Genie Superlift SL-5 Parts & Service Manual
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Genie Superlift SL-5 Parts & Service Manual

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Parts & Service Manual
Part No. 32283
Rev A1
June 2005

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Summary of Contents for Genie Superlift SL-5

  • Page 1 Parts & Service Manual Part No. 32283 Rev A1 June 2005...

  • Page 2: Table Of Contents

    Inspect the Cable and Cable Pulleys ................. 4 - 3 Check the Mast for Proper Sequencing ..............4 - 4 Inspect the Casters and Wheels ................4 - 4 Inspect the Column Hold Down System ..............4 - 5 Part No. 32283 Genie Superlift...
  • Page 3 How to Replace a Lifting Pulley - Mast Installed ............6 - 6 Winches How To Disassemble the Winch - Single Speed ............6 - 7 How To Disassemble the Winch - Two Speed ............6 - 9 Genie Superlift Part No. 32283...
  • Page 4 Load Handling Attachments - Rotating Barrel Handler ..........7 - 26 Figure 7-L Single Speed Winch ....................7 - 30 Figure 7-M Two Speed Winch ....................7 - 32 Numeric Index ..........................7 - 36 Part No. 32283 Genie Superlift...

  • Page 5: Part

    Parts and Service Manual - First Edition This page intentionally left blank. Genie Superlift Part No. 32283...

  • Page 6: Load Handling Attachments

    74 cm 79 cm 38.6 kg Pipe Cradle 6 in 10 lbs 70 cm 63 cm 11.5 cm 4.5 kg Load Platform 26.5 lbs 70 cm 60 cm 6.5 cm 12.0 kg Part No. 32283 Genie Superlift 2 - 1...
  • Page 7 Note: can be used with standard forks and adjustable forks only (see above for working heights) Fork Extension Option Note: can be used with standard forks and adjustable forks only (see above for working heights) 2 - 2 Genie Superlift Part No. 32283...

  • Page 8: Bolt Torque Specification

    Torque specifications for lubricated bolts are 25% less than dry torque specifications for each bolt size. These bolt torque specifications are for general use only. Specification may vary depending on application of bolt. Part No. 32283 Genie Superlift 2 - 3...
  • Page 9 Section 2 - Specifications Part and Service Manual - First Edition This page intentionally left blank. 2 - 4 Genie Superlift Part No. 32283...

  • Page 10: Scheduled Maintenance Inspections

    The maintenance inspection report contains checklists for each type of scheduled inspection. Make copies of the Maintenance Inspection Report to use for each inspection. Keep records on all inspections for three years. Part No. 32283 Genie Superlift 3 - 1...
  • Page 11 Check the Mast for Proper Sequencing Inspect the Casters and Wheels Table B Inspect the Column Hold Downs Inspect All Welds Clean the Columns Inspect and Lubricate the Winch Inspect and Lubricate the Rotating Barrel Handler 3 - 2 Genie Superlift Part No. 32283...
  • Page 12 New parts Tools are suggested required required Lubricate the Casters and Wheels Inspect the Mast Assembly for Wear Replace the Winch Friction Disks Inspect the Safety Brake System Inspect the Painted Surfaces Part No. 32283 Genie Superlift 3 - 3...

  • Page 13: Maintenance Inspection Report

    · If any inspection receives an “N”, remove the machine from use, repair and re-inspect it. After repair, place a check in the “R” box. Legend Y = yes, acceptable N = no, unacceptable R = repaired Comments 3 - 4 Genie Superlift Part No. 32283...

  • Page 14: Scheduled Maintenance Procedures

    Unless otherwise specified, perform each procedure with the machine in the following configuration: · machine positioned on a flat level surface · carriage fully lowered · casters locked · load handling attachment installed Part No. 32283 Genie Superlift 4 - 1...

  • Page 15: Inspect The Operator's Manual

    1 Inspect the entire machine for damage and Contact your authorized Genie improperly installed or missing parts including: distributor or Genie Industries if a replacement manual is needed. · cable anchor · cable and pulleys ·...

  • Page 16: Check The Winch Operation

    1 Visually inspect the exterior of each column for properly secured the following: · no broken or damaged pulleys · dents, gouges or abrasions · no unusual or excessive pulley wear · bends or warping Part No. 32283 Genie Superlift 4 - 3...

  • Page 17: Check The Mast For Proper Sequencing

    4 Be sure the rotation lock functions properly in order by each column. each position. 2 Lower the columns to the stowed position. Result: The columns should lower in reverse order, followed by the carriage. 4 - 4 Genie Superlift Part No. 32283...

  • Page 18: Inspect The Column Hold Down System

    1 Visually inspect the welds in the following locations: · winch mounting plate · loading wheels/steer handle · base · legs and stabilizers · load handling attachment(s) Part No. 32283 Genie Superlift 4 - 5...

  • Page 19: Inspect And Lubricate The Winch

    5 Rotate the barrel cradle 2 full turns or until the 5 Lubricate the frame drum spacer. Tighten the grease is completely worked into the gears. drum bolt to 20 ft-lbs (27 Nm). Do not overtighten. Oil Type Multipurpose grease 4 - 6 Genie Superlift Part No. 32283...

  • Page 20: Lubricate The Casters And Wheels

    0.062 inches (1.57 mm) between the roller wheel and the column. If mast inspection results in a measurement that is not within specification, refer to Repair procedure 2-1, How to Disassemble the Mast. Part No. 32283 Genie Superlift 4 - 7...

  • Page 21: Replace The Winch Friction Disks

    Attempting this procedure without these skills may result in death or serious injury or significant component damage. Dealer service is strongly recommended. 4 - 8 Genie Superlift Part No. 32283...

  • Page 22: Inspect The Painted Surfaces

    The number one column (column attached to base) does not have a safety brake and will not need to be tested. Part No. 32283 Genie Superlift 4 - 9...
  • Page 23 Parts and Service Manual - First Edition Section 4 - Scheduled Maintenance Procedures This page intentionally left blank. 4 - 10 Genie Superlift Part No. 32283...

  • Page 24: Troubleshooting Flow Charts

    Section 5 - Troubleshooting Flow Charts Troubleshooting Flow Charts Before Troubleshooting: Read, understand and obey the safety rules and operating instructions printed in the Genie Superlift Operator's Manual. Be sure that all necessary tools and test equipment are available and ready for use.

  • Page 25: Mast Will Not Sequence Properly

    OR no roller wheel(s) OR apply grease. grease to the roller bolt. Check each mast Replace the damaged column for damage. column OR consult Genie Industries Service Department. Consult Genie Industries Service Department. 5 - 2 Genie Superlift Part No. 32283...

  • Page 26: Carriage Will Not Raise, But Winch Will Operate

    Re-install cable (if removed during inspection). Inspect winch drum and Replace damaged pinion gear for damage. components OR contact Genie Industries Service Department. good Contact Genie Industries Service Department. Part No. 32283 Genie Superlift 5 - 3...

  • Page 27: Winch Will Not Operate

    A-4, Check the Winch Repair the Winch - Operation. Single Speed. good Check carraige and Replace damaged mast for damaged column OR consult column(s). Genie Industries Service Department. good Consult Genie Industries Service Department. 5 - 4 Genie Superlift Part No. 32283...

  • Page 28: Repair Procedures

    Before Repairs Start: problem still exists Read, understand and obey the safety rules and operating instructions in the Genie Superlift Operator's Manual. Return to Inspect Perform service repair and test problem Be sure that all necessary tools and parts are solved available and ready for use.

  • Page 29: Base Assembly

    8 Attach an overhead crane to the lifting bracket on the number 1 mast. 9 Place a sawhorse on the carriage side of the mast. 6 - 2 Genie Superlift Part No. 32283...

  • Page 30: How To Remove The Base - Straddle Base

    Repeat for the other side. 8 Place a sawhorse on the carriage side of the 13 Remove the base mounting fasteners. Then mast. remove the base from the machine. Part No. 32283 Genie Superlift 6 - 3...

  • Page 31: Mast Assembly

    Slide the carriage away from the base out the bottom of the mast assembly. 1 inch (2.5 cm) while reaching through both slots. Position the hex key above the safety brake rollers and pull back on the wrench. 6 - 4 Genie Superlift Part No. 32283...

  • Page 32: How To Replace The Lifting Cable

    How to Replace the Lifting Cable 9 With the other end of the cable in hand, feed it through the box section (web) of the carriage All Genie replacement cables into the pulley and push it through the pulley come with one preswaged end until it comes out the back side of the carriage.

  • Page 33: How To Replace A Lifting Pulley - Mast Installed

    If replacing the lower pulley, secure the hold- down latch to the same column that the pulley is on. 6 - 6 Genie Superlift Part No. 32283...

  • Page 34: Winches

    Screw onto the large of the winch housing to prevent threads hand tight. the housing from bending while removing the bushings. 10 Remove the winch housing from the machine. Part No. 32283 Genie Superlift 6 - 7...
  • Page 35 Component damage hazard. Be winch and through the slotted portion of the sure the cable winds onto the drum gear cover. Place the nut on the end of winch drum evenly. the bolt and tighten. 6 - 8 Genie Superlift Part No. 32283...

  • Page 36: How To Disassemble The Winch - Two Speed

    15 Slide the pinion shaft to the right and remove the pinion spacer, pinion plate, ratchet gear, half way. and friction disks. Remove the pinion gear by turning it counterclockwise, then slide it off the left side of the shaft. Part No. 32283 Genie Superlift 6 - 9...
  • Page 37 12 Rotate the input shaft until the drive pin hole is visible. Install the drive pin with a soft metal drift. 6 - 10 Genie Superlift Part No. 32283...
  • Page 38 23 While holding the cable tight on the drum, rotate the drum with a handle and spool the cable onto the drum neatly. Component damage hazard. Be sure the cable winds onto the winch drum evenly. Part No. 32283 Genie Superlift 6 - 11...
  • Page 39 Parts and Service Manual - First Edition Section 6 - Repair Procedures This page intentionally left blank. 6 - 12 Genie Superlift Part No. 32283...

  • Page 40: How To Order Parts

    How To Order Parts How To Order Service Parts Machine Information Please be prepared with the following information Model when ordering replacement parts for your Genie product: Serial Number · Machine model number Date of Purchase · Machine serial number Authorized Genie Distributor ·...

  • Page 41: Decals And Paint

    Section 7 - Service Parts Parts and Service Manual - First Edition Figure 7-A Decals and Paint - View 1 7 - 2 Genie Superlift Part No. 32283...
  • Page 42 — 1483 Paint - Genie Blue, 1 Gallon (3.78 liters) ..............— — 1484 Paint - Genie Blue, 12 Ounces (340.5 grams) Aerosol ..........— 32686 Warning - Machine Safety and Set-up ............... 1 32688 Genie Superlift ......................2 31072 Operator’s Manual Storage Container ................
  • Page 43 Section 7 - Service Parts Parts and Service Manual - First Edition Figure 7-A Decals and Paint - View 2 7 - 4 Genie Superlift Part No. 32283...
  • Page 44 Notice - Vertical Barrel Stacker Set-up ............... 1 32771 Warning - Vertical Barrel Stacker Safety ..............1 32715 Notice - Flat Fork Set-up .................... 1 32718 Warning - Flat Fork Safety ..................1 Part No. 32283 Genie Superlift 7 - 5...

  • Page 45: Number 1 Mast Attached Parts

    Section 7 - Service Parts Parts and Service Manual - First Edition Figure 7-B Number 1 Mast Attached Parts 7 - 6 Genie Superlift Part No. 32283...
  • Page 46 Container - Manual Storage ..................1 — 32282 Operator’s Manual ..................... — 7265 Rivet - Steel, 0.375 x 0.25 inch .................. 2 32375 Lock Pin Assembly ..................... 1 6412 Handle - Grip ......................2 Part No. 32283 Genie Superlift 7 - 7...

  • Page 47: Standard Base Components

    Section 7 - Service Parts Parts and Service Manual - First Edition Figure 7-C Standard Base Components 7 - 8 Genie Superlift Part No. 32283...
  • Page 48 7 x 7 strands (12 inches 30.4 cm required) ........— — 2238 Cable Oval Sleeve, inch ..................— — 33298 Screw - HHC, Drilled, -13 x 3 inches ..............— This parts list continues on page 7-11. Part No. 32283 Genie Superlift 7 - 9...
  • Page 49 Section 7 - Service Parts Parts and Service Manual - First Edition FIGURE 7-C 7 - 10 Genie Superlift Part No. 32283...
  • Page 50 Spring - Stabilizer Latch ..................... 2 32897 Kit - Plate Latch, Stabilizer (includes 1 each index number 31) ......... 2 32516 Brace - Stabilizer ......................2 11337 Pin - Roll, 0.25 x 1.25 inches ..................2 Part No. 32283 Genie Superlift 7 - 11...

  • Page 51: Straddle Base Components

    Section 7 - Service Parts Parts and Service Manual - First Edition Figure 7-D Straddle Base Components 7 - 12 Genie Superlift Part No. 32283...
  • Page 52 Washer - Shim, 1.01 x 1.63 x 0.062 inch (25.6 x 41.4 x 1.5 mm) ....... 8 32524 Tube - Axle ......................... 2 32531 Arm - Adjustable Right Side ..................1 32479 Caster - Swivel Lock, 5 x 2 inches (12.7 x 5.1 cm) ............. 2 Part No. 32283 Genie Superlift 7 - 13...
  • Page 53 Section 7 - Service Parts Parts and Service Manual - First Edition Figure 7-E REV B (JUNE 2005) Mast Components - View 1 7 - 14 Genie Superlift Part No. 32283...
  • Page 54 Screw - HHC, -16 x 1.25 inches, GR 5 ..............3 12013 Washer - Flat, 0.375 x 0.063 inches ................3 33198 Down Stop ........................3 4828 Nut - Nylock, -16 ....................3 Part No. 32283 Genie Superlift 7 - 15...

  • Page 55: Mast Components - View 2

    Section 7 - Service Parts Parts and Service Manual - First Edition Figure 7-F Mast Components - View 2 7 - 16 Genie Superlift Part No. 32283...
  • Page 56 Carriage Assembly - SL-5, 10 and 15 models ............1 — 32896 Carriage Assembly - SL-20 and 25 models ..............1 32894 Column Assembly - Number 2 Through 5, All Models ..........2 Part No. 32283 Genie Superlift 7 - 17...

  • Page 57: Mast Components - Pulleys And Cable

    Section 7 - Service Parts Parts and Service Manual - First Edition Figure 7-G Mast Components - Pulleys and Cable 7 - 18 Genie Superlift Part No. 32283...
  • Page 58 Column Assembly - Number 2 Through 5, All Models ..........4 32895 Carriage Assembly - SL-5, 10 and 15 models ............1 — 32896 Carriage Assembly - SL-20 and 25 models ..............1 Part No. 32283 Genie Superlift 7 - 19...
  • Page 59 Section 7 - Service Parts Parts and Service Manual - First Edition Figure 7-H Load Handling Attachments - Forks 7 - 20 Genie Superlift Part No. 32283...
  • Page 60 Pin - Detent, 0.5 x 2.5 inches (1.3 x 6.35 cm) ............2 32526 Pin - Retaining ......................3 32908 Carrier - Adjustable Fork (includes decals) ..............1 32907 Carrier - Adjustable Flat (includes decals), SL-5, 10 and 15 models only ....1 Part No. 32283 Genie Superlift 7 - 21...

  • Page 61: Load Handling Attachments - Boom, Pipe Cradle And Load Platform

    Section 7 - Service Parts Parts and Service Manual - First Edition Figure 7-I Load Handling Attachments - Boom, Pipe Cradle and Load Platform 7 - 22 Genie Superlift Part No. 32283...
  • Page 62 Weldment - Lifting Clevis .................... 1 32500 Pin - 0.5 x 2.5 inches (1.27 x 6.35 cm) ............... 1 32526 Pin - 0.5 x 7.75 inches (1.27 x 19.9 cm) ..............1 Part No. 32283 Genie Superlift 7 - 23...

  • Page 63: Load Handling Attachments - Vertical Barrel Stacker

    Section 7 - Service Parts Parts and Service Manual - First Edition Figure 7-J Load Handling Attachment - Vertical Barrel Stacker 7 - 24 Genie Superlift Part No. 32283...
  • Page 64 Arm - Lifting, Left Side (includes 1 each index number 5) SL-5, 10 and 15 models only ..................1 32910 Arm - Lifting, Right Side (includes 1 each index number 5) SL-5, 10 and 15 models only ..................1 Part No. 32283 Genie Superlift 7 - 25...

  • Page 65: Load Handling Attachments - Rotating Barrel Handler

    Section 7 - Service Parts Parts and Service Manual - First Edition Figure 7-K Load Handling Attachment - Rotating Barrel Handler 14 30 7 - 26 Genie Superlift Part No. 32283...
  • Page 66 Screw - FHS, -16 x 1 inch ..................1 * Quantity listed for this item is approximate. Actual quanity may vary, to ensure proper fit. This parts list continues on page 7-29. Part No. 32283 Genie Superlift 7 - 27...
  • Page 67 Section 7 - Service Parts Parts and Service Manual - First Edition FIGURE 7-K 14 30 7 - 28 Genie Superlift Part No. 32283...
  • Page 68 Plate - Support, Drive Gear ..................1 33218 Bushing - Flange, 0.875 x 1 x 0.625 inch ..............1 33220 Gear - Drive ........................ 1 6326 Screw - HHC, -16 x 3 inches, GR 5 ............... 2 Part No. 32283 Genie Superlift 7 - 29...

  • Page 69: Single Speed Winch

    Section 7 - Service Parts Parts and Service Manual - First Edition Figure 7-L Single Speed Winch 7 - 30 Genie Superlift Part No. 32283...
  • Page 70 6190 Cable Keeper Kit ......................1 6184 Spacer - Drum ......................1 Ref. Drum Assembly ......................— 6770 Cover - Drum Gear ..................... 1 6034 Nut - Hex Jam, -13 ....................2 Part No. 32283 Genie Superlift 7 - 31...

  • Page 71: Two Speed Winch

    Section 7 - Service Parts Parts and Service Manual - First Edition Figure 7-M Two Speed Winch 7 - 32 Genie Superlift Part No. 32283...
  • Page 72 Shaft - Input........................ 1 32867 Frame and Drum Support ..................1 32868 Bushing, 0.75 inch I.D....................2 32869 Gear - Pinion Shaft, 24 Tooth ..................1 This parts list continues on page 7-35. Part No. 32283 Genie Superlift 7 - 33...
  • Page 73 Section 7 - Service Parts Parts and Service Manual - First Edition FIGURE 7-M 7 - 34 Genie Superlift Part No. 32283...
  • Page 74 12460 Screw - HHC, -13 x 6.5 inches, GR 5 ..............1 Ref. Ratchet Kit (not available as service part) ..............— Ref. Winch Drum (not available as service part) ............... — Part No. 32283 Genie Superlift 7 - 35...
  • Page 76 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 Genie Scandinavia Phone +86 21 53852570 Phone +46 31 3409612 Fax +86 21 53852569...

This manual is also suitable for:

Superlift sl-10Superlift sl-25Superlift sl-15Superlift sl-20

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