AWP Super Series IWP Super Series: Serial Number Range

Serial Number Range
AWP® Super Series from 3869-101

to 3801-99999
from AWP02-21194
to AWP16G-87799
from AWPG-87800
to AWPP-99999
IWP® Super Series from 4096-101

to 4001-4413
from IWP02-4205
to IWP16G-11999
from IWPG-12000
to IWPP-12999
Part No. 38139GT

Rev C
June 2023
June 2023
Introduction
Intr oducti on Intr oducti on
Important Technical Publications

Read, understand and obey the safety rules and Genie has endeavored to deliver the highest
operating instructions in the appropriate Operator's degree of accuracy possible. However, continuous
Manual on your machine before attempting any improvement of our products is a Genie policy.
maintenance procedure. Therefore, product specifications are subject to
change without notice.
This manual provides detailed scheduled
maintenance information for the machine owner Readers are encouraged to notify Genie of errors
and user. It also provides troubleshooting and and send in suggestions for improvement. All
repair procedures for qualified service communications will be carefully considered for
professionals. future printings of this and all other manuals.
Basic mechanical, hydraulic and electrical skills

are required to perform most procedures. Contact Us:
However, several procedures require specialized
skills, tools, lifting equipment and a suitable Internet: www.genielift.com
workshop. In these instances, we strongly E-mail: [email protected]
recommend that maintenance and repair be
performed at an authorized Genie dealer service Find a Manual for this Model
center.
Go to http://www.genielift.com
Use the links to locate Service Manuals,
Compliance Maintenance Manuals, Service and Repair
Manuals, Parts Manuals and Operator's Manuals.
Machine Classification
Group A/Type 1 as defined by ISO 16368
Copyright © 1996 by Terex Corporation
Machine Design Life
38139GT Rev C, June 2023
Unrestricted with proper operation, inspection and
scheduled maintenance. First Edition, Third Printing
Genie, 'AWP' and 'IWP' are registered trademarks of Terex
South Dakota. in the U.S.A. and many other countries.
ii AWP® Super Series • IWP® Super Series Part No. 38139GT

June 2023
Introduction
Revision History
Revision Date Section Procedure / Page / Description
B8 5/2015 Maintenance Removed C-6
B9 8/2016 Repair 5-4
B10 9/2016 Introduction Serial Number Legend
B11 9/2016 Schematics Page 166
B12 9/2017 Maintenance B-9
C 6/2023 Front cover Add ending serial break
Specifications Lift capacities
Schematics Electrical schematics
Reference Examples:
Section – Maintenance, B-3
Section – Repair Procedure, 4-2 Electronic Version
Click on any content or procedure in the Table of Contents to view
Section – Fault Codes, All charts the update.
Section – Schematics, Legends and schematics
Part No. 38139GT AWP® Super Series • IWP® Super Series iii
June 2023
Introduction
Revision History (continued)

Revision Date Section Procedure / Page / Description
Reference Examples:
Section – Maintenance, B-3
Section – Repair Procedure, 4-2 Electronic Version
Click on any content or procedure in the Table of Contents to view
Section – Fault Codes, All charts the update.
Section – Schematics, Legends and schematics
iv AWP® Super Series • IWP® Super Series Part No. 38139GT

June 2023
Introduction
Serial Number Legend

To August 31, 2016
1 Model 4 Sequence number

2 Model year 5 Serial number (stamped on chassis)
3 Facility code 6 Serial label
From September 1, 2016
1 Model 4 Serial number (stamped on chassis)

2 Facility code 5 Serial label
3 Sequence number
Part No. 38139GT AWP® Super Series • IWP® Super Series v

June 2023
Safety Rules
Section 1 Safety R ules
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 modify or alter a MEWP without prior
written permission from the manufacturer.
Do Not Perform Maintenance

Unless:
 You are trained and qualified to perform
maintenance on this machine.
 You read, understand and obey:
• manufacturer's instructions and safety rules
• employer's safety rules and worksite
regulations
• applicable governmental regulations
 You have the appropriate tools, lifting
equipment and a suitable workshop.
vi AWP® Super Series • IWP® Super Series Part No. 38139GT

June 2023
Safety Rules
Personal Safety Workplace Safety

Any person working on or around a machine must Any person working on or around a machine must
be aware of all known safety hazards. Personal be aware of all known safety hazards. Personal
safety and the continued safe operation of the safety and the continued safe operation of the
machine should be your top priority. machine should be your top priority.
Read each procedure thoroughly. This Be sure to keep sparks, flames and
manual and the decals on the machine, lighted tobacco away from flammable and
use signal words to identify the following: combustible materials like battery gases
and engine fuels. Always have an
Safety alert symbol—used to approved fire extinguisher within easy
alert personnel to potential reach.
personal injury hazards. Obey all
safety messages that follow this Be sure that all tools and working areas
symbol to avoid possible injury or are properly maintained and ready for
death. use. Keep work surfaces clean and free
of debris that could get into machine
Indicates a imminently hazardous components and cause damage.
situation which, if not avoided,
will result in death or serious Be sure any forklift, overhead crane or
injury. other lifting or supporting device is fully
capable of supporting and stabilizing the
Indicates a potentially hazardous weight to be lifted. Use only chains or
situation which, if not avoided, straps that are in good condition and of
could result in death or serious ample capacity.
injury.
Be sure that fasteners intended for one
Indicates a potentially hazardous time use (i.e., cotter pins and self-locking
situation which, if not avoided, nuts) are not reused. These components
may cause minor or moderate may fail if they are used a second time.
injury.
Be sure to properly dispose of old oil or
Indicates a potentially hazardous other fluids. Use an approved container.
situation which, if not avoided, Please be environmentally safe.
may result in property damage.
Be sure that your workshop or work area
Be sure to wear protective eye wear and is properly ventilated and well lit.
other protective clothing if the situation
warrants it.
Be aware of potential crushing hazards

such as moving parts, free swinging or
unsecured components when lifting or
placing loads. Always wear approved
steel-toed shoes.
Part No. 38139GT AWP® Super Series • IWP® Super Series vii
June 2023
Table of Contents
Introduction Introduction ........................................................................................................... ii

Important Information ............................................................................................. ii
Find a Manual for this Model .................................................................................. ii
Revision History ..................................................................................................... iii
Serial Number Legend ............................................................................................ v
Section 1 Safety Rules .........................................................................................................vi

General Safety Rules ............................................................................................ vi
Section 2 Specifications ....................................................................................................... 1

AWP-15S, 20S and 25S Specifications .................................................................. 1
AWP30S, 36S and 40S Specifications ................................................................... 2
AWP Narrow Base Specifications .......................................................................... 3
AWP Rough Terrain Base Specifications ............................................................... 4
IWP Specifications .................................................................................................. 5
AWP/IWP Performance and Hydraulic Specifications............................................6
Hydraulic Hose and Fitting Torque Specifications..................................................7
Torque Procedure ................................................................................................... 8
SAE and Metric Fasteners Torque Charts ...........................................................10
viii AWP® Super Series • IWP® Super Series Part No. 38139GT
June 2023
Table of Contents
Section 3 Scheduled Maintenance Procedures ............................................................... 11

Introduction ........................................................................................................... 11
Pre-Delivery Preparation Report .......................................................................... 15
Maintenance Inspection Report............................................................................ 17
Checklist A Procedures ..................................................................................... 19

A-1 Inspect the Manuals and Decals.................................................................... 19
A-2 Perform Pre-operation Inspection .................................................................. 20
A-3 Perform Function Tests ................................................................................. 20
A-4 Inspect for Damage and Loose or Missing Parts........................................... 21
A-5 Check for Hydraulic Leaks ............................................................................. 22
A-6 Check the Hydraulic Oil Level........................................................................ 22
A-7 Test the Base Operation - IWPS Models ....................................................... 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 ................................................................ 24
A-11 Check the Sequencing Cables .................................................................... 25
A-12 Check the Interlock System for Proper Operation ....................................... 25
A-13 Test the Power and Function Controls ........................................................ 27
A-14 Inspect the Lifting Chains and Idler Wheels ................................................ 28
A-15 Inspect the Breather Cap ............................................................................. 28
A-16 Check the Tire Pressure - AWPS Models with Rough Terrain Base Option
29
A-17 Check the Air Supply Lubricator Oil Level - Air Models ............................... 29
A-18 Check the Air Supply Lubricator Drip Rate - Air Models ............................. 30
A-19 Check the Air Filter/Regulator Canister - Air Models ................................... 30
Part No. 38139GT AWP® Super Series • IWP® Super Series ix

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Table of Contents
Checklist B Procedures .....................................................................................31

B-1 Inspect the Battery .........................................................................................31
B-2 Inspect the Electrical Wiring...........................................................................32
B-3 Inspect All Welds ...........................................................................................32
B-4 Test the Tilt-back Operation (if equipped) .....................................................33
B-5 Check the Lifting Chain Adjustment ...............................................................34
B-6 Clean and Lubricate the Columns .................................................................35
B-7 Test the Lifting Capacity ................................................................................36
B-8 Adjust the Sequencing Cables .......................................................................36
B-9 Inspect for Proper Outrigger Length - AWPS Models ....................................38
B-10 Inspect and Lubricate the Outrigger Leveling Jack Footpads -
AWPS Models .............................................................................................39
B-11 Test the Level Sensing Operation - IWPS Models ......................................39
B-12 Check the Chain Adjustment, IWP-20S Models with Outreach Option .......40
Checklist C Procedures .....................................................................................41

C-1 Inspect and Lubricate the Casters and Wheels .............................................41
C-2 Inspect the Mast Assembly for Wear .............................................................41
C-3 Inspect and Lubricate the Lifting Chains .......................................................43
C-4 Replace the Hydraulic Oil ..............................................................................43
C-5 Replace the Auxiliary Platform Lowering Batteries .......................................45
x AWP® Super Series • IWP® Super Series Part No. 38139GT

June 2023
Table of Contents
Section 4 Repair Procedures ............................................................................................. 47

Introduction ........................................................................................................... 47
Base Assembly ................................................................................................... 49

1-1 Interlocks ........................................................................................................ 49
1-2 Base Components IWPS Models ................................................................... 50
1-3 Foot Pump Manifold Components -
IWPS Models (to SN IWP09-8269) .............................................................. 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) ................................................................... 56
IWPS Models (from SN 4097-997 to 4099-2532)......................................... 57
IWPS Models (from SN 4099-2533) ............................................................. 58
Ground Controls ................................................................................................. 59

2-1 How to Test the Transformer - AC Models .................................................... 59
2-2 How to Test the AC Contactor - AC Models .................................................. 60
Hydraulic Power Unit ......................................................................................... 61

3-1 Hydraulic Power Unit - AC Models
(to SN AWP03-27389 and IWP03-5150) ...................................................... 61
(from SN AWP03-27390 to AWP08-60145, IWP03-5151 to IWP08-7708) .. 63
(from SN AWP08-60146, IWP08-7709) ....................................................... 65
3-4 Hydraulic Power Unit - DC Models
(to SN AWP08-60547 and IWP08-7754) ...................................................... 67
3-5 Hydraulic Power Unit - DC Models
(from SN AWP08-60548 and IWP08-7755) ................................................. 69
3-6 Hydraulic Power Unit Components - Air Powered Models
(to SN AWP04-27779) .................................................................................. 71
3-7 Hydraulic Power Unit Components - Air Powered Models
(from SN AWP04-27780) .............................................................................. 73
3-8 Hydraulic Power Unit ...................................................................................... 75
3-9 Hydraulic Pump .............................................................................................. 77
3-10 Valve Adjustment ......................................................................................... 77
3-11 How to Test the Motor Start Solenoid - DC Models ..................................... 78
Part No. 38139GT AWP® Super Series • IWP® Super Series xi

June 2023
Table of Contents
Power Pack..........................................................................................................79
4-1 Power Pack ....................................................................................................79
Mast Components ..............................................................................................80

Mast Components ................................................................................................80
5-1 Lift Cylinder ....................................................................................................81
5-2 Mast Assembly ...............................................................................................82
5-3 Glide Pads ......................................................................................................87
5-4 Lifting Chains ..................................................................................................87
Tilt-back Frame, AWP-36S and 40S Models.....................................................90

6-1 Tilt-back Frame ..............................................................................................90
Platform ...............................................................................................................92
7-1 Platforms ........................................................................................................92
7-2 Platform Control Box ......................................................................................93
7-3 Platform Outreach Chain ................................................................................94
xii AWP® Super Series • IWP® Super Series Part No. 38139GT
June 2023
Table of Contents
Section 5 Schematics.......................................................................................................... 96
Introduction ........................................................................................................... 96
Electrical Component and Wire Color Legends ................................................... 97
Electrical Symbol Legend ..................................................................................... 99
Hydraulic Symbols Legend ................................................................................. 100
Electrical Schematics - AWP Models ............................................................. 101

Electrical Schematic - AWP Super Series DC Models
(from SN 3896-101 to 3896-300)................................................................ 102
(from SN 3896-301 to 3896-430)................................................................ 103
(from SN 3896-431 to AWP07-54898) ....................................................... 106
Electrical Schematic - AWP Super Series DC Models with Standard Base
(from SN AWP07-54899) ............................................................................ 107
Electrical Schematic - AWP Super Series DC Models with Narrow Base
(from SN AWP07-54899) ............................................................................ 110
Electrical Schematic - AWP Super Series DC CE Models
(from SN 3896-432 to AWP07-54898) ....................................................... 111
Electrical Schematic - AWP Super Series DC CE Models with Standard Base
(from SN AWP07-54899) ............................................................................ 114
Electrical Schematic - AWP Super Series DC CE Models with Narrow Base
(from SN AWP07-54899) ............................................................................ 115
Electrical Schematic - AWP Super Series DC TUV Models
(from SN 3896-431) .................................................................................... 118
Electrical Schematic - AWP Super Series AC Models
(from SN 3896-103 to 3896-303)................................................................ 119
(from SN 3896-304 to 3896-450)................................................................ 122
(from SN 3896-451 to AWP07-54898) ....................................................... 123
Part No. 38139GT AWP® Super Series • IWP® Super Series xiii
June 2023
Table of Contents
Electrical Schematic - AWP Super Series AC Models with Standard Base

(from SN AWP07-54899 to AWP07-57594) ...............................................126
Electrical Schematic - AWP Super Series AC Models with Narrow Base
(from SN AWP07-54899 to AWP-57594) ...................................................127
(from SN AWP07-57595) ............................................................................130
(from SN AWP07-57595) ............................................................................131
Electrical Schematic - AWP Super Series AC CE Models
(from SN 3896-451 to AWP07-54898) .......................................................134
Electrical Schematic - AWP Super Series AC CE Models with Standard Base
(from SN AWP07-54899 to AWP07-57594) ...............................................135
Electrical Schematic - AWP Super Series AC CE Models with Narrow Base
(from SN AWP07-54899 to AWP07-57594) ...............................................138
(from SN AWP-57595) ................................................................................139
(from SN AWP07-57595) ............................................................................142
Electrical Schematic - AWP Super Series AC TUV Models
(from SN 3896-461) ....................................................................................143
xiv AWP® Super Series • IWP® Super Series Part No. 38139GT
June 2023
Table of Contents
Electrical Schematics - IWP Models ............................................................... 145

Electrical Schematic - IWP Super Series DC Models
(from SN 4096-101 to 4096-287)................................................................ 146
(from SN 4096-288 to 4096-341)................................................................ 147
(from SN 4096-342 to IWP07-7065) ........................................................... 150
(from SN IWP07-7066 to IWP15-9621) ...................................................... 151
(from SN IWP15-9622 to IWPP-12398) ..................................................... 154
(from SN IWPP-12399) ............................................................................... 155
Electrical Schematic - IWP Super Series DC Models with Power Assist ........... 158
Electrical Schematic - IWP Super Series DC Models with Power Assist
(Directional Valve Coils Powering Function Manifold)................................ 159
Electrical Schematic - IWP Super Series DC TUV Models ................................ 162
Electrical Schematic - IWP Super Series DC TUV Models with Outreach......... 163
Electrical Schematic - IWP Super Series DC TUV Models with Power Assist .. 166
Electrical Schematic - IWP Super Series DC TUV Models with
Power Assist and Outreach ........................................................................ 167
Electrical Schematic - IWP Super Series DC TUV Models with Power Assist
(Directional Valve Coils Powering Function Manifold)................................ 170
Electrical Schematic - IWP Super Series AC Models
(from SN 4096-105 to 4096-285)................................................................ 171
(from SN 4096-286 to 4096-355)................................................................ 174
(from SN 4096-356 to IWP07-7065) ........................................................... 175
(from SN IWP07-7066 to IWP07-57594) .................................................... 178
(from SN IWP07-57595) ............................................................................. 179
Electrical Schematic - IWP Super Series AC TUV Models
(With Base Mounted Junction Box) ............................................................ 182
(Without Base Mounted Junction Box) ....................................................... 183
Electrical Schematic - IWP Super Series AC TUV Models with Outreach ......... 186
Part No. 38139GT AWP® Super Series • IWP® Super Series xv

June 2023
Table of Contents
Hydraulic Schematics ......................................................................................187

Hydraulic Schematic - AWP Super Series Models .............................................187
Hydraulic/Pneumatic Schematic - AWP Super Series Models ...........................190
Hydraulic Schematic - IWP Super Series Models without Power Assist ............191
Hydraulic Schematic - IWP Super Series Models with Power Assist .................194
Hydraulic Schematic - IWP Super Series Models with
Power Assist and Brake..............................................................................195
xvi AWP® Super Series • IWP® Super Series Part No. 38139GT
June 2023
Specifications
Section 2 Specific ati ons
Model AWP-15S AWP-20S AWP-25S

Standard Base
Height, working maximum 21 ft 4 in 26 ft 1 in 30 ft 9 in
6.5 m 8.0 m 9.4 m
Height, platform maximum 15 ft 4 in 20 ft 1 in 24 ft 9 in
4.7 m 6.1 m 7.6 m
Lift capacity 350 lbs 350 lbs 350 lbs
all models except Canada 159 kg 159 kg 159 kg
models sold in Canada only 136 kg 136 kg 136 kg
to serial No. AWP05-49999
from serial No. AWP05-50000
Machine weight 718 / 628 lbs 764 / 674 lbs 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 cm 117 cm 117 cm
Outrigger footprint 60 ¾ x 52 ¾ in 60 ¾ x 52 ¾ in 60 ¾ x 52 ¾ in
(l x w) Domestic 154 x 134 cm 154 x 134 cm 154 x 134 cm
Outrigger footprint 60 ¾ x 52 ¾ in 69 ¼ x 61 ¼ in 83 ½ x 75 ½ in
(l x w) CSA 154 x 134 cm 175.6 x 155.3 cm 212 x 191 cm
Outrigger footprint 60 ¾ x 52 ¾ in 60 ¾ x 52 ¾ in 69 ¼ x 61 ¼ in
(l x w) CE Indoor 154 x 134 cm 154 x 134 cm 175.6 x 155.3 cm
Outrigger footprint* 69 ¼ x 61 ¼ in 83 ¼ x 75 ¼ in 89 x 81 in
(l 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* 15 ¾ / 8 in 14 ½ / 5 ½ in 14 / 3 in
Domestic 39.7 / 20.3 cm 36.9 / 7.4 cm 35.1 / 7.4 cm
Corner access/wall access* 15 ¾ / 8 in 20 ¼ / 9 ¾ in 28 ¾ / 14 ¼ in
CSA 39.7 / 20.3 cm 51.2 / 24.5 cm 73 / 36.2 cm
Corner access/wall access* 15 ¾ / 8 in 14 ¼ / 5 ½ in 19 ¼ / 7 ¼ in
CE Indoor 39.7 / 20.3 cm 36.9 / 7.4 cm 48.6 / 18.2 cm
Corner access/wall access* 21 ½ / 12 ¼ in 30 / 16 ¾ in 32 ½ / 17 in
CE Outdoor 54.6 / 30.8 cm 76 / 42.4 cm 82.5 / 43.4 cm
*Corner of platform top rail to corner of wall with ability to rotate the leveling jack.
Platform Dimensions - all models
Standard platform 27 x 26 x 44 ¾ in Gated narrow platform 26 x 20 x 44 ¾ in

(L x W x H) gated or sliding mid-rail 69 x 66 x 114 cm (L x W x H) 66 x 51 x 114 cm
Gated ultra-narrow platform 22 x 18 x 44 ¾ in Standard fiber platform 29 x 26 ½ x 43 ½ in
(L x W x H) 56 x 46 x 114 cm (L x W x H) 74 x 67 x 110 cm
Part No. 38139GT AWP® Super Series • IWP® Super Series 1

June 2023
Specifications
Model AWP-30S AWP-36S AWP-40S

Standard Base
10.8 m 12.9 m 14.1 m
9.0 m 6.1 m 12.3 m
to serial No. AWP05-49999
from serial No. AWP05-50000
(DC / AC and Air models) 377 / 336 kg 502 / 461 kg 513 / 472 kg
Height, stowed 78 in 109 ½ in 109 ½ in
198 cm 278 cm 278 cm
Width 29 in 29 in 29 in
73.6 cm 73.6 cm 73.6 cm
Length 46 in 55 in 55 in
117 cm 140 cm 140 cm
Outrigger footprint 69 ¼ x 61 ¼ in 83 ¼ x 75 ¼ in 89 x 81 in
(l x w) Domestic 175.6 x 155.3 cm 211.5 x 191.2 cm 225.9 x 205.6 cm
Outrigger footprint 97 ½ x 89 ½ in 117 ¼ x 109 ¼ in 117 ¼ x 109 ¼ in
(l x w) CSA 247.5 x 227.2 cm 297.8 x 278 cm 297.8 x 278 cm
Outrigger footprint 75 ½ x 67 ½ in 83 ¼ x 75 ¼ in 89 x 81 in
(l x w) CE Indoor 192 x 171.4 cm 211.5 x 191.2 cm 225.9 x 205.6 cm
Outrigger footprint* 117 ¼ x 109 ½ in 117 ¼ x 109 ¼ in 117 ¼ x 109 ¼ in
(l x w) CE Outdoor 297.8 x 278 cm 297.8 x 278 cm 297.8 x 278 cm
Corner access/wall access* 18 ½ / 4 ¾ in 28 ½ / 14 ½ in 31 ¼ / 14 ½ in
Domestic 46.6 / 11.9 cm 72.7 / 36.2 cm 79.4 / 37.1 cm
Corner access/wall access* 37 / 18 ¾ in 52 / 31 ¼ in 50 ¾ / 28 ¾ in
CSA 94.1 / 47.8 cm 132.5 / 79.3 cm 128.8 / 73 cm
Corner access/wall access* 22 ¼ / 8 in 28 ½ / 14 ½ in 31 ¼ / 14 ½ in
CE Indoor 56.6 / 20.3 cm 72.7 / 36.2 cm 79.4 / 37.1 cm
Corner access/wall access* 50 ¾ / 28 ¾ in 52 / 31 ¼ in 50 ¾ / 28 ¾ in
CE Outdoor 128.8 / 73 cm 132.5 / 79.3 cm 128.8 / 73 cm
Platform Dimensions - all models
Narrow fiber platform 26 x 22 x 43 ½ in Extra large platform 30 x 28 x 44 ¾ in

Front and side entry platform 30 x 28 x 44 ¾ in
(L x W x H) 76 x 71 x 114 cm
2 AWP® Super Series • IWP® Super Series Part No. 38139GT

June 2023
Specifications
Model AWP-15S AWP-20S AWP-25S AWP-30S

Narrow Base
Machine weight 711 / 621 lbs 745 / 655 lbs 780 / 690 lbs 814 / 724 lbs
(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 ½ in 49 ½ in 49 ½ in 49 ½ in
125.7 cm 125.7 cm 125.7 cm 125.7 cm
Outrigger footprint 64 x 48 ¼ in 64 x 48 ¼ in 64 x 48 ¼ in 71 ½ x 58 in
(l 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 ½ x 58 in 74 ½ x 65 ½ in 83 ¼ x 74 in 95 ¼ x 89 ¾ in
(l x 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 ¼ in 71 ¼ x 58 in 71 ¼ x 58 in 74 ½ x 65 ½ in
(l 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 ¼ x 74 in 83 ¼ x 74 in 95 ¼ x 89 ¾ in 112 x 112 in
(l x w) CE Outdoor 211.4 x 187.9 cm 211.4 x 187.9 cm 241.9 x 227.9 cm 284.4 x 284.4 cm
Corner access/wall access* 16 / 11 in 14 ¼ / 8 ½ in 13 / 6 in 18 ½ / 7 ¼ in
Domestic 40.6 / 27.9 cm 36.2 / 7.4 cm 33 / 15.2 cm 47 / 18.4 cm
Corner access/wall access* 22 ½ / 14 ¾ in 24 ½ / 14 in 28 ¾ / 15 in 37 ½ / 18 ½ in
CSA 57.1 / 37.5 cm 62.2 / 35.5 cm 73 / 38.1 cm 95.2 / 47 cm
Corner access/wall access* 16 / 11 in 21 / 12 ¼ in 19 ½ / 9 ¾ in 22 / 9 in
CE Indoor 40.6 / 27.9 cm 53.3 / 31.1 cm 49.5 / 24.7 cm 55.8 / 22.8 cm
Corner access/wall access* 31 ½ / 20 ¼ in 30 / 17 ½ in 38 ¾ / 21 in 51 / 26 ½ in
CE Outdoor 80 / 50.8 cm 76.2 / 44.4 cm 98.4 / 53.3 cm 129.5 / 67.3 cm
Platform Dimensions
Gated ultra-narrow platform 22 x 18 x 44 ¾ in Narrow fiber platform 26 x 22 x 43 ½ in

Gated narrow platform 26 x 20 x 44 ¾ in
(L x W x H) 66 x 51 x 14 cm

June 2023
Specifications
Model AWP-15S AWP-20S AWP-25S AWP-30S

Rough Terrain Base
Machine weight 715 / 625 lbs 750 / 660 lbs 784 / 694 lbs 819 / 729 lbs
(DC / 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 ½ in 29 ½ in 29 ½ in 29 ½ in
75 cm 75 cm 75 cm 75 cm
Length 58 in 58 in 58 in 58 in
147 cm 147 cm 147 cm 147 cm
Outrigger footprint 64 x 48 ¼ in 64 x 48 ¼ in 64 x 48 ¼ in 71 ½ x 58 in
(l 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 ½ x 58 in 74 ½ x 65 ½ in 83 ¼ x 74 in 95 ¼ x 89 ¾ in
(l x 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 ¼ in 71 ¼ x 58 in 71 ¼ x 58 in 74 ½ x 65 ½ in
(l 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 ¼ x 74 in 83 ¼ x 74 in 95 ¼ x 89 ¾ in 112 x 112 in
(l x w) CE Outdoor 211.4 x 187.9 cm 211.4 x 187.9 cm 241.9 x 227.9 cm 284.4 x 284.4 cm
Corner access/wall access* 16 / 11 in 14 ¼ / 8 ½ in 13 / 6 in 18 ½ / 7 ¼ in
Domestic 40.6 / 27.9 cm 36.2 / 7.4 cm 33 / 15.2 cm 47 / 18.4 cm
Corner access/wall access* 22 ½ / 14 ¾ in 24 ½ / 14 in 28 ¾ / 15 in 37 ½ / 18 ½ in
CSA 57.1 / 37.5 cm 62.2 / 35.5 cm 73 / 38.1 cm 95.2 / 47 cm
Corner access/wall access* 16 / 11 in 21 / 12 ¼ in 19 ½ / 9 ¾ in 22 / 9 in
CE Indoor 40.6 / 27.9 cm 53.3 / 31.1 cm 49.5 / 24.7 cm 55.8 / 22.8 cm
Corner access/wall access* 31 ½ / 20 ¼ in 30 / 17 ½ in 38 ¾ / 21 in 51 / 26 ½ in
CE Outdoor 80 / 50.8 cm 76.2 / 44.4 cm 98.4 / 53.3 cm 129.5 / 67.3 cm
Platform Dimensions
Standard platform 27 x 26 x 44 ¾ in Narrow fiber platform 26 x 22 x 43 ½ in

(L x W x H) gated or sliding mid-rail 69 x 66 x 114 cm (L x W x H) 66 x 56 x 110 cm
Gated ultra-narrow platform 22 x 18 x 44 ¾ in Front and side entry platform 30 x 28 x 44 ¾ in
Gated narrow platform 26 x 20 x 44 ¾ in Extra large platform 30 x 28 x 44 ¾ in
Standard fiber platform 29 x 26 ½ x 43 ½ in
(L x W x H) 74 x 67 x 110 cm

June 2023
Specifications
Model IWP-20S IWP-25S IWP-30S

8.1 m 9.3 m 10.8 m
6.2 m 7.4 m 9.0 m
Lift capacity 300 lbs 300 lbs --
models sold in Canada only 136 kg 136 kg --
to serial No. IWP09-8293
from serial No. IWP09-8294
Lift capacity 300 lbs -- --
with outreach option 136 kg -- --
(DC / AC models) 565 / 610 kg 585 / 630 kg 585 / 630 kg
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 ¾ in 44 ¾ in 44 ¾ in
114 cm 114 cm 114 cm
Corner access 6 in 6 in 6 in
15 cm 15 cm 15 cm

June 2023
Specifications
Platform function speed, maximum Hydraulic System

AWP-15S, 20S, 25S AC DC Hydraulic fluid Chevron Rando HD
and 30S equivalant
Platform up 40 seconds 30 seconds Hydraulic tank capacity - 3 quarts
Platform down 28 seconds 28 seconds all models 2.8 liters
AWP-36S AC DC Hydraulic System Pressure
Platform up 40 seconds 52 seconds All models 1600 psi
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
IWP - All models AC DC
AWP-15S 3.7 quarts 3.5 liters
Platform up 40 seconds 30 seconds
Power Source AWP Models
DC models 12V
AC model 110V or 220V
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

June 2023
Specifications
Hydraulic Hose and Fitting SAE O-ring Boss Port

Torque Specifications (tube fitting - installed into Aluminum)
(all types)
Your machine is equipped with Parker Seal-Lok™
SAE Dash Size Torque
ORFS or 37° JIC fittings and hose ends. Genie
specifications require that fittings and hose ends -4 14 ft-lbs / 19 Nm
be torqued to specification when they are removed -6 23 ft-lbs / 31.2 Nm
and installed or when new hoses or fittings are -8 36 ft-lbs / 49 Nm
installed.
-10 62 ft-lbs / 84 Nm
-12 84 ft-lbs / 114 Nm
Seal-Lok™ Fittings -16 125 ft-lbs / 169.5 Nm
(hose end - ORFS)
-20 151 ft-lbs / 204.7 Nm
-24 184 ft-lbs / 249.5 Nm
-4 18 ft-lbs / 25 Nm
-6 30 ft-lbs / 41 Nm
-8 40 ft-lbs / 55 Nm
-10 60 ft-lbs / 81 Nm
-12 85 ft-lbs / 115 Nm
-16 110 ft-lbs / 150 Nm
-20 150 ft-lbs / 205 Nm
Adjustable Fitting Non-adjustable fitting
-24 230 ft-lbs / 315 Nm
1 jam nut
JIC 37° Fittings

(swivel nut or hose connection)
SAE O-ring Boss Port
SAE Dash Size Thread Size Flats
(tube fitting - installed into Steel)
-4 7/16-20 2
-6 9/16-18 1 1/2 15 ft-lbs / 20.3 Nm
-4 ORFS / 37° (Adj)
-8 3/4-16 1 1/2 ORFS (Non-adj) 26 ft-lbs / 35.3 Nm
37° (Non-adj) 22 ft-lbs / 30 Nm
-10 7/8-14 1 1/2
-6 ORFS (Adj / Non-adj) 35 ft-lbs / 47.5 Nm
-12 1 1/16-12 1 1/4
37° (Adj / Non-adj) 29 ft-lbs / 39.3 Nm
-16 1 5/16-12 1
-8 ORFS (Adj / Non-adj) 60 ft-lbs / 81.3 Nm
-20 1 5/8-12 1 37° (Adj / Non-adj) 52 ft-lbs / 70.5 Nm
-24 1 7/8-12 1 -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

June 2023
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
1 Replace the O-ring. The O-ring must be
hand tight, approximately 30 in-lbs / 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 a
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
hex fitting. Refer to Illustration 1.
Note: The O-ring in Parker Seal Lok™ fittings and
hose end are custom-size O-rings. They are not
standard size O-rings. They are available in the O-
ring field service kit (Genie part number 49612).
2 Lubricate the O-ring before installation.
3 Be sure the O-ring face seal is seated and
retained properly.
4 Position the tube and nut squarely on the face
seal end of the fitting, and tighten the nut
finger tight. Illustration 1
5 Tighten the nut or fitting to the appropriate 1 hex nut

torque. Refer to the appropriate torque chart 2 reference mark
in 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.

June 2023
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.

June 2023
Specifications

June 2023
Scheduled Maintenance Procedures
Machine Configuration:
Section 3 Schedul ed Mai ntenance Pr ocedures
 Unless otherwise specified, perform each

procedure with the machine in the following
configuration:
• Machine parked on a firm, level surface
Observe and Obey:
• Key switch in the off position with the key
 Maintenance inspections shall be completed removed
by a person trained and qualified on the
maintenance of this machine. • The red Emergency Stop button in the off
position at both the ground and platform
 Scheduled maintenance inspections shall be controls
completed daily, quarterly, and annually as
specified on the Maintenance inspection • Wheels chocked
Report. The frequency and extent of periodic • All external AC power supply disconnected
examinations and tests may also depend on from the machine
national regulations.
• Platform in the stowed position
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 that have been out of service for a
period longer than 3 months must complete
the quarterly inspection.

June 2023
About This Section Maintenance Symbols Legend

This section contains detailed procedures for each Note: The following symbols have been used in
scheduled maintenance inspection. this manual to help communicate the intent of the
instructions. When one or more of the symbols
Each procedure includes a description, safety appear at the beginning of a maintenance
warnings and step-by-step instructions. procedure, it conveys the meaning below.
Symbols Legend Indicates that tools will be required to

perform this procedure.
Safety alert symbol—used to alert
personnel to potential personal
injury hazards. Obey all safety Indicates that new parts will be required to
messages that follow this symbol perform this procedure.
to avoid possible injury or death.
Indicates a imminently hazardous Indicates that dealer service will be

situation which, if not avoided, will required to perform this procedure.
result in death or serious injury.
Indicates a potentially hazardous Indicates that a cold motor or pump will be

situation which, if not avoided, required to perform this procedure.
could result in death or serious
injury.
Indicates a potentially hazardous

may cause minor or moderate
injury.

Indicates that a specific result is expected

after performing a series of steps.
Indicates that an incorrect result has occurred

June 2023
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 Checklist
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.

June 2023
This page intentionally left blank.

June 2023
Pre-Delivery Preparation Report
Fundamentals Instructions
It is the responsibility of the owner or dealer to Use the operator’s manual on your machine.
perform the Pre-delivery Preparation.
The Pre-delivery Preparation consists of
The Pre-delivery Preparation is performed prior to completing the Pre-operation Inspection, the
each delivery. The inspection is designed to Maintenance items and the Function Tests.
discover if anything is apparently wrong with a
machine before it is put into service. Use this form to record the results. Place a check
in the appropriate box after each part is
A damaged or modified machine must never be completed. Follow the instructions in the operator’s
used. If damage or any variation from factory manual.
delivered condition is discovered, the machine
must be tagged and removed from service. If any inspection receives an N, remove the
machine from service, repair and re-inspect it.
Repairs to the machine may only be made by a After repair, place a check in the R box.
qualified service technician, according to the
manufacturer's specifications. Legend
Y = yes, acceptable
Scheduled maintenance inspections shall be N = no, remove from service
performed by qualified service technicians, R = repaired
according to the manufacturer's specifications and Comments
the requirements listed in the responsibilities
manual.
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
June 2023

June 2023
Maintenance Inspection Report

Model Checklist A Y N R Checklist B Y N R
Serial number A-1 Inspect the manuals B-1 Batteries
Date and decals
B-2 Electrical wiring
Hour meter A-2 Pre-operation
inspection B-3 Welds
Machine owner
A-3 Function tests B-4 Tilt-back operation
Inspected by (print)
A-4 Damage, loose or B-5 Lifting chain
Inspector signature
missing parts adjustment
Inspector title
A-5 Hydraulic Leaks B-6 Clean and lubricate
Inspector company columns
A-6 Check Hydraulic Oil
Level B-7 Lifting capacity
Instructions A-7 Test base operation B-8 Sequencing cables
• Make copies of this report to use for - IWP only
B-9 Proper outrigger
each inspection. A-8 Auxiliary lowering length
• Select the appropriate checklist(s) for
the type of inspection(s) to perform. A-9 Manual lowering B-10 Outrigger footpads
Daily or every 8 hours A A-10 Columns B-11 Level sensing - IWP

models
Quarterly or every A+B A-11 Sequencing cables
250 hours B-12 Chain adjustment -
A-12 Interlock system IWP-20S with
Annually or every A+B+C
outreach
1000 hours A-13 Power and function
controls Checklist C Y N R
• Place a check in the appropriate box
after each inspection procedure is A-14 Lifting chains and C-1 Caster and wheels
completed. idler wheels
C-2 Mast assembly
• Use the step-by-step procedures in A-15 Breather cap
this section to learn how to perform C-3 Lifting chains
these inspections.
• If any inspection receives an "N," tag C-4 Hydraulic oil
and remove the machine from service, C-5 Auxiliary platform
repair and re-inspect it. After repair, lowering batteries
place a check in the "R" box.
Comments
Legend
Y = yes, acceptable
N = no, remove from service
R = repaired

June 2023

June 2023
Checklist A Procedures
A-1 3 Open the operator's manual to the decals

inspection section. Carefully and thoroughly
Inspect the Manuals and Decals inspect all decals on the machine for legibility
Genie specifications require that this procedure be and damage.
performed every 8 hours or daily, whichever Result: The machine is equipped with all
comes first. required decals, and all decals are legible and
Maintaining the operator’s and safety manuals in in good condition.
good condition is essential to safe machine Result: The machine is not equipped with all
operation. Manuals are included with each required decals, or one or more decals are
machine and should be stored in the container illegible or in poor condition. Remove the
provided in the platform. An illegible or missing machine from service until the decals are
manual will not provide safety and operational replaced.
information necessary for a safe operating
condition. 4 Always return the manuals to the storage
container after use.
In addition, maintaining all of the safety and
Note: Contact your authorized Genie distributor or
instructional decals in good condition is mandatory
Genie if replacement manuals or decals are
for safe machine operation. Decals alert operators
and personnel to the many possible hazards needed.
associated with using this machine. They also
provide users with operation and maintenance
information. An illegible decal will fail to alert
personnel of a procedure 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.

June 2023
A-2 A-3
Perform Pre-operation Inspection Perform Function Tests
Genie specifications require that this procedure be Genie specifications require that this procedure be
performed every 8 hours or daily, whichever performed every 8 hours or daily, whichever
comes first. comes first.
Completing a Pre-operation Inspection is essential Completing the function tests is essential to safe
to safe machine operation. The Pre-operation machine operation. Function tests are designed to
Inspection is a visual inspection performed by the discover any malfunctions before the machine is
operator prior to each work shift. The inspection is put into service. A malfunctioning machine must
designed to discover if anything is apparently never be used. If malfunctions are discovered, the
wrong with a machine before the operator machine must be tagged and removed from
performs the function tests. The Pre-operation service.
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.
Complete information to perform this procedure is Refer to the Operator's Manual on your machine.
available in the appropriate operator's manual.
Refer to the Operator's Manual on your machine.

June 2023
A-4 IWPS models with Power Wheel Assist Option:
Inspect for Damage and Loose or • Steer handle

Missing Parts • Hydraulic motor and hoses
IWP-20S models with Outreach Option:
• Locking bracket
Genie specifications require that this procedure be
performed every 8 hours or daily, whichever • Handle and handle lock
comes 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 Inspect the entire machine for damage and
improperly installed or missing parts including:
• Electrical components, wiring and electrical
cables
• Electrical cable anchors and pulleys
• Hydraulic power unit, hoses, fittings,
cylinder(s) and manifolds
• Sequencing cables, anchors and pulleys
• Lifting chains and idler wheels
• Adjustable glide pads
• Mast columns and counterweight(s)
• Mast covers
• Nuts, bolts and other fasteners
• Platform entry mid-rail or gate
• Breather cap
• Dents or damage to machine
• Corrosion or oxidation
• Cracks in welds or structural components
• IWPS models: Hydraulic manifolds and foot
pump
• IWPS models: Foot pads
• AWPS models: Outriggers, leveling jacks
and foot pads

June 2023
A-5 A-6
Check for Hydraulic Leaks Check the Hydraulic Oil Level
Detecting hydraulic fluid leaks is essential to Maintaining the hydraulic oil at the proper level is
operational safety and good machine essential to machine operation. Improper hydraulic
performance. Undiscovered leaks can develop into oil levels can damage hydraulic components. Daily
hazardous conditions, impair machine functions checks allow the inspector to identify changes in
and damage machine components. oil level that might indicate the presence of
hydraulic system problems.
1 Inspect for hydraulic oil puddles, dripping or
residue on or around the following areas: 1 Be sure the platform is fully lowered.
• Hydraulic power unit—tank, valves, fittings 2 Remove the fasteners from the hydraulic
power unit cover.
• Flow control valve
3 Remove the power unit cover.
• Ground area under the machine
4 Check the sight gauge on the side of the
• Hydraulic hoses and fittings hydraulic tank.
• Hydraulic cylinder(s) Result: The hydraulic oil level should be
IWPS models: Hydraulic manifolds and foot pump visible in the middle of the sight gauge.
IWPS models with Power Wheel Assist Option: 5 Add oil if needed. Do not overfill.
6 Replace the cover.
• Hydraulic motor and hoses
Hydraulic System
Hydraulic fluid Chevron Rando HD
equivalent
Hydraulic tank capacity - 3 quarts
all models 2.8 liters

June 2023
A-7 A-8
Test the Base Operation - IWPS Test the Auxiliary Platform
Models Lowering Operation
Testing the base for proper operation is essential The auxiliary platform lowering is powered by a
for safe machine operation. An unsafe working secondary battery pack that is located in the
condition exists if the base fails to operate ground control box. The auxiliary platform lowering
properly. The base should operate smoothly and can be activated from the ground or platform
be free of hesitation, jerking and binding. controls. Detection of an auxiliary lowering
malfunction is essential for safe machine
1 Pump the foot pedal 7 to 9 complete strokes. operation. An unsafe working condition exists if the
Result: The non-adjustable foot pads should auxiliary platform lowering function does not
raise 1 ½ to 2 inches / 4 to 5 cm off the operate in the event of a main power failure.
ground.
1 Raise the platform slightly.
2 Pull the base lowering handle.
2 Disconnect the power source from the
Result: The base should lower, putting all four machine.
foot pads in firm contact with the ground.
3 Push in the auxiliary platform lowering button
3 Raise the platform slightly. at the gound controls.
Result: The inner frame wheels should lift off Result: Platform should lower.
the ground.
4 Connect the power source to the machine.
6 Disconnect the power source from the
machine.
7 Push in the control activate button and rotate
the up/down switch in the down direction.
Result: Platform should lower.

June 2023
A-9 A-10
Test the Manual Platform Inspect the Columns for Damage
Lowering Operation Genie specifications require that this procedure be
Genie specifications require that this procedure be performed every 8 hours or daily, whichever
performed every 8 hours or daily, whichever comes first.
comes first. Detection of damage to columns is essential for
Detection of a manual lowering malfunction is safe machine operation. An unsafe working
essential for safe machine operation. An unsafe condition exists if the columns are damaged and
working condition exists if the manual lowering do not operate smoothly, free of hesitation and
function does not operate in the event of a main binding. A daily check of the columns allows the
and auxiliary power failure. inspector to identify changes in the operating
condition of the column assembly that might
1 Raise the platform slightly. indicate damage.
2 Activate the manual lowering valve located at 1 Visually inspect each column for the following:
the bottom of the hydraulic cylinder.
• Dents, gouges or abrasions
Result: Platform should lower.
• Bends or warping
• 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.

June 2023
A-11 A-12
Check the Sequencing Cables Check the Interlock System for
Genie specifications require that this procedure be Proper Operation
performed every 8 hours or daily, whichever Genie specifications require that this procedure be
comes first. performed every 8 hours or daily, whichever
Detection of damage to sequencing cables or comes first.
components is essential for safe machine Testing the interlock system for malfunctions is
operation. An unsafe working condition exists if the essential for safe machine operation. An unsafe
sequencing components are damaged and do not working condition exists if any interlock display
operate smoothly. A daily check of the sequencing light fails to operate properly.
system allows the inspector to identify changes in
the operating condition that might indicate AWPS models
damage.
1 Turn the key switch to ground control and pull
1 Visually inspect the cables and components out the red Emergency Stop button to the ON
for the following: position. Twist to release the red Emergency
Stop button at the platform controls.
• Frayed or broken wire strands
Result: AC & DC models: .The power should
• Kinks in the cable be on.
• Corrosion Air models: The air pressure gauge should
read 80 - 110 psi / 5.5 - 7.8 bar
• Paint or foreign materials
2 Slide each outrigger into a base socket until
• Broken or damaged pulleys the outrigger lock pin snaps into place. Adjust
• Unusual or excessive pulley wear outriggers to level using the outrigger screw
jack until the base casters are slightly off the
• Split or cracked threaded swage ends ground.
2 Confirm the following:
• Cables are on the pulleys
• Upper and lower cable ends are properly
secured
• Upper and lower mounting brackets are
properly secured

June 2023
3 Check the interlock display lights at the 5 Pull the base lowering handle to fully lower
ground controls. the base.
Result: Confirm that the corresponding light is Result: The base will lower and both foot pad
on. interlock display lights should be on.
6 Pump the foot pedal to raise the base.
7 Turn both leveling jacks clockwise to the
full/extended position.
8 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.
4 Repeat steps 2 and 3 for each of the 9 Push in the red Emergency Stop button at the
remaining outriggers. platform controls.
IWPS models 10 Push in the control activate button and rotate

the up/down switch in the up position, then
1 Turn the key switch to ground control and pull the down position.
out the red Emergency Stop button to the ON
Result: Platform up/down functions should not
position. Twist to release the red Emergency
operate.
Result: The power light should be on.
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 3 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.

June 2023
A-13 5 Push in the control activate button and rotate

the up/down switch in the UP position, then
Test the Power and Function the DOWN position.
Controls Result: The up/down functions should not
Genie specifications require that this procedure be operate.
performed every 8 hours or daily, whichever 6 Push in the red Emergency Stop button at
comes first. both platform and ground controls.
Testing the machine functions and the Emergency 7 Push in the control activate button and rotate
Stop buttons for malfunctions is essential for safe the up/down switch in the UP position, then
machine operation. An unsafe working condition the DOWN position.
exists if any function fails to operate properly or
either red Emergency Stop button fails to stop all Result: The up/down functions should not
the machine functions. Each function should operate.
operate smoothly and be free of hesitation, jerking
and unusual noise.
1 AWP models: Install the outriggers and level
the machine.
Note: Confirm the interlock display lights are
on.
IWP models: Level the machine.
Note: Confirm the level sensor interlock
display and foot pad interlock display lights
are on.
2 Turn the key switch to ground control and pull
out the red Emergency Stop button to the ON
Result: The power light should be on.
3 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
operate.
4 Push in the red Emergency Stop button at the
platform controls to the OFF position.

June 2023
A-14 A-15
Inspect the Lifting Chains and Inspect the Breather Cap
Idler Wheels Genie specifications require that this procedure be
comes first. The hydraulic tank is vented to the atmosphere.
Maintaining the lifting chains and idler wheels in The breather cap has an internal air filter that can
good condition is essential to safe machine clog and may cause the power unit to operate
operation. Failure to find and replace damaged improperly. If the breather cap is not properly
chains or idler wheels could result in unsafe installed and checked daily, impurities can enter
operating conditions and may cause component the hydraulic system and may cause component
damage damage.
1 Raise the platform approximately 3 feet / 1 m. 1 Be sure the breather cap is installed on the
hydraulic power unit tank and is not damaged.
2 Visually inspect the chains and idler wheels Do not remove it.
near the top of each column for the following:
• Excessive corrosion
• Broken or missing chain leafs and pins
• Tight or kinked joints in the chain
• Missing or damaged idler wheels and
related components
3 Inspect the chain terminations near the
bottom of each column to confirm that each
termination has a lock nut.
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

June 2023
A-16 A-17
Check the Tire Pressure - AWPS Check the Air Supply Lubricator
Models with Rough Terrain Base Oil Level - Air Models
Option

comes first. Maintaining the proper oil level in the lubricator
It is essential to maintain proper pressure in all air- canister is essential to safe operation and good
filled tires. Improperly inflated tires can affect machine performance. Failure to keep the
machine handling. lubricator canister at the proper oil level could
result in unsafe operating conditions and may
1 Check each tire with an air pressure gauge. cause component damage.
Add air as needed.
1 Be sure the platform is fully lowered.
Models before serial number 3899-11837.
2 Inspect the lubricator canister for proper oil
Tire pressure should be 30 psi / 2 bar in the level.
front and rear tires.
Result: The oil level must be within ½ inch /
Models after serial number 3899-11836. 12.7 mm from the top of the lubricator
canister.
Tire pressure should be 50 psi / 3.4 bar in the
front and rear tires. 3 To add oil, 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
Oil Specification
Oil Type 10W automotive engine oil

June 2023
A-18 A-19
Check the Air Supply Lubricator Check the Air Filter/Regulator
Drip Rate - Air Models Canister - Air Models
Maintaining the proper oil drip rate into the air It is essential to drain the air filter/regulator
supply is essential to safe operation and good canister of water to ensure good air motor
machine performance. Failure to maintain the performance and service life. A water-filled
proper drip rate could result in machine canister could cause the air motor to perform
component damage. poorly and continued use may cause component
damage.
1 While raising the platform, visually inspect the
oil lubricator sight gauge. 1 Check the air filter/regulator canister for any
water accumulation.
Result: There should be a maximum of 1 to
2 drops of oil visible in the sight gauge. 2 If water is visible, loosen the drain plug at the
bottom of the canister and allow the water to
2 To adjust the drip rate, turn the oil flow control
drain out.
valve clockwise to decrease the flow or
counterclockwise to increase the flow. 3 Tighten the drain plug.
3 Repeat this procedure until the proper oil drip
rate is achieved.
1 air filter/regulator
2 air filter/regulator canister
1 oil lubricator flow control valve 3 air filter/regulator canister drain plug
2 oil lubricator sight gauge

June 2023
Checklist B Procedures
B-1 5 If equipped: Set the battery charger AC

Selector switch to the proper voltage.
Inspect the Battery
6 Set the power switch to the AUTO position.
performed every 250 hours or quarterly, whichever Result: The charger ammeter should be on.
comes first. Note: For further information regarding the battery
Proper battery condition is essential to good charger, refer to the Supplemental User's Manual.
machine performance and operational safety. Copy and paste or type the link into a web
Improper fluid levels or damaged cables and browser.
connections can result in component damage and https://manuals.genielift.com/Parts%20And%
hazardous conditions. 20Service%20Manuals/ServPersonnelLiftsInd
ex.htm
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 are
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 Check the battery acid level. If needed,
replenish with distilled water to the bottom of
the battery fill tube. Do not overfill.
4 Install the battery vent caps.

June 2023
B-2 B-3
Inspect the Electrical Wiring Inspect All Welds
performed every 250 hours or quarterly, whichever
comes first.
Genie requires that this procedure be performed
every 250 hours or quarterly, whichever comes Weld inspections are essential to safe machine
first. operation and good machine performance. Failure
to locate and repair damage may result in an
Maintaining electrical wiring in good condition is
unsafe operating condition.
essential to safe operation and good machine
performance. Failure to find and replace burnt, 1 Visually inspect the welds in the following
chafed, corroded or pinched wires could result in locations:
unsafe operating conditions and may cause
component damage. • Platform
• Base
Contact with electrically charged • Mast brace mounting bracket
circuits could result in death or
serious injury. Remove all rings, AWPS models:
watches and other jewelry. • Loading pivot bar
1 Inspect the following areas for burnt, chafed, • Outrigger storage sockets
corroded, pinched and loose wires:
• Tilt-back frame (if equipped)
• All base wiring
• Tilt-back frame mounting bracket (if
• Inside ground control box equipped)
• Hydraulic power unit IWPS models:
• All external electrical cables • Foot pads
• DC models: battery pack • Power wheel assist (if equipped)
• AC power supply cord
• IWP models: inside base junction box
• IWP models: power wheel assist manifold
(if equipped)

June 2023
B-4 5 Insert the retaining pin into the strut socket.
Test the Tilt-back Operation (if

equipped)
comes first.
A tilt-back frame is standard equipment on AWP-
36S and 40S and optional on AWP-15S, 20S, 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
Crushing hazard. The machine
unsafe operating conditions and may cause injury
will fall if the retaining pin is not
and component damage.
locked into the strut socket.
1 Fully lower the platform to the stowed
position. 6 Slide out the T-handle until the lock pin snaps
into the locked position.
2 Remove the outriggers from the base and
place in the storage sockets. Crushing hazard. The machine
3 Maintain a firm grasp on the tilt-back frame could fall if the T-handle lock pin
and remove the retaining pin. is not locked into the base.
7 Lift the machine with the T-handle to the mid-

tilt position (casters on tilt-back frame contact
the floor, and machine supported by the
extended tilt-back strut). Use the appropriate
number of people and proper lifting
techniques.
4 Lower the tilt-back frame and guide the tilt-

back strut into the strut socket.

June 2023
8 Continue lifting until telescoping tilt-back strut B-5

is completely compressed.
Check the Lifting Chain
Adjustment

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
9 Return the machine to the standing position. component damage.
Carefully pull down T-handle until machine 1 Fully lower the platform to the stowed
rests at mid-tilt position. position.
10 Lower the machine with the T-handle until 2 Measure the maximum height of the machine.
base casters are in contact with the ground.
Use the appropriate number of people and IWPS models: Turn the screw jacks
proper lifting techniques. counterclockwise to the full up position. Pull
the base lowering handle to lower the base.
11 Return the sliding T-handle to stowed Refer to Specifications.
position.
Note: If measurement does not meet specification,
12 Stow the tilt-back frame in the upright position adjust the chains. Refer to Repair Procedure, How
and insert the retaining pin. to Adjust the Lifting Chains.
3 AWPS models: Measure the distance
between the top of the base frame and the
bottom edge of the platform.

June 2023
IWP models: Measure the distance between B-6
the bottom edge of the platform to the top of
the counterweight. Clean and Lubricate the Columns

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
Result: The measurement should be no less
of the columns for debris or foreign material. If
than specification.
necessary, use a mild cleaning solvent to
Note: If measurement does not meet clean he columns.
specification, adjust the chains. Refer to
Repair Procedure, How to Adjust the Lifting Bodily injury hazard. This
Chains. procedure will require the use of
additional access equipment. Do
Specifications not place ladders or scaffold on
or against any part of the
Model Height Measurement machine. Performing this
(step 2) procedure without the proper
IWP-20S 76 in 3 in skills and tools could result in
193 cm 7.6 cm death or serious injury. Dealer
service is strongly
IWP-25S 76 in 3 in
193 cm 7.6 cm
recommended.
IWP-30S 76 in 3 in 3 If needed, apply a generous amount of Boe-

193 cm 7.6 cm lube wax (Genie part number 90337) to the
AWP-15S 78 in 3 in inside and outside channels of each column.
198 cm 7.6 cm
AWP-20S 78 in 3 in
198 cm 7.6 cm
AWP-25S 78 in 3 in
198 cm 7.6 cm
AWP-30S 78 in 3 in
198 cm 7.6 cm
AWP-36S 109 ½ in 3 in
278 cm 7.6 cm
AWP-40S 109 ½ in 3 in
278 cm 7.6 cm

June 2023
B-7 B-8
Test the Lifting Capacity Adjust the Sequencing Cables
Genie requires that this procedure be performed Genie requires that this procedure be performed
every 250 hours or quarterly, whichever comes every 250 hours or quarterly, whichever comes
first. first.
Proper lifting capacity is essential to safe machine Maintaining proper adjustment of the sequencing
operation. Improper lifting capacity adjustment cables is essential for safe machine operation. An
could allow machine to be overloaded and may unsafe working condition exists if the sequencing
cause death or serous injury. cables are improperly adjusted. A daily check of
the sequencing cables allows the inspector to
Bodily injury hazard. This identify changes in the operating condition that
procedure requires specific repair might indicate damage.
skills, lifting equipment and a
suitable workshop. Attempting To serial number 3899-11843
this procedure without these
1 Fully lower the platform.
skills and tools could result in
death or serious injury and 2 Check the deflection on each sequencing
significant component damage. cable by grasping the cable halfway down the
Dealer service is strongly column and pulling the cable to one side then
recommended. the other. Measure the total distance between
the two points (this is the maximum
1 Place the maximum rated load in the platform. deflection)
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.
Result: The hydraulic power unit should raise
the platform.
3 Fully lower the platform. 1 adjustment (tension) nut
2 threaded swage end
4 Add additional weight to the platform that is
3 sequencing cable
equal to, but does not exceed 20% of the
maximum rated load. Secure the additional 3 If needed, adjust the sequencing cable
weight. Refer to the machine serial plate. deflection.
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 load or lifts more than rated load,
refer to Repair Procedure, Valve Adjustment.

June 2023
4 Hold the threaded swage end of the cable 3 Compress the spring to 15/16 in / 2.4 cm by
from turning and adjust the tension nut to turning the nylock nut clockwise to increase
obtain correct deflection. Turn the adjustment the spring compression or counterclockwise
nut clockwise to decrease the deflection or to decrease the spring compression.
counterclockwise to increase the deflection.
Component damage hazard. Do
Component damage hazard. Do not exceed the recommended
not exceed the recommended spring compression.
deflection.
4 Confirm the spring measurement on each
5 Raise and lower the platform through three sequencing cable.
complete cycles and confirm deflection.
5 Raise and lower the platform through three
6 Repeat adjustment for each cable as complete cycles and confirm the spring
required. compression.
Deflection, Maximum 1 ½ to 2 ½ inches 6 Repeat adjustment for each cable as
3.8 to 6.4 cm required.
After serial number 3899-11843
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
bracket.
1 nylock nut
2 spring
3 upper sequencing bracket
4 sequencing cable

June 2023
B-9 ANSI / CSA Models

Inspect for Proper Outrigger AWP-15S 20 inches
Length - AWPS Models (including narrow and rough terrain 50.8 cm
base options)
AWP-20S 20 inches
(including narrow and rough terrain 50.8 cm
Genie specifications require that this procedure be base options)
performed every 250 hours or quarterly, whichever AWP-25S 20 inches
comes first. (including narrow and rough terrain 50.8 cm
base option)
Proper outrigger length is essential to safe
AWP-30S 26 inches
machine operation. Operating a machine with (including narrow and rough terrain 66 cm
outriggers different from those originally designed base option)
for the model will result in death or serious injury.
AWP-36S 36 inches
1 Measure each outrigger and verify for proper 91.4 cm
length. AWP-40S 40 inches
101.6 cm
CE / AS Models
AWP-15S 20 inches
50.8 cm
AWP-20S 20 inches
50.8 cm
AWP-20S 26 inches
(narrow and rough terrain base options) 66 cm
AWP-25S 26 inches
(including narrow and rough terrain 66 cm
base option)
AWP-30S 30.5 inches
(including narrow and rough terrain 77 cm
base option)
AWP-30S 36 inches
(narrow and rough terrain base with air 91.4 cm
power option)
AWP-36S 36 inches
91.4 cm
AWP-40S 40 inches
102 cm

June 2023
B-10 B-11
Inspect and Lubricate the Test the Level Sensing Operation
Outrigger Leveling Jack - IWPS Models
Footpads - AWPS Models

first.
first. Detection of level sensing malfunctions is essential
for safe machine operation. An improperly
Detection of unusual wear of the leveling jack
functioning level sensing system could result in
footpads is essential for safe machine operation.
unsafe operating conditions.
An improperly lubricated and or damaged footpad
could result in an unsafe condition. 1 Position the machine on a firm, level surface
1 Visually inspect the leveling jack footpads for 2 Turn the key switch to ground control and pull
any unusual wear. out the red Emergency Stop button to the ON
2 Liberally apply grease to the top of the
footpads at the swivel point and the leveling
jack threads. 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.
remain on.
1 outrigger leveling jack threads 4 Pump the foot pedal to raise the base.
2 outrigger footpad swivel point 5 Place a ¼ inch / 6.35 mm thick spacer under
3 outrigger footpad one adjustable and one non-adjustable foot
pad on the same side of the machine.
Grease Type Lithium-based
the base.
remain on.

June 2023
7 Repeat steps 4 and 5 using a ½ inch / B-12

12.7 mm spacer.
Check the Chain Adjustment,
8 Pull the base lowering handle to fully lower IWP-20S Models with Outreach
the base.
Option
Result: Within 1 to 4 seconds, two interlock
display lights should turn off and remain off.
9 Repeat steps 4 through 8 to test the opposite
side of the machine. Genie requires that this procedure be performed
10 Pump the foot pedal to raise the base. first.
11 Place a ¾ inch / 19 mm thick spacer under Detection of a improperly adjusted platform
both adjustable foot pads. outreach chain is essential for safe machine
12 Pull the base lowering handle to fully lower operation. Failure to detect an improperly adjusted
the base. platform outreach chain could result in unsafe
operating conditions and may cause injury and
Result: Within 1 to 4 seconds, all four component damage.
remain on. 1 Fully lower the platform.
13 Pump the foot pedal to raise the base. 2 Lower the base and turn the key switch off.
14 Turn the leveling jacks counterclockwise 3 Fully extend the outreach and lock the handle.
enough to fit a 1½ inch / 3.8 cm spacer under
each adjustable foot pad. 4 Locate the chain between the lower sprocket
and the lower brace.
15 Turn the leveling jacks clockwise until the foot
pads just touch the spacers. 5 Grasp the two chain sections and lightly pinch
them together.
the base. Result: There should be a minimum of a ¼
inch / 6.4 mm gap between the chain
Result: Within 1 to 4 seconds, two interlock sections.
Note: If measurement does not meet specification,
17 Pump the foot pedal to raise the base. adjust the chains. Refer to Repair Procedure, How
to Adjust the Platform Outreach Chain.
18 To test the non-adjustable foot pads, turn the
leveling jacks counterclockwise all the way.
19 Place a 1½ inch / 3.8 cm spacer under each
non-adjustable foot pad.
the base.
Result: Within 1 to 4 seconds, two interlock

June 2023
Checklist C Procedures
C-1 C-2
Inspect and Lubricate the Casters Inspect the Mast Assembly for
and Wheels Wear
performed every 1000 hours or annually, performed every 1000 hours or annually,
whichever comes first. whichever comes first.
Extremely dirty conditions may require that the Detection of excessive or unusual wear in the
casters and wheels be inspected and lubricated mast assembly is essential for safe machine
more often. operation. An unsafe working condition exists if the
mast assembly has excessive wear or does not
1 Visually inspect each caster and wheel for operate smoothly, free of hesitation and binding.
cuts, cracks or unusual wear.
1 Remove the mast covers.
2 Push the machine on a flat smooth surface
and check that the casters and wheels roll 2 Raise the platform until 3 to 5 inches / 7.6 to
smoothly. 12.7 cm of each column is visible.
3 Pump grease into the zerk fitting on each 3 Visually inspect the top of each column for
caster and wheel until it can be seen coming clearance between the roller wheels and the
out of the bearing seal gap. adjacent column surface.
Grease Type Lithium-based 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 to Adjust the Glide Pads.

June 2023
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
the first column. • Excessive wear on the side flanges
• Unusual wear
• Movement side to side in excess of
0.079 inch / 2 mm
• Any movement of wheel front to back
5 Raise the platform approximately 3 feet / 1 m

above the top of the base.
6 Place a jack stand on the top of the base,
centered 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.
Crushing hazard. Keep away
from lowering platform.

June 2023
C-3 C-4
Inspect and Lubricate the Lifting Replace the Hydraulic Oil
Chains Genie specifications require that this procedure be
Genie specifications require that this procedure be performed every 1000 hours or annually,
performed every 1000 hours or annually, whichever comes first.
whichever comes first. Replacement or testing of the hydraulic oil is
Lubricated chains are essential to good machine essential for good machine performance and
performance and safe operation. Extremely dirty service life. Dirty oil and a clogged suction strainer
conditions may require that the chains be cleaned may cause the machine to perform poorly and
and lubricated more often. continued use may cause component damage.
Extremely dirty conditions may require oil changes
1 Raise the platform to the maximum height. to be performed more often. For hydraulic oil
specifications, Refer to Specifications, Hydraulic
2 Inspect each lifting chain. Refer to Repair Specifications.
Procedure, How to Inspect the Lifting Chains.
3 Lubricate each chain with a dry-type spray
lubricant. 2 Remove the plastic cover from the power unit.
Bodily injury hazard. This 3 Remove the drain plug from the tank and
procedure will require the use of allow all of the oil from the tank to drain into a
additional access equipment. Do suitable container.
not place ladders or scaffold on
or against any part of the Bodily injury hazard. Spraying
machine. Performing this hydraulic oil can penetrate and
procedure without the proper burn skin. Loosen hydraulic
skills and tools could result in connections very slowly to allow
death or serious injury. Dealer the oil pressure to dissipate
service is strongly gradually. Do not allow oil to
recommended. 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.
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 Remove the tank from the hydraulic power

unit.
6 Remove the suction strainer from the pick-up
tube and the magnet from inside the tank and
clean them using a mild solvent.
7 Install the suction strainer.

June 2023
8 Install the drain plug using thread sealer on Hydraulic System
the threads.
Hydraulic fluid Chevron Rando HD
9 Install the hydraulic tank. equivalent
10 Fill the tank with hydraulic oil until the level is Hydraulic tank capacity - all 3 quarts
visible in the sight gauge on the side of the models 2.8 liters
tank. Do not overfill. Hydraulic System Capacity (includes tank)
11 Replace the breather cap with a new one. IWP AC and DC models
IWP-20S 3.7 quarts
12 Raise and lower the platform through three
3.5 liters
complete cycles. Add hydraulic oil if needed
to allow platform to reach full height. IWP-25S 3.7 quarts
3.5 liters
13 Clean up any oil that may have spilled. IWP-30S 3.7 quarts
Properly discard the used oil. 3.5 liters
Component damage hazard. Do AWP AC, DC and Air
not allow the hydraulic tank to Powered models
completely empty when raising AWP-15S 3.7 quarts
the platform. Pressurized air in 3.5 liters
the hydraulic system can AWP-20S 3.7 quarts
damage hydraulic components. 3.5 liters
AWP-25S 3.7 quarts
3.5 liters
AWP-30S 3.7 quarts
3.5 liters
AWP-36S 4 quarts
3.8 liters
AWP-40S 3.9 quarts
3.7 liters

June 2023
C-5
Replace the Auxiliary Platform
Lowering Batteries

performed every 1000 hours or annually,
whichever comes first.
1 Turn 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.

June 2023

June 2023
Repair Procedures
Machine Configuration:
Section 4 Repair Pr oc edures
 Unless otherwise specified, perform each

repair procedure with the machine in the
following configuration:
• Machine parked on a firm, level surface
Observe and Obey:
• Key switch in the off position with the key
 Repair procedures shall be completed by a removed
person trained and qualified on the repair of
this machine. • The red Emergency Stop button in the off
position at both the ground and platform
 Immediately tag and remove from service a controls
damaged or malfunctioning machine.
• Wheels chocked
 Repair any machine damage or malfunction
before operating the machine. • All external AC power supply disconnected
from the machine
• Platform in the stowed position
Before Repairs Start:
 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.

June 2023
Repair Procedures
About This Section Symbols Legend

Most of the procedures in this section should only Safety alert symbol—used to alert
be performed by trained service professional in a personnel to potential personal
suitably equipped workshop. Select the injury hazards. Obey all safety
appropriate repair procedure after troubleshooting messages that follow this symbol
the problem. to avoid possible injury or death.
Perform disassembly procedures to the point Indicates a imminently hazardous

where repairs can be completed. Then to re- situation which, if not avoided, will
assemble, perform the disassembly steps in result in death or serious injury.
reverse order.
could result in death or serious
injury.

may cause minor or moderate
injury.

Indicates that a specific result is expected

Indicates that an incorrect result has occurred

June 2023
Base Assembly
1-1 8 Follow the wires to the grommets where the

wire enters and exits the base. Pull the wires
Interlocks through the grommets and the base.
AWPS models: The interlock contacts indicate Note: Only pull the wires out far enough to access
proper installation of the outriggers and only allow the interlock contact bracket mounting fasteners.
the machine to operate when the outriggers are
properly installed and adjusted. 9 Remove the interlock contact bracket
mounting fasteners from the outrigger base
IWPS models: The base interlock switches socket.
indicate that the foot pads are in firm contact with
the ground.
How to Remove a Base Interlock
How to Remove an Interlock Switch - IWPS Models
Contact - AWP Models 1 Fully lower the platform.
1 Fully lower the platform. 2 Turn the key switch off and remove the key.
2 Turn the key switch off and remove the key. 3 Pull the base lowering handle to fully lower
the base.
3 Store the outriggers in the storage sockets.
4 Remove the foot pad switch bracket
4 Remove the rear base cover. fasteners.
5 Pull the foot pad switch bracket out of the
base.
1 base
2 terminal switch 1 switch bracket cover
2 switch bracket fasteners
5 Trace the interlock contact wires to the rear of
the base. 6 Remove the wires from the switch. Note the
6 Locate the terminal strip. wire positions.
7 Remove the fastener that attaches the switch
7 Label and remove the contact wires by
inserting a small screwdriver into the hole to the switch bracket.
below the wire and gently push in while
pulling on the wire.

June 2023
Base Assembly
1-2 6 From under the base, remove the inner frame

support tube mounting fasteners. The tube is
Base Components IWPS Models mounted directly under the number 1 column.
7 Carefully lift the machine off of the inner base
How to Remove the Inner Base frame. Do not allow the inner base frame to
Frame fall when lifting the machine
Bodily injury hazard. This Crushing hazard. The machine

procedure requires specific repair may fall, if it is not properly
skills, lifting equipment and a supported by the overhead
suitable workshop. Attempting crane when removed from the
this procedure without these base.
death or serious injury and
significant component damage.
Dealer service is strongly
recommended.

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 Tag, disconnect and plug the three hydraulic
hoses from the base manifold. Cap the ports
on the manifold
squirt or spray.
5 Pull the hoses through the channel of the

base inner frame.

June 2023
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.
the base.
2 Remove the cover from the base manifold.
3 Be sure the cable is properly connected to the
manual valve at the base manifold.
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
5 spring
4 Be sure the cable is attached to the cable
mounting bracket with a lock nut on each 6 lock nut
side. There should be ¼ to ½ inch / 6.35 to 7 cable mounting bracket
12.7 mm of threads on the manifold side of
6 Loosen the mounting fasteners on the cable
the bracket.
mounting bracket and the cable striker
bracket on the number 1 column. Do not
remove the fasteners.

June 2023
Base Assembly
7 Measure from the bottom of the number How to Adjust the Foot Pump
1 column, make a reference mark 6 inches / Pressure Relief Valve
15.2 cm up the column.
8 Slide the cable mounting bracket up, until the Component damage hazard.
top of the bracket is even with the reference The work area and surfaces
mark from step 7. Tighten the mounting where this procedure will be
fasteners. performed must be clean and
free of debris that could get into
9 Measure from the bottom of the number the hydraulic system.
2 column, make a reference mark 10 inches /
25.4 cm up the column. 1 Pull the base lowering handle to fully lower
the base.
10 Slide the cable striker bracket down until the
top of the bracket is even with the reference 2 Tag and disconnect the hydraulic hose from
mark from step 9. The spring will need to be the port at the rod end of the base cylinder.
compressed, when the cable striker bracket is Cap the cylinder port
pulled down. Tighten the mounting fasteners.
11 Pump the foot pedal to raise the base. hydraulic oil can penetrate and
12 Pull the base release handle to be sure the burn skin. Loosen hydraulic
base lowers. Adjust if necessary. connections very slowly to allow
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.
5 Remove the manifold cover.
6 Hold the lift relief valve with a wrench and
remove the 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.
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.

June 2023
Base Assembly
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.

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

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.
5 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 discard the used oil.

June 2023
Base Assembly
1-3
Foot Pump Manifold Components - IWPS Models (to SN IWP09-8269)
Index No. Description Schematic Item 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 I 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

June 2023
Base Assembly
1-4
Foot Pump Manifold Components - IWPS Models (from SN IWP09-
8270)
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
4 Manual release valve I Lowers base 8-10 ft-lbs / 11-14 Nm
6 Relief valve, 1600 psi / J Base lift cylinder 8-10 ft-lbs / 11-14 Nm
110 bar
7 Check valve G System pressure 8-10 ft-lbs / 11-14 Nm
9 Pilot to open check valve K Base lift cylinder 35-40 ft-lbs / 47-54 Nm
10 Foot pump L Base lift cylinder 8-10 ft-lbs / 11-14 Nm
11 Orifice, 0.3 inch / 0.76 mm M Foot Pump

June 2023
Base Assembly
1-5
Power Wheel Assist Manifold Components - IWPS Models (to SN 4097-
990)
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

June 2023
Base Assembly
1-6
Power Wheel Assist Manifold Components - IWPS Models
(from SN 4097-991 to 4099-2532)
1 Check valve BA System pressure 25-35 ft-lbs / 34-41 Nm
2 Solenoid Valve, 2 position BB All 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

June 2023
Base Assembly
1-7
Power Wheel Assist Manifold Components - IWPS Models (from SN
4099-2533)
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

June 2023
Ground Controls
2-1
How to Test the Transformer - AC
Models
2 Turn the key switch off and disconnect the
power supply.
transformer.
4 Tag and disconnect all wiring from the
transformer.
5 Connect the leads from an ohmmeter to the
following terminal combinations and check the
continuity/resistance.
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 22Ω
black wire to white wire 16 to 19Ω
yellow wire to white wire 16 to 19Ω
red/yellow wire to red wire #1 0.5 to 1.5Ω
red/yellow wire to red wire #2 0.5 to 1.5Ω
red wire #1 to red wire #2 0.5 to 1.5Ω
yellow wire to black wire 0.5 to 1.5Ω
all other wire combinations no continuity (infinite Ω)

June 2023
Ground Controls
2-2
How to Test the AC Contactor -
AC Models
power supply.
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
1 terminal no. 1
2 terminal no. 8
3 terminal no. 6
4 terminal no. 2
5 terminal no. 4
6 terminal no. 0
Test Desired result

terminal 0 to 1 80 to 85Ω
all other terminal combinations no continuity (infinite Ω)

June 2023
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
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

June 2023

June 2023
3-2
(from SN AWP03-27390 to AWP08-60145, IWP03-5151 to IWP08-7708)
6 Pump 0.5 to 0.6 gallons per minute at 2000 psi /1.89 to 2.27 liters per
minute at 138 bar
9 O-ring Seals tank

June 2023

June 2023
3-3
(from SN AWP08-60146, IWP08-7709)
9 Breather cap (models with standard base) Hydraulic tank vent/filler
10 Reducer (models with narrow or rough terrain 3/4 NPT x 3/8 NPT
base)
11 Street tee (models with narrow or rough terrain 3/8 NPT
base)
12 Breather cap (models with narrow or rough Hydraulic tank vent/filler
terrain base)
13 Check valve (models with narrow or rough 3/8 NPT
terrain base)
14 Coupling (models with narrow or rough terrain 3/8 x 1.12
base)
terrain base)
16 Pipe adapter (Japanese models with narrow or 3/4-11 NPT
rough terrain base)
17 Pump 0.5 to 0.6 gallons per minute at 2000 psi /1.89 to
2.27 liters per minute at 138 bar
19 Bell housing Power unit

June 2023

June 2023
3-4
Hydraulic Power Unit - DC Models
(to SN AWP08-60547 and IWP08-7754)
1 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
11 O-ring Seals tank
12 Pump 0.7 to 1 gpm at 2000 psi /2.6 to 3.76 L/min at 138 bar

June 2023

June 2023
3-5
Hydraulic Power Unit - DC Models
(from SN AWP08-60548 and IWP08-7755)
1 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
7 O-ring Seals tank
10 Reducer (models with narrow or rough 3/4 NPT x 3/8 NPT
terrain base)
11 Street tee (models with narrow or rough 3/8 NPT
terrain base)
12 Breather cap (models with narrow or Hydraulic tank vent/filler
rough terrain base)
terrain base)
15 Coupling (models with narrow or rough 3/8 x 1.12
terrain base)
16 Breather cap (models with narrow or Hydraulic tank vent/filler
rough terrain base)
17 Pipe adapter (Japanese models) 3/4-11 NPT
18 Pump 0.7 to 1 gpm at 2000 psi /2.6 to 3.76 L/min at 138 bar

June 2023

June 2023
3-6
Hydraulic Power Unit Components - Air Powered Models
(to SN AWP04-27779)
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 N.O. Air Pilot Diverts pump output back to tank during motor start up
5 O-ring Seals tank
9 Tee fitting (models with narrow or rough Tank vent adaptor
terrain base)
10 Plug fitting (models with narrow or rough Plug
terrain base)
12 Breather cap (from SN 3897-4545) Hydraulic tank vent/filler
13 Breather cap (to SN 3897-4544) Hydraulic tank vent/filler
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

June 2023

June 2023
3-7
Hydraulic Power Unit Components - Air Powered Models
(from SN AWP04-27780)
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 N.O. air pilot Diverts pump output back to tank during motor start up
5 O-ring Seals tank
10 Reducer (models with narrow or rough 3/4 NPT x 3/8 NPT
terrain base)
11 Street tee (models with narrow or rough 3/8 NPT
terrain base)
terrain base)
14 Coupling (models with narrow or rough 3/8 x 1.12
terrain base)
terrain base)
16 Pipe adapter (Japanese models) 3/4-11 NPT
18 Pump 0.7 to 1 gpm at 2000 psi / 2.6 to 3.76 L/min at 138 bar
19 Pump/Motor adapter housing Protects coupling components
20 Pump adapter Connects pump to spider coupler
21 Spider coupler Connects motor to pump
22 Motor adapter Connects motor to spider coupler

June 2023

June 2023
3-8 7 Remove the cover from the junction box on

the motor. Tag and disconnect the electrical
Hydraulic Power Unit wiring in the junction box. Loosen the
squeeze connector on the junction box and
How to Remove the Hydraulic pull the wiring out through the squeeze
connector.
Power Unit - AC Models
DC models: Tag and disconnect the electrical
1 Fully lower the platform. wiring from the motor start solenoid.
2 Turn the key switch off and disconnect the Air models: Tag and disconnect the pneumatic
power supply. hoses from the power unit.
3 IWPS models: Pull the base lowering handle
to fully lower the base. 8 Support the hydraulic power unit with a lifting
device.
9 Remove the power unit mounting fasteners,
5 Tag, disconnect and plug the hydraulic hoses. then remove the power unit from the machine.
Cap the fittings on the power unit.
Crushing hazard. The power unit
Bodily injury hazard. Spraying will fall unless it is properly
hydraulic oil can penetrate and supported.
connections very slowly to allow Note: If a new power unit is installed, the pressure
the oil pressure to dissipate relief valve must be properly adjusted. See 3-10,
gradually. Do not allow oil to How to Adjust the Pressure Relief Valve.
squirt or spray.
6 Tag and disconnect the electrical wiring from

the valve coil.

June 2023
How to Remove the Hydraulic How to Remove the Hydraulic

Power Unit - DC Models Power Unit - Air Models
1 Fully lower the platform. 1 Fully lower the platform.
2 Turn the key switch off and disconnect the 2 Turn the key switch off and disconnect the
power supply. power supply.
3 IWPS models: Pull the base lowering handle 3 Tag, disconnect and plug the hydraulic hoses.
to fully lower the base. Cap the fittings on the power unit.
4 Remove the power unit cover. Bodily injury hazard. Spraying
5 Tag, disconnect and plug the hydraulic hoses. hydraulic oil can penetrate and
Cap the fittings on the power unit. burn skin. Loosen hydraulic
Bodily injury hazard. Spraying the oil pressure to dissipate
hydraulic oil can penetrate and gradually. Do not allow oil to
burn skin. Loosen hydraulic squirt or spray.
the oil pressure to dissipate 4 Support the hydraulic power unit with a lifting
gradually. Do not allow oil to device.
squirt or spray. 5 Loosen the power unit mounting plate
fasteners. Do not remove them.
the valve coil. 6 Rotate the mounting plate away from the mast
to access the power unit mounting fasteners.
the motor start solenoid. 7 Remove the power unit mounting fasteners,
then remove the power unit from the machine.
8 Support the hydraulic power unit with a lifting
device. Crushing hazard. The power unit
9 Loosen the power unit mounting plate will fall unless it is properly
fasteners. Do not remove them. supported.
10 Rotate the mounting plate away from the mast Note: If a new power unit is installed, the pressure
to access the power unit mounting fasteners. relief valve must be properly adjusted. See 3-10,
How to Adjust the Pressure Relief Valve.
11 Remove the power unit mounting fasteners,
then remove the power unit from the machine.
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 3-10,
How to Adjust the Pressure Relief Valve.

June 2023
3-9 3-10
Hydraulic Pump Valve Adjustment
How to Remove the Hydraulic How to Adjust the Platform Lift

Pump Relief Valve
Note: When removing a hose assembly or fitting, Note: Be sure the hydraulic oil level is between the
the O-ring (if equipped) on the fitting and/or hose FULL and ADD marks on the oil level indicator.
end must be replaced. All connections must be
torqued to specification during installation. Refer to 1 Remove the power unit cover.
Specifications, Hydraulic Hose and Fitting Torque 2 Loosen the locknut on the relief valve located
Specifications. on the right side of the motor.
1 Fully lower the platform. 3 Follow the appropriate operator's manual to
set up the machine for operation.
power supply. 4 Place maximum rated load into the platform.
Secure the load to the platform. Refer to
3 IWPS models: Pull the base lowering handle
Specifications, Machine Specifications.
to fully lower the base.
5 Hold the relief valve screw and loosen the
lock nut.
5 Remove the power unit. See 3-8, How to
6 While activating the platform up function, turn
Remove the Power Unit.
the relief valve screw clockwise, just until the
6 Support the hydraulic tank with a lifting platform begins to raise.
device.
7 Remove the mounting fasteners from the
8 Add additional weight to the platform that is
tank. Remove the tank from the power unit.
equal to, but does not exceed 20% of the
Do not allow the hydraulic oil to spill.
maximum rated load. Secure the additional
Note: It may be necessary to tap the side of the weight. Refer to the machine serial plate.
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.

June 2023
9 Activate the platform up function. 3-11

10 The power unit should not be able to lift the How to Test the Motor Start
platform. If the power unit lifts the platform, Solenoid - DC Models
turn the relief valve counterclockwise until the
platform does not lift. Repeat steps 11 and Electrocution/burn hazard.
12 until the lift relief valve is properly adjusted. Contact with electrically charged
11 Hold the relief valve screw and tighten the circuits could result in death or
lock nut. Be sure the relief valve screw does serious injury. Remove all rings,
not turn. watches and other jewelry.
12 Remove the weight from the platform.
13 Bleed the hydraulic system by raising the
Electrocution hazard.
platform to full height. If the pump cavitates or
Disconnect the ground cable
the platform fails to reach full height, add
from the battery before
hydraulic oil until the pump is functioning
performing this procedure.
correctly. Do not overfill the hydraulic tank.
Component damage hazard. Do 1 Tag and disconnect the electrical wiring from
not continue to operate the the motor start solenoid.
machine if the hydraulic pump is 2 Connect the leads from an ohmmeter to the
cavitating. following terminal combinations and check the
14 Install the breather cap and the power unit
cover. Test Desired result
Small post to ground 13 to 17Ω
2 large posts no continuity (infinite Ω)
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 Ω)

June 2023
Power Pack
4-1 8 Remove the breather cap from the hydraulic

power unit and install a pipe plug in the filler
Power Pack hole.
9 Tag, disconnect and plug the hydraulic hoses
How to Change a Power Pack from the power unit.
1 Fully lower the platform. Bodily injury hazard. Spraying
2 Turn the key switch off and disconnect the hydraulic oil can penetrate and
power supply. burn skin. Loosen hydraulic
IWP models: Pull the base lowering handle to the oil pressure to dissipate
fully lower the base. gradually. Do not allow oil to
3 Remove the power unit cover. squirt or spray.
4 AC and DC models: Separate both control 10 Support the power pack and remove the
cable quick disconnect couplers from the power pack mounting bolts.
ground control box.
Crushing hazard. The power
Air models: Disconnect the air lines from the pack will fall if not properly
air valve container, filter regulator and air supported when removed from
lubricator. the machine.
5 AC and DC models: Separate the battery
quick disconnects. 11 Remove the power pack.
6 DC models: Disconnect the battery cables

from the motor start solenoid. Installation
7 AWPS models with Narrow Base or Rough Tip-over hazard. On Narrow
Terrain Base: Remove the loading wheels. Base and Rough Terrain Base
models, the counterweights
must be installed on the new
power pack.
Component damage 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.

June 2023
Mast Components
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

June 2023
Mast Components
5-1 6 Lift the machine off the ground and then while
lowering it, guide it over onto the saw horse.
Lift Cylinder Be sure the saw horse is of ample capacity.
How to Remove the Lift Cylinder will fall unless it is properly
Bodily injury hazard. This supported by the saw horse.
procedure requires specific repair
skills, lifting equipment and a 7 Remove the socket head retaining bolt from
suitable workshop. Attempting the clevis block on the lift cylinder rod end.
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
1 top of no. 1 column
torqued to specification during installation. Refer to
2 retaining fastener
Specifications, Hydraulic Hose and Fitting Torque
3 clevis block
Specifications.
1 Fully lower the platform. 8 Tag, disconnect and plug the lift cylinder
hydraulic hoses. Cap the fittings on the lift
2 Turn the key switch to the off position. cylinder.
AWPS models: Remove the outriggers from Bodily injury hazard. Spraying
the outrigger storage socket. hydraulic oil can penetrate and
DC models: Remove the battery pack. burn skin. Loosen hydraulic
3 Remove the breather cap from the hydraulic the oil pressure to dissipate
power unit and install a pipe plug in the filler gradually. Do not allow oil to
hole. squirt or spray.
the top of the mast. 9 Remove the cylinder mounting fasteners from
the barrel end of the cylinder.
5 Place a saw horse in front of the machine
where the top of the mast will rest.

June 2023
Mast Components
10 Loosen the cylinder mounting bracket 5-2

fasteners
Mast Assembly
How to Remove the Mast

Assembly - AWPS Models
Bodily injury hazard. This
suitable workshop. Attempting
recommended.
1 Bracket mounting fasteners
2 Cylinder mounting fasteners 1 Fully lower the platform.
3 Hydraulic cylinder
4 Cylinder mounting plate
3 Remove the platform. Refer to Repair
11 Support the cylinder and carefully slide it out Procedure, How to Remove an Aluminum
of the bottom of the mast. Platform.
Crushing hazard. The lift cylinder 4 Remove the power pack. Refer to Repair
will fall unless it is properly Procedure, How to Change a Power Pack.
supported. 5 AWP-36S and 40S models: Remove the tilt-
back frame. Refer to Repair Procedure, How
to Remove the Tilt-back Frame.
the top of the mast.
7 Place a saw horse in front of the machine
where the top of the mast will rest.

June 2023
Mast Components
8 Lift the machine off the ground and then while 12 Tag, disconnect and plug the lift cylinder
lowering it, guide it over onto the saw horse. hydraulic hoses. Remove the flow control
Be sure the saw horse is of ample capacity. valve from the cylinder. Cap the cylinder ports
squirt or spray.
13 Remove the mast brace mounting bracket

fasteners.
14 Remove the four mast mounting fasteners.
Push the fasteners toward the mast for
clearance during mast removal.
will fall unless it is properly 15 AWP-15S, 20S, 25S, and 30S models:
supported by the saw horse. Remove the power cable brackets from the
side of the mast.
9 Attach the overhead crane to the base. AWP-36S and 40S models: Remove the
10 Lift the base until the mast is level then place rubber grommet from the access hole in the
a second saw horse under the mast near the mast stiffener. Carefully pull the electrical
base. Lower the mast onto the saw horse. cables and hydraulic hoses down and out
through the bottom of the mast.
11 Remove the cover on the rear of the base.
16 Attach the overhead crane to the base.
17 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.

June 2023
Mast Components
How to Remove the Mast 10 Attach an overhead crane to the lifting eye at
Assembly - IWPS Models the top of the mast.
11 Remove the four mast mounting fasteners.
Bodily injury hazard. This Push the fasteners toward the mast for
procedure requires specific repair clearance during mast removal.
suitable workshop. Attempting 12 Carefully lift the mast out of the base
skills and tools could result in Crushing hazard. The mast will
death or serious injury and fall unless it is properly
significant component damage. supported when it is removed
Dealer service is strongly from the base.
recommended.
13 Place two saw horses under the mast.
1 Fully lower the platform. 14 Lower the mast onto the saw horses with the
2 Turn the key switch off and remove the key. carriage facing down.

the base.
4 Remove the platform. Refer to Repair
Procedure, How to Remove an Aluminum
Platform.
5 Remove the power pack. Refer to Repair
Procedure, How to Change a Power Pack.
6 Tag, disconnect and plug the lift cylinder
hydraulic hoses. Remove the flow control
valve from the cylinder. Cap the cylinder ports
squirt or spray.
7 Remove the level sensor assembly mounting

fasteners.
8 Remove the base lowering cable mounting
fasteners from the side of the mast.
9 Disconnect the control cable tension spring.

June 2023
Mast Components
How to Disassemble the Mast 10 Remove the adjustment nuts from all of the
sequencing cables.
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 12 Slide the column below the carriage toward
skills and tools could result in the top of the mast about 6 inches / 15.2 cm
death or serious injury and to access the idler wheel mounting fasteners.
Dealer service is strongly 13 Hold the idler wheel axle from turning by
recommended. placing a screwdriver in the hole of the axle.
Remove the axle mounting fasteners and
1 Remove the mast. Refer to Repair Procedure, remove the idler wheel assembly.
How to Remove the Mast Assembly.
Be sure to label the location and
2 Remove the cylinder mounting fasteners from orientation of each idler wheel
the barrel end of the cylinder. assembly.
3 Remove the socket head retaining bolt from
14 Remove the adjustment nuts from the chain
the clevis block on the lift cylinder rod end.
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 18 Slide the column out the bottom of the mast.
2 retaining fastener 19 Push the next column toward the top of the
3 clevis block mast to access the idler wheel assembly
mounting fasteners.
4 Support the cylinder and carefully slide it out
of the bottom of the mast. 20 Hold the idler wheel axle from turning by
placing a screwdriver in the hole of the axle.
5 Carefully rotate the mast until the carriage is Remove the axle mounting fasteners, and
facing up. remove the idler wheel assembly.
6 Remove the mast covers. 21 Remove the adjustment nuts from the chain
7 Remove the cover from the platform control tension rocker on the column.
box. Remove the control box mounting 22 Slide the column out the bottom of the mast.
fasteners.
23 Repeat steps 19 through 22 for each
8 Remove the control box and control cable and remaining column.
set them aside.
Note: If the chains are removed, mark the location
9 IWPS models: Remove the base lowering and label each chain before removal.
cable bracket from the mast.

June 2023
Mast Components
How to Assemble the Mast 12 Follow steps 4 through 11 for each remaining
column and the carriage.
13 After all the columns are assembled, the idler
wheel assemblies can be installed.
suitable workshop. Attempting 14 Remove the tension from the lifting chains on
this procedure without these the number 2 column by pushing the number
skills and tools could result in 3 column towards the top of the mast.
15 Install the idler wheel assembly into the top of
the number 2 column. Securely tighten the
mounting fasteners. Do not over tighten.
recommended.
Note: Confirm that all idler wheels rotate with no
1 Thoroughly clean all columns. excessive side movement. Confirm that they do
not rub on the inside of the column. Replace worn
2 Secure the number 1 column to the saw
spacers if necessary. Refer to Maintenance
horses and lay the chains out on the floor at
Procedure, Inspect the Mast Assembly for Wear.
the top. Do not allow the chains to become
twisted or dirty.
Specification
3 Apply a generous amount of Boe-lube wax Side movement, Maximum 0.079 inch
(Genie part number 90337) to the inside and 2 cm
outside channels of each column.
16 Repeat steps 14 and 15 for each remaining
4 Slide the number 2 column into the number idler wheel assembly.
1 column.
17 Confirm that all of the idler wheel axle
5 Lay the number 2 column chains on the floor. mounting fasteners are flush with the column.
Do not allow the chains to become twisted or
dirty. Component damage hazard.
The roller wheels may be
6 Lay the number 1 column chains inside the damaged if the idler wheel axle
number 2 column. mounting fasteners are not flush
7 Slide the number 3 column into the number with the column.
2 column.
18 Install the mast assembly on the base.
8 When the number 3 column is almost all the
way in, guide the number 1 column chains 19 Adjust the lifting chains. Refer to Repair
into the chain tension rocker on the number Procedure, How to Adjust the Lifting Chains.
3 column. Note: IWPS Models: Adjust the base release
9 Install the adjustment nuts on the number cable. Refer to Repair Procedure, How to Adjust
1 column chains. Tighten the adjustment nuts the Base Release Cable.
until the lifting chains have equal tension and
the chain tension rocker is centered in the
inspection hole in the column.
10 Lay the number 3 column chains on the floor.
Do not allow the chains to become twisted or
dirty.
11 Lay the number 2 column chains inside the
number 3 column.

June 2023
Mast Components
5-3 5-4
Glide Pads Lifting Chains
How to Adjust the Glide Pads How to Adjust the Lifting Chains
1 Fully lower the platform. 1 Fully lower the machine and check if all the
columns are adjusted correctly.
Result: The top of each column is
3 Locate the upper and lower glide pad
approximately 3/8 inch / 1.0cm higher than
adjustment bolts below each upper roller bolt
the previous column. The columns are
on both sides of each column.
adjusted properly.
4 Hold the glide pad bolt and loosen the lock
Result: Any column is more than 3/8 inch /
nut on all the glide pads.
1.0cm higher than the previous column. The
5 Turn all the glide pad adjustment bolt columns must be adjusted.
clockwise until the glide pad makes contact
Note: The two columns closest to the base are not
with the column. Adjust the slide pads on both
adjustable and should be approximately even
sides of all column mast. Be sure the sides of
across the top.
the columns are even to within 1/8 inch /
3.17 mm of each other. To adjust column chains:
6 Starting at the number 1 column, torque the 2 Mark the column to be adjusted.
upper and lower glide pad bolts to 12 in-lbs /
1.35 Nm. Hold the glide pad adjustment bolt 3 Raise the platform 6 feet / 2 m.
and tighten the lock nut. Be sure the glide pad 4 Turn the adjustment lock nuts evenly on both
bolt does not turn. chain terminals clockwise to raise the column
7 Repeat step 5 for each remaining upper and or counterclockwise to lower the column.
lower glide pad on both sides of the mast. 5 Fully lower the machine and confirm the
Start at the number 1 column and work alignment of the columns. Adjust if necessary.
toward the carriage.
6 Confirm that the chain terminals on each
8 Repeat step 5 for all of the upper and lower column have equal tension and the lock nuts
glide pads. are tight.
Note: Make sure glide pad bolts are adjusted
evenly on each side to maintain squareness of the
columns.

June 2023
Mast Components
How to Inspect the Lifting Chains

Inspection Procedure Inspection Failure Inspection Remedy
Wear Count out 16 chain links and When the length of the Replace both chains on that
measure pin to pin 16 links (pin to pin) measure column. Replace entire
centerline dimension with a more than 8.25 inches / chain. Do not repair just the
steel measuring tape. 21 cm for 1/2 inch / 12.7mm affected portion of the chain.
chain or 10.31 inches /
26.1 cm for 5/8 inch /
15.9 mm chain.
Note: Measure a section of
chain that moves over the
idler wheels.
Rust and Corrosion Visually inspect the chains Evidence of rust or Remove chain and inspect
for rust and corrosion. corrosion. for cracked plates (see
inspection of cracked
plates). If no cracks are
found, lubricate chain with
motor oil (SAE 40) and
install chain.
Visually inspect the chains When external surfaces are Lubricate chain with motor
for lubrication. not protected with a layer of oil (SAE 40W).
oil.
Tight Joints Inspect chain link joints for Joints that do not flex freely If rust and corrosion is
easy movement. or are binding. 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.

June 2023
Mast Components
Inspection Procedure Inspection Failure Inspection Remedy
Raised or Turned Pins Visually inspect for raised Raised pins. Replace both chains on that
pins. column section. Do not
repair just the affected
portion of the chain.
Visually inspect for turned Misalignment of flats on all Replace both chains on that
pins by insuring all the flats "V" heads. column section. Do not
on the "V" heads are repair just the affected
aligned. portion of the chain.
Chain Side Visually inspect for wear Wear on pin heads or Replace both chains on that
patterns on heads of link noticeable wear in the column section. Do not
pins and outside link plates profile of the outside link repair just the affected
where they contact the idler plate. portion of the chain.
wheel.
Check alignment of chain
anchors and idler wheels.
link plate wear

Chain Anchors Visually inspect chain Broken chain anchor Replace chain anchor.
anchors. fingers.
Bent or damaged anchor. Replace chain anchor.
Twisted or misaligned chain Re-align chain anchor to
anchor. ensure even loading of
chain.
Threaded rod not visible in Replace chain anchor and
chain anchors threaded rod inspection hole. threaded rod.
Idler Wheels Visually inspect chain idler Idler wheels have badly Replace idler wheel and
wheels. worn flanges. check chain alignment.
Idler wheels have grooves Replace idler wheel.
worn into chain contact
surface.
idler wheel
Cracked Link Plates Visually inspect chain link Cracks in any chain link Replace both chains on that
plates for cracks. plate. column section. Replace
entire chain. Do not repair
just the affected portion of
the chain.

June 2023
Tilt-back Frame, AWP-36S and 40S Models

3 Slide the pivot slider and the stop bracket out
6-1 of the frame and add shims as necessary to
Tilt-back Frame obtain zero clearance and zero drag.
How to Remove the Tilt-back

frame
3 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

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.
1 shock absorber assembly

2 tilt-back frame
3 shock absorber mounting bolt
4 loading pivot bar
5 loading stop bracket

June 2023
Tilt-back Frame, AWP-36S and 40S Models
How to Disassemble the Shock

Absorber
3 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 fastener 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 Pull the shock absorber out of the upper tube.
7 Remove the metric nut from each end of the
shock absorber and remove the mounting
blocks.
Bodily injury hazard. Contents of
the shock absorber are under
pressure. Use care during
removal.
1 shock absorber
2 lower shock mounting block
3 lower tube
4 upper tube
5 upper shock mounting block

June 2023
Platform
7-1 How to Install a Fiberglass

Platforms Platform
1 Remove the aluminum platform. Refer to
How to Remove an Aluminum Repair Procedure, How to Remove an
Aluminum Platform.
Platform
2 Support the platform with a lifting device,
1 Place support blocks between the platform place the platform against the mounting
and base. Lower the platform onto the block. angles.
Crushing hazard. Keep away 3 Install the mounting fastener.
from the lowering platform.
Bodily injury hazard. Safety
2 Remove the mounting fasteners from the decals are essential to safe
platform. machine operation. Failure to
replace all safety and instructional
3 Pull the platform away from the mast and decals could result in death or
remove it from the machine. serious injury. If a platform must
be replaced, be sure that all
Bodily injury hazard. Safety
appropriate safety and
decals are essential to safe
instructional decals are applied to
machine operation. Failure to
the new platform.
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.

June 2023
Platform
7-2 How to Test Power to Platform

Platform Control Box GFCI Outlet
How to Test the Contacts 2 Turn the key switch off and remove the key.
1 Fully lower the platform. 3 AC and DC models: Be sure the AC power
2 Turn the key switch off and disconnect the supply is properly connected.
power supply. 4 Connect a volt meter or a small electric
3 Remove the platform control box cover powered tool to the platform GFCI receptacle.
fasteners and open the control box. 5 Confirm the voltage or test the electric
4 Note the markings on the contact to be tested. powered tools operation.
N.O. designates the contact as normally Result: The voltage should be 115V AC
open. nominal or the electric powered tool should
N.C. designates the contact as normally operate normally.
closed.
6 Push the black TEST button on the GFCI
5 Connect a continuity tester to the exposed receptacle.
screw terminal.
Result: The voltage should be 0V or the
Result: Normally open contacts should read electric powered tool should not operate.
no continuity. Normally closed contacts
should read continuity. 7 Push the red RESET button on the GFCI
receptacle.
6 Push the small triangular button on the top of
the contactor. Result: The voltage should be 115V AC
nominal or the hand tool should operate
Result: Normally open contactor should read normally.
continuity. Normally closed contacts should
read no continuity.

June 2023
Platform
7-3 How to replace the Outreach

Platform Outreach Chain Chain, IWP-20S Models
How to Adjust the Platform 2 Turn the key switch off and remove the key.
Outreach Chain, IWP-20S Models 3 Pull the base lowering handle to fully lower
1 Fully lower the platform. the base.
2 Turn the key switch off and remove the key. 4 Remove the platform.. Refer to Repair
Procedure, How to Remove an Aluminum
3 Fully extend the platform outreach. Lock the Platform.
handle in position.
5 Remove the platform control box cover
4 Place a block of wood between the carriage fasteners and open the control box.
and the platform outreach to prevent the
outreach from collapsing when the fasteners 6 Remove the platform control box mounting
are loosened. fasteners. Remove the platform control box
and set it aside.
Crushing hazard. The platform
outreach will collapse if it is not 7 Extend the outreach approximately 14 inches
properly supported when the /36 cm. Lock the handle in position.
fasteners are loosened. 8 Attach an overhead crane to the center brace
pivot pin on the outreach assembly.
5 Locate the lower sprocket housing fasteners.
9 Remove the assembly mounting fastener.
6 Loosen but do not remove both sprocket
housing fasteners. Crushing hazard. When the
mounting fasteners are removed,
7 Push downward on the sprocket housing to the platform outreach will become
remove excess slack from the chain. unbalanced and may fall if it is not
8 Tighten the sprocket housing fasteners. properly supported.
9 Confirm proper chain adjustment. Refer to 10 Lay the outreach assembly onto a workbench
Maintenance Procedure, Check the Chain or table of ample capacity. Be sure the chain
Adjustment. is facing up.
11 Place a block of wood under the inner frame
assembly for support while removing the
chain.
Crushing hazard. The platform
outreach will collapse if it is not
properly supported when the
chain is removed.

June 2023
Platform
12 Remove the lower sprocket housing mounting 24 Thread the chain through the upper sprocket
fasteners. Do not allow the chain to become housing over the sprocket, then back through
twisted. the housing.
13 Remove the upper sprocket housing mounting 25 Thread the chain through the lower sprocket
fasteners. Do not allow the chain to become housing over the sprocket, then back through
twisted. the housing. Don't allow the chain to become
twisted.
14 Remove the fasteners from the outreach
locking bracket. 26 Do not re-use the old master link. Install a
new master link.
15 Slide the platform mount off the inner frame
extension arms and set it aside. 27 Slide the platform mount onto the extension
arms.
16 Locate the two allen head screws in the
platform mount slide pad. 28 Install the outreach locking bracket on the
platform mount.
17 Remove the roller from the same side of the
slide pad. 29 Install the upper sprocket housing to the
platform mount.
18 Remove the two allen head screws.
Note: When fasteners are installed, be sure the
19 Remove the master link from the chain.
center bolt is in between the two chains inside the
20 Pull the chain out of the slide pad and both housing.
sprocket housings.
30 Pull the slack out of the chain by pushing
21 Install the new chain through the slidepad. down on the lower sprocket housing.
22 Push the chain through the slide pad until 31 Install the lower sprocket housing fasteners.
approximately 2 inches / 5 cm of the chain is
extended past the slide pad. 32 Adjust the chain. Refer to Repair Procedure,
How to Adjust the Platform Outreach Chain.
23 Install the two allen head screws. Install the
roller wheel. 33 Install the outreach assembly onto the
carriage.

June 2023
Schematics
About This Section

Section 5 Schem atics
There are two groups of schematics in this section.
Electrical Schematics
Observe and Obey: Contact with electrically charged
 Troubleshooting and repair procedures shall circuits could result in death or
be completed by a person trained and serious injury. Remove all rings,
qualified on the repair of this machine watches and other jewelry.
 Immediately tag and remove from service a

damaged or malfunctioning machine. Hydraulic Schematics
 Repair any machine damage or malfunction Bodily injury hazard. Spraying
before operating the machine. hydraulic oil can penetrate and
Before Troubleshooting: connections very slowly to allow
 Read, understand and obey the safety rules
and operating instructions in the appropriate
squirt or spray.
operator's manual on your machine.
 Be sure that all necessary tools and test
equipment are available and ready for use.

June 2023
Electrical Component and Wire Color Legends
Item Description Item Description

B Battery L Led or light cont.
B2 12V DC L15 Outrigger – rear right (ground)
B4 8 AA batteries L66 Level sensor interlock (IWP)
CB Circuit Breaker L67 Footpad interlock (IWP)
CB4 15 AMP – 120V AC / 8 AMP – 240V AC M5 Hydraulic power unit
CB9 6 AMP – 120V AC / 3 AMP – 240V AC N.C. Normally closed
CR96 Power wheel (IWP) N.O Normally open
D5 Power supply AC *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
EN4 Power to platform GFCI receptacle replace BL and OR wires
EN5 Power unit – 110V AC *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 =
3A) For 120V operation jumper brown to
F11 175 Amp
black and blue to white as shown with
FB2 Warning light dashed lines (CB4 = 15A, CB9 = 6A)
GND Ground *N29 (N) Denotes a neutral wire to be tagged with
an (N) sleeve
H4 Descent alarm
*N30 110V AC / 220V AC terminal strip detail
KS1 Key switch ground/platform
P Power switch
LS1 Limit switch - platform extension (IWP
option) P1 Emergency Stop button at ground controls
L Led or light P2 Emergency Stop button at platform controls
L5 Power indicator (ground) P3 Emergency Stop button at steer handle
controls (IWP)
L6 Low battery indicator for auxiliary (ground)
PR Power relay
L7 Low battery indicator – main (ground)
PR4 Function pump (M5)
L12 Outrigger – front left (ground)
L13 Outrigger – front right (ground)
L14 Outrigger – rear left (ground)

June 2023
Electrical Component and Wire Color Legends
Item Description Color Description

QD Quick disconnect BK Black
QD1 Battery quick disconnect BK/RD Black/Red
QD3 Control cable – to platform control box BL Blue
QD4 Control cable – to base BL/BK Blue/Black
QD7 Control cable – to motor BL/OR Blue/Orange
S7 Tilt sensor BL/WH Blue/White
SW Switch BR Brown
SW 8 Control activate GN Green
SW11 Platform up/down GN/BK Green/Black
SW12 Auxiliary down GN/WH Green/White
SW13 Outrigger interlock – front left (AWP) GR/YL Green/Yellow
SW14 Outrigger interlock – front right (AWP) LB Light Blue
SW15 Outrigger interlock – rear left (AWP) OR Orange
SW16 Outrigger interlock – rear right (AWP) OR/BK Orange/Black
SW17 Foot pad, left side (IWP) OR/RD Orange/Red
SW18 Foot pad, right side (IWP) OR/WH Orange/White
SW21 Power assist, Direction – reversing safety RD Red
switch (IWP) RD/BK Red/Black
SW22 Power assist, Forward/Reverse switch (IWP) RD/WH Red/White
SW24 Power assist, Lift enable (IWP) WH White
U Electronic component WH/BK White/Black
U9 Transformer YL Yellow
U10 PC board
U12 Thermal device
W Wiring component
W3 Terminal strip – 3 pole 3 pin (U10)
W4 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)
Y7 Platform down
Y30 Normally open dump valve
Y32 Function solenoid (IWP)

June 2023
Electrical Symbol Legend
Wire with description or color Limit switch Toggle Switch Switch
Emergency Stop
Circuits crossing no connection Fuse Circuit breaker
button
Diode LED Motor U12 Thermal Device
Circuit connection Connector 8 AA Batteries 12V Battery (s)
Lift Enable Solenoid Valve Solenoid valve with diode

June 2023
Hydraulic Symbols Legend
Filter Orifice with size Check valve Pressure Gauge
Check Valve, pilot Pump prime mover, Fixed displacement pump Wheel motor, fixed displacement
operated electric motor
Cylinder, single acting Cylinder, double acting Relief valve Adjustable relief valve
Foot pump valve Priority flow regulator Differential sensing valve Solenoid operated dump valve
Solenoid operated Solenoid valve, 2 position Solenoid operated Button operated 2 position 2 way
2 position 2 way valve, 2 way valve (normally 2 position 2 way directional directional valve
normally open closed) valve
June 2023

(from SN 3896-101 to 3896-300)
101
June 2023

(from SN 3896-101 to 3896-300)
June 2023

(from SN 3896-301 to 3896-430)
June 2023

(from SN 3896-301 to 3896-430)
104
June 2023

(from SN 3896-431 to AWP07-54898)
105
June 2023

(from SN 3896-431 to AWP07-54898)
June 2023

RD/BLK FRONT RIGHT

WH RD INTERLOCK
RD
FRONT LEFT
WH
KS1 INTERLOCK
PLATFORM RD RD
RD/BLK
MODE
BK REAR RIGHT
KEY 3 RD
OR RD INTERLOCK
SWITCH 4 BK REAR LEFT
BK BL RD INTERLOCK
BK
B1
P2 B 2
BK BK BK SW15
WH
EMERGENCY 1 BK SW16
EN1 W3
STOP RD 16.0V DC INPUT 1
BN
BASE 1 2 3
WH RD
MODE
12V DC POWER INPUT CENTER TAP INPUT 2 BK SW13
PLATFORM SW14
+
N.C. NEGATIVE 12V DC AUX. INPUT 16.0V DC INPUT 3
WH BK
POSITIVE 12V DC AUX. INPUT LED 13 FRONT RIGHT
P1 4
CONTROL LEVELING OR
RD
LEVELING
EMERGENCY INDICATORS INDICATOR
LED 15 REAR RIGHT 5
W6
BOX
STOP LED 14 REAR LEFT BL N.C.
L6
6
RD RD
INPUTS
LED 12 FRONT LEFT 7
RD
TERMINAL
STRIP Y7 PLATFORM
DOWN
LOW BATTERY
BK
SW8 BK L13 L15 INDICATOR FOR
AUXILIARY LOWERING
12V DC OUTPUT 8
RD/BLK
YL
CONTROL BK BK 12V DC OUTPUT 9
GN/YL
ACTIVATE N.C. B4 L7 12V DC OUTPUT 9A
WHT
BK WH 8 AA
BATTERIES L12 L14 DC MODEL:
LOW BATTERY
GROUND 10
RD
UP SIGNAL OUTPUT 11
L5
INDICATOR
UP SIGNAL OUTPUT (DELAYED) 12 STANDARD
SW11
U10 BASE
OR
UP POWER INDICATOR UP SIGNAL INPUT 13
PLATFORM BK
UP/DOWN
DOWN
SW12 PC BOARD W4
AUXILIARY
DOWN
N.O.
*N17 BN BN
NARROW PLATFORM UNITS

WH
BK
WH AND BK WIRES REPLACE BK

BL(2) AND OR(3) WIRES.
OR
RD
WH
BL
WH
GND
GROUND
RD
STUD
EN4 GND GN/YL
POWER TO GROUND QD4
EN2
PLATFORM STUD
WH
RD
BK
GFCI BK 7 7 BK
RECEPTACLE RD 6 6 RD
W5 GROUND BN 5 5 YL
TERMINAL WH 4 4 GN/YL
*N27
STRIP
CONTROL OR 3 3 OR
BK
WH
GN/YL
2
BOX
BL 2 BL
WH
WH
RD
OR
BK
UNITS WITHOUT PLUG
WH AND BK WIRES WH 1 1 WH
REPLACE BL(1) AND BN(7) WIRES.
GROUND
STUD
GN/YL
BN
BL
GN/YL
GN/YL
WH
RD
BK
OR
RD
BN
BL
STRAIN RELIEF STRAIN RELIEF

TO PLUG TO MOTOR
QD3 1 2 3 4 5 6 7
D5 WH
1 2 3 4 5 6 7 POWER
SUPPLY
AC GN/YL
GN/YL
RD
OR
BL
BK
H4
DESCENT
ALARM
OR
POWER UNIT
RD
WH
BK
FB2 RD
MOTOR
WARNING RD CONTACTOR
BK
LIGHT
BATTERY
OPTIONAL
B2 12V DC
WARNING LIGHT RD + QD1 M5
AND
DESCENT ALARM U9 + RD RD
MOTOR WH
BATTERY
CHARGER BK BK
F11 Y30 ES0070H
175 AMP FUSE N.O.
BK DUMP
VALVE
AC
INPUT
June 2023

108
June 2023

109
June 2023

RD/BLK FRONT LEFT

RD WH RD INTERLOCK
FRONT RIGHT
WH
KS1
PLATFORM OR RD INTERLOCK
RD/BLK
MODE
3 RD BK REAR RIGHT
KEY BL RD INTERLOCK
BK RD RD INTERLOCK
BK
B1
P2 B 2
BK BK BK SW15
WH
EMERGENCY 1 BK SW16
EN1 W3
BN
BASE 1 2 3
WH RD
MODE
PLATFORM SW13
+
POSITIVE 12V DC AUX. INPUT WH BK
P1 LED 12 FRONT LEFT 4
CONTROL OR
RD
LEVELING LEVELING LED 13 FRONT RIGHT 5
EMERGENCY INDICATORS INDICATOR BL W6
BOX
STOP N.C.
L6 INPUTS LED 15 REAR RIGHT 6
RD RD LOW BATTERY LED 14 REAR LEFT 7

RD
TERMINAL
STRIP Y7 PLATFORM
DOWN
BK
AUXILIARY LOWERING
12V DC OUTPUT 8
RD/BLK
YL
GN/YL
WHT
BK WH 8 AA
LOW BATTERY
GROUND 10
RD
UP SIGNAL OUTPUT 11
L5
INDICATOR
UP SIGNAL OUTPUT (DELAYED) 12 NARROW
SW11
U10 BASE
OR
PLATFORM BK
UP/DOWN
DOWN
SW12 PC BOARD W4
AUXILIARY
DOWN
N.O.
*N17 BN BN

WH
BK

GND
OR
RD
WH
BL
WH
GROUND
STUD
RD
EN4 GND GN/YL

POWER TO GROUND QD4
STUD
EN2
PLATFORM
WH
RD
BK
GFCI BK 7 7 BK
W5 GROUND BN 5 5 YL
*N27
STRIP
CONTROL OR 3 3 OR
BK
WH
GN/YL
2 2
BOX
BL BL
WH
WH
RD
BK
UNITS WITHOUT PLUG
OR
GROUND
STUD
GN/YL
BN
BL
GN/YL
WH
GN/YL
RD
BK
OR
RD
BN
BL

TO PLUG TO MOTOR
QD3 1 2 3 4 5 6 7
D5 WH
1 2 3 4 5 6 7 POWER
SUPPLY
AC GN/YL
H4
GN/YL
RD
OR
BL
BK
DESCENT
ALARM
OR
POWER UNIT
RD
WH
BK
FB2 RD MOTOR
CONTACTOR
WARNING RD
BK
LIGHT
BATTERY
OPTIONAL
B2 12V DC
AND
MOTOR WH
BATTERY
CHARGER BK BK
F11 Y30
BK
175 AMP FUSE N.O.
DUMP ES0070H
VALVE
AC
INPUT
June 2023

(from SN 3896-432 to AWP07-54898)
June 2023

(from SN 3896-432 to AWP07-54898)
112
June 2023

113
June 2023

RD/ BLK FRONT RIGHT

WH RD INTERLOCK
RD
FRONT LEFT
WH
KS1 INTERLOCK
PLATFORM RD RD
RD/BLK
MODE
BK REAR RIGHT
KEY 3 RD
OR RD INTERLOCK
BK BL RD INTERLOCK
BK
B1
P2 B 2
BK BK BK SW15
WH
EMERGENCY 1 BK SW16
EN1 W3
BN
BASE 1 2 3
WH RD
MODE
PLATFORM SW14
+
WH BK
POSITIVE 12V DC AUX. INPUT LED 13 FRONT RIGHT
P1 4
CONTROL OR
RD
LEVELING LEVELING
EMERGENCY INDICATORS INDICATOR
LED 15 REAR RIGHT 5
BL W6
BOX
STOP N.C.
L6 INPUTS LED 14 REAR LEFT 6
RD RD LED 12 FRONT LEFT 7

RD
TERMINAL
STRIP Y7 PLATFORM
DOWN
LOW BATTERY
BK
AUXILIARY LOWERING
12V DC OUTPUT 8
RD/BLK
YL
GN/ YL
WHT
BK WH 8 AA
LOW BATTERY
GROUND 10
RD
UP SIGNAL OUTPUT 11
L5
INDICATOR
UP SIGNAL OUTPUT (DELAYED ) 12 STANDARD
SW11
U10 BASE
OR
PLATFORM BK
UP/DOWN DOWN
SW12 PC BOARD W4
AUXILIARY
DOWN
N.O.
*N17 BN BN

WH
BK

OR
RD
WH
BL
WH
GND
GROUND
RD
STUD
EN4 GND GN/YL
POWER TO GROUND QD4
EN2
PLATFORM STUD
WH
RD
BK
GFCI BK 7 7 BK
W5 GROUND BN 5 5 YL
TERMINAL WH 4 4 GN/ YL
*N27
STRIP
CONTROL OR 3 3 OR
BK
WH
GN/YL
BOX
BL 2 2 BL
WH
WH
RD
OR
BK
UNITS WITHOUT PLUG
GROUND
GN/YL
STUD
BN
BL
GN/YL
GN/YL
WH
RD
BK
OR
RD
BN
BL

TO PLUG TO MOTOR
QD3 1 2 3 4 5 6 7
D5 WH
1 2 3 4 5 6 7 POWER
SUPPLY
AC GN/ YL
GN/YL
RD
OR
BL
BK
H4
DESCENT
ALARM
OR
POWER UNIT
RD
WH
BK
FB2 RD
MOTOR
WARNING RD CONTACTOR
BK
LIGHT
BATTERY
OPTIONAL
B2 12V DC
ES0070H
AND
MOTOR WH
BATTERY
CHARGER BK BK
F11 Y30
175 AMP FUSE N.O.
BK DUMP
VALVE
AC
INPUT
June 2023

RD/BLK FRONT LEFT

RD WH RD INTERLOCK
FRONT RIGHT
WH
KS1
PLATFORM OR RD INTERLOCK
RD/BLK
MODE
3 RD BK REAR RIGHT
KEY BL RD INTERLOCK
BK RD RD INTERLOCK
BK
B1
P2 B 2
BK BK BK SW15
WH
EMERGENCY 1 BK SW16
EN1 W3
BN
BASE 1 2 3
WH RD
MODE
PLATFORM SW13
+
POSITIVE 12V DC AUX. INPUT WH BK
CONTROL LEVELING OR
RD
LEVELING LED 13 FRONT RIGHT 5
EMERGENCY INDICATORS INDICATOR BL W6
BOX
STOP LED 15 REAR RIGHT 6 N.C.
RD
L6 INPUTS
LED 14 REAR LEFT 7
RD
TERMINAL
STRIP Y7 PLATFORM
RD LOW BATTERY DOWN
BK
AUXILIARY LOWERING
12V DC OUTPUT 8
RD/BLK
YL
GN/YL
WHT
BK WH 8 AA
LOW BATTERY
GROUND 10
RD
UP SIGNAL OUTPUT 11
L5
INDICATOR
UP SIGNAL OUTPUT (DELAYED) 12 NARROW
SW11
U10 BASE
OR
PLATFORM BK
UP /DOWN DOWN
SW12 PC BOARD W4
AUXILIARY
DOWN
N.O.
*N17 BN BN

WH
BK

GND
OR
RD
WH
BL
WH
GROUND
STUD
RD
EN4 GND GN/YL

POWER TO GROUND QD4
STUD
EN2
PLATFORM
WH
RD
BK
GFCI BK 7 7 BK
W5 GROUND BN 5 5 YL
*N27
STRIP
CONTROL OR 3 3 OR
BK
WH
GN/YL
BOX
BL 2 2 BL
WH
WH
RD
BK
OR
UNITS WITHOUT PLUG
GROUND
GN/YL
STUD
BN
BL
GN/YL
WH
GN/YL
RD
BK
OR
RD
BN
BL

TO PLUG TO MOTOR
QD3 1 2 3 4 5 6 7
D5 WH
1 2 3 4 5 6 7 POWER
SUPPLY
AC GN/YL
H4
GN/ YL
RD
OR
BL
BK
DESCENT
ALARM
OR
POWER UNIT
RD
WH
BK
FB2 RD MOTOR
CONTACTOR
WARNING RD
BK
LIGHT
BATTERY
OPTIONAL
B2 12V DC
AND
U9 + MOTOR WH
DESCENT ALARM RD RD
ES0070H
BATTERY
CHARGER BK BK
F11 Y30
175 AMP FUSE N.O.
BK DUMP
VALVE
AC
INPUT
June 2023

116
June 2023

(from 3896-431)
117
June 2023

(from SN 3896-431)
June 2023

(from SN 3896-103 to 3896-303)
June 2023

(from SN 3896-103 to 3896-303)
120
June 2023

(from SN 3896-304 to 3896-450)
121
June 2023

(from SN 3896-304 to 3896-450)
June 2023

(from SN 3896-451 to AWP07-54898)
June 2023

(from SN 3896-451 to AWP07-54898)
124
June 2023

(from SN AWP07-54899 to AWP07-57594)
125
June 2023

(from SN AWP07-54899 to AWP07-57594)
June 2023

(from SN AWP07-54899 to AWP07-57594)
June 2023

(from SN AWP07-54899 to AWP07-57594)
128
June 2023

129
June 2023

June 2023

June 2023

132
June 2023

(from SN 3896-451 to AWP07-54898)
133
June 2023

(from SN 3896-451 to AWP07-54898)
June 2023

(from SN AWP07-54899 to AWP07-57594)
June 2023

(from SN AWP07-54899 to AWP07-57594)
136
June 2023

(from SN AWP07-54899 to AWP07-57594)
137
June 2023

(from SN AWP07-54899 to AWP07-57594)
RD/BLK
RD
WH
KS1
PLATFORM
RD/BLK
MODE
KEY
SWITCH
3 RD
4 BK EN2 FOR 240 V OPERATION
GROUND CONTROL BOX

JUMPER BROWN TO WHITE
BK
U9
BK
B1 BK THROUGH TERMINAL STRIP FRONT LEFT
P2 B 2
WH
TRANSFORMER YL
AND LEAVE BLACK UNCONNECTED
AS SHOWN
WH RD INTERLOCK
FRONT RIGHT
EMERGENCY 1 RD BK
OR RD INTERLOCK
EN1 W3
STOP BK 16.0V DC INPUT 1
BN
BASE 1 2 3 BN REAR RIGHT
MODE RD/YL BL
WH RD 12V DC POWER INPUT CENTER TAP INPUT 2 BL RD INTERLOCK
RD REAR LEFT
PLATFORM N.C. NEGATIVE 12V DC AUX. INPUT 16.0V DC INPUT 3 WH
POSITIVE 12V DC AUX. INPUT WH RD RD INTERLOCK
SW15
CONTROL LEVELING OR BK BK
RD
EMERGENCY LEVELING LED 15 FRONT RIGHT 5
INDICATORS INDICATOR BL SW16
BOX
STOP
+
LED 14 REAR RIGHT 6
L6 INPUTS
RD
BK
RD RD RD
B4 LOW BATTERY LED 12 REAR LEFT 7
BK BK SW14
SW8 8 AA L13 L14AUXILIARY
INDICATOR FOR
LOWERING
12V DC OUTPUT 8
RD/BLK BK SW13
CONTROL BK YL BATTERIES 12V DC OUTPUT 9
ACTIVATE N.C.
L7 12V DC OUTPUT 9A
WHT W6
BK WH
L15 L16 DC MODEL: GROUND 10 N.C.
LOW BATTERY
INDICATOR
UP SIGNAL OUTPUT 11
OR TERMINAL
STRIP Y7 PLATFORM
DOWN
BK
UP SIGNAL OUTPUT (DELAYED) 12
SW11 L5
U10
OR YL
PLATFORM BK GN/YL
UP/DOWN DOWN
SW12 RD RD
PC BOARD W4
AUXILIARY
DOWN
N.O. NARROW
*N17 BN BN
NARROW PLATFORM UNITS OR

BASE
WH
BK
WH AND BK WIRES REPLACE

WH
WH
OR
GND WH
OR
RD
BL
GROUND BK PR4
STUD
EN4
15A CIRCUIT BREAKER 8A CIRCUIT BREAKER
CB4 110V AC MODELS 220V AC MODELS
QD4
POWER TO
PLATFORM
BK BK 7 7 BK
GFCI
BN 5 5 YL
*N7
WH
WH
WH
WH
WH 4 4 GN/ YL
BK
BK
BL
*N27 110V AC OR 3 3 OR
BK
WH
GN/YL
TERMINAL STRIP
UNITS WITHOUT PLUG W5 DETAIL
BL
WH
2
1
2
1
BL
WH
WH AND BK WIRES TERMINAL
REPLACE BL AND BN WIRES. STRIP
BN WH
GROUND
GN/YL
STUD
GN/YL
WH
BN
WH
BK
BN
BL
BL
GN/YL
GN/YL
WH
RD
BK
OR
RD
BK
BL
STRAIN RELIEF
GROUND
TO PLUG STUD
QD3 1 2 3 4 5 6 7
1 2 3 4 5 6 7
D5 WH
POWER
GND
GN/YL
SUPPLY
WH
GN/YL GROUND
BK
GN/YL
AC
OR
RD
BL
BK
H4 STRAIN RELIEF
STUD
DESCENT
ALARM TO MOTOR
RD
GROUND GROUND
BK
Y30 Y30
BK
SCREW
BK
SCREW
FB2 N.O. N.O.
WARNING
EN5 EN6
GN/YL
DUMP
GN/YL
DUMP
WH
WH
BK
BK
LIGHT
J-BOX VALVE J-BOX VALVE
WH
WH
OPTIONAL
WARNING LIGHT BL 1 M5 BL 1 M5
AND
DESCENT ALARM OR 3 *N8 OR 3 *N10
WH 2 110V AC WH 2 220 V AC
YL 4 MOTOR DETAIL YL 4 MOTOR DETAIL
GND GND
ES0071_F
June 2023

June 2023

140
June 2023

141
June 2023

June 2023

(from SN 3896-461)
June 2023

(from SN 3896-461)
144
June 2023
Electrical Schematic - IWP Super SeriesDC Models

(from SN 4096-101 to 4096-287)
145
June 2023

(from SN 4096-101 to 4096-287)
June 2023

(from SN 4096-288 to 4096-341)
June 2023

(from SN 4096-288 to 4096-341)
148
June 2023

(from SN 4096-342 to IWP07-7065)
149
June 2023

(from SN 4096-342 to IWP07-7065)
June 2023

(from SN IWP07-7066 to IWP15-9621)
June 2023

152
June 2023

(from SN IWP15-9622 to IWPP-12398)
153
June 2023

(from SN IWP15-9622 to IWPP-12398)
RD/BLK
RD
WH
KS1
PLATFORM
RD/BLK
EN2
MODE
3 RD BK
KEY
SWITCH 4 BK
BK
GROUND
BK
B1
P2 B 2
WH
BK
CONTROL
EMERGENCY 1
EN1 STOP RD
W3 16.0V DC INPUT 1
BOX
BR
BASE 1 2 3
MODE
WH RD 12V DC POWER INPUT CENTER TAP INPUT 2
PLATFORM
+
POSITIVE 12V DC AUX. INPUT WH
P1 LED 66 LEVEL INTERLOCK 4
CONTROL LEVELING OR
RD
EMERGENCY LED 66 LEVEL INTERLOCK 5
INDICATORS
BL
BOX
STOP LED 67 FOOTPAD INTERLOCK 6
11 12
L6
RD 10
RD RD LED 67 FOOTPAD INTERLOCK 7
BK
SW8 BK L66 L66 LOW BATTERY
INDICATOR FOR
12V DC OUTPUT 8
RD/BLK
7 8 9
CONTROL BK BK AUXILIARY LOWERING 12V DC OUTPUT 9
ACTIVATE N.C. B4 12V DC OUTPUT 9A 4 5 6
BK WH 8 AA
BATTERIES L67 L67 L7 GROUND 10
WHT
DC MODEL: RD 1 2 3
UP SIGNAL OUTPUT 11
LOW BATTERY
INDICATOR
SW11
U10
OR
UP SIGNAL INPUT 13
PLATFORM BK
UP
L5 P3
UP/DOWN DOWN
SW12 W4 EMERGENCY
AUXILIARY
POWER INDICATOR
PC BOARD STOP
(OPTION)
DOWN
N.O.
*N17 BR BR
WH
Y32
BK

BL AND OR WIRES.
Y5 Y6
OR
RD
BL
WH
WH
GND
GROUND
RD
STUD
EN4 GND GR/YL
POWER TO GROUND
PLATFORM STUD
WH
RD
BK
GFCI
GR/YL 85 86 BK
RECEPTACLE
W5 87A
TERMINAL 30 CR96 J BOX
*N27 STRIP
BK
WH
GR/YL
87 POWER
WH
RD
WH
BK
OR
UNITS WITHOUT PLUG BK WHEEL
WH AND BK WIRES OPTION
Y7
REPLACE BL(1) AND BN(7) WIRES. BK
QD4
GROUND
N.C.
GR/YL
STUD
BK 7 7 BK PLATFORM
BR
BL
DOWN
RD 6 6 RD
GR/YL
GR/YL
BR 5 5 YL
WH
RD
BK
OR
RD
BR
WH 4 4 GR/ YL
BL
STRAIN RELIEF STRAIN RELIEF OR 3 3 OR

TO PLUG TO MOTOR BL 2 2 BL
QD3 1 2 3 4 5 6 7
D5 WH
WH 1 1 WH
1 2 3 4 5 6 7 POWER SW17
SUPPLY
AC GR/YL
GR/YL
BR
OR
RD
H4
BL
DESCENT
SW18
ALARM
OR
POWER UNIT
RD RD
BL WH NC
OR BK
GR/YL
WH
FB2 RD
MOTOR LEVEL
SENSOR
S7
WARNING RD CONTACTOR PCB
TILT
BK BK SENSOR
LIGHT
BATTERY
OPTIONAL
B2 12V DC
AND
U9 + MOTOR WH
DESCENT ALARM RD RD
F11
BATTERY
CHARGER BK BK 175 AMP FUSE Y30
NON U.S. PLUGS N.O.
BK DUMP
VALVE
AC
INPUT ES0072J
June 2023

(from SN IWPP-12399)
RD/BLK
RD
WH
KS1
PLATFORM
RD/BLK
MODE
KEY
SWITCH
3 RD
4 BK
BK
EN2
BK
GROUND
BK
B1
P2 B 2
WH
BK
CONTROL
EMERGENCY 1
EN1 STOP RD
W3 16.0V DC INPUT 1
BOX
BR
BASE 1 2 3
MODE
WH RD 12V DC POWER INPUT CENTER TAP INPUT 2
PLATFORM
+
POSITIVE 12V DC AUX. INPUT WH
P1 LED 66 LEVEL INTERLOCK 4
CONTROL LEVELING OR
RD
EMERGENCY LED 66 LEVEL INTERLOCK 5
INDICATORS
BOX
STOP LED 67 FOOTPAD INTERLOCK BL
6
10 11 12
RD RD L6 LED 67 FOOTPAD INTERLOCK 7
RD
BK
SW8 BK L66 L66 LOW BATTERY
INDICATOR FOR
12V DC OUTPUT 8
RD/BLK
7 8 9
CONTROL BK BK AUXILIARY LOWERING 12V DC OUTPUT 9
ACTIVATE N.C. B4 12V DC OUTPUT 9A 4 5 6
BK WH 8 AA
BATTERIES L67 L67 L7 GROUND 10
WHT
DC MODEL: RD 1 2 3
UP SIGNAL OUTPUT 11
LOW BATTERY
INDICATOR
SW11
U10
OR
UP SIGNAL INPUT 13
PLATFORM BK UP
L5 P3
UP/DOWN
DOWN
SW12 W4 EMERGENCY
AUXILIARY
POWER INDICATOR
PC BOARD STOP
(OPTION)
DOWN
N.O.
*N17 BR BR
WH
Y32
BK

BL AND OR WIRES.
Y5 Y6
OR
RD
BL
WH
WH
GND
GROUND
RD
STUD
EN4 GND GR/YL
POWER TO GROUND
PLATFORM STUD
WH
RD
BK
GFCI 85 86
BK
GR/YL
RECEPTACLE
W5 87A
TERMINAL 30 CR96 J BOX
*N27 STRIP
BK
WH
GR/YL
87 POWER
WH
WH
RD
BK
OR
UNITS WITHOUT PLUG BK WHEEL
WH AND BK WIRES
REPLACE BL(1) AND BN(7) WIRES. BK
OPTION
QD4 Y7
GROUND
N.C.
STUD
GR/YL
BK 7 7 BK PLATFORM
BR
BL
DOWN
RD 6 6 RD
GR/YL
GR/YL
BR 5 5 YL
WH
RD
BK
OR
RD
BR
WH 4 4 GR/ YL
BL
STRAIN RELIEF STRAIN RELIEF OR 3 3 OR

TO PLUG TO MOTOR BL 2 2 BL
QD3 1 2 3 4 5 6 7
D5 WH
WH 1 1 WH
1 2 3 4 5 6 7 POWER SW17
SUPPLY
AC GR/YL
GR/YL
BR
OR
RD
BL
H4 SW18
DESCENT
ALARM
OR
POWER UNIT
RD RD
BL WH NC
OR BK
GR/YL
WH
FB2 RD
MOTOR LEVEL
SENSOR
S7
WARNING RD CONTACTOR PCB
TILT
BK BK SENSOR
LIGHT
BATTERY
OPTIONAL
B2 12V DC
AND
U9 + MOTOR WH
DESCENT ALARM RD RD
F11
BATTERY
CHARGER BK BK 175 AMP FUSE Y30
NON U.S. PLUGS N.O.
BK DUMP
VALVE
AC
INPUT ES0072K
June 2023

(from SN IWPP-12399)
156
June 2023
157
June 2023
June 2023

(Directional Valve Coils Powering Function Manifold)
June 2023

160
June 2023
Electrical Schematic - IWP Super Series DC TUV Models
161
June 2023
Electrical Schematic - IWP Super Series DC TUV Models
June 2023
Electrical Schematic - IWP Super Series DC TUV Models with Outreach
June 2023
Electrical Schematic - IWP Super Series DC TUV Models with Outreach
164
June 2023
165
June 2023
June 2023
Electrical Schematic - IWP Super Series DC TUV Models with Power Assist and Outreach
June 2023
Electrical Schematic - IWP Super Series DC TUV

Models with Power Assist and Outreach
168
June 2023
169
June 2023
June 2023

(from SN 4096-105 to 4096-285)
June 2023

(from SN 4096-105 to 4096-285)
172
June 2023

(from SN 4096-286 to 4096-355)
173
June 2023

(from SN 4096-286 to 4096-355)
June 2023

(from SN 4096-356 to IWP07-7065)
June 2023

(from SN 4096-356 to IWP07-7065)
176
June 2023

177
June 2023

June 2023

(from SN IWP07-57595)
June 2023

(from SN IWP07-57595)
180
June 2023

(With Base Mounted Junction Box)
181
June 2023

(With Base Mounted Junction Box)
June 2023

(Without Base Mounted Junction Box)
June 2023

(Without Base Mounted Junction Box)
184
June 2023
Electrical Schematic - IWP Super Series AC TUV Models with Outreach
185
June 2023
Electrical Schematic - IWP Super Series AC TUV Models with Outreach
June 2023
Hydraulic Schematic - AWP Super Series Models
CYLINDER ASSEMBLY
D
Y7
F
TANK PRESSURE
TANK PRESSURE
A Y30
M5 M 1600 psi
110 bar
HS0004C
POWER UNIT ASSEMBLY
June 2023
Hydraulic Schematic - AWP Super Series Models
188
June 2023
Hydraulic/Pneumatic Schematic - AWP Super Series Models
189
June 2023
Hydraulic/Pneumatic Schematic - AWP Super Series Models
June 2023
Hydraulic Schematic - IWP Super Series Models without Power Assist
June 2023
Hydraulic Schematic - IWP Super Series Models without Power Assist
192
June 2023
Hydraulic Schematic - IWP Super Series Models with Power Assist
193
June 2023
Hydraulic Schematic - IWP Super Series Models with Power Assist
June 2023
Hydraulic Schematic - IWP Super Series Models with Power Assist and Brake
June 2023
Hydraulic Schematic - IWP Super Series Models with Power Assist and Brake
AWP® Super Series • IW P® Super Series Part No. 38139GT June 2023
196

AWP Super Series IWP Super Series: Serial Number Range

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AWP Super Series IWP Super Series: Serial Number Range

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Serial Number Range

AWP® Super Series from 3869-101

IWP® Super Series from 4096-101

Part No. 38139GT

Important Technical Publications

Basic mechanical, hydraulic and electrical skills

ii AWP® Super Series • IWP® Super Series Part No. 38139GT

Revision History (continued)

iv AWP® Super Series • IWP® Super Series Part No. 38139GT

Serial Number Legend

1 Model 4 Sequence number

1 Model 4 Serial number (stamped on chassis)

Part No. 38139GT AWP® Super Series • IWP® Super Series v

Do Not Perform Maintenance

vi AWP® Super Series • IWP® Super Series Part No. 38139GT

Personal Safety Workplace Safety

Be aware of potential crushing hazards

Introduction Introduction ........................................................................................................... ii

Section 1 Safety Rules .........................................................................................................vi

Section 2 Specifications ....................................................................................................... 1

Section 3 Scheduled Maintenance Procedures ............................................................... 11

Checklist A Procedures ..................................................................................... 19

Part No. 38139GT AWP® Super Series • IWP® Super Series ix

Checklist B Procedures .....................................................................................31

Checklist C Procedures .....................................................................................41

x AWP® Super Series • IWP® Super Series Part No. 38139GT

Section 4 Repair Procedures ............................................................................................. 47

Base Assembly ................................................................................................... 49

Ground Controls ................................................................................................. 59

Hydraulic Power Unit ......................................................................................... 61

Part No. 38139GT AWP® Super Series • IWP® Super Series xi

Mast Components ..............................................................................................80

Tilt-back Frame, AWP-36S and 40S Models.....................................................90

Electrical Schematics - AWP Models ............................................................. 101

Electrical Schematic - AWP Super Series AC Models with Standard Base

Electrical Schematics - IWP Models ............................................................... 145

Part No. 38139GT AWP® Super Series • IWP® Super Series xv

Hydraulic Schematics ......................................................................................187

Model AWP-15S AWP-20S AWP-25S

Platform Dimensions - all models

Standard platform 27 x 26 x 44 ¾ in Gated narrow platform 26 x 20 x 44 ¾ in

Part No. 38139GT AWP® Super Series • IWP® Super Series 1

Model AWP-30S AWP-36S AWP-40S

Platform Dimensions - all models

Narrow fiber platform 26 x 22 x 43 ½ in Extra large platform 30 x 28 x 44 ¾ in

2 AWP® Super Series • IWP® Super Series Part No. 38139GT

Model AWP-15S AWP-20S AWP-25S AWP-30S

Gated ultra-narrow platform 22 x 18 x 44 ¾ in Narrow fiber platform 26 x 22 x 43 ½ in

Part No. 38139GT AWP® Super Series • IWP® Super Series 3

Model AWP-15S AWP-20S AWP-25S AWP-30S

Standard platform 27 x 26 x 44 ¾ in Narrow fiber platform 26 x 22 x 43 ½ in

4 AWP® Super Series • IWP® Super Series Part No. 38139GT

Model IWP-20S IWP-25S IWP-30S

Part No. 38139GT AWP® Super Series • IWP® Super Series 5

Platform function speed, maximum Hydraulic System

6 AWP® Super Series • IWP® Super Series Part No. 38139GT

Hydraulic Hose and Fitting SAE O-ring Boss Port

JIC 37° Fittings

Part No. 38139GT AWP® Super Series • IWP® Super Series 7