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1. eu 33498 97539 32927 or 32928 97539 6 6 Genie Super Tower Part No 32951 November 2005 Section 6 Decals REV B FIGURE 6 C Item Part No Description Gty 1 32927 Cosmetic ST 20 2 2 32928 Cosmetic ST 25 1 1 2 3 33498 Label Serial Plate 3 4 52985 Cosmetic Genie Super TOWE en 2 5 82487 Label Read the Manual 2 82964 Warning No Riders 1 7 97532 Caution Bodily Injury Hazard 1 8 97539 Danger Electrocution Hazard nre ee 2 9 97541 Label Use This Winch 1 10 97544 Warning Load Center Chart uius 1 11 97545 Warning Lock Brake 1 12 97546 Label Two speed Shift 1 Part No 32951 Genie Super Tower 6 7 Section 6 Decals November 2005 Notes 6 8 Genie Super Tower Part No 32951 November 2005 Section 7 e Base Components ZZ i TEST base Components Part No 32951 Genie Super Tower 7 1 November 2005 Section 7 Base Components Figure 7 REV C A Base Components Part No 32951 Genie Super Tower November 2005 Section 7 Ba
2. eee CHECKLIST C PROCEDURES REV B C 5 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 the welds in the following locations Blistering Rust Peeling Fading Corrosion Replace any component if it is damaged 3 14 Genie Super Tower Part No 32951 November 2005 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 gualified 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 withstand machine weight Refer to Specifications 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 Super Tower Operator s Manual M Be sure that all necessary tools and test eguipment are available and ready for use M Read each appropriate flow chart thorou
3. IL A a i Parts amp Service Manual 27 Rev C1 January 2006 Super Tower from serial number 7794 00101 to 7799 00101 November 2005 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 Basic mechanical hydraulic and electrical skills are required to perform most procedures However several procedures require specialized skills tools lifting equipment and a suitable workshop In these instances we strongly recommend that maintenance and repair be performed at an authorized Genie dealer service center Technical Publications Genie 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 techsup genieind com Copyright 1994 by Genie Industries 32951 Rev C November 2005 First Edition Third Printing Genie and Super Tower are registered trademarks of Genie Industries in the USA and many other countries gt P
4. i 8 10 Figure 8 F C Winch Components Two speed enne enne 8 12 Section 9 Rev Accessories Figure 9 A B Adjustable Forks 9 2 viii Genie Super Tower Part No 32951 January 2006 Parts Stocking List Reguired Parts Recommended Parts The following parts are reguired to perform Description Part No maintenance procedures as outlined in the Genie Gray Paint 12 Ounce 355 ml Aerosol 1268 Genie Super Tower Parts and Service Manual Genie Blue Paint 12 Ounce 355 ml Aerosol 1484 Description PartNo Genie Blue Paint 1 Gallon 3 78 liters 32150 White Lithium Grease mmm 91670 Genie Gray Paint 1 Gallon 3 78 liters 32151 Cable Replacement Coupler 12402 pinion Plate One speed Winch 7591 Disc Brake One speed Winch 7571 Pinion Plate Two speed Winch 40122 Disc Brake Two speed Winch 37061 Ratchet Gear One speed Winch 6777 Ratchet Gear Two speed Winch 40121 Manuals Pinion Gear One speed Winch 7590 Genie Industries offers the following support Pinion Gear Two speed Winch 80157 documents for these models Pinion Shaft One speed Winch 32891 Title Part No Ratchet Pawl K
5. 2 7794 00001 to 7794 00336 1 16 33080 Coupler Bar 33398 Coumi Number 1 All models ST 20 and ST 25 1 from serial number 7794 00337 to 7799 00001 17 6019 Screw HHC 57036 S Column Number 1 all models 3 8 16 x 1 25 inches GR 5 ft jal b EROS E 18 12013 Shim Washer 0 375 x 0 063 inch 2 32475 Roller Bolt 15 19 32522 Don O 3 3 32473 Roller nt 15 20 4828 Nylock Nut 3 8 16 4 33701 Roller Guard 11 5 6095 Flat Washer 1 2 inch 6 6086 Low Profile Nylock Nut 2 13 7 32965 Column Assembly Numbers 2 5 all models from serial number 7794 00001 to 7794 00358 sss 2 35480 Column Assembly Numbers 2 5 all models from serial number 7794 00359 to 7799 00001 57037 S Column Assembly Numbers 2 5 all models after serial number 7799 00001 8 6198 Nylock Nut 1 2 13 9 35100 Safety Brake Stop Assembly before serial number 7795 00358 sss 2 35101 Safety Brake Stop Assembly after serial number 7795 00357 10 21442 Flat Washer 0 75 x 0 45 x 0 032 inch 4 11 32481 Safety Brake Spring 2 12 17712 Screw FHS 3 8 16 x 1 75 inches 13 35100 Safety Brake Ramp before serial number 7795 00359 2 35101 Safety Brake Ramp after serial number 7795 00358 14 33541 Shim 0 75 x 0 10 inch 3 Part No 32951 Genie Super Tower 8 5 Section 8
6. Part No 32951 November 2005 Section 5 Repair Procedures REV B How to Assemble the One speed Winch Bodily injury hazard Cables can ACAUTION fray Always wear adequate hand protection when handling cable Refer to Section Eight Figure 8 E One speed Winch for an 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 3 Add two drops of 30W oil to both pivot points on each ratchet pawl Do not allow grease or oil onto the CAUTION brake 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 left bushing approximately half way 6 Apply a small 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 7 Install a friction disk ratchet gear friction disk pinion plate and pinion spacer in respective order onto the pinion
7. 1 8 80149 Carriage Bolt 1 4 20 x 0 5 inch GR 2 9 37065 Cable Keeper 1 10 80150 Flat Washer 1 2 inch 11 40113 Reel Spacer 1 12 80151 Gear Cover 1 13 40117 Ratchet Pawl Kit al 8516 Screw HHC 3 8 16 x 1 5 inches GR 5 5397 Flat Washer 5 16 inch 80154 Ratchet Pawl 80153 Ratchet Spring 80152 Ratchet Spacer 4828 Nylock Nut 3 8 16 14 40116 Retaining Ring 0 75 inch 1 15 40126 Sintered Iron Bearing 0 75 inch 16 80155 Pinion Shaft Assembly 1 Part No 32951 Genie Super Tower 8 13 Section 8 Mast and Winch Components November 2005 Notes 8 14 Genie Super Tower Part No 32951 November 2005 Section 9 e Accessories SSS MMMM Accessories Part No 32951 Genie Super Tower 9 1 Section 9 Accessories November 2005 Figure 9 A Adjustable Forks 2 3 REV B 9 2 Genie Super Tower Part No 32951 November 2005 Section 9 Accessories REV B ltem PartNo 33543 1 80679 2 33542 107221 3 33707 S 32375 Description Qty Adjustable Fork Option Complete Detent Pin u Adjustable Fork Carrier with Word Decals all models before serial number 7794 101 USA Canada and Australia models after serial number 779
8. CAUTION Component damage hazard Be sure the cable winds onto the winch drum evenly Part No 32951 Genie Super Tower 5 11 November 2005 Section 6 Decals nn Decals Part No 32951 Genie Super Tower 6 1 Section 6 Decals November 2005 Figure 6 A Decals with Words before serial number 7794 101 REV B 6 2 Genie Super Tower Part No 32951 November 2005 Section 6 Decals REV B FIGURE 6 A Item Part No Description Gty 1 31072 Label Operator s Manual Storage Container 1 2 32934 Label Outrigger Storage Socket n 1 3 33498 Serial Plate 1 32939 Warning Brake Lock 1 5 32770 Notice Two speed Shift INSTRUCTIONS crt 1 6 32938 Label Use This Winch 1 7 32885 Warning Silent Winch 1 8 32929 Warning Machine Safety and Setup esee 1 9 32926 Genie Super Tower Logo 2 10 32931 Warning Adjustable Fork Safety and Setup 1 11 6724 Serial Plate 12 111221111 1 12 33468 Warning No Riders 1 13 27865 Label Bubble Level 1 14 32927 Cosmetic ST 20 2 32928 Cosmetic ST 25 Part No 32951 Genie Super
9. 7794 00358 2 Column Assembly Numbers 2 5 all models from serial number 7794 00357 to 7799 00001 Column Assembly Numbers 2 5 all models after serial number 7799 00000 2 Section 8 Mast and Winch Components _ O eee ee Item Part No 17 32966 35484 57035 FIGURE 8 D Description Qty Carriage Assembly ST 20 and ST 25 from serial number 7794 00001 to 7794 003958 1 Carriage Assembly ST 20 and ST 25 from serial number 7794 00357 to 7799 00001 Carriage Assembly ST 20 and ST 25 after serial number 7799 00000 Part No 32951 Genie Super Tower Section 8 Mast and Winch Components November 2005 Figure 8 E Winch Components One speed REV C 8 10 Genie Super Tower Part No 32951 November 2005 Section 8 Mast and Winch Components _ Oy M REV C FIGURE 8 E Item Part No Description Qty tem Part No Description Qty 32945 Winch Assembly One speed 16 6034 Jam Nut 1 2 13 GR 2 with Word Decals all models 17 7584 Frame Spacer 1 before serial number 7794 101 USA Canada and 18 32890 Pinion Shaft Spacer 1 Australia models after serial La number 7794 100 19 7591 Pinion Plate 1 107494 Winch Assembly One speed 20 6777 Ratchet Gear 1 with Symbol Decals One speed Asi
10. Inspect the Painted SurfaceS esse non rn rr 3 14 Part No 32951 Genie Super Tower vii January 2006 TABLE OF CONTENTS Section4 Rev Troubleshooting Flow Charts Introduction RPP nn 4 1 Chart 1 Mast Will Not Sequence Properly 4 2 Chart 2 Carriage Will Not Raise But Winch Will Operate nn 4 3 B Chart 3 Winch Will Not Operate aaa eee nn 4 4 Section5 Rev Repair Procedures Introduction u eier 5 1 B 1 1 Howto Remove The Bassa 5 2 B 2 1 How to Disassemble the Mast Assembly uuusssssssnnnnnennennnnnnnnnnnen nenn 5 3 B 2 2 Howto Replace the Lifting Cable i 5 5 B 2 3 How to Replace a Lifting Pulley Mast Installed 5 5 B 3 1 How to Disassemble the One speed Winch i 5 6 B 3 2 How to Disassemble the Two speed Winch 5 8 Section6 Rev Decals and Paint Figure 6 A BI Te nee E an 6 2 Figure 6 B BEST 6 4 Figure 6 C Decals with Symbols messen 6 6 Section7 Rev Base Components Figure 7 A C BaseComponenis nt ui ei nl luna Rd 7 2 Section8 Rev Mastand Winch Components Figure 8 A C Number 1 Mast Attached Parts eene nnne 8 2 Figure 8 B D Mast Components View 1 8 4 Figure 8 C C MastComponents View 22a E Ra dad he in 8 6 Figure 8 D C Mast Components Pulleys and Cables sse 8 8 Figure 8 E C Winch Components One speed
11. Mast and Winch Components November 2005 Figure 8 C m Mast Components View 2 Q 600 2 3 4 4 5 5 5 4 OG 8 6 Genie Super Tower Part No 32951 November 2005 Section 8 e Mast and Winch Components REV C FIGURE 8 C Item Part No Description Qty 1 32474 Roller Guard 8 2 32473 Roller Wheel 15 3 32475 Roller Bolt os 15 4 6095 Flat Washer 1 2 inch 5 6198 Nylock Nut 1 2 13 6 33704 Cable Anchor 2 7 10587 Screw HHC 1 2 13 x 1 75 inches GR 5 8 32904 Cable Assembly ST 20 32905 Cable Assembly ST 25 12402 Cable Replacement Coupler 9 32966 Carriage Assembly ST 20 and ST 25 from serial number 7794 00001 to 7794 00358 1 35484 Carriage Assembly ST 20 and ST 25 from serial number 7794 00357 to 7799 00001 57035 Carriage Assembly ST 20 and ST 25 after serial number 7799 00000 10 32965 Column Assembly Numbers 2 5 all models from serial number 7794 00001 to 7794 00358 2 35480 Column Assembly Numbers 2 5 all models from serial number 7794 00357 to 7799 00001 57036 Column Assembly Numbers 2 5 all models after serial number 7799 00000 Part No 32951 Genie Super Tower 8 7 Section 8 Mast and Winch Components November 2005 Figure 8 D REV C Mast Components Pulleys a
12. cable is properly routed damage Check pulley and pulley guard for damage Re install cable if removed during inspection Replace damaged column OR consult the Genie Industries Service Department Inspect winch drum and pinion gear for damage Consult the Genie Industries Service Department Replace damaged cable See Repair Procedure 502 3 How to Replace the pa Cable Then check the pulley and guard for damage and replace if needed Replace the damaged component Part No 32951 Genie Super Tower Section 4 e Troubleshooting Flow Charts November 2005 Chart 3 Winch Will Not Operate REV B Check position of load Obstructions Re position load to for proper centering and eliminate obstruction Be no obstructions sure load is properly centered Replace the damaged part Remove the bound up cable and inspect the cable and related components for damage no obstructions Check the hold down latches for proper operation Check the cable for binding at the winch drum and inside the mast Replace the damaged component s Check winch for proper Replace the damaged operations See component See Repair Maintenence Procedure Procedure 503 1 How 304 1 Check the Winch to Repair the One speed Operation Winch Check carriage and Replace damaged mast for damaged column OR consult the column s Genie Industri
13. pulls free MAST ASSEMBLY 2 3 How to Replace a Lifting Pulley Mast Installed 1 Fully lower the carriage 2 Unwind 1 to 2 feet 0 30 to 0 60 cm 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 If replacing 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 5 Remove the column stop 6 Slide the column backwards until the pulley to be replaced is exposed 7 Remove the two mounting fasteners from the pulley mounting block Then remove the pulley assembly 8 Remove the bolt that attaches the pulley to the mounting block Note where the shims are located before dissembling Part No 32951 Genie Super Tower 5 5 Section 5 Repair Procedures MAST ASSEMBLY 9 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 10 Attach the pulley assembly to the column 11 Assem
14. remove the load handling attachment 2 Remove the cable retaining fasteners from the winch drum Remove the cable from the drum 3 Remove both handle retaining fasteners from the pinion shaft Remove the handles 4 Remove the drum bolt and spacer Remove the drum drum gear cover and housing spacer 5 Remove the input shaft cover 6 Remove the mounting fasteners from the spring and ball housing 7 Remove the two springs and balls from the spring and ball housing 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 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 5 8 Genie Super Tower Part No 32951 November 2005 Section 5 Repair Procedures REV B 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 CAUTION a block between the walls of the winch housing to prevent the housing from bending while removing the bushings WINCHES How to Assemble the Two speed Winch ACAUTION Bodily injury hazard Cables can fray Always wea
15. the columns forward until you can install the column stops Do not slide the columns forward further than necessary 16 Install all the components removed during disassembly 17 Attach the cable to the winch and be sure cable is routed correctly 18 Raise all the columns to full height to release the safety brakes and verify proper operation Genie Super Tower Part No 32951 November 2005 Section 5 Repair Procedures REV B 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 carriage 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 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 Pullthe 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
16. this procedure cd ELE 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 annual 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 Annual or every 1000 hours A B C Maintenance Inspection Report The maintenance inspection report contains checklists for each type of scheduled inspection Make copies of the Maintenance Inspection Report to use for each inspection Store completed forms for three years 3 2 Genie Super Tower Part No 32951 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
17. 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 Genie Genie Industries USA 18340 NE 76th Street PO Box 97030 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 RevA Instructions Use the operator s manual on your machine The Pre delivery Preparation consists of completing the Pre operation Inspection the Maintenance items and the Function Tests Use this form to record the results Place a check in the appropriate box after each part is completed Follow the instructions in the operator s manual If any inspection receives an N remove the machine from service repair and re inspect it After repair place a check in the R box Legend Y yes 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 numbe
18. 1 6034 6033 6095 33651 33781 6198 10598 33652P 32972 33151 55737 32973 107176 107177 107178 107179 FIGURE 7 A Description Qty Screw HHC 5 16 18 x 0 75 inch GR 5 Lock Washer 5 16 inch Flat Washer 5 16 inch Flat Washer 5 s inch Jam Nut 2 13 Lock Washer 1 2 inch Flat Washer 1 2 inch Stem Caster 5 x 11 2 inches 4 Caster Spacer 2 Nylock Nut 1 2 13 Screw HHC 1 2 13 x 3 inches GR 5 Caster Mount Bracket 4 Front Outrigger Assembly 2 Front Outrigger Tube Caster Swivel Lock 4 x 2 inches eene 2 Base Assembly includes item 7 all models before serial number 7794 100 1 Base Assembly with Word Decals includes item 7 ST 20 USA Canada and Australia models after serial number 7794 101 Base Assembly with Symbol Decals includes item 7 ST 20 Asia South America and Europe models after serial number 7794 101 Base Assembly with Word Decals includes item 7 ST 25 USA Canada and Australia models after serial number 7794 101 Base Assembly with Symbol Decals includes item 7 ST 25 Asia South America and Europe models after serial number 7794 101 Part No 32951 Genie Super Tower Section 7 e Base Components November 2005 Notes 7 4 Genie Super Tower Part No
19. 25 ft Ibs 27 to 34 Nm CAUTION Overtightening the drum bolt jam nut may cause damage to the frame spacer and prevent the drum from spinning freely Part No 32951 Genie Super Tower 5 7 Section 5 Repair Procedures WINCHES 18 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 CAUTION friction disks or the ratchet gear 19 Rotate the drum so that the two sguare 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 20 Route the end of the cable around 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 21 Insert the end of the cable under the cable keeper clip approximately 1 2 inch 13 mm and tighten the cable keeper clip 22 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 CAUTION sure the cable winds onto the winch drum evenly November 2005 REV B 3 2 How to Disassemble the Two speed Winch ACAUTION Bodily injury hazard Cables can fray Always wear adequate hand protection when handling cable 1 Fully lower the carriage and
20. 32951 November 2005 Section 8 e Mast and Winch Components r _ t l 1 _FTF W _rr_r HH Mast and Winch Components Part No 32951 Genie Super Tower 8 1 Section 8 Mast and Winch Components November 2005 Figure 8 A Number 1 Mast Attached Parts REV C 8 2 Genie Super Tower Part No 32951 November 2005 Section 8 e Mast and Winch Components _ ar ZZOZ REV C FIGURE 8 A Item Part No Description Qty tem Part No Description Qty 1 Ref Winch Assembly 21 32375 Lock Pin Assembly 1 refer to 8 E or 8 F 35830 Snap Pin Kit 2 4828 Nylock Nut 3 8 16 22 33191 Outrigger Storage Socket 1 3 6638 Flat Washer 1 4 inch 23 100309 Pin Assembly with Lanyard 1 4 6175 Screw HHC 80679 Detent Se x 2 7 inches 3 8 16 x 1 inch GR 5 2163 Cable 1 16 inch i 2238 Cable Oval Sleeve 1 16 inch 5 6198 Nylock Nut 1 2 13 10598 Screw HHC 1 2 13 x 3 inches 6 13005 Screw HHC 1 2 13 x 6 inches GR 8 1 gt div 24 6564 Shim Washer d sd Winch Mount Plate with Word 0 781 x 1 312 x 0 093 inch 6 Decals all models before serial number 7794 100 25 6086 Low Profile Nylock Nut 1 2 13 103 NAA And Australia 26 6587 Grip Handle cia 2 models after serial number 7794 101 27 33385 Shaft Washer 0 75 inch 2 107493 Winch Mount Plate with Symbol Decals Asia South 28 57788 Whee
21. 4 100 Adjustable Fork Carrier with Symbol Decals Asia South America and Europe models after serial number 7794 100 Adjustable Fork Fork Lock Pin FIGURE 9 A Part No 32951 Genie Super Tower Section 9 e Accessories November 2005 Notes 9 4 Genie Super Tower Part No 32951 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 Scandinavia Phone 46 31 3409612 Fax 46 31 3409613 Genie China Phone 86 21 53852570 Fax 86 21 53852569 Genie France Phone 33 0 2 37 26 09 99 Fax 33 0 2 37 26 09 98 Genie Malaysia Phone 65 98 480 775 Fax 65 67 533 544 Genie Iberica Phone 434 93 579 5042 Fax 34 93 579 5059 Genie Germany Phone 49 0 4202 88520 Fax 49 0 4202 8852 20 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 10 220 7911 Fax 31 10 220 6642 Parts and Service Manual Super Tower from serial number 7794 101 t
22. FIGURE 8 F Item Part No Description Qty Item Part No Description Qty 32946 Winch Assembly Two speed 17 38028 Low Profile Nylock Nut 5 8 11 aj 18 40125 Handle 8 inches 2 before serial number 7794 101 USA Canada 19 72264 Input Shaft Assembly 1 and Australia models after serial number 7794 100 20 6145 i Pe 107495 Winch Assembly Two speed SA NEI with Symbol Decals Asia 21 40115 Brake Spring Spacer 2 South America and Europe models after serial number 22 6889 Low Profile Nylock Nut 1 4 20 7794 100 l 23 40127 Detent Block Assembly 1 40130 Cable Keeper Kit 40509 Detent Spring 2 includes items 5 8 and 9 40510 Detent Ball 2 1 78037 Screw HHC 80156 Detent Block 1 3 8 16 x 5 5 inches 24 80157 Pinion Gear 1 2 4828 Nylock Nut 3 8 16 25 37061 Dist Bake acciaio 2 80145 Reel Lock Bolt 1 26 37062 Ratchet Gear 1 4 80146 Screw HHC 27 40122 Pinion Plate 1 1 1 4 20 x 5 25 inches 28 40123 Brake Spacer 1 5 6091 Nylock Nut 1 4 20 m 29 37064 Pinion Shaft Bushing 1 6 80147 Threaded Screw FHC 1 2 inch 30 40128 Base Spacer 1 7 80148 Reel Cover
23. REV B Over Remove excess weight loaded from machine and re check Verify weight of load against machine capacity not over loaded Check position of load for proper centering centered Center load and re check Clean the columns See Maintenence procedure 304 1 Clean the Columns Inspect the column channels and pulley tracks for foreign debris debris Check for cable binding on cable pulleys binding Inspect pulley and pulley Inspect cable for guard for damage amage yes N the pulley or pulley guard See Repair Procedure 502 3 How to replace the um Pulley Mast Installed Replace the cable See Repair Procedure 502 3 How to Replace the Lifting Cable Check the Roller Wheels for damage OR no grease Check each Mast for damage Consult the Genie Replace the damaged Roller Wheel s OR apply grease to the Roller Bolt Replace the damaged column OR consult Genie Inustries Service Departmet Industries Service Department Genie Super Tower Part No 32951 Section 4 e Troubleshooting Flow Charts November 2005 REV B Chart 2 Carriage Will uf 9 Check for broken cable A ot aise 502 3 How to Replace But Winch the Lifting Cable Will Operate Be sure the carriage hold down bar is not engaged Check all cable i incorrect Inspectthe cable for pulleys to verify that kinks frays and the
24. Tower 6 3 Section 6 Decals November 2005 Figure 6 B Decals with Words after serial number 7794 100 REV C 32927 27865 or 32928 82959 6 4 Genie Super Tower Part No 32951 November 2005 Section 6 e Decals EHS S SO REV C FIGURE 6 B Item Part No Description Gty 1 27865 Label Bubble Level 1 2 31072 Label Operators Manual 1 3 32770 Notice Two speed Shift InStructions ss 1 4 32885 Warning Silent Winch 1 5 32927 Cosmetic ST 20 2 6 32928 Cosmetic ST 25 1 111111 2 7 32929 Warning Machine Safety and Setup ooroonnnnnnn nn 1 8 32938 Label Use This Winch 1 9 32939 Warning Brake Lock 1 10 33493 Warning Adjustable Forks Safety Setup i 1 11 33468 Warning No Riders 1 12 33498 Label Serial Plate 2 13 32934 Label Outrigger Storage Socket 1 14 52985 Cosmetic Genie Super TOWER een 2 15 82959 Danger Electrocution Hazard ua di te 2 16 97529 Caution Bodily Injury Hazard nn ee 1 Part No 32951 Genie Super Tower 6 5 Section 6 Decals November 2005 Figure 6 C Decals with Symbols REV B 82487 82964
25. a South America and Europe models after serial number 7794 100 1 7571 Disc Brake ee 2 2 7590 Pinion Gear 1 3 32891 Pinion Shaft 1 4 6200 Retaining Ring 0 75 inch il 5 6199 Pinion Shaft Bushing 2 6 33144 Winch Handle 8 inches Perpendicular slot 2 16343 Winch Handle 8 inches Parallel slot 7 6086 Low Profile Nylock Nut 1 2 13 8 40458 Ratchet Pawl Kit 1 8516 Screw HHC 3 8 16 x 1 5 inches GR 5 35734 Seguencing Cable Bracket 4500 Cable 1 8 7 x 19 4517 Stop Sleeve Cable Tension 4518 Cable Swage Mast Tension 4828 Nylock Nut 3 8 16 9 6190 Cable Keeper Kit 1 80159 Carriage Bolt 10 24 x 0 63 inch GR 2 80160 Cable Keeper 80161 Internal Star Washer 5 8 inch 25625 Hex Nut 10 24 10 6184 Drum Spacer 1 11 31946 Drum Lock Bolt 1 12 6770 Winch Gear Cover 1 13 7256 Screw HHC 5 16 18 x 6 inches GR 2 14 6782 Lock Nut 5 16 18 15 6185 Drum BOL iii 1 Part No 32951 Genie Super Tower 8 11 Section 8 e Mast and Winch Components November 2005 Figure 8 F Winch Components Two speed REV C 8 12 Genie Super Tower Part No 32951 November 2005 Section 8 Mast and Winch Components _ na REV C
26. am 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 CAUTION Component damage hazard Do not allow grease or oil onto the friction disks or the ratchet gear 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 Genie Super Tower Part No 32951 November 2005 Section 5 Repair Procedures TFT HH EEE REV B WINCHES 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 proprely 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 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
27. ber Date of Purchase Authorized Genie Distributor Phone Number Genie North America Telephone 425 556 6551 Toll Free 877 367 5606 in U S A and Canada Fax 425 556 8659 Genie UK Parts Telephone 44 0 1476 584352 Parts Fax 44 0 1476 584340 Genie Australia Parts Telephone 617 03375 1660 Parts Fax 617 03375 1002 Genie France Parts Telephone 33 0 237 26 09 99 Parts Fax 33 0 237 31 50 10 Genie Germany Parts Telephone 49 0 4202 885223 Parts Fax 49 0 4202 885225 Genie Scandinavia Parts Telephone 46 31 3409612 Parts Fax 46 31 3409613 Genie Iberica Parts Telephone 34 93 5795042 Genie Brazil Parts Telephone 55 114 1665755 Parts Fax 55 114 1665754 Genie Japan Parts Telephone 81 33 4536082 Parts Fax 81 33 4536083 Genie China Parts Telephone 86 215 3852570 Parts Fax 86 215 3852569 Genie Super Tower Part No 32951 remove this page and make copies remove this page and make copies enie Service Parts Fax Order Form A TEREX COMPANY Fax to 425 556 8659 or Toll Free 888 274 6192 International 1 425 556 8659 Please fill out completely Date Account Number Your Name Your Fax Number Your Phone Number Bill To Ship To Purchase Order Number Ship Via Model s Serial No s Optional Equipment Part Number Description Quantity Price All back ordered parts will be shipped when ava
28. ble the columns in reverse order of disassembly 12 Repeat the procedure for other pulleys to be replaced November 2005 Winches 3 1 How to Disassemble the One speed Winch ACAUTION Bodily injury hazard Cables can fray Always wear adequate hand protection when handling cable 1 Fully lower the carriage 2 Remove 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 from the winch 5 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 CAUTION threads while holding the pinion shaft 6 Remove the retaining ring from the pinion shaft 7 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 8 Remove the pinion shaft from the winch housing 9 Remove both pinion bushings Use a soft metal drift egual to the outside diameter of the bushing and tap with rubber mallet Place a block in between the walls CAUTION of the winch housing to prevent the housing from bending while removing the bushings 10 Remove the winch housing from the machine Genie Super Tower
29. bserve 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 and annually as specified on the maintenance inspection report AWARNING Failure to properly complete each inspection when required could 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 Specifications section for the machine weight M Be sure overhead cranes or other lifting devices are of ample capacity to handle machine weight See Specifications section for machine weight 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 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 Safety alert symbol used to alert personnel to potential personal injury hazards Obey all safety m
30. de of the carriage and lift it approximately 5 inches 12 7 cm then drop it Result The carriage should stop within 3 inches 7 6 cm and the safety brake should lock ACAUTION Crushing hazard Do not stand directly under columns 4 Raise the carriage 6 inches 15 2 cm to unlock the safety brake CHECKLIST C PROCEDURES 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 a then drop it le edi ACAUTION Crushing hazard Do not stand directly under columns 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 12 7 cm then drop it ACAUTION Crushing hazard Do not stand directly under columns 10 Repeat steps 7 through 9 to test all remaining columns 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 the base does not have a safety brake and will not need to be tested Part No 32951 Genie Super Tower Section 3 Scheduled Maintenance Procedures November 2005 pem
31. disk a pinion plate and a pinion spacer onto the pinion shaft CAUTION Component damage hazard Do not allow grease or oil onto the brake disk ratchet gear or the teflon spacer 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 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 November 2005 REV B 13 Install the ball and spring into the spring and ball housing Install the mounting fasteners 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 ft Ibs 27 to 34 Nm Component damage hazard CAUTION Overtightening the drum bolt j
32. embly 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 inch 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 Assembly Part No 32951 Genie Super Tower Section 3 Scheduled Maintenance Procedures November 2005 CHECKLIST C PROCEDURES 4 Visually inspect the bottom 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 Assembly REV B C 3 Replace the Winch Friction Disks Maintaining the w
33. es Service Department Consult the Genie Industries Service Department Genie Super Tower Part No 32951 November 2005 Section 5 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 Super Tower 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 Specifications section for specific weight M Be sure overhead cranes or other lifting devices are of ample 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 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 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 works
34. essages that follow this symbol to avoid possible injury or death ADANGER Red used to indicate the presence of an imminently hazardous situation which if not avoided will result in death or serious injury AWARNING Orange used to indicate the presence of a potentially hazardous situation which if not avoided could result in death or serious injury ACAUTION Yellow with safety alert symbol used to indicate the presence of a potentially hazardous situation which if not avoided may cause minor or moderate injury Yellow without safety alert symbol used to indicate the presence of a potentially hazardous situation which if not avoided may result in property damage CAUTION Green used to indicate operation or maintenance information O Indicates that a specific result is expected after performing a series of steps Part No 32951 Genie Super Tower 3 1 Section 3 Scheduled Maintenance Procedures November 2005 SCHEDULED MAINTENANCE PROCEDURES Maintenance Symbols Legend The following symbols have been used in this manual to help communicate the intent of the instructions When one or more of the symbols appear at the beginning of a maintenance procedure it conveys the meaning below Indicates that tools will be required to perform this procedure Indicates that new parts will be required to perform this procedure Indicates that dealer service will be required to perform
35. 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 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 6 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 7 Remove the carriage by sliding it out the bottom of the mast towards the base while holding the safety brake rollers in position with the hex key wrench 8 Repeat steps 5 through 7 for each remaining column Mast Assembly 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 6 and 7 B The second method allows you to release any column i
36. ghly Attempting shortcuts may produce hazardous conditions M Be aware of the following hazards and follow generally accepted safe workshop practices Crushing hazard When testing or replacing the primary component always support the structure and secure it from movement A DANGER Perform all troubleshooting on a firm level surface 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 Troubleshoot discovered symptoms problem Still exists Perform repair Retum to service problem solved Part No 32951 Genie Super Tower 4 1 Section 4 e Troubleshooting Flow Charts Chart 1 Mast Will Not Seguence Properly Be sure safety brake if eguipped is not engaged by fully raising and lowering all columns Improper seguencing of the mast columns may occur when the machine is at or near maximum capacity If improper seguencing 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 always raise first and lower last November 2005
37. hop Select the appropriate repair procedure after troubleshooting the problem Perform disassembly procedures to the point where repairs can be completed To re assemble perform the disassembly steps in reverse order Symbols Legend Safety alert symbol used to alert personnel to potential personal injury hazards Obey all safety messages that follow this symbol to avoid possible injury or death ADANGER Red used to indicate the presence of an imminently hazardous situation which if not avoided will result in death or serious injury AWARNING Orange used to indicate the presence of a potentially hazardous situation which if not avoided could result in death or serious injury ACAUTION Yellow with safety alert symbol used to indicate the presence of a potentially hazardous situation which if not avoided may cause minor or moderate injury Yellow without safety alert symbol used to indicate the presence of a potentially hazardous situation which if not avoided may result in property damage CAUTION Green used to indicate operation or maintenance information Indicates that a specific result is expected after performing a series of steps Part No 32951 Genie Super Tower 5 1 Section 5 Repair Procedures November 2005 Base Assembly REV B 1 1 7 Secure the top of the mast to the sawhorse How to Remove the Base 8 Attach a lifting strap from an overhead crane to 1 2
38. ilable via the same ship method as the original order unless Noted below O Ship complete order only No back orders H Ship all available parts and contact customer on disposition of back ordered parts 0 Other please specify FOR GENIE INDUSTRIES USE ONLY Order Number Origin Code Comments Date Scheduled Ship Condition Order Total Terms Code November 2005 Section 2 Specifications ua Specifications Model ST 20 ST 25 Height Stowed 783 4 in 783 4 in Dimensions ST 20 ST 25 200 cm 200 cm N LLL Adjustable Forks Width Stowed 22 in 22 in forks down 19 ft 6 in 24 ft 4 in 56 cm 56 cm 6m 7 4m ims des Length Stowed 251 4 in 251 4 in forks up 21 ft 21 2 in 26 ft 1 2 in 6 5m 7 9m 64 cm 64 cm Length Operating 813 4 in 813 4 in Load Handling 208 cm 208 cm Attachment LxWxD Net Weight Ground 2 in 2 in Adjustable e Clearance 50 8 mm 50 8 mm 271 2 x 111 2 to 30 x 21 2 in 52 5 Ibs o 70x29 to 76 x 6 5 23 8 kg Outrigger 813 4 in 813 4 in Footprint 208 cm 208 cm Load Capacity 800 Ibs 650 Ibs at 18 load center 363 kg 295 kg Net Weight 437 Ibs 476 Ibs 198 kg 216 kg Part No 32951 Genie Super Tower 2 1 Section 2 Specifications November 2005 _ ae SE This page intentionally left blank 2 2 Genie Super Tower Part No 32951 November 2005 Section 3 Scheduled Maintenance Procedures Scheduled Maintenance Procedures O
39. inch 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 Refer to Repair Procedures 3 1 How to Disassemble the One speed Winch and 3 2 How to Disassemble the Two speed Winch 3 12 Genie Super Tower Part No 32951 November 2005 Section 3 Scheduled Maintenance Procedures REV B 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 Bodily Injury Hazard Metal edges ACAUTION can be sharp Be sure to wear protective gloves to perform this procedure 1 Install a load handling attachment into the carriage use forks or the boom if possible C Do not place any l weight on the load handling attachment iz xj 2 Raise the carriage until it is half way up the front column 3 Physically hold the bottom si
40. it One speed Winch 40458 Genie Super Tower Operator s Manual Ratchet Pawl Kit Two speed Winch 40117 before serial number 7794 101 32950 Cable Keeper Kit One speed Winch 6190 EMI Safety Manual sss 27581 Cable Keeper Kit Two speed Winch 40130 Primary Shaft Assembly nenn 72264 Pin Assembly with Lanyard 211111111111 32940 Roller Bolt 13 x 1 84 inches 32475 Nylatron Roller 1 75 x 0 72 inch 32473 Safety Brake Assembly i 35101 Loctite Thread Lock n 65764 Part No 32951 Genie Super Tower ix November 2005 How To Order 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 NARRRAaRAN Use the Service Parts Fax Order Form on the next page and fax your order to our Parts Department If you don t know the name of your authorized distributor or if your area is not currently serviced by an authorized distributor please call Genie Industries Machine Information Model Serial Num
41. k 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 REV B 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 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 Do not apply grease to brake friction disks or rachet gear 2 Carefully lubricate both pivot points on each ratchet pawl with 30W oil 3 8 Genie Super Tower Part No 32951 November 2005 Section 3 Scheduled Maintenance Procedures REV B 3 Measure each friction disk for wear Replace the friction disk if it measures less than specification Fric
42. l 6 x 0 75 x 2 inches 2 America and Europe models 29 33540 Loading Wheel Assembly after serial number 7794 101 includes items 24 and Z lele 1 8 32473 Nylatron Roller 1 75 X 0 72 inch sss a oz 5809 Loading Whee 9 33843 Mast Stiffener Spacer 4 56 x 0 75 inch 1 10 109579 Mast Siiffener Right Gray 1 109580 Mast Siiffener Left Gray 11 6019 Screw HHC 3 8 16 x 1 25 inches GR 5 12 6600 Manual Storage Container 1 31822 Cap 13 6653 Rubber Cushioned Clamp 1 88 iINches 2 14 7265 Steel Rivet 0 375 x 0 25 inch 2 15 33653P Carriage Hold down Latch 1 16 33720 Flange Bearing 3 8 1 17 7713 Low Profile Nylock Nut 3 8 16 18 33674 Lock Pin Assembly 1 19 32483 Roll Pin 0 25 x 0 5 inch 1 20 33663P Carriage Hold Down Latch Bracket 1 Part No 32951 Genie Super Tower 8 3 January 2006 Section 8 Mast and Winch Components A gt m z o gt m 2 I 0 0 5 o DE 2 O O y LL Part No 32951 Genie Super Tower 8 4 January 2006 Section 8 Mast and Winch Components a REV D FIGURE 8 B Item Part No Description Qty Item Part No Description Qty 1 35105 Column Number 1 all models 15 6052 Shim Washer from serial number 0 5 x 0 875 x 0 063 inch
43. n the assembly regardless of position but requires a custom made tool The tool is a piece of 1 8 to 3 16 inch 3 to 4 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 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 Part No 32951 Genie Super Tower Section 5 Repair Procedures MAST ASSEMBLY How to Assemble the Mast 1 ACAUTION Inspect all mast parts for wear and damage and replace as necessary Clean all of the columns and rollers Clean all of the safety brake assemblies 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 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 Slide the number two column into the number one from the bottom Stop inserting the column when the top of the safe
44. nd Cables 9 09000 Part No 32951 Genie Super Tower November 2005 REV C ltem PartNo 1 10597 2 33420 3 49999 32904 32905 12402 5 6052 6 32476 7 32470 8 8255 9 6019 10 6097 11 4828 12 33700 13 32483 14 6086 15 35105 33308 57036 16 32965 35480 57036 Description Gty Screw HHC 1 2 13 x 1 25 inches GR 5 Outer Cable Guard 1 Pulley with Bearing 10 Cable Assembly ST 20 refer to 8 C Cable Assembly ST 25 Cable Replacement Coupler Shim Washer 0 5 x 0 875 x 0 063 inch 20 Pulley Guard 10 Pulley Mount 9 Screw HHC 3 g 16 x 0 75 inch GR 5 Screw HHC 3 8 16 x 1 25 inches GR 5 Flat Washer 3 8 inch Nylock Nut 3 8 16 Pulley Mount Number 1 Mast 1 Roll Pin 0 25 x 0 5 inch 10 Low Profile Nylock Nut 1 2 13 Column Number 1 all models from serial number 7794 00001 to 7794 00337 1 Column Number 1 all models from serial number 7794 00336 to 7799 00001 Column Number 1 all models after serial number 7799 00000 Column Assembly Numbers 2 5 all models from serial number 7794 00001 to
45. nspect it After repair place a check in the R box Legend Y yes acceptable N no remove from service R repaired Comments Part No 32951 Genie Super Tower 3 5 Section 3 Scheduled Maintenance Procedures November 2005 Checklist A Procedures A 1 Perform Pre operation Inspection 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 REV B A 2 Perform Function Tests Completing the function tests is essential to safe machine operation Function tests are designed to discover any malfunctions before the machine is put into service A malfunctioning machine must never be used If malfunctions are discovered the machine must be tagged and removed from Service Complete information to perform this procedure is available in the appropriate operator s manual Refer to the Operator s Manual on your machine Genie Super Tower Part No 32951 November 2005 Section 3 Scheduled Maintenance Pr
46. o 7799 101 Part No 32951
47. ocedures Checklist B Procedures REV B B 1 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 2 Clean the Columns Clean columns are essential to good machine performance and safe operation Extremely dirty conditions may reguire 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 cleaning solvent to clean the columns AWARNING Pod 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 32951 Genie Super Tower 3 7 Section 3 Scheduled Maintenance Procedures November 2005 CHECKLIST B PROCEDURES B 3 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 chec
48. otective eye wear and ce other protective clothing if the situation Be aware of potential crushing hazards such as moving parts free swinging or warrants it JI unsecured components when lifting or placing loads Always wear approved steel toed shoes Workplace Safety Be sure to keep sparks flames and M lighted tobacco away from flammable and combustible materials like battery gases and engine fuels Always have an approved fire extinguisher within easy reach ANY are properly maintained and ready for use Keep work surfaces clean and free of debris that could get into machine components and cause damage Be sure that all tools and working areas Be sure that your workshop or work area is properly ventilated and well lit D a Be sure any forklift overhead crane or d other lifting or supporting device is fully capable of supporting and stabilizing the weight to be lifted Use only chains or straps that are in good condition and of ample capacity Be sure that fasteners intended for one PA time use i e cotter pins and self locking nuts are not reused These components may fail if they are used a second time Be sure to properly dispose of old oil or other fluids Use an approved container Please be environmentally safe OY ed Part No 32951 Genie Super Tower November 2005 o This page intentionally left blank vi Genie Super Tower Part No 32951 November 2005 Table of Con
49. oyer s safety rules and worksite regulations applicable governmental regulations M You have the appropriate tools lifting equipment and a suitable workshop n Genie Super Tower Part No 32951 November 2005 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 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 A Red used to indicate the presence of an imminently hazardous situation which if not avoided will result in death or serious injury AWARNING Orange used to indicate the presence of a potentially hazardous situation which if not avoided could result in death or serious injury Yellow with safety alert symbol used to indicate the presence of a potentially hazardous situation which if not avoided may cause minor or moderate injury ACAUTION Yellow without safety alert symbol used to indicate the presense of a potentially hazardous situation which if not avoided may result in property damage CAUTION Green used to indicate operation or maintenance information SAFETY RULES Be sure to wear pr
50. r Date Machine owner Inspected by print Inspector signature Inspector title Inspector company Section 3 Scheduled Maintenance Procedures November 2005 z gez OOOO ZOZ ZO This page intentionally left blank 3 4 Genie Super Tower Part No 32951 November 2005 Section 3 Scheduled Maintenance Procedures Maintenance Inspection Report Model Checklist A Rev B Y NIR Checklist C Rev B Y NIR Sena number A 1 Pre Operation C 1 Casters and wheels Inspection C 2 Inspect the Mast Date o A 2 Function Assembly for Wear Tests C 3 Friction Disks Machine owner C 4 Brake System _ Checklist B Rev B Y NIR C 5 Inspect the Inspected by print B 1 Inspect All Welds painted surfaces B 2 Clean the Columns B 3 Winch operation Inspector title B 4 Inspect Lubricate winch Inspector signature Inspector company Instructions 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 Annual 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 i
51. r adequate hand protection when handling cable Refer to Figure 8 F Two speed Winch for exploded view of the 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 Use a piece of flatbar or wood between the drift and the bushing to prevent any damage to the bushing 4 Addtwo drops of 30W oil to both pivot points on each ratchet pawl CAUTION Component damage hazard Do not allow grease or oil onto the friction disks or the ratchet gear 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 32951 Genie Super Tower 5 9 Section 5 Repair Procedures WINCHES 7 Apply a small 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 a friction disk a ratchet gear a friction
52. rinted on recycled paper Printed in U S A Genie Super Tower Part No 32951 November 2005 How To Read Your Serial Number Genie Model GS 1930 Serial number GS3005A 12345 Model year 2005 Manufacture date 04 12 05 Electrical schematic number ES0141 Machine unladen weight 2 714 Ib 1 231 kg Rated work load including occupants 500 Ib 227 kg Maximum allowable inclination of the chassis N A GS30 05 A 12345 Gradeability N A Model Maximum allowable side force 100 Ib 445 kg Sequence Maximum number of platform occupants 2 number Model year Country of manufacture USA This machine complies with Facility code used only for model manufactured ANSI A92 6 1999 in multiple facilities B354 2 01 Genie Industries 18340 NE 76th Street Redmond WA 98052 USA PN 77055 Part No 32951 Genie Super Tower iii November 2005 Safety Rules Warning Failure to obey the instructions and safety rules in this manual and the Genie Super Tower 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 empl
53. se Components REV C ltem PartNo 11 12 13 14 15 16 17 18 19 20 21 22 23 33666 23491 4828 8178 32576 32971 33152 S 6825 6714 8516 6097 33307 33306 33670 32375 35830 6019 32480 6708 6022 6021 6082 8214 6145 6889 33673 14538 Description Qty Leveling Jack Assembly includes items 1 and 15 27 Leveling Jack Rod 19 25 inches Nylock Nut 3 8 16 Screw HHC 3 8 16 x 2 5 inches GR 5 Pivot TUDO yy zawo eterno Rear Outrigger Assembly complete Rear Outrigger Tube Lock Pin Assembly Bubble Level Screw HHC 3 8 16 x 1 5 inches GR 5 Flat Washer 3 8 inch Left Side Mast Brace Right Side Mast Brace Skid Pad Loading Lock Pin Assembly Snap Pin Kit Screw HHC 3 8 16 x 1 25 inches GR 5 Swivel Plate Caster 4x 1 5 inches ciet Screw HHC 3 8 16 x 2 25 inches GR 5 Hex Nut 3 8 16 Lock Washer 3 8 inch Ball Knob Handle Leveling Jack Handle Screw HHC 1 4 20 x 1 5 inches GR 5 Low Profile Nylock Nut 1 4 20 Leveling Jack Casting Leveling Jack Foot Pad Item Part No 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 10107 6886 5397 2226
54. shaft CAUTION Do not allow grease or oil onto the friction disks or the ratchet gear WINCHES 8 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 9 Install the two jam nuts to the right side of the pinion shaft one at a time and tighten 10 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 11 Lubricate the outside of the frame spacer that goes through the cable drum with automotive grease and then insert it into the drum 12 Install the cable drum so that the drum gears mesh with the ratchet gears 13 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 14 Place the drum gear cover into position with the drum bolt slot under the drum bolt keeper 15 Install the drum bolt jam nut hand tight 16 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 17 Tighten and torque the drum bolt nut to 20 to
55. tents Introduction Section 1 Section2 Rev A Section3 Rev Importantlnformation usa wes A aa ii How to Read Your Serial Number 2244044244B0nnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnn iii Recommended Parts Stocking List non nn ix How TO Order Palts 2 et een ana X Service Parts Fax Order Form zu uoi deni Rude REEL D pua FERE Ma da xi Safety Rules General Safety Rules eeee no en RR iv Specifications Machine Specifications oed een 2 1 Scheduled Maintenance Procedures Introduction ae 3 1 Pre delivery Preparation Report nennen nnn 3 3 Maintenance Inspection Report ene 3 5 Checklist A Procedures A 1 Perform Pre operation Inspection iii 3 6 A 2 Perform Function Tests ueaaae aaa aaa aaa aaa emen nnn nnnenn nnne r nnne aa 3 6 Checklist B Procedures B 1 Inspect all Welds rn een 3 7 B 2 Clean the Columns saec iaia 3 7 B 3 Check the Winch Operation nnns 3 8 B 4 Inspect and Lubricate the Winch uuuuursssssssnennssnnnnnnennnnnnnnnnnennnnennnnnennn nn 3 8 Checklist C Procedures C 1 Lubricate the Casters and Wheels i 3 11 C 2 Inspect the Mast Assembly for Wear i 3 11 C 3 Replace the Winch Friction Disks ii 3 12 C 4 Inspect the Safety Brake System i 3 13 C 5
56. the base and lift the machine enough to slide a Fully lower the carriage second sawhorse under the mast next to the Remove the load handling attachment from the base machine Crushing hazard The machine will ACAUTION iti Remove the outriggers from the outrigger fall unless it is properly supported storage sockets with the overhead crane Attach a lifting strap from an overhead crane to the lifting bracket on the number 1 mast Place a sawhorse on the carriage side of the mast Lift the machine slightly and then while lowering it guide the machine over onto the sawhorse Crushing hazard The machine will A ACAUTION fall unless it is properly supported with the overhead crane 9 Remove the mounting fasteners from the mast brace to the base Repeat for other side 10 Remove the base mounting fasteners Then remove the base from the machine 5 2 Genie Super Tower Part No 32951 November 2005 Section 5 Repair Procedures REV B 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 Tipthe 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
57. tion disk specification Thickness minimum 1 16 inch 1 6 mm 4 Measure both shaft bushings for wear Replace the bushings if the wall thickness measurements are less than specification Pinion shaft bushing specification Wall thickness minimum 1 8 inch 3 1 mm 5 Lubricate the surface of the frame drum spacer with a thin layer of lithium grease Tighten the drum bolt to 20 ft Ibs 27 Nm Do not overtighten CHECKLIST B PROCEDURES Part No 32951 Genie Super Tower Section 3 Scheduled Maintenance Procedures November 2005 som ZZ WO Er gt gt pe This page intentionally left blank 3 10 Genie Super Tower Part No 32951 November 2005 Section 3 Scheduled Maintenance Procedures Checklist C Procedures REV B C 1 Lubricate the Casters and Wheels Regular application of lubrication to the Caster or Wheel is essential to good machine performance and service life Extremely dirty conditions may require that the casters and wheels be inspected and libricated 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 been 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 ass
58. ty brake assembly is even with the bottom of the number one column 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 Attach the swagged end of the cable to the cable anchor on the top of the front column 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 fray Always wear adequate hand protection when handling cable Refer to Section Eight Figure 8 D Mast Components Pulleys and Cables to identify the cable routing November 2005 REV B 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 1 k 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 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

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