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Summary of Contents for Genie 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...
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Page 2: Find A Manual For This Model
Copyright © 1994 by Genie Industries E-mail: awp.techpub@terex.com 115411 Rev A, February 2009 Second Edition, First Printing 'Genie'' and "Super Tower" are registered trademarks of Terex South Dakota. in the U.S.A. and many other countries. Super Tower Part No. 115411... -
Page 3: Revision History
Section – Maintenance, B-3 Electronic Version Section – Repair Procedure, 4-2 Click on any content or procedure in the Table of Contents to view Section – Fault Codes, All charts the update. Section – Schematics, Legends and schematics Part No. 115411 Super Tower... -
Page 4: Serial Number Legend
5 Serial number (stamped on base) 3 Facility code 6 Serial label (located on base) From September 1, 2016 1 Model 4 Serial number (stamped on base) 2 Facility code 5 Serial label (located on base) 3 Sequence number Super Tower Part No. 115411... -
Page 5: Safety Rules
You read, understand and obey: • manufacturer's instructions and safety rules • employer's safety rules and worksite regulations • applicable governmental regulations You have the appropriate tools, lifting equipment and a suitable workshop. Part No. 115411 Super Tower... - Page 6 Be sure that your workshop or work area warrants it. is properly ventilated and well lit. Be aware of potential crushing hazards such as moving parts, free swinging or unsecured components when lifting or placing loads. Always wear approved steel-toed shoes. Super Tower Part No. 115411...
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Page 7: Table Of Contents
B-1 Inspect All Welds ................... 12 B-2 Clean the Columns ..................12 B-3 Check the Winch Operation ................13 B-4 Inspect the Carriage Hold-down Bar ............. 13 B-5 Inspect and Lubricate the Winch ..............14 Part No. 115411 Super Tower... - Page 8 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-speed Winch ..................33 Two-speed Winch Assembly ................35 viii Super Tower Part No. 115411...
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Page 9: Specifications
24" load center 272 kg 204 kg Continuous improvement of our products is a 507 lbs 555 lbs Net Weight Genie policy. Product specifications are 230 kg 252 kg subject to change without notice. Part No. 115411 Super Tower... -
Page 10: Sae And Metric Fasteners Torque Charts
Service Manual September 2016 Specifications SAE and M etric F asteners Tor que C harts Super Tower Part No. 115411... -
Page 11: Scheduled Maintenance Procedures
may result in property damage. Use only Genie approved replacement parts. Machines that have been out of service for a Indicates that a specific result is expected period longer than 3 months must complete the after performing a series of steps. - Page 12 Maintenance Inspection Repor Make copies of the 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. Super Tower Part No. 115411...
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Page 14: Pre-Delivery Preparation Report
Service Manual September 2016 Pre-Delivery Preparation Report Pre-Deliv ery Prepar ati on Repor t Fundamentals Instructions It is the responsibility of the owner or dealer to Use the operator’s manual on your machine. perform the Pre-delivery Preparation. The Pre-delivery Preparation consists of The Pre-delivery Preparation is performed prior to completing the Pre-operation Inspection, the each delivery. - Page 15 September 2016 Service Manual This page intentionally left blank. Part No. 115411 Super Tower...
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Page 16: Maintenance Inspection Report
• 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 Super Tower Part No. 115411... - Page 17 September 2016 Service Manual This page intentionally left blank. Part No. 115411 Super Tower...
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Page 18: Checklist A Procedures
Carefully and thoroughly Inspect the Manuals and Decals inspect all decals on the machine for legibility and damage. Genie specifications require that this procedure be performed every 8 hours or daily, whichever comes Result: The machine is equipped with all first. -
Page 19: Perform Pre-Operation Inspection
A-3 Per form F uncti on Tes ts Perform Pre-operation Inspection Perform Function Tests Genie specifications require that this procedure be Genie specifications require that this procedure be performed every 8 hours or daily, whichever comes performed every 8 hours or daily, whichever comes first. -
Page 20: Checklist B Procedures
B-2 Cl ean the C olum ns B-1 Ins pect All W elds Clean the Columns Inspect All Welds Genie specifications require that this procedure be performed every 250 hours or quarterly, whichever comes first. Genie requires that this procedure be performed... -
Page 21: Check The Winch Operation
B-4 Ins pect the C arriage Hol d-down Bar Check the Winch Operation Inspect the Carriage Hold-down Genie specifications require that this procedure be performed every 250 hours or quarterly, whichever Genie specifications require that this procedure be comes first. -
Page 22: Inspect And Lubricate The Winch
Inspect and Lubricate the Winch specification. Friction disk specification Thickness, minimum 0.065 inch Genie specifications require that this procedure be 1.5 mm performed every 250 hours or quarterly, whichever comes first. Measure both shaft bushings for wear. Replace the bushings if the wall thickness Maintaining the winch is essential to good machine measurements are less than specification. -
Page 23: Checklist C Procedures
Inspect the Mast Assembly for Rotate the mast assembly until the carriage is on top. 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. -
Page 24: Inspect The Safety Brake System (If Equipped)
Raise the carriage until it is half way up the front column 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. - Page 25 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 Super Tower...
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Page 26: Replace The Winch Friction Disks
C-4 Repl ace the Winc h Fricti on Disks Replace the Winch Friction Disks Replace the Winch Friction Disks Genie specifications require that this procedure be performed every 1000 hours or annually, whichever comes first. Genie specifications require that this procedure be... -
Page 27: Lubricate The Casters And Wheels
C-6 Inspec t the Pai nted Surfac es Lubricate the Casters and Wheels Inspect the Painted Surfaces Genie specifications require that this procedure be performed every 1000 hours or annually, whichever comes first. Genie specifications require that this procedure be... -
Page 28: Repair Procedures
Use only Genie approved replacement parts. Indicates a potentially hazardous Read each procedure completely and adhere to the instructions. Attempting shortcuts may... -
Page 29: Base Assembly
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. Secure the top of the mast to the support. Part No. 115411 Super Tower... -
Page 30: Mast Assembly
Remove the mounting fastener from the cable anchor at the top of the last column (carriage side). 1 Brake roller 2 Brake release tool 3 Column or carriage Super Tower Part No. 115411... - Page 31 This tool is available from Genie rollers in the released position with the hex key Industries (Genie part number 33875).
- Page 32 20 Raise the machine to full height to release the Bodily injury hazard. Beware of safety brakes (if equipped) and verify proper sharp edges. Wear protective operation. gloves when performing this procedure. Super Tower Part No. 115411...
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Page 33: Cable Routing
September 2016 Service Manual Repair Procedures Cabl e R outing Cable Routing Part No. 115411 Super Tower... -
Page 34: Lifting Cable
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 Using the optional cable threading tool (Genie the winch. - Page 35 Pull on the old cable while feeding the new cable through the machine. When the taped area appears at the winch, loosen the set screws and remove the old cable. Part No. 115411 Super Tower...
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Page 36: Lifting Pulley
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. Super Tower Part No. 115411... -
Page 37: Winches
Component damage hazard. Be careful not to damage the threads while holding the pinion shaft. Remove the retaining ring from the pinion shaft. Part No. 115411 Super Tower... - Page 38 11 Position both handles on the pinion shaft in opposite directions. Install and tighten the lock Install the winch housing onto the mast. Be nuts. sure the winch drum is toward the top. Super Tower Part No. 115411...
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Page 39: One-Speed Winch Assembly - Ansi
Do not allow any oil on the brake or pressure plate. One-speed Winc h Ass embly - AN SI Part No. 115411 Super Tower... - Page 40 Pinion Shaft Screw Retaining Ring Lock Nut Pinion Shaft Bushing Drum Bolt Winch Handle Hex Jam Nut Nylock Nut Frame Spacer Ratchet Pawl Kit Winch Handle Cable Keeper Kit Pinion Plate Drum Spacer Ratchet Gear Super Tower Part No. 115411...
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Page 41: Two-Speed Winch
Remove the mounting fasteners from the spring and ball housing. Remove the two springs and balls from the spring and ball housing. Slide the input shaft out of the winch housing. Remove the retaining ring from the pinion shaft. Part No. 115411 Super Tower... - Page 42 Install the winch housing on the mast. Be sure the winch drum is toward the top. Insert the longer threaded end of the pinion shaft approximately halfway through the right side bushing. Super Tower Part No. 115411...
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Page 43: Two-Speed Winch Assembly
Component damage hazard. through from the inside. Install the lock washer Be sure the cable winds onto and nut finger tight. Do not tighten the nut. the winch drum evenly. Two-speed Winc h Ass embly Part No. 115411 Super Tower... - Page 44 Ratchet Pawl Kit Ratchet Gear Retaining Ring Pinion Plate Sintered Iron Ring Brake Spacer Pinion Shaft Assembly Pinion Shaft Bushing Handle Base Spacer Super Tow er Part No. 115411 Servic e M anual September 2016 Super Tower Part No. 115411...
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