Genie Super Tower ST-20 Guida rapida

Parts & Service Manual Part No. 32951

Rev C

November 2005

Refer to inside cover for additional serial number information

(from serial number 7794-101 to 7799-101)

November 2005

Genie SuperTower Part No.32951

www.genieindustries.com

e-mail:[email protected]

32951 Rev C November 2005

First Edition, Third Printing

"Genie" and "Super Tower" are registered

trademarks of Genie Industries in the USA and

many other countries.

Printed on recycled paper

Printed in U.S.A.

Important

Read, understand and obey the safety rules and

operating instructions in the appropriate Operator's

Manual on your machine before attempting any

maintenanceprocedure.

Basic mechanical, hydraulic and electrical

skills are required to perform most procedures.

However, several procedures require specialized

skills, tools, lifting equipment and a suitable

workshop. In these instances, we strongly

recommend that maintenance and repair be

performed at an authorized Genie dealer

service center.

Technical Publications

Genie Industries has endeavored to deliver the

highest degree of accuracy possible. However,

continuous improvement 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.

November 2005

Part No.32951 Genie Super Tower

iii

GS30 05 A - 12345

Model

Facility code

(

)

used only for model manufactured

in multiple facilities

Sequence

number

PN - 77055

Model:

Model year: Manufacture date:

Maximum allowable inclination of the chassis:

Country of manufacture: USA

This machine complies with:

Serial number:

Rated work load (including occupants):

Genie Industries

18340 NE 76th Street

Redmond, WA 98052

USA

Electrical schematic number:

Gradeability:

Maximum allowable side force :

Maximum number of platform occupants:

Machine unladen weight:

ANSI A92.6-1999

B354.2-01

GS-1930

GS3005A-12345

04/12/05

ES0141

2,714 lb / 1,231 kg

500 lb / 227 kg

N/A

100 lb / 445 kg

2005

Model year

HowTo ReadYour Serial Number

November 2005

Genie SuperTower Part No.32951

Warning

Failure to obey the instructions and safety rules in

this manual and the

Genie Super Tower

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.

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 governmental regulations

You have the appropriate tools, lifting equipment

and a suitable workshop.

Safety Rules

November 2005

Part No.32951 Genie Super Tower

Personal 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.

Read each procedure thoroughly. This

manual and the decals on the machine,

use signal words to identify the following:

Safety alert symbol—used to alert

personnel to potential personal

injury hazards. Obey all safety

messages that follow this symbol

to avoid possible injury or death.

Red—used to indicate the

presence of an imminently

hazardous situation which, if not

avoided, will result in death or

serious injury.

Orange—used to indicate the

presence of a potentially

hazardous situation which, if not

avoided, could result in death or

serious injury.

Yellow with safety alert symbol—

used to indicate the presence of a

potentially hazardous situation

which, if not avoided, may cause

minor or moderate injury.

Yellow without safety alert

symbol—used to indicate the

presense of a potentially

hazardous situation which, if not

avoided, may result in property

damage.

Green—used to indicate operation

or maintenance information.

SAFETY RULES

Be sure to wear protective eye wear and

other protective clothing if the situation

warrants it.

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.

Workplace Safety

Be sure to keep sparks, flames and

lighted tobacco away from flammable

and combustible materials like battery

gases and engine fuels. Always have an approved

fire extinguisher within easy reach.

Be sure that all tools and working areas

are properly maintained and ready for

use. Keep work surfaces clean and free

of debris that could get into machine components

and cause damage.

Be sure that your workshop or work area

is properly ventilated and well lit.

Be sure any forklift, overhead crane or

other lifting or supporting device is fully

capable of supporting and stabilizing the

weight to be lifted. Use only chains or straps that

are in good condition and of ample capacity.

Be sure that fasteners intended for one

time use (i.e., cotter pins and self-locking

nuts) are not reused. These components

may fail if they are used a second time.

Be sure to properly dispose of old oil or

other fluids. Use an approved container.

Please be environmentally safe .

November 2005

Genie SuperTower Part No.32951

This page intentionally left blank.

November 2005

Part No.32951 Genie Super Tower

Table of Contents

vii

Introduction

ImportantInformation ..................................................................................................

How to Read Your Serial Number ..............................................................................

iii

Recommended Parts Stocking List ............................................................................

How To Order Parts ...................................................................................................

Service Parts Fax Order Form ...................................................................................

Section 1 Safety Rules

General Safety Rules .................................................................................................

Section 2 Rev Specifications

A Machine Specifications.......................................................................................... 2 - 1

Section 3 Rev Scheduled Maintenance Procedures

Introduction ........................................................................................................... 3 - 1

Pre-delivery Preparation Report ............................................................................ 3 - 3

Maintenance Inspection Report ............................................................................. 3 - 5

B Checklist A Procedures

A-1 Perform Pre-operation Inspection.................................................................. 3 - 6

A-2 Perform Function Tests ................................................................................. 3 - 6

BChecklist B Procedures

B-1 Inspect all Welds ........................................................................................... 3 - 7

B-2 Clean the Columns........................................................................................ 3 - 7

B-3 Check the Winch Operation........................................................................... 3 - 8

B-4 Inspect and Lubricate the Winch ................................................................... 3 - 8

B Checklist C Procedures

C-1 Lubricate the Casters and Wheels .............................................................. 3 - 11

C-2 Inspect the Mast Assembly for Wear........................................................... 3 - 11

C-3 Replace the Winch Friction Disks................................................................ 3 - 12

C-4 Inspect the Safety Brake System ................................................................ 3 - 13

C-5 Inspect the Painted Surfaces....................................................................... 3 - 14

November 2005

Genie SuperTower Part No.32951

viii

TABLE OF CONTENTS

Section 4 Rev Troubleshooting Flow Charts

Introduction ........................................................................................................... 4 - 1

B Chart 1: Mast Will Not Sequence Properly ............................................................ 4 - 2

B Chart 2: Carriage Will Not Raise, But Winch Will Operate ..................................... 4 - 3

B Chart 3: Winch Will Not Operate............................................................................ 4 - 4

Section 5 Rev Repair Procedures

Introduction ........................................................................................................... 5 - 1

B 1-1 How to Remove The Base ............................................................................ 5 - 2

B 2-1 How to Disassemble the Mast Assembly....................................................... 5 - 3

B 2-2 How to Replace the Lifting Cable .................................................................. 5 - 5

B 2-3 How to Replace a Lifting Pulley - Mast Installed ............................................ 5 - 5

B 3-1 How to Disassemble the One-speed Winch .................................................. 5 - 6

B 3-2 How to Disassemble the Two-speed Winch .................................................. 5 - 8

Section 6 Rev Decals and Paint

Figure 6-A B Decals ................................................................................................................... 6 - 2

Figure 6-B B Decals with Words................................................................................................. 6 - 4

Figure 6-C B Decals with Symbols ............................................................................................. 6 - 6

Section 7 Rev Base Components

Figure 7-A C Base Components................................................................................................. 7 - 2

Section 8 Rev Mast and Winch Components

Figure 8-A C Number 1 Mast Attached Parts ............................................................................. 8 - 2

Figure 8-B C Mast Components, View 1..................................................................................... 8 - 4

Figure 8-C C Mast Components, View 2..................................................................................... 8 - 6

Figure 8-D C Mast Components, Pulleys and Cables................................................................. 8 - 8

Figure 8-E C Winch Components, One-speed ......................................................................... 8 - 10

Figure 8-F C Winch Components, Two-speed ......................................................................... 8 - 12

Section 9 Rev Accessories

Figure 9-A B Adjustable Forks.................................................................................................... 9 - 2

November 2005

Part No.32951 Genie Super Tower

Recommended Parts

Description Part No.

Genie Gray Paint, 12 Ounce / 355 ml Aerosol ...... 1268

Genie Blue Paint, 12 Ounce / 355 ml Aerosol ....... 1484

Genie Blue Paint, 1 Gallon / 3.78 liters................ 32150

Genie Gray Paint, 1 Gallon / 3.78 liters ............... 32151

Pinion Plate (One-speed Winch) ........................... 7591

Pinion Plate (Two-speed Winch) ......................... 40122

Ratchet Gear (One-speed Winch) ......................... 6777

Ratchet Gear (Two-speed Winch) ....................... 40121

Pinion Gear (One-speed Winch)............................ 7590

Pinion Gear (Two-speed Winch).......................... 80157

Pinion Shaft (One-speed Winch) ......................... 32891

Ratchet Pawl Kit (One-speed Winch) .................. 40458

Ratchet Pawl Kit (Two-speed Winch) .................. 40117

Cable Keeper Kit (One-speed Winch) ................... 6190

Cable Keeper Kit (Two-speed Winch) ................. 40130

Primary Shaft Assembly....................................... 72264

Pin Assembly with Lanyard.................................. 32940

Roller Bolt, 1/2-13 x 1.84 inches ........................... 32475

Nylatron Roller, 1.75 x 0.72 inch ......................... 32473

Safety Brake Assembly........................................ 35101

Loctite Thread Lock ............................................. 65764

Required Parts

The following parts are required to perform

maintenance procedures as outlined in the

Genie

Super Tower Parts and Service Manual.

Description Part No.

White Lithium Grease .......................................... 91670

Cable Replacement Coupler................................ 12402

Disc Brake (One-speed Winch) ............................. 7571

Disc Brake (Two-speed Winch) ........................... 37061

Manuals

Genie Industries offers the following support

documents for these models:

Title Part No.

Genie Super Tower Operator's Manual

(before serial number 7794-101) ......................... 32950

EMI Safety Manual............................................... 27581

Parts Stocking List

November 2005

Genie SuperTower Part No.32951

HowTo Order Parts

Please be prepared with the following information

when ordering replacement parts for your Genie

product:

Machine model number

Machine serial number

Genie part number

Part description and quantity

Purchase order number

"Ship to" address

Desired method of shipment

Name and telephone number of the authorized

Genie Distributor in your area

Use the Service Parts Fax Order Form on the next

page and fax your order to our Parts Department.

If you don't know the name of your authorized

distributor, or if your area is not currently serviced

by an authorized distributor, please call Genie

Industries.

Machine Information

Model

Serial Number

Date of Purchase

Authorized Genie Distributor

Phone Number

Genie North America

Telephone (425) 556-6551

Toll Free (877) 367-5606 in U.S.A. and Canada

Fax (425) 556-8659

Genie UK

Parts Telephone (44) (0) 1476 584352

Parts Fax (44) (0) 1476 584340

Genie Australia

Parts Telephone (617) 03375 1660

Parts Fax (617) 03375 1002

Genie France

Parts Telephone (33) (0) 237 26 09 99

Parts Fax (33) (0) 237 31 50 10

Genie Germany

Parts Telephone (49) (0) 4202 885223

Parts Fax (49) (0) 4202 885225

Genie Scandinavia

Parts Telephone (46) (31) 3409612

Parts Fax (46) (31) 3409613

Genie Iberica

Parts Telephone (34) (93) 5795042

Genie Brazil

Parts Telephone (55) (114) 1665755

Parts Fax (55) (114) 1665754

Genie Japan

Parts Telephone (81) (33) 4536082

Parts Fax (81) (33) 4536083

Genie China

Parts Telephone (86) (215) 3852570

Parts Fax (86) (215) 3852569

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