEL UP SIGNALINPUT 136 LOW BATTERY AUXILIARY INDICATOR PC BOARD WA 1 BN AD SS SS SS 2 BK WIRE DISCONNECTED l N9 REMOTE 4 sx PLATFORM pee CONTROL 15 CIRCUIT BREAKER CB4 MODELS CIRCUITBREAKER 58 2 220 AG MODELS GONTROL EMERGENCY STOP pe wus m GND 5 GROUND SS STUD sug 7 110V AC 416 114 TERMINAL STRIP W5 DETAIL TERMINAL BK STRIP GNAL 3 4 ee ee ee ee o swit GND PLATFORM UP DOWN L GROUND m 1 6 DOWN x eee 2 NARROW UNITS b ii GROUND OE o a A TT CONTROL i fy be Le ps 55 85 58 Sup BOX SD 58 cel 52 0312 34687 1234658687 Ex ge 5 SUPPLY Id d 4d QD4 1 iii Ei 7 QUICK DISCONNECT STRAIN RELIEF QUICK DISCONNECT B 44
139. M UNITS WH AND BK WIRES REPLACE OR BL 2 AND OR 3 WIRES 4 E 1 GND wa Ga x GROUND 2 BK PR4 J BOX 5 AD e 1 EN4 POWER TO CB4 foo Se astra ey Se anite QD4 ye FZX PLATFORM ma BK PLATFORM RECEPTACLE DOWN s EL lx T 27 Lj TERMINAL STRIP jH 5 UNITS WITHOUT PLUG 1 5 W5 DETAIL WH AND BK WIRES w n Hi REPLACE BL AND BN WIRES WH 1 Swi 4 1 dz Nr 4 E 855 Ll ae 11 4 IZ uu __ ty ____ sw17 28566 amp zo 5 EE L AN EE 22 2 5 GROUND 6 TUERI LE E POWER State te SUPPLY 5 GND kag 2 AC SNYL 34 5 GROUND 57 5 T B STRAINRELIEF 372 _ ro LT 9 DESCENT SS SENSOR ALARM MOTOR gt gt BD i cogs 1 j GROUND GROUND van 2 screw 4 30 screw ere dug Bw EN HHE BOX VALVE E VAVE 5 M5 BL 1 BL 1 AND nesc NTALAm 408 3 Lr N7 2 3 N10 ee 4 liwa 2
140. MOTOR I TEN QD1 CONTACTOR T c 10284 BT BATTERY A 12 3 4 5 6 7 RD CONNECTOR sk I z zzz B2 H m RD ze en OOo 0 BK BK WHO 1 4 Y30 EX BL ec RD we o QD1 N O RD EN4 wH BATTERY DUMP CONNECTOR VALVE POWER TO Y 8 PLATFORM N C T GROUND BATTERY BK PLATFORM RECEPTACLE M 12V DC zd Eg Le IE Eu x _ au 38139 Super Series IWP Super Series 107 Service Manual May 2015 Electrical Schematic AWP Super Series CE Models from SN 3896 432 to AWP07 54898 108 2015 Service Manual Electrical Schematic AWP Super Series DC Models with Narrow Base from SN AWP07 54899 109 Service Manual May 2015 Electrical Schematic AWP Super Series DC CE Models with Standard Base from SN AWP07 54899 A B C D E F G H 1 4 KS1 p Aron gt 2 4 BK T SWITCH f 7 2 B
141. NGTION Bk 2 INDICATORS L5 LED 12 12V DC INPUT 5 _ SW22 OR IE T 1 EUM 7x7 BL INDICATOR LED 13 12V DC INPUT 6 REVERSE zh 3 DRIVE Y6 BK Q0 HE LED 15 12V DC INPUT 7 SWITCH ADL REVERSE 112 16 12V DC OUTPUT 1 A ILOW BATTERY 12V DC OUTPUT 9 Hic LL J s J INDICATOR FOR 12V DC OUTPUT 15 L13 AUXILIARY LOWERING ae L 5 EE 12V DC MOTOR SOLENOID OUTPUT 11 EE aa a pe BATTERIES 641 1 SECOND TIME DELAY 12 DG OUTPUT 12 3 SW12 DG MODEL 12V DC UP SIGNAL INPUT 13 8 AUXILIARY RIGO U WA DOWN MCN PC BOARD ae dg _ 4 22 4 EMERGENCY TERMINAL 1 MEN 2H NE QD4 8K e RD ELAT ORM e Jl ECT Gera 519 EX Y7 WH LO CONTROL GND AO Ja e zs PLATFORM STUD BL YL b z u s5 BOX SW8 GND CONTROL GROUND 48 STUR EN2 SWITCH 5 6 SW18 BK WT GROUND M 2 8 c9 7 CONTROL SW17 eo BK sw11 BOX dios PLATFORM UP 7 UP DOWN DOWNS SWITCH 4 SS SS 6 REL _ PLATFORM gt
142. PLATFORM INDICATORS LED12 12V DC INPUT BD T AD LED13 12V DC INPUT s POWER INDICATOR EAN DC NUT NON gk EE 114 112 12V DC OUTPUT INDICATOR FOR TEX BG OUTPUT BK AUXILIARY LOWERING 12V DC OUTPUT 115 113 GROUND wa I 12V DC MOTOR RELAY OUTPUT 3 BATTERIES L7 1 SECOND TIME DELAY 12V DC OUTPUT SW12 DGMODEL 12V DC UP SIGNAL INPUT LOW BATTERY PROTA INDICATOR U10 NO ______ _ _ _ d 4 EMERGENCY 1 STOP 1 1 PLATFORM 52 aps BK CONTROL GND we n aD foe GROUND a b i BOX N mm 5 d WH 9 Loa CONTROL 8 la m NEN ACTIVATE CB1 083 8 La 2 ae SWITCH a 8 2 8L AD 2 _________ _____ _ GROUND 50 18 p CONTROL 5 11 PLATFORM BK UP DOWN DOWN 6 SWITCH u esu usa Jd i PLATFORM DN amp 5 8 NARROW PLATFORM UNITS eur Md OPTION PLATFORM WHAND BK WIRES REPLACE g T Tomon D BL AND OR WIRES P WER UNIT M oly m 05 a o 151 T d 58 POWER 0312 34 67 2 PLATFORM QUICK DISCONNECT
143. Pneumatic Schematic AWP Super Series Models 2015 Electrical Pneumatic Schematic AWP Super Series Models Service Manual gt l gt ae E 5 lt i o 5 82 E Br T gt gt T gt M 5 tr e amp 5 4 9 E 5 lt gt 5 EH Do jg 5 v 3 e e 1 rM PET T H 1 lt 91 mom ceu bd 2775 mem DA og 252 2 21 e iz ME ag gt by E ee 254 lt E 412 2 EN amp L4 4 E 1 o Fri ip Qua se zn E lt i s o L N Le See eee 9 238 6 1228 bn Q Qi
144. SN IWP07 7066 to IWPOT 57594 esee iie UE 170 Electrical Schematic IWP Super Series AC Models from SN IWP07 57595 171 Electrical Schematic IWP Super Series AC TUV Models With Base Mounted BOX 174 Electrical Schematic IWP Super Series Models Without Base Mounted J rniction BOX 175 Electrical Schematic Super Series AC Models with Outreach 178 Genie BRAND Part No 38139 Super Series IWP Super Series 2015 c ____ ____ _ Table of Contents Hydraulic Schematics All Models 222 4 0 41 4401 179 Hydraulic Schematic AWP Super Series Models 179 Hydraulic Pneumatic Schematic AWP Super Series Models 182 Hydraulic Schematic Super Series Models without Power Assist 183 Hydraulic Schematic Super Series Models with Power Assist 186 Hydraulic Schematic IWP Super Series Models with Power Assist and Brake187 a GN 1 1 1 1 1 xvi AWP Super Series IWP Super Series Part No 38139 2015 Service Manual Specifications Model AWP 15S AWP 20S AWP 25S Standard Base Height working maximum 21 ft 4 in 26 1 in 30 ft 9 in 6 5m 8 0m 9 4 Hei
145. Series IWP Super Series Part No 38139 2015 Service Manual Hydraulic Symbols Legend lt gt Filter 0 037 0 84 Orifice with size C Check valve Q Pressure Gauge Check Valve Pilot oz Pump prime mover Fixed displacement pump Wheel motor fixed displacement Foot pump valve Priority flow regulator Differential sensing valve Operated electric motor iol b e e 1 cm Cylinder single acting Cylinder double acting Relief valve Adjustable relief valve 5 un Solenoid operated dump valve 32 nO Solenoid operated 2 position 2 way valve normally open 30 Solenoid operated 2 position 2 way valve normally closed Solenoid operated 2 position 2 way directional valve NCV X Button operated 2 position 2 way directional valve Part No 38139 Genie BRAND Super Series IWP Super Series 95 Service Manual May 2015 sees This page intentionally left blank 96 AWP Super Series IWP Super Series Part No 38139 97 2015 Electrica
146. Series Part No 38139 2015 Observe and Obey Repair procedures shall be completed by person trained and qualified on the repair of this machine Immediately tag and remove from service a damaged or malfunctioning machine Repair any machine damage or malfunction before operating the machine Before Repairs Start K RI Part No 38139 Read understand and obey the safety rules and operating instructions in the appropriate operator s manual on your machine Be sure that all necessary tools and parts are available and ready for use Use only Genie approved replacement parts Read each procedure completely and adhere to the instructions Attempting shortcuts may produce hazardous conditions Repair Procedures Machine Configuration Unless otherwise specified perform each repair procedure with the machine in the following configuration Genie BRAND Super Series IWP Super Series Machine parked on a firm level surface Key switch in the off position with the key removed The red Emergency Stop button in the off position at both ground and platform controls Wheels chocked All external AC power supply disconnected from the machine Platform in the stowed position 47 Service Manual May 2015 Repair Procedures About This Section Most of the procedures in this section should
147. T wH ee EN1 s T hilws i WH 7 RD L12VDC POWER INPUT CENTER TAP INPUT 2 ME L NEGATIVE 12V DG AUX INPUT 16 0V DC INPUT 8 2 PLATFORM n 1 L POSITIVE 12V DO AUX INPUT TED 13 FRONT RIGHT WH CONTROL 9 LEVELING o LEVELING LED 15 REAR RIGHT 5 en BOX STOP age 646 INDICATORS LED 14REARLEFT 8 BL T PD BE oy LOW BATT LED 12 FRONT LEFT 7 m INDICATOR FOR BK 8 BK 113 1 S AUXILIARY LOWERING 5 RD BLK B4 e oa cn rev oc BK 8AA 112 L14ipc MODEL GROUND 10 BATTERIES UP SIGNAL OUTPUT n 3 W 15 UP SIGNAL OUTPUT DELAYED 12 Swit UPS power inoicator PP SIONALIMEUT fae 5 ie SW12 PC BOARD al AUXILIARY ra NACH da cda 77 2 BK 4 AND OR 3 WIRES a 45 E GROUND GNE STUD POWER GROUND QD4 SIE LE 2 5 EN2 5 RECEPTACLE I na w5 GROUND a 22 N ESI 49 Ter CONTROL Tum E 5 a UNITS WITHOUT PLUG 2 2 AND WIRES s 85 2 4 BOX wi 1 2 1 x Hi REPLACE BL 1 BN 7 WIRES
148. TERMINAL GROUND 5 N27 DN 71 CONTROL 11522 55 wH 12 14 wH REPLACE BL 1 AND BN 7 WIRES mm a ee ee See 25 _ IN REI STRAIN RELIEF 24 6 HHE H aa TO MOTOR 7 1244441 2 3 4 5 67 GNNL aor mm E H4 _ DESCENT L POWER UNIT ADI 7 BK FB2 WARNING B RD CONTACTOR LIGHT BATTERY OPTIONAL 12v 06 1 WARNING LIGHT Q2 _ QD1 DESCENT ALARM 509 BD BD t a 5 CHARGER E 175 FUSE Y30 459 LL NON u s 8 CL eur ee ES0070_G BRAND Part No 38139 Super Series IWP Super Series 103 Service Manual May 2015 ___ _ _ __ ______________ ____ _ ____ Electrical Schematic AWP Super Series DC Models with Standard Base from SN AWP07 54899 104 2015 Service Manual Electrical Schematic AWP Super Series DC Models with Narrow Base from SN AWP07 54899 105 Service Manual May 2015 lt _____________ ___ _ Electrical Schematic Super Series DC Models with Narrow from SN AWP07 54899
149. TREACH 17 QD7 smrawreier _ OPTION PLATFORM Le raiz me POWER UNIT BL AND OR WIRES 4 zal 58 ae 05 58 181 a 52 POWER 031 2 34 67 m WH PLATFORM SUR QUICK DISGONNECT A 08 EXTENTION ne H WH l QD1 4 5 a p Cc SEMIS N PLATFORM QDs PLATFORM GROUND POWER SUPPLY M LM STUD GNNL AC DUMP VALVE 110V 2200 AC __ ______ oo J Genie BRAND AWP Super Series IWP Super Series Part No 38139 2015 _________________________________________________________________________________________________________________ Electrical Schematic Super Series Models with Outreach
150. Tighten the sprocket housing fasteners Confirm proper chain adjustment Refer to Maintenance Procedure Check the Chain Adjustment Service Manual Platform How to replace the Outreach Chain IWP 20S Models 1 2 3 9 Fully lower the platform Turn the key switch off and remove the key Pull the base lowering handle to fully lower the base Remove the platform Refer to Repair Procedure How to Remove an Aluminum Platform Remove the platform control box cover fasteners and open the control box Remove the platform control box mounting fasteners Remove the platform control box and set it aside Extend the outreach approximately 14 inches 36 cm Lock the handle in position Attach an overhead crane to the center brace pivot pin on the outreach assembly Remove the assembly mounting fastener AWARNING Crushing hazard When the 10 11 mounting fasteners are removed the platform outreach will become unbalanced and may fall if it is not properly supported Lay the outreach assembly onto a workbench or table of ample capacity Be sure the chain is facing up Place a block of wood under the inner frame assembly for support while removing the chain AWARNING Crushing hazard The platform Genie outreach will collapse if it is not properly supported when the chain is removed Super Series IWP Super Series 89 i Platform 12 1
151. Use the appropriate number of people and proper lifting techniques Genie BRAND Part No 38139 AWP Super Series Super Series 33 Service Manual May 2015 Checklist B Procedures B 5 IWP models Measure the distance between the bottom edge of the platform to the top of Check the Lifting Chain the counterweight Adjustment Genie specifications require that this procedure be performed every 250 hours or quarterly whichever comes first 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 1 Fully lower the platform to the stowed position Result The measurement should be no less 2 Measure the maximum height of the machine than specification IWPS models Turn the screw jacks Note If measurement does not meet counterclockwise to the full up position Pull specification adjust the chains Refer to the base lowering handle to lower the base Repair Procedure How to Adjust the Lifting Chains Result The machine should be no taller than specification Specifications Note If measurement does not meet specification adjust the chains Refer to Repair Procedure How Model Height dare to Adjust the Lifting Chains step 2 IWP 20S 76 in in 3 AWPS mod
152. a Sr 907 _ Smawnuer OPTION PLATFORM z TO MOTOR E R J 05 Ea 5 2 POWER UNIT 151 POWER 00312 34687 5 PLATFORM 7 SUPPLY QUICK DISCONNECT A EATENTION p 12 3467 WH RD E D 5 5 1 a Pal FROMBASE WH WH QUICK DISGONNECT GND 8 Y30 TO PLATFORM 903 8 PLATFORM GROUND GROUND Doe VALVE RECEPTACLE om t RE Au Uo M ee Genie 178 AWP Super Series IWP Super Series Part No 38139 2015 Service Manual Hydraulic Schematic AWP Super Series Models K J D C B A MENSES nC nc LL CYLINDER ASSEMBLY 2 D y ERN Woe ti TANK PRESSURE 4 5 TANK PRESSURE SS Ep UE SS SS SS OF vao 1940 ncn 1600 psi Ms M Q 110 7 EN POWER UNIT ASSEMBLY 8 Genie BRAND Part No 38139 Super Series IWP Super Series 179 Service Manual May 2015 Hydraulic Schematic AWP Super Series Models 180 181 2015 Service Manual Tt Hydraulic
153. a ME LS LED312VDCINPUT 5 8 S 12 LED 412V DCINPUT 7 SWITCH 15 RD J A ly BK n 15 AUXILIARY LOWERING 12V DC OUTPUT 9A 1 NO p T s 3 BATTERIES L7 1 SECOND TIME DELAY 12V DC OUTPUT 12 SW12 DG MODEL 12V DC UP SIGNAL INPUT 13 iss AUXILIARY TON BATTERY U 10 W4 P gt PC BOARD ea POBOARD __ J a 0 cen 2 EM EMERGENGY E PE am NO _ 004 ele RD GND WH e Y7 pLatronm PLATFORM 20 L 5 CONTROL swe GND E CONTROL GROUND 4 8 ST 4 STUD EN2 OR 4 4 OR GROUND 2 BL um WH WH CONTROL SW17 mw SW sw BOX 6 7 PLATFORM x 8 NARROW PLATFORM UNITS zov N Mur een 2 UE POWER UNIT PLATFORM WHANDBK WIRES REPLACE 5 MOTOR BLAND OR WIRE b 5 2 gx X RD T 7 i ya e x il EXTENTION jannn ee penen 4 WH TO PLATFORM BK WH B2 ue 5 1
154. achine operation Operating a machine with outriggers different from those originally designed for the model will result in death or serious injury 1 Measure each outrigger and verify for proper length Genie BRAND Super Series IWP Super Series 37 Part No 38139 Service Manual May 2015 A t Checklist Procedures ANSI Models CE Indoor Models AWP 15S 20 inches AWP 15S 20 inches including narrow and rough terrain 50 8 including narrow and rough terrain 50 8 cm base opti ptions base options 205 20 inches WP 208 4 including narrow and rough terrain 50 8 cm options AWP 20S 26 inches 2 narrow and rough terrain base options 66 cm 25 20 inches 5 including narrow and rough terrain 50 8 AWP 25S 26 inches base option including narrow and rough terrain 66 cm 30 26 inches including narrow and rough terrain 66cm 305 30 5 inches base option 77 365 36 inches _ AWP 30S 36 inches 91 4 narrow and rough terrain base option 91 4 405 40 inches AWP 36S 36 inches 101 6 cm 91 4 CSA Models AWP 40S 40 inches 102 cm AWP 15S 20 inches including narrow and rough terrain 50 8cm Outdoor Models base options AWP 15S 46 inches AWP 20S 26 inches including narrow and r
155. ard the used oil Genie BRAND Part No 38139 Super Series IWP Super Series Base Assembly 53 Service Manual May 2015 Base Assembly 1 3 Foot Pump Manifold Components IWPS Models to SN IWP09 8269 Index No Description Schematic Function Torque 1 Check valve G System pressure 8 10 ft lbs 11 14 Nm 2 Check valve H Directs flow to the tank 3 Manual release valve Lowers base 8 10 ft lbs 11 14 Nm 4 Relief valve 1600 psi 110 bar J Base lift cylinder 35 40 ft lbs 47 54 Nm 5 Pilot to open check valve K Base lift cylinder 35 40 ft lbs 47 54 Nm 6 Foot pump L Base lift cylinder 8 10 ft lbs 11 14 Nm Gi __________________ 54 AWP Super Series Super Series Part No 38139 2015 Service Manual Base Assembly 1 4 Foot Pump Manifold Components IWPS Models from SN IWP09 8270 Index No Description Schematic Item Function Torque 1 Plug SAE No 6 17 19 ft lbs 23 25 Nm 2 Check valve H Directs flow to the tank 8 10 ft lbs 11 14 Nm 3 Plug SAE No 4 12 14 ft lbs 17 19 Nm 4 Manual release valve Lowers base 8 10 ft lbs 11 14 Nm 5 Plug SAE No 6 17 19 ft Ibs 23 25 Nm 6 Relief valve 1600 psi J Base lift cylinder 8 10 ft Ibs 11 14 Nm 110 bar 7 Check valve G System pressure 8 10 ft Ibs 11 14 Nm 8 Plug SAE No 6 17 19 ft Ibs 23 25 Nm 9 Pilot to open check valve K Base lift cylinder 35 40 ft Ibs 47 54
156. ast mounting fasteners Push the fasteners toward the mast for clearance during mast removal Carefully lift the mast out of the base Crushing hazard The mast will fall unless it is properly supported when it is removed from the base Place two saw horses under the mast Lower the mast onto the saw horses with the carriage facing down Part No 38139 2015 Service Manual Tee Mast Components How to Disassemble the Mast 10 Remove the adjustment nuts from all of the sequencing cables AWARNING Bodily injury hazard This q g procedure requires specific repair 11 Slide the carriage towards the top of the mast skills lifting equipment and a assembly enough to remove the tension on suitable workshop Attempting the lifting chain this procedure without these skills 12 and tools could result in death or serious injury and significant component damage Dealer Slide the column below the carriage toward the top of the mast about 6 inches 15 2 cm to access the idler wheel mounting fasteners service is strongly recommended 13 Hold the idler wheel axle from turning by placing a screwdriver in the hole of the axle 1 Remove the mast Refer to Repair Procedure Remove the axle mounting fasteners and How to Remove the Mast Assembly remove the idler wheel assembly 2 Remove the cylinder mounting fasteners from Be sure to label the location and the barrel end of the cylinder orientation of each idler wheel assembly
157. ce Manual May 2015 Base Assembly 1 7 Power Wheel Assist Manifold Components IWPS Models from SN 4099 2533 Index No Description Schematic Item Function Torque 1 Check valve CA System pressure 25 35 ft lbs 34 41 Nm 2 Solenoid valve 2 position CB All functions 25 35 ft lbs 34 41 Nm 2 way 3 Solenoid valve 3 position cc Forward Reverse 25 35 ft lbs 34 41 Nm 4 way 4 Relief valve 1600 psi 110 bar CD System relief 25 35 ft lbs 34 41 Nm 5 Cross port relief valve CE Brake 25 35 ft lbs 34 41 Nm CA 1 0 Gs o o0 7T QO e CC 3 CD 4 CE 8 Qai 1 1 1 58 AWP Super Series IWP Super Series Part No 38139 2015 Service Manual 2 1 How to Test the Transformer AC Models 1 Fully lower the platform 2 Turn the key switch off and disconnect the power supply 3 Open the ground control box and locate the transformer 4 and disconnect all wiring from the transformer 5 Connect the leads from an ohmmeter to the following terminal combinations and check the continuity resistance Ground Controls 1 red wire 2 2 red yellow wire 3 red wire 1 4 yellow wire 5 black wire 6 white wire 7 brown wire 8 blue wire Test Desired result brown wire to blue wire 20 to 220 black wire to white wire 16 to 190 yellow wire to white wire 16 to 190 red yellow wire to red wire 1 0
158. cklist Daily or every 8 hours A Quarterly or every 250 hours A B Annually or every 1000 hours A B C Maintenance Inspection Report The maintenance inspection report contains checklists for each type of scheduled inspection Make copies of the Maintenance Inspection Report to use for each inspection Maintain completed forms for a minimum of 4 years or in compliance with your employer jobsite and governmental regulations and requirements Genie BRAND Part No 38139 Super Series IWP Super Series 13 Service Manual May 2015 sees This page intentionally left blank __ Genie ____________________ 14 AWP Super Series IWP Super Series Part No 38139 2015 Service Manual Pre Delivery Preparation Report Fundamentals It is the responsibility of the dealer to perform the Pre delivery Preparation The Pre delivery Preparation is performed prior to each delivery The inspection is designed to discover if anything is apparently wrong with a machine before it is put into service A damaged or modified machine must never be used If damage or any variation from factory delivered condition is discovered the machine must be tagged and removed from service Repairs to the machine may only be made by a qualified service technician according to the manufacturer s specifications Scheduled maintenance inspections shall be performed by qualified service technicians according to the
159. commended 3 If needed apply a generous amount of Boe lube wax Genie part number 90337 to the inside and outside channels of each column Checklist B Procedures B 7 Test the Lifting Capacity Genie requires that this procedure be performed every 250 hours or quarterly whichever comes first Proper lifting capacity is essential to safe machine operation Improper lifting capacity adjustment could allow machine to be overloaded and may cause death or serous injury Bodily injury hazard This procedure requires specific repair skills lifting equipment and a suitable workshop Attempting this procedure without these skills and tools could result in death or serious injury and significant component damage Dealer service is strongly recommended AWARNING 1 Place the maximum rated load in the platform Secure the load to the platform Note Refer to the operator s manual or the load capacity decal on the machine to determine the maximum load capacity 2 Raise the platform slightly Result The hydraulic power unit should raise the platform Fully lower the platform 4 Add additional weight to the platform that is equal to but does not exceed 20 of the maximum rated load Secure the additional weight Refer to the machine serial plate 5 Raise the platform slightly Result The hydraulic power unit should not be able to raise the platform 6 Note If the hydraulic power unit is unable to lift rated
160. ct the electrical wiring in the junction box Loosen the squeeze connector on the junction box and pull the wiring out through the squeeze connector DC models Tag and disconnect the electrical wiring from the motor start solenoid Air models Tag and disconnect the pneumatic hoses from the power unit 8 Support the hydraulic power unit with a lifting device 9 Remove the power unit mounting fasteners then remove the power unit from the machine AWARNING Crushing hazard The power unit will fall unless it is properly supported Note If a new power unit is installed the pressure relief valve must be properly adjusted See 3 6 How to Adjust the Pressure Relief Valve Genie BRAND Super Series IWP Super Series Part No 38139 69 2015 Hydraulic Power Unit How to Remove the Hydraulic Power Unit DC Models 1 Fully lower the platform 2 Turnthe key switch off and disconnect the power supply 3 IWPS models Pull the base lowering handle to fully lower the base 4 Remove the power unit cover Tag disconnect and plug the hydraulic hoses Cap the fittings on the power unit AWARNING Bodily injury 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 6 Tag and disconnect the electrical wiring from t
161. ct the idler wheel Visually inspect chain anchors threaded rod Visually inspect chain idler wheels Misalignment of flats on all heads Wear on pin heads or noticeable wear in the profile of the outside link plate link plate wear Broken chain anchor fingers Bent or damaged anchor Replace both chains on that column section Do not repair just the affected portion of the chain 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 Replace chain anchor Replace chain anchor Twisted or misaligned chain anchor Threaded rod not visible in inspection hole Idler wheels have badly worn flanges Re align chain anchor to ensure even loading of chain Replace chain anchor and threaded rod Replace idler wheel and check chain alignment Visually inspect chain link plates for cracks Idler wheels have grooves worn into chain contact surface Cracks in any chain link plate Genie BRAND 84 AWP Super Series Super Series Replace idler wheel Replace both chains on that column section Replace entire chain Do not repair just the affected portion of the chain Part No 38139 2015 Service Manual Tilt back Frame AWP 36S and 40S Models 6 1 3 Slide the pivot slider and the stop bracket out of the frame and add sh
162. d with a layer of oil Joints that do not flex freely or are binding Genie BRAND Super Series IWP Super Series Inspection Remedy Replace both chains on that column Replace entire chain Do not repair just the affected portion of the chain Remove chain and inspect for cracked plates see inspection of cracked plates If no cracks are found lubricate chain with motor oil SAE 40 and install chain Lubricate chain with motor oil SAE 40W If rust and corrosion is found refer to Failure Remedy for rust and corrosion 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 83 Service Manual May 2015 _ ______________ _ _ __ Mast Components Inspection Raised or Turned Pins Chain Side Chain Anchors Idler Wheels idler wheel Cracked Link Plates Procedure Visually inspect for raised pins Inspection Failure Raised pins SS Inspection Remedy Replace both chains on that column section Do not repair just the affected portion of the chain Visually inspect for turned pins by insuring all the flats on the V heads are aligned Visually inspect for wear patterns on heads of link pins and outside link plates where they conta
163. dels Be sure the AC power supply is properly connected 4 Connect a volt meter or a small electric powered tool to the platform GFCI receptacle 5 Confirm the voltage or test the electric powered tools operation Result The voltage should be 115V nominal or the electric powered tool should operate normally 6 Push the black TEST button on the receptacle Result The voltage should be OV or the electric powered tool should not operate 7 Pushthe red RESET button on the GFCI receptacle Result The voltage should be 115V AC nominal or the hand tool should operate normally 1 1 1 h1 88 AWP Super Series IWP Super Series Part No 38139 2015 4 7 3 Platform Outreach Chain How to Adjust the Platform Outreach Chain IWP 20S Models 1 2 AWARNING Part No 38139 Fully lower the platform Turn the key switch off and remove the key Fully extend the platform outreach Lock the handle in position Place a block of wood between the carriage and the platform outreach to prevent the outreach from collapsing when the fasteners are loosened Crushing hazard The platform outreach will collapse if it is not properly supported when the fasteners are loosened Locate the lower sprocket housing fasteners Loosen but do not remove both sprocket housing fasteners Push downward on the sprocket housing to remove excess slack from the chain
164. dure or hazard and could result in unsafe operating conditions 1 Check to make sure that the operator s and safety manuals are present and complete in the storage container on the platform 2 Examine the pages of each manual to be sure that they are legible and in good condition Result The operator s manual is appropriate for the machine and all manuals are legible and in good condition Result The operator s manual is not appropriate for the machine or all manuals are not in good condition or is illegible Remove the machine from service until the manual is replaced Checklist A Procedures 3 Open the operator s manual to the decals inspection section Carefully and thoroughly inspect all decals on the machine for legibility and damage Result The machine is equipped with all required decals and all decals are legible and in good condition Result The machine is not equipped with all required decals or one or more decals are illegible or in poor condition Remove the machine from service until the decals are replaced 4 Always return the manuals to the storage container after use Note Contact your authorized Genie distributor or Genie if replacement manuals or decals are needed Genie BRAND Super Series IWP Super Series 19 Part No 38139 Service Manual May 2015 Checklist A Procedures A 2 Perform Pre operation Inspection Genie specifications require
165. e Electrical 31 B 3 Inspect All 32 4 Test the Tilt back Operation if 32 B 5 Check the Lifting Chain 34 B 6 Clean and Lubricate the 35 7 Test the Lifting Capacity cesses eene entire aea 35 B 8 Adjust the Sequencing 36 B 9 Inspect for Proper Outrigger Length AWPS 37 B 10 Inspect and Lubricate the Outrigger Leveling Jack Footpads AWPS Models oi detinet diese x c dee 39 B 11 Test the Level Sensing Operation IWPS 39 B 12 Check the Chain Adjustment IWP 20S Models with Outreach Option 40 Checklist C nennen nennen 41 C 1 Inspect and Lubricate the Casters and Wheels 41 C 2 Inspect the Mast Assembly for 41 Inspect and Lubricate the Lifting 43 C 4 Replace the Hydraulic 43 C 5 Replace the Auxiliary Platform Lowering 45 Genie x AWP
166. e Hydraulic power unit All external electrical cables DC models battery pack e AC power supply cord IWP models inside base junction box IWP models power wheel assist manifold if equipped Genie BRAND AWP Super Series Super Series 31 Part No 38139 Service Manual May 2015 Checklist B Procedures B 3 Inspect All Welds Genie specifications require that this procedure be performed every 250 hours or quarterly whichever comes first 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 1 Visually inspect the welds in the following locations e Platform e Base e Mast brace mounting bracket AWPS models e Loading pivot bar e Outrigger storage sockets e Tilt back frame if equipped e Tilt back frame mounting bracket if equipped IWPS models e Foot pads e Power wheel assist if equipped B 4 Test the Tilt back Operation if equipped Genie specifications require that this procedure be performed every 250 hours or quarterly whichever comes first A tilt back frame is standard equipment on AWP 36S and 405 and optional AWP 15S 205 25S and 30S The tilt back rame 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 in
167. ection Fault Codes All charts Section Schematics Legends and schematics Electronic Version view the update Click on any content or procedure in the Table of Contents to Genie Super Series IWP Super Series Part No 38139 2015 Service Manual Introduction Serial Number Legend ON MANUFATURED BY FABRIQUE PAR Terex South Dakota Inc 18340 NE 76th Street Redmond WA 98052 USA e A TEREX BRAND Model AWP 30S Serial number 7 12345 Model year 2007 Manufacture date 1 11 07 Elec Hydr Ed ower supply voltage Pneumatlc Pressure 110 VAC 50 60 Hz 8 Amps AWP 07 12345 Nominal Power 1 5 Hp 1 1 KW Machine unladen welght 783 Ibs 355 kg Max Load 350 Ibs 159 kg Occupants and Equipment must not exceed 1 350 Ibs 159 k Meximum allowable inclination of the chassis Model Sequence Maximum Wind Speed number Indoor REFER TO OUTRIGGER DECAL 2 Outdoor REFER TO OUTRIGGER DECAL Model year Gradeability N A Maximum allowable side force 45 LBS 200 N Maximum platform height 29 5 9 0 Maximum Travel Heigh Maximum number of platform occupants 1 Country of manufacture USA This machine complies with EN 280 98 37 EC EN 77172
168. ectrical Schematic AWP Super Series AC CE Models from SN 3896 451 to AWP07 54898 129 Service Manual Electrical Schematic AWP Super Series AC CE Models from SN 3896 451 to AWP07 54898 B A May 2015 a KS1 12 BK THERMAL PLATFORM DEVICE BD brano TRANSFORMER BK _ 1 BK jos ee ee ee x KSI 1218 46 0V DC INPUT 1 n He GROUND L42V DC POWER INPUT CENTETLTAP INPUT Bot M t NEGATIVE 12V DG AUX INPUT 16 0 DG INPUT 99 tE mj 2 D o LPOSITIVE 12V DC AUX INPUT LED34FBONTUEFT 4 9 WH BK EE ENS us LEVELING NLED 12 FRONT RIGHT 5 9 wy LED 13 REAR RIGHT 6
169. ed threaded swage ends 2 Confirm the following e Cables are on the pulleys e Upper and lower cable ends are properly secured e Upper and lower mounting brackets are properly secured Checklist A Procedures A 12 Check the Interlock System for Proper Operation Genie specifications require that this procedure be performed every 8 hours or daily whichever comes first Testing the interlock system for malfunctions is essential for safe machine operation An unsafe working condition exists if any interlock display light fails to operate properly AWPS models 1 Turn the key switch to ground control and pull out the red Emergency Stop button to the ON position Twist to release the red Emergency Stop button at the platform controls Result AC amp DC models The power should be on Air models The air pressure gauge should read 80 110 psi 5 5 7 8 bar 2 Slide each outrigger into a base socket until the outrigger lock pin snaps into place Adjust outriggers to level using the outrigger screw jack until the base casters are slightly off the ground Genie BRAND Super Series IWP Super Series 25 Part No 38139 Service Manual May 2015 Checklist A Procedures 3 Check the interlock display lights at the ground 5 controls Result Confirm that the corresponding light is on 7 8 4 Repeat steps 2 and for each of the 9 remaining outriggers IWPS model
170. els Measure the distance 193 cm 7 6 cm between the top of the base frame and the IWP 25S 76 in 3in bottom edge of the platform 193 cm 7 6 IWP 30S 76 in 193 7 6 AWP 15S 78 in in 198 7 6 FL AWP 20S 78 in 3 in 198 7 6 e AWP 25S 78 in in 198 7 6 3 y AWP 30S 78 in in 198 7 6 AWP 36S 109 in lt 278 7 6 AWP 40S 109 in in 278 7 6 Genie 34 Super Series Super Series Part No 38139 2015 6 Clean and Lubricate the Columns Genie requires that this procedure be performed every 250 hours or quarterly whichever comes first Clean and properly lubricated columns are essential to good machine performance and safe operation Extremely dirty conditions may require that the columns be cleaned and lubricated more often 1 Raise the platform to the maximum height 2 Visually inspect the inner and outer channels of the columns for debris or foreign material If necessary use a mild cleaning solvent to clean he columns AWARNING Bodily injury hazard This procedure will require the use of additional access equipment Do not place ladders or scaffold on or against any part of the machine Performing this procedure without the proper skills and tools could result in death or serious injury Dealer service is strongly re
171. ential for safe machine operation An unsafe working condition exists if the auxiliary platform lowering function does not operate in the event of a main power failure 1 Raise the platform slightly 2 Disconnect the power source from the machine 3 Push in the auxiliary platform lowering button at the gound controls Result Platform should lower Connect the power source to the machine Raise the platform slightly a Disconnect the power source from the machine 7 Pushin the control activate button and rotate the up down switch in the down direction Result Platform should lower Genie BRAND Part No 38139 AWP Super Series Super Series 23 Service Manual May 2015 Checklist A Procedures A 9 Test the Manual Platform Lowering Operation Genie specifications require that this procedure be performed every 8 hours or daily whichever comes first Detection of a 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 and auxiliary power failure 1 Raise the platform slightly 2 Activate the manual lowering valve located at the bottom of the hydraulic cylinder Result Platform should lower A 10 Inspect the Columns for Damage Genie specifications require that this procedure be performed every 8 hours or daily whichever comes first
172. eries Super Series 49 Part No 38139 Service Manual May 2015 Base Assembly 1 2 6 Base Components IWPS Models How to Remove the Inner Base Frame AWARNING Bodily injury hazard This procedure requires specific repair skills lifting equipment and a suitable workshop Attempting this procedure without these skills and tools could result in death or serious injury and significant component damage Dealer service is strongly recommended 1 Pull the base lowering handle to fully lower the base 2 Attach an overhead crane to the lifting eye at the top of the mast 3 Remove the mounting fastener from the lift cylinder rod end Lift the rod end of the cylinder up and attach it to the base 4 disconnect and plug the three hydraulic hoses from the base manifold Cap the ports on the manifold AWARNING Bodily injury 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 5 Pullthe hoses through the channel of the base inner frame Genie From under the base remove the inner frame support tube mounting fasteners The tube is mounted directly under the number 1 column Carefully lift the machine off of the inner base frame Do not allow the inner base frame to fall when lifting the machine AWARNING Crushing hazard The machine may fall if it is not proper
173. ght platform maximum 15 ft 4 in 20 ft 1 in 24 ft 9 in m 6 1m 7 6 Lift capacity 350 Ibs 350 Ibs 350 Ibs all models except Canada 159 kg 159 kg 159 kg Lift capacity 300 Ibs 300 Ibs 300 Ibs models sold in Canada only 136 kg 136 kg 136 kg Machine weight 718 628 Ibs 764 674 Ibs 817 727 lbs DC AC and Air models 326 285 kg 347 306 kg 371 330 kg Height stowed 78 in 78 in 78 in 198 cm 198 cm 198 cm Width 29 in 29 in 29 in 73 6 cm 73 6 cm 73 6 cm Length 46 in 46 in 46 in 117 117 117 Outrigger footprint 60 x 52 60 x 52 60 x 52 in I x w Domestic 154 x 134 cm 154 x 134 cm 154 x 134 cm Outrigger footprint 6074 x 52 in 69 61 in 83 72x75 in Ix w CSA 154 x 134 cm 175 6 x 155 3 cm 212 x 191 cm Outrigger footprint 6074 x 52 60 74 x 52 7A in 69 x 61 1 x w CE Indoor 154 x 134 cm 154 x 134 cm 175 6 x 155 3 cm Outrigger footprint 69 4 x 61 83 4x 75 89 x 81 in I x w CE Outdoor 175 6 x 155 3 cm 211 5 x 191 2 cm 225 9 x 205 6 cm Corner access wall access 153418 in 14 5 in 14 3 in Domestic 39 7 20 3 cm 36 9 7 4 35 1 7 4 Corner access wall access 153418 in 20 9 28 34 1 14 A in CSA 39 7 20 3 cm 51 2 24 5 cm 73 36 2 cm Corner access wall access 153418 in 14 7415 in 19 417 14 39 7 20 3 36 9 7 4 48 6 18 2 Corner access wall access 21 12 12 A4 in 30 16 in 32 751 17 in CE Outdoor 54 6 30 8 cm 7
174. h Terrain Base Specifications 4 Specifications 5 AWP IWP Performance and Hydraulic 6 Hydraulic Hose and Fitting Torque 7 Torque Procedlre serre ed nna das 8 SAE and Metric Fasteners Torque 10 Genie viii AWP Super Series IWP Super Series Part No 38139 2015 Table of Contents Section 3 Scheduled Maintenance Procedures nri nnns 11 E dence 11 Pre Delivery Preparation 15 Maintenance Inspection 17 Checklist Procedures inaani 19 A 1 Inspect Manuals and 19 2 Perform Pre operation 20 A 3 Perform Function Tests i rdiet 20 4 Inspect Damage and Loose or Missing 21 5 Check for Hydraulic 22 A 6 Check the Hydraulic Oil enn 22 A 7 Test the Base Operation
175. hazard Do not overtighten the hydraulic fittings Note Do not install the motor cover until the relief valve adjustment is complete Refer to Repair Procedure How to adjust the Pressure Relief Valve Genie BRAND AWP Super Series Super Series 73 Part No 38139 Service Manual May 2015 Mast Components 5 6 AWP 15S AWP 208 NK 3M AN 4 q ii 255 amp AWP 36S 305 amp AWP 40S 500 9 7 Bi
176. he reference mark from step 7 Tighten the mounting fasteners Measure from the bottom of the number 2 column make a reference mark 10 inches 25 4 cm up the column Slide the cable striker bracket down until the top of the bracket is even with the reference mark from step 9 The spring will need to be compressed when the cable striker bracket is pulled down Tighten the mounting fasteners Pump the foot pedal to raise the base Pull the base release handle to be sure the base lowers Adjust if necessary How to Adjust the Foot Pump 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 1 Pull the base lowering handle to fully lower the base 2 Tag and disconnect the hydraulic hose from the port at the rod end of the base cylinder Cap the cylinder port AWARNING Bodily injury 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 3 Connect a 0 to 3000 psi 0 to 250 bar pressure gauge to the hydraulic hose 4 Slowly pump the foot pedal and note the pressure Result The pressure gauge should read 1600 psi 50 psi 110 bar 3 4 bar Adjust if necessary Remove the manifold cover 6 Hold the lift relief valve with a wrench and remove the
177. he valve coil 7 and disconnect the electrical wiring from the motor start solenoid 8 Support the hydraulic power unit with a lifting device 9 Loosen the power unit mounting plate fasteners Do not remove them 10 Rotate the mounting plate away from the mast to access the power unit mounting fasteners 11 Remove the power unit mounting fasteners then remove the power unit from the machine AWARNING Crushing hazard The power unit will fall unless it is properly supported Note If a new power unit is installed the pressure relief valve must be properly adjusted See 3 6 How to Adjust the Pressure Relief Valve How to Remove the Hydraulic Power Unit Air Models 1 Fully lower the platform 2 Turn the key switch off and disconnect the power supply 3 Tag disconnect and plug the hydraulic hoses Cap the fittings on the power unit AWARNING Bodily injury 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 4 Support the hydraulic power unit with a lifting device 5 Loosen the power unit mounting plate fasteners Do not remove them 6 Rotate the mounting plate away from the mast to access the power unit mounting fasteners 7 Remove the power unit mounting fasteners then remove the power unit from the machine AWARNING Crushing hazard The power unit will fa
178. igh Strength THREAD Grade 5 Grade 8 65 LUBED LUBED LUBED indbs Nm _ Nm Nm 44 __ 20 _ 80 9 100 113 10 124 140 158 _ 130 147 28 90 101 120 135 120 135 160 18 140 158 El LUBED DRY LUBED ft lbs Nm ftibs Nm fttbs Nm ftbs Nm sig __18 13 176 17 23 18 24 25 339 21 284 __24 14 19 19 257 20 271 27 366 24 325 _16 23 312 31 42 33 447 44 596 58 515 __24 35 2 50 1 49 664 50 678 70 947 61 827 55 745 eo 813 80 1084 68 921 773 75 101 6 80 1084 110 149 93 126 867 85 115 90 122 120 162 105 142 108 4 122 _162 130 176 170 230 140 489 176 271 270 366 280 379 380 515 320 433 298 300 406 310 420 420 569 350 474 433 430 583 450 610 610 827 50 691 474 470 637 500 678 670 908 560 759 640 867 680 922 910 1233 770 1044 718 710 962 750 1016 990 1342 840 1139 800 908 1138 1120 1518 1360 1844 1820 2467 1530 2074 1260 1979 tose 200 2870 3218 5160 4284 2670 3620 2223 3000 METRIC FASTENER TORQUE CHART This chart is to be used as a guide only unless noted elsewhere in this manual Class 4 6 Class 8 8 Class
179. ims as necessary to Tilt back Frame obtain zero clearance and zero drag How to Remove the Tilt back frame 1 Fully lower the platform 2 Turn the key switch off and remove the key Maintain a firm grasp on the tilt back frame and remove the retaining pin Lower the tilt back frame to the ground 4 Remove the fasteners that mount the tilt back frame hinges to the base Note Note the amount of shims used between the hinges and the base 5 Remove the frame from the machine How to Adjust the Loading Pivot uz or Stop Bracket Note Check for side to side movement of 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 necessary 1 Remove the tilt back frame Refer to Repair Procedure How to Remove the Tilt back Frame 2 Remove the mounting fasteners from the tilt back frame hinges shock absorber assembly tilt back frame shock absorber mounting bolt loading pivot bar loading stop bracket ah c0 Genie BRAND Part No 38139 Super Series IWP Super Series 85 Service Manual May 2015 Tilt back Frame AWP 36S and 40S Models How to Disassemble the Shock Absorber 1 Fully lower the platform 2 Turn the key switch off and remove the key Maintain a firm grasp on the tilt back frame and remove the retaining pin Lower the tilt back frame to the ground 4 Remove the faste
180. interlock switches indicate that the foot pads are in firm contact with the ground How to Remove an Interlock Contact AWP Models 1 Fully lower the platform 2 Turn the key switch off and remove the key 3 Store the outriggers in the storage sockets 4 Remove the rear base cover 1 base 2 terminal switch 5 Trace the interlock contact wires to the rear of the base 6 Locate the terminal strip 7 Label and remove the contact wires by inserting a small screwdriver into the hole below the wire and gently push in while pulling on the wire Base Assembly 8 Follow the wires to the grommets where the wire enters and exits the base Pull the wires through the grommets and the base Note Only pull the wires out far enough to access the interlock contact bracket mounting fasteners 9 Remove the interlock contact bracket mounting fasteners from the outrigger base Socket How to Remove a Base Interlock Switch IWPS Models 1 Fully lower the platform 2 Turn the key switch off and remove the key Pull the base lowering handle to fully lower the base 4 Remove the foot pad switch bracket fasteners 5 Pullthe foot pad switch bracket out of the base 1 switch bracket cover 2 switch bracket fasteners 6 Remove the wires from the switch Note the wire positions 7 Remove the fastener that attaches the switch to the switch bracket Genie BRAND AWP Super S
181. ising 3 5 liters the platform Pressurized air in AWP 36S 4 quarts the hydraulic system can 3 8 liters damage hydraulic components AWP 40S 3 9 quarts 3 7 liters Genie AWP Super Series IWP Super Series Part No 38139 2015 Service Manual Checklist C Procedures C 5 Replace the Auxiliary Platform Lowering Batteries Genie specifications require that this procedure be performed every 1000 hours or annually whichever comes first 1 the key switch off and remove the key 2 Remove the ground control box cover fasteners 3 Open the ground control box and locate the auxiliary battery pack inside 4 Remove the fasteners that hold the battery pack in place 5 Carefully slide the battery pack out of the holder Note The wires connected to the battery pack are very small Be careful not to damage the wires 6 Remove the old batteries from the pack 7 Insert new batteries into the pack Note Make sure the batteries are installed correctly by following the diagram on the inside of the battery pack 8 Install the battery pack into the ground control box and tighten the fasteners 9 Close the ground control box cover and tighten the fasteners Do not overtighten Genie BRAND Part No 38139 Super Series IWP Super Series 45 Service Manual May 2015 sees This page intentionally left blank __ Genie ____________________ 46 AWP Super Series IWP Super
182. jury and component damage 1 Fully lower the platform to the stowed position 2 Remove the outriggers from the base and place in the storage sockets 3 Maintain a firm grasp on the tilt back frame and remove the retaining pin 4 Lower the tilt back frame and guide the tilt back strut into the strut socket Genie 32 Super Series Super Series Part No 38139 2015 Service Manual Checklist B Procedures 5 _ Insert the retaining pin into the strut socket 8 Continue lifting until telescoping tilt back strut is completely compressed AWARNING Crushing hazard The machine will fall if the retaining pin is not locked into the strut socket 9 Return the machine to the standing position Carefully pull down T handle until machine 6 Slide out the T handle until the lock pin snaps rests at mid tilt position into the locked position 10 Lower the machine with the T handle until AWARNING Crushing hazard The machine base casters are in contact with the ground could fall if the T handle lock pin Use the appropriate number of people and is not locked into the base proper lifting techniques 7 Lift the machine with the T handle to the 11 Return the sliding T handle to stowed position mid tilt position casters on tilt back frame 12 Stow the tilt back frame in the upright position contact the floor and machine supported by and insert the retaining pin the extended tilt back strut
183. justment How to Adjust the Platform Lift Relief Valve Note Be sure the hydraulic oil level is between the FULL and ADD marks on the oil level indicator 1 Remove the power unit cover 2 Loosen the locknut on the relief valve located on the right side of the motor 3 Follow the appropriate operator s manual to set up the machine for operation 4 Place maximum rated load into the platform Secure the load to the platform Refer to Specifications Machine Specifications 5 Hold the relief valve screw and loosen the lock nut 6 While activating the platform up function turn the relief valve screw clockwise just until the platform begins to raise Fully lower the platform 8 Add additional weight to the platform that is equal to but does not exceed 20 of the maximum rated load Secure the additional weight Refer to the machine serial plate Genie BRAND Super Series IWP Super Series 71 Part No 38139 Service Manual Hydraulic Power Unit 10 11 12 13 14 72 Activate the platform up function 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 platform does not lift Repeat steps 11 and 12 until the lift relief valve is properly adjusted Hold the relief valve screw and tighten the lock nut Be sure the relief valve screw does not turn
184. klist A Procedures A 14 Inspect the Lifting Chains and Idler Wheels Genie specifications require that this procedure be performed every 8 hours or daily whichever comes first 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 Raise the platform approximately 3 feet 1 m Visually inspect the chains and idler wheels near the top of each column for the following e Excessive corrosion Broken or missing chain leafs and pins e Tight or kinked joints in the chain Missing or damaged idler wheels and related components 3 Inspectthe chain terminations near the bottom of each column to confirm that each termination has a lock nut Service Manual May 2015 Checklist A Procedures 4 Inspect the chain terminations near the bottom of each column to confirm that the chain tensioner bracket is centered in the inspection hole 1 chain tensioner bracket 2 adjustment nut hidden from view 3 termination rod hidden from view 4 column A 15 Inspect the Breather Cap Genie specifications require that this procedure be performed every 8 hours or daily whichever comes first The hydraulic tank is vented to the atmosphere The breather cap has an internal air filter that can clog and may cause the power unit to
185. l Schematic AWP Super Series DC Models from SN 3896 101 to 3896 300 Service Manual May 2015 Electrical Schematic Super Series DC Models from SN 3896 101 to 3896 300 A B C D E F G H J K L M RI TAa ee ee ee ee 1 1 EMERGENCY STOP BK BK s BK KS1 4 712151 W3 1 1 gt i POWERINPUT CENTER TAP INPUT 2 o NEGATIVE 12V DC AUX INPUT 16 0V DC INPUT a E POSITIVE 12V DC AUX INPUT 14 FRONT LEFT 4 WH 2 LEVELING LEVELING LEVELING LED 12 FRONT RIGHT 5 gt 1 INPUTS LED 13 REAR RIGHT 6 cd L5 LED 15 REAR LEFT 7 14 13 o POWER INDICATOR 12V DC OUTPUT D ET L6 12V DC OUTPUT 3
186. ld on or against any part of the machine Performing this procedure without the proper skills and tools could result in death or serious injury Dealer service is strongly recommended Checklist C Procedures C 4 Replace the Hydraulic Oil Genie specifications require that this procedure be performed every 1000 hours or annually whichever comes first Replacement or testing of the hydraulic oil is essential for good machine performance and service life Dirty oil and a clogged 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 often For hydraulic oil specifications Refer to Specifications Hydraulic Specifications 1 Fully lower the platform 2 Remove the plastic cover from the power unit Remove the drain plug from the tank and allow all of the oil from the tank to drain into a suitable container AWARNING Bodily injury 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 4 IWPS models with Power Wheel Assist Option Tag and disconnect the hose at the bottom of the tank and drain oil into a suitable container AWARNING Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressu
187. lease cable Refer to Repair Procedure How to Adjust the Base Release Cable Mast Components 5 3 Glide Pads How to Adjust the Glide Pads 1 Fully lower the platform 2 Turn the key switch off and remove the key 3 Locate the upper and lower glide pad adjustment bolts below each upper roller bolt on both sides of each column 4 Hold the glide pad bolt and loosen the lock nut on all the glide pads 5 the glide pad adjustment bolt clockwise until the glide pad makes contact with the column Adjust the slide pads on both sides of all column mast Be sure the sides of the columns are even to within 1 8 inch 3 17 mm of each other 6 Starting at the number 1 column torque the upper and lower glide pad bolts to 12 in Ibs 1 35 Nm Hold the glide pad adjustment bolt and tighten the lock nut Be sure the glide pad bolt does not turn 7 Repeat step 5 for each remaining upper and lower glide pad on both sides of the mast Start at the number 1 column and work toward the carriage 8 Repeatstep 5 for all of the upper and lower glide pads Note Make sure glide pad bolts are adjusted evenly on each side to maintain squareness of the columns Genie BRAND Super Series IWP Super Series 81 Part No 38139 Service Manual May 2015 Mast Components 5 4 Lifting Chains How to Adjust the Lifting Chains 1 Fully lower the machine and check to see if all the columns excep
188. ler 10 Suction strainer Filters hydraulic fluid 11 O ring Seals tank 12 Pump 0 7 to 1 at 2000 psi 2 6 to 3 76 L min at 138 bar 13 Check valve Pump output 14 Motor seal Seals motor from contaminants 15 Motor bearing Aligns motor shaft into pump Part No 38139 Genie BRAND Super Series IWP Super Series 65 Service Manual May 2015 Hydraulic Power Unit 2 Q 14 3 3 4 5 12 41 10 6 NC s m Genie 66 AWP Super Series Super Series Part No 38139 2015 Service Manual Hydraulic Power Unit 3 4 Hydraulic Power Unit Components Air Powered Models to SN AWP04 27778 Index No Description Function 1 Air motor 100 psi 6 9 bar 80 cfm 37760 cc sec 2 Exhaust Muffler Controls sound emissions 3 Relief valve Relief valve 4 Valve Air Pilot Diverts pump output back to tank during motor start up 5 O ring Seals tank 6 Hydraulic tank 3 quarts 2 8 liters 7 Drain plug Drains hydraulic tank 8 Sight gauge Hydraulic fluid level 9 Tee fitting models with Narrow or Tank vent adaptor Rough Terrain Base Option 10 Plug fitting models with Narrow or Rough Plug Terrain Base Option 11 Suction strainer Filters hydraulic fluid 12 Breather cap from SN 3897 4545 Hydraulic tank vent filler 13 Breather
189. ll unless it is properly supported Note If a new power unit is installed the pressure relief valve must be properly adjusted See 3 6 How to Adjust the Pressure Relief Valve Genie 70 AWP Super Series Super Series Part No 38139 2015 Service Manual 3 6 Hydraulic Pump How to Remove the Hydraulic Pump Note When removing a hose assembly or fitting the O ring if equipped on the fitting and or hose end must be replaced All connections must be torqued to specification during installation Refer to Specifications Hydraulic Hose and Fitting Torque Specifications 1 Fully lower the platform 2 Turn the key switch off and disconnect the power supply 3 IWPS models Pull the base lowering handle to fully lower the base 4 Remove the power unit cover Remove the power unit See 3 4 How to Remove the Power Unit 6 Supportthe hydraulic tank with a lifting device 7 Remove the mounting fasteners from the tank Remove the tank from the power unit Do not allow the hydraulic oil to spill Note It may be necessary to tap the side of the tank with a soft rubber mallet to loosen it 8 Remove the mounting fastener from the suction cover assembly on the pump Then remove the suction cover 9 Remove the mounting fasteners from the pump Then remove the pump from the power unit Note When installing the tank be sure not to damage the o ring Hydraulic Power Unit 3 7 Valve Ad
190. ls with Narrow Base from SN 07 54899 to 57594 123 Electrical Schematic AWP Super Series AC Models with Standard Base from SN 07 57595 126 Electrical Schematic AWP Super Series AC Models with Narrow from AWPO7 57595 i ctt eet tied 127 Electrical Schematic AWP Super Series AC CE Models from SN 3896 451 to AWPO07 54898 sss 130 Electrical Schematic AWP Super Series AC CE Models with Standard Base from SN AWP07 54899 to 07 57594 00 131 Electrical Schematic AWP Super Series AC CE Models with Narrow Base from SN AWP07 54899 to 07 57594 0 134 Electrical Schematic AWP Super Series AC CE Models with Standard Base from SN AWP 57595 ceni eux MERE eee 135 Electrical Schematic AWP Super Series AC CE Models with Narrow Base from SN 07 57595 138 Electrical Schematic AWP Super Series AC TUV Models from SN 3896 401 eee dece nnd denn aide hn na a Re 139 Genie xiv AWP Super Series IWP Super Series Part No 38139 2015 Table of Contents Electrical Schematics IWP 202012012 4411 141 Electrical Schematic IWP Super Series DC Models from SN 4096 101 to 4096 2871 142 Electrical Schematic IWP Super Series D
191. ls with Power Assist Directional Valve Coils Powering Function Manifold 161 Service Manual May 2015 Electrical Schematic Super Series DC Models with Power Assist Directional Valve Coils Powering Function Manifold A B D E F G H L ee ye we eee een ee 2 25 2202 2 2 71 2 22 1 STEER HANDLE 1 1 E CONTROLS EMERGENCY a DRIVE i A EMERGENCY 21 MANIFOLD acc ae Ye p BK NC RD 51915 3 1 NAE Se FORWARD dim i KS1 12 DC POWER INPUT 2 PLATFORM L NEGATIVE 12V DG INPUT 2 ET sw
192. ly supported by the overhead crane when removed from the base 50 AWP Super Series IWP Super Series Part No 38139 2015 Service Manual Base Assembly How to Adjust the Base Release 5 Locate the base release cable mounting bracket on the bottom side of the number Cable 1 column 1 Pullthe base lowering handle to fully lower the base 2 Remove the cover from the base manifold Be sure the cable is properly connected to the manual valve at the base manifold 0 890 9 2 mounting bracket with a lock nut on each side There should be to inch 6 35 to 12 7 mm of threads on the manifold side of the bracket 1 lock nut 1 number 1 column 2 coupler 2 base release cable 3 base release cable 3 cable striker bracket 4 cable mounting bracket 4 slider bracket 4 Besure the cable is attached to the cable S sping 6 lock nut 7 cable mounting bracket 6 Loosen the mounting fasteners on the cable mounting bracket and the cable striker bracket on the number 1 column Do not remove the fasteners Genie BRAND Part No 38139 Super Series IWP Super Series 51 Service Manual May 2015 Base Assembly 10 11 12 52 Measure from the bottom of the number 1 column make a reference mark 6 inches 15 2 cm up the column Slide the cable mounting bracket up until the top of the bracket is even with t
193. n before removal Genie BRAND Part No 38139 AWP Super Series Super Series 79 Service Manual e Mast Components How to Assemble the Mast AWARNING 80 Bodily injury hazard This procedure requires specific repair skills lifting equipment and a suitable workshop Attempting this procedure without these skills and tools could result in death or serious injury and significant component damage Dealer service is strongly recommended Thoroughly clean all columns Secure the number 1 column to the saw horses and lay the chains out on the floor at the top Do not allow the chains to become twisted or dirty Apply a generous amount of Boe lube wax Genie part number 90337 to the inside and outside channels of each column Slide the number 2 column into the number 1 column Lay the number 2 column chains on the floor Do not allow the chains to become twisted or dirty Lay the number 1 column chains inside the number 2 column Slide the number 3 column into the number 2 column When the number 3 column is almost all the way in guide the number 1 column chains into the chain tension rocker on the number 3 column 10 11 12 13 14 15 May 2015 Install the adjustment nuts on the number 1 column chains Tighten the adjustment nuts until the lifting chains have equal tension and the chain tension rocker is centered in the inspection hole in the column
194. ndard fiber platform 29 x 26 43 in L x W x H 74 x 67 x 110 cm Genie 4 AWP Super Series Super Series Part No 38139 2015 Service Manual ip n Specifications Model IWP 20S IWP 25S IWP 30S Height working maximum 26 ft 5 in 30 ft 5 in 35 ft 6 in 8 1m 9 3m 10 8m Height platform maximum 20 ft 5 in 24 ft 5 in 29 ft 6 in 6 2m 7 4 9 0 Lift capacity 350 Ibs 350 Ibs 350 Ibs 159 kg 159 kg 159 kg Lift capacity 300 Ibs with outreach option 136 kg Machine weight 1245 1345 Ibs 1290 1390 Ibs 1290 1390 Ibs DC AC models 565 610 kg 585 630 585 630 Height stowed 76 in 78 in 76 in 78 in 76 in 78 in base fully lowered base raised 198 cm 203 cm 198 cm 203 cm 198 cm 203 cm Width Standard Base 32 in 32 in 81 cm 81 cm Length Standard base 60 in 60 in 152 cm 152 cm Width Wide Base 40 in 102 cm Length Wide Base 60 in 152 4 cm Platform length 27 in 27 in 27 in 69 cm 69 cm 69 cm Platform width 26 in 26 in 26 in 66 cm 66 cm 66 cm Platform height 44 in 44 in 44 in 114 cm 114 cm 114 cm Corner access 6 in 6 in 6 in 15 cm 15 cm 15 cm Genie Part No 38139 AWP Super Series Super Series 5 Service Manual May 2015 Specifications Platform function speed maximum Hydraulic System AWP 15S
195. ndle Missing Parts e Hydraulic motor and hoses IWP 20S models with Outreach Option e Locking bracket Genie specifications require that this procedure be performed every 8 hours or daily whichever comes Handle and handle lock first Outreach extension arms Daily machine condition inspections are essential Chain and sprocket 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 Inspectthe entire machine for damage and improperly installed or missing parts including e Electrical components wiring and electrical cables Electrical cable anchors and pulleys Hydraulic power unit hoses fittings cylinder s and manifolds e Sequencing cables anchors and pulleys Lifting chains and idler wheels Adjustable glide pads e Mast columns and counterweight s e Mast covers e Nuts bolts and other fasteners e Platform entry mid rail or gate Breather Dents or damage to machine Corrosion or oxidation e Cracks in welds or structural components e IWPS models Hydraulic manifolds and foot pump e IWPS models Foot pads e AWPS models Outriggers leveling jacks and foot pads Genie BRAND Part No 38139 Super Series IWP Super Series 21 Service Manual May 2015 Checklist A Procedures A 5 Check for Hydraulic Leaks Genie specifica
196. ner that mounts the shock absorber assembly to the frame 5 Remove the shock absorber assembly from the frame and separate the lower tube from the assembly 6 Pullthe shock absorber out of the upper tube 7 Remove the metric nut from each end of the shock absorber and remove the mounting blocks A WARNING Bodily injury hazard Contents of 86 the shock absorber are under pressure Use care during removal Genie ak lt A BSS shock absorber lower shock mounting block lower tube upper tube upper shock mounting block AWP Super Series IWP Super Series Part No 38139 2015 Service Manual l Platform 7 1 How to Install a Fiberglass Platforms Platform 1 Remove the aluminum platform Refer to How to Remove an Aluminum Platform Repair Procedure How to Remove an Aluminum Platform 2 Supportthe platform with a lifting device place 1 Place support blocks between the platform the platform against the mounting angles and base Lower the platform onto the block 3 Install the mounting fastener Crushing hazard Keep away from A WARNING the ONES AWARNING Bodily injury hazard Safety decals are essential to safe machine 2 Remove the mounting fasteners from the operation Failure to replace all platform safety and instructional decals could result in death or serious 3 Pullthe platform away from the mast and injury If a
197. nto Aluminum all types SAE Dash Size Torque and installed or when new hoses or fittings are installed Seal Lok Fittings hose end ORFS 4 14 ft lbs 19 Nm 6 23 ft lbs 31 2 Nm 8 36 ft lbs 54 2 Nm 10 62 ft lbs 84 Nm 12 84 ft lbs 114 Nm 16 125 ft lbs 169 5 Nm 20 151 ft lbs 204 7 Nm 24 184 ft Ibs 249 5 Nm SAE Dash Size Torque 4 10 ft lbs 13 6 Nm 6 30 ft lbs 40 7 Nm 8 40 ft lbs 54 2 Nm 10 60 ft lbs 81 3 Nm 12 85 ft lbs 115 Nm 16 110 ft lbs 150 Nm 20 140 ft lbs 190 Nm 24 180 ft lbs 245 Nm JIC 37 Fittings swivel nut or hose connection Adjustable Fitting 1 jam nut Non adjustable fitting SAE O ring Boss Port tube fitting installed into Steel SAE Dash Size Torque SAE Dash Size Thread Size Flats 4 7 16 20 2 6 9 16 18 1 8 3 4 16 1 10 718 14 1 12 1 1 16 12 1 16 1 5 16 12 1 20 1 5 8 12 1 24 1 7 8 12 1 BRAND Super Series IWP Super Series Part No 38139 4 ORFS 37 Adj 15 ft lbs 20 3 Nm ORFS Non adj 26 ft lbs 35 3 Nm 37 Non adj 22 ft lbs 30 Nm 6 ORFS Adj Non adj 35 ftlbs 47 5 Nm 37 Adj Non adj 29 ft lbs
198. nute at 2000 psi 1 89 to 2 27 liters per minute at 138 bar 7 Solenoid operated N O dump valve Diverts pump output back to tank during motor start up 8 10V DC coil Activates N O dump valve 9 O ring Seals tank 10 Return tube Returns fluid to tank 11 Hydraulic tank 3 quarts 2 8 liters 12 Drain plug Drains hydraulic tank 13 Breather cap Hydraulic tank vent filler 14 Suction strainer Filters hydraulic fluid 15 Suction tube Sends fluid to pump 16 Check valve Pump output Part No 38139 Genie BRAND Super Series IWP Super Series 63 Service Manual May 2015 Hydraulic Power Unit OEC CIO CS S OS 1 1 64 AWP Super Series IWP Super Series Part No 38139 2015 Service Manual 3 3 Hydraulic Power Unit Hydraulic Power Unit DC Models to SN AWP03 27401 and IWP03 5122 Index No Description Function 12V DC electric motor 12V DC standard duty 1 terminal 180 A at 2650 psi 183 bar 2 Motor starter solenoid Power supply to electric motor 3 Relief valve Lift relief 4 Solenoid operated N O dump valve Diverts pump output back to tank during motor start up 5 10V DC coil Activates N O dump valve 6 Hydraulic tank 3 quarts 2 8 liters 7 Drain plug Drains hydraulic tank 8 Sight gauge Hydraulic fluid level 9 Breather cap Hydraulic tank vent fil
199. only be performed by trained service professional in a suitably equipped workshop Select the appropriate Symbols Legend repair procedure after troubleshooting the problem Perform disassembly procedures to the point where repairs can be completed Then to re assemble perform the disassembly steps in reverse order AWARNING CAUTION Genie A A DANGER Safety alert symbol used to alert personnel to potential personal injury hazards Obey all safety messages that follow this symbol to avoid possible injury or death Indicates a imminently hazardous situation which if not avoided will result in death or serious injury Indicates a potentially hazardous situation which if not avoided could result in death or serious injury Indicates a potentially hazardous situation which if not avoided may cause minor or moderate injury Indicates a potentially hazardous situation which if not avoided may result in property damage Indicates that a specific result is expected after performing a series of steps Indicates that an incorrect result has occurred after performing a series of steps 48 AWP Super Series Super Series Part No 38139 2015 Service Manual 1 1 Interlocks AWPS models The interlock contacts indicate proper installation of the outriggers and only allow the machine to operate when the outriggers are properly installed and adjusted IWPS models The base
200. ough terrain 117 including narrow and rough terrain 66cm base options base options AWP 20S 46 inches AWP 25S 36 inches 117 including narrow and rough terrain 91 4 AWP 20S 60 inches base option narrow and rough terrain base options 152 30 46 inches AWP 25S 60 inches including narrow and rough terrain 117 including narrow and rough terrain 152 base option base option AWP 36S 60 inches AWP 30S 60 inches 152 cm 152 cm AWP 40S 60 inches _ AWP 30S 75 inches 152cm narrow and rough terrain base option 191 cm AWP 36S 75 inches 191 cm AWP 40S 85 inches 216 cm Genie 38 AWP Super Series IWP Super Series Part No 38139 2015 10 Inspect and Lubricate the Outrigger Leveling Jack Footpads AWPS Models Genie requires that this procedure be performed every 250 hours or quarterly whichever comes first Detection of unusual wear of the leveling jack footpads is essential for safe machine operation An improperly lubricated and or damaged footpad could result in an unsafe condition 1 Visually inspect the leveling jack footpads for any unusual wear 2 Liberally apply grease to the top of the footpads at the swivel point and the leveling jack threads 1 outrigger leveling jack threads 2 outrigger footpad swivel point 3 outrigger footpad Grease Type Lithium based Checklist B Procedures B 11 Test the Level Sensing Operation
201. platform must be remove it from the machine replaced be sure that all appropriate safety and AWARNING Bodily injury hazard Safety decals instructional decals are applied to are essential to safe machine the new platform operation Failure to replace all safety and instructional decals could result in death or serious injury If a platform must be replaced be sure that all appropriate safety and instructional decals are applied to the new platform Genie BRAND Part No 38139 Super Series IWP Super Series 87 Service Manual May 2015 Platform 7 2 Platform Control Box How to Test the Contacts 1 Fully lower the platform 2 Turn the key switch off and disconnect the power supply 3 Remove the platform control box cover fasteners and open the control box 4 Note the markings on the contact to be tested N O designates the contact as normally open N C designates the contact as normally closed 5 Connect a continuity tester to the exposed screw terminal Result Normally open contacts should read no continuity Normally closed contacts should read continuity 6 Pushthe small triangular button on the top of the contactor Result Normally open contactor should read continuity Normally closed contacts should read no continuity How to Test Power to Platform Outlet 1 Fully lower the platform 2 Turn the key switch off and remove the key 3 ACand DC mo
202. r the platform 2 Turn the key switch to the off position AWPS models Remove the outriggers from the outrigger storage socket DC models Remove the battery pack 3 Remove the breather cap from the hydraulic power unit and install a pipe plug in the filler hole 4 Attach an overhead crane to the lifting eye at the top of the mast 5 Place a saw horse in front of the machine where the top of the mast will rest Mast Components 6 Liftthe machine off the ground and then while lowering it guide it over onto the saw horse Be sure the saw horse is of ample capacity CAUTION Ctushing hazard The machine will fall unless it is properly supported by the saw horse 7 Remove the socket head retaining bolt from the clevis block on the lift cylinder rod end 1 top of no 1 column 2 retaining fastener 3 clevis block 8 Tag disconnect and plug the lift cylinder hydraulic hoses Cap the fittings on the lift cylinder AWARNING Bodily injury 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 9 Remove the cylinder mounting fasteners from the barrel end of the cylinder Genie BRAND Super Series IWP Super Series 75 Part No 38139 Service Manual May 2015 Mast Components 10 Loosen the cylinder mounting bracket 5 2 Mast Assembl
203. raulic System Hydraulic fluid Chevron Rando HD equivalent Hydraulic tank capacity 3 quarts all models 2 8 liters Genie 22 AWP Super Series Super Series Part No 38139 2015 7 Test the Base Operation IWPS Models Genie specifications require that this procedure be performed every 8 hours or daily whichever comes first 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 7 to 9 complete strokes Result The non adjustable foot pads should raise 1 7 to 2 inches 4 to 5 cm off the ground 2 Pullthe base lowering handle Result The base should lower putting all four foot pads in firm contact with the ground 3 Raisethe platform slightly Result The inner frame wheels should lift off the ground Checklist A Procedures A 8 Test the Auxiliary Platform Lowering Operation Genie specifications require that this procedure be performed every 8 hours or daily whichever comes first The auxiliary platform lowering is powered by a secondary battery pack that is located in the ground control box The auxiliary platform lowering can be activated from the ground or platform controls Detection of an auxiliary lowering malfunction is ess
204. re 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 capacity Be sure that fasteners intended for one time use i e cotter pins and self locking nuts are not reused These components may fail if they are used a second time 52 Be sure to properly dispose of old or 7 other fluids Use approved container Please be environmentally safe Be sure that your workshop or work area is properly ventilated and well lit Genie BRAND AWP Super Series Super Series vii Part No 38139 2015 2 22 42 2 77 Table of Contents Introduction UI CUO IN ii Important Information eu iecit ii Find a Manual for this ii Revision iii Serial Number Legend ioter ed abt teat rt ner ER b a e iv Section 1 CLA fte vi General Safety Rules e da edet aet A YR ERR aL aera vi Section 2 Specifications ener rece daten r 1 AWP Specifications 1 AWP Specifications 2 Narrow Base 3 AWP Roug
205. re to dissipate gradually Do not allow oil to squirt or spray Genie BRAND AWP Super Series Super Series 43 Part No 38139 Service Manual Checklist Procedures 10 11 12 13 44 Remove the tank from the hydraulic power unit Remove the suction strainer from the pick up tube and the magnet from inside the tank and clean them using a mild solvent Install the suction strainer Install the drain plug using thread sealer on May 2015 Hydraulic System Hydraulic fluid Chevron Rando HD equivalent Hydraulic tank capacity all 3 quarts models 2 8 liters Hydraulic System Capacity includes tank IWP AC and DC models the threads IWP 20S 3 7 quarts 3 5 liters Install the hydraulic tank IWP 25S 3 7 quarts Fill the tank with hydraulic oil until the level is 3 5 liters visible in the sight gauge on the side of the IWP 30S 3 7 quarts tank Do not overfill 3 5 liters Replace the breather cap with a new one AWP AC DC and Air Powered models Raise and lower the platform through three AWP 158 3 7 quarts complete cycles Add hydraulic oil if needed to 3 5 liters allow platform to reach full height AWP 20S 3 7 quarts Clean up any oil that may have spilled 3 5 liters Properly discard the used oil AWP 25S 3 7 quarts Component damage hazard Do eo lets not allow the hydraulic tank to AWP 30S 3 7 quarts completely empty when ra
206. red under the platform Adjust the jack stand to 24 inches 61 cm 1 Chain 2 Idler Wheel 3 Spacer Note If idler wheel inspection results in a measurement that is not within specification replace the idler spacers Refer to Repair Procedure How to Assemble the Mast 9 Raise the platform and remove the jack stand and the support blocks Then lower the platform 10 Install the mast covers and adjust the sequencing cable Refer to Maintenance Procedure Adjust the Sequencing Cables 7 Lower the platform onto the jack stand just enough to take the weight off the lifting chains A WARNING Crushing hazard Keep away from lowering platform a ____________________ 42 AWP Super Series IWP Super Series Part No 38139 2015 Service Manual C 3 Inspect and Lubricate the Lifting Chains Genie specifications require that this procedure be performed every 1000 hours or annually whichever comes first Lubricated chains are essential to good machine performance and safe operation Extremely dirty conditions may require that the chains be cleaned and lubricated more often 1 Raise the platform to the maximum height 2 Inspect each lifting chain Refer to Repair Procedure How to Inspect the Lifting Chains 3 Lubricate each chain with a dry type spray lubricant AWARNING Bodily injury hazard This procedure will require the use of additional access equipment Do not place ladders or scaffo
207. ring patentes completed Comments Use the step by step procedures in this section to learn how to perform these inspections If any inspection receives tag and remove the machine from service repair and re inspect it After repair place a check in the R box Legend Y yes acceptable no remove from service repaired Genie Part No 38139 Super Series IWP Super Series 17 Service Manual May 2015 sees This page intentionally left blank __ ____________________ 18 AWP Super Series IWP Super Series Part No 38139 2015 Service Manual A 1 Inspect the Manuals and Decals Genie specifications require that this procedure be performed every 8 hours or daily whichever comes first Maintaining the operator s and safety manuals in good condition is essential to safe machine operation Manuals are included with each machine and should be stored in the container provided in the platform An illegible or missing manual will not provide safety and operational information necessary for a safe operating condition In addition maintaining all of the safety and instructional decals in good condition is mandatory for safe machine operation Decals alert operators and personnel to the many possible hazards associated with using this machine They also provide users with operation and maintenance information An illegible decal will fail to alert personnel of a proce
208. s 10 1 Turn the key switch to ground control and pull out the red Emergency Stop button to the ON position Twist to release the red Emergency Stop button at the platform controls Result The power light should be on 2 Pull the base lowering handle to fully lower the base 3 Use the bubble level and adjust the leveling jacks until the machine is level and all four foot pads are in firm contact with the ground Result Within 1 to seconds all four interlock display lights should turn on and remain on 4 Pump the foot pedal to raise the base Result Both foot pad interlock display lights should be off Genie 26 AWP Super Series IWP Super Series Pull the base lowering handle to fully lower the base Result The base will lower and both foot pad interlock display lights should be on Pump the foot pedal to raise the base Turn both leveling jacks clockwise to the full extended position Pull the base lowering handle to fully lower the base Result The base will lower and the two level sensor interlock display lights should be off and remain off Push in the red Emergency Stop button at the platform controls Push in the control activate button and rotate the up down switch in the up position then the down position Result Platform up down functions should not operate Part No 38139 2015 13 Test the Power and Function Controls Genie specification
209. s require that this procedure be performed every 8 hours or daily whichever comes first 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 red Emergency Stop button fails to stop all the machine functions Each function should operate smoothly and be free of hesitation jerking and unusual noise 1 Turn the key switch to ground control and pull out the red Emergency Stop button to the ON position Twist to release the red Emergency Stop button at the platform controls Result The power light should be on 2 Pushin the control activate button and rotate the up down switch in the UP position then the DOWN position Result Platform up down functions should operate 3 in the red Emergency Stop button at the platform controls to the OFF position 4 Push the control activate button and rotate the up down switch in the UP position then the DOWN position Result The up down functions should not operate 5 in the red Emergency Stop button at both platform and ground controls 6 Pushin the control activate button and rotate the up down switch in the UP position then the DOWN position Result The up down functions should not operate Gen BRAND Super Series IWP Super Series 27 Part No 38139 Chec
210. t WH BK U9 Transformer YL U10 PC board U12 Thermal device Wiring component W3 Terminal strip 3 pole 3 pin U10 WA Terminal strip 14 pole 14 pin U10 W5 Terminal strip 13 pole 26 pin N7 N9 W6 Terminal strip 8 pole 16 pin base AWP W6 Terminal strip 10 pole 20 pin base IWP Y Valve coil Y5 Drive forward IWP Y6 Drive reverse IWP YT Platform down Y30 Normally open dump valve Y32 Function solenoid Genie Part No 38139 BRAND Description Black Black Red Blue Blue Black Blue Orange Blue White Brown Green Green Black Green White Green Yellow Light Blue Orange Orange Black Orange Red Orange White Red Red Black Red White White White Black Yellow AWP Super Series Super Series 93 Service Manual May 2015 Electrical Symbol Legend 9 D N C i 8 B a Wire with description or color Limit Switch Toggle Switch Switch AG Emergency Stop Circuits crossing no connection Fuse Circuit breaker button y M5 Diode LED Motor U12 Thermal Device Circuit connection Connector 8 AA Batteries 12V Battery s 1 X A X Lift Enable Solenoid Valve Solenoid valve with diode Genie 94 AWP Super
211. t have been out of service for a Machine Configuration V Unless otherwise specified perform each procedure with the machine in the following configuration period longer than 3 months must complete the quarterly inspection Genie BRAND Super Series IWP Super Series Machine parked on a firm level surface Key switch in the off position with the key removed The red Emergency Stop button in the off position at both ground and platform controls Wheels chocked All external AC power supply disconnected from the machine Platform in the stowed position 11 2015 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 Symbols Legend Safety alert symbol used to alert personnel to potential personal injury hazards Obey all safety messages that follow this symbol to avoid possible injury or death ADANGER Indicates a imminently hazardous situation which if not avoided will result in death or serious injury AWARNING Indicates a potentially hazardous situation which if not avoided could result in death or serious injury ACAUTION Indicates a potentially hazardous situation which if not avoided may cause minor or moderate injury Indicates a potentially ha
212. t is properly supported by the saw horse 9 Attach the overhead crane to the base AWARNING 13 14 15 10 Lift the base until the mast is level then place a second saw horse under the mast near the base Lower the mast onto the saw horse 11 Remove the cover on the rear of the base Part No 38139 16 17 CAUTION Genie BRAND Mast Components Tag disconnect and plug the lift cylinder hydraulic hoses Remove the flow control valve from the cylinder Cap the cylinder ports Bodily injury 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 Remove the mast brace mounting bracket fasteners Remove the four mast mounting fasteners Push the fasteners toward the mast for clearance during mast removal AWP 15S 20S 25S and 30S models Remove the power cable brackets from the side of the mast AWP 36S and 40S models Remove the rubber grommet from the access hole in the mast stiffener Carefully pull the electrical cables and hydraulic hoses down and out through the bottom of the mast Attach the overhead crane to the base Carefully lift and remove the base from the mast Do not damage the lift cylinder hydraulic fittings when removing the base Crushing hazard The base will fall unless it is properly supported when it is removed from the mast
213. t the carriage are even at the top The chains are adjusted correctly if all the columns are even at the top To adjust column chains 2 the column to be adjusted 3 Raise the platform 6 feet 2 m 4 Turnthe adjustment lock nuts evenly on both chain terminals clockwise to raise the column or counterclockwise to lower the column 5 Fully lower the machine and confirm the alignment of the columns Adjust if necessary 6 Confirm that the chain terminals on each column have equal tension and the lock nuts are tight 1 1 1 82 AWP Super Series IWP Super Series Part No 38139 2015 Service Manual ___ Mast Components How to Inspect the Lifting Chains Inspection Wear Rust and Corrosion Tight Joints Part No 38139 Procedure Count out 16 chain links and measure pin to pin centerline dimension with a steel measuring tape Note Measure a section of chain that moves over the idler wheels Visually inspect the chains for rust and corrosion Visually inspect the chains for lubrication Inspect chain link joints for easy movement Inspection Failure When the length of the 16 links pin to pin measure more than 8 25 inches 21 for 1 2 inch 12 7mm chain or 10 31 inches 26 1 cm for 5 8 inch 15 9 mm chain Evidence of rust or corrosion When external surfaces are not protecte
214. t this procedure be performed every 1000 hours or annually whichever comes first 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 or does not operate smoothly free of hesitation and binding 1 Remove the mast covers 2 Raise the platform until to 5 inches 7 6 to 12 7 cm of each column is visible 3 Visually inspect the top of each column for clearance between the roller wheels and the adjacent column surface Result There should be a equal amount of distance between the roller wheel and the column on each side Note If mast inspection results in a measurement that is not within specification refer to Repair Procedure How Adjust the Glide Pads Genie BRAND Super Series IWP Super Series 41 Part No 38139 2015 Checklist Procedures 4 Loosen but do not remove the adjustment nut 8 Inspect each idler wheel for the following on the sequencing cable located at the top of thefirst col mn e Excessive wear on the side flanges e Unusual wear e Movement side to side in excess of 0 079 inch 2 mm e Any movement of wheel front to back 5 Raise the platform approximately feet 1 above the top of the base 6 Place a jack stand on the top of the base cente
215. ten the nut or fitting to the appropriate 1 hex nut torque Refer to the appropriate torque chart in 2 reference mark this section 3 body hex fitting 6 Operate all machine functions and inspect the hose fittings and related components to confirm there are no leaks Gri 8 Super Series Super Series Part No 38139 2015 Service Manual Specifications 3 Working clockwise on the body hex fitting make a second mark with a permanent ink marker to indicate the proper tightening position Refer to Illustration 2 Note Use the JIC 37 Fitting table in this section to determine the correct number of flats for the proper tightening position Note The marks indicate the correct tightening positions have been determined Use the second mark on the body hex fitting to properly tighten the joint after it has been loosened Illustration 2 1 body hex fitting 2 reference mark 3 second mark 4 Tighten the hex nut until the mark on the hex nut is aligned with the second mark on the body hex fitting 5 Operate all machine functions and inspect the hose fittings and related components to confirm there are no leaks Genie BRAND Part No 38139 Super Series IWP Super Series 9 Service Manual May 2015 Specifications SAE FASTENER TORQUE CHART This chart is to be used as a guide only unless noted elsewhere this manual A574 H
216. that this procedure be performed every 8 hours or daily whichever comes first Completing a Pre operation Inspection is essential to safe machine operation The Pre operation Inspection is a visual inspection performed by the operator prior to each work shift The inspection is designed to discover if anything is apparently wrong with a machine before the operator performs the function tests The Pre operation Inspection also serves to determine if routine maintenance procedures are required Complete information to perform this procedure is available in the appropriate operator s manual Refer to the Operator s Manual on your machine A 3 Perform Function Tests Genie specifications require that this procedure be performed every 8 hours or daily whichever comes first Completing the function tests is essential to safe machine operation Function tests are designed to discover any malfunctions before the machine is put into service A malfunctioning machine must never be used If malfunctions are discovered the machine must be tagged and removed from service Complete information to perform this procedure is available in the appropriate operator s manual Refer to the Operator s Manual on your machine Genie 20 Super Series Super Series Part No 38139 2015 Service Manual Checklist A Procedures A 4 IWPS models with Power Wheel Assist Option Inspect for Damage and Loose or Steer ha
217. the base Result Within 1 to 4 seconds two interlock display lights should turn off and remain off Repeat steps 4 through 8 to test the opposite side of the machine Pump the foot pedal to raise the base Place a inch 19 mm thick spacer under both adjustable foot pads Pull the base lowering handle to fully lower the base Result Within 1 to 4 seconds all four interlock display lights should turn on and remain on Pump the foot pedal to raise the base Turn the leveling jacks counterclockwise enough to fit a 172 inch 3 8 cm spacer under each adjustable foot pad Turn the leveling jacks clockwise until the foot pads just touch the spacers Pull the base lowering handle to fully lower the base Result Within 1 to 4 seconds two interlock display lights should turn off and remain off Pump the foot pedal to raise the base To test the non adjustable foot pads turn the leveling jacks counterclockwise all the way Place 1 inch 3 8 cm spacer under each non adjustable foot pad Pull the base lowering handle to fully lower the base Result Within 1 to 4 seconds two interlock display lights should turn off and remain off B 12 Check the Chain Adjustment IWP 20S Models with Outreach Option Genie requires that this procedure be performed every 250 hours or quarterly whichever comes first Detection of a improperly adjusted platform outreach chain is essential for safe machine operation
218. tions require that this procedure be performed every 8 hours or daily whichever comes first 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 e Hydraulic power unit tank valves fittings e Flow control valve e Ground area under the machine e Hydraulic hoses and fittings e Hydraulic cylinder s IWPS models Hydraulic manifolds and foot pump IWPS models with Power Wheel Assist Option e Hydraulic motor and hoses A 6 Check the Hydraulic Oil Level Genie specifications require that this procedure be performed every 8 hours or daily whichever comes first Maintaining the hydraulic oil at the proper level is essential to machine operation Improper hydraulic oil levels can damage hydraulic components Daily checks allow the inspector to identify changes in oil level that might indicate the presence of hydraulic system problems 1 Be sure the platform is fully lowered 2 Remove the fasteners from the hydraulic power unit cover 3 Remove the power unit cover 4 Check the sight gauge on the side of the hydraulic tank Result The hydraulic oil level should be visible in the middle of the sight gauge 5 Add oil if needed Do not overfill 6 Replace the cover Hyd
219. y How to Remove the Mast Assembly AWPS Models AWARNING Bodily injury hazard This procedure requires specific repair skills lifting equipment and a suitable workshop Attempting this procedure without these skills and tools could result in death or serious injury and significant component damage Dealer service is strongly recommended 1 Bracket mounting fasteners 1 Fully lower the platform 2 Cinder mounting festenels 2 Turn the key switch off and remove the key 3 Hydraulic cylinder 4 Cylinder mounting plate 3 Remove the platform Refer to Repair Procedure How to Remove an Aluminum 11 Support the cylinder and carefully slide it out of Platform he baton 4 Remove the power pack Refer to Repair ACAUTION Crushing hazard The lift cylinder Procedure How to Change a Power Pack wil 51 itis properly 5 AWP 36S and 40S models Remove the lt tilt back frame Refer to Repair Procedure How to Remove the Tilt back Frame 6 Attach an overhead crane to the lifting eye at the top of the mast 7 Place a saw horse in front of the machine where the top of the mast will rest a ____________________ 76 AWP Super Series IWP Super Series Part No 38139 2015 Service Manual 8 Liftthe machine off the ground and then while 12 lowering it guide it over onto the saw horse Be sure the saw horse is of ample capacity ACAUTION Crushing hazard The machine will fall unless i
220. zardous situation which if not avoided may result in property damage Indicates that a specific result is expected after performing a series of steps W Indicates that an incorrect result has occurred after performing a series of steps Maintenance Symbols Legend Note The following symbols have been used in this manual to help communicate the intent of the instructions When one or more of the symbols appear at the beginning of a maintenance procedure it conveys the meaning below Indicates that tools will be required to perform this procedure Indicates that new parts will be required to perform this procedure Indicates that dealer service will be required to perform this procedure Indicates that a cold motor or pump will be required to perform this procedure Genie 12 AWP Super Series Super Series Part No 38139 2015 Service Manual ___ __ __ _ _ Scheduled Maintenance Procedures Pre delivery Preparation Report The pre delivery preparation report contains checklists for each type of scheduled inspection Make copies for each inspection Store completed forms as required Maintenance Schedule The Scheduled Maintenance Procedures section and the Maintenance Inspection Report have been divided into subsections Use the following chart to determine which group s of procedures are required to perform a scheduled inspection Inspection Che

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