Genie Super Tower, Service Manual

Page: 32 / 45

Service Manual September 2016
Mast Assembly
24 Super Tower Part No. 115411
How to Assemble the Mast
Refer to the illustration on the following page to
identify the cable routing.
1 Inspect all mast parts for wear and damage.
Replace as necessary.
2 Clean all columns and rollers.
3 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
cable 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.
Bodily injury hazard. Beware of
sharp edges. Wear protective
gloves when performing this
procedure.
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 have 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.