Genie Super-Straddle Service Manual Download Page 36

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Service Manual

September 2016

Repair Procedures

Super Straddle

Part No. 115429

One-speed Winch Assembly - CE

One-speed Winch assembly - CE

Index

No.

Description

Index

No.

Description

Friction Disc

Screw

Pinion Gear

Nylock Nut

Pinion Shaft

Drum Bolt

Retaining Ring

Nylock Nut

Pinion Shaft Bushing

Winch Handle

Ratchet pawl Kit

Nylock Nut

Cable Keeper Kit

Jam Nut

Drum Spacer

Frame Spacer

Winch Drum

Pinion Shaft Spacer

Drum Bolt Lock, Winch Bracket

Pinion Plate

Drum Gear Cover

Ratchet Gear

Summary of Contents for Super-Straddle

Page 1: ...Service Manual Serial Number Range Super Straddle from SS08 2976 to SS16G 6299 from SSG 6300 Part No 115429 Rev A1 September 2016 ...

Page 2: ...fication Group A Type 1 as defined by ISO 16368 Machine Design Life Unrestricted with proper operation inspection and scheduled maintenance Technical Publications Genie 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 noti...

Page 3: ...rocedure Page Description A 7 2009 Initial Release A1 9 2016 Introduction Serial Number Legend Reference Examples Section Maintenance B 3 Electronic Version Click on any content or procedure in the Table of Contents to view the update Section Repair Procedure 4 2 Section Fault Codes All charts Section Schematics Legends and schematics ...

Page 4: ...429 Serial Number Legend To August 31 2016 1 Model 2 Model year 3 Facility code 4 Sequence number 5 Serial label 6 Serial number stamped inside end frame From September 1 2016 1 Model 2 Facility code 3 Sequence number 4 Serial label 5 Serial number stamped inside end frame ...

Page 5: ...ous injury Many of the hazards identified in the operator s manual are also safety hazards when maintenance and repair procedures are performed Do Not Perform Maintenance Unless You are trained and qualified to perform maintenance on this machine You read understand and obey manufacturer s instructions and safety rules employer s safety rules and worksite regulations applicable governmental regula...

Page 6: ...hing hazards such as moving parts free swinging or unsecured components when lifting or placing loads Always wear approved steel toed shoes Workplace 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 Be sure to keep sparks flames and lighted tobacco away from flammab...

Page 7: ...cheduled Maintenance Procedures 3 Introduction 3 Pre Delivery Preparation Report 7 Maintenance Inspection Report 9 Checklist A Procedures 11 A 1 Inspect the Manuals and Decals 11 A 2 Perform Pre operation Inspection 12 A 3 Perform Function Tests 12 Checklist B Procedures 13 B 1 Inspect All Welds 13 B 2 Check the Winch Operation 13 B 3 Inspect All Welds 14 Checklist C Procedures 15 C 1 Inspect the ...

Page 8: ...9 Base Assembly 20 1 1 Wear Pads 20 Limit Switches 22 2 1 Limit Switches 22 Lifting Cable 23 3 1 How to Replace the Lifting Cable 23 Winch 24 4 1 One speed Winch 24 One speed Winch Assembly ANSI 26 One speed Winch Assembly CE 28 Section 5 Schematics 29 Introduction 29 Limit Switch Legend 30 Electrical Schematic 33 ...

Page 9: ...ith 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 lbs 263 kg Outrigger Floor loading Information SS AWP 20S 525 lbs 239 kg SS AWP 25S 507 lbs 230 kg SS AWP 30S 554 lbs 252 kg SS AWP 36S 601 lbs 273 kg SS AWP 40S 602 lbs 274 kg Note Floor loading information is approximate an...

Page 10: ...Service Manual September 2016 Specifications 2 Super Straddle Part No 115429 SAE and M etric Fasteners Tor que C harts ...

Page 11: ...nd tests may also depend on national regulations Failure to perform each procedure as presented and scheduled may cause death serious injury or substantial damage Immediately tag and remove from service a 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 peri...

Page 12: ... a potentially hazardous 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 Indicates that an incorrect result has occurred after performing a series of steps Maintenance Symbols Legend Note The following symbo...

Page 13: ...e been divided into subsections Use the following chart to determine which group s of procedures are required to perform a scheduled inspection Inspection Checklist Daily or every 8 hours A Quarterly or every 250 hours A B Annually or every 1000 hours A B C Maintenance Inspection Report The maintenance inspection report contains checklists for each type of scheduled inspection Make copies of the M...

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Page 15: ...l be performed by qualified service technicians according to the manufacturer s specifications and the requirements listed in the responsibilities manual 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 appropri...

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Page 17: ...n 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 Checklist A Rev A Y N R A 1 Inspect the manual...

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Page 19: ...r hazard and could result in unsafe operating conditions 1 Check to make sure that the operator s safety and responsibilities 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 ...

Page 20: ...lso 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 A 3 Per form Functi on Tests A 3 Perform Function Tests Genie specifications require that this procedure be performed every 8 hours or daily whichever comes first Completing the functio...

Page 21: ...ti on B 2 Check the Winch Operation Genie requires 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...

Page 22: ...se to brake friction disk or ratchet gear 2 Carefully lubricate both pivot points on each ratchet pawl with 30W oil Bodily Injury Hazard Over lubrication 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 disk pinion plate pinion gear or ratchet gear 3 Measure each friction d...

Page 23: ...e 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 1 Measure the wear pads See Repair procedure How to Access the Wear Pads C 2 Repl ace the Friction Disks C 2 Replace the Fric...

Page 24: ...ged end s Bodily injury hazard Beware of sharp edges Wear protective gloves when performing this procedure C 4 Lubricate the C asters and W heels C 4 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 s...

Page 25: ...rformed 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...

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Page 27: ... frame fully lowered Casters locked About This Section Most of the procedures in this section should only be performed by trained service professional in a suitably equipped workshop Select the appropriate repair procedure after troubleshooting the problem Perform disassembly procedures to the point where repairs can be completed Then to re assemble perform the disassembly steps in reverse order S...

Page 28: ...e 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 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 mea...

Page 29: ...ement 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 e...

Page 30: ...m 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 cover from the straddle frame assembly Set the retaining pin plate to the side 5 Remove the fasteners securing the limit switch es...

Page 31: ... mounting 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 At the 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 dr...

Page 32: ... 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 7 Slide the pinion shaft towards the small pinion bushing and remove the pinion plate thr...

Page 33: ... 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 shaft retaining ...

Page 34: ...ble 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 1 outer frame winch mount 2 cable 3 winch drum 4 cable keeper clip 2...

Page 35: ...e 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 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 ...

Page 36: ...cription 1 Friction Disc 12 Screw 2 Pinion Gear 13 Nylock Nut 3 Pinion Shaft 14 Drum Bolt 4 Retaining Ring 15 Nylock Nut 5 Pinion Shaft Bushing 16 Winch Handle 6 Ratchet pawl Kit 17 Nylock Nut 7 Cable Keeper Kit 18 Jam Nut 8 Drum Spacer 19 Frame Spacer 9 Winch Drum 20 Pinion Shaft Spacer 10 Drum Bolt Lock Winch Bracket 21 Pinion Plate 11 Drum Gear Cover 22 Ratchet Gear ...

Page 37: ... the safety rules and operating instructions in the appropriate operator s manual on your machine Be sure that all necessary tools and test equipment are available and ready for use About This Section There are two groups of schematics in this section Electrical Schematics Electrocution burn hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings ...

Page 38: ...Service Manual September 2016 Schematics 30 Super Straddle Part No 115429 Limit Swi tch Legend Limit Switch Legend ...

Page 39: ...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...

Page 40: ... No 115429 WIRE COLOR LEGEND Color Description BL Blue BK Black GN YL Green Yellow OR Orange RD Red WH White WH BK White Black ELECTRICAL SYMBOL LEGEND Limit Switch Wire with description or color Male contact Female contact Circuits crossing no connection Connector ...

Page 41: ...September 2016 Service Manual Electrical Schematic Part No 115429 Super Straddle 33 Electrical Schem atic Electrical Schematic Part 1 of 2 ...

Page 42: ...Service Manual September 2016 Electrical Schematic 34 Super Straddle Part No 115429 Electrical Schematic Part 2 of 2 Super Str addl e Part No 115429 Service M anual September 2016 ...

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