115429 SS Service Manual
Contents
1. EI 7 EEE eo Ol Ou I D o sg o lt Bina ux ag pee e i d 1 Ol o S 777 9 OL 2 ox E Z 6 a2 6 6 6 m OT NO s o No x o Olio lll ll SC UU ull S Z A Ol natn qo 0255 SEE Em cO x PE a c tt es DEG o se E d E T pop SO pop O a ba o o 66 a zZ r r r a NO o 5 No d o lt g m RINT 4 9 NN NNN 4 9 I Ol ao oe T Diaen ee a oe a a o ve a a m oO m See Q z AOC Q 8 z 2 5 z Oo z l a o Lo o d 6 m m 5 g m m amp Jj e e lt lt 6 8 lt lt 6 8 ES0502B a Super Straddle G Part No 115429 Genie Scandinavia Phone 46 31 575100 Fax 46 31 579020 Genie France Phone 33 0 2 37 26 09 99 Fax 33 0 2 37 26 09 98 Genie Iberica Phone 434 93 579 5042 Fax 34 93 579 5059 Genie Germany Phone 0800 180 9017 Phone 49 422 149 1818 Fax 49 422 149 1820 Genie North America Phone 425 881 1800 Toll Free USA and Canada 800 536 1800 Fax 425 883 3475 Genie Australia Pty Ltd Phone 61 7 3375 1660 Fax 61 7 3375 1002 Genie China2. Genie A TEREX BRAND Serial Number Range Super Straddle from SS08 2976 Part No 115429 Rev July 2009 July 2009 Introduction Important Read understand and obey the safety rules and operating instructions in the appropriate Operator s Manual on your machine before attempting any maintenance or repair procedure This manual provides detailed scheduled maintenance information for the machine owner and user It also provides troubleshooting and repair procedures for qualified service professionals Basic mechanical skills are required to perform most procedures However several procedures require specialized skills tools lifting equipment and a suitable workshop In these instances we strongly recommend that maintenance and repair be performed at an authorized Genie dealer service center Technical Publications Genie Industries has endeavored to deliver the highest degree of accuracy possible However continuous improvement of our products is a Genie policy Therefore product specifications are subject to change without notice Readers are encouraged to notify Genie of errors and send in suggestions for improvement All communications will be carefully considered for future printings of this and all other manuals Contact Us PO Box 97030 Redmond WA 98073 9730 USA www genieindustries com e mail awp techpub terex com Genie Copyright 1994 by Genie Industries
3. Schematics About This Section An illustration legend precedes the electrical schematics Electrical Schematics AWARNING Electrocution burn hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry General Repair Process Identify symptoms Malfunction gt Troubleshoot discovered Perform repair Return to service problem solved Section 5 Schematics July 2009 Limit Switch Legend REVA Limit Switches Front Right LS33A LS33B Limit Switches E Front Left 3 271 LS32A LS32B Limit Switches 2 Rear Right LS34A LS34B Limit Switches Rear Left LS35A LS35B Genie 5 2 Super Straddle Part No 115429 July 2009 Section 5 Schematics REVA ELECTRICAL COMPONENT LEGEND Item Description EN Endosure EN11A Pin switch box front left EN11B Pin switch box front right EN11C Pin switch box rear right EN11D Pin switch box rear left LS LS32A Front left pin interlock LS32B Front left pin interlock LS33A Front right pin interlock LS33B Front right pin interlock LS34A Rear right pin interlock LS34B Rear right pin interlock LS35A Rear left pin interlock LS35B Rear left pin interlock Quick Disconnect QD22A Front left sta
4. 252 kg SS AWP 36S 601 Ibs 273 kg SS AWP 40S 602 Ibs 274 kg Note Floor loading information is approximate and does not incorporate different option configurations It should be used only with adequate safety factors Continuous improvement of our products is a Genie policy Product specifications are subject to change without notice or obligation Super Straddle 2 1 Section 2 Specifications July 2009 SPECIFICATIONS REVA SAE FASTENER TORQUE CHART This chart is to be used as a guide only unless noted elsewhere in this manual A574 High Strength Grade8 69 Black Oxide Bolts CUBED DRY LUBED Nm inis Nm Nm inbs Nm 9 10 113 mo 124 140 158 130 147 10 1 120 135 120 135 160 18 140 4158 LUBED es 13 23 14 257 23 22 26 77 4 37 664 50 678 70 947 627 di 745 60 813 50 1084 568 91 w C 5 773 75 1016 80 1084 110 1 93 126 20 e 667 85 115 0 i22 10 i162 15 12 one 12 80 1084 110 146 120 162 150 208 130 176 18 6 122 120 162 180 16 10 230 140 89 M 10 188 150 203 160 217 20 264 0 244 18 130 176 10 2 80 244 0 325 00 271 sa 10 20 21 20 366 280 370 380 515 30 43 20 298 300 406 310 420 420 569 so ama 8 8 30 433 280 583 450 610 60 827
5. 8 Pinion Bushing Small 19 Winch Handle 9 Ratchet pawl Kit 20 Nylock Nut 10 Winch Frame 21 Jam Nut 11 Winch Reinforcement Plate 22 Pinion Plate Genie Part No 115429 Super Straddle 4 9 Section 4 Repair Procedures July 2009 WINCH One speed Winch Assembly CE REVA Description Screw Nylock Nut Drum Bolt Nylock Nut Winch Handle Nylock Nut Jam Nut Frame Spacer Pinion Shaft Spacer Pinion Plate Ratchet Gear Index Index No Description No Friction Disc 12 2 Pinion Gear 13 3 Pinion Shaft 14 4 Retaining Ring 15 5 Pinion Shaft Bushing 16 6 Ratchet Pawl Kit 17 7 Cable Keeper Kit 18 8 Drum Spacer 19 9 Winch Drum 20 10 Drum Bolt Lock Winch Bracket 21 11 Drum Gear Cover 22 4 10 Super Straddle Part No 115429 July 2009 Section 5 Schematics Observe and Obey M Troubleshooting and repair procedures shall be completed by a person trained and qualified on the repair of this machine M Immediately tag and remove from service a damaged or malfunctioning machine Repair any machine damage or malfunction before operating the machine Before Troubleshooting M Read understand and obey the safety rules and operating instructions printed in the Genie Super Straddle Operator s Manual M Be sure that all necessary tools and test equipment are available and ready for use Part No 115429 Genie Super Straddle 5 1
6. BOX T STRIP Y7 LS32A LS32B h C BA le le e J PY N O N O CBA WH BL RD m STC5 abae BK OR GR SSS Sh Dass QD26 RD 1 1 RD L BK 2 2 BK GR 3 3 GR 432 1 MD EX WH WH 765432 1 904 Se 5 5 3 FH l 6 6 OR BK RD BNWH OR BLWH Ground 2 1 Control e Box AWP NARROW BASE _ FRONT 1 1 RD RD WH RD RIGHT 2 2 BK BK FRONT E OR RD LEFT e REAR BL RD RIGHT 4 4 BL BL RD RD LEFT 5 5 WH WH CN BK BK LERT 6 6 OR OR Sa E EN11D PIN NU zaa WH BL RD BK OR GR We LS35A LS35B TERMINAL B A STRIP KN ob YL 2 N O N O C BA WH BL RD ZE a QD25C nes PLATFORM 1 QD29 _ __ __ DOWN RD 1 RD L BK 2 2 BK e KEN GR 3 3 GR GN YL NE BL 4 4 BL BK RD YL OR BLWH ig e let WH 5 5 WH 7654321 i ANNAN NS ie I OR EE ER d 7654 8 2 1 To BK RD BN WH OR BLWH Grune ontrol Box ES0502B Genie Part No 115429 Part 2 of 2 Section 5 Schematics Electrical Schematic July 2009 REVA
7. Machine owner C 4 Lubricate the casters Checklist B Rev A Y NR and wheels Inspected by print B 1 Welds C 5 Painted surfaces Inspector signature B 2 Winch operation B 3 Inspect and lubricate Inspector title winch Inspector company Instructions Comments Make copies of this report to use for each inspection Select the appropriate checklist s for the type of inspection to be performed Daily or 8 hour Inspection A Quarterly or 250 hour Inspection A B Annually or 1000 hour Inspection A B C Place a check in the appropriate box after each inspection procedure is completed Use the step by step procedures in this section to learn how to perform these inspections If any inspection receives an N tag and remove the machine from service repair and re inspect it After repair place a check in the R box Legend Y yes acceptable no remove from service R repaired Genie Part No 115429 Super Straddle 3 5 Section Scheduled Maintenance Procedures July 2009 Checklist A Procedures A 1 Inspect the Manuals and Decals Genie specifications require that this procedure be performed every 8 hours or daily whichever comes first Maintaining the operator s and safety manuals in good condition is essential to safe machine operation Manuals are included with each machine and should be stored in the container provid
8. Phone 86 21 53852570 Fax 86 21 53852569 Genie Malaysia Phone 65 98 480 775 Fax 65 67 533 544 Genie Japan Phone 81 3 3453 6082 Fax 81 3 3453 6083 Genie Korea Phone 82 25 587 267 Fax 82 25 583 910 Genie U K Phone 44 0 1476 584333 Fax 44 0 1476 584334 Genie Brasil Phone 55 11 41 665 755 Fax 55 11 41 665 754 Genie Mexico City Phone 52 55 5666 5242 Fax 52 55 5666 3241 Genie Holland Phone 31 183 581 102 Fax 31 183 581 566
9. Do not apply any lifting pressure AWARNING Crushing hazard The end frames could become unbalanced and fall if not properly supported 3 Atthe base of the end frame tag and disconnect each cable from the limit switch pigtails 4 Using the illustration as a guide remove the fasteners securing the lifting bars to the lifting peg at the base of the straddle frame Set the fasteners to the side Place the lifting bars in the stowed position and secure the lifting bars to the end frames Genie i Super Straddle REVA 5 Working at an end frame remove the fasteners securing the outer wear pad to the straddle frame mounting brackets Set the fasteners to the side and measure the wear pads Refer to the chart below Repeat this procedure for the opposite end frame The wear pad measurement is between 0 50 inch 12 7 mm and 0 375 inch 9 5 mm There is no need to replace the wear pads The wear pad measurement is less than 0 375 inch 9 5 mm Replace the wear pads Note To maintain proper balance of the end frames while removing the wear pads and fasteners the lifting straps used to support the end frames will have to be adjusted with the overhead crane Wear pad specification 0 375 inch 9 5 mm Measurement minimum end frame lifting bar straddle frame straddle frame mounting bracket wear pad oo Oo OC om Part No 115429 July 2009 Section 4 e R
10. after performing a series of steps W Indicates that an incorrect result has occurred after performing a series of steps Section 3 Scheduled Maintenance Procedures July 2009 SCHEDULED MAINTENANCE PROCEDURES Maintenance Symbols Legend Note The following symbols have been used in this manual to help communicate the intent of the instructions When one or more of the symbols appear at the beginning of a maintenance procedure it conveys the meaning below Indicates that tools will be required to perform this procedure Indicates that new parts will be required to perform this procedure Indicates that dealer service will be required to perform this procedure z EE Genie 3 2 Super Straddle Pre delivery Preparation Report The pre delivery preparation report contains checklists for each type of scheduled inspection Make copies of the Pre delivery Preparation Report to use for each inspection Store completed forms as required Maintenance Schedule There are three types of maintenance inspections that must be performed according to a schedule daily quarterly and annually The Scheduled Maintenance Procedures Section and the Maintenance Inspection Report have been divided into three subsections A B and C Use the following chart to determine which group s of procedures are required to perform a scheduled inspection Inspection Checklist Daily or every 8 hours A Quarterly or every 250 hour
11. damaged 3 12 Super Straddle Genie REVA Part No 115429 July 2009 Section 4 Repair Procedures Observe and Obey Repair procedures shall be completed by a person trained and qualified on the repair of this machine Immediately tag and remove from service a damaged or malfunctioning machine 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 Straddle Operator s Manual Be sure that all necessary tools and parts are available and ready for use Use only Genie approved replacement parts Be sure the capacities of sawhorses or other supports are sufficient to withstand machine weight See Specifications section for the machine weight Be sure overhead cranes or other lifting devices are of ample capacity to handle machine weight See Specifications section for specific weight Read each procedure completely and adhere to the instructions Attempting shortcuts may produce hazardous conditions MI Unless otherwise specified perform each procedure with the machine in the following configuration Machine positioned on a firm level surface Straddle frame fully lowered Casters locked Part No 115429 Genie Super Straddle SS Repair Procedures About This Section Most of the procedures in this section should only be perf
12. machine is put into service A malfunctioning machine must never be used If malfunctions are discovered the machine must be tagged and removed from service Complete information to perform this procedure is available in the appropriate operator s manual Refer to the Operator s Manual on your machine Section Scheduled Maintenance Procedures July 2009 Checklist B Procedures B 1 Inspect All Welds Genie specifications require that this procedure be performed every 250 hours or quarterly whichever comes first Weld inspections are essential to safe machine operation and good machine performance Failure to locate and repair damage may result in an unsafe operating condition 1 Visually inspect the welds in the following locations Winch mounting plate Loading wheels Straddle frame end frames Ladder Outrigger sockets Genie 3 8 Super Straddle REVA B 2 Check the Winch Operation Genie specifications require that this procedure be performed every 250 hours or quarterly whichever comes first Detection of damage to the winch is essential to safe machine operation An unsafe working condition exists if the winch is damaged or not operating correctly A daily check of the winch operation allows the inspector to identify changes in the operating condition of the winch that might indicate damage 1 Visually inspect all the winch components for damage 2 Raise the straddle frame t
13. shaft retaining ring Note Use your fingers to push the ratchet pawls outward while pushing the pinion shaft through the large bushing Be sure the ratchet pawls are in firm contact with the ratchet gear and that all parts move freely 9 Install in order the thrust washer pinion plate and two jam nuts onto the threaded end of the pinion shaft Tighten the jam nuts 10 Install the handle onto the pinion shaft and secure into place with the nylock nut Section 4 Repair Procedures July 2009 WINCH 11 Lubricate the outside of the drum spacer with multi purpose grease Insert the frame spacer into the drum 12 Install the cable drum Be sure the drum gears mesh with the ratchet gears 13 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 14 Place the drum gear cover in position with the drum bolt slot under the drum bolt keeper 15 Install the drum bolt jam nut hand tight 16 Torque the drum bolt nut to 20 to 25 ft lbs 27 to 34 Nm Component damage hazard Overtightening the drum bolt jam nut may cause damage to the frame spacer and prevent the drum from spinning freely 17 Lubricate the teeth of the drum gear and the pinion nut that meshes with the drum gear with multi purpose grease ACAUTION Dodiv Injury Hazard Overlubrication of the ratchet pawl may result in oil coming in contac
14. 1 Measure the wear pads See Repair procedure 2 1 How to Access the Wear Pads 0 50 to 0 375 inches 12 7 to 9 5 mm SUPER STRADDLE WEAR PAD Genie Super Straddle Winch Friction Disks Genie specifications require that this procedure be performed every 1000 hours or annually whichever comes first Maintaining the winch is essential to good machine performance and safe operation An unsafe working condition exists if the winch has excessive wear and or does not operate smoothly free of hesitation and binding 1 Replace the winch friction disks See Repair procedure 3 1 How to Disassemble a One speed Winch Part No 115429 July 2009 Section Scheduled Maintenance Procedures REVA CHECKLIST C PROCEDURES C 3 C 4 Inspect the Cables Genie specifications require that this procedure be performed every 1000 hours or annually whichever comes first Detection of damage to cables is essential for safe machine operation An unsafe working condition exists if this component is damaged and does not operate smoothly The inspection of this system allows the inspector to identify changes in the operating condition that might indicate damage 1 Visually inspect the cable for the following Frayed or broken wire strands Kinks in the cable Corrosion Paint or foreign materials Split or cracked swagged end s ACAUTION Bodily injury hazard Beware of sharp edges Wear protective g
15. 115429 Rev A July 2009 First Edition First Printing Genie is a registered trademark of Genie Industries in the USA and many other countries SS is a trademark of Genie Industries 4 Printed on recycled paper Printed in U S A ii Super Straddle Part No 115429 July 2009 INTRODUCTION Serial Number Legend Sx Q IQ P N 77173 Model SS Serial Number SS09 1234 Model Year 2009 Manufacture Date 01 01 09 Electrical Schematic Number ES0502 Machine Unladen Weight 580 Ibs 263 kg Max Load Refer to AWP unit Country of Manufacture USA Manufacturer European Representative 15340 NE 76th Street The Maltings Redmond WA 98052 USA Wharf Road Grantham Lin 55109 1234 This machine complies with NG31 6BH United Kingdom C Model Sequence Ka R E number Model year Serial number stamped on inside of end frame assembly Genie Part No 115429 Super Straddle lii Section 1 Safety Rules July 2009 Safety Rules Warning Failure to obey the instructions and safety rules in this manual and the Genie Super Straddle 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 Maint
16. 50 om 4 550 474 40 687 5060 678 60 98 50 7 e 480 650 640 867 680 92 910 1283 770 104 18 580 78 70 962 750 1016 660 3342 80 mo LUB i L JJ m U o o Q o a e e i le z o o 15 s m 6 908 890 1205 1080 1464 1440 1955 1220 1654 T 15 1260 12 1681 1510 2047 2010 2725 1700 2304 16 1460_ 1979 1950 2643 2370 3213 3160 4284 260 3620 des 6 2223 2190 2969 2670 3620 3560 4826 3000 4067 METRIC FASTENER TORQUE CHART This chart is to be used as a guide only unless noted elsewhere in this manual Size Class 4 6 Class 8 8 Class 10 9 03 Class 12 9 DRY Y c el i ile d c iv d c el 1 NI Of 0f CO c1 zal Pl co et zu A ala n lt A p a oio O EN R D alo D o R A 5 e 844 N clo Flo mi c el Bic d c el Bal c Bia e js c 8 N O z R O ale zlej gt wo N N R 8 d e 3 e O R a _ b E E R e SS g E r zi O oj al
17. Immediately tag and remove from service damaged or malfunctioning machine Repair any machine damage or malfunction before operating the machine Use only Genie approved replacement parts Machines that have been out of service for a period longer than 3 months must complete the quarterly inspection MI Unless otherwise specified perform each procedure with the machine in the following configuration Machine positioned on a firm level surface Straddle frame fully lowered Casters locked Part No 115429 Genie Super Straddle B About This Section This section contains detailed procedures for each scheduled maintenance inspection Each procedure includes a description safety warnings and step by step instructions Symbols Legend Safety alert symbol used to alert personnel to potential personal injury hazards Obey all safety messages that follow this symbol to avoid possible injury or death Indicates an imminently hazardous situation which if not avoided will result in death or serious injury A DANGER AWARNING Indicates a potentially hazardous situation which if not avoided could result in death or serious injury Indicates a potentially hazardous ACAUTION situation which if not avoided may cause minor or moderate injury Indicates a potentially hazardous situation which if not avoided may result in property damage Indicates that a specific result is expected
18. Industries Rev B Genie Industries USA 18340 NE 76th Street PO Box 97030 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 no unable to complete R repaired Comments Pre Delivery Preparation Y N R Pre operation inspection completed Maintenance items completed Function tests completed Model Serial number Date Machine owner Inspected by print Inspector signature Inspector title Inspector company Section Scheduled Maintenance Procedures July 2009 SSeS SSS LLL gt Se This page intentionally left blank Genie 3 4 Super Straddle Part No 115429 July 2009 Section Scheduled Maintenance Procedures Maintenance Inspection Report Model Checklist A Rev A Y NR Checklist C Rev A Y NR A 1 Manuals decals C 1 Wear pads Serial number 5 2 Pre operation C 2 Replace winch Date inspection friction disks A 3 Function tests C 3 Inspect cables
19. R LEGEND Color Description BL Blue BK Black GN YL Green Yellow OR Orange RD Red WH White WH BK White Black Part No 115429 Genie Super Straddle ELECTRICAL SYMBOL LEGEND NC NoHo OH e 1 8 Limit switch 2 m 8 Ki Male contact Wire with description or color Female contact Circuits crossing no connection Connector 5 3 Section 5 Schematics July 2009 Electrical Schematic REV A Part 1 of2 AWP STANDARD BASE aon 212 FRONT QD22A QD22B RD RD LEFT 1 RD RD 1 1 RD REAR 2 BK BK 2 2 BL Reeg 3 GR GR 3 3 GR Sk ae TNR 4 BL BL 4 4 BL REAR 5 WH WH 5 5 wH RIGHT mE 6 OR OR 6 6 YL BK LEFT FRONT BK RIGHT EN11A PIN 5 SWITCH WH RD BK OR GR WG
20. SS TABLE OF CONTENTS Section 4 Rev Repair Procedures uj ifo ro 4 1 A 1 1 Wear PAGS icto E E exuere tret tutes auct eh beau pro pd enda 4 2 A 2 1 Limit Switches 4 4 A 3 1 lt lt AE 4 5 4 1 One speed Winch 4 6 Section 5 Rev Schematics puc EE 5 1 lLimit SwitchiEegerid 5 2 Electrical Legend 5 3 Electrical Schematic Super Straddle Standard Base amp Narrow Basel 5 4 Genie viii Super Straddle Part No 115429 July 2009 Section 2 Specifications REVA Operating Dimensions Specifications Outrigger Floor Loading Information Length 110 in 2 8m Width 37 in 94 cm Height 70 in 1 8m Adjustable length 110 to 128 in 2 8 to 3 25 m Straddle clearance height maximum 48 in 1 2m Stowed Dimensions Length 80 in 2 0m Width 37 in 94 cm Height 24 in 61 cm Lifting system Dual winch Caster diameter four 4 position swivel locks with brake 6 in 15 2 cm Adjustable outriggers required from Genie AWP 4 Load capacity of Super Straddle is the same as the load capacity of the Genie AWP being used Weight 580 Ibs 263 kg Genie Part No 115429 SS AWP 20S 525 Ibs 239 kg SS AWP 25S 507 Ibs 230 kg SS AWP 30S 554 16
21. ST B PROCEDURES 3 Measure each friction disk for wear Replace the friction disk if it measures less than specification Friction disk specification 1 16 inch 1 5mm Thickness minimum 4 Measure both shaft bushings for wear Replace the bushings if the wall thickness measurements are less than specification Pinion shaft bushing specification 1 8 inch 3 1 mm Wall thickness minimum 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 Section Scheduled Maintenance Procedures July 2009 Checklist C Procedures C 1 C 2 Inspect the Wear Pads Replace the Genie specifications require that this procedure be performed every 1000 hours or annually whichever comes first Maintaining the wear pads in good condition is essential to safe machine operation Wear pads on the Super Straddle are used to provide a uniform fit between the end frames and straddle frame as well as a means to prevent wear to the frame assemblies during the extend and retract functions Over time it may be necessary to replace the wear pads to ensure good machine performance Wear pads are placed on the outer ends of the straddle frame assemblies and should be replaced when the surface of the wear pad is reduced by 25 or more Continued use of worn wear pads may result in component damage and unsafe operating conditions
22. bilizer to platform control box 6 pin QD22B Front left stabilizer to platform control box 6 pin QD22C Front left stabilizer to platform control box 6 pin QD23A Front right stabilizer to platform control box 6 pin QD23B Front right stabilizer to platform control box 6 pin QD23C Front right stabilizer to platform control box 6 pin QD24A Rear right stabilizer to platform control box 6 pin QD24B Rear right stabilizer to platform control box 6 pin QD24C Rear right stabilizer to platform control box 6 pin QD25A Rear left stabilizer to platform control box 6 pin QD25B Rear left stabilizer to platform control box 6 pin QD25C Rear left stabilizer to platform control box 6 pin QD26 Front left interlock connector 3 pin QD27 Front right interlock connector 3 pin QD28 Rear right interlock connector 3 pin QD29 Rear left interlock connector 3 pin Electrical Legend Socket Contact SC1 SS frame front left SC2 SS frame front right 3 SS frame rearright 4 SS frame rear left 5 AWP front left SC6 AWP front right SC7 AWP rear right SC8 AWP rear left Stabilizer Contact STC1 Outrigger front left STC2 Outrigger front right STC3 Outrigger rear right STC4 Outrigger rear left STC5 SS boot front left STC6 SS boot front right STC7 SS boot rearright STC8 SS boot rearleft WIRE COLO
23. ed in the platform An illegible or missing manual will not provide safety and operational information necessary for a safe operating condition In addition maintaining all of the safety and instructional decals in good condition is mandatory for safe machine operation Decals alert operators and personnel to the many possible hazards associated with using this machine They also provide users with operation and maintenance information An illegible decal will fail to alert personnel of a procedure or hazard and could result in unsafe operating conditions 1 Check to make sure that the operator s and safety manuals are present and complete in the storage container on the machine 2 Examine the pages of each manual to be sure that they are legible and in good condition Result The operator s manual is appropriate for the machine and all manuals are legible and in good condition Result The operator s manual is not appropriate for the machine or all manuals are not in good condition or is illegible Remove the machine from service until the manual is replaced Genie Super Straddle REVA 3 Open the operator s manual to the decals inspection section Carefully and thoroughly inspect all decals on the machine for legibility and damage Result The machine is equipped with all required decals and all decals are legible and in good condition Result The machine is not equipped with all required decals o
24. enance Unless M You are trained and qualified to perform maintenance on this machine M You read understand and obey manufacturer s instructions and safety rules employer s safety rules and worksite regulations applicable governmental regulations M You have the appropriate tools lifting equipment and a suitable workshop Genie iv Super Straddle Part No 115429 July 2009 Section 1 Safety Rules Personal Safety Any person working on or around a machine must be aware of all known safety hazards Personal safety and the continued safe operation of the machine should be your top priority 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 Indicates an imminently hazardous situation which if not avoided will result in death or serious injury ADANGER AWARNING Indicates a potentially hazardous situation which if not avoided could result in death or serious injury Indicates a potentially hazardous ACAUTION situation which if not avoided may cause minor or moderate injury Indicates a potentially hazardous situation which if not avoided may result in property damage Be sure to wear protective eye wear and e other protective clothing i
25. epair Procedures WEAR PADS REV A 6 Working at the straddle frame mounting bracket locate and remove the wear pad adjustment screws securing the inner wear pads to the adjustment plate Set the fasteners to the side and measure the wear pads Refer to the chart at step 5 Repeat this procedure at the opposite end of the straddle frame The wear pad measurement is between 0 50 inch 12 7 mm and 0 375 inch 9 5 mm There is no need to replace the wear pads The wear pad measurement is less than 0 375 inch 9 5 mm Replace the wear pads 7 Install the wear pads and assemble the Super Straddle in reverse order of this procedure 8 Using the wear pad adjustment screws adjust the wear pads to maintain a uniform non binding fit around the vertical tubes of the end frames 9 Remove the lifting straps from the end frames 10 With help from another person cycle the straddle frame up and down and check for binding or loose operation Adjust the wear pads as necessary Genie Part No 115429 Super Straddle 4 3 Section 4 Repair Procedures July 2009 Limit Switches 2 1 Limit Switches How to Access the Limit Switches 1 Position the Super Straddle on a firm level surface and apply the brakes to swivel casters at the end frames 2 Fully lower the straddle frame and remove the retaining pin from the straddle frame 3 Atthe base of the end frame tag and disconnect each cable from the lim
26. f the situation warrants it such as moving parts free swinging or unsecured components when lifting or placing loads Always wear approved steel toed shoes zj Be aware of potential crushing hazards EJ Part No 115429 Genie Super Straddle SAFETY RULES Workplace Safety Be sure to keep sparks flames and lighted tobacco away from flammable and combustible materials like battery gases and engine fuels Always have an approved fire extinguisher within easy reach are properly maintained and ready for use Keep work surfaces clean and free of debris that could get into machine components and cause damage NN Be sure that all tools and working areas other lifting or supporting device is fully capable of supporting and stabilizing the weight to be lifted Use only chains or straps that are in good condition and of ample capacity Be sure any forklift overhead crane or Be sure fasteners intended for one 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 Be sure that your workshop or work area is properly ventilated and well lit July 2009 E This page intentionally left blank Genie vi Super Straddle Part No 115429 July 2009 Introduction Section 1 Section 2 Rev A Sec
27. hrough 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 straddle frame Result The winch should operate smoothly free of hesitation or binding Part No 115429 July 2009 Section e Scheduled Maintenance Procedures REVA B 3 Inspect and Lubricate the Winch Genie specifications require that this procedure be performed every 250 hours or quarterly whichever comes first Maintaining the winch is essential to good machine performance and safe operation An unsafe working condition exists if the winch has excessive wear and or does not operate smoothly free of hesitation and binding 1 Carefully lubricate the following areas with automotive grease Cable drum gear Teeth on the pinion gear that mesh with the cable drum gear Threads on the pinion shaft under the pinion gear Note Do not apply grease to brake friction disc or rachet gear 2 Carefully lubricate both pivot points on each ratchet pawl with 30W oil ACAUTION Bodily Injury Hazard Overlubrication of the ratchet pawl may result in oil coming in contact with the surface of the winch brake leading to an unsafe working condition Do not allow any grease oil on the friction disc pinion plate pinion gear or ratchet gear Part No 115429 Genie Super Straddle 3 9 CHECKLI
28. it switch pigtails Note While performing step 4 use caution when removing the limit switch cover from the straddle frame The retaining pin plate may separate from the assembly 4 Using the illustration below as a guide remove the fasteners securing the limit switch cover to the straddle frame assembly Set the fasteners to the side and carefully remove the limit switch REVA cover from the straddle frame assembly Set Limit Switch Assembly the retaining pin plate to the side a 5 Remove the fasteners securing the limit switch es to the switch cover and switch d bracket Set the fasteners the switch cover and e bracket to the side f h 6 Replace the limit switch es as necessary Use the wiring schematic on page 5 4 to wire the new switch es screw nylock nut retaining pin retaining pin plate limit switch limit switch bracket limit switch cover screw nylock nut Genie B Super Straddle Part No 115429 July 2009 Section 4 Repair Procedures REVA 3 1 How to Replace the Lifting Cable Bodily injury hazard Cables can ACAUTION fray Always wear adequate hand protection when handling the cable 1 Fully lower the straddle frame 2 Unwind the cable from the winch drum Remove the cable retaining fasteners from the winch drum side wall Set the fasteners to the side 3 Pullall the remaining cable out of the cable mounting hole 4 Remove the cable mou
29. loves when performing this procedure Part No 115429 Genie Super Straddle Lubricate the Casters and Wheels Genie specifications require that this procedure be performed every 1000 hours or annually whichever comes first 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 lubricated more often 1 Visually inspect each caster and wheel for cuts cracks or unusual wear 2 Move the machine on a flat smooth surface to confirm 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 Specification Chevron Ultra duty grease EP NLGI 1 lithium based or equivalent Section Scheduled Maintenance Procedures July 2009 CHECKLIST C PROCEDURES C 5 Inspect the Painted Surfaces Genie specifications require that this procedure be performed every 1000 hours or annually whichever comes first Inspecting the painted surfaces of your machine is essential to safe operation and long machine life An unsafe working condition exists if there is damage to painted surfaces that is not corrected 1 Visually inspect all painted surfaces for the following conditions Blistering Rust Peeling Fading Corrosion Note Replace any component that is
30. nting fastener from the top of the lifting bar Set the fasteners to the side 5 Using the fasteners removed in step 4 attach the new cable to the top of the lifting bar Do not over tighten the fasteners 6 Atthe opposite side of the winch handle wrap the cable 1 time clockwise around the winch drum Thread the cable through the cable mounting hole on the drum side wall Attach the cable to the drum side wall with the cable retaining fasteners removed in step 2 Do not over tighten the fasteners Genie Lifting Cable 7 While holding the cable tightly on the drum rotate the winch handle counterclockwise until the cable is spooled onto the drum Be sure there are at least 4 wraps of cable on the winch drum winch drum b lifting bar Part No 115429 Super Straddle 4 5 Section 4 Repair Procedures July 2009 Winch 4 1 One speed Winch How to Disassemble a One speed Winch ACAUTION Bodily injury hazard Cables can fray Always wear adequate hand protection when handling cable Note Refer to the illustration on page 4 9 for an exploded view of an ANSI winch and page 4 10 for an exploded view of a CE winch 1 Fully lower the straddle frame 2 Remove the cable retaining fastener from the winch drum and set the fasteners to the side Remove the cable from the winch drum 3 Remove the handle retaining fasteners Remove the handle from the pinion shaft Set the handle and the fasteners t
31. o 52 NI ojo N olo BIN lio ge u olo ola oye ola N i io Od n R N al co V b i oN SS WE SH A E a zi ra a a ra A ra NI w ra a Ka A A m D EE ojojo T o oo 2 Po p E OLR 5 00 0 NJD S S ol gt O1 Po RINI N 021 GIN GIG Ni ojoj o N Nf O AOIN Af N W ATO of O Of J O oo 4 Oo OIN o O17 G9 PO NI ON A G9 NIN o oj O NIA f Co O1 aj a Sal Jo ei a Alo N M a Ou gt aa ojo ays R NID 85 6 Genie 2 2 Super Straddle Part No 115429 July 2009 Section Scheduled Maintenance Procedures Scheduled Maintenance Procedures Observe and Obey MI Maintenance inspections shall be completed by a person trained and qualified on the maintenance of this machine Scheduled maintenance inspections shall be completed daily quarterly and annually as specified on the Maintenance Inspection Report AWARNING Failure to perform each procedure as presented and scheduled could result in death serious injury or substantial damage
32. o the side 4 Remove the drum bolt and lock nut Remove the winch drum drum cover and drum spacer from the winch Set all parts to the side 5 Remove the lock nut from the pinion shaft by holding the shaft at the flattened portion of the threads Component damage hazard Be careful not to damage the threads while holding the pinion shaft 6 Remove the retaining ring from the pinion shaft Genie Super Straddle REVA 7 Slide the pinion shaft towards the small pinion bushing and remove the pinion plate thrust washer ratchet gear friction disk and pinion gear Slide the pinion shaft through and out the large pinion bushing 8 Remove the pinion bushings Use a soft metal drift equal to the outside diameter of the bushing and tap with a rubber mallet Component damage hazard Place a block in between the walls of the winch housing to prevent the housing from bending while removing the bushings 9 Remove fasteners securing the winch housing to the end frame and remove the winch housing from the end frame Set housing and fasteners to the side Part No 115429 July 2009 Section 4 Repair Procedures REV A How to Assemble a One speed Winch Bodily injury hazard Cables can ACAUTION fray Always wear adequate hand protection when handling cable Note Refer to the illustration on page 4 9 for an exploded view of an ANSI winch and page 4 10 for an exploded view of a CE winch 1 Place one side
33. of the winch housing over the jaws of a vise Open the vise until the jaws are wider than the outside diameter of the large pinion bushing 2 Insert a soft metal drift through the opposite bushing hole Tap the drift with a rubber mallet to push the pinion bushing into place 3 Repeat steps 1 and 2 to insert the other bushing Note Use a piece of flatbar or wood in between the drift and the bushing to prevent any damage to the bushing 4 Add two drops of 30W oil to both pivot points on each ratchet pawl ACAUTION Bodily Injury Hazard Overlubrication of the ratchet pawl may result in oil coming in contact with the surface of the winch brake leading to an unsafe working condition Do not allow any grease oil on the friction disc pinion plate pinion gear or ratchet gear Part No 115429 Genie Super Straddle WINCH 5 Insert the non threaded end of the pinion shaft approximately halfway through the small bushing 6 Apply a small amount of multi purpose grease to the threaded section of the pinion shaft Screw the pinion gear onto the pinion shaft with the gears toward the left side of the small bushing 7 Install in order the friction disk ratchet gear and thrust washer onto the pinion shaft Component damage hazard Do not allow grease or oil onto the brake disks or the ratchet gear 8 Push the pinion shaft towards the large bushing and at the non threaded end of the pinion shaft install the pinion
34. ormed by a trained service professional in a Suitably equipped workshop Select the appropriate repair procedure after troubleshooting the problem Perform disassembly procedures to the point where repairs can be completed 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 Indicates an imminently hazardous situation which if not avoided will result in death or serious injury ADANGER Indicates a potentially hazardous AWARNING situation which if not avoided could result in death or serious injury Indicates a potentially hazardous ACAUTION situation which if not avoided may cause minor or moderate injury Indicates a potentially hazardous situation which if not avoided may result in property damage Indicates that a specific result is expected after performing a series of steps W Indicates that an incorrect result has occurred after performing a series of steps Section 4 Repair Procedures July 2009 Wear Pads 1 1 Wear Pads How to Access the Wear Pads 1 Position the Super Straddle on a firm level surface and apply the brakes to swivel casters at the end frames 2 Fully lower the straddle frame Attach a lifting strap from an overhead crane to each end frame Support the end frames
35. r one or more decals are illegible or in poor condition Remove the machine from service until the decals are replaced 4 Always return the manuals to the storage container after use Note Contact your authorized Genie distributor or Genie Industries if replacement manuals or decals are needed Part No 115429 July 2009 Section Scheduled Maintenance Procedures REVA A 2 Perform Pre operation Inspection Genie specifications require that this procedure be performed every 8 hours or daily whichever comes first Completing a Pre operation Inspection is essential to safe machine operation The Pre operation Inspection is a visual inspection performed by the operator prior to each work shift The inspection is designed to discover if anything is apparently wrong with a machine before the operator performs the function tests The Pre operation Inspection also serves to determine if routine maintenance procedures are required Complete information to perform this procedure is available in the appropriate operator s manual Refer to the Operator s Manual on your machine Part No 115429 Genie Super Straddle CHECKLIST A PROCEDURES A 3 Perform Function Tests Genie specifications require that this procedure be performed every 8 hours or daily whichever comes first Completing the function tests is essential to safe machine operation Function tests are designed to discover any malfunctions before the
36. s A B Annually 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 Maintain completed forms for a minimum of 4 years or in compliance with your employer jobsite and governmental regulations and requirements Part No 115429 Pre Delivery Preparation Fundamentals It is the responsibility of the dealer to perform the Pre delivery Preparation The Pre delivery Preparation is performed prior to each delivery The inspection is designed to discover if anything is apparently wrong with a machine before it is put into service A damaged or modified machine must never be used If damage or any variation from factory delivered condition is discovered the machine must be tagged and removed from service Repairs to the machine may only be made by a qualified service technician according to the manufacturer s specifications Scheduled maintenance inspections shall be performed by qualified service technicians according to the manufacturer s specifications and the requirements listed in the responsibilities manual Genie A TEREX BRAND 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
37. t with the surface of the winch brake leading to an unsafe working condition Do not allow any oil on the brake or pressure plate 18 Install the winch assemble onto the end frame with the handle facing out Genie Super Straddle REVA 19 Rotate the drum so that the two square cable keeper holes are at the top Install the cable keeper clip to the outside of the drum with the two carriage bolts coming through from the inside Install the lock washers and nuts finger tight Do not tighten 20 Route the end of the cable around the winch drum and out through the remaining hole on the inner side wall of the drum a outer frame winch mount b cable winch drum d cable keeper clip 21 Insert the end of the cable under the cable keeper clip approximately inch 13 mm and tighten the cable keeper clip fasteners 22 While holding the cable tight on the drum rotate the drum and spool the cable onto the drum evenly Component damage hazard Be sure the cable winds onto the winch drum evenly Part No 115429 July 2009 Section 4 e Repair Procedures REV WINCH One speed Winch Assembly ANSI Index Index No Description No Description 1 Pinion Bushing Large 12 Cable Keeper Kit bracket type 2 Thrust Washer 13 Drum Spacer 3 Ratchet Gear 14 Cable Keeper Kit threaded stud 4 Friction Disc 15 Winch Drum 5 Pinion Gear 16 Drum Gear Cover 6 Pinion Shaft 17 Screw 7 Retaining Ring 18 Nylock Nut
38. tion 3 Rev A A A Table of Contents Important Information ee sad A reni ii Serial Number Legend kasa A iii Safety Rules General Safety Rules e eeee aaa aanita nns iv Specifications Super Straddle AA 2 1 SAE and Metric Fasteners Torque Charts 2 2 Scheduled Maintenance Procedures treie 3 1 Pre delivery Preparation Report 3 3 Maintenance Inspection 3 5 Checklist A Procedures A 1 Inspect the Manual and Decals 3 6 2 Perform Pre operation Inspection 3 7 Perform Function 3 7 Checklist Procedures B 1 Inspect all Welds inidan inanan 3 8 B 2 Check the Winch Operation 3 8 B 3 Inspect and Lubricate the WING 3 9 Checklist C Procedures C 1 Inspect the Wear 2 0 0000 nennen 3 10 C 2 Replace the Winch Friction 3 10 C 3 Inspectthe Cables a s aa ci Re eerta cbe ce choise 3 11 C 4 Lubricate the Casters Wees 3 11 C 5 Inspected the Painted Surfaces aaa aaa anna aaa aecsanaa 3 12 Genie Part No 115429 Super Straddle vii July 2009 S
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