Service Manual - Genie Industries
Contents
1. Section Ae Troubleshooting Flow Charts February 2009 Chart 3 m Winch Will Not Operate Check position of load 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 Obstructions 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 Industries Service Department Consult the Genie Industries Service Department Geni QNI pz 4 4 Super Tower Part No 115411 February 2009 Section 5 Repair Procedures Observe and Obey EI 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 MI Repair any machine damage or malfunction before operating the machine Before Repairs Start M Read understand and obey the safety rules and operating instruction2. Result The winch should operate smoothly free of hesitation or binding The load should not lower when the handles are released 3 Fully lower the carriage Result The winch should operate smoothly free of hesitation or binding Part No 115411 A TEREX CO Super Tower 3 9 MANY CHECKLIST B PROCEDURES B 4 Inspect the Carriage Hold down Bar Genie specifications require that this procedure be performed every 250 hours or quarterly whichever comes first Detection of damage to the column hold down System is essential for safe machine operation An unsafe working condition exists if the system is damaged and does not operate properly 1 Using proper lifting techniques lay the machine back against a sawhorse or other suitable support 2 Visually inspect the carriage hold down bar for damage 3 Check the carriage hold down bar for smooth operation Section 3 Scheduled Maintenance Procedures February 2009 CHECKLIST B PROCEDURES B 5 Inspect and Lubricate the Winch Genie specifications require that this procedure be performed every 250 hours or quarterly whichever comes first Maintaining the winch is essential to good machine performance and safe operation An unsafe working condition exists if the winch has excessive wear and or does not operate smoothly free of hesitation and binding 1 Carefully lubricate the following areas with automotive grease Cable drum gear Teet
3. Note The teeth on the ratchet gear must curve away from the right side of the winch housing 9 Push the pinion shaft to the right through the right pinion bushing and install the pinion shaft retaining ring Note Use your fingers to push the ratchet pawls outward while pushing the pinion shaft through the right bushing Be sure the ratchet pawls are in firm contact with the ratchet gear and that all parts move freely 10 Install the two jam nuts to the right side of the pinion shaft one at a time and tighten 11 Position both handles on the pinion shaft in opposite directions Install and tighten the lock nuts Section 5 Repair Procedures February 2009 WINCHES 12 Lubricate the outside of the frame spacer with multi purpose grease Insert the frame spacer into the drum 13 Install the cable drum Be sure the drum gears mesh with the ratchet gears 14 Install the drum bolt keeper Push the drum bolt through the winch housing drum cover and drum Be sure the head of the drum bolt is on the drum gear side of the winch 15 Place the drum gear cover in position with the drum bolt slot under the drum bolt keeper 16 Install the drum bolt jam nut hand tight 17 Install the housing spacer with the head of the housing spacer bolt on the right side of the winch and through the slotted portion of the drum gear cover Place the nut on the end of the bolt and tighten 18 Torque the drum bolt nut to 20 to 25 ft lb
4. enie A TEREX COMPANY Super Tower Serial Number Range from serial number 7794 00101 to 7702 01600 and from ST02 1601 Part No 115411 RevA February 2009 February 2009 Introduction Important Read understand and obey the safety rules and operating instructions in the appropriate Operator s Manual on your machine before attempting any maintenance procedure This manual provides detailed scheduled maintenance information for the machine owner and user It also provides troubleshooting and repair procedures for qualified service professionals Basic mechanical skills are required to perform most procedures However several procedures require specialized skills tools lifting equipment and a suitable workshop In these instances we strongly recommend that maintenance and repair be performed at an authorized Genie dealer Service center Technical Publications Genie Industries has endeavored to deliver the highest degree of accuracy possible However continuous improvement of our products is a Genie policy Therefore product specifications are subject to change without notice Readers are encouraged to notify Genie of errors and send in suggestions for improvement All communications will be carefully considered for future printings of this and all other manuals Contact Us www genieindustries com e mail awp techpub terex com A TEREX CON ii Super Tower MPANY Seri
5. z o Description ch Disc Brake Pinion Gear Pinion Shaft Retaining Ring Pinion Shaft Bushing Winch Handle Nylock Nut Ratchet Pawl Kit Cable Keeper Kit AN DOO R Iv Drum Spacer Part No 115411 WINCHES Index No Description 11 Drum Lock Bolt 12 Winch Gear Cover 13 Screw 14 Lock Nut 15 Drum Bolt 16 Hex Jam Nut 17 Frame Spacer 18 Pinion Shaft Spacer 19 Pinion Plate 20 Ratchet Gear Super Tower 5 13 Section 5 Repair Procedures February 2009 WINCHES 3 2 Two speed Winch How to Disassemble a Two speed Winch ACAUTION Bodily injury hazard Cables can fray Always wear adequate hand protection when handling cable 1 Fully lower the carriage and 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 A TEREX COMI Super Tower REV A 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 No
6. Section 3 Rev Scheduled Maintenance Procedures continued A Checklist C Procedures C 1 Inspect the Mast Assembly for West 3 11 C 2 Inspect the Safety Brake System ssssssssssssseeeeen 3 12 C 3 Replace the Winch Friction Disks sseeseeenm 3 13 C 4 Inspect the Cable and Cable Pulleys ccccceeeseeeeeeeeeeeeeeeneeeseeeeeeseaees 3 14 C 5 Lubricate the Casters and Wheels ccccceeeeeeeeseneeeeteeeeeeeeneeeeseeeeeeeaeees 3 15 C 6 Inspect the Painted Surfaces cccccccceeeeeeeeeeseeceeeeeeeeeseeeeeseneeeeeeneeesenaeees 3 15 Section4 Rev Troubleshooting Flow Charts lniigejo Ua e BE 4 1 A Chart 1 Mast Will Not Sequence Properly sessseeeen 4 2 A Chart 2 Carriage Will Not Raise But Winch Will Operate centers 4 3 A Chart3 Winch Will Not Operalo center anaa NEE 4 4 Section5 Rev Repair Procedures lueft e p s 5 1 A 1 1 Howto Remove The Base iter tette este te p tese PA 5 2 A 2 1 How to Disassemble the Mast Assembly AAA 5 3 A 2 2 How to Replace the Lifting Cable esssssenennn 5 7 A 2 8 Howto Replace a Lifting Pulley Mast Installed 0 0 0 0 eeeeeeeeeeeeeneeeeees 5 9 A 3 1 Howto Disassemble the One speed Winch aa aaaaacena 5 10 A 3 2 Howto Disassemble the Two speed Winch AA 5 14 Genie A TEREX COMPANY viii Super Tower Part No 115411 February 2009 Section 2 e Specifications Specification
7. a potentially hazardous situation which if not avoided could result in death or serious injury Indicates a potentially hazardous ACAUTION situation which if not avoided may cause minor or moderate injury Indicates a potentially hazardous situation which if not avoided may result in property damage Indicates that a specific result is expected after performing a series of steps W Indicates that an incorrect result has occurred after performing a series of steps Section 3 Scheduled Maintenance Procedures February 2009 SCHEDULED MAINTENANCE PROCEDURES Maintenance Symbols Legend Note The following symbols have been used in this manual to help communicate the intent of the instructions When one or more of the symbols appear at the beginning of a maintenance procedure it conveys the meaning below Indicates that tools will be required to perform this procedure Indicates that new parts will be required to perform this procedure Indicates that dealer service will be required to perform this procedure ZEE A TEREX CON 3 2 Super Tower 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 t
8. column Result The carriage should stop within 3 inches 7 6 cm and the safety brake should engage Crushing hazard Do not stand ACAUTION directly under the columns or load handling attachment 10 Repeat steps 7 through 9 to test all remaining columns Note When disengaging the safety brake it may be necessary to hold down the column behind the column to be disengaged Note The number one column column attached to the base does not have a safety brake and will not need to be tested Part No 115411 A TEREX CO Super Tower MPANY CHECKLIST C PROCEDURES C 3 Replace the Winch Friction Disks Genie specifications require that this procedure be performed every 1000 hours or annually whichever comes first Maintaining the winch is essential to good machine performance and safe operation An unsafe working condition exists if the winch has excessive wear and or does not operate smoothly free of hesitation and binding 1 Replace the winch friction disks See Repair procedure 3 1 How to Disassemble a One speed Winch or 3 2 How to Disassemble a Two speed Winch Section 3 Scheduled Maintenance Procedures February 2009 CHECKLIST C PROCEDURES C 4 Inspect the Cable and Cable Pulleys Genie specifications require that this procedure be performed every 1000 hours or annually whichever comes first Detection of damage to cable or pulleys is essential for safe machine operation An u
9. condition or is illegible Remove the machine from service until the manual is replaced A TEREX COMI 3 6 Super Tower REV A 3 Open the operator s manual to the decals inspection section Carefully and thoroughly inspect all decals on the machine for legibility and damage Result The machine is equipped with all required decals and all decals are legible and in good condition XK Result The machine is not equipped with all required decals or one or more decals are illegible or in poor condition Remove the machine from service until the decals are replaced 4 Always return the manuals to the storage container after use Note Contact your authorized Genie distributor or Genie Industries if replacement manuals or decals are needed Part No 115411 February 2009 Section 3 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 per
10. hex key above the safety brake rollers Slide the carriage away from the base while pulling back on the wrench Models with safety brake Remove the column by sliding it out the bottom of the mast toward the base while holding the safety brake rollers in the released position with the hex key wrench Models without safety brake Remove the column by sliding it out the bottom of the mast toward the base 12 Repeat steps 10 through 12 for each remaining column A TEREX CON 5 4 Super Tower How to Release the Safety Brake When Servicing the Mast The safety brake system can engage when the machine is tilted horizontally if the hold down bar is not used When the brake is engaged the columns can extend but not retract If the safety brake system engages while you are servicing the mast use one of the following methods described below to release the brake Method A This method allows you to release each column in sequence starting at the carriage and removing columns one at a time See 2 1 How to Disassemble the Mast Assembly Method B This method allows you to release any column in the assembly regardless of it s position but requires a custom tool The tool is a piece of 1 8 to 5 16 inch 3 2 to 8 mm diameter stiff wire bent in an L shape with one end 1 inch 25 mm long and the other end 16 inches 41 cm long The installation of a handle on the long end will make it easier to use This tool is avail
11. pulling on the cable anchor end of the cable Bodily injury hazard Cables can ACAUTION fray Always wear adequate hand protection when handling cable 6 Slide the carriage up approximately 12 inches 30 cm to expose the column stop mounting fastener attached to the bottom end of the top column Remove the fasteners and the column stop 7 Models with safety brake Insert a hex key wrench through the access holes in the carriage to release the safety brake Position the hex key above the safety brake rollers Slide the carriage away from the base while pulling back on the wrench i O c Idi SE O 7 m JR o a Brake roller b Brake release tool c Column or carriage Section 5 Repair Procedures February 2009 MAST ASSEMBLY 8 Models with safety brake Remove the carriage by sliding it out the bottom of the mast toward the base while holding the safety brake rollers in the released position with the hex key wrench Models without safety brake Remove the carriage by sliding it out the bottom of the mast toward the base 9 Slide the column up approximately 12 inches 30 cm to expose the column stop mounting fasteners attached to the bottom end of the top column Remove the fasteners and the column stops 10 Models with safety brake Insert a hex key wrench through the access holes in the column up to release the safety brake Position the
12. 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 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 Specification Chevron Ultra duty grease EP NLGI 1 lithium based or equivalent Part No 115411 A TEREX CO Super Tower MANY 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 damaged Section 3 Scheduled Maintenance Procedures February 2009 p This page intentionally left blank A TEREX COMPANY 3 16 Super Tower Part No 115411 February 2009 Section 4 e Troubleshooting Flow Charts Troubleshooting Flow
13. with one carriage bolt coming through from the inside Install the lock washer and nut finger tight Do not tighten the nut A TEREX COMI Super Tower REV A 22 Route the end of the cable between the winch drum and the number one column Proceed around the drum and up through the horizontal slot in the winch drum The cable is then fed under the lefthand side of the cable clip pulled forward looped and then fed under the right hand side of the cable keeper clip The raw end of the cable is then fed into the righthand side of the horizontal slot in the winch drum AWARNING Crushing hazard Failure to properly route the cable may result in a winch brake failure a Number one column b Cable c Cable keeper clip d Winch drum 23 Tighten the cable keeper fastener 24 While holding the cable tight on the drum rotate the drum with a handle and spool the cable onto the drum evenly Component damage hazard Be sure the cable winds onto the winch drum evenly Part No 115411 February 2009 Section 5 Repair Procedures REVA Two speed Winch Assembly Index z o Description Reel Lock Bolt Reel Cover Cable Keeper Reel Spacer Gear Cover Ratchet Pawl Kit Retaining Ring Sintered Iron Ring AN O R DN Pinion Shaft Assembly Handle Part No 115411 WINCHES Index No Description 11 Input Shaft Assembly 12 Brake Spring Spacer 13 De
14. 5411 Super Tower 3 5 Section 3 Scheduled Maintenance Procedures February 2009 Checklist A Procedures A 1 Inspect the Manuals and Decals Genie specifications require that this procedure be performed every 8 hours or daily whichever comes first Maintaining the operator s and safety manuals in good condition is essential to safe machine operation Manuals are included with each machine and should be stored in the container provided 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 Checkto make sure that the operator s and safety manuals are present and complete in the storage container on the platform 2 Examine the pages of each manual to be sure that they are legible and in good condition Result The operator s manual is appropriate for the machine and all manuals are legible and in good condition amp Result The operator s manual is not appropriate for the machine or all manuals are not in good
15. Charts Observe and Obey MI 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 MI Repair any machine damage or malfunction before operating the machine H Be sure the capacities of sawhorses or other supports are sufficient to withstand machine weight Refer to Specifications section for specific weight H Be sure overhead cranes or other lifting devices are of ample capacity to handle machine weight See Specification section for specific weight Part No 115411 A TEREX CO Super Tower 4 1 MANY 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 equipment are available and ready for use H Read each appropriate flow chart thoroughly Attempting shortcuts may produce hazardous conditions H Be aware of the following hazards and follow generally accepted safe workshop practices ISVs Crushing hazard When testing or A DANGER replacing the primary component always support the structure and secure it from movement Note Perform all troubleshooting on a firm level surface Note Two people will be required to safely perform some troubleshooting procedures About This Section When a malfunction is dis
16. Inspect cable for damage Replace the cable See Repair Procedure 502 3 How to Replace the Lifting Cable be the pulley or ey guard See epair Procedure 502 3 How to replace the Lifting Pulley Mast Installed 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 b b di Super Tower Part No 115411 February 2009 Section 4 e Troubleshooting Flow Charts Chart 2 REV A Carriage Will H Check for broken cable apana br oan Ge Not Raise ee Repair Procedure ides 502 3 How to Replace But Winch the Lifting Cable T Operar tears a that incorrect Inspect the cable for Replace damaged Be sure the carriage the cable is properly d s frays and oe See irt routed amage rocedure 502 3 How hold down bar is not to Replace the Liting able Then check the PAR pulley and guard for damage and replace if needed Replace the damaged component Check pulley and pulley guard for damage Re install cable if removed during inspection Inspect winch drum and bs fo acz the pinion gear for damage i Genie Industries Service Department Consult the Genie Industries Service Department Part No 115411 Super Tower 4 3
17. Tower Part No 115411 February 2009 Section 3 Scheduled Maintenance Procedures Maintenance Inspection Report Model Checklist A Rev A YNR Checklist C Rev A Y NR A 1 Manuals and decals C 1 Mast assembly wear Serial number A 2 Pre operation C 2 Safety brake system Date c inspection if equipped A 3 Function C 3 Replace winch Machine owner tests friction disk C 4 Inspect cable and Inspected by print Checklist B Rev A Y NR pulleys S C 5 Lubricate the casters Inspector signature B 1 Welds and wheels B 2 Clean columns Inspector title B 3 Winch operation EE B 4 Carriage hold down Inspector company bar B 5 Inspect and lubricate winch Instructions Comments Make copies of this report to use for each inspection Select the appropriate checklist s for the type of inspection to be performed Daily or 8 hour Inspection A Quarterly or 250 hour Inspection A B 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 inspect it After repair place a check in the R box Legend Y yes acceptable N no remove from service R repaired A TEREX COMPANY Part No 11
18. Y DRY 884 _68 775 91 105 DRY DRY 2 125 8 110 168 147 337 610 304 535 525 713 600 458 622 612 830 536 727 715 970 0 570 562 762 583 791 778 1055 682 925 909 1293 Genie A TEREX COMPAN 2 2 Super Tower Part No 115411 iz a H Eh ile Eh 1 bet bet ee EE 0 R O ee O En S w ou Oo Al A 91 o k A W o GI o mE co g a o e A co o R oa o E Mi ak ao IW Er i B z B ile Eh i B CO O mi K 9 S 9 1 i or OFS A 9 oj A o 0 BAIN olx o o wo NIS oo olo ANIC n ge c1 Go CO O l O aj A o Qo eo E o a zi co 0 ra a a ra o A ra NI w io SIE uj mi AN 0 GN RIO EE ee QIN EI GEI ala Sfo o 2 o oo amp hv ES S E DN w 8 BR R o a A w N N A m o a Ol Q a A o R o a a Oo E OLR amp Wuel 00 0 NJD lot o f E ol P Gif J oo nj AININ f 01 fN afoj N ojojo fN N ofo AOIN AJ N A 2 o NI R 91 0 R a ND o MIN M A R a A R n A 85 February 2009 Section 3 Scheduled Maintenance Procedures Scheduled Maintenance Procedures Observe and Obey M Maintenance inspections shall be completed by a person trained and qualified on the mainte
19. able from Genie Industries Genie part number 33875 Insert the tool from the bottom of the column into the safety brake access slot in the inner side wall of the column Reach through the far upper end of the slot and position the short end of the tool above the safety brake rollers Slide the carriage away from the base while pulling back on the tool Part No 115411 February 2009 Section 5 Repair Procedures How to Assemble the Mast Note Refer to the figure on page 5 6 to identify the cable routing 1 Inspect all mast parts for wear and damage Replace as necessary 2 Clean all columns and rollers O Clean all safety brake assemblies if equipped 4 Position the number one column so that it is open side up and level If it is not attached to the base secure the column to the supports 5 Install all column assembly components removed during disassembly except the column down stops Apply a small amount of multi purpose grease between the roller bolt head and the inside of the roller wheel 6 Slide the number two column into the number one from the bottom Stop inserting the column when the top of the up stop or the safety brake assembly is even with the bottom edge of the number one column 7 Repeat steps 4 through 6 with all remaining columns Do not install the carriage Note The cable is installed after all columns are together as an assembly 8 Attach the swaged end of the cable to the cabl
20. al Number Information Genie Industries offers the following Service Manuals for these models Title Part No Genie Super Tower Parts and Service Manual First Edition from serial number 7794 00101 to 7702 to 01600 and from ST02 1601 ENEE 32951 Note Genie Super Tower Service Manual 115411 and Genie Super Tower Part s Manual 115412 replaces Genie Super Tower Parts and Service Manual 32951 Copyright O 1994 by Genie Industries 115411 Rev A February 2009 Second Edition First Printing Genie and Super Tower are registered trademarks of Genie Industries in the USA and many other countries 2 Printed on recycled paper Printed in U S A Part No 115411 February 2009 INTRODUCTION Serial Number Legend ez R G I GNIC A TEREX COMPANY Genie Industries 18340 NE 76th Street Redmond WA 98052 USA Model ST Serial Number ST07 12345 Manufacture Date 01 11 2007 Electrical Schematic N A Country of manufacture USA C C Ne w ST 07 12345 Model Sequence number Model year Serial label Or Part No 115411 Super Tower iii Section 1 Safety Rules February 2009 Safety Rules Warning Failure to obey the instructions and safety rules i
21. all the input shaft approximately half way through the left side of the winch housing 12 Slide the left side bushing spring and ball housing spacer input shaft gears and right side bushing onto the input shaft 13 Install the ball and spring into the spring and ball housing Install the mounting fasteners Section 5 Repair Procedures February 2009 WINCHES 14 Lubricate the outside of the frame spacer with multi purpose grease and insert it into the drum 15 Install the cable drum Be sure the drum gears mesh with the ratchet gears 16 Install the drum bolt keeper Push the drum bolt through the winch housing drum cover and drum Be sure the head of the drum bolt is on the drum gear side of the winch 17 Install the drum bolt jam nut and torque to 20 to 25 ft Ibs 27 to 34 Nm Component damage hazard Overtightening the drum bolt jam nut may cause damage to the frame spacer and prevent the drum from spinning freely 18 Lubricate the teeth of the drum gear and the pinion nut with multi purpose grease ACAUTION POTY Injury Hazard Overlubrication of the ratchet pawl may result in oil coming in contact with the surface of the winch brake leading to an unsafe working condition Do not allow any oil on the brake or pressure plate 19 Install the input shaft cover 20 Rotate the winch drum so that the oblong slot is visible and horizontal 21 Install the cable keeper clip on the outside of the winch drum
22. ave been securely tightened 19 Attach the cable to the winch and be sure the cable is routed correctly 20 Raise the machine to full height to release the safety brakes if equipped and verify proper operation Section 5 Repair Procedures February 2009 MAST ASSEMBLY fa Cable Routing a NIc A TEREX COMPANY REV A Super Tower Part No 115411 February 2009 Section 5 Repair Procedures REVA 2 2 Lifting Cable How to Replace the Lifting Cable ACAUTION Bodily injury hazard Cables can fray Always wear adequate hand protection when handling cable Note All Genie replacement cables come with one pre swaged end that terminates at the top of the last column and one taped end that terminates at the winch Note For additional information refer to instructional video Genie Superlift Cabling Procedure This video is available from Genie Industries Genie part number 52701 1 Fully lower the carriage 2 Remove the retaini
23. covered 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 tts Troubleshoot discovered symptoms problem still exists Perform repair Return to service problem solved Section 4 e Troubleshooting Flow Charts February 2009 Chart 1 Mast Will Not Sequence Properly Be sure safety brake if equipped is not engaged by fully raising and lowering all columns Improper sequencing of the mast columns may occur when the machine is at or near maximum capacity If improper sequencing occurs the columns may shift to their correct position during operation or when the load is removed The forks will not change position if the columns shift position The carriage should always raise first and lower last REVA Over Remove excess weight loaded from machine and re check Center load and re check Clean the columns See Maintenence procedure 304 1 Clean the Columns Inspect pulley and pulley guard for damage yes Re ul Verify weight of load against machine capacity not over loaded Check position of load for proper centering centered Inspect the column channels and pulley debris tracks for foreign debris Check for cable binding on cable pulleys
24. e anchor on the top of the front column 9 Feed the other end of the cable through the box section web of the carriage into the pulley then push the cable through the pulley until it comes out the back side of the carriage ACAUTION Bodily injury hazard Cables can fray Always wear adequate hand protection when handling cable Part No 115411 Super Tower 5 5 MAST ASSEMBLY 10 Insert the carriage into the bottom end of the top column Hold the carriage in place and pull the cable up to the top of the column leaving enough slack to feed the cable through the next pulley 11 Push the cable through the exposed portion of the pulley at the top of the column until the cable reaches the pulley at the bottom of the column 12 Remove the lower pulley assembly from the upper column 13 Route the cable into and around the lower pulley 14 Apply Loctite removable thread sealant to the pulley mounting fastener and install the lower pulley into the column 15 Push the cable between the two mast sections until it comes out the top of the column 16 Repeat steps 11 through 15 with all remaining columns 17 Slide all the columns forward until you can install the column stops Do not slide the columns forward any farther than necessary 18 Install all the components removed during disassembly Note Be sure that all fasteners have Loctite removable thread sealant applied to the threads and that all fasteners h
25. e use the forks or the boom if possible Do not place any weight on the load handling attachment 2 Raise the carriage until it is half way up the front column A TEREX COMI Super Tower REV A 3 Grasp the bottom carriage and lift it approximately 5 inches 12 7 cm then release the carriage Result The carriage should stop within 3 inches 7 6 cm and the safety brake should engage Crushing hazard Do not stand ACAUTION directly under the carriage or load handling attachment 4 Raise the carriage approximately 6 inches 15 2 cm to disengage the safety brake 5 Operate the winch until the front column is half way up the adjacent column 6 Grasp the bottom of the front column and lift it approximately 5 inches 12 7 cm then release the column Result The carriage should stop within 3 inches 7 6 cm and the safety brake should engage ACAUTION Crushing hazard Do not stand directly under the columns or load handling attachment Part No 115411 February 2009 Section 3 Scheduled Maintenance Procedures REVA 7 Raise the front column approximately 6 inches 15 2 cm to disengage the safety brake 8 Operate the winch until the front column is fully raised and the second column is half way up the adjacent column 9 Grasp the bottom side of the next column and lift it approximately 5 inches 12 7 cm then release the
26. e roller wheel and the column Note If the mast inspection results in a measurement that is not within specification refer to Repair procedure 2 1 How to Disassemble the Mast Assembly 10 Grasp the bottom of the carriage and lift it approximately 12 inches 30 5 cm then release the carriage Result The carriage should stop within 5 to 8 inches 12 7 to 20 3 cm and the safety brake should engage Crushing hazard Do not stand ACAUTION directly under the carriage or load handling attachment Section 3 Scheduled Maintenance Procedures February 2009 CHECKLIST C PROCEDURES C 2 Inspect the Safety Brake System if equipped Genie specifications require that this procedure be performed every 1000 hours or annually whichever comes first Detection of damage or a faulty safety brake system is essential for safe machine operation An unsafe working condition exists if the system is damaged or faulty and does not allow the mast to sequence properly free of hesitation and binding AWARNING Bodily injury hazard This procedure requires specific repair skills and a suitable workshop Attempting this procedure without these skills could result in death or serious injury or significant component damage Dealer service is strongly recommended ACAUTION Body injury hazard Beware of sharp edges Wear protective gloves when performing this procedure 1 Fasten a load handling attachment to the carriag
27. ervice technicians according to the manufacturer s specifications and the requirements listed in the responsibilities manual E GNIG A TEREX COMPANY Genie UK The Maltings Wharf Road Grantham Lincolnshire Redmond WA 98073 9730 NG31 6BH England 425 881 1800 44 1476 584333 Copyright 2002 by Genie Industries Genie is a registered trademark of Genie Industries 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 N no unable to complete R repaired Comments Pre Delivery Preparation Y N R Pre operation inspection completed Maintenance items completed Function tests completed Model Serial number Date Machine owner Inspected by print Inspector signature Inspector title Inspector company Section 3 Scheduled Maintenance Procedures February 2009 p This page intentionally left blank A TEREX COMPANY 3 4 Super
28. form this procedure is available in the appropriate operator s manual Refer to the Operator s Manual on your machine Part No 115411 A TEREX CO Super Tower MANY 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 machine is put into service A malfunctioning machine must never be used If malfunctions are discovered the machine must be tagged and removed from service Complete information to perform this procedure is available in the appropriate operator s manual Refer to the Operator s Manual on your machine Section 3 Scheduled Maintenance Procedures February 2009 Checklist B Procedures B 1 Inspect All Welds Genie specifications require that this procedure be performed every 250 hours or quarterly whichever comes first Weld inspections are essential to safe machine operation and good machine performance Failure to locate and repair damage may result in an unsafe operating condition 1 Visually inspect the welds in the following locations Winch mounting plate Loading wheels steer handle Base Legs and stabilizers Load handling attachment s A TEREX CON 3 8 Super Tower REV A B 2 Clean the Columns Genie specifica
29. h on the pinion gear that mesh with the cable drum gear Threads on the pinion shaft under the pinion gear Models with Two speed winch The teeth on the slow and the fast speed gears where they mesh together Note Do not apply grease to brake friction disks or rachet gear 2 Carefully lubricate both pivot points on each ratchet pawl with 30W oil A TEREX CON Super Tower REV A 3 Measure each friction disk for wear Replace the friction disk if it measures less than specification Friction disk specification 1 16 inch 1 5 mm 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 lbs 27 Nm Do not overtighten Part No 115411 February 2009 Section 3 Scheduled Maintenance Procedures Checklist C Procedures REVA C 1 Inspect the Mast Assembly for Wear Genie specifications require that this procedure be performed every 1000 hours or annually whichever comes first Detection of excessive or unusual wear in the mast assembly is essential for safe machine operation An unsafe working condition exists if the mast assembly has excessive wear and or does not operate smoothly free of hesita
30. il or other fluids Use an approved container Please be environmentally safe Genie Part No 115411 A TEREX COMPANY Super Tower February 2009 M This page intentionally left blank vi Super Tower Part No 115411 February 2009 Table of Contents Introduction Section 1 Section2 Rev B Section3 Rev Important InformaliON TEE ii SGetialiNiimberi nformatio ua zwala oz dod dead cte etr eei ea a Pa Aa a ii Serial Number Legend iii Safety Rules General Safety Rules ced A ad da oneal aa iv Specifications Machine Specifications eeee aaa aaa aaa aaa aaa ie eene ener nennen 2 1 SAE and Metric Fasteners Torque Chart 2 2 Scheduled Maintenance Procedures IntrOdUGUON E EE 3 1 Pre delivery Preparation Report kk 3 3 Maintenance Inspection Report ANNER 3 5 A Checklist A Procedures A 1 Inspect the Manual and Decals eeeeeeea aaa aaa aaa aaa ee 3 6 A 2 Perform Pre operation Inspection ssen 3 7 A 3 Perform Function Tests keen 3 7 A Checklist B Procedures B 1 Inspect all WIS aaa EE nete nuca unn ias 3 8 B 2 Clean the Columns suite pee nep Etre de ia YA 3 8 B 3 Check the Winch Operation enne 3 9 B 4 Inspect the Carriage Hold down Bar 3 9 B 5 Inspect and Lubricate the Winch ossicsaisisisnsiioariai a 3 10 Part No 115411 Super Tower vii February 2009 iJ TABLE OF CONTENTS
31. ion 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 5 Repair Procedures February 2009 Base Assembly 1 1 How to Remove the Base 1 2 Fully lower the carriage Remove the load handling attachment from the machine Remove the outriggers from the outrigger storage sockets Attach a lifting strap from an overhead crane to the lifting eye on the number 1 mast Place a suitable structure capable of supporting the machine on the carriage side of the mast Carefully lift the machine slightly with the overhead crane While lowering it guide the machine over onto a suitable structure capable of supporting it ACAUTION Bodily injury hazard Use proper lifting techniques when rolling the mast assembly over A TERI Super Tower 7 REVA Secure the top of the mast to the support 8 Attach a lifting strap from an overhead crane to the base and lift the machine
32. lbs Nm Nm inis Nm _ 8 100 115 TiO 10 1 120 135 120 135 160 18 140 158 LUBED LUBED LUBED d R I po m gt U es Wm U 13 23 14 257 28 42 26 77 4 37 66 4 i 745 60 8135 1084 58 521 w C 5 73 75 1016 80 1084 10 149 03 126 0 54 867 68 115 00 122 320 362 106 1 one 12 80 1084 110 149 18 6 12 180 62 1130 16 170 230 140 189 18 1 16 10 20 16 244 0 88 00 271 sa 10 20 21 270 366 280 379 380 515 820 433 16 20 298 300 406 50 420 420 569 80 am 8 8 320 438 280 583 450 610 610 827 510 om a 550 474 aro 687 500 ers 670 908 seo 759 e 480 650 640 867 680 922 910 1283 770 104 12 5 78 no 962 750 106 60 1342 840 15 N el a lei o o 15 s 72 8 908 560 1206 1080 1464 1440 1952 1220 1654 H 4 1 15 1280 120 1661 1570 2047 2010 2725 1700 2304 vu 16 0 1978 1950 2643 2370 3218 3160 4284 2670 3620 2 312 1640 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 Class 8 8 Class 10 9 Class 12 9 DR
33. ly hazardous situation which if not avoided may cause minor or moderate injury AWARNING ACAUTION Indicates a potentially hazardous situation which if not avoided may result in property damage Be sure to wear protective eye wear and other protective clothing if the situation warrants it Be aware of potential crushing hazards such as moving parts free swinging or 3l 3l unsecured components when lifting or placing loads Always wear approved steel toed shoes SAFETY RULES Workplace Safety Be sure to keep sparks flames and lighted tobacco away from flammable and J combustible materials like battery gases and engine fuels Always have an approved fire extinguisher within easy reach WA properly maintained and ready for use Keep work surfaces clean and free of debris that could get into machine components and cause damage 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 7 time use i e cotter pins and self locking nuts are not reused These components may fail if they are used a second time 9 B sam _ Be sure that your workshop or work area is JO properly ventilated and well lit ons Be sure that all tools and working areas are Be sure any forklift overhead crane or Be sure Mia fasteners intended for one Be sure to properly dispose of old o
34. n 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 employer s safety rules and worksite regulations applicable governmental regulations M You have the appropriate tools lifting equipment and a suitable workshop A TEREX COMPANY iv Super Tower Part No 115411 February 2009 Section 1 Safety Rules Personal Safety Any person working on or around a machine must be aware of all known safety hazards Personal safety and the continued safe operation of the machine should be your top priority 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 ADANGER Indicates an imminently hazardous situation which if not avoided will result in death or serious injury Indicates a potentially hazardous situation which if not avoided could result in death or serious injury Indicates a potential
35. nance of this machine M Scheduled maintenance inspections shall be completed daily quarterly semi annually annually and every 2 years 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 M Immediately tag and remove from service a damaged or malfunctioning machine M Repair any machine damage or malfunction before operating the machine M Use only Genie approved replacement parts EI 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 Carriage fully lowered Casters locked Load handling attachment installed Part No 115411 A TEREX CO Super Tower 3 1 MANY 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 ADANGER AWARNING Indicates
36. ng fasteners from the eyelet end of the cable at the mast anchor plate and cut the eyelet off below the copper sleeve Part No 115411 Super Tower 5 7 MAST ASSEMBLY 3 Remove the old cable from the winch drum Unwind the outer strands and trim them back 1 2 inch 18 mm leaving the core longer Repeat this process on the open end of the new cable gt Using the optional cable threading tool Genie part number 12402 insert even amounts of cable into each end of the tool Securely tighten the set screws i Section 5 Repair Procedures February 2009 pu re o MAST ASSEMBLY REVA ACAUTION Body injury hazard This tool is intended for cable replacement only Do not use as a load carrying cable splice 6 Place a smooth layer of strapping tape over the joint section of the two cables and the tool SSC C CE Note If the cable gets caught as you are pulling it through the columns and pulleys avoid pulling too hard as you may break the connection between the two cables Try pulling the cable back and forth until the cable pulls freely 7 Pull on the old cable while feeding the new cable through the machine 8 When the taped area appears at the winch loosen the set screws and remove the old cable 9 Attach the new cable to both the mast anchor and the winch drum 10 Wind the new cable evenly onto the winch drum Be sure there are at least four w
37. njury Hazard Overlubrication of the ratchet pawl may result in oil coming in contact with the surface of the winch brake leading to an unsafe working condition Do not allow any oil on the brake or pressure plate 5 Install the winch housing on the mast Be sure the winch drum is toward the top 6 Insert the longer threaded end of the pinion shaft approximately halfway through the right side bushing Part No 115411 Super Tower 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 disk a pinion plate and a pinion spacer onto the pinion shaft Component damage hazard Do not allow grease or oil onto the brake disk ratchet gear or the teflon spacer Note The teeth on the ratchet gear must curve toward the left side of the winch housing 9 Install the pinion shaft retaining ring onto the pinion shaft Note Use your fingers to push the ratchet pawls outwards while pushing the pinion shaft through the left bushing Be sure the ratchet pawls are in firm contact with the ratchet gear and that all parts move freely 10 Install the lock nut on the left side of the pinion shaft 11 Inst
38. nsafe working condition exists if these components are damaged and do not operate smoothly The inspection of this system allows the inspector to identify changes in the operating condition that might indicate damage Note The mast must be disassembled during the annual inspection of the machine otherwise the cable cable pulleys and mast rollers are only partially visible for inspection 1 Disassemble the mast assembly Refer to Repair Procedures 2 1 How to Disassemble the Mast Assembly A TEREX CON Super Tower REV A 2 Visually inspect the cable and components for the following frayed or broken wire strands kinks in the cable corrosion paint or foreign materials split or cracked swagged end s upper and lower mounting brackets are properly secured no broken or damaged pulleys no unusual or excessive pulley wear no broken or damaged mast rollers no unusual or excessive mast roller wear ACAUTION Bodily injury hazard Beware of sharp edges Wear protective gloves when performing this procedure 3 Assemble the mast assembly Refer to Repair Procedures 2 1 How to Assemble the Mast Assembly Part No 115411 February 2009 Section 3 Scheduled Maintenance Procedures REV A CHECKLIST C PROCEDURES C 5 C 6 Lubricate the Casters and Wheels Genie specifications require that this procedure be performed every 1000 hours or annually whichever comes first Regular application of lubrication to
39. o 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 Maintain completed forms for a minimum of 4 years or in compliance with your employer jobsite and governmental regulations and requirements Part No 115411 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 s
40. om the pulley mounting block Remove the pulley assembly 9 Remove the retaining fastener that attaches the pulley to the mounting block Note Note the quantity and location of the shims and spacers before disassembling Part No 115411 Super Tower 5 9 MAST ASSEMBLY 10 Remove the old pulley 11 Install the cable onto the new pulley 12 Apply Loctite removable thread sealant to the pulley mounting fastener and install the fastener through the pulley and pulley guard into the pulley mounting block AWARNING Crushing hazard Failure to properly route the cable could result in a winch brake failure Component damage hazard Do not allow the cable to become twisted during installation or mast sequencing problems may occur Note Be sure the cable guard is located over the retaining pin on the pulley mounting block Be sure the pulley spins freely after reassembling the pulley assembly g a pulley b pulley guard c pulley mounting block 13 Apply Loctite removable thread sealant to the fastener and install the pulley assembly onto the column 14 Assemble the columns in reverse order of disassembly Section 5 Repair Procedures February 2009 Winches REVA 3 1 7 Slide the pinion shaft to the right and remove the pinion spacer pinion plate ratchet gear and One speed Winch friction disks Turn the pinion gear E counterclockwise and slide it off the left side of How to Disa
41. raps of cable on the winch drum 11 Fully raise and lower the carriage without a load to check for proper operation The carriage should raise and lower smoothly 12 Fully raise and lower the carriage again with a load and check for proper operation The carriage should raise and lower smoothly Do not use as a load carrying A CAUTION cable splice This tool is intended for cable replacement only A TEREX COMPANY 5 8 Super Tower Part No 115411 February 2009 Section 5 Repair Procedures REVA 2 3 Lifting Pulley How to Replace a Lifting Pulley Mast Installed 1 Fully lower the carriage 2 Unwind approximately 1 to 2 feet 30 to 60 cm of cable from the winch drum 3 Tip the machine backwards and rest the top of the number one mast on a suitable structure capable of supporting it Secure the top of the mast to the structure 4 Attach an overhead crane to the base Lift the machine to a horizontal position and slide a second structure under the mast next to the base 5 If replacing an upper pulley 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 approximately 6 inches 15 cm to expose the lower column stop 6 Remove the column stop mounting fasteners 7 Slide the column backwards until the pulley that is to be replaced is exposed 8 Remove the two mounting fasteners fr
42. s REV A Model ST 20 ST 25 Dimensions ST 20 ST 25 Height Stowed 78 8 in 78 8 in Standard Forks 200 cm 200 cm forks down 19 ft 6 in 24 ft 4 in anon 5 9m 7 4m Width Stowed p oid forks up 21 ft 2 5 in 26 ft 5 in Ge 6 5m 7 9 m Length Stowed 25 3 in 25 3 in 64 cm 64 cm Adjustable Forks l l ee forks down 24 ft 4 in 24 ft 4 in Length Operating 81 8 in 81 8 in 7 4m 7 4 m 208 cm 208 cm forks up 26ft 5 in 26 ft 5 in SE 7 9m 7 9m Ground 2 in 2 in Clearance 5 1 cm 5 1 cm Load Handling Outrigger 81 8 in 81 8 in Attachment LxWxD Net Weight Footprint 208 cm 208 cm Adjustable Forks Load Capacity 800 Ibs 650 Ibs Eee sa Es at 18 load center 363 kg 295 kg OR K S A Sm ST Load Capacity 733 Ibs 583 Ibs Standard Forks ren 2e at 20 load center 332 kg 264 kg 76 2x51x76cm 2 kg Load Capacity 667 Ibs 517 lbs at 22 load center 303 kg 235 kg e Continuous improvement of our products is a Load Capacity Pops 450 bs Genie policy Product specifications are at 24 load center 272 kg 204 kg p s 6 E Subject to change without notice Net Weight 507 Ibs 555 Ibs 230 kg 252 kg Genie A TEREX COMPANY Part No 115411 Super Tower 2 1 Section 2 e Specifications February 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 Grade 5 7 Grade 8 C2 Black Oxide Bolts DRY DRY LUBED Nm_ in
43. s 27 to 34 Nm Component damage hazard Overtightening the drum bolt jam nut may cause damage to the frame spacer and prevent the drum from spinning freely 19 Lubricate the teeth of the drum gear and the pinion nut that meshes with the drum gear with multi purpose grease ACAUTION Dodiv Injury Hazard Overlubrication of the ratchet pawl may result in oil coming in contact with the surface of the winch brake leading to an unsafe working condition Do not allow any oil on the brake or pressure plate A TEREX COMI Super Tower PANY REV A 20 Rotate the drum so that the two square cable keeper holes are at the top Install the cable keeper clip to the outside of the drum with the two carriage bolts coming through from the inside Install the lock washers and nuts finger tight Do not tighten 21 Route the end of the cable around the winch drum and out through the remaining hole on the left side wall of the drum a number one column b cable 6 winch drum d cable keeper clip 22 Insert the end of the cable under the cable keeper clip approximately 1 2 inch 13 mm and tighten the cable keeper clip fasteners 23 While holding the cable tight on the drum rotate the drum and spool the cable onto the drum evenly Component damage hazard Be sure the cable winds onto the winch drum evenly Part No 115411 February 2009 Section 5 Repair Procedures REVA One speed Winch Assembly Index
44. s in the Genie Superlift Advantage Operator s Manual M Be sure that all necessary tools and parts are available and ready for use MI Use only Genie approved replacement parts H 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 specific weight MI Read each procedure completely and adhere to the instructions Attempting shortcuts may produce hazardous conditions MI Unless otherwise specified perform each procedure with the machine in the following configuration Machine positioned on a firm level surface Carriage fully lowered Casters locked Part No 115411 Super Tower 5 1 Repair Procedures About This Section Most of the procedures in this section should only be performed by a trained service professional in a suitably equipped workshop Select the appropriate repair procedure after troubleshooting the problem Perform disassembly procedures to the point where repairs can be completed 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 situat
45. ssemble a the shaft One speed Winch 8 Remove the pinion shaft from the winch MERNE housing ACAUTION Bodily injury hazard Cables can ree fray Always wear adequate hand 9 Remove both pinion bushings Use a soft metal protection when handling cable drift equal to the outside diameter of the 1 Fully lower the carriage bushing and tap with a rubber mallet Component damage hazard Place a block in between the walls of the winch housing to prevent the housing from bending while 3 Remove both handle retaining fasteners removing the bushings Remove the handles from the pinion shaft 2 Remove the cable retaining fastener from the winch drum Remove the cable from the winch drum 10 Remove the winch housing from the machine 4 Remove the drum bolt and the drum bolt spacer Remove the drum drum gear cover and housing spacer from the winch 5 Remove the two lock nuts from the pinion shaft by holding the opposite end of the shaft at the flattened portion of the threads Component damage hazard Be careful not to damage the threads while holding the pinion shaft 6 Remove the retaining ring from the pinion shaft A TEREX COMPANY 5 10 Super Tower Part No 115411 February 2009 Section 5 Repair Procedures REVA How to Assemble a One speed Winch Bodily injury hazard Cables can ACAUTION fray Always wear adequate hand protection when handling cable Note Refer to the figure on page 5 13 for an exploded
46. te Note the location and position of the components on the pinion shaft 11 Slide the pinion shaft to the right and remove the pinion spacer pinion plate ratchet gear and friction disks Turn the pinion gear counterclockwise and slide it off the left side of the shaft 12 Remove both pinion bushings Use a soft metal drift equal to the outside diameter of the bushing and tap with a rubber mallet Component damage hazard Place a block between the walls of the winch housing to prevent the housing from bending while removing the bushings Part No 115411 February 2009 Section 5 Repair Procedures REVA How to Assemble a Two speed Winch Bodily injury hazard Cables can ACAUTION fray Always wear adequate hand protection when handling cable Note Refer to the figure on page 5 17 for an exploded view of the Two speed Winch 1 Place one side of the winch housing over the jaws of a vise Open the vise until the jaws are wider than the outside diameter of the bushing 2 Insert a soft metal drift through the opposite bushing hole Line up the tab on the bushing to the hole in the winch housing Tap the drift with a rubber mallet to push the bushing into place 3 Repeat steps 1 and 2 to insert the other bushing Note Use a piece of flatbar or wood between the drift and the bushing to prevent any damage to the bushing 4 Add two drops of 30W oil to both pivot points on each ratchet pawl ACAUTION POTY I
47. tent Block Assembly 14 Pinion Gear 15 Disc Brake 16 Ratchet Gear 17 Pinion Plate 18 Brake Spacer 19 Pinion Shaft Bushing 20 Base Spacer Super Tower 5 17 Genie Scandinavia Phone 46 31 575100 Fax 46 31 579020 Genie France Phone 33 0 2 37 26 09 99 Fax 33 0 2 37 26 09 98 Genie Iberica Phone 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 China Phone 86 21 53852570 Fax 86 21 53852569 Genie Malaysia Phone 65 98 480 775 Fax 65 67 533 544 Genie Japan Phone 81 3 3453 6082 Fax 81 3 3453 6083 Genie Korea Phone 82 25 587 267 Fax 82 25 583 910 Genie U K Phone 44 0 1476 584333 Fax 44 0 1476 584334 Genie Brasil Phone 55 11 41 665 755 Fax 55 11 41 665 754 Genie Mexico City Phone 52 55 5666 5242 Fax 52 55 5666 3241 Genie Holland Phone 31 183 581 102 Fax 31 183 581 566 Service Manual Super Tower from serial number 7794 101 to 7702 1600 and fom ST02 1601 Part No 115411 Rev A G A TEREX COMPANY
48. tion and binding 1 Attach a lifting strap from an overhead crane or similar lifting device to the lifting point on the top of the mast Rotate the carriage hold down bar over the carriage and operate the winch to apply tension to the lifting cable 2 Liftthe machine slightly with the overhead crane and guide it onto a suitable structure capable of supporting it AWARNING Crushing hazard The machine will fall if not properly supported by the overhead crane 3 Lower the top of the mast onto the suitable structure 4 Attach a lifting strap from an overhead crane to the base of the machine 5 Liftthe base with the overhead crane until the mast is level and place another suitable structure under the mast Part No 115411 A TEREX CO Super Tower MPANY 6 Lower the base end of the machine 7 Rotate the mast assembly until the carriage is on top 8 Visually inspect the top of each column for clearance between the roller wheel and the adjacent column surface O Result There should be a gap of less than 0 062 inch 1 57 mm between the roller wheel and the column Note If the mast inspection results in a measurement that is not within specification See Repair procedure 2 1 How to Disassemble the Mast Assembly 9 Visually inspect the bottom of each column for clearance between the roller wheel and the adjacent column surface Result There should be a gap of less than 0 062 inch 1 57 mm between th
49. tions require that this procedure be performed every 250 hours or quarterly whichever comes first Clean columns are essential to good machine performance and safe operation Extremely dirty conditions may require that the columns be cleaned more often 1 Raise all columns to full height 2 Visually inspect the inner and outer channels of the columns for debris or foreign material If necessary use a mild cleaning solvent to clean the columns AWARNING Bodiv 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 115411 February 2009 Section 3 Scheduled Maintenance Procedures REVA B 3 Check the Winch Operation Genie specifications require that this procedure be performed every 250 hours or quarterly whichever comes first Detection of damage to the winch is essential to safe machine operation An unsafe working condition exists if the winch is damaged or not operating correctly A daily check of the winch operation allows the inspector to identity 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
50. to a horizontal position Slide a second suitable structure capable of supporting it under the mast next to the base A CAUTION Crushing hazard The machine 9 may become unbalanced and fall if not properly supported by the overhead crane A Remove the mounting fasteners from both mast braces at the base 10 Remove the base mounting fasteners Remove the base from the machine Note When installing the base be sure that the mast and the base are square EX COMPANY Part No 115411 February 2009 Section 5 Repair Procedures REVA 2 1 How to Disassemble the Mast Assembly Note Removal of the base is only necessary when the number one column is to be removed See 1 1 How to Remove the Base 1 Fully lower the carriage and remove the load handling attachment 2 Remove the cable retaining fasteners from the winch drum Remove all of the cable from the drum 3 Liftthe machine slightly with an overhead crane While tilting backwards with the carriage facing up guide the machine over onto a suitable structure Bodily injury hazard Use proper ACAUTION lifting techniques when lifting the mast assembly ACAUTION Crushing hazard The machine may become unbalanced and fall if not properly supported 4 Remove the mounting fastener from the cable anchor at the top of the last column carriage side Part No 115411 Super Tower 5 93 Mast Assembly 5 Remove the cable from the mast by
51. view of the One speed Winch 1 Place one side of the winch housing over the jaws of a vise Open the vise until the jaws are wider than the outside diameter of the bushing 2 Insert a soft metal drift through the opposite bushing hole Tap the drift with a rubber mallet to push the bushing into place 3 Repeat steps 1 and 2 to insert the other bushing Note Use a piece of flatbar or wood in between the drift and the bushing to prevent any damage to the bushing 4 Add two drops of 30W oil to both pivot points on each ratchet pawl ACAUTION Bodily Injury Hazard Overlubrication of the ratchet pawl may result in oil coming in contact with the surface of the winch brake leading to an unsafe working condition Do not allow any oil on the brake or pressure plate 5 Install the winch housing onto the mast Be sure the winch drum is toward the top Part No 115411 Super Tower WINCHES 6 Insert the longer threaded end of the pinion shaft approximately halfway through the left bushing 7 Apply a small amount of multi purpose grease to the large threaded section of the pinion shaft under the gear nut Screw the pinion gear onto the pinion shaft with the gears toward the left side of the winch housing 8 Install in order a brake disk a ratchet gear a brake disk a pinion plate and a pinion spacer onto the pinion shaft Component damage hazard Do not allow grease or oil onto the brake disks or the ratchet gear
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