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Parts Manual Parts & Service Manual

1. gt A 2 NS Z 8 5 45 9 O 00000 7 18 Genie Superlift Advantage Part No 32283 August2007 Section 7 Service Parts REVC Index Part No 1 32901 32902 gt 32903 32904 32905 10597 6052 32469 2 3 4 5 32476P 6 32470P 7 8255 8 6019 9 6097 10 4828 11 32471P 12 32483 13 6086 14 32670 35475 33777 15 32894 FIGURE 7 G Description Quantity This Figure Cable Assembly 21 5 1 Cable Assembly SLEs10 5 areas nr Cable Assembly GL 218 Cable Assembly SL 20 EE Cable Assembly SL 25 aaa anane een nn on Screw HHC 1 2 13 x 1 25 inches GPP 10 Washer Shim 0 5 x 0 875 x 0 063 inch iii 20 Pulley witb Bearing He it a 10 Guard Pulley aa ata AAA eh bn KEN a al ova 10 Mount PUSY oa aia 9 Screw HHC 3 8 16 x 0 75 inch GR 5 18 Screw HHC 3 8 16 x 1 25 inches GR 5 ssssssssssssserssrsrrnrrerrstistrstnstnntnrtntntntnartnrene ent 2 Washer Flat 0 375 inch rrrrronnnronnrnnnnrvonrnnnnrrnnrnnnnnvrnrnnsnnvnnrnnsnernnrnnsnernnrnusnernnsnnsssennne 2 lee LEE 2 Mount Pulley Number 1 Mast
2. M BOG 00660 OO e 7 34 Genie Superlift Part No 32283 July 2007 Section 7 Service Parts Cm HT REVB FIGURE 7 M Index Part No Description Quantity This Figure gt 32946 Two Speed Winch Assembly Complete handles not included 1 32776 Cover Drum Gear 1 2 32777 Washer Drum Bolt a tete etd e Rai e abere te 1 3 6190 Cable Ke perKit Lunar age t ee A Ai 1 4 32778 Spacer Drum E 1 5 32779 Spacer Frame ice ede PIER earum e ders 1 6 32780 Cover Input Shaft reri me o deberse reflet ikea 1 7 32859 Bushi g 0 63 Inch Di zas KANGA et en un eet e ios 2 8 32860 Housing Spring and Ball Detent rnrarnnrnnnnnnrnnnonvrnrnrnnrnnnennrnnnrnnrnnnenrrnesernrnesennrensennr 1 9 32861 Spacer INPUT Shaft 5 deret dede e Pp eere ar e le ir 1 10 32862 Gear Input Shaft 24 Tooth iii 1 11 32863 Gear Input Shaft 12 Tooth iii 1 12 32864 Pin Drive 0187 Mecha A de 1 13 32865 Spring D tente eed tiani ae 2 14 32866 Ball Detention A en uti Ee rs 2 15 6086 Nut Low Profile Nylock 1 2 19 2 16 33143 Handle 6 inches 15 2 cm SL 5 models 2 33144 Handle 8 inches 20 3 cm SL 10 15 20 and 25 models n 2 17 32873 Shaft Input c etae ERR ied 1 18 32867 Frame and Drum Support iii 1 19 32868 Bushing 0 75 inchil D uses area sen een as 2 20 32869 Gear Pinion Shaft 24 Tooth araid e a a a a a a a 1 This part
3. 85 8 amp 69 9 9 9 9 23 e Oo 9 OG 7 28 Genie Superlift Part No 32283 October 2006 Section 7 Service Parts Index Part No 32571 1 6198 2 33143 3 33187 4 33108 5 6898 6 33222 7 33096 8 33223 9 33112 10 6563 11 33221 12 33113 13 6605 14 7713 15 33118 16 33246 17 33248 18 6002 19 33250 20 33225 21 33249 22 6097 23 16439 FIGURE 7 K Description Quantity This Figure Option Rotating Barrel Handler Complete SL 5 10 and 15 models only sis Nute Nylock 11213 i ies BE o ettet ts 1 Handles Crank 6 inches i ei KEN i rr rd ve e P ra on RD Ree adress 1 Bushing Flange 0 625 x 0 75 x 0 50 inch 6 Carrier Mounting Rotating Barrel Handler 1 Washer Shim 0 625 x 1 188 x 0 064 inch 3 Snap Ring 0 625 ID ch eee t mota Tete ess 3 A we 1 Key Woodruff O18 xv0I8 x0p bmch ann 1 Block Grank Shafa aas satang E e Pied eda n vic abeam 1 Washer Shim 0 781 x 1 312 x 0 030 inch 3 Gear Worm na ak inedite TG ER Tere Heute eta aaa ko ep no Ree dn 1 Block Mounting Crank Shaft sise 1 Screw HHC 38 16 x 3 5 inches GR 2 Nut Low Profile Nylock 3 8 26 5 Bracket Mounting Barrel Cradle ss 1 Bracket Gate usuwa ni o Rai A beeline maii rn 1 Glamp B rrel suisse Ma 1 Nut Low Profile Nylock 5 16 x 18 4 Screw FHS 5 16 x 18 x 0 75 INCH saja GENENG NENG ga E nennen nnne n
4. 1 11 111 111 111 2238 Cable Oval Sleeve jieimnch na nana n oran nro nano roca annnn rn 33298 Screw HHC Drilled 1 2 13 x 3 inches 10 6086 Nut Low Profile Nylock 1 2 19 2 11 32879 Weldment Leg SL 5 and SL 10 models occonnoococcnnccnnnoooncnnncnnnnnnnnonnconannnnncnnccnnnnnnnnos 2 32880 Weldment Leg SL 15 models ss 2 32881 Weldment Leg SL 20 and SL 25 models uuususssssnnnnnnnnnnnnnnnennnnnnnnnnnnnenennnnnnnnn 2 12 32480 Caster Swivel Plate 4 x 1 5 inches 10 1 x 3 5 cm 2 13 32534 Wedge Adjustable Arm suisses 2 14 32527 Weldment Straddle Base ooconnccccinoccccconcccconaccnnnnncn nono can naar cnn nar nn rra n ran rnnr rc cnn rca 1 15 32509 Tube Leg Pivot u He eek 2 16 32495 Welt tente erat atta NS utt sengen 2 17 32499 E clip 0 875 inch ee a in 4 18 30748 Washer Shim 1 01 x 1 63 x 0 062 inch 25 6 x 41 4 x 1 5 mm 8 19 32524 T be EE 2 20 32531 Arm Adjustable Right Side oooococoncccconoccccnonoccnonnncnnonancnnonnn co ronnn canon c aran nc narran 1 21 32479 Caster Swivel Lock 5 x 2 inches 12 7 x 5 1 cm 2 PartNo 32283 Genie Superlift Advantage 7 13 Section 7 Service Parts August2007 Figure 7 E Mast Components View 1 O ILI OY 0000 OG REVC OBE 7 14 Genie Superlift Advantage Part No 32283 August2007 Section 7 Service Parts REVC F
5. 32691 Decal Model Height SL 15 rere enit ean a euis 2 32692 Decal Model Height GL 20 2 32693 Decal Model Height SL 25 sise 2 9 6724 Plate Serial Number before serial number 5594 03264 sse nnne nnne 1 33523 Plate Serial Number from serial number 5594 03264 to 5501 15094 and from SLAO2 15095to SLA03 20337 anrrnnnnnvrnnnnnnrnnnnnvrnnnrnrrennrnnrnnrsnrrnnssnrrensrnnnn 80939 Plate Serial Number from SLAOS 20338 ii e et ia Part No 32283 Genie Superlift Advantage 7 3 October 2006 vice Parts Section 7 Ser Figure 7 A Decals and Paint View 2 Part No 32283 Genie Superlift October 2006 Section 7 Service Parts BEER FIGURE 7 A Index Part No Description Quantity This Figure 10 32687 Warning Standard Fork Safety and Set Up ssssssssssssseees 1 11 32775 Warning Fall Hazard sise 1 12 32714 Warning Standard Fork Safety and Set up sssssssssseseees 1 13 32716 Notice Boom Setup auto Det c ea ee e E tees 2 14 32717 NI A 1 15 32773 Warning Rotating Barrel Handler Safety rrnnrnnrnnnnnnvvnnnnnrrnnnnnrnnnnnnvrnnnnnvrnnnnnrnnnnnnnnne 1 16 32774 Notice Rotating Barrel Handler Set up oooonoccconnncccnncccccnonaccnonnanccnnnn cnn aaa aaa aaa aaa 1 17 32772 Notice Vertical Barrel Stacker Set up aaa anana nean naen 1 18 32771 Warning Vertical Barrel Stacker Safe
6. But Winch Will Operate Chart 2 Check for broken cable Replace broken cable See Repair procedure 2 2 How to Replace the Lifting Cable Check all cable pulleys Inspect the cable for Replace damaged to verify that the cable kinks frays and cable See Repair is properly routed damage rocedure 2 2 How to eplace the Lifting Cable Then check pulley and guard for damage and replace if needed incorrect Check pulley and pulley guard for damage Replace damaged component correct Re install cable if removed during inspection Inspect winch drum and Replace damaged pinion gear for damage components OR contact Genie Industries Service Department H Contact Genie Industries Service Department Part No 32283 Genie Superlift Advantage 5 3 Section 5 Troubleshooting Flow Charts Parts and Service Manual First Edition Chart 3 Winch Will Not Operate Check position of load Re position load to for proper centering and eliminate obstruction no obstructions Be sure load is properly centered obstructions no obstructions Check hold down latches for proper Replace damaged part operation Check the cable for Remove the bound up binding at the winch binding cable and inspect the drum and inside the cable and related mast components for damage Replace the damaged component s not binding Check winch for proper Replace the d
7. enie A TEREX COMPANY Parts amp Service Manual Serial Number Range Superlift from serial number 9594 101 to 5501 15094 Advantage 1 422 Part No 32283 Rev A6 August 2007 Parts and Service Manual First July 2007 Table of Contents Introduction Important Information are Reken eke ate Ri ii Section One Safety Rules General Safety Rules issues iii Section Two Specifications super seele ist eee 2 1 Superlft 10 Tak alaka gah a aapa ab tla a a Sa baa Porn E eg ad ena ga ab 2 1 S perift 15 nain NENG AAA lerne heh OO nant 2 1 Stperli t20 ope ee EE NGNE AK aa 2 1 elle dl SE 2 1 Load Handling Attachments ne RE 2 1 Bolt Torque Specification ceo riter eene tan ad 2 3 Section Three Scheduled Maintenance Inspections Introduction gie 3 1 BEIEN SE 3 2 TablesB Bape At aneh das velcro solid eser Dana a d 3 2 TAPIS Anita Nei a Rai ar a Aaah aet ar Ast M Lc 3 2 Maintenance Inspection Report sise 3 3 Section Four A 1 A 2 A 3 A 4 A 5 A 6 A 7 A 8 B 1 Scheduled Maintenance Procedures Introduction ei innen 4 1 Inspect the Operator s Manuel 4 2 Inspect the Decals and PlacardS AAA 4 2 Inspect for Damage Loose or Missing Parts nrn nn 4 2 Check the Winch Operation iii 4 3 Inspect the Columns for Damage nenn 4 3 Inspect the Cable and Cable Pulleys sess 4 3 Check the Mast for Proper Sequencing aana aaane aane o nn nn rn 4 4 Inspect th
8. 1 Pins ROMO 2596000 Incident AE ton ee e SE O eee ess 10 Nut Low Profile Nylock 1 2 13 s sssnssnnnsnsnnnnnnnennnsninnnnsrnnsnnesnnssinsrienrnerrnsrrnnrnnsrnsrennenne 1 Column Number 1 All Models before serial number 5594 00000 1 Column Number 1 All Models from serial number 5594 00001 thru 5594 03941 Column Number 1 All Models after serial number 5594 03942 Column Assembly Number 2 Through 5 4 SL 5 from serial number 5594 00101 thru 5594 04447 sse SL 10 from serial number 5594 00101 thru 5594 04302 sss SL 15 from serial number 5594 00101 thru 5594 04293 sese SL 20 from serial number 5594 00101 thru 5594 04286 eeseeesseeeeseesereeerreernee SL 25 from serial number 5594 00101 thru 5594 04350 sss Column Assembly Number 2 Through 5 4 SL 5 after serial number 5594 04447 iii SL 10 after serial number 5594 04302 no r SL 15 after serial number 5594 04293 rrnnnnnnvrnnnnnvrnnnnnvnnnnrnvrnnnrnrrnnrnnrnnnrrnrnnnernnrennn SL 20 after serial number 5594 04286 essseesseeessieeesrrserirterirttrirntsinserintsrinnssrneet SL 25 after serial number 5594 04350 rrnrnnnvrnnnnnvrnnnnnvnnnnrnrrnnrrnrrensnnrnnsnrnrnnnernrrennn This parts list continues on page 7 21 Part No 32283 Geni
9. 32283 Genie Superlift Advantage Section 6 Repair Procedures Parts and Service Manual First Edition Mast Assembly 2 1 How to Disassemble the Mast Assembly 1 Remove the cable retaining fasteners from the winch drum Then remove all of the cable from the drum 2 Tip the machine backwards and rest the top of the number one mast on an appropriate support The mast assembly should be level with the carriage up Bodily injury hazard Use proper ACAUTION lifting techniques 3 Remove the mounting fastener from the cable anchor on the last column carriage side 4 Remove the cable from the mast by pulling on the cable anchor end of the cable Bodily injury hazard Cables can ACAUTION fray Always wear adequate hand protection when handling cable 5 Secure the hold down latch to its respective column with a piece of tape so that it does not fall off during disassembly 6 Slide the carriage forward about 1 foot 30 cm to expose the column stop mounting fastener attached to the bottom end of the top column below the carriage Remove the fastener and the stop 7 Use a hex key wrench through the access holes in the carriage to release the safety brake Slide the carriage away from the base 1 inch 2 5 cm while reaching through both slots Position the hex key above the safety brake rollers and pull back on the wrench 8 Remove the carriage by sliding it out the bottom of the mast towards the base w
10. includes 1 each index number 31 2 33 32516 Brace StabiliZei ten td rea ei ale is abi 2 34 11337 Pin Roll 0 25 x 1 25 INCHES oec Trees Elle n He nde n RR EE e ann 2 Part No 32283 Genie Superlift Advantage 7 11 Section 7 Service Parts August2007 Figure 7 D Straddle Base Components aa 00 D BY 8 REVA 4 e e OG W 7 12 Genie Superlift Advantage Part No 32283 August2007 Section 7 Service Parts REVA FIGURE 7 D Index Part No Description Quantity This Figure 1 32562 Option Rear Wheel iii 1 32529 Weldment Transport Wheels AAA 32486 Weldment Axle Right Side sisi 33047 Weldment Axle Left Side ii a E nn gega a nennen nnn 6030 Wheel 0 75 x 2 75 x 10 inches 1 9 x 7 x 25 4 CM sessseesseressrierrrissrrresrrrerrrrsern 2 4828 Nut Nylock 3 8 16 is 20 3 6175 Screw HHC 3 8 16 x 1 inch GR 8 4 6019 Screw HHC 3 8 16 x 1 25 inches Gpp nnne nnns 12 5 32883 Mast Brace Right Side shown enne 1 32884 Mast Brace Left Side iii 1 6 33148 Knob Leg LOCK ici Torrico A en Bahn 2 7 1416 300 Spacer Leg LOCK REM 2 8 32532 Arm Adjustable Left Side ir 1 9 32940 Pin Assembly with Layat sanun kana aaa KEN ro nn nn 2 32500 Pin Detent 0 5 x 2 5 inches 1 3 x 6 35 cm 2163 Cable 1 16 inch 7 x 7 strands 12 inches 30 4 cm required
11. 04350 sess 35486 Carriage Assembly ot ee RER eb 1 SL 20 after serial number 5594 04286 eeeuee eee aaa ren rn SL 25 after serial number 5594 04350 rrnrannvnnnnnnvrnnnnnvrnnnrnrrnnnrnrrnnrsnrrenernrensrrnrnennn Part No 32283 Genie Superlift Advantage 7 21 Section 7 Service Parts October 2006 Figure 7 H Load Handling Attachments Forks O ZAL i EN Q 66 7 22 Genie Superlift Part No 32283 October 2006 Section 7 Service Parts y __ M n t FIGURE 7 H Index Part No Description Quantity This Figure 32563 Option Standard Fork Complete includes index numbers 7 and 8 32564 Option Adjustable Fork Complete includes index numbers 1 6 8 and 9 32566 Option Flat Fork Complete includes index numbers 1 through 5 8 and 10 SL 5 10 and 15 models only 32565 Option Non marking Extrusion Standard and Adjustable Forks 32944 Option Fork Extensions Standard and Adjustable Forks A 1 32375 PirisFork Lock u ee at 4 2 8220 Screw HHC 1 2 13 x 4 inches Gpnp ni 4 3 6086 Nut Low Profile Nylock 1 2 219 2 4 32541 Weldme
12. 109 1 2 13 75 102 110 149 20 90 122 120 163 9 16 12 110 149 150 204 18 120 163 170 231 5 8 11 150 204 220 298 18 170 231 240 326 3 4 10 260 353 380 515 16 300 407 420 570 7 8 9 430 583 600 814 14 470 637 660 895 1 8 640 868 900 1221 12 700 949 1000 1356 Torque specifications for lubricated bolts are 25 less than dry torque specifications for each bolt size These bolt torque specifications are for general use only Specification may vary depending on application of bolt PartNo 32283 Genie Superlift Advantage 2 3 Section 2 Specifications Part and Service Manual First Edition nee This page intentionally left blank 2 4 Genie Superlift Advantage PartNo 32283 Parts and Service Manual First Edition Section 3 Scheduled Maintenance Inspections Scheduled Maintenance Inspections Observe and Obey M Maintenance inspections shall be completed by a person trained and qualified on the maintenance of this machine M Scheduled maintenance inspections shall be completed daily quarterly and annually as specified on the maintenance inspection report Failure to properly complete each AWARNING inspection when required may result in death serious injury or substantial machine damage M Immediately tag and remove from service a damaged or malfunctioning machine M Repair any machine damage or malfunction before operating machine M Keep records on all inspections for three yea
13. 4 Check winch winch A 5 Columns B 5 Rotating Barrel Inspector signature Handler A 6 Inspect cable and Inspector title pulleys inspector company A 7 Check mast for proper Checklist C Y N R sequencing C 1 Lubricate casters A 8 Inspect casters and wheels Instructions and wheels Make copies of this page to use for C 2 Mast assembly wear each inspection C 3 Replace winch Select the appropriate checklist s for friction disks the type of inspection to be rmed C 4 Safety brake system Daily Inspection A C 5 Inspect painted Quarterly Inspection A B Annual Inspection A B C Place a check in the appropriate box after each inspection procedure is completed If any inspection receives an N remove the machine from use repair and re inspect it After repair place a check in the R box Legend Y yes acceptable N no unacceptable R repaired Comments surfaces Genie Superlift Advantage Part No 32283 Parts and Service Manual First Edition Section 4 Scheduled Maintenance Procedures Scheduled Maintenance Procedures Observe and Obey M Maintenance procedures shall be completed by a person trained and qualified on the maintenance of this machine M Scheduled maintenance procedures shall be completed daily quarterly every 3 months and annually as specified on the maintenance inspection report Failure to properly complete each AWARNING inspection when required
14. 7590 10 32891 11 6200 12 33143 33144 13 6086 14 40458 15 23415 16 6184 17 6185 18 32892 19 6190 20 6184 21 Ref 22 6770 23 6034 FIGURE 7 L Description Guantity This Figure Single Speed Winch Assembly Complete handles not included Screw HHC 5 16 18 x 6 inches GR 1 Spacer Frame e n cer ete ae e o ce te en eed redde gea 1 N ut Eock 9 16 518 eot ete a nn 1 Bushing Pinion Shaft AA 2 Spacer Pinion Shaft urn tem ee e EN AN aa aa EET De ak t 1 Pinon Plate vna enerne 1 O nase Lee O 2 Ratchet Gear RR 1 dl ALSJAKS ZE um O aa nn 1 el Ile TEE 1 Retaining Ring 0 75 inches A 1 Handle 6 inches 15 2 cm SL 5 models 2 Handle 8 inches 20 3 cm SL 10 15 20 and 25 models ssssuaaaaaaasssaaa 2 Nut Low Profile Nylock 1 2 13 sssssssesnnessnnsssrrssrnsserrnsntrnneeirnstirnstrnnsnrtnsrrernnrennnen 2 Ratchet Kit ne ee ee ne ee en ne KANE RAN a 1 Nut Low Profile Lock 1219 1 Spacef Drum aa oni brote i 1 Drum BOB x ek EG eA aS EE KARA KE dus 1 Frame and Drum Support iii 1 Cable Keeper Kit nenne teen Henn lien 1 Spacer Drum Hs EEE tte m t i tua 1 Drum Assembly xe e ea er wa i YER ene Cover Drum Gear eer uit eee iL erue Tet rn REESEN 1 Nut Hex Jar 12 13 a OE Re aloe od 2 Part No 32283 Genie Superlift 7 33 Section 7 Service Parts July 2007 Figure 7 M mm Two Speed Winch OJO O
15. A 1 Inspect the Operator s Manual A 2 Inspect the Decals and Placards A 3 Inspect for Damage Loose or Missing Parts A 4 Check the Winch Operation A 5 Inspect the Columns for Damage A 6 Inspect the Cable and Cable Pulleys A 7 Check the Mast for Proper Sequencing A 8 Inspect the Casters and Wheels Table B B 1 Inspect the Column Hold Downs B 2 Inspect All Welds B 3 Clean the Columns B 4 Inspect and Lubricate the Winch B 5 Inspect and Lubricate the Rotating Barrel Handler 3 2 Genie Superlift Advantage Part No 32283 Parts and Service Manual First Edition Section 3 Scheduled Maintenance Inspections MAINTENANCE TABLES Table C Dealer Tools are New parts service required required suggested C 1 Lubricate the Casters and Wheels o C 2 Inspect the Mast Assembly for Wear C 3 Replace the Winch Friction Disks C 4 Inspect the Safety Brake System C 5 Inspect the Painted Surfaces Part No 32283 Genie Superlift Advantage 3 3 Section 3 Scheduled Maintenance Inspections Parts and Service Manual First Edition Maintenance Inspection Report Model Checklist B Y NR Checklist A Y NR Serial number A 1 Operator s manual B 1 Column hold down Date A 2 Decals and placards B 2 Inspect welds A 3 Damage loose or B 3 Clean columns Machine owner missing parts BA Inspect and lubricate Inspected by print A
16. Procedures 1 2 How to Remove the Base Straddle Base 4 2 Fully lower the carriage Remove the load handling attachment from the machine Using proper lifting techniques tilt the machine back and rest the loading wheels against a sawhorse or other suitable support Remove the mounting fastener and retaining pin from each leg Then remove the legs from the machine Remove the stopper bolt from the adjustable arm located inside the base tube Remove the adjustable arm from the machine Repeat for the other side Using proper lifting techniques tilt the machine to the upright position Attach an overhead crane to the lifting bracket on the number 1 mast Place a sawhorse on the carriage side of the mast BASE ASSEMBLY 9 Lift the machine slightly and then while lowering it guide the machine over onto the sawhorse A Crushing hazard The machine will fall unless it is properly supported with the overhead crane ACAUTION 10 Secure the top of the mast to the sawhorse 11 Attach an overhead crane to the base and lift the machine enough to slide a second sawhorse under the mast next to the base ACAUTION Crushing hazard The machine will fall unless it is properly supported with the overhead crane 12 Remove the mounting fasteners from the mast brace to the base Repeat for the other side 13 Remove the base mounting fasteners Then remove the base from the machine Part No
17. and then insert the drum bolt through the winch housing drum cover and drum with the head of the drum bolt on the drum gear side of the winch 17 Install the drum bolt jam nut and torque to 20 to 25 ft Ibs Overtightening the drum bolt jam ACAUTION nut may cause damage to the frame spacer and prevent the drum from spinning freely 18 Lubricate with automotive grease the teeth of the drum gear and the pinion nut where they mesh Do not allow grease or oil onto the ACAUTION friction disks or the ratchet gear 19 Install the input shaft cover Genie Superlift Advantage Part No 32283 Parts and Service Manual First Edition Section 6 Repair Procedures E WINCHES 20 Rotate the drum so that the two square cable keeper holes are at the top Install the cable keeper clip to the outside of the drum with the two carriage bolts coming through from the inside Install the lock washers and nut Do not tighten down the nuts at this point 21 Route the end of the cable over then under the winch drum and out through the remaining hole on the left side wall of the drum a number one column b cable c winch drum d cable keeper clip AWARNING Crushing hazard Failure to properly route the cable may result in a winch brake failure 22 Insert the end of the cable under the cable keeper clip approximately 1 2 inch and tighten the cable keeper clip 23 While holding the cable tight on the drum rotate the d
18. ateisme meet iim dien noe 3 21 4828 Nut Nylock 3 8 16 ins 3 Part No 32283 Genie Superlift Advantage 7 15 August2007 Section 7 Service Parts Figure 7 F Mast Components View 2 REVB Part No 32283 Genie Superlift Advantage 7 1 August2007 u 2 5 Section 7 Service Parts REV B FIGURE 7 F Index Part No Description Quantity This Figure 1 32474P Guards ROBI ara RE ETAT 8 2 32473 Roller Nylatron iii 15 3 32475 Bolt Roller decy ch en ete te eb bata ee ee len 15 4 6095 Washer Flat UI siot meet nat edad toc Una aa AA 16 5 6198 Nut Nylocks 1 2819 A EG 18 6 80988 Kit Cable Anchor before serial number SLA03 20409 sss 1 80985 Cable Anchor after serial number SLAO3 20408 7 10587 Screw HHC 1 2 13 x 1 75 inches GR 3 8 32901 Cable Assembly SL 5 usines 1 32902 Cable Assembly GL 10 32903 Cable Assembly SL 15 cin ee ee el 32904 Cable Assembly SL 20 iii 32905 Cable Assembly SL 25 4 ae He 9 32895 Carriage Assembly SL 5 10 and 15 models ccccoooocccccccnnnooncnnnconnnnncnnnnconannnnnnnnconns 1 32896 Carriage Assembly SL 20 and 25 models sss 1 10 32894 Column Assembly Number 2 Through 5 All Models A 2 Part No 32283 Genie Superlift Advantage 7 17 Section 7 Service Parts August2007 Figure 7 G Mast Components Pulleys and Cable
19. decal from 5501 14371 to 5501 15094 and from SLA02 15095 to SLA04 25258 iii 9 6019 Screw HHC 3 8 16 x 1 25 inches GR 5 ssssssessssssrssrsrerrstrstnstnstnntartnrtntnntnttntenreneene 4 10 32482 Weldment Pulley Guard AA 1 11 6653 Clamp Rubber Cushioned A 2 12 6600 Container Manual Storage iii 1 32282 Operators Manual gemeinsamen 13 7265 Rivet Steel 0 375 x 0 25 inch aaa aa a a aa baga aa KN araga TKa a en aa a Ka D EA ma KE Kaga Kan 2 14 32375 Lock Pin Assembly sise 1 15 6412 Hardi IT iro mh e UE Uu e RUM 2 Part No 32283 Genie Superlift Advantage 7 7 Section 7 Service Parts August2007 Figure 7 C Standard Base Components Y 69 5 69 62 O 6 06968 OM 7 8 Genie Superlift Advantage Part No 32283 0099 August2007 Section 7 Service Parts REVA Index Part No 80171 S 80172 S 80173 S 80174 5 80175 S 1 10598 2 6086 3 32576 4 32578 5 4828 6 6019 7 32502P 8 6097 9 32883 32884 10 32486 11 6030 12 32562 13 33047 14 32509 15 6175 16 32480 17 82879 32880 82881 18 32524 19 32495 FIGURE 7 C Description Quantity This Figure Standard Base Assembly with Decals SLA 5 sssssssse Standard Base Assembly with Decals SLA 10 sese Standard Base Assembly with Decals GL A 2181 Stand
20. housing Do not allow grease or oil onto the ACAUTION friction disks or the ratchet gear 10 Push the pinion shaft to the right through the right pinion bushing and install the pinion shaft retaining ring Use your fingers to push the ratchet pawls outwards while pushing pinion shaft through the right bushing Be sure the ratchet pawls are in firm contact with the ratchet gear and all parts move freely 11 Install the two jam nuts to the right side of the pinion shaft one at a time and tighten 12 Install a handle to both sides of the pinion shaft in opposite directions and secure with a lock nut on each end of the pinion shaft 13 Lubricate the outside of the frame spacer that goes through the cable drum with automotive grease and then insert it into the drum 14 Install the cable drum so that the drum gears mesh with the ratchet gears 15 Install the drum bolt keeper onto the drum bolt and then insert the drum bolt through the winch housing and drum with the head of the drum bolt on the drum gear side of the winch 16 Place the drum gear cover into position with the drum bolt slot under the drum bolt keeper 17 Install the drum bolt jam nut hand tight 18 Install the housing spacer with the head of the housing spacer bolt on the right side of the winch and through the slotted portion of the drum gear cover Place the nut on the end of the bolt and tighten 19 Tighten and torque the drum bolt nut to 20 to 25 ft I
21. points on each ratchet pawl 3 Inspect the friction disks for excessive wear Replace if pad is less than 1 16 inch 1 5 mm thick 4 Inspect pinion shaft bushings for excessive wear Replace if wall thickness of bushing is less than 1 8 inch 3 1 mm 5 Lubricate the frame drum spacer Tighten the drum bolt to 20 ft lbs 27 Nm Do not overtighten B 5 Inspect and Lubricate the Rotating Barrel Handler Maintaining the barrel handler is essential to good performance and safe operation An unsafe working condition exists if the barrel handler has excessive wear and or does not operate smoothly free of hesitation and binding 1 Visually inspect the following components for damage all bushings chain and clamp gears snap rings fasteners crank handle 2 Raise the barrel handler to a comfortable working height chest height Do not put a load on it 3 Pump grease onto the drive gear Locate the gear from the bottom side of the barrel handler 4 Using the crank handle rotate the barrel cradle 1 4 turn and apply more grease 5 Rotate the barrel cradle 2 full turns or until the grease is completely worked into the gears Oil Type Multipurpose grease 4 6 Genie Superlift Advantage Part No 32283 Parts and Service Manual First Edition Section 4 Scheduled Maintenance Procedures Table C Procedures C 1 Lubricate the Casters and Wheels Extremely dirty conditions may require that the casters and
22. withstand machine weight See Specification section for specific weight M Be sure overhead cranes or other lifting devices are of ample capacity to handle machine weight See Specification section for specific weight Before Troubleshooting M Read understand and obey the safety rules and operating instructions printed in the Genie Superlift Operator s Manual M Be sure that all necessary tools and test equipment are available and ready for use M Read each appropriate flow chart thoroughly Attempting shortcuts may produce hazardous conditions M Be aware of the following hazards and follow generally accepted safe workshop practices o Try Crushing hazard When testing or 11 ADANGER replacing primary component always support the structure and secure it from movement Perform all troubleshooting on a firm level surface Two persons will be required to safely perform some troubleshooting procedures About This Section When a malfunction is discovered the flow charts in this section will help a service professional pinpoint the cause of the problem To use this section basic hand tools are required General Repair Process Malfunction Identify Troubleshoot discovered symptoms problem still exists Return to Perform service problem repair solved Part No 32283 Genie Superlift Advantage 5 1 Section 5 Troubleshooting Flow Charts Parts and Service Manual Fi
23. 283 Genie Superlift Advantage Section 4 Scheduled Maintenance Procedures Parts and Service Manual First Edition TABLE C PROCEDURES adjacent column surface Result There should be a maximum gap of 0 062 inches 1 57 mm between the roller wheel and the column If mast inspection results in a measurement that is not within specification refer to Repair procedure 2 1 How to Disassemble the Mast C 3 Replace the Winch Friction Disks Maintaining the winch is essential to good machine performance and safe operation An unsafe working condition exists if the winch has excessive wear and or does not operate smoothly free of hesitation and binding 1 Replace the winch friction disks See Repair procedure 3 1 or 3 2 How to Disassemble the Winch C 4 Inspect the Safety Brake System Detection of damage or a defect to the safety brake system is essential for safe machine operation An unsafe working condition exists if the system is damaged or defective and does not allow the mast to sequence properly free of hesitation and binding This procedure requires specific AWARNING repair skills and a suitable workshop Attempting this procedure without these skills may result in death or serious injury or significant component damage Dealer service is strongly recommended Be sure to wear protective gloves ACAUTION to perform this procedure 1 Install a load handling attachment into the carriage use forks o
24. 3 Remove the mounting fasteners from the stabilizer mounting bracket on the back of the mast 4 Remove the mounting fastener from each of the stabilizers at the base Remove the stabilizers from the machine All Models 5 Using proper lifting techniques tilt the machine back and rest the loading wheels against a sawhorse or other suitable support 6 Remove the mounting fastener and retaining pin from each leg Then remove the legs from the machine 7 Using proper lifting techniques tilt the machine to the upright position 8 Attach an overhead crane to the lifting bracket on the number 1 mast 9 Place a sawhorse on the carriage side of the mast 10 Lift the machine slightly and then while lowering it guide the machine over onto the sawhorse A Crushing hazard The machine will ACAUTION fall unless it is properly supported with the overhead crane 11 Secure the top of the mast to the sawhorse 12 Attach an overhead crane to the base and lift the machine enough to slide a second sawhorse under the mast next to the base Crushing hazard The machine will ACAUTION fall unless it is properly supported with the overhead crane 13 Remove the mounting fasteners from the mast brace to the base Repeat for other side 14 Remove the base mounting fasteners Then remove the base from the machine 6 2 Genie Superlift Advantage Part No 32283 Parts and Service Manual First Edition Section 6 Repair
25. 83 Genie Superlift Advantage 4 1 Section 4 Scheduled Maintenance Procedures Parts and Service Manual First Edition Table A Procedures A 1 Inspect the Operator s Manual Maintaining the operator s manual in good condition is essential to safe machine operation The operator s manual is included with each machine and should be stored in the box provided on the mast An illegible or missing manual will not provide safety and operational information necessary for a safe operating condition 1 Check to make sure the operator s manual is present and complete in the storage container on the mast 2 Examine the pages of the manual to be sure that they are legible and in good condition 3 Always return the manual to the storage container after use Contact your authorized Genie distributor or Genie Industries if a replacement manual is needed A 2 Inspect the Decals and Placards Maintaining all of the safety and instructional decals and placards in good condition is essential for safe machine operation Decals alert operators and personnel to the many possible hazards associated with using 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 Refer to the decals section in the operator s manual and use the decal list and illustration to determine that all decals and p
26. Cradle Pipe eent eent ana in el lien 2 Weldment Load Platform includes decals aaa aaa anna a anana nean ane 1 Boom Assembly includes decals anana anaa nooo nn rn 1 Weldment Lifting Clevis ss 1 Pin 0 5 x 2 5 inches 1 27 x 6 35 cm 2uusss4ssnssnnnennnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnn nn 1 Pin 0 5 x 7 75 inches 1 27 x 19 9 cm is 1 Part No 32283 Genie Superlift 7 25 Section 7 Service Parts October 2006 Figure 7 J Load Handling Attachment Vertical Barrel Stacker 7 26 Genie Superlift Part No 32283 October 2006 Section 7 Service Parts oO FIGURE 7 J Index Part No Description Quantity This Figure 32570 Option Vertical Barrel Stacker Complete SL 5 10 and 15 models only 1 32526 Pin 0 5 x CH TER 1 2 32909 Carrier Vertical Barrel Stacker includes decals SL 5 10 and 15 models only 1 3 33126 Pin 1 x 6 inches 2 54 x 15 24 emt 2 4 33247 Pin Cotter 0 188 x 1 75 inches sise 4 5 33217 Bushing 1 25 x 1 x 2 5 inches 3 2 x 2 54 x 6 35 CM een 2 6 32911 Arm Lifting Left Side includes 1 each index number 5 SL 5 10 and 15 models only is 1 7 32910 Arm Lifting Right Side includes 1 each index number 5 SL 5 10 and 15 models only sisi 1 Part No 32283 Genie Superlift 7 27 Section 7 Service Parts October 2006 Figure 7 K Load Handling Attachment Rotating Barrel Handler
27. IGURE 7 E Index Part No Description Quantity This Figure 1 32670 Column Number 1 All Model 1 2 32475 Bolt FROMOK 15 3 32473 Roller VE oT Em 15 4 32474P Guard Ee 11 5 6095 Washer Flat 2 Inch eerte ee al an 15 6 6086 Nut Low Profile Nylock 112 2 7 32894 Column Assembly Number 2 through 5 All Models includes index numbers 8 through 13 2 8 6198 Nute Nylock Vae g e etie RR eege ee 13 9 32899 Safety Brake Stop Assembly nn 2 10 6638 Washer Flat io acia aisi nea Dv ha rA ta d api a ete 4 11 32481 Spring Safety Brake AAA 2 12 17712 Screw FHS 3 8 218xlzbinches nono n nono non cnn nana n arc n acc na nana 2 13 32497 Ramp Safety Blake ien cct nase ai len 2 14 33252 Shim 0 75 x O 10 IRCh ta ay DP n e ee Oeo ie 3 15 33744 Hold Down Latch Kit SL2 20 and SL2 25 before serial number 5599 3362 2 58095 Hold down Assembly with Decals SLA 20 and SLA 25 from serial number 5599 3362 33771 Hold Down Latch Kit SL2 5 SL2 10 and SL2 15 before serial number 5599 3362 sse ennemis 58750 Hold Down Assembly with Decals SL2 5 SL2 10 and SL2 15 from serial number 5599 3362 16 6052 Washer Shim 0 5 x 0 875 x 0 063 inch ss 2 17 33080 Coupler SL 20 and SL 25 models only oco none 1 18 6019 Screw HHC 3 8 16 x 1 25 inches GRp nono n nono nnnnnnnnn cnn nana nanins 3 19 12013 Washer Flat O32 pxv00p2mmches 3 20 33198 B wniStop une
28. Screw onto large threads hand tight 7 Install a friction disk ratchet gear friction disk pinion plate and pinion spacer in respective order onto the pinion shaft The teeth on the ratchet gear must curve towards the left side wall of the winch housing Do not allow grease or oil onto the ACAUTION brake disk the ratchet gear or the teflon spacer 8 Slide the pinion shaft gears over the woodruff keys Then install the pinion shaft retaining ring onto the pinion shaft Use your fingers to push the ratchet pawls outwards while pushing pinion shaft through the left bushing Be sure the ratchet pawls are in firm contact with the ratchet gear and all parts move freely 9 Install the lock nut on the left side of the pinion shaft 10 Install the input shaft through the left side of the winch housing approximately half way 11 Slide the left side bushing spring and ball housing spacer input shaft gears and right side bushing onto the input shaft 12 Rotate the input shaft until the drive pin hole is visible Install the drive pin with a soft metal drift 13 Install the ball and spring into the spring and ball housing then install the mounting fasteners 14 Lubricate with automotive grease the outside of the frame spacer that goes through the cable drum and then insert it into the drum 15 Install the cable drum so that the drum gears mesh with the ratchet gears 16 Install the drum bolt keeper onto the drum bolt
29. amaged operation See component See Repair Maintenance procedure rocedure 3 1 How to A 4 Check the Winch epair the Winch Operation Single Speed Check carraige and Replace damaged mast for damaged column OR consult column s Genie Industries Service Department Consult Genie Industries Service Department Genie Superlift Advantage Part No 32283 Parts and Service Manual First Edition Section 6 Repair Procedures Observe and Obey M Repair procedures shall be completed by a person trained and qualified on the repair of this machine M Immediately tag and remove from service a damaged or malfunctioning machine M Repair any machine damage or malfunction before operating the machine Before Repairs Start M Read understand and obey the safety rules and operating instructions in the Genie Superlift Operator s Manual M Be sure that all necessary tools and parts are available and ready for use M Be sure the capacities of sawhorses or other supports are sufficient to withstand machine weight See Specification section for specific weight M Be sure overhead cranes or other lifting devices are of ample capacity to handle machine weight See Specification section for specific weight M Read each procedure completely and adhere to the instructions Attempting shortcuts may produce hazardous conditions M Unless otherwise specified perform each procedure with the machine in the following c
30. ard Base Assembly with Decals SLA 20 sse Standard Base Assembly with Decals SLA 25 seeessseeesseeeseeessrreesrireerrserrrrssrrnene Screw HHC 1 2 13 x 3 inches GR 6 Nut Low Profile Nylock 1 2 19 6 Tube Stabilizer PVOt mtra diete Ran Na te ae de 2 Tube Stabilizer Clamp iii 2 Nut Nylock 3 8 16 or e na e ere ul 24 Screw HHC 3 8 16 x 1 25 inches Gpp nono nnnnnnncnnnnnnananananinins 10 Bracket Stabilizer Mounting sesssssesseeseeeeeeeenneeeen nennen nnne nennen 1 Washer Flat 0 375 inch rrrnrnnnnronnrnnnnrvenrnnnnrvnnrnnnnnvrnrnnsnnvnnrnnsnsrnnrnnsnernnrnnsnerensnnssseenne 4 Mast Brace Right Side shown nennen 1 Mast Brace Left Side Lunar eid Ka AAK a A ln ANE A 1 Weldment Axle Right Side iii 1 Wheel 0 75 x 2 75 x 10 inches 1 9 x 7 x 25 4 CM aana anana aana aane a nana anaa anana nne 2 Weldment Axe Left Side mere ses idee la 1 Weldment Transport Wheels oooocinccncocococonccococonnnnnnnccnccncnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnncn 1 Tube Leg Pivot He an ee ee eben 2 Screw HHC 3 8 16 x 1 inch GR 8 Caster Swivel Plate 4 x 1 5 inches 10 1 x 3 5 cm 2 Weldment Leg SL 5 and SL 10 models rrrrnnnrrnrrnnrnnnnrrnnrrrrrnnnnrnnerrrrnnnnrnnessrsrnnnnsnene 2 Weldment Leg SL 15 models issus 2 Weldment Leg SL 20 and SL 25 models uuusssssssnnnnnnnnsennnnnnnnnnnnnnnnnnnnnnnennnnnnnn 2 T be e Axle ase us eR NM EE 2 Wheel 3 5
31. bs Overtightening the drum bolt jam ACAUTION nut may cause damage to the frame spacer and prevent the drum from spinning freely 20 Lubricate with automotive grease the teeth of the drum gear and the pinion nut that meshes with the drum gear Do not allow grease or oil onto the ACAUTION friction disks or the ratchet gear 21 Rotate the drum so that the two square cable keeper holes are at the top Install the cable keeper clip to the outside of the drum with the two carriage bolts coming through from the inside Install the lock washers and nut Do not tighten down the nuts at this point 22 Route the end of the cable around the winch drum and out through the remaining hole on the left side wall of the drum number one column cable winch drum cable keeper clip ao oo 23 Insert the end of the cable under the cable keeper clip approximately 1 2 inch and tighten the cable keeper clip 24 While holding the cable tight on the drum rotate the drum with a handle and spool the cable onto the drum neatly Component damage hazard Be ACAUTION sure the cable winds onto the winch drum evenly 6 8 Genie Superlift Advantage Part No 32283 Parts and Service Manual First Edition Section 6 Repair Procedures 3 2 How to Disassemble the Winch Two Speed Bodily injury hazard Cables can ACAUTION fray Always wear adequate hand protection when handling cable 1 Fully lower the carriage 2 R
32. cm 6 5 cm 23 8 kg Flat Forks 32 in 16 in to 31 in 11 2 in 73 Ibs 81 cm 41 cm to 79 cm 4 cm 33 1 kg Boom 18 in to 42 in 11 2 in 61 2 in 34 5 lbs 46 cm to 107 cm 4 cm 16 cm 15 6 kg Vertical Barrel Stacker 21 in 29 in NA 50 5 lbs 53 cm 74 cm 22 9 kg Rotating Barrel Handler 29 in 31 in NA 85 Ibs 74 cm 79 cm 38 6 kg Pipe Cradle 271 2 in 24 1 2 in 6 in 10 Ibs 70 cm 63 cm 11 5 cm 4 5 kg Load Platform 271 2 in 231 2 in 21 2 in 26 5 lbs 70 cm 60 cm 6 5 cm 12 0 kg Part No 32283 Genie Superlift Advantage 2 1 Section 2 Specifications Part and Service Manual First Edition EH SPECIFICATIONS Dimensions Operating SL 5 SL 10 SL 15 SL 20 SL 25 Standard Forks forks down 4 ft 101 2 in 9 ft 9 in 14 ft 71 2 in 19 ft 6 in 24 ft 4 in 1 5m 3m 4 5m 6m 7 4 m forks up 6 ft 7 in 11 ft 51 2 in 16 ft 4 in 21 ft 21 2 in 26 ft 1 2 in 2m 3 5m 5m 6 5m 7 9 m Adjustable Forks forks down 4 ft 101 2 in 9 ft 9 in 14 ft 71 2 in 19 ft 6 in 24 ft 4 in 1 5m 3m 4 5m 6m 7 4m forks up 6 ft 7 in 11 ft 51 2 in 16 ft 4 in 21 ft 21 2 in 26 ft 1 2 in 2m 3 5m 5m 6 5m 7 9 m Flat Forks 4 ft 101 2 in 9 ft 9 in 14 ft 71 2 in NA NA 1 5m 3m 4 5m Boom 5 ft 101 2 in 10 ft 9 in 15 ft 71 2 in 20 ft 6 in 25 ft4in 1 8m 3 3m 4 8m 6 3m 7 7 m Note measured from ground to bottom of shackle Vertical Barrel Stacker 30 gallon 4 ft 8 ft 10 in 13 ft 9 in NA NA 24 Load Center 1 2m 2 7m 4 2m 55 gallon 3ft10 in 8 ft 8 in 13 ft 7 in 1 2m 2 6m 4 1 m Note measured from grou
33. e Casters and Wheels aaa nnrr nen nn 4 4 Inspect the Column Hold Down System sasarane e anane anana nana ca rca aca nann naen eea 4 5 Part No 32283 Genie Superlift Advantage Parts and Service Manual First Edition BEE TABLE OF CONTENTS Section Four B 2 B 3 B 4 B 5 C 1 C 2 C 3 C 4 C 5 Section Five Scheduled Maintenance Procedures cont Eeer Mor E 4 5 Clean the Col mris u nee r 4 5 Inspect and Lubricate the Winch 4 6 Inspect and Lubricate the Rotating Barrel Handler eee eres teen eens 4 6 Lubricate the Casters and Wheels AA 4 7 Inspect the Mast Assembly for Wear sse 4 7 Replace the Winch Friction Disks A 4 8 Inspect the Safety Brake System 4 8 Inspect the Painted Surfaces A 4 9 Troubleshooting Flow Charts I trodUCHON tai ibas 5 1 1 Mast Will Not Sequence Properly su 5 2 Carriage Will Not Raise But Winch Will Operate sesseeeeseeeeseeesereerreerrrerrreerneee 5 3 Winch Will Not Operate iii 5 4 Section Six Repair Procedures Introduction EE 6 1 Base Assembly 1 1 How To Remove the Base Standard Base sse 6 2 1 2 How To Remove the Base Straddle Base oooooonoccccnncccccnnccccnononcnnonancnnanancn nana ncnnannns 6 3 Mast Assembly 2 1 How to Disassemble the Mast Assembly nenn 6 4 2 2 How to Replace the Lifting Cable enne 6 5 2 3 How to Replace a Lifting Pulley Mast Installed AA 6 6 Winches 3 1 How To Disassemble the Winch Singl
34. e Speed 6 7 3 2 How To Disassemble the Winch Two Speed 6 9 vi Genie Superlift Advantage Part No 32283 Parts and Service Manual First August 2007 gt gt gt gt gt gt gt gt Section Seven Figure 7 A Figure 7 B Figure 7 C Figure 7 D Figure 7 E Figure 7 F Figure 7 G Figure 7 H Figure 7 1 Figure 7 J Figure 7 K Figure 7 L Figure 7 M TABLE OF CONTENTS Service Parts How To OrderiParts 1 ud fin ore bee pb trei be bero ends 7 1 Decals and Paint Rev A August 2007 ssssesseeessreesreesrrrssrirserirterirtsrrrnesrinserens 7 2 Number 1 Mast Attached Parts Rev A August 2007 7 6 Standard Base Components Rev A August 2007 7 8 Straddle Base Components Rev A August 2007 7 12 Mast Components View 1 Rev C October 2006 7 14 Mast Components View 2 Rev B August 2007 7 16 Mast Components Pulleys and Cable Rev C August 2007 1111 1 1 7 18 Load Handling Attachments FOrkS AAA 7 22 Load Handling Attachments Boom Pipe Cradle and Load Platform 7 24 Load Handling Attachments Vertical Barrel Stacker ooooonccccnnnccccnocccccnnocaninancccnnn 7 26 Load Handling Attachments Rotating Barrel Handler 7 28 Single Speed Winch Rev B July 2007 7 32 Two Speed Winch Rev B July 2007 UV 7 34 Part No 32283 Genie Superlift Advantage vii Parts and Service Manual First Edition This page intentionally left blank Genie Su
35. e Superlift Advantage 7 19 Section 7 Service Parts August2007 FIGURE 7 G REV C 8 5 45 9 O 00000 7 20 Genie Superlift Advantage Part No 32283 August 2007 Section 7 Service Parts pemn ZZ REVC FIGURE 7 G Index Part No Description Quantity This Figure 16 32895 Carriage Assembly iii 1 SL 5 from serial number 5594 00101 thru 5594 04447 ssessessssseesseressereerrrrserreesrenees SL 10 from serial number 5594 00101 thru 5594 04302 esee SL 15 from serial number 5594 00101 thru 5594 04293 sess 35488 Carriage Assembly iii 1 SL 5 after serial number 5594 04447 ire SL 10 after serial number 5594 04302 rrrnnnnnvrnnnnnvrnnnnnvrvnnrnvrnnrsnrrnnrsnrrennsnrensnrnrrnnnn SL 15 after serial number 5594 04293 rrrnnnnnnrnnnnnvrnnnnnrrnnnrnvrnnrrnvrnnrsnrrennrnrensernrrennn 32896 Carriage Assembly iii 1 SL 20 from serial number 5594 00101 thru 5594 04286 sss SL 25 from serial number 5594 00101 thru 5594
36. e same column that the pulley is on 5 Ifreplacing an upper pulley slide the column that is above the pulley to be replaced forward If replacing a lower pulley slide the column with the pulley to be replaced forward Push the column forward about 6 inches 15 2 cm to expose the lower column stop 6 Remove the column stop 7 Slide the column backwards until the pulley to be replaced is exposed 8 Remove the two mounting fasteners from the pulley mounting block Then remove the pulley assembly 9 Remove the bolt that attaches the pulley to the mounting block Note where the shims are located before dissembling 10 Remove the old pulley Install the cable onto the new pulley then install the pulley onto the column When installing the cable onto the ACAUTION pulley make sure the cable does not get twisted or sequencing and other mast related problems will occur Make sure the cable guard is located over the retaining pin on the pulley mounting block Make sure the pulley spins freely after reassembling the pulley assembly 11 Attach the pulley assembly to the column 12 Assemble the columns in reverse order of disassembly 13 Repeat the procedure for other pulleys to be replaced Remember to remove the tape from the hold down latches before putting machine back in service 6 6 Genie Superlift Advantage Part No 32283 Parts and Service Manual First Edition 3 1 How to Disassemble the Winch S
37. emove the cable retaining fastener from the winch drum Then remove the cable from the drum 3 Remove the handles from the pinion shaft 4 Remove the drum bolt and the drum bolt spacer Then remove the drum and drum gear cover and the housing spacer 5 Remove the input shaft cover 6 Remove the mounting fasteners from the spring and ball housing 7 Remove both the springs and the balls from the housing 8 Shift the input shaft into the neutral position 9 Rotate the input shaft until the drive pin is visible inside the input shaft gear 10 Remove the drive pin with a soft metal drift 11 Slide the input shaft out of the winch housing Note the location and position of the components on the input shaft 12 Remove the retaining ring from the pinion shaft 13 Gently pry the pinion shaft gears to the left over the woodruff keys 14 Remove the lock nut from the end of the pinion shaft located on the outside of the winch housing 15 Slide the pinion shaft to the right and remove the pinion spacer pinion plate ratchet gear and friction disks Remove the pinion gear by turning it counterclockwise then slide it off the left side of the shaft WINCHES 16 Remove both pinion bushings Use a soft metal drift equal to the outside diameter of the bushing and tap with rubber mallet Place a block in between the walls ACAUTION of the winch housing to prevent the housing from bending while removing the bushings Ho
38. ential to good machine performance and safe operation Extremely dirty conditions may require that the columns be cleaned more often 1 Raise all columns to the maximum height 2 Visually inspect the inner and outer channels of the columns for debris or foreign material If necessary use a mild cleaning solvent to clean the columns This procedure will require the use AWARNING of additional access equipment Do not place ladders or scaffold on or against any part of the machine Performing this procedure without the proper skills and tools may result in death or serious injury Dealer service is strongly recommended Part No 32283 Genie Superlift Advantage 4 5 Section 4 Scheduled Maintenance Procedures Parts and Service Manual First Edition TABLE B PROCEDURES B 4 Inspect and Lubricate the Winch Maintaining the winch is essential to good machine performance and safe operation An unsafe working condition exists if the winch has excessive wear and or does not operate smoothly free of hesitation and binding 1 Carefully lubricate the following areas with automotive grease the cable drum gear the teeth on the pinion gear that meshes with the cable drum gear the threads on the pinion shaft under the pinion gear the teeth on the slow and the fast speed gears where they mesh together Do not apply grease to brake friction disks or rachet gear 2 Carefully lubricate with 30W oil both pivot
39. er to Section Six Figure 4 A Single Speed Winch for exploded view of the winch 1 Place one side of the winch housing over a vise Open the vise until it is wider than the outside diameter of the bushing 2 Insert a soft metal drift through the opposite bushing hole Tap the drift with a rubber mallet to push the bushing into place Repeat steps 1 and 2 to insert the other bushing Use a piece of flatbar in between the drift and the bushing to prevent any damage to the bushing 5 Add two drops of 30W oil to both pivot points on each ratchet pawi Do not allow grease or oil onto the ACAUTION brake friction disks or the ratchet gear 6 Install the winch housing onto the mast Be sure the winch drum is towards the top 7 Insert the longer threaded end of the pinion shaft through the left bushing approximately half way 8 Apply asmall amount of automotive grease to the large threaded section of the pinion shaft under the gear nut Install the pinion gear onto the pinion shaft with the gears towards the left wall of the winch housing Screw onto the large threads hand tight Part No 32283 Genie Superlift Advantage 6 7 Section 6 Repair Procedures Parts and Service Manual First Edition WINCHES 9 Install a friction disk ratchet gear friction disk pinion plate and pinion spacer in respective order onto the pinion shaft The teeth on the ratchet gear must curve away from the right side wall of the winch
40. ermany Phone 0800 180 9017 Phone 49 422 149 1818 Fax 49 422 149 1820 Genie North America Phone 425 881 1800 Toll Free USA and Canada 800 536 1800 Fax 425 883 3475 Genie Australia Pty Ltd Phone 61 7 3375 1660 Fax 61 7 3375 1002 Genie China Phone 86 21 53852570 Fax 86 21 53852569 Genie Malaysia Phone 65 98 480 775 Fax 65 67 533 544 Genie Japan Phone 81 3 3453 6082 Fax 81 3 3453 6083 Genie Korea Phone 82 25 587 267 Fax 82 25 583 910 Genie U K Phone 44 0 1476 584333 Fax 44 0 1476 584334 Genie Brasil Phone 55 11 41 665 755 Fax 55 11 41 665 754 Genie Mexico City Phone 52 55 5666 5242 Fax 52 55 5666 3241 Genie Holland Phone 31 183 581 102 Fax 31 183 581 566 Parts amp Service Manual Superlift Advantage from serial number 9594 101 to 5501 15094 and from SLA02 15095 to SLA04 25258 Part No 32283 Rev A6 G a enie A TEREX COMPANY
41. hat might indicate damage 1 Visually inspect the all winch components for damage 2 Raise the carriage through a partial cycle and release the winch handles Result The winch should operate smoothly free of hesitation or binding The load should not lower when the handles are released 3 Fully lower the carriage Result The winch should operate smoothly free of hesitation or binding A 5 Inspect the Columns for Damage Detection of damage to columns is essential for safe machine operation An unsafe working condition exists if the columns are damaged and do not operate smoothly free of hesitation and binding A daily check of the columns allows the inspector to identify changes in the operating condition of the mast assembly that might indicate damage 1 Visually inspect the exterior of each column for the following dents gouges or abrasions bends or warping excessive wear TABLE A PROCEDURES 2 Raise and lower all columns through a complete cycle Result Columns should raise and lower smoothly free of hesitation and binding A 6 Inspect the Cable and Cable Pulleys Detection of damage to cable or pulleys is essential for safe machine operation An unsafe working condition exists if these components are damaged and do not operate smoothly A daily check of this system allows the inspector to identify changes in the operating condition that might indicate damage 1 Visually inspect the cab
42. he casters and wheels be inspected and lubricated more often 1 Visually inspect each caster and wheel for cuts cracks or unusual wear 2 Move the machine on a flat smooth surface and check that the casters and wheels roll smoothly free of hesitation and binding 3 Lock the base swivel casters Result The wheels should not turn 4 Be sure the rotation lock functions properly in each position 4 4 Genie Superlift Advantage Part No 32283 Parts and Service Manual First Edition Section 4 Scheduled Maintenance Procedures Table B Procedures B 1 Inspect the Column Hold Down System Detection of damage to the column hold down system is essential for safe machine operation An unsafe working condition exists if the system is damaged and does not operate properly 1 Using proper lifting techniques lay the machine back against a sawhorse or other suitable support 2 Visually inspect the hold down latches for damage 3 Move each hold down latch back and forth to ensure that the latch moves freely B 2 Inspect All Welds Weld inspections are essential to safe machine operation and good machine performance Failure to locate and repair damage may result in an unsafe operating condition 1 Visually inspect the welds in the following locations winch mounting plate loading wheels steer handle base legs and stabilizers load handling attachment s B 3 Clean the Columns Clean columns are ess
43. hile holding the safety brake rollers in position with the hex key wrench 9 Repeat steps 6 through 8 for each remaining column How to Release the Safety Brake When Servicing the Mast The safety brake system will lock when the machine is tilted horizontally When the brake is locked the columns can extend but not retract If the safety brake system locks while you are servicing the mast use one of the following methods described below to release the brake A The first method allows you to release each column successively starting at the carriage and removing columns one by one This is described above in How to Disassemble the Mast Assembly steps 7 and 8 B The second method allows you to release any column in the assembly regardless of position but requires a custom made tool The tool is a piece of 1 8 to 3 16 inch diameter stiff wire bent in an L shape with one end 1 inch long and the other end 16 inches long The installation of a handle on the 16 end will make it easier to use Using the special tool reach from the bottom of the column and into the safety brake access slot in the inner side wall of the column Slide the carriage away from the base about 1 inch 2 5 cm while reaching through the far upper end of the slot Position the short end of the tool above the safety brake rollers and pull back on the tool Slide the released column out the bottom of the mast assembly How to Assemble the Mast 6 4 Genie Su
44. iage 2 Wrap a piece of strapping tape around the cable just below the swagged end of the cable 3 Remove the cable from the winch drum 4 Cutthe cable where you placed the tape Part No 32283 Genie Superlift Advantage 6 5 Section 6 Repair Procedures Parts and Service Manual First Edition MAST ASSEMBLY Cable must be cut using a cutting tool which will not leave frays on the end of the cable 5 Using the cable re threading tool that came with your cable insert even amounts of cable into each end of the tool 6 Pull the old cable out from the winch and pull in new cable at the same time If cable gets caught as you are pulling it through the columns and pulleys take care not to pull too hard as you can break the connection between the two cables Try pulling the cable back and forth until the cable pulls free 2 3 How to Replace a Lifting Pulley Mast Installed 1 Fully lower the carriage 2 Unwind approximately 1 to 2 feet 0 30 to 0 60 meters of cable from the winch drum 3 Using proper lifting techniques lay the machine on the floor on its back on the loading wheels 4 Using a piece of strapping tape secure the hold down latch to its respective column so that it does not fall off during disassembly If replacing an upper pulley secure the hold down latch to the column above the one you wish to replace the pulley on If replacing the lower pulley secure the hold down latch to th
45. ingle Speed Bodily injury hazard Cables can ACAUTION fray Always wear adequate hand protection when handling cable Fully lower the carriage Remove the cable retaining fastener from the winch drum Then remove the cable from the drum Remove the handles from the pinion shaft 4 Remove the drum bolt and the drum bolt spacer Then remove the drum and drum gear cover and the housing spacer from the winch Remove the two lock nuts from the pinion shaft by holding the opposite end of the shaft by the flattened portion of the threads Be careful not to damage the ACAUTION threads while holding the pinion shaft Remove the retaining ring from the pinion shaft Slide the pinion shaft to the left and remove the pinion spacer pinion plate ratchet gear and friction disks Remove the pinion gear by turning it counterclockwise then slide it off the right side of the shaft Remove the pinion shaft from the winch housing Remove both pinion bushings Use a soft metal drift equal to the outside diameter of the bushing and tap with rubber mallet Place a block in between the walls ACAUTION of the winch housing to prevent the housing from bending while removing the bushings 10 Remove the winch housing from the machine Section 6 Repair Procedures Winches How to Assemble the Winch Single Speed Bodily injury hazard Cables can ACAUTION fray Always wear adequate hand protection when handling cable Ref
46. lacards are in place 2 Inspect all decals for legibility and damage Replace any damaged or illegible decal immediately Contact your authorized Genie distributor or Genie Industries if replacement decals are needed A 3 Inspect for Damage Loose or Missing Parts Daily machine condition inspections are essential to safe machine operation and good machine performance Failure to locate and repair damage and discover loose or missing parts may result in an unsafe operating condition 1 Inspect the entire machine for damage and improperly installed or missing parts including cable anchor cable and pulleys mast columns exterior plastic shims for safety brake nuts bolts and other fasteners load handling attachment winch and related components legs and casters stabilizers latch plates and casters loading wheels and snap pin dents or damage to machine cracks in welds or structural components corrosion to painted surfaces corrosion or oxidation to all other surfaces 4 2 Genie Superlift Advantage Part No 32283 Parts and Service Manual First Edition Section 4 Scheduled Maintenance Procedures A 4 Check the Winch Operation Detection of damage to the winch is essential to safe machine operation An unsafe working condition exists if the winch is damaged or not operating correctly A daily check of the winch operation allows the inspector to identify changes in the operating condition of the winch t
47. le and components for the following frayed or broken wire strands kinks in the cable corrosion paint or foreign materials split or cracked swagged end s cable is properly secured to the winch cable is properly secured to the mast 2 Using proper lifting techniques lay the machine back against a sawhorse or other suitable support and check to be sure of the following cable is on the pulleys upper and lower mounting brackets are properly secured no broken or damaged pulleys no unusual or excessive pulley wear Part No 32283 Genie Superlift Advantage 4 3 Section 4 Scheduled Maintenance Procedures Parts and Service Manual First Edition TABLE A PROCEDURES A 7 Check the Mast for Proper Sequencing Detection of damage to the mast is essential for safe machine operation An unsafe working condition exists if the mast is damaged and does not sequence properly free of hesitation and binding A daily check of the sequencing allows the inspector to identify changes in the operating condition of the mast assembly that might indicate damage 1 Raise all columns to full height Result The carriage should rise to the top of the front column section followed in consecutive order by each column 2 Lower the columns to the stowed position Result The columns should lower in reverse order followed by the carriage A 8 Inspect the Casters and Wheels Extremely dirty conditions may require that t
48. may result in death serious injury or substantial machine damage M Immediately tag and remove from service a damaged or malfunctioning machine M Repair any machine damage or malfunction before operating machine M Keep records on all inspections for three years M Be sure the capacities of sawhorses or other supports are sufficient to withstand machine weight See Specification section for specific weight M Be sure overhead cranes or other lifting devices are of ample capacity to handle machine weight See Specification section for specific weight M Unless otherwise specified perform each procedure with the machine in the following configuration machine positioned on a flat level surface carriage fully lowered casters locked load handling attachment installed About This Section This section contains detailed procedures for each scheduled maintenance inspection Each procedure includes a description safety warnings and step by step instructions Symbols Legend TTY Indicates the presence of a hazard ADANGER that will cause death or serious injury Indicates the presence of a hazard AWARNING that may cause death or serious injury Indicates the presence of a hazard ACAUTION that will or may cause serious injury or damage to the machine Indicates special operation or maintenance information Indicates that a specific result is expected after performing a series of steps Part No 322
49. nd to bottom of barrel Rotating Barrel Handler 55 gallon 3 ft 10 in 8 ft 8 in 13 ft 7 in NA NA 24 inch Load Center 1 2m 2 6m 4 1m Note measured from ground to bottom of barrel Load Platform forks down 4 ft 101 2 in 9 ft 9 in 14 ft 71 2 in 19 ft 6 in 24 ft 4 in 1 5m 3m 4 5m 6m 7 4m forks up 6 ft 7 in 11 ft 51 2 in 16 ft 4 in 21 ft 21 2 in 26 ft 1 2 in 2m 3 5m 5m 6 5m 7 9 m Note can be used with standard forks and adjustable forks only Pipe Cradle handles round objects up to 30 in 76 cm in diameter Note can be used with standard forks and adjustable forks only see above for working heights Non marking Fork Option Note can be used with standard forks and adjustable forks only see above for working heights Fork Extension Option Note can be used with standard forks and adjustable forks only see above for working heights 2 2 Genie Superlift Advantage Part No 32283 Part and Service Manual First Edition Section 2 Specifications SPECIFICATIONS Bolt Torque Specifications Size Threads SAE Grade 5 Bolts SAE Grade 8 Bolts Torque Dry Torque Dry Torque Dry Torque Dry Torque Dry Torque Dry inch pounds foot pounds Newton meters inch pounds foot pounds Newton meters 10 24 43 5 60 7 32 49 6 68 8 1 4 20 96 11 144 16 28 120 14 168 19 5 16 18 17 23 25 34 24 19 28 25 34 3 8 16 30 41 45 61 24 35 48 50 68 7 16 14 50 68 70 95 20 55 75 80
50. nne ndis 12 Hinge Barrel Cradle edet attt a Tett ens 1 Chain Barrel Cradle sisi 1 Washer Flat 0 3 McCain ee 1 Screw FHS 3 8 16 x NGA akan ai ii E ag a Sg DG nn nana aab aha 1 Quantity listed for this item is approximate Actual quanity may vary to ensure proper fit This parts list continues on page 7 29 Part No 32283 Genie Superlift 7 29 Section 7 Service Parts October 2006 FIGURE 7 K 69 4 7 30 Genie Superlift Part No 32283 October 2006 Section 7 Service Parts oa FIGURE 7 K Index Part No Description Quantity This Figure 24 33117 Bracket Mounting Barrel Cradle ss 1 25 28986 125 Key Square 0 188 x 0 188 x 1 25 inch 4 7 x 4 7 31 7 mm 1 26 33116 Bracket Barrel Cradle moon naaa 1 27 33120 Plate Support Drive Gear A 1 28 33218 Bushing Flange 0 875 x 1 x 0 625 inch 1 29 33220 Gear Drive cune ate te ei n e M ue ade pete rede fa esp E uu ces 1 30 6326 Screw HHC 3 8 16 x 3 inches Gpnp nnnnnnnnnnnn cnn canario na nc nana 2 Part No 32283 Genie Superlift 7 31 Section 7 Service Parts July 2007 Figure 7 L Single Speed Winch REVB 7 32 Genie Superlift Part No 32283 July 2007 Section 7 Service Parts REVB Index Part No 32945 1 7256 2 7584 3 5319 4 6199 5 32890 6 7591 7 7571 8 6777 9
51. nt Fork Slider SL 5 10 and 15 models only 2 5 32539 Fork Flat SL 5 10 and 15 models only 2 6 32548 Forks Adjustable mrt oet reti ene RR nes 2 7 32906 Fork Standard includes decal oooconnccccininccccnccccnonooccnnnnccnnnnnaccnnnnn cnn nano nnn naar cn nnnnncnnnnns 1 8 32943 Tube Fork Extension Standard and Adjustable Forks A 2 9 32500 Pin Detent 0 5 x 2 5 inches 1 3 x 6 35 cm 2 10 32526 iiec 3 11 32908 Carrier Adjustable Fork includes decals eseeeeem 1 12 32907 Carrier Adjustable Flat includes decals SL 5 10 and 15 models only 1 Part No 32283 Genie Superlift 7 23 Section 7 Service Parts October 2006 Figure 7 Load Handling Attachments Boom Pipe Cradle and Load Platform D 7 24 Genie Superlift Part No 32283 October 2006 Section 7 Service Parts Index Part No 32569 32568 32567 1 8170 6638 33045 33044P 2 3 4 5 32937 6 32887 7 32579 8 32500 9 32526 FIGURE 7 1 Description Quantity This Figure Option Pipe Cradle Complete includes index numbers 1 through 4 ssssssssssessesees Option Load Platform Complete includes index number 5 Option Boom Complete includes index number 5 Nuts Wing 1 4520 7 7 Re nn men NA agat t ER 8 Washer Flat 1 4 inch caiie a an aaa Raa Taa aAA aaae A AE EONA 8 Belt Ee vr ete Eesen er A
52. onfiguration machine positioned on a flat level surface carriage fully lowered casters locked Repair Procedures About This Section Most of the procedures in this section should only be performed by a trained service professional in a suitably equipped workshop Select the appropriate repair procedure after troubleshooting the problem Perform disassembly procedures to the point where repairs can be completed Then to re assemble perform the disassembly steps in reverse order General Repair Process Malfunction Identify Troubleshoot discovered symptoms problem still exists Retum to Perform Service problem repair solved Symbols Legend Indicates the presence of a hazard ADANGER a that will cause death or serious injury Indicates the presence of a hazard AWARNING that may cause death or serious injury Indicates the presence of a hazard ACAUTION that will or may cause serious injury or damage to the machine Indicates special operation or maintenance information Indicates that a specific result is expected after performing a series of steps Part No 32283 Genie Superlift Advantage 6 1 Section 6 Repair Procedures Parts and Service Manual First Edition Base Assembly 1 1 How to Remove the Base Standard Base 1 Fully lower the carriage 2 Remove the load handling attachment from the machine Machines with stabilizers
53. perlift Advantage Part No 32283 Parts and Service Manual First Edition Section 6 Repair Procedures 1 Inspect all mast parts for wear and damage replace as necessary 2 Clean all of the columns and rollers 3 Clean all of the safety brake assemblies 4 Position the number one column so that it is open side up and level If it is not attached to the base secure the column to your sawhorses or work table before proceeding 5 Install all column assembly components if removed during disassembly Apply a small amount of grease between the roller bolt head and the inside of the roller wheel 6 Slide the number two column into the number one from the bottom Stop inserting the column when the top of the safety brake assembly is even with the bottom of the number one column 7 Repeat with all remaining columns All columns should be sticking out of the next lower column Do not install the carriage Cable is installed after all columns are together as an assembly 8 Attach the swagged end of the cable to the cable anchor on the top of the front column 9 With the other end of the cable in hand feed it through the box section web of the carriage into the pulley and push it through the pulley until it comes out the back side of the carriage Bodily injury hazard Cables can ACAUTION fray Always wear adequate hand protection when handling cable Refer to figure 7 G in the parts section to identify the cable
54. perlift Advantage Part No 32283 Part and Service Manual First Edition Section 2 Specifications Specifications Model SL 5 SL 10 SL 15 SL 20 SL 25 Height Stowed 781 2 in 781 2 in 781 2 in 781 2 in 781 2 in 199 cm 199 cm 199 cm 199 cm 199 cm Width 311 2 in 311 2 in 311 2 in 311 2 in 311 2 in Standard Base 80 cm 80 cm 80 cm 80 cm 80 cm Width stabilizers lowered 785 8 in 785 8 in 785 8 in 785 8 in 785 8 in Standard Base 185 cm 185 cm 185 cm 185 cm 185 cm Width Min 311 2 in 311 2 in 311 2 in NA NA Straddle Base 80 cm 80 cm 80 cm Width Max 58 in 58 in 58 in NA NA Straddle Base 147 cm 147 cm 147 cm Length Stowed 29 in 29 in 29 in 29 in 31 in 74 cm 74 cm 74 cm 74 cm 79 cm Length Operating 571 2 in 571 2 in 721 2 in 801 2 in 801 2 in 146 cm 146 cm 184 cm 204 cm 204 cm Ground 2 in 2 in 2 in 2 in 2 in Clearance 50 8 mm 50 8 mm 50 8 mm 50 8 mm 50 8 mm Load Capacity 1000 Ibs 1000 Ibs 800 Ibs 800 Ibs 650 lbs at 18 load center 454 kg 454 kg 363 kg 363 kg 295 kg Net Weight Standard Base 215 lbs 260 lbs 317 lbs 405 lbs 450 lbs no load handling attachment 97 5 kg 117 9 kg 143 8 kg 183 7 kg 204 1 kg Net Weight Straddle Base 258 lbs 303 Ibs 360 Ibs NA NA no load handling attachment 117 0 kg 137 4 kg 163 3 kg Load Handling Attachments Length Width Depth Net Weight Standard Forks 271 2 in 231 2 in 21 2 in 38 lbs 70 cm 60 cm 6 5 cm 17 2 kg Adjustable Forks 271 2 in 111 2 in to 30 in 21 2 in 52 5 lbs 70 cm 29 cm to 76
55. r the boom if possible Do not place any weight on the load handling attachment 2 Raise the carriage until it is half way up the front column 3 Physically hold the bottom side of the carriage and lift it approximately 5 inches 12 7 cm then drop it O Result The carriage should stop within 3 inches 7 6 cm and the safety brake should A I lock Crushing hazard ACAUTION gt s Do not stand directly under columns 4 Raise the carriage 6 inches 15 2 cm to unlock the safety brake 5 Continue raising the carriage until the front column is half way up the adjacent column 6 Physically hold the bottom side of the front column and lift it approximately 5 inches 12 7 cm then drop it ACAUTION Crushing hazard Do not stand A directly under columns f 7 Raise the front column 6 inches 15 2 cm to unlock the safety brake 8 Continue raising the carriage until the front column is fully raised and the next column is half way up the adjacent column 9 Physically hold the bottom side of the next column and lift it approximately 5 inches 4 8 Genie Superlift Advantage Part No 32283 Parts and Service Manual First Edition Section 4 Scheduled Maintenance Procedures JB TABLE C PROCEDURES 12 7 cm then d
56. rop it Inspect the Painted Surfaces Inspecting the painted surfaces of your machine is essential to safe operation An unsafe working condition exists if there is damage to painted surfaces that is not corrected 1 Visually inspect all painted surfaces for the following conditions s blistering n M rust Crushing pealing ACAUTION hazard Do not stand directly fading under columns 10 Repeat steps 7 through 9 to test all remaining NS un Replace any component if it is damaged When unlocking the safety brake it may be necessary to hold down the column behind the brake to be unlocked The number one column column attached to base does not have a safety brake and will not need to be tested Part No 32283 Genie Superlift Advantage 4 9 Section 4 Scheduled Maintenance Procedures Parts and Service Manual First Edition EE EE se This page intentionally left blank 4 10 Genie Superlift Advantage Part No 32283 Parts and Service Manual First Edition Section 5 Troubleshooting Flow Charts Troubleshooting Flow Charts Observe and Obey M Troubleshooting and repair procedures shall be completed by a person trained and qualified on the repair of this machine M Immediately tag and remove from service a damaged or malfunctioning machine M Repair any machine damage or malfunction before operating the machine M Be sure the capacities of sawhorses or other supports are sufficient to
57. routing 10 Insert the carriage into the bottom end of the top column Hold the carriage from moving and pull the cable up to the top of the column leaving enough slack so that you can feed the cable through the next pulley 11 Push the cable through the exposed portion of MAST ASSEMBLY the pulley at the top of the column until the cable reaches the pulley at the bottom of the column 12 Using needle nose pliers insert the cable end into the cable pulley Push the cable through the pulley until the end comes out 13 Push the cable between the two mast sections until it comes out the top of the column 14 Repeat steps 11 through 13 until all the columns are cabled 15 Slide all the columns forward until you can install the column stops Do not slide the columns forward further than necessary 16 Remove the tape from the hold down latches making sure that they move freely 17 Install all the components removed during disassembly 18 Attach the cable to the winch and be sure cable is routed correctly 19 Raise all the columns to full height to release the safety brakes and verify proper operation 2 2 How to Replace the Lifting Cable All Genie replacement cables come with one preswaged end that terminates to the last column and one taped end that terminates to the winch Bodily injury hazard Cables can ACAUTION fray Always wear adequate hand protection when handling cable 1 Fully lower the carr
58. rs M Machines that have been out of service for a period longer than 3 months must complete the quarterly inspection About This Section Schedule There are three types of maintenance inspections that must be performed according to a schedule daily quarterly and annually To account for repeated procedures the Maintenance Tables and the Maintenance Inspection Report have been divided into three subsections A B C Use the following chart to determine which group s of procedures are required to perform a scheduled inspection Inspection Table or Checklist Daily A Quarterly every 150 hours or three months A B Annual A B C Maintenance Tables The maintenance tables contained in this section provide summary information on the specific physical requirements for each inspection Complete step by step instructions for each scheduled maintenance procedure are provided in section 4 Scheduled Maintenance Procedures Maintenance Inspection 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 Keep records on all inspections for three years Part No 32283 Genie Superlift Advantage 3 1 Section 3 Scheduled Maintenance Inspections Parts and Service Manual First Edition Maintenance Tables Dealer Table A Tools are New parts service required required suggested
59. rst Edition Chart 1 Mast Will Not Sequence Properly Be sure safety brake is not locked by raising and lowering all columns over E Verify weight of load Remove excess weight against machine loaded from machine and capacity re check not over loaded not centered Center load and Check position of load re check for proper centering centered Inspect the column Clean the columns See channels and pulley Maintenance procedure tracks for foreign debris B 3 Clean the Columns no debris binding Check for cable binding Inspect pulley and on cable pulleys pilky guard for damage Replace the pulley or not binding pule guard See epair procedure 2 3 How to Replace the Lifting Pulley Mast Installed Check the roller wheels yes Replace the damaged for damage OR no roller wheel s OR apply grease grease to the roller bolt Check each mast Replace the damaged column OR consult Genie Industries Service Department column for damage Consult Genie Industries Service Department Inspect cable for damage yes Replace the cable See Repair procedure 2 2 How to Replace the Lifting Cable Genie Superlift Advantage Part No 32283 Parts and Service Manual First Edition Section 5 Troubleshooting Flow Charts Carriage Will Not Raise
60. rum with a handle and spool the cable onto the drum neatly Component damage hazard Be ACAUTION sure the cable winds onto the winch drum evenly Part No 32283 Genie Superlift Advantage 6 11 Section 6 Repair Procedures Parts and Service Manual First Edition TX This page intentionally left blank 6 12 Genie Superlift Advantage Part No 32283 August2007 Section 7 Service Parts How To Order Parts How To Order Service Parts Please be prepared with the following information when ordering replacement parts for your Genie product Machine model number Machine serial number Genie part number Part description and quantity Purchase order number Ship to address Desired method of shipment Name and telephone number of the authorized Genie Distributor in your area If you don t know the name of your authorized distributor or if your area is not currently serviced by an authorized distributor call Genie Genie North America Telephone 206 881 1800 Toll Free 800 536 1800 in U S A Toll Free 800 426 8089 in Canada Fax 206 883 3475 Genie Europe Telephone 44 0636 813943 Fax 44 0636 815270 Machine Information Model Serial Number Date of Purchase Authorized Genie Distributor Phone Number Manuals Genie Industries offers the following support document for this machine Title Part No Operator s Manual 33499 from serial number 5594 101
61. s list continues on page 7 35 Part No 32283 Genie Superlift 7 35 Section 7 Service Parts July 2007 FIGURE 7 M REVB 010 00660 66 e 7 36 Genie Superlift Part No 32283 July 2007 A nr REV B Index 21 22 23 24 25 26 27 28 29 30 31 32 33 Part No 32870 6200 32871 32872 7590 7571 6777 7591 7598 23415 12460 40117 Ref Section 7 Service Parts FIGURE 7 M Description Quantity This Figure Gear Pinion Shaft 12 Tooth rrrrerennnnnvrrnrnnnnnrernnrnvevennnnrrrrnnnnnnnnnnssssvnnnnnrvrvrnnnunnsnnssee 1 Retaining Ring 0 75 inches A 1 Key Woodruff No 4039 u He Heiner lee 2 Pinion Sai eod ie Rte RT C eto te Brei 1 Pinion GOA m ER 1 Friction DISK iere enr emat tnm test 2 Ratchet Gear ukas d diae 1 PINOT Plate tn eee emite e s 1 Spacer Pinion Shaft eene nnne nnne nnns nnn nnns 1 Nut Low Profile Lock 1 2 13 iii 2 Screw HHC 1 2 13 x 6 5 inches GR 5 iii 1 Ratchet Kit nn 1 Winch Drum not available as service part sesanan anae aane aaa nana anana nenen a ee Part No 32283 Genie Superlift 7 97 Genie Scandinavia Phone 46 31 575100 Fax 46 31 579020 Genie France Phone 33 0 2 37 26 09 99 Fax 33 0 2 37 26 09 98 Genie Iberica Phone 34 93 579 5042 Fax 34 93 579 5059 Genie G
62. to 5501 15094 and from SLAO2 15095 to SLA05 28239 EMI Safety Manual sense 27581 Part No 32283 Genie Superlift Advantage 7 1 Section 7 Service Parts August2007 Figure 7 A Decals and Paint View 1 REVA 7 2 Genie Superlift Advantage Part No 32283 August2007 Section 7 Service Parts REVA FIGURE 7 A Index Part No Description Quantity This Figure 1483 Paint Genie Blue 1 Gallon 3 78 liters rrrnrrnnnnnrrnnnrnrrnnnnnrrnnnnnrrnnnnnrrnnnrnrrennrnnrnen 1484 Paint Genie Blue 12 Ounces 340 5 grams Aerosol sse 1 32686 Warning Machine Safety and Set up eeeeeea eaaa nn 1 2 32688 ENER EE 2 3 31072 Operator s Manual Storage Container 1 4 32939 Warning Crushing Hazard Brake Lock 1 5 32770 Notice Two speed Winch Shift Instructions ooooonnccnnnnccconnccccnoncncnnnnnccnnnnrccnonnancnnno 1 6 32938 Use This Winchester tte a o eth ends 1 7 32885 Warning Silent Ratchet System arrnrrnnnnvrnnnnnvrnnnnnnvnnnnnnrrnnrnnrnnnnrnrrnnnnnrrensnnnrensnnnnne 1 8 32689 Decal Model Height Enunciado its 2 32690 Decal Model Height GL 210 2
63. ty rrnnrnnrnnnnnnrrnnnnnrrnnnnnrnnnnnnvrnnnnnvrnnnnnrnnnennnnn 1 19 32715 Notice Flat Fork Get up 1 20 32718 Warning Flat Fork Safety AA 1 Part No 32283 Genie Superlift 7 5 Section 7 Service Parts August2007 Figure 7 B Number 1 Mast Attached Parts ve OSK Go Se 2 REVA G9 000 2 D 7 6 Genie Superlift Advantage Part No 32283 August2007 a zz en Section 7 Service Parts REVA FIGURE 7 B Index Part No Description Quantity This Figure 26 57788 Wheel 6X2 INCHES eee t kata e A E Lebe TAE UR E EET 2 37202 Inner Axle Bushing 2 6564 Washer Shim 0 781 x 1 312 x 0 093 inch iii 4 3 32935 Weldment Loading Wheels wheels not included before 5595 03794 1 32302 Tape Shim 0 75 x 0 10 inch 13 inches 33 cm 35819 Weldment Loading Wheel includes decal from 5595 03794 4 Ref Winch Assembly refer to figures 7 L or 7 M pages 7 30 or 7 32 11111 111 5 4828 Nut Nyl ck 2 6 216 autore dard t ccm ve e da d dde 7 6 6638 Washer Flat zinch Jti ee me ea a dei iei 3 7 6175 Screw HHC 3 8 16 x 1 inch GR 3 8 32888 Plate Winch Mounting includes decal before 5595 03794 21122 1 33539 Plate Winch Mounting includes decal from 5595 03794 to 5501 14370 80162 Plate Winch Mounting includes
64. w to Assemble the Winch Two Speed Bodily injury hazard Cables can ACAUTION fray Always wear adequate hand protection when handling cable Refer to Section Six Figure 7 N Two Speed Winch for exploded view of the winch 1 Place one side of the winch housing over a vise Open the vise until it is wider than the outside diameter of the bushing 2 Insert a soft metal drift through the opposite bushing hole Line up the tab on the bushing to the hole in the winch housing Tap the drift with a rubber mallet to push the bushing into place Repeat steps 1 and 2 to insert the other bushing Use a piece of flatbar in between the drift and the bushing to prevent any damage to the bushing 3 Add two drops of 30W oil to both pivot points on each ratchet pawl Do not allow grease or oil onto the ACAUTION friction disks or the ratchet gear 4 Install the winch housing onto the mast Be sure the winch drum is towards the top 5 Insert the longer threaded end of the pinion shaft through the right bushing approximately half way Part No 32283 Genie Superlift Advantage Section 6 Repair Procedures Parts and Service Manual First Edition WINCHES 6 Apply a small amount of automotive grease to the large threaded section of the pinion shaft under the gear nut Slide the pinion shaft gears onto the pinion shaft Install the pinion gear onto the pinion shaft with the gears towards the right wall of the winch housing
65. wheels be inspected and lubricated more often 1 Visually inspect each caster and wheel for cuts cracks or unusual wear 2 Move the machine on a flat smooth surface and check that the casters and wheels roll smoothly free of hesitation and binding 3 Pump grease into the caster or wheel until it can be seen coming out of the bearing gap Grease Type Lithium based C 2 Inspect the Mast Assembly for Wear Detection of excessive or unusual wear in the mast assembly is essential for safe machine operation An unsafe working condition exists if the mast assembly has excessive wear and or does not operate smoothly free of hesitation and binding 1 Attach an overhead crane or similar lifting device to the lifting bracket on the mast 2 Lift the machine slightly and then guide it over onto the ground so that the machine is laying on the loading wheels Crushing hazard The machine will AWARNING fall unless it is properly supported with the overhead crane 3 Visually inspect the top of each column for clearance between the roller wheel and the adjacent column surface Result There should be a maximum gap of 0 062 inches 1 57 mm between the roller wheel and the column If mast inspection results in a measurement that is not within specification refer to Repair procedure 2 1 How to Disassemble the Mast 4 Visually inspect the bottom of each column for clearance between the roller wheel and the Part No 32
66. x 1 5 inches 8 9 x 3 8 cm 2 This parts list continues on page 7 11 Part No 32283 Genie Superlift Advantage 7 9 Section 7 Service Parts August2007 FIGURE 7 C REVA 517078 9 D 3 Go i 2806606606 9 7 10 Genie Superlift Advantage Part No 32283 August2007 Section 7 Service Parts REVA FIGURE 7 C Index Part No Description Quantity This Figure 20 30748 Shim 1 01 x 1 63 x 0 062 inch GpGxvA1 AN bmmi 8 21 32499 E clip 0 875 inch O 4 22 32489 Weldment Standard Base iii 1 23 32940 Pin Assembly with Lanyard ES 2 32500 Pin Detent 0 5 x 2 5 inches 1 3 x 6 3 cm 2163 Cable 1 16 inch 7 x 7 strands 12 inches 30 4 cm required 2238 Cable Oval Sleeve jieinch nnne nnne 33298 Screw HHC Drilled 1 2 13 x 3 inches 24 32479 Caster Swivel Lock bxv imnches 2 xvbtoemi nn 2 25 5224 Screw HHC 3 8 16 x 2 inches GR 2 26 32882 Weldment gt Stabilizer econ e e rt t tete ee e Ee ein res 2 27 32307 Caster Swivel Stem 5 x 1 5 inches 12 7 x 3 8 cm ssssssssssse 2 28 23270 Nut Low Profile M2 edere he nase wd w 2 29 6033 Washer EE ai rear ei Ina 2 30 6035 Washer Flat 0 625 x 1 75 inches ss 2 31 32519 Spring Stabilizer Latines EE ea A Aaaa 2 32 32897 Kit Plate Latch Stabilizer

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