TechnicalPublications

First Edition, Second PrintingPart No. 31758

ServiceManual

®AWPTM® IWP TM

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Table of ContentsSection 1 • Safety RulesSection 2 • SpecificationsIWP-19IWP-24AWP-19AWP-24AWP-30AWP-36Bolt Torque Specification

Section 3 • Scheduled Maintentance InspectionsMaintenance TablesMaintenance Inspection Report

Section 4 • Schedule Maintenance ProceduresIntroductionTable A ProceduresA-1 Inspect the Operator's and Responsibility ManualsA-2 Inspect the Decals and PlacardsA-3 Inspect for Damage and Loose or Missing PartsA-4 Check for Hydraulic LeaksA-5 Check the Manual Lowering OperationA-6 Check the Battery and Battery Charger - DC ModelsA-7 Inspect the Columns for DamageA-8 Check the Sequencing CablesA-9 Check the Interlock System for Proper OperationA-10 Test the Power and Function ControlsA-11 Inspect the Lifting Chains and Idler WheelsA-12 Inspect the Breather Cap(s)A-13 Text the Base Operation - IWP Models

Table B ProceduresB-1 Inspect the Electrical WiringB-2 Inspect All WeldsB-3 Test the Tilt-back Operation - AWP-30 and 36 ModelsB-4 Check the Lifting Chain AdjustmentsB-5 Check the BatteryB-6 Clean the Lubricate the ColumnsB-7 Test the Lifting CapacityB-8 Test the Power To Platform OperationB-9 Adjust the Sequencing CablesB-10 Inspect for Proper Outrigger Length - AWP ModelsB-11 Test the Level Sensing Operation - IWP Models

Table C ProceduresC-1 Inspect and Lubricate the Casters and WheelsC-2 Inspect the Mast Assembly for WearC-3 Lubricate the Lifting ChainsC-4 Replace the Hydraulic Oil

Section 5 • Troubleshooting Flow ChartsIntroductionChart 1 - Power Light Will Not Turn On - AC ModelsChart 2 - Power Light Will Not Turn On - DC ModelsChart 3 - Interlock Lights Will Not Turn On - AWP AC ModelsChart 4 - Interlock Lights Will Not Turn On - AWP DC ModelsChart 5 - Interlock Lights Will Not Turn On - IWP ModelsChart 6 - Machine Will Not Lift - AC ModelsChart 7 - Machine Will Not Lift, But Power Unit Will Operate - AC ModelsChart 8 - Machine Will Not Lift - DC ModelsChart 9 - Machine Will Not Lift, But Power Unit Will Operate - DC ModelsChart 10 - Machine Will Not Lower - Up Function OperatesChart 11 - Base Will Not Raise With Foot Pump - IWP ModelsChart 12 - Base Will Raise, But WIll Not Hold in Up Position - IWP ModelsChart 13 - Base Will Not Lower - IWP ModelsChart 14 - Platform Will Not Hold in Up PositionChart 15 - Power Unit Will Not Lift Rated Load

Section 6 • SchematicsIntroductionSymbols LegendElectrical SchematicsAWP AC ModelsAWP DC ModelsIWP AC ModelsIWP DC Models

Electrical Wiring DiagramsAWP AC ModelsAWP DC ModelsIWP AC ModelsIWP DC Models

Hydraulic SchematicsAWP ModelsIWP Models

Section 7 • Repair ProceduresIntroductionBase Assembly1-1 Proximity Switches1-2 Inner Base Frame - IWP Models1-3 Hydraulic Manifold Components - IWP Models

Ground Control Box2-1 Ground Control Box2-2 How to Test the Transformer - AC Models2-3 How to Test the AC Contactor - AC Models2-4 How to Test the Rectifier - AC Models

Hydraulic Power Units3-1 Hydraulic Power Unit Components - AC Models3-2 Hydraulic Power Unit Components - DC Models3-3 How to Remove the Hydraulic Power Unit3-4 How to Remove the Hydraulic Pump3-5 How to Adjust the Pressure Relief Valve3-6 How to Adjust the Down Solenoid3-7 How to Check the Resistance of a Valve Coil3-8 How to Test the Motor Start Solenoid

Power Pack4-1 How to Change a Power Pack

Mast Assembly5-1 Lift Cylinder5-2 How to Remove the MAst Assembly - AWP Models5-3 How to Adjust the Lifting Chains5-4 How to Inspect the Lifting Chains

Tilt-back Frame - AWP-30 and 366-1 How to Remove the Tilt-back Frame6-2 How to Adjust the Pivot Slider or Stop Bracket6-3 How to Disassemble the Shock Absorber Assembly

Platform7-1 How to Remove an Aluminum Platform7-2 How to Install a Fiberglass Platform7-3 Platform Control Box