SAFETY NOTICE
Contents
1. second friction disc counter plate DN gt G o Terex Aerial Work Platforms 18340 NE 76th Street Redmond WA 98052 Ph 800 536 1800 425 881 1800 6 of 7 SAFETY NOTICE Reimbursement Only Genie Dealers will be reimbursed for labor or any other costs associated with this bulletin under the provisions of our LIMITED PRODUCT WARRANTY statement Machine owners without a valid Genie account can contact their nearest Terex AWP dealership or Terex Service North America for assistance Search for your nearest Terex AWP dealership by visiting our website at http www genielift com dealersearch Warranty The labor and travel miles required to perform this inspection and installation are covered under the provisions of our LIMITED PRODUCT WARRANTY statement Warranty claims can be submitted by paper claims fax or email If you need more information about filing a warranty claim call Terex AWP Warranty department Genie and ANSI requires that the seller of a Genie machine report to Genie the model and serial number of each machine sold as well as the name address and telephone number of the new owner within 60 days of the sale OSHA and ANSI also require that the manufacturer s safety notices be completed It is your responsibility to communicate this important information to all machine owners and applicable branches If you require additional copies of this safety notice or have any questions please contact Genie s service2. wheel assembly from both ends of the axle 5 Remove the fasteners securing the front drive shaft to the transmission Lower the end of the drive shaft to the ground 6 Remove the fasteners securing the drive shaft to the front axle Remove the drive shaft from the machine 7 Support and secure the axle to an overhead crane Procedure 8 Remove the fasteners securing the sway cylinder rod end pivot pin to the chassis 9 Use a soft metal drift to remove the pivot pin 10 Remove the fasteners securing the axle to the chassis Remove the axle from the machine Crushing hazard The axle will fall if not properly supported when the fasteners are removed from the machine Bolt torque specification 380 ft lbs 515 Nm Axle mounting bolts Confirm the Proper Brake and Coupler Stacking Order Follow the procedure to disassemble the axle using the Dana 213 Axle Maintenance and Repair information included with these instructions Note Refer to the illustration on page 5 for the correct stacking order Genie Part No 822725 GTH 1056 Brake Inspection Installation Instructions REVA Procedure 11 Install the axle drive shaft and tire and wheel assembly 12 Remove the jack stands or blocks 13 Start the machine and fully raise the outriggers Turn the machine off 14 Torque the lug nuts to 465 ft lbs 630 Nm Test the Brakes 15 Step on the brake pedal and start the machine 16 Push the bottom o
3. GTH1012 16457 GTH1012 16458 GTH1012 16460 GTH1012 16462 GTH1012 16464 GTH1012 16467 GTH1012 16469 GTH1012 16471 GTH1012 16472 GTH1012 16476 GTH1012 16478 GTH1012 16479 GTH1012 16481 GTH1012 16483 GTH1012 16485 GTH1012 16486 GTH1012 16490 GTH1012 16492 GTH1012 16493 GTH1012 16495 GTH1012 16497 GTH1012 16499 GTH1012 16506 GTH1012 16516 GTH1012 16518 GTH1012 16520 GTH1012 16521 GTH1012 16523 GTH1012 16525 GTH1012 16527 GTH1012 16528 GTH1012 16530 GTH1012 16532 GTH1012 16534 SAFETY NOTICE Procedure Inspection Repair A Determine if the front axle installed on your machine is affected 1 Locate the front axle serial number tag axle serial number tag 2 Inspect for the serial number stamped on the serial number tag Use the attached axle serial number inspection form to record the axle serial number installed on your machine axle serial number SES Ee O lf the axle serial number is in the affected list see page 5 proceed to section B Ifthe axle serial number is not in the affected list fill out the Completion Form for Inspection and return to Genie This will serve as verification that you have completed this safety notice No further action is required List of affected axle serial numbers Terex Aerial Work Platforms 18340 NE 76th Street Redmond WA 98052 Ph 800 536 1800 425 881 1800 4 of 7 SAFETY NOTICE R ITA 729594 R ITA 729595 R ITA 729607 R ITA 729608 R ITA 729
4. department at United States 800 536 1800 Canada 425 881 1800 Europe 31 653 221 908 Australia 61 733751660 All other locations 001 425 881 1800 Enclosures Machine List Report New Owner Update Form Completion Form for Inspection Map Terex Service North America Instruction 822725 Terex Aerial Work Platforms 18340 NE 76th Street Redmond WA 98052 Ph 800 536 1800 425 881 1800 7 of 7 Genie New Owner Update Form for updating machine owner information only Genie and ANSI requires that the seller of a Genie machine report to Genie the model and serial number of each machine sold as well as the name address and telephone number of the new owner within 60 days of the sale e If you have sold a machine list the complete model and serial number examples GTH1012 16303 or GTH1012 16418 and the name address and phone number of the new owner New Owner Information Machine 1 Machine 2 Machine 3 Model Serial Number Owner Name Address 1 Address 2 City State Zip Phone Number Contact Person Required fields Seller Information Date Company Name Account Address street city State zip code Phone List any machines that could not be inspected or repaired because of the following Model amp Serial Number Scrapped Exported Stolen Others explain Fax to United States 877 738 7530 Canada 425 498 7530 All other locations 001 425 498 7530 Terex Aerial Work Platforms 18340
5. 6 and sprinos 11 at the same time NOTE Write down direction of installation Write down direction of installation of coupling 14 in rela tion to brake disc 16 ASM 0026E 213 Axle Service Manual Dana Holding Corporation 19 ASSEMBLY FIGURE 30 Lubricate the friction disc 16 with oil SAE FIGURE 33 Tighten screws 9 sequentially and in several 85W90 install friction disc and coupling 14 stages to a torque of 20 30 N m CAUTION Check coupling s direction of installation carefully FIGURE 34 Fit a new o ring 83 on the brake cylinder 23 Connect the complete arm 4 to a hoist and install it in the main body 7 FIGURE 31 Install parts in the following sequence interme diate disc 15 friction disc 13 and second intermediate disc 12 Le FIGURE 35 Fasten the arm to the brake cylinder 23 and at tach the arm with screws and washers 6 FIGURE 32 Install the thrust disc 10 springs 11 and I screws 9 NOTE NCAUTION eachother Orient disc 10 to align on horizontal axis the negative brake release screws 36 recesses 24 Dana Holding Corporation ASM 0026E 213 Axle Service Manual ASSEMBLY FIGURE 36 Using tool T2 See drawing T2 p 26 check that FIGURE 39 Rotate pinion 19 clockwise to obtain the accu the arms are level then finally lock them with screws 5 and rate clearance washers 6 using the criss cross method Axles wi
6. 610 R ITA 729611 R ITA 731410 R ITA 731411 R ITA 731412 R ITA 731413 R ITA 731414 R ITA 731415 R ITA 731416 R ITA 731417 R ITA 731418 R ITA 731419 R ITA 731420 R ITA 731421 R ITA 731422 R ITA 731423 R ITA 731424 R ITA 731425 R ITA 735515 R ITA 735516 R ITA 735517 R ITA 735518 R ITA 735519 R ITA 735520 R ITA 735521 R ITA 735522 Terex Aerial Work Platforms 18340 NE 76th Street Redmond WA 98052 Ph 800 536 1800 425 881 1800 5 of 7 R ITA 735523 R ITA 735524 R ITA 735525 R ITA 735526 R ITA 735527 R ITA 735528 R ITA 735529 R ITA 735530 R ITA 735531 R ITA 735532 R ITA 735533 R ITA 735534 R ITA 735535 R ITA 735536 R ITA 735537 R ITA 735538 R ITA 735539 R ITA 735540 R ITA 735541 R ITA 735542 R ITA 735543 R ITA 735544 R ITA 735545 R ITA 735546 R ITA 735547 R ITA 735548 R ITA 735549 R ITA 735550 R ITA 735551 R ITA 735552 R ITA 735553 R ITA 735554 R ITA 740592 R ITA 740594 R ITA 740595 R ITA 740596 R ITA 740597 R ITA 740598 R ITA 740599 R ITA 740600 R ITA 740602 R ITA 740603 R ITA 740604 R ITA 740605 R ITA 740606 R ITA 744442 R ITA 744443 R ITA 744444 R ITA 744445 R ITA 744446 R ITA 744447 R ITA 744448 R ITA 744449 R ITA 744450 R ITA 744451 R ITA 744452 R ITA 744453 R ITA 744454 R ITA 744455 R ITA 744458 R ITA 744459 R ITA 744460 R ITA 744462 R ITA 744464 R ITA 744465 R ITA 744466 R ITA 744467 R ITA 744468 R ITA 744469 R ITA 744470 R ITA 744471 R ITA 744472 R ITA 744473 R IT
7. A 744474 R ITA 744475 R ITA 744476 R ITA 744477 R ITA 744478 R ITA 744479 R ITA 744480 R ITA 744481 R ITA 744482 R ITA 744483 R ITA 744484 R ITA 744485 R ITA 744486 R ITA 751717 R ITA 751722 R ITA 751736 R ITA 754077 SAFETY NOTICE B Inspection and repair of the brake discs on affected axle Genie and the axle supplier have determined that the nature and complexity of the inspection and repair to be performed requires special training and tooling Use the option below that best fits your situation Option 1 You can have your machine inspected and repaired by one of Terex s service centers Just locate and call the nearest Terex Service North America location and schedule an appointment Refer to the attached Terex Service North America map Option 2 The procedure requires the removal and disassembly of the front axle on your machine You will need the following tools to perform this Lifting straps capable of supporting 2000 Ib 1000 kg or greater Overhead crane capable of supporting 2000 Ib 1000 kg or greater Jack stands or blocks capable of supporting 10 ton 10 000 kg or greater Assorted wrenches Assorted impact sockets Impact wrench Instruction 822725 attached For more information on this procedure contact Genie s service department 1 800 536 1800 ext 6818 and refer to SN 130001 INCORRECT STACKING CORRECT STACKING Intermediate disc friction disc second intermediate disc coupler
8. ALIFORNIA CU D VIRGINIA Stockton Glen Allen 2610 Lycoming St 11072 Washington Hwy Arizona Phoenix SOUTH CAROLINA 4920 W Magnolia St Rock Hill Phoenix AZ 85043 T 605 256 0612 1205 Galleria Blvd Rock Hill SC 29730 T 803 326 4869 SEENEN TEXAS ARKANSAS urora 18000 E 22nd Ave Fort Worth North Little Rock Aurora CO 80011 1300 S Sylvania Ave 309 Dixie St ALABAMA T 303 202 0304 Fort Worth TX 76111 N Little Rock AR 72114 T 501 945 6100 Birmingham T 817 698 8005 4120 Lewisburg Rd Waco Birmingham AL 35207 s ey T 205 985 5200 1 800 800 6411 Waco TX 76712 T 254 714 0088 Genie A TEREX BRAND Inspection Instructions Brake Inspection GTH 1056 Part No 822725 RevA Installation Instructions REVA Introduction Observe and Obey W This procedure 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 W Repair any machine damage or malfunction before operating the machine Before Starting Installation VM Read understand and obey the safety rules and operating instructions in the appropriate operator s manual M Be sure that all necessary tools and parts are available and ready for use MI Read this procedure completely and adhere to the instructions Attempting shortcuts may produce hazardous conditions Indicates that a specific resul
9. NE 76th Street Redmond WA 98052 Ph 800 536 1800 425 881 1800 Genie Completion Form for Inspection Your signature on this form will verify that the front axle Genie P N 117505 installed on your machine and or in you inventory have been inspected and verified to be not affected by this Safety Notice List the complete model and serial number examples GTH1012 16303 or GTH1012 16418 model of the machine inspected or the invoice number of the front axle in your inventory Machine Model Build Date Machine Serial Number Front Axle Serial Number Invoice Date indicate inventory if the axle is in N A if the axle is in your Invoice number your inventory inventory Date Company Name Account Address street city State zip code Phone service Manager Print Name Signature Fax to United States 877 738 7530 Canada 425 498 7530 All other locations 001 425 498 7530 E mail AWP Warranty terex com Terex Aerial Work Platforms 18340 NE 76th Street Redmond WA 98052 Ph 800 536 1800 425 881 1800 TEREX Services North America OHIO Quebec Columbus Montreal 2350 Refugee Park 3524 Rue Ashby OREGON Columbus OH 43207 St Laurent QC H4R 2C1 T 614 444 7373 1 800 292 1931 T 514 336 5556 Portland 12805 SE 77th Place Portland OR 97223 T 503 620 0611 7a gang lt x Glen Allen VA 23059 T 804 752 2811 Stockton CA 95206 T 209 652 0103 Lei C
10. SAFETY NOTICE Date April 29 2013 Models Affected GIH 1056 see serial number list on page 3 Part Number Affected 117505 Front Axle Dana Model 213 142 Subject Service and Parking Brakes Allowable Hours 10 hours Issue Genie was notified of a product service bulletin by Dana Corporation affecting Model 213 142 Drive Axles installed on the below referenced machines and sold as service parts replacement from J uly 26 2012 to September 25 2012 The service and parking brakes on these axles may malfunction due to improper assembly of the internal brake components Malfunctioning service and or parking brakes may result in unintended machine movement collision or loss of control Actions Required This safety notice requires the inspection and possible repair of the brake assembly in the front axle installed on the affected machines or in your inventory 1 Verify if your machine is affected by comparing the machine serial number to the serial number list on page 3 2 Ifthe machine is affected immediately perform the actions described in the Procedure section on page 4 of this Safety Notice If the machine is not affected no further action is required For axles purchased as service parts replacement e Ifthe axle is installed on a machine immediately perform the actions described in the Procedure section on page 4 of this Safety Notice e lf the axle is in your inventory inspect the serial number of the axle Fo
11. e UK 0044 1476 584 333 France 0033 237 260 986 Germany 49 4221 491 821 Iberica 0034 935 725 090 Italy 0039 075 941 8132 Scandinavia 0046 3157 5154 Other locations 0031 653 221 908 Middle East 0097 143 391 800 or 0097 150 459 7937 Australia 61 7 3456 4444 All other locations 001 425 881 1800 Genie 4 GTH 1056 Brake Inspection Part No 822725 Installation Instructions REVA ion Illustrat intermediate disc friction disc 1 2 3 4 5 second intermediate disc coupler second friction disc counter plate 6 CORRECT STACKING INCORRECT STACKING GTH 1056 Brake Inspection Part No 822725 Installation Instructions e I I I III Ol This page intentionally left blank Geni 6 GTH 1056 Brake Inspection Part No 822725 Genie A TEREX BRAND SAFETY NOTICE 130001 Completion Form Your signature on this form will verify that you have completed the brake inspection Fax to United States 877 738 7530 United Kingdom 0044 1476 584 330 Canada 425 498 7530 France 0033 237 260 998 Australia 61 733751002 Germany 0049 4221 491 820 All other locations 001 425 498 7530 Italy 0039 075 941 8146 Iberica 0034 935 725 080 Sweden 0046 3157 5104 Middle East 0097 143 990 382 All other locations 0031 165 510 826 Email to AWP Warranty terex com Date Company Name Account if applicable Address street city state zip code Phone Please list the co
12. f the parking brake switch The parking brake is off when the indicator light is off 17 Move the transmission control lever to forward Slowly let up on the brake pedal As soon as the machine starts to move push the brake pedal Result The machine should move forward and then come to an abrupt stop 18 Move the transmission control lever to reverse Slowly let up on the brake pedal As soon as the machine starts to move push the brake pedal Result The machine should move in reverse and then come to an abrupt stop The back up alarm should sound when the transmission control lever is in reverse 19 Move the transmission control lever to neutral 20 Push the top of the parking brake switch Result The red parking brake indicator light should come on indicating the parking brake is on 21 Move the transmission control lever forward and then in reverse Result The machine should not move 22 Perform function test Refer to the Operator s Manual on your machine 23 Return the machine to service 24 Fill out and sign the attached completion form and fax or email to Terex AWP Warranty Department This will serve as verification that you have completed Safety Notice 130001 If you have any further questions regarding these instructions or need assistance please contact the Genie Service Department at one of the following telephone numbers United States 800 536 1800 Canada 425 881 1800 Europ
13. ft until this safety notice is completed 9 As always follow all of the parking procedures listed in the operator s manual Serial Numbers Affected GTH1012 15426 GTH1012 16360 GTH1012 16402 GTH1012 16446 GTH1012 16488 Terex Aerial Work Platforms 18340 NE 76th Street Redmond WA 98052 Ph 800 536 1800 425 881 1800 2 of 7 SAFETY NOTICE GTH1012 15878 GTH1012 16299 GTH1012 16301 GTH1012 16303 GTH1012 16304 GTH1012 16311 GTH1012 16320 GTH1012 16322 GTH1012 16324 GTH1012 16332 GTH1012 16334 GTH1012 16336 GTH1012 16338 GTH1012 16339 GTH1012 16343 GTH1012 16346 GTH1012 16348 GTH1012 16353 GTH1012 16355 GTH1012 16357 GTH1012 16359 Terex Aerial Work Platforms 18340 NE 76th Street Redmond WA 98052 Ph 800 536 1800 425 881 1800 GTH1012 16364 GTH1012 16366 GTH1012 16367 GTH1012 16371 GTH1012 16373 GTH1012 16374 GTH1012 16376 GTH1012 16378 GTH1012 16380 GTH1012 16381 GTH1012 16383 GTH1012 16385 GTH1012 16387 GTH1012 16388 GTH1012 16390 GTH1012 16392 GTH1012 16394 GTH1012 16395 GTH1012 16397 GTH1012 16399 GTH1012 16401 GTH1012 16404 GTH1012 16406 GTH1012 16409 GTH1012 16411 GTH1012 16413 GTH1012 16415 GTH1012 16416 GTH1012 16418 GTH1012 16420 GTH1012 16422 GTH1012 16425 GTH1012 16427 GTH1012 16430 GTH1012 16432 GTH1012 16434 GTH1012 16436 GTH1012 16437 GTH1012 16439 GTH1012 16441 GTH1012 16443 GTH1012 16444 3 of 7 GTH1012 16448 GTH1012 16450 GTH1012 16451 GTH1012 16453 GTH1012 16455
14. llow the procedure section on page 4 starting at step 2 Continued Use Machines affected by this safety notice may remain in service provided the test below is followed before and after each working shift until this safety notice is completed This test procedure is best performed with two people 1 Move the machine onto a firm level surface with the boom in the stowed position 2 Engage the parking brake and set the transmission to neutral 3 Engage the service brake and lower the stabilizers until both front tires are off the ground Terex Aerial Work Platforms 18340 NE 76th Street Redmond WA 98052 Ph 800 536 1800 425 881 1800 1 of 7 SAFETY NOTICE Turn the engine off and set the key switch to the on position Release the service and parking brakes 6 Have the second person stand in front of a tire and push D on a lug with their foot Illustration 1 It should spin with some effort The other tire should turn in the opposite direction w SS a E ae ee Illustration 1 7 Engage the parking brake and attempt to turn the same tire again O The tires did not spin The parking brake is functional The machine may remain in service Engage the service brakes and raise the stabilizers G The tires continue to spin The parking brake is malfunctioning Engage the service brake and raise the stabilizers Chock the wheels Remove the machine from service 8 Repeat this test before and after each working shi
15. mplete serial number example GTH1011 15238 or GTH1012 16472 Machine Serial Number Axle Serial Number if replacement is required Print Service manager Signature Date DISASSEMBLY DISASSEMBLY FIGURE 3 If axle is positioned on an overhaul bench place a safety anti tilting stand B under the arm that remains con FIGURE REPLACING DISCS nected and block wheels if any Remove the rocking support 2 from non drive end NOTE If bushing 3 will be replaced because it is worn write down direction of installation of joint split A FIGURE 4 Loosen and remove the screws 5 and washers 6 that fix the arm 4 to the main body 7 FIGURE 2 Disconnect steering bar pivots from the steering cases See STEERING CYLINDER p 61 Sling arm 4 to be removed and slightly tighten the sling rope FIGURE 5 Remove arm 4 along with brake discs pack 8 Lay the arm on a workbench 18 Dana Holding Corporation ASM 0026E 213 Axle Service Manual DISASSEMBLY FIGURE 6 Loosen check and guide screws 9 of thrust disc FIGURE 8 Remove in sequence first intermediate disc 12 10 friction disc 13 and second intermediate disc 15 Loosen screws 9 in several stages sequentially and slow Check friction disc thickness if thickness is 5 mm or less ly replace discs on both sides FIGURE 7 Remove the thrust disc 10 along with screws 9 FIGURE 9 Remove both coupling 14 and friction disc 1
16. t is expected after performing a series of steps w Indicates that an incorrect result has occurred after performing a series of steps Note These installation instructions only apply to the Genie models listed below as required by Safety Notice 130001 e GTH 1056 Tools required Lifting straps capable of supporting 2000 Ib 1000 kg or greater Overhead crane capable of supporting 2000 Ib 1000 kg or greater Jack stands or Blocks capable of supporting 10 ton 10 000 kg or greater Assorted wrenches Assorted impact sockets Impact wrench Genie 2 GTH 1056 Brake Inspection Part No 822725 REV A Installation Instructions Note Perform this procedure on a firm level surface with the boom in the stowed position Chock the rear wheels How to Remove the Front Axle AWARNING Body injury hazard This procedure requires specific repair skills lifting equipment and a suitable workshop Attempting this procedure without these skills and tools could result in death or serious injury and significant component damage Dealer service is required 1 Loosen the lug nuts of both wheels on the axle to be removed Do not remove the lug nuts 2 Start the machine Fully lower the outriggers Turn off the machine and remove the key 3 Place jack stands or blocks under the front chassis for support Crushing hazard The chassis will fall if not properly supported 4 Remove the lug nuts Remove the tire and
17. th two friction discs 3 turns 3 sides clearance Tightening torque 283 312 N m 0 75 mm Axles with three friction discs 5 turns clearance 1 mm NOTE Every turn of the pinion produces a clearance of 0 2 mm FIGURE 37 ADJUSTING BRAKES sx hh z t When adjusting the brakes connect a hydraulic pump to the a ee ito access hole of the negative brake and introduce pressure at LAT GE S 20 25 bar to release the brake disc FIGURE 40 Release pressure fit the catch 18 and lock with screw 38 coated with Loctite 242 Tighten screw to a torque of 20 30 N m FIGURE 38 Rotate the pinion 19 counter clockwise until it reaches the end of stroke and a slight torque is obtained NOTE All existing clearances between discs are eliminated as a result of this operation ASM 0026E 213 Axle Service Manual Dana Holding Corporation 25
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