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September 2016

Service Manual

Repair Procedures

Part No. 115411

Super Tower

25

Cabl e R outing

Cable Routing

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Summary of Contents for Super Tower

Page 1: ...Service Manual Serial Number Range Super Tower from 7794 101 to 7702 1600 from ST02 1601 to ST16 4786 from ST16G 4787 to ST16G 6899 from STG 6900 Part No 115411 Rev A1 September 2016 ...

Page 2: ...ment 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 Internet www genielift com E mail awp techpub terex com Serial Number Information Genie Indu...

Page 3: ...cedure Page Description A 2 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: ...al Number Legend To August 31 2016 1 Model 2 Model year 3 Facility code 4 Sequence number 5 Serial number stamped on base 6 Serial label located on base From September 1 2016 1 Model 2 Facility code 3 Sequence number 4 Serial number stamped on base 5 Serial label located on base ...

Page 5: ...th or serious 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 governmen...

Page 6: ...ng 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 flammable...

Page 7: ...ications 1 SAE and Metric Fasteners Torque Charts 2 Section 3 Scheduled Maintenance Procedures 3 Introduction 3 Pre Delivery Preparation Report 6 Maintenance Inspection Report 8 Checklist A Procedures 10 A 1 Inspect the Manuals and Decals 10 A 2 Perform Pre operation Inspection 11 A 3 Perform Function Tests 11 Checklist B Procedures 12 B 1 Inspect All Welds 12 B 2 Clean the Columns 12 B 3 Check th...

Page 8: ... Winch Friction Disks 18 C 5 Lubricate the Casters and Wheels 19 C 6 Inspect the Painted Surfaces 19 Section 4 Repair Procedures 20 Base Assembly 21 1 1 How to Remove the Base 21 Mast Assembly 22 2 1 How to Disassemble the Mast Assembly 22 Cable Routing 25 2 2 Lifting Cable 26 2 3 Lifting Pulley 28 Winches 29 3 1 One speed Winch 29 3 1 One speed Winch 29 One speed Winch Assembly ANSI 31 3 1 Two sp...

Page 9: ...acity 667 lbs 517 lbs at 22 load center 303 kg 235 kg Load Capacity 600 lbs 450 lbs at 24 load center 272 kg 204 kg Net Weight 507 lbs 555 lbs 230 kg 252 kg Dimensions ST 20 ST 25 Standard Forks forks down 19 ft 6 in 24 ft 4 in 5 9 m 7 4 m forks up 21 ft 2 5 in 26 ft 0 5 in 6 5 m 7 9 m Adjustable Forks forks down 24 ft 4 in 24 ft 4 in 7 4 m 7 4 m forks up 26 ft 0 5 in 26 ft 0 5 in 7 9 m 7 9 m Load...

Page 10: ...Service Manual September 2016 Specifications 2 Super Tower Part No 115411 SAE and M etric Fasteners Tor que C harts ...

Page 11: ... otherwise specified perform each procedure with the machine in the following configuration Machine parked on a firm level surface Carriage fully lowered Casters locked Load handling attachment installed 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 L...

Page 12: ...ns checklists for each type of scheduled inspection Make copies for each inspection Store completed forms as required Maintenance Schedule The Scheduled Maintenance Procedures section and the Maintenance Inspection Report have 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 e...

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Page 14: ...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 16: ... 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 manuals and decals A 2 Pre operation inspection A 3 Function t...

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Page 18: ... 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 R...

Page 19: ...so 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 function...

Page 20: ...B 2 Cl ean the C olum ns B 2 Clean the Columns Genie requires 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...

Page 21: ...tial 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 carriage Result The winch should operate smoothly free of hesitation or binding B 4 Inspect the C arriage Hol d down Bar B 4 Inspect the Carriage Hold down Bar Genie specifications require that this procedure be pe...

Page 22: ...le 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 disk or ratchet gear 2 Carefully lubricate both pivot points on each ratchet pawl with 30W oil 3 Measure each friction disk for wear Replace the friction disk if it measures less than specificat...

Page 23: ...head crane to the base of the machine 5 Lift the base with the overhead crane until the mast is level and place another suitable structure under the mast 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 Result There should be a gap of less than...

Page 24: ...hout these skills and tools could result in death or serious injury and significant component damage Dealer service is strongly recommended Bodily injury hazard Beware of sharp edges Wear protective gloves when performing this procedure 1 Fasten a load handling attachment to the carriage use the forks or the boom if possible Do not place any weight on the load handling attachment 2 Raise the carri...

Page 25: ...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 column Result The carriage should stop within 3 inches 7 6 cm and the safety brake should engage Crushing hazard Do not stand directly under the columns or load handling attachment 10 Repeat steps 7 th...

Page 26: ...afe machine operation An unsafe 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 f...

Page 27: ...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 be seen coming out of the bearing gap Grease Specification Chevron Ultra duty grease EP NLGI 1 lithium based or equivalent C 6 Inspect the Pai nted Surfaces C 6 Inspect the Painted Surfaces Genie specifications require that this procedure be performed ev...

Page 28: ...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 Symbols Legend...

Page 29: ...le lowering it guide the machine over onto a suitable structure capable of supporting it Bodily injury hazard Use proper lifting techniques when rolling the mast assembly over 7 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 to a horizontal position Slide a second suitable structure capable of supporting it under the mast ...

Page 30: ...es when lifting the mast assembly 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 5 Remove the cable from the mast by pulling on the cable anchor end of the cable Bodily injury hazard Cables can fray Always wear adequate hand protection when handling cable 6 Slide t...

Page 31: ...hrough 12 for each remaining column 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 bra...

Page 32: ...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 thro...

Page 33: ...September 2016 Service Manual Repair Procedures Part No 115411 Super Tower 25 Cabl e R outing Cable Routing ...

Page 34: ...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 retaining fasteners from the eyelet end of the cable at the mast anchor plate and cut the eyelet off below the copper sleeve 3 Remove the old cable from the winch drum 4 Unwind the outer strands and trim them back1 2 inch 13 mm...

Page 35: ...s 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 wraps of cable on the winch drum 11 Fully raise and lower the carriage without a l...

Page 36: ... pulley that is to be replaced is exposed 8 Remove the two mounting fasteners from 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 10 Remove the old pulley 11 Install the cable onto the new pulley 12 Apply Loctite removable thread sea...

Page 37: ...acer 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 7 Slide the pinion shaft to the right and remove the pinion spacer pinion plate ratchet gear and friction di...

Page 38: ...um is toward the top 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 ...

Page 39: ... 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 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 oil on the brake or pressure plate 20 Rotate the drum so that the two s...

Page 40: ...dex No Description 1 Disc Brake 11 Drum Lock Bolt 2 Pinion Gear 12 Winch Gear Cover 3 Pinion Shaft 13 Screw 4 Retaining Ring 14 Lock Nut 5 Pinion Shaft Bushing 15 Drum Bolt 6 Winch Handle 16 Hex Jam Nut 7 Nylock Nut 17 Frame Spacer 8 Ratchet Pawl Kit 18 Winch Handle 9 Cable Keeper Kit 19 Pinion Plate 10 Drum Spacer 20 Ratchet Gear ...

Page 41: ... the spring and ball housing 7 Remove the two springs and balls from the spring and ball housing 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 Note Note the location and position of the components on the pinion shaft 11 Slide the pinion shaft to t...

Page 42: ...e winch drum is toward the top 6 Insert the longer threaded end of the pinion shaft approximately halfway through the right side bushing 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 ...

Page 43: ...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 with one carriage bolt coming through from the inside Install the lock washer and nut finger tight Do not tighten the nut 22 Route the end of the cable between the winch drum and the number one column Proceed ar...

Page 44: ... Assembly 2 Reel Cover 12 Brake Spring Spacer 3 Cable Keeper 13 Detent Block Assembly 4 Reel Spacer 14 Pinion Gear 5 Gear Cover 15 Disc Brake 6 Ratchet Pawl Kit 16 Ratchet Gear 7 Retaining Ring 17 Pinion Plate 8 Sintered Iron Ring 18 Brake Spacer 9 Pinion Shaft Assembly 19 Pinion Shaft Bushing 10 Handle 20 Base Spacer Super Tow er Part No 115411 Service M anual September 2016 ...

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