Terex Genie Superlift SLA-20 Service Manual
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Terex Genie Superlift SLA-20 Service Manual

Terex Genie Superlift SLA-20 Service Manual

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Service Manual
Superlift
Advantage
Serial Number Range
from SLA04-25259
Part No. 115407
Rev A
February 2009

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Summary of Contents for Terex Genie Superlift SLA-20

  • Page 1 Service Manual Serial Number Range Superlift Advantage from SLA04-25259 Part No. 115407 Rev A February 2009...

  • Page 2: Introduction

    Third Edition, First Printing Redmond, WA 98073-9730 USA "Genie" is a registered trademark of Genie www.genieindustries.com Industries in the USA and many other countries. e-mail: awp.techpub@terex.com "SLA" is a trademark of Genie Industries. Printed on recycled paper Printed in U.S.A. Superlift Advantage...

  • Page 3: Serial Number Legend

    February 2009 INTRODUCTION Serial Number Legend Genie Industries 18340 NE 76th Street Redmond, WA 98052 USA Model: SLA-20 SLA07-12345 Serial Number: 01/11/2007 Manufacture Date: SLA 07 - 12345 Electrical Schematic: Country of manufacture: USA Model Sequence number Model year Model year Serial label Serial number (stamped on base)

  • Page 4: Safety Rules

    Section 1 • Safety Rules February 2009 Safety Rules Warning Failure to obey the instructions and safety rules in this manual and the Genie Superlift Advantage Operator's Manual could result in death or serious injury. Many of the hazards identified in the operating instruction manual are also safety hazards when maintenance and repair procedures are performed.
  • Page 5 February 2009 Section 1 • Safety Rules SAFETY RULES Workplace Safety Personal Safety Be sure to keep sparks, flames and Any person working on or around a machine must lighted tobacco away from flammable and be aware of all known safety hazards. Personal combustible materials like battery gases safety and the continued safe operation of the and engine fuels.
  • Page 6 February 2009 This page intentionally left blank. Superlift Advantage Part No. 115407...

  • Page 7: Table Of Contents

    February 2009 Table of Contents Introduction Important Information ..................ii Serial Number Information ................. ii Serial Number Legend ..................iii Section 1 Safety Rules General Safety Rules ..................iv Section 2 Specifications SLA-5 ......................2 - 1 SLA-10 ......................2 - 1 SLA-15 ......................
  • Page 8 February 2009 TABLE OF CONTENTS Section 3 Scheduled Maintenance Procedures, continued Checklist C Procedures C-1 Inspect the Mast Assembly for Wear ..........3 - 11 C-2 Inspect the Safety Brake System (if equipped) ......... 3 - 12 C-3 Replace the Winch Friction Discs ............. 3 - 13 C-4 Inspect the Cable and Cable Pulleys ..........

  • Page 9: Sla-25

    February 2009 Section 2 • Specifications Specifications REV A Model SLA-5 SLA-10 SLA-15 SLA-20 SLA-25 Height - Stowed 78.5 in 78.5 in 78.5 in 78.5 in 78.5 in Width 31.5 in 31.5 in 31.5 in 31.5 in 31.5 in Standard Base 80 cm 80 cm 80 cm...
  • Page 10 Section 2 • Specifications February 2009 SPECIFICATIONS REV A Dimensions - Operating SLA-5 SLA-10 SLA-15 SLA-20 SLA-25 Standard Forks Forks Down 4 ft 10.5 in 9 ft 9 in 14 ft 7.5 in 19 ft 6 in 24 ft 4 in 1.5 m 4.5 m 5.9 m...
  • Page 11 February 2009 Section 2 • Specifications REV A SPECIFICATIONS SAE FASTENER TORQUE CHART • This chart is to be used as a guide only unless noted elsewhere in this manual • A574 High Strength Grade 5 Grade 8 SIZE THREAD Black Oxide Bolts LUBED LUBED...
  • Page 12 Section 2 • Specifications February 2009 This page intentionally left blank. 2 - 4 Superlift Advantage Part No. 115407...
  • Page 13 February 2009 Section 3 • Scheduled Maintenance Procedures Scheduled Maintenance Procedures 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. Observe and Obey: Symbols Legend Safety alert symbol—used to alert Maintenance inspections shall be completed by personnel to potential personal a person trained and qualified on the...

  • Page 14: Pre-Delivery Preparation Report

    Section 3 • Scheduled Maintenance Procedures February 2009 SCHEDULED MAINTENANCE PROCEDURES Maintenance Symbols Legend Pre-delivery Preparation Report Note: The following symbols have been used in The pre-delivery preparation report contains this manual to help communicate the intent of the checklists for each type of scheduled inspection. instructions.
  • Page 15 Pre-Deliver Pre-Deliver y Preparation y Preparation Pre-Deliver Pre-Deliver y Preparation Pre-Deliver y Preparation y Preparation February 2009 Section 3 • Scheduled Maintenance Procedures Fundamentals Instructions It is the responsibility of the dealer to perform the Use the operator’s manual on your machine. Pre-delivery Preparation.
  • Page 16 Section 3 • Scheduled Maintenance Procedures February 2009 This page intentionally left blank. 3 - 4 Superlift Advantage Part No. 115407...

  • Page 17: Maintenance Inspection Report

    February 2009 Section 3 • Scheduled Maintenance Procedures Maintenance Inspection Report REV A Model Checklist A - Rev A Y N R Checklist C - Rev A Y N R A-1 Manuals and decals C-1 Mast assembly wear Serial number A-1 Pre-operation C-2 Safety brake system inspection...

  • Page 18: Checklist A Procedures

    Section 3 • Scheduled Maintenance Procedures February 2009 Checklist A Procedures REV A 3 Open the operator's manual to the decals inspection section. 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 Result: The machine is equipped with all...

  • Page 19: Perform Pre-Operation Inspection

    February 2009 Section 3 • Scheduled Maintenance Procedures REV A CHECKLIST A PROCEDURES 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 performed every 8 hours or daily, whichever comes first.

  • Page 20: Checklist B Procedures

    Section 3 • Scheduled Maintenance Procedures February 2009 Checklist B Procedures REV A Inspect All Welds Clean the Columns Genie specifications require that this procedure be performed every 250 hours or quarterly, whichever comes first. Genie specifications require that this procedure be Weld inspections are essential to safe machine performed every 250 hours or quarterly, whichever operation and good machine performance.

  • Page 21: Check The Winch Operation

    February 2009 Section 3 • Scheduled Maintenance Procedures REV A CHECKLIST B PROCEDURES Check the Winch Operation Inspect the Carriage Hold-down Bar 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

    Section 3 • Scheduled Maintenance Procedures February 2009 CHECKLIST B PROCEDURES REV A 3 Measure each friction disk for wear. Replace the friction disk if it measures less than Inspect and Lubricate the Winch specification. Friction disk specification Genie specifications require that this procedure be Thickness, minimum inch 1.5 mm...

  • Page 23: A Checklist C Procedures

    February 2009 Section 3 • Scheduled Maintenance Procedures Checklist C Procedures REV A 6 Lower the base end of the machine. Inspect the 7 Rotate the mast assembly until the carriage is on top. Mast Assembly for Wear Genie specifications require that this procedure be performed every 1000 hours or annually, whichever comes first.

  • Page 24: Inspect The Safety Brake System (If Equipped)

    Section 3 • Scheduled Maintenance Procedures February 2009 CHECKLIST C PROCEDURES REV A 3 Grasp the bottom carriage and lift it approximately 12 inches / 30 cm, then release Inspect the Safety Brake System the carriage. (if equipped) Result: The carriage should stop within 5 to 8 inches / 12.7 to 20.3 cm and the safety brake should engage.

  • Page 25: Replace The Winch Friction Discs

    February 2009 Section 3 • Scheduled Maintenance Procedures REV A CHECKLIST C PROCEDURES 7 Raise the front column approximately 12 inches / 30 cm to disengage the safety Replace the brake. Winch Friction Disks 8 Operate the winch until the front column is fully raised and the second column is half way up the adjacent column.

  • Page 26: Inspect The Cable And Cable Pulleys

    Section 3 • Scheduled Maintenance Procedures February 2009 CHECKLIST C PROCEDURES REV A 2 Visually inspect the cable and components for the following: Inspect the Cable and Cable · frayed or broken wire strands Pulleys · kinks in the cable Genie specifications require that this procedure be ·...

  • Page 27: Lubricate The Casters Wheels

    February 2009 Section 3 • Scheduled Maintenance Procedures REV A CHECKLIST C PROCEDURES Lubricate the Inspect the Painted Surfaces Casters and Wheels Genie specifications require that this procedure be performed every 1000 hours or annually, whichever comes first. Inspecting the painted surfaces of your machine is Genie specifications require that this procedure be essential to safe operation and long machine life.
  • Page 28 Section 3 • Scheduled Maintenance Procedures February 2009 This page intentionally left blank. 3 - 16 Superlift Advantage Part No. 115407...
  • Page 29 February 2009 Section 4 • Troubleshooting Flow Charts Troubleshooting Flow Charts Before Troubleshooting: Read, understand and obey the safety rules and operating instructions printed in the Genie Superlift Advantage Operator's Manual . Be sure that all necessary tools and test equipment are available and ready for use.
  • Page 30 February 2009 Section 4 • Troubleshooting Flow Charts Chart 1 REV A Mast Will Not over- Remove excess weight Verify weight of load loaded from machine and against machine Sequence re-check. capacity. Properly not over- loaded Be sure safety brake (if equipped) centered Center load and Check position of load for proper centering.
  • Page 31 February 2009 Section 4 • Troubleshooting Flow Charts Chart 2 REV A Carriage Will Replace broken cable. Check for broken cable. Not Raise, See Repair procedure 2-2, How to Replace the But Winch Lifting Cable. Will Operate Be sure the carriage Check all cable pulleys Inspect the cable for Replace damaged...
  • Page 32 February 2009 Section 4 • Troubleshooting Flow Charts Chart 3 REV A Winch Will Is the load centered Re-position load to properly and free of eliminate obstruction. Be Not Operate obstructions? sure load is properly centered. Check the cable for Remove the bound Replace the damaged binding...
  • Page 33 February 2009 Section 5 • Repair Procedures Repair Procedures About This Section Most of the procedures in this section should only be performed by a trained service professional in a suitably equipped workshop. Select the appropriate repair procedure after troubleshooting the problem.

  • Page 34: Base

    Section 5 • Repair Procedures February 2009 Base Assembly REV A 7 Remove the mounting fastener and retaining pin from each leg. Remove the legs from the Base machine. 8 Using proper lifting techniques, carefully tilt the How to Remove the Base machine to the upright position.

  • Page 35: Mast Assembly

    February 2009 Section 5 • Repair Procedures Mast Assembly REV A 12 Secure the top of the mast to the support. Mast Assembly 13 Attach a lifting strap from an overhead crane to the base and lift the machine to a horizontal position.
  • Page 36 Section 5 • Repair Procedures February 2009 MAST ASSEMBLY REV A 5 Remove the cable from the mast by pulling on 8 Models with safety brake: Remove the the cable anchor end of the cable. carriage by sliding it out the bottom of the mast toward the base while holding the safety brake Bodily injury hazard.
  • Page 37 February 2009 Section 5 • Repair Procedures REV A MAST ASSEMBLY How to Release the Safety Brake How to Assemble the Mast When Servicing the Mast 1 Inspect all mast parts for wear and damage. Replace as necessary. The safety brake system can engage when the machine is tilted horizontally if the hold-down bar is 2 Clean all columns and rollers.
  • Page 38 Section 5 • Repair Procedures February 2009 MAST ASSEMBLY REV A 9 Feed the other end of the cable through the box 14 Apply Loctite® removable thread sealant to the section (web) of the carriage into the pulley, pulley mounting fastener and install the lower then push the cable through the pulley until it pulley into the column.

  • Page 39: Lifting Cable

    February 2009 Section 5 • Repair Procedures REV A MAST ASSEMBLY 3 Remove the old cable from the winch drum. Lifting Cable 4 Unwind the outer strands and trim them back inch / 13 mm leaving the core longer. Repeat this process on the open end of the new cable.

  • Page 40: Lifting Pulley

    Section 5 • Repair Procedures February 2009 MAST ASSEMBLY REV A 6 Place a smooth layer of strapping tape over the joint section of the two cables and the tool. Lifting Pulley Note: If the cable gets caught as you are pulling it through the columns and pulleys, avoid pulling too How to Replace a hard as you may break the connection between...
  • Page 41 February 2009 Section 5 • Repair Procedures REV A MAST ASSEMBLY 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.

  • Page 42: One-Speed Winch

    Section 5 • Repair Procedures February 2009 Winches REV A 7 Slide the pinion shaft to the right and remove the pinion spacer, pinion plate, ratchet gear and One-speed Winch friction disks. Turn the pinion gear counterclockwise and slide it off the left side of How to Disassemble a the shaft.
  • Page 43 February 2009 Section 5 • Repair Procedures REV A WINCHES How to Assemble a 6 Insert the longer threaded end of the pinion shaft approximately halfway through the left One-speed Winch bushing. Bodily injury hazard. Cables can 7 Apply a small amount of multi-purpose grease fray.
  • Page 44 Section 5 • Repair Procedures February 2009 WINCHES REV A 12 Lubricate the outside of the frame spacer with 20 Rotate the drum so that the two square cable multi-purpose grease. Insert the frame spacer keeper holes are at the top. Install the cable into the drum.
  • Page 45 February 2009 Section 5 • Repair Procedures REV A WINCHES One-speed Winch Assembly Index Index Description Description Disc Brake Drum Lock Bolt Pinion Gear Winch Gear Cover Pinion Shaft Screw Retaining Ring Lock Nut Pinion Shaft Bushing Drum Bolt Winch Handle Hex Jam Nut Nylock Nut Frame Spacer...

  • Page 46: Two-Speed Winch

    Section 5 • Repair Procedures February 2009 WINCHES REV A 8 Slide the input shaft out of the winch housing. Two-speed Winch 9 Remove the retaining ring from the pinion shaft. 10 Remove the lock nut from the end of the pinion How to Disassemble a shaft (located on the outside of the winch housing).
  • Page 47 February 2009 Section 5 • Repair Procedures REV A WINCHES How to Assemble a 7 Apply a small amount of multi-purpose grease to the large threaded section of the pinion shaft, Two-speed Winch under the gear nut. Slide the pinion shaft gears onto the pinion shaft.
  • Page 48 Section 5 • Repair Procedures February 2009 WINCHES REV A 14 Lubricate the outside of the frame spacer with 22 Route the end of the cable between the winch multi-purpose grease and insert it into the drum. drum and the number one column. Proceed around the drum and up through the horizontal 15 Install the cable drum.
  • Page 49 February 2009 Section 5 • Repair Procedures REV A WINCHES Two-speed Winch Assembly Index Index Description Description Reel Lock Bolt Input Shaft Assembly Reel Cover Brake Spring Spacer Cable Keeper Detent Block Assembly Reel Spacer Pinion Gear Gear Cover Disc Brake Ratchet Pawl Kit Ratchet Gear Retaining Ring...
  • Page 50 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 Scandinavia Genie China Phone +46 31 575100 Fax + 46 31 579020 Phone +86 21 53852570 Fax +86 21 53852569 Genie France...

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