Related Manuals for Terex Genie 9595-101
Summary of Contents for Terex Genie 9595-101
- Page 1 Service Manual Serial Number Range Superlift from 9595-101 to 9501-19014 Contractor from SLC02-19015 to SLC16-66775 from SLC16G-66776 to SLC16G-70799 from SLCG-70800 Part No. 115409 Rev A2 June 2018...
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Page 2: Find A Manual For This Model
Internet: www.genielift.com E-mail: awp.techpub@terex.com Copyright © 1995 by Genie Industries 115409 Rev A, February 2009 Third Edition, First Printing 'Genie'' and "SLC" are registered trademarks of Terex South Dakota. in the U.S.A. and many other countries. Superlift Contractor Part No. 115409... -
Page 3: Revision History
June 2018 Service Manual Introduction Revision History Revision Date Section Procedure / Page / Description 2/2009 Initial Release 9/2016 Introduction Serial Number Legend 6/2018 Maintenance Reference Examples: 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 –... -
Page 4: Serial Number Legend
Service Manual June 2018 Introduction Serial Number Legend To August 31, 2016 1 Model 4 Sequence number 2 Model year 5 Serial label 3 Facility code 6 Serial number (stamped on base) From September 1, 2016 1 Model 4 Serial label 2 Facility code 5 Serial number (stamped on base) 3 Sequence number... -
Page 5: Safety Rules
June 2018 Service Manual Safety Rules Section 1 Safety R ules Danger Failure to obey the instructions and safety rules in this manual and the appropriate Operator's Manual on your machine will result in death or serious injury. Many of the hazards identified in the operator's manual are also safety hazards when maintenance and repair procedures are performed. - Page 6 Service Manual June 2018 Safety Rules Personal Safety Workplace Safety Any person working on or around a machine must Any person working on or around a machine must be aware of all known safety hazards. Personal be aware of all known safety hazards. Personal safety and the continued safe operation of the safety and the continued safe operation of the machine should be your top priority.
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Page 7: Table Of Contents
June 2018 Table of Contents Introduction Introduction ......................ii Important Information ..................... ii Find a Manual for this Model .................. ii Revision History..................... iii Serial Number Legend ..................iv Section 1 Safety Rules ......................v General Safety Rules ..................... v Section 2 Specifications ....................... - Page 8 June 2018 Table of Contents Checklist C Procedures ..................24 C-1 Inspect the Mast Assembly for Wear ............24 C-2 Inspect the Safety Brake System (if equipped) ..........25 C-3 Replace the Winch Friction Disks ..............27 C-4 Inspect the Cable and Cable Pulleys ............27 C-5 Lubricate the Casters and Wheels ..............
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Page 9: Specifications
June 2018 Service Manual Specifications Section 2 Specific ati ons Model SLC-6 SLC-12 SLC-18 SLC-24 Height-stowed 86 in 86 in 86 in 86 in 2.2 m 2.2 m 2.2 m 2.2 m Width 31.5 in 31.5 in 31.5 in 31.5 in Standard Base 80 cm 80 cm... - Page 10 Service Manual June 2018 Specifications Dimensions-Operating SLC-6 SLC-12 SLC-18 SLC-24 Standard Forks Forks Down 5 ft 8 in 11 ft 2in 16 ft 9 in 22 ft 3 in 1.7 m 3.4 m 5.1 m 6.8 m Forks Up 7 ft 5 in 12 ft 11 in 18 ft 6 in 24 ft...
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Page 11: Sae And Metric Fasteners Torque Charts
June 2018 Service Manual Specifications Part No. 115409 Superlift Contractor... -
Page 12: Scheduled Maintenance Procedures
Service Manual June 2018 Scheduled Maintenance Procedures About This Section Section 3 Schedul ed Mai ntenance Pr ocedures 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 ... - Page 13 June 2018 Service Manual Scheduled Maintenance Procedures Maintenance Symbols Legend Pre-delivery Preparation Report Note: The following symbols have been used in this The pre-delivery preparation report contains manual to help communicate the intent of the checklists for each type of scheduled inspection. instructions.
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Page 15: Pre-Delivery Preparation Report
June 2018 Service Manual Pre-Delivery Preparation Report 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 16 Service Manual June 2018 This page intentionally left blank. Superlift Contractor Part No. 115409...
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Page 17: Maintenance Inspection Report
June 2018 Service Manual Maintenance Inspection Report Model Y N R Y N R Checklist A- Rev A Checklist B Inspect the manuals Welds Serial number and decals Clean columns Pre-operation Winch operation Date inspection Carriage hold down Function tests Hour meter Inspect and lubricate winch... - Page 18 Service Manual June 2018 This page intentionally left blank. Superlift Contractor Part No. 115409...
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Page 19: Checklist A Procedures
June 2018 Service Manual Checklist A Procedures 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 comes Result: The machine is equipped with all first. -
Page 20: Perform Pre-Operation Inspection
Service Manual June 2018 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 comes performed every 8 hours or daily, whichever comes first. -
Page 21: Checklist B Procedures
June 2018 Service Manual Checklist B Procedures 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 Weld inspections are essential to safe machine every 250 hours or quarterly, whichever comes operation and good machine performance. -
Page 22: Check The Winch Operation
Service Manual June 2018 Checklist B Procedures 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. performed every 250 hours or quarterly, whichever comes first. -
Page 23: Inspect And Lubricate The Winch
June 2018 Service Manual Checklist B Procedures Measure each friction disk for wear. Replace the friction disk if it measures less than 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. -
Page 24: Checklist C Procedures
Service Manual June 2018 Checklist C Procedures Lower the base end of the machine. 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. -
Page 25: Inspect The Safety Brake System (If Equipped)
June 2018 Service Manual Checklist C Procedures 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 26 Service Manual June 2018 Checklist C Procedures Grasp the bottom of the front column and lift it Grasp the bottom side of the next column and approximately 5 inches / 12.7 cm, then lift it approximately 5 inches / 12.7 cm, then release the column.
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Page 27: Replace The Winch Friction Disks
June 2018 Service Manual Checklist C Procedures Replace the Winch Friction Disks Inspect the Cable and Cable Pulleys Genie specifications require that this procedure be performed every 1000 hours or annually, Genie specifications require that this procedure be whichever comes first. performed every 1000 hours or annually, whichever comes first. -
Page 28: Lubricate The Casters And Wheels
Service Manual June 2018 Checklist C Procedures 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 Inspecting the painted surfaces of your machine is performed every 1000 hours or annually, essential to safe operation and long machine whichever comes first. -
Page 29: Repair Procedures
June 2018 Service Manual Repair Procedures About This Section Section 4 Repair Pr oc edures 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 Observe and Obey: where repairs can be completed. -
Page 30: Base Assembly
Service Manual June 2018 Base Assembly Attach a lifting strap from an overhead crane to the base and lift the machine to a horizontal How to Remove the Base position. Slide a second suitable structure capable of supporting it under the mast, next Fully lower the carriage. -
Page 31: Mast Assembly
June 2018 Service Manual Mast Assembly Remove the cable from the mast by pulling on the cable anchor end of the cable. How to Disassemble the Mast Assembly Bodily injury hazard. Cables can fray. Always wear adequate hand protection when handling Note: Removal of the base is only necessary when cable. - Page 32 Service Manual June 2018 Mast Assembly How to Release the Safety Brake Models with safety brake: Remove the carriage by sliding it out the bottom of the mast When Servicing the Mast toward the base while holding the safety brake rollers in the released position with the hex key The safety brake system can engage when the wrench.
- Page 33 June 2018 Service Manual Mast Assembly How to Assemble the Mast 10 Insert the carriage into the bottom end of the top column. Hold the carriage in place and pull Refer to the illustration on the following page to the cable up to the top of the column, leaving identify the cable routing.
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Page 34: Cable Routing
Service Manual June 2018 Repair Procedures Cable Routing Superlift Contractor Part No. 115409... -
Page 35: Lifting Cable
June 2018 Service Manual Mast Assembly Remove the old cable from the winch drum. Lifting Cable Unwind the outer strands and trim them back1/2 inch / 13 mm leaving the core longer. Repeat this process on the open end of the How to Replace the Lifting Cable new cable. - Page 36 Service Manual June 2018 Mast Assembly Bodily injury hazard. This tool is Attach the new cable to both the mast anchor intended for cable replacement and the winch drum. only. Do not use as a load 10 Wind the new cable evenly onto the winch carrying cable splice.
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Page 37: Lifting Pulley
June 2018 Service Manual Mast Assembly Crushing hazard. Failure to properly route the cable could Lifting Pulley result in a winch brake failure. Component damage hazard. How to Replace a Lifting Pulley - Do not allow the cable to Mast Installed become twisted during installation or mast sequencing Fully lower the carriage. -
Page 38: Winches
Service Manual June 2018 Winches Slide the pinion shaft to the right and remove the pinion spacer, pinion plate, ratchet gear One-speed Winch and friction disks. Turn the pinion gear counterclockwise and slide it off the left side of the shaft. How to Disassemble a One-speed Winch Remove the pinion shaft from the winch... - Page 39 June 2018 Service Manual Winches How to Assemble a One-speed Insert the longer threaded end of the pinion shaft approximately halfway through the left Winch bushing. Bodily injury hazard. Cables can Apply a small amount of multi-purpose grease fray. Always wear adequate to the large threaded section of the pinion hand protection when handling shaft, under the gear nut.
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Page 40: One-Speed Winch Assembly - Ansi
Service Manual June 2018 Winches 20 Rotate the drum so that the two square cable 12 Lubricate the outside of the frame spacer with keeper holes are at the top. Install the cable multi-purpose grease. Insert the frame spacer keeper clip to the outside of the drum with the into the drum. - Page 41 June 2018 Service Manual Repair Procedures One-speed Winch Assembly - ANSI 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 Ratchet Pawl Kit...
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Page 42: Two-Speed Winch
Service Manual June 2018 Winches 10 Remove the lock nut from the end of the pinion shaft (located on the outside of the winch Two-Speed Winch housing). Note: Note the location and position of the How to Disassemble a Two-speed components on the pinion shaft. - Page 43 June 2018 Service Manual Winches How to Assemble a Two-speed Apply a small amount of multi-purpose grease to the large threaded section of the pinion Winch shaft,under the gear nut. Slide the pinion shaft gears onto the pinion shaft. Install the pinion Bodily injury hazard.
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Page 44: Two-Speed Winch Assembly
Service Manual June 2018 Winches 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 and the number one column. Proceed drum. around the drum and up through the horizontal slot in the winch drum. - Page 45 June 2018 Service Manual Repair Procedures 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 Pinion Plate...
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