Parts Manual Service Manual
Contents
1. Section 1 Safety Rules February 2009 Safety Rules Warning Failure to obey the instructions and safety rules in this manual and the Genie Superlift Contractor Operator s Manual could result in death or serious injury Many of the hazards identified in the operating instruction manual are also safety hazards when maintenance and repair procedures are performed Do Not Perform Maintenance Unless M You are trained and qualified to perform maintenance on this machine M You read understand and obey manufacturer s instructions and safety rules employer s safety rules and worksite regulations applicable governmental regulations M You have the appropriate tools lifting equipment and a suitable workshop A TEREX COMPANY iv Superlift Contractor Part No 115409 February 2009 Section 1 Safety Rules Personal Safety Any person working on or around a machine must be aware of all known safety hazards Personal safety and the continued safe operation of the machine should be your top priority A Read each procedure thoroughly This manual and the decals on the machine use signal words to identify the following Safety alert symbol used to alert personnel to potential personal injury hazards Obey all safety messages that follow this symbol to avoid possible injury or death Indicates an imminently hazardous situation which if not avoided will result in death or serious injury2. Verify weight of load against machine Sequence capacity Properly not over loaded Be sure safety brake if equipped is not engaged by fully raising and not Check position of load centered for proper centering lowering all centered columns ene AE debris channels and pulley Improper tracks for foreign debris sequencing of the mast columns may occur when the machine is at or near maximum capacity If improper sequencing occurs the columns may shift to their correct position during operation or when the load is removed The forks will not change position if the columns shift position The carriage should no debris Check for cable binding binding on cable pulleys not binding Check the roller wheels for damage OR no always raise first grease and lower last no Check each mast yes column for damage no Consult the Genie Industries Service Department Superlift Contractor Remove excess weight from machine and re check Center load and re check Clean the columns See Maintenance procedure B 2 Clean the Columns Inspect pulley and pulley no guard for damage yes Papae the pulley or pulley guard See Repair procedure 2 3 How to Replace the Lifting Pulley Mast Installed Replace the damaged roller wheel s OR apply grease to the roller bolt Replace the damaged column OR consult the Genie Industries Service Department
3. 10 20 21 270 366 280 379 380 515 820 488 6 20 2 300 06 50 20 0 56 80 am 8 8 320 488 280 588 450 610 610 827 50 om a 550 474 aro 687 500 678 670 908 seo 78 e 20 650 640 867 680 922 910 1283 770 104 _ 12 5 78 no 962 750 106 60 12 s0 15 N of a slo a a 1 s 72 8 9068 560 1206 1080 1464 1440 1952 1220 1654 11 4 1 15 1260 120 1661 1570 20 20 2785 100 2304 14 16 0 1978 1650 2648 2370 3213 3160 4284 2670 320 2 M2 6 2225 10 2666 2670 3620 3560 4826 00 4067 METRIC FASTENER TORQUE CHART This chart is to be used as a guide only unless noted elsewhere in this manual Class 8 8 Class 10 9 Class 12 9 DRY DRY 884 _68 775 91 105 i DRY DRY 2 125 81 110 168 147 337 e10 304 535 525 713 600 458 622 612 830 536 727 715 970 o 570 562 762 583 791 778 1055 682 925 90 1285 Part No 115409 Superlift Contractor 2 3 ile zl iz Eh ile Eh i o o gt ee EE 0 R O ee D NO 4 u o gy IO co o a W f GI D N 1 co g a col 1 a R oa o N ao N i g z g ile Eh i g W gt N A co p ol ol rol NX a RANI ENR fio r CP AL a R fe
4. A TEREX COMPANY Serial Number Range Superlift Contractor A eae Part No 115409 RevA February 2009 February 2009 Introduction Important Read understand and obey the safety rules and operating instructions in the appropriate Operator s Manual on your machine before attempting any maintenance procedure This manual provides detailed scheduled maintenance information for the machine owner and user It also provides troubleshooting and repair procedures for qualified service professionals Basic mechanical skills are required to perform most procedures However several procedures require specialized skills tools lifting equipment and a suitable workshop In these instances we strongly recommend that maintenance and repair be performed at an authorized Genie dealer service center Technical Publications Genie Industries has endeavored to deliver the highest degree of accuracy possible However continuous improvement of our products is a Genie policy Therefore product specifications are subject to change without notice Readers are encouraged to notify Genie of errors and send in suggestions for improvement All communications will be carefully considered for future printings of this and all other manuals Contact Us www genieindustries com e mail awp techpub terex com A TEREX COMI ii Superlift Contractor Serial Number Information Genie Industries offers the following
5. ADANGER AWARNING Indicates a potentially hazardous situation which if not avoided could result in death or serious injury Indicates a potentially hazardous ACAUTION situation which if not avoided may cause minor or moderate injury Indicates a potentially hazardous situation which if not avoided may result in property damage Be sure to wear protective eye wear and other protective clothing if the situation warrants it Be aware of potential crushing hazards 3 such as moving parts free swinging or unsecured components when lifting or placing loads Always wear approved steel toed shoes Part No 115409 A TEREX COMI Superlift Contractor V SAFETY RULES Workplace Safety Be sure to keep sparks flames and W lighted tobacco away from flammable and combustible materials like battery gases and engine fuels Always have an approved fire extinguisher within easy reach Be sure that all tools and working areas N are properly maintained and ready for use Keep work surfaces clean and free of debris that could get into machine components and cause damage other lifting or supporting device is fully capable of supporting and stabilizing the weight to be lifted Use only chains or straps that are in good condition and of ample capacity Be sure any forklift overhead crane or Be sure that fasteners intended for one 7 time use i e cotter pins and self locking nuts are not reused These co
6. REV A Inspect cable for damage yes Replace the cable See Repair procedure 2 2 How to Replace the Lifting Cable Part No 115409 February 2008 Section 4 Troubleshooting Flow Charts Chart 2 Carriage Will 9 Check for broken cable Replace broken cable Not Raise See Fri wake r 2 2 How to Replace the But Winch Lifting Cable Will Operate Be sure the carriage hold down bar is not engaged Replace damaged cable See Repair procedure 2 2 How to Replace the Lifting Cable Check pulley and guard for damage and replace if needed Check all cable pulleys Inspect the cable for to verify that the cable is kinks frays and properly routed damage Replace damaged component Check pulley and pulley guard for damage Re install cable if removed during inspection Replace damaged components OR contact the Genie Industries Service Department Inspect winch drum and pinion gear for damage H Contact the Genie Industries Service Department Part No 115409 A TEREX COMPANY Superlift Contractor 4 3 Section 4 Troubleshooting Flow Charts February 2009 Chart 3 Winch Will Not Operate Is the load centered properly and free of obstructions Check the cable for binding at the winch drum or inside the mast assembly not binding Check winch for proper operation See Maintenance procedure A 4 Check the Winch Operation Check
7. 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 Service Manual Superlift Contractor from serial number 9595 101 Part No 115409 RevA A TERE a X COMPANY
8. REV A 3 Measure each friction disk for wear Replace the friction disk if it measures less than specification Friction disk specification 1 16 inch 1 5 mm Friction disk 4 Measure both shaft bushings for wear Replace the bushings if the wall thickness measurements are less than specification Pinion shaft bushing specification 1 8 inch 3 1 mm Pinion shaft bushing 5 Lubricate the surface of the frame drum spacer with a thin layer of lithium grease Tighten the drum bolt to 20 ft lbs 27 Nm Do not over tighten Part No 115409 February 2009 Section 3 e Scheduled Maintenance Procedures Checklist C Procedure REVA C 1 Inspect the Mast Assembly for Wear Genie specifications require that this procedure be performed every 1000 hours or annually whichever comes first Detection of excessive or unusual wear in the mast assembly is essential for safe machine operation An unsafe working condition exists if the mast assembly has excessive wear and or does not operate smoothly free of hesitation and binding 1 Attach a lifting strap from an overhead crane or similar lifting device to the lifting point on the top of the mast Rotate the carriage hold down bar over the carriage and operate the winch to apply tension to the lifting cable 2 Lift the machine slightly with the overhead crane and guide it onto a suitable structure capable of supporting it AWARNING Crushing hazard The ma
9. Remove the cable from the drum Remove both handle retaining fasteners from the pinion shaft Remove the handles Remove the drum bolt and spacer Remove the drum drum gear cover and housing spacer Remove the input shaft cover Remove the mounting fasteners from the spring and ball housing Remove the two springs and balls from the spring and ball housing A TEREX COMPANY Superlift Contractor REVA 8 Slide the input shaft out of the winch housing 9 Remove the retaining ring from the pinion shaft 10 Remove the lock nut from the end of the pinion shaft located on the outside of the winch housing Note Note the location and position of the components on the pinion shaft 11 Slide the pinion shaft to the right and remove the pinion spacer pinion plate ratchet gear and friction disks Turn the pinion gear counterclockwise and slide it off the left side of the shaft 12 Remove both pinion bushings Use a soft metal drift equal to the outside diameter of the bushing and tap with a rubber mallet Component damage hazard Place a block between the walls of the winch housing to prevent the housing from bending while removing the bushings Part No 115409 February 2009 Section 5 e Repair Procedures REVA How to Assemble a Two speed Winch ACAUTION Bodily injury hazard Cables can fray Always wear adequate hand protection when handling cable Note Refer to the figure on page 5 17 for an
10. a friction disk a ratchet gear a friction disk a pinion plate and a pinion spacer onto the pinion shaft Component damage hazard Do not allow grease or oil onto the brake disk ratchet gear or the teflon spacer Note The teeth on the ratchet gear must curve toward the left side of the winch housing 9 Install the pinion shaft retaining ring onto the pinion shaft Note Use your fingers to push the ratchet pawls outwards while pushing the pinion shaft through the left bushing Be sure the ratchet pawls are in firm contact with the ratchet gear and that all parts move freely 10 Install the lock nut on the left side of the pinion shaft 11 Install the input shaft approximately half way through the left side of the winch housing 12 Slide the left side bushing spring and ball housing spacer input shaft gears and right side bushing onto the input shaft 13 Install the ball and spring into the spring and ball housing Install the mounting fasteners Section 5 e Repair Procedures February 2009 WINCHES 14 Lubricate the outside of the frame spacer with multi purpose grease and insert it into the drum 15 Install the cable drum Be sure the drum gears mesh with the ratchet gears 16 Install the drum bolt keeper Push the drum bolt through the winch housing drum cover and drum Be sure the head of the drum bolt is on the drum gear side of the winch 17 Install the drum bolt jam nut and torque to 20 to 25 f
11. Contractor WINCHES 6 Insert the longer threaded end of the pinion shaft approximately halfway through the left bushing 7 Apply asmall amount of multi purpose grease to the large threaded section of the pinion shaft under the gear nut Screw the pinion gear onto the pinion shaft with the gears toward the left side of the winch housing 8 Install in order a brake disk a ratchet gear a brake disk a pinion plate and a pinion spacer onto the pinion shaft Component damage hazard Do not allow grease or oil onto the brake disks or the ratchet gear Note The teeth on the ratchet gear must curve away from the right side of the winch housing 9 Push the pinion shaft to the right through the right pinion bushing and install the pinion shaft retaining ring Note Use your fingers to push the ratchet pawls outward while pushing the pinion shaft through the right bushing Be sure the ratchet pawls are in firm contact with the ratchet gear and that all parts move freely 10 Install the two jam nuts to the right side of the pinion shaft one at a time and tighten 11 Position both handles on the pinion shaft in opposite directions Install and tighten the lock nuts 12 Lubricate the outside of the frame spacer with multi purpose grease Insert the frame spacer into the drum Section 5 e Repair Procedures February 2009 WINCHES 13 Install the cable drum Be sure the drum gears mesh with the ratchet gears 14
12. Machinery 85 dB 85 dB 85 dB 85 dB Maximum sound level at normal operating work stations A weighted Load Handling Attachments Length Width Depth Net Weight Standard Forks 28 in 23 in 2 5 in 26 5 lbs 71 1 cm 58 4 cm 6 4 cm 12 kg Adjustable Forks 27 5 in 11 5 to 30 in 2 5 in 52 5 Ibs 69 9 cm 29 2 to 76 2 cm 6 4 cm 23 8 kg Boom 44 in 1 5 in 6 in 40 Ibs 111 8 cm 3 8 cm 15 2 cm 18 kg Pipe Cradle 27 5 in 24 5 in 6 in 10 Ibs 69 9 cm 62 2 cm 15 2 cm 4 5 kg Load Platform 26 3 in 23 in 2 5 in 24 Ibs 69 9 cm 58 4 cm 6 4 cm 11 kg Fork Extensions each 30 in 2 in 3 in 4 5 lbs 76 2 cm 5 1 cm 7 6 cm 2 kg Continuous improvement of our products is a Genie policy Product specifications are subject to change without notice A TEREX COMPANY Part No 115409 Superlift Contractor 2 1 Section 2 Specifications February 2009 OR EEE ee SPECIFICATIONS REVA Dimensions Operating SLC 6 SLC 12 SLC 18 SLC 24 Standard Forks forks down 5 ft 8 in 11 ft2in 16 ft 9 in 22 ft 3 in 1 7m 3 4m 5 1m 6 8m forks up 7 ft5in 12 ft 11 in 18 ft 6 in 24ft 2 3 m 3 9 m 5 6 m 7 3 m Adjustable Forks forks down 5 ft 8 in 11 ft2 in 16 ft 9 in 22 ft 3 in 1 7 m 3 4 m 5 1m 6 8m forks up 7 ft5in 12 ft 11 in 18 ft 6 in 24 ft 2 3m 3 9m 5 6m 7 3 m Boom 6 ft 8 in 12 ft 2 in 17 ft 9 in 23 ft 3 in 2m 3 7m 5 4m 71m Note measured from ground to bottom of shackle Load Platform forks down 5 ft 8 in 11 ft 2 in 16 ft 9 in 19 ft 6 in 22 ft 3 in 1 7 m 3 4m 51m 6m 6 8 m fork
13. Scheduled Maintenance Procedures February 2009 SCHEDULED MAINTENANCE PROCEDURES Maintenance Symbols Legend Note The following symbols have been used in this manual to help communicate the intent of the instructions When one or more of the symbols appear at the beginning of a maintenance procedure it conveys the meaning below Indicates that tools will be required to perform this procedure Indicates that new parts will be required to perform this procedure Indicates that a cold motor or pump will be required to perform this procedure Indicates that dealer service will be required to perform this procedure I BEE MPANY 3 2 Superlift Contractor Pre delivery Preparation Report The pre delivery preparation report contains checklists for each type of scheduled inspection Make copies of the Pre delivery Preparation report to use for each inspection Store completed forms as required Maintenance Schedule There are three types of maintenance inspections that must be performed according to a schedule daily quarterly and annually The Scheduled Maintenance Procedures Section and the Maintenance Inspection Report have been divided into three subsections A B and C Use the following chart to determine which group s of procedures are required to perform a scheduled inspection Inspection Checklist Daily or every 8 hours A Quarterly or every 250 hours A B Annually or every 1000 hours A B C Mainte
14. capacity to handle machine weight See Specifications section for specific weight M Read each procedure completely and adhere to the instructions Attempting shortcuts may produce hazardous conditions MI Unless otherwise specified perform each procedure with the machine in the following configuration Machine positioned on a firm level surface Carriage fully lowered Casters locked Part No 115409 Genie A TEREX COMPAN 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 Symbols Legend A ADANGER Indicates an imminently hazardous situation which if not avoided will result in death or serious injury Safety alert symbol used to alert personnel to potential personal injury hazards Obey all safety messages that follow this symbol to avoid possible injury or death Indicates a potentially hazardous AWARNING situation which if not avoided could result in death or serious injury Indicates a potentially hazardous ACAUTION situation which if not avoided may cause minor or moderate injury Indicates a potentially hazardous situation which if not
15. carriage and mast for damaged column s Consult the Genie Industries Service Department binding Geni NIC ee Re position load to eliminate obstruction Be sure load is properly centered Remove the bound cable and inspect the cable and related components for damage Replace the damaged component See Repair procedure 3 1 How to Disassemble a One Speed Winch or 3 2 How to Disassemble a Two Speed Winch Replace damaged column OR consult the Genie Industries Service Department Replace the damaged component s REVA Superlift Contractor Part No 115409 February 2009 Section 5 e Repair Procedures Observe and Obey M Repair procedures shall be completed by a person trained and qualified on the repair of this machine MI Immediately tag and remove from service a damaged or malfunctioning machine MI 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 Contractor Operator s Manual MI Be sure that all necessary tools and parts are available and ready for use MI Use only Genie approved replacement parts MI Be sure the capacities of sawhorses or other supports are sufficient to withstand machine weight See Specifications section for the machine weight MI Be sure overhead cranes or other lifting devices are of ample
16. cleaning solvent to clean the columns AWARNING 20dily injury hazard This procedure will require the use of additional access equipment Do not place ladders or scaffold on or against any part of the machine Performing this procedure without the proper skills and tools could result in death or serious injury Dealer service is strongly recommended Part No 115409 February 2009 Section 3 e Scheduled Maintenance Procedures REVA B 3 Check the Winch Operation Genie specifications require that this procedure be performed every 250 hours or quarterly whichever comes first 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 that might indicate damage 1 Visually inspect all the 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 Part No 115409 A TEREX CO Superlift Contractor 3 9 MPANY CHECKLIST B PROCEDURES B 4 Inspect the Carriage Hold down Bar Genie specifications require
17. columns B 3 Winch operation Inppestor title B 4 Carriage hold down bar Inspector company B 5 Inspect and lubricate winch Instructions Comments Make copies of this report to use for each inspection Select the appropriate checklist s for the type of inspection to be performed Daily or 8 hour Inspection A Quarterly or 250 hour Inspection A B Annually or 1000 hour Inspection A B C Place a check in the appropriate box after each inspection procedure is completed Use the step by step procedures in this section to learn how to perform these inspections If any inspection receives an N tag and remove the machine from service repair and re inspect it After repair place a check in the R box Legend Y yes acceptable N no remove from service R repaired A TEREX COMPANY C 3 Replace winch friction disks C 4 Inspect cable and pulleys C 5 Casters and wheels C 6 Painted surfaces Part No 115409 Superlift Contractor Section 3 e Scheduled Maintenance Procedures February 2009 Checklist A Procedures A 1 Inspect the Manuals and Decals Genie specifications require that this procedure be performed every 8 hours or daily whichever comes first Maintaining the operator s and safety manuals in good condition is essential to safe machine operation Manuals are included with each machine and should be stored in the container provi
18. exploded view of the Two speed Winch 1 Place one side of the winch housing over the jaws of a vise Open the vise until the jaws are 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 3 Repeat steps 1 and 2 to insert the other bushing Note Use a piece of flatbar or wood between the drift and the bushing to prevent any damage to the bushing 4 Add two drops of 30W oil to both pivot points on each ratchet pawl ACAUTION POJ Injury Hazard Overlubrication of the ratchet pawl may result in oil coming in contact with the surface of the winch brake leading to an unsafe working condition Do not allow any oil on the brake or pressure plate 5 Install the winch housing on the mast Be sure the winch drum is toward the top 6 Insert the longer threaded end of the pinion shaft approximately halfway through the right side bushing Part No 115409 Genie A TEREX COMPAN Superlift Contractor WINCHES 7 Apply asmall amount of multi purpose 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 toward the right side of the winch housing Screw onto large threads hand tight 8 Install in order
19. from the upper column 13 Route the cable into and around the lower pulley z A TEREX COMPANY Superlift Contractor REV A 14 Apply Loctite removable thread sealant to the pulley mounting fastener and install the lower pulley into the column 15 Push the cable between the two mast sections until it comes out the top of the column 16 Repeat steps 11 through 15 with all remaining columns 17 Slide all the columns forward until you can install the column stops Do not slide the columns forward any farther than necessary 18 Install all the components removed during disassembly Note Be sure that all fasteners have Loctite removable thread sealant applied to the threads and that all fasteners have been securely tightened 19 Attach the cable to the winch and be sure the cable is routed correctly 20 Raise the machine to full height to release the safety brakes if equipped and verify proper operation Part No 115409 February 2009 Section 5 e Repair Procedures REVA 2 2 Lifting
20. parts MI Machines that have been out of service for a period longer than 3 months must complete the quarterly inspection MI 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 Part No 115409 A TEREX CO Superlift Contractor 3 1 MPANY About This Section This section contains detailed procedures for each scheduled maintenance inspection Each procedure includes a description safety warnings and step by step instructions Symbols Legend Safety alert symbol used to alert personnel to potential personal injury hazards Obey all safety messages that follow this symbol to avoid possible injury or death Indicates an imminently hazardous situation which if not avoided will result in death or serious injury A DANGER AWARNING Indicates a potentially hazardous situation which if not avoided could result in death or serious injury Indicates a potentially hazardous ACAUTION situation which if not avoided may cause minor or moderate injury Indicates a potentially hazardous situation which if not avoided may result in property damage Indicates that a specific result is expected after performing a series of steps W Indicates that an incorrect result has occurred after performing a series of steps Section 3 e
21. removed during disassembly except the column down stops Apply a small amount of multi purpose 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 up stop or the safety brake assembly is even with the bottom edge of the number one column 7 Repeat steps 4 through 6 with all remaining columns Do not install the carriage Note The cable is installed after all columns are together as an assembly 8 Attach the swaged end of the cable to the cable anchor on the top of the front column Section 5 Repair Procedures February 2009 MAST ASSEMBLY 9 Feed the other end of the cable through the box section web of the carriage into the pulley then push the cable through the pulley until it comes out the back side of the carriage ACAUTION Bodily injury hazard Cables can fray Always wear adequate hand protection when handling cable Note Refer to the figure below to identify the cable routing 10 Insert the carriage into the bottom end of the top column Hold the carriage in place and pull the cable up to the top of the column leaving enough slack to feed the cable through the next pulley Push the cable through the exposed portion of the pulley at the top of the column until the cable reaches the pulley at the bottom of the column 12 Remove the lower pulley assembly
22. that this procedure be performed every 250 hours or quarterly whichever comes first 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 carriage hold down bar for damage 3 Check the carriage hold down bar for smooth operation Section 3 e Scheduled Maintenance Procedures February 2009 CHECKLIST B PROCEDURES B 5 Inspect and Lubricate the Winch Genie specifications require that this procedure be performed every 250 hours or quarterly whichever comes first 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 Cable drum gear Teeth on the pinion gear that mesh with the cable drum gear Threads on the pinion shaft under the pinion gear Models with two speed winch The teeth on the slow and the fast speed gears where they mesh together Note Do not apply grease to brake friction disks or rachet gear 2 Carefully lubricate both pivot points on each ratchet pawl with 30W oil A TEREX COMI Superlift Contractor
23. the fastener and install the pulley assembly onto the column 14 Assemble the columns in reverse order of disassembly Genie MAST ASSEMBLY A TEREX COMPAN Part No 115409 Superlift Contractor Section 5 e Repair Procedures February 2009 Winches REVA 3 1 7 Slide the pinion shaft to the right and remove the pinion spacer pinion plate ratchet gear and One speed Winch friction disks Turn the pinion gear Bo a aeons ee es ek vent counterclockwise and slide it off the left side of How to Disassemble a One speed the shaft Winch 8 Remove the pinion shaft from the winch RY housing ACAUTION Bodily injury hazard Cables can ree fray Always wear adequate hand 9 Remove both pinion bushings Use a soft metal protection when handling cable drift equal to the outside diameter of the 1 Fully lower the carriage bushing and tap with a rubber mallet Component damage hazard Place a block in between the walls of the winch housing to prevent the housing from bending while 3 Remove both handle retaining fasteners removing the bushings Remove the handles from the pinion shaft 2 Remove the cable retaining fastener from the winch drum Remove the cable from the winch drum 10 Remove the winch housing from the machine 4 Remove the drum bolt and the drum bolt spacer Remove the drum drum gear cover and housing spacer from the winch 5 Remove the two lock nuts from the pinion shaft by holding the opposite end of
24. the shaft at the flattened portion of the threads Component damage hazard Be careful not to damage the threads while holding the pinion shaft 6 Remove the retaining ring from the pinion shaft A TEREX COMPANY 5 10 Superlift Contractor Part No 115409 February 2009 Section 5 e Repair Procedures REVA How to Assemble a One speed Winch Bodily injury hazard Cables can ACAUTION fray Always wear adequate hand protection when handling cable Note Refer to the figure on page 5 13 for an exploded view of the One speed Winch 1 Place one side of the winch housing over the jaws of a vise Open the vise until the jaws are 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 3 Repeat steps 1 and 2 to insert the other bushing Note Use a piece of flatbar or wood in between the drift and the bushing to prevent any damage to the bushing 4 Add two drops of 30W oil to both pivot points on each ratchet pawl ACAUTION Bodily Injury Hazard Overlubrication of the ratchet pawl may result in oil coming in contact with the surface of the winch brake leading to an unsafe working condition Do not allow any oil on the brake or pressure plate 5 Install the winch housing onto the mast Be sure the winch drum is toward the top Part No 115409 Genie A TEREX COMPAN Superlift
25. Cable How to Replace the Lifting Cable ACAUTION POTY injury hazard Cables can fray Always wear adequate hand protection when handling cable Note All Genie replacement cables come with one pre swaged end that terminates at the top of the last column and one taped end that terminates at the winch Note For additional information refer to instructional video Genie Superlift Cabling Procedure This video is available from The Genie Industries Service Parts Department Genie part number 52701 1 Fully lower the carriage 2 Remove the retaining fasteners from the eyelet end of the cable at the mast anchor plate and cut the eyelet off below the copper sleeve MAST ASSEMBLY 3 Remove the old cable from the winch drum 4 Unwind the outer strands and trim them back 1 2 inch 12 7 mm leaving the core longer Repeat this process on the open end of the new cable 5 Using the optional cable threading tool Genie part number 12402 insert even amounts of cable into each end of the tool Securely tighten the set screws ACAUTION POTY injury hazard This tool is intended for cable replacement only Do not use as a load carrying cable j ij Genie Part No 115409 A TEREX COMPANY Superlift Contractor 5 7 Section 5 e Repair Procedures February 2009 MAST ASSEMBLY 6 Place a smooth layer of strapping tape over the joint section of the two cables and the tool Note If the cabl
26. Install the drum bolt keeper Push the drum bolt through the winch housing drum cover and drum Be sure the head of the drum bolt is on the drum gear side of the winch 15 Place the drum gear cover in position with the drum bolt slot under the drum bolt keeper 16 Install the drum bolt jam nut hand tight 17 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 18 Torque the drum bolt nut to 20 to 25 ft lbs 27 to 34 Nm Component damage hazard Overtightening the drum bolt jam nut may cause damage to the frame spacer and prevent the drum from spinning freely 19 Lubricate the teeth of the drum gear and the pinion nut that meshes with the drum gear with multi purpose grease ACAUTION Bo y Injury Hazard Overlubrication of the ratchet pawl may result in oil coming in contact with the surface of the winch brake leading to an unsafe working condition Do not allow any oil on the brake or pressure plate A TEREX CON Superlift Contractor REV A 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 nuts finger tight Do not tighten 21 Route the end of the cable around the winch drum and out through
27. Service Manuals for these models Title Part No Genie Superlift Contractor Parts and Service Manual First Edition before serial number 9595 101 33953 Genie Superlift Contractor Parts and Service Manual Second Edition from serial number 9595 101 80140 Note Genie Superlift Contractor Service Manual 115409 and Genie Superlift Contractor Part s Manual 115410 replaces Genie Superlift Contractor Parts and Service Manual 80140 Copyright 1995 by Genie Industries 115409 Rev A February 2009 Third Edition First Printing Genie is a registered trademark of Genie Industries in the USA and many other countries SLC is a trademark of Genie Industries amp Printed on recycled paper Printed in U S A Part No 115409 February 2009 INTRODUCTION Serial Number Legend p G I GNIC A TEREX COMPANY Genie Industries 18340 NE 76th Street Redmond WA 98052 USA Model SLC 24 Serial Number SLCO7 12345 Manufacture Date 01 11 2007 Electrical Schematic N A SLC 07 12345 Country of manufacture USA ERA GG a 0 vil Model Sequence 99 number AEK Model year OZ Ni fi Serial label erial number stamped on base A TEREX COMPANY Part No 115409 Superlift Contractor iii
28. a anna a aaa asiinaa 3 6 A 2 Perform Pre operation Inspection seseeea aaa aaa aaa siinaa 3 7 A3 Perform Function Test saa esa waza aaa A WPW AAA PEAKS 3 7 A Checklist B Procedures B 1 Inspect all Welds uoee eee aaa aaa aaa aaa aaa aanaca 3 8 B 2 Clean the Colums ssrin dE OO OE EA da LSA zenia 3 8 B 3 Check the Winch Operation siisii ironiese an 3 9 B 4 Inspect the Carriage Hold Down Bar ee uaeoeeaaaa aa eaaaaaecsnaae 3 9 B 5 Inspect and Lubricate the Winch oseeeee aaa aaa aaa aaa aan aaniace 3 10 Part No 115409 Superlift Contractor vii February 2009 TABLE OF CONTENTS Section 3 Rev Scheduled Maintenance Procedures continued A Checklist C Procedures C 1 Inspect the Mast Assembly for Wear cecceceeeeeeeeeseeeeeeeeneeeteees 3 11 C 2 Inspect the Safety Brake System if equipped 21111 3 12 C 3 Replace the Winch Friction DISCS 0 cccceeeeeteeeeeeeeeeeteeeeeeeeneeeeees 3 13 C 4 Inspect the Cable and Cable Pulleys essuaaassaaaase 3 14 C 5 Lubricate the Casters and Wheels ee uueeuaaa aaa aaanaaa 3 15 C 6 Inspect the Painted Surfaces eeuuee eau aaa 3 15 Section 4 Rev Troubleshooting Flow Charts INTRODUCTION OP RPA 4 1 A Chart 1 Mast Will Not Sequence Properly ee eeesaaaaas aaa a saaaaccccaa 4 2 A Chart 2 Carriag
29. anes or other lifting devices are of ample capacity to handle machine weight See Specification section for specific weight Part No 115409 A TEREX CO Superlift Contractor 4 1 MPANY Before Troubleshooting M Read understand and obey the safety rules and operating instructions printed in the Genie Superlift Contractor Operators 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 ISVs Crushing hazard When testing or A DANGER replacing the primary component always support the structure and secure it from movement Note Perform all troubleshooting on a firm level surface Note Two people 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 tt Troubleshoot discovered symptoms problem still exists Perform repair Retum to service problem solved Section 4 Troubleshooting Flow Charts February 2009 Chart 1 over loaded Mast Will Not
30. avoided may result in property damage Indicates that a specific result is expected after performing a series of steps W Indicates that an incorrect result has occurred after performing a series of steps Superlift Contractor 5 1 Section 5 Repair Procedures February 2009 Base Assembly 1 1 Base How to Remove the Base 1 Fully lower the carriage 2 Remove the load handling attachment from the machine Models with stabilizers 3 Remove the mounting fasteners from the stabilizer mounting bracket on the back of the mast 4 Remove the mounting fastener from each stabilizer at the base Remove each stabilizer from the machine All Models 5 Using proper lifting techniques tilt the machine back and rest the loading wheels against a suitable structure capable of supporting it ACAUTION Bodily injury hazard Use proper lifting techniques when rolling the mast assembly over Genie A TEREX COMPAN 5 2 Superlift Contractor REV A 6 Remove the mounting fastener and retaining pin from each leg Remove the legs from the machine 7 Using proper lifting techniques carefully tilt the machine to the upright position ACAUTION Bodily injury hazard Use proper lifting techniques when tilting the machine to the upright position 8 Attach a lifting strap from an overhead crane to the lifting eye at the top of the number one mast column 9 Position a suitable structure capable of supp
31. cable keeper fastener 24 While holding the cable tight on the drum rotate the drum with a handle and spool the cable onto the drum evenly Component damage hazard Be sure the cable winds onto the winch drum evenly Part No 115409 February 2009 Section 5 e Repair Procedures REVA Two speed Winch Assembly Index z o Description Reel Lock Bolt Reel Cover Cable Keeper Reel Spacer Gear Cover Ratchet Pawl Kit Retaining Ring Sintered Iron Ring 4 O R OD Pinion Shaft Assembly Handle Part No 115409 WINCHES Index No Description 11 Input Shaft Assembly 12 Brake Spring Spacer 13 Detent Block Assembly 14 Pinion Gear 15 Disc Brake 16 Ratchet Gear 17 Pinion Plate 18 Brake Spacer 19 Pinion Shaft Bushing 20 Base Spacer Superlift Contractor 5 17 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 Germany 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
32. chine will fall if not properly supported by the overhead crane 3 Lower the top of the mast onto the suitable structure 4 Attach a lifting strap from an overhead crane to the base of the machine 5 Lift the base with the overhead crane until the mast is level and place another suitable structure under the mast Part No 115409 A TEREX CO Superlift Contractor MPANY 6 Lower the base end of the machine N Rotate the mast assembly until the carriage is on top 8 Visually inspect the top of each column for clearance between the roller wheel and the adjacent column surface Result There should be a gap of less than 0 062 inch 1 57 mm between the roller wheel and the column Note If the mast inspection results in a measurement that is not within specification replace the roller wheels See Repair procedure 2 1 How to Disassemble the Mast Assembly 9 Visually inspect the bottom of each column for clearance between the roller wheel and the adjacent column surface Result There should be a gap of less than 0 062 inch 1 57 mm between the roller wheel and the column Note If the mast inspection results in a measurement that is not within specification replace the roller wheels See Repair procedure 2 1 How to Disassemble the Mast Assembly 10 Grasp the bottom of the carriage and lift it approximately 12 inches 30 5 cm then release the carriage Result The carriage should stop w
33. ded in the platform An illegible or missing manual will not provide safety and operational information necessary for a safe operating condition In addition maintaining all of the safety and instructional decals in good condition is mandatory for safe machine operation Decals alert operators and personnel to the many possible hazards associated with using this machine They also provide users with operation and maintenance information An illegible decal will fail to alert personnel of a 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 amp 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 A TEREX COMI 3 6 Superlift Contractor REV A 3 Open the operator s manual to the decals inspection section Carefully and thoroughly inspect all decals on the machine for legibility and damage Result The machine is equipped with all required decals and all decals are legible and in good condition XK Result The machine is not equipped with al
34. e Will Not Raise But Winch Will Operate 4 3 A Chart 3 Winch Will Not Operate eeuaa eo eee aaa aa aaa aaa aaa eanaaaccea 4 4 Section 5 Rev Repair Procedures IRirOJUCHOMz sai WE A E Pa ES w 5 1 A 1 1 Base ASSOMDIY wsie desa Z a AE az da dA OE 5 2 A 2 1 Mast Assembly sasz A b a Yar ESSEK 5 3 A 2 2 Lifting Gable ae kd EA on e a la oai 5 7 A 23 EG PUNY o waza A dA ad a A AS Kp AA aieiaa 5 8 A 3 1 O e speed WINCH isisisi Sarosar oO Ka EA PZA YES PASA PASA E 5 10 A 32 Two Speed WINCH swcscscnniesscicseiuniiirniioninnae aa 5 14 A TEREX COMPANY viii Superlift Contractor Part No 115409 February 2009 Section 2 Specifications Specifications REVA Model SLC 6 SLC 12 SLC 18 SLC 24 Height Stowed 86 in 86 in 86 in 86 in 2 2m 2 2m 2 2m 2 2m Width 31 5 in 31 5 in 31 5 in 31 5 in 80 cm 80 cm 80 cm 80 cm Width stabilizers lowered if equipped 66 in 66 in 66 in 66 in 1 7m 1 7m 1 7m 1 7m Length Stowed 34 in 34 in 34 in 34 in 86 4 cm 86 4 cm 86 4 cm 86 4 cm Length Operating 59 in 63 in 73 in 81 in 1 5m 1 6m 1 9m 2m Ground 2 in 2 in 2 in 2 in Clearance 50 8 mm 50 8 mm 50 8 mm 50 8 mm Load Capacity 650 Ibs 650 Ibs 650 Ibs 650 Ibs at 14in 36cm load center 295 kg 295 kg 295 kg 295 kg Note see Load Capacity Charts section for load capacities at other load centers Net Weight 166 Ibs 225 lbs 307 Ibs 347 lbs 75 kg 102 kg 139 kg 157 kg Airborne Noise Emissions by
35. e gets caught as you are pulling it through the columns and pulleys avoid pulling too hard as you may break the connection between the two cables Try pulling the cable back and forth until the cable pulls freely BSC C Cts 7 Wind the old cable onto the winch drum while feeding the new cable through machine 8 When the taped area appears at the winch loosen the set screws and remove the old cable from the winch drum 9 Attach the new cable to both the mast anchor and the winch drum 10 Wind the new cable evenly onto the winch drum Be sure there are at least four wraps of cable on the winch drum 11 Fully raise and lower the carriage without a load to check for proper operation The carriage should raise and lower smoothly 12 Fully raise and lower the carriage again with a load and check for proper operation The carriage should raise and lower smoothly A TEREX COMI Superlift Contractor REVA 2 3 Lifting Pulley How to Replace a Lifting Pulley Mast Installed 1 Fully lower the carriage 2 Unwind approximately 1 to 2 feet 30 to 61 cm of cable from the winch drum 3 Tip the machine backwards and rest the top of the number one mast on a suitable structure capable of supporting it Secure the top of the mast to the structure 4 Attach an overhead crane to the base Lift the machine to a horizontal position and slide a second structure under the mast next to the base 5 If replacing an upper pulley s
36. erhead crane While tilting backwards with the carriage facing up guide the machine over onto a suitable structure ACAUTION Bodily injury hazard Use proper lifting techniques when lifting the mast assembly ACAUTION Crushing hazard The machine may become unbalanced and fall if not properly supported when the mast is lifted 4 Remove the mounting fastener from the cable Genie A TEREX COMPAN anchor at the top of the last column carriage side Part No 115409 Superlift Contractor 5 3 Section 5 e Repair Procedures February 2009 MAST ASSEMBLY 5 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 6 Slide the carriage up approximately 12 inches 30 cm to expose the column stop mounting fastener attached to the bottom end of the top column Remove the fasteners and the column stop 7 Models with safety brake Insert a hex key wrench through the access holes in the carriage to release the safety brake Position the hex key above the safety brake rollers Slide the carriage away from the base while pulling back on the wrench Ose O O e ZE H a P a Brake roller b Brake release tool c Column or carriage REVA 8 Models with safety brake Remove the carriage by sliding it out the bottom
37. gned to discover any malfunctions before the machine is put into service A malfunctioning machine must never be used If malfunctions are discovered the machine must be tagged and removed from service Complete information to perform this procedure is available in the appropriate Operator s Manual Refer to the Operator s Manual on your machine Section 3 e Scheduled Maintenance Procedures February 2009 Checklist B Procedures B 1 Inspect All Welds Genie specifications require that this procedure be performed every 250 hours or quarterly whichever comes first Weld inspections are essential to safe machine operation and good machine performance Failure to locate and repair damage may result in an unsafe operating condition 1 Visually inspect the welds in the following locations Winch mounting plate Loading wheels steer handle Base Legs and stabilizers Load handling attachment s Genie A TEREX COMPAN 3 8 Superlift Contractor REV A B 2 Clean the Columns Genie specifications require that this procedure be performed every 250 hours or quarterly whichever comes first Clean columns are essential to good machine performance and safe operation Extremely dirty conditions may require that the columns be cleaned more often 1 Raise all columns to full height 2 Visually inspect the inner and outer channels of the columns for debris or foreign material If necessary use a mild
38. ithin 5 to 8 inches 12 7 to 20 3 cm and the safety brake should engage Crushing hazard Do not stand ACAUTION directly under the carriage or load handling attachment Section 3 e Scheduled Maintenance Procedures February 2009 CHECKLIST C PROCEDURE C 2 Inspect the Safety Brake System if equipped Genie specifications require that this procedure be performed every 1000 hours or annually whichever comes first Detection of damage or a faulty safety brake system is essential for safe machine operation An unsafe working condition exists if the system is damaged or faulty and does not allow the mast to sequence properly free of hesitation and binding AWARNING Bodily injury hazard This procedure requires specific repair skills and a suitable workshop Attempting this procedure without these skills could result in death or serious injury or significant component damage Dealer service is strongly recommended ACAUTION Bodily injury hazard Wear protective gloves when performing this procedure 1 Fasten a load handling attachment to the carriage use the forks or 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 A TEREX COMI Superlift Contractor REVA 3 Grasp the bottom of the carriage and lift it approximately 12 inches 30 5 cm then release the carriage Result The carriage should stop wi
39. l required decals or one or more decals are illegible or in poor condition Remove the machine from service until the decals are replaced 4 Always return the manuals to the storage container after use Note Contact your authorized Genie distributor or Genie Industries if replacement manuals or decals are needed Part No 115409 February 2009 Section 3 e Scheduled Maintenance Procedures REVA A 2 Perform Pre operation Inspection Genie specifications require that this procedure be performed every 8 hours or daily whichever comes first Completing a Pre operation Inspection is essential to safe machine operation The Pre operation Inspection is a visual inspection performed by the operator prior to each work shift The inspection is designed to discover if anything is apparently wrong with a machine before the operator performs the function tests The Pre operation Inspection also serves to determine if routine maintenance procedures are required Complete information to perform this procedure is available in the appropriate Operator s Manual Refer to the Operator s Manual on your machine Part No 115409 A TEREX CO Superlift Contractor MPANY CHECKLIST A PROCEDURES A 3 Perform Function Tests Genie specifications require that this procedure be performed every 8 hours or daily whichever comes first Completing the function tests is essential to safe machine operation Function tests are desi
40. ld down the column behind the column to be disengaged Note The number one column column attached to the base does not have a safety brake and will not need to be tested Part No 115409 A TEREX CON Superlift Contractor MPANY CHECKLIST C PROCEDURE C 3 Replace the Winch Friction Disks Genie specifications require that this procedure be performed every 1000 hours or annually whichever comes first 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 How to Disassemble a One Speed Winch or 3 2 How to Disassemble a Two Speed Winch Section 3 e Scheduled Maintenance Procedures February 2009 CHECKLIST C PROCEDURE C 4 Inspect the Cable and Cable Pulleys Genie specifications require that this procedure be performed every 1000 hours or annually whichever comes first 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 The inspection of this system allows the inspector to identify changes in the operating condition that might indicate damage Note The mast must be disassembled during the annual inspection of the machine otherwise the cable cable pul
41. leys and mast rollers are only partially visible for inspection 1 Disassemble the mast assembly Refer to Repair Procedures 2 1 How to Disassemble the Mast Assembly A TEREX COMPANY Superlift Contractor REVA 2 Visually inspect the cable 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 upper and lower mounting brackets are properly secured no broken or damaged pulleys no unusual or excessive pulley wear no broken or damaged mast rollers no unusual or excessive mast roller wear ACAUTION Bodily injury hazard Beware of sharp edges Wear protective gloves when performing this procedure 3 Assemble the mast assembly Refer to Repair Procedures 2 1 How to Assemble the Mast Assembly Part No 115409 February 2009 Section 3 e Scheduled Maintenance Procedures REV A CHECKLIST C PROCEDURE C 5 C 6 Lubricate the Casters and Wheels Genie specifications require that this procedure be performed every 1000 hours or annually whichever comes first Extremely dirty conditions may require that the casters and wheels be inspected and lubricated more often 1 Visually inspect each caster and wheel for cuts cracks or unusual wear 2 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 u
42. lide 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 approximately 6 inches 15 cm to expose the lower column stop Remove the column stop mounting fasteners 7 Slide the column backwards until the pulley that is to be replaced is exposed 8 Remove the two mounting fasteners from the pulley mounting block Remove the pulley assembly 9 Remove the retaining fastener that attaches the pulley to the mounting block Note Note the quantity and location of the shims and spacers before disassembling Part No 115409 February 2009 Section 5 e Repair Procedures REVA 10 Remove the old pulley 11 Install the cable onto the new pulley 12 Apply Loctite removable thread sealant to the pulley mounting fastener and install the fastener through the pulley and pulley guard into the pulley mounting block AWARNING Crushing hazard Failure to properly route the cable could result in a winch brake failure Component damage hazard Do not allow the cable to become twisted during installation or mast sequencing problems may occur Note Be sure the cable guard is located over the retaining pin on the pulley mounting block Be sure the pulley spins freely after reassembling the pulley assembly A a Pulley b Pulley guard c Pulley mounting block 13 Apply Loctite removable thread sealant to
43. mponents may fail if they are used a second time y Be sure to properly dispose of old oil or E other fluids Use an approved container w Please be environmentally safe sam Be sure that your workshop or work area 3 is properly ventilated and well lit February 2009 I This page intentionally left blank A TEREX COMPANY vi Superlift Contractor Part No 115409 February 2009 Table of Contents Introduction Important Information esa A A A chet eevee vue EE AAAA ii Serial Number InfortmatiON sss zes ia O o WE ZEE AAA aai ii Serial Number Legend eeeeea eee aaa eee aaa aaa aaa eaaa a aeanaaeieiaa iii Section 1 Safety Rules General Safety RUl6S seees1uu aaa ad aa dA O a ka AAAA EE aaa WY iv Section 2 Rev Specifications A SLC G wzi AEO E aasadueatecdue W dada eadskdee 2 1 SLC 22 raat A seh fancea tp tea dooeess Gey scehasueeasl CZ AA ee elcome 2 1 SECT Bozia l E ra brak AE eles 2 1 SECZZ R W OP AZ A dE Aaa dA 2 1 SAE and Metric Fasteners Torque Charts se uu ee aaa as aaaaaa inna 2 3 Section 3 Rev Scheduled Maintenance Procedures WMFOCUCTI OM R A A RNA PONAR OATAT A 3 1 Pre delivery Preparation Report essseeea aaa aaa aaa aaa zza aaa a0a 3 3 Maintenance Inspection Report sseeee aaa asa eee naa aaa ana aaa innaa 3 5 A Checklist A Procedures A 1 Inspect The Manual and Decals eeeeeaa aaa aa
44. nance 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 Part No 115409 Pre Delivery Preparation Fundamentals It is the responsibility of the dealer to perform the Pre delivery Preparation The Pre delivery Preparation is performed prior to each delivery The inspection is designed to discover if anything is apparently wrong with a machine before it is put into service A damaged or modified machine must never be used If damage or any variation from factory delivered condition is discovered the machine must be tagged and removed from service Repairs to the machine may only be made by a qualified service technician according to the manufacturer s specifications Scheduled maintenance inspections shall be performed by qualified service technicians according to the manufacturer s specifications and the requirements listed in the responsibilities manual a GNIG A TEREX COMPANY Genie UK The Maltings Wharf Road Grantham Lincolnshire Redmond WA 98073 9730 NG31 6BH England 425 881 1800 44 1476 584333 Copyright 2002 by Genie Industries Genie is a registered trademark of Genie Industries RevB Genie Industries USA 18340 NE 76
45. ntil it can been seen coming out of the bearing gap Grease Specification Chevron Ultra duty grease EP NLGI 1 lithium based or equivalent Part No 115409 A TEREX CO Superlift Contractor MPANY Inspect the Painted Surfaces Genie specifications require that this procedure be performed every 1000 hours or annually whichever comes first 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 Blistering Rust Peeling Fading Corrosion Note Replace any component that is damaged Section 3 e Scheduled Maintenance Procedures February 2009 SSS SS SS ss EEE This page intentionally left blank 3 16 Superlift Contractor Part No 115409 February 2009 Section 4 e 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 MI Immediately tag and remove from service a damaged or malfunctioning machine MI Repair any machine damage or malfunction before operating the machine MI Be sure the capacities of sawhorses or other supports are sufficient to withstand machine weight See Specifications section for specific weight MI Be sure overhead cr
46. of the mast toward the base while holding the safety brake rollers in the released position with the hex key wrench Models without safety brake Remove the carriage by sliding it out the bottom of the mast toward the base 9 Slide the column up approximately 12 inches 30 cm to expose the column stop mounting fasteners attached to the bottom end of the top column Remove the fasteners and the column stops 10 Models with safety brake Insert a hex key wrench through the access holes in the column up to release the safety brake Position the hex key above the safety brake rollers Slide the carriage away from the base while pulling back on the wrench 1 k Models with safety brake Remove the column by sliding it out the bottom of the mast toward the base while holding the safety brake rollers in the released position with the hex key wrench Models without safety brake Remove the column by sliding it out the bottom of the mast toward the base 12 Repeat steps 10 through 12 for each remaining column A TEREX COMPANY 5 4 Superlift Contractor Part No 115409 February 2009 Section 5 e Repair Procedures REVA How to Release the Safety Brake When Servicing the Mast The safety brake system can engage when the machine is tilted horizontally if the hold down bar is not used When the brake is engaged the columns can extend but not retract If the safety brake system engages while you are servicing the ma
47. orting the machine on the carriage side of the mast 10 Carefully lift the machine slightly with the overhead crane While lowering it guide the machine over onto a suitable structure capable of supporting it ACAUTION Crushing hazard The machine may become unbalanced and fall if not properly supported by the overhead crane A Part No 115409 February 2009 Section 5 e Repair Procedures REVA 11 Secure the top of the mast to the support 12 Attach a lifting strap from an overhead crane to the base and lift the machine to a horizontal position Slide a second suitable structure capable of supporting it under the mast next to the base AWARNING Crushing hazard The machine could become unbalanced and fall if not properly supported by the overhead crane when the mast is lifted 13 Remove the mounting fasteners from both mast braces at the base 14 Remove the base mounting fasteners Remove the base from the machine Note When installing the base be sure that the mast and the base are square Mast Assembly 2 1 Mast Assembly How to Disassemble the Mast Assembly Note Removal of the base is only necessary when the number one column is to be removed See 1 1 How to Remove the Base 1 Fully lower the carriage and remove the load handling attachment Remove the cable retaining fasteners from the winch drum Remove all of the cable from the drum Lift the machine slightly with an ov
48. r w 4 y R Rn d o a p si sA Q o O foe a ro A a un za ro zA z N oO NI w QIN EI NS Ni oj A o 0 AYP NI F o o wo NIS c olo BIN co N g o Go CO O NI O oro AYR oye a Sfo o 2 o oo amp Po oye DN o amp QTR Q1 o 00 0 PIN ATO o 0 ol gt Gif N oo nj a AININ O lt OF GIN JO NI ojojo GOJN NJD oj O AJOIN a N alo pl N W A Oo ND ON LO f OF R a ND o NIN A M u R a DA R Dn 85 Section 2 Specifications February 2009 _ ZZ OOOQOQOOQ ODL This page intentionally left blank 2 4 Superlift Contractor Part No 115409 February 2009 Section 3 e Scheduled Maintenance Procedures Scheduled Maintenance Procedures Observe and Obey MI Maintenance inspections shall be completed by a person trained and qualified on the maintenance of this machine MI Scheduled maintenance inspections shall be completed daily quarterly annually and every 2 years as specified on the Maintenance Inspection Report AWARNING ilure to perform each procedure as presented and scheduled could result in death serious injury or substantial damage MI Immediately tag and remove from service a damaged or malfunctioning machine M Repair any machine damage or malfunction before operating the machine MI Use only Genie approved replacement
49. s up 7ft5 in 12 ft 11 in 18 ft 6 in 21 ft 2 5 in 24 ft 2 3 m 3 9 m 5 6 m 6 5 m 7 3 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 Continuous improvement of our products is a Genie policy Product specifications are subject to change without notice A TEREX COMPANY 2 2 Superlift Contractor Part No 115409 February 2009 Section 2 Specifications REVA SPECIFICATIONS SAE FASTENER TORQUE CHART e This chart is to be used as a guide only unless noted elsewhere in this manual A574 High Strength Grade 5 amp Grade 8 3 Black Oxide Bolts DRY DRY LUBED Nm LUBED LUBED Nm ibs Nm ies NA 9 10 11 3 10 LUBED R I po m gt U es Nm 13 23 14 257 23 42 25 77 4 37 66 4 71 745 60 8135 1684 521 wa C 5 73 75 1016 80 1084 110 149 03 126 0 54 867 68 115 o 122 10 2 106 742 one 12 80 1084 110 149 8 6 12 180 62 180 16 170 80 140 9 8 1 16 10 20 16 84 0 88 00 5 aa
50. st use one of the following methods described below to release the brake Method A This method allows you to release each column in sequence starting at the carriage and removing columns one at a time See 2 1 How to Disassemble the Mast Assembly Method B This method allows you to release any column in the assembly regardless of it s position but requires a custom tool The tool is a piece of 1 8 to 5 16 inch 3 2 to 8 mm diameter stiff wire bent in an L shape with one end 1 inch 25 mm long and the other end 16 inches 41 cm long The installation of a handle on the long end will make it easier to use This tool is available from Genie Industries Genie part number 33875 Insert the tool from the bottom of the column into the safety brake access slot in the inner side wall of the column Reach through the far upper end of the slot and position the short end of the tool above the safety brake rollers Slide the carriage away from the base while pulling back on the tool Part No 115409 Genie A TEREX COMPAN Superlift Contractor 5 5 MAST ASSEMBLY How to Assemble the Mast 1 Inspect all mast parts for wear and damage Replace as necessary 2 Clean all columns and rollers 3 Clean all safety brake assemblies if equipped 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 the supports 5 Install all column assembly components
51. t lbs 27 to 34 Nm Component damage hazard Overtightening the drum bolt jam nut may cause damage to the frame spacer and prevent the drum from spinning freely 18 Lubricate the teeth of the drum gear and the pinion nut with multi purpose grease ACAUTION PY Injury Hazard Overlubrication of the ratchet pawl may result in oil coming in contact with the surface of the winch brake leading to an unsafe working condition Do not allow any oil on the brake or pressure plate 19 Install the input shaft cover 20 Rotate the winch drum so that the oblong slot is visible and horizontal 21 Install the cable keeper clip on the outside of the winch drum with one carriage bolt coming through from the inside Install the lock washer and nut finger tight Do not tighten the nut A TEREX CON Superlift Contractor MPANY REVA 22 Route the end of the cable between the winch drum and the number one column Proceed around the drum and up through the horizontal slot in the winch drum The cable is then fed under the lefthand side of the cable clip pulled forward looped and then fed under the right hand side of the cable keeper clip The raw end of the cable is then fed into the righthand side of the horizontal slot in the winch drum AWARNING Crushing hazard Failure to properly route the cable may result in a winch brake failure a Number one column b Cable c Cable keeper clip d Winch drum 23 Tighten the
52. th Street PO Box 97030 Instructions Use the operators manual on your machine The Pre delivery Preparation consists of completing the Pre operation Inspection the Maintenance items and the Function Tests Use this form to record the results Place a check in the appropriate box after each part is completed Follow the instructions in the operators manual If any inspection receives an N remove the machine from service repair and re inspect it After repair place a check in the R box Legend Y yes completed N no unable to complete R repaired Comments Pre Delivery Preparation Y N R Pre operation inspection completed Maintenance items completed Function tests completed Model Serial number Date Machine owner Inspected by print Inspector signature Inspector title Inspector company Section 3 e Scheduled Maintenance Procedures February 2009 SSS SS SS ss EEE This page intentionally left blank 3 4 Superlift Contractor Part No 115409 February 2009 Section 3 e Scheduled Maintenance Procedures Maintenance Inspection Report Model Checklist A Rev A Y Checklist C Rev A Y NR gt A 1 Manuals and decals Serial number C 1 Mast assembly wear A 2 Pre operation Date inspection C 2 Safety brake system if equipped A 3 Function tests Machine owner Inspected by print Checklist B Rev A Y p w B 1 Welds Inspector signature B 2 Clean
53. the remaining hole on the left side wall of the drum a number one column b cable c winch drum d cable keeper clip 22 Insert the end of the cable under the cable keeper clip approximately 1 2 inch 13 mm and tighten the cable keeper clip fasteners 23 While holding the cable tight on the drum rotate the drum and spool the cable onto the drum evenly Component damage hazard Be sure the cable winds onto the winch drum evenly MPANY Part No 115409 February 2009 Section 5 Repair Procedures L L LL L _ _ _ _ESEeE CDD CIOOC REV A WINCHES One speed Winch Assembly Index Index No Description No Description 1 Disc Brake 11 Drum Lock Bolt 2 Pinion Gear 12 Winch Gear Cover 3 Pinion Shaft 13 Screw 4 Retaining Ring 14 Lock Nut 5 Pinion Shaft Bushing 15 Drum Bolt 6 Winch Handle 16 Hex Jam Nut 7 Nylock Nut 17 Frame Spacer 8 Ratchet Pawl Kit 18 Pinion Shaft Spacer 9 Cable Keeper Kit 19 Pinion Plate 10 Drum Spacer 20 Ratchet Gear 1502 Genie A TEREX COMPA Part No 115409 Superlift Contractor 5 13 Section 5 Repair Procedures February 2009 WINCHES 3 2 Two speed Winch How to Disassemble a Two speed Winch ACAUTION Bodily injury hazard Cables can fray Always wear adequate hand protection when handling cable Fully lower the carriage and remove the load handling attachment Remove the cable retaining fasteners from the winch drum
54. thin 5 to 8 inches 12 7 to 20 3 cm and the safety brake should engage A Crushing hazard Do not stand ACAUTION directly under the carriage or load handling attachment 4 Raise the carriage approximately 12 inches 30 cm to disengage the safety brake 5 Operate the winch until the front column is half way up the adjacent column 6 Grasp the bottom of the front column and lift it approximately 5 inches 12 cm then release the column Result The carriage should stop within 5 to 8 inches 12 to 20 cm and the safety brake should engage ACAUTION Crushing hazard Do not stand directly under the columns or load handling attachment Part No 115409 February 2009 Section 3 e Scheduled Maintenance Procedures REV A 7 Raise the front column approximately 12 inches 30 cm to disengage the safety brake 8 Operate the winch until the front column is fully raised and the second column is half way up the adjacent column 9 Grasp the bottom side of the next column and lift it approximately 12 inches 30 cm then release the column Result The carriage should stop within 5 to 8 inches 12 to 20 cm and the safety brake should engage Crushing hazard Do not stand ACAUTION directly under the columns or load handling attachment S A 10 Repeat steps 7 through 9 to test all remaining columns Note When disengaging the safety brake it may be necessary to ho
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