Genie Super-Straddle Service Manual
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Genie Super-Straddle Service Manual

Genie Super-Straddle Service Manual

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Download this manual See also: Operator's Manual
Service Manual
Super-Straddle
Serial Number Range
from SS08-2976 to
SS16G-6299
from SSG-6300
Part No. 115429
Rev A1
September 2016

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Summary of Contents for Genie Super-Straddle

  • Page 1 Service Manual Serial Number Range Super-Straddle from SS08-2976 to SS16G-6299 from SSG-6300 Part No. 115429 Rev A1 September 2016...

  • Page 2: Find A Manual For This Model

    Copyright © 1994 by Terex Corporation 115429 Rev A, July 2009 First Edition, First Printing 'Genie'' is a registered trademark of Terex South Dakota. in the U.S.A. and many other countries. “Super Series” is a trademark of Terex South Dakota.

  • Page 3: Revision History

    September 2016 Service Manual Introduction Revision His tory Revision History Revision Date Section Procedure / Page / Description 7/2009 Initial Release 9/2016 Introduction Serial Number Legend 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 September 2016 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 inside end frame) From September 1, 2016 1 Model 4 Serial label 2 Facility code 5 Serial number (stamped inside end frame) 3 Sequence number...

  • Page 5: Safety Rules

    September 2016 Service Manual Safety Rules Section 1 Safety R ules Gener al 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.
  • Page 6 Service Manual September 2016 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.

  • Page 7: Table Of Contents

    September 2016 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 September 2016 Table of Contents Section 4 Repair Procedures ..................... 19 Introduction ......................19 Base Assembly....................20 1-1 Wear Pads ..................... 20 Limit Switches ....................22 2-1 Limit Switches ....................22 Lifting Cable ....................... 23 3-1 How to Replace the Lifting Cable ..............23 Winch ........................

  • Page 9: Specifications

    It should be used only 2.8 to 3.25 m with adequate safety factors. Straddle clearance height, maximum 48 in Continuous improvement of our products is a Genie policy. 1.2 m Product specifications are subject to change without notice or obligation. Stowed Dimensions...

  • Page 10: Sae And Metric Fasteners Torque Charts

    Service Manual September 2016 Specifications SAE and M etric F asteners Tor que C harts Super Straddle Part No. 115429...

  • Page 11: Scheduled Maintenance Procedures

     Repair any machine damage or malfunction before operating the machine.  Use only Genie approved replacement parts.  Machines that have been out of service for a period longer than 3 months must complete the quarterly inspection.

  • Page 12: About This Section

    Service Manual September 2016 Scheduled Maintenance Procedures About This Section Maintenance Symbols Legend Note: The following symbols have been used in this This section contains detailed procedures for each manual to help communicate the intent of the scheduled maintenance inspection. instructions.
  • Page 13 September 2016 Service Manual Scheduled Maintenance Procedures Pre-delivery Preparation Report The pre-delivery preparation report contains checklists for each type of scheduled inspection. Make copies for each inspection. Store completed forms as required. Maintenance Schedule The Scheduled Maintenance Procedures section and the Maintenance Inspection Report have been divided into subsections.
  • Page 14 Service Manual September 2016 This page intentionally left blank. Super Straddle Part No. 115429...

  • Page 15: Pre-Delivery Preparation Report

    September 2016 Service Manual 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 16 Service Manual September 2016 This page intentionally left blank. Super Straddle Part No. 115429...

  • Page 17: Maintenance Inspection Report

    September 2016 Service Manual Maintenance Inspection Report Maintenanc e Ins pection R eport Model Y N R Y N R Checklist A- Rev A Checklist B Serial number Inspect the manuals Welds and decals Date Pre-operation Winch operation inspection Hour meter Function tests Inspect and lubricate winch...
  • Page 18 Service Manual September 2016 This page intentionally left blank. Super Straddle Part No. 115429...

  • Page 19: 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 20: 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 21: Checklist B Procedures

    B-2 C heck the Winch Oper ati on B-1 Ins pect All W elds Check the Winch Operation Inspect All Welds Genie requires that this procedure be performed every 250 hours or quarterly, whichever comes first. Genie specifications require that this procedure be...

  • Page 22: Inspect All Welds

    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

    C-1 Inspec t the Wear Pads Replace the Friction Disks Inspect the Wear Pads Genie specifications require that this procedure be Genie specifications require that this procedure be performed every 1000 hours or annually, performed every 1000 hours or annually, whichever comes first.

  • Page 24: Inspect The Cables

    C-4 Lubricate the C asters and W heels C-4 Lubricate the Casters and Wheels Inspect the Cables Genie specifications require that this procedure be performed every 1000 hours or annually, whichever comes first. Genie specifications require that this procedure be...

  • Page 25: Inspect The Painted Surfaces

    Service Manual Checklist C Procedures C-5 Inspec t the Pai nted Surfac es Inspect the Painted Surfaces Genie specifications require that this procedure be performed every 1000 hours or annually, whichever comes first. Inspecting the painted surfaces of your machine is essential to safe operation and long machine life.
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  • Page 27: Repair Procedures

     Use only Genie approved replacement parts. Indicates a potentially hazardous  Read each procedure completely and adhere situation which, if not avoided, to the instructions.

  • Page 28: Base Assembly

    Service Manual September 2016 Repair Procedures Note: To maintain proper balance of the end Base A ssembly 1-1 W ear Pads frames while removing the wear pads and Wear Pads fasteners, the lifting straps used to support the end frames will have to be adjusted with the overhead crane.
  • Page 29 September 2016 Service Manual Repair Procedures Working at the straddle frame mounting bracket, locate and remove the wear pad adjustment screws securing the inner wear pads to the adjustment plate. Set the fasteners to the side and measure the wear pads. Refer to the chart at step 5.

  • Page 30: Limit Switches

    Service Manual September 2016 Limit Switches Limit Switch es 2-1 Limit Switc hes Limit Switches How to Access the Limit Switches Position the Super Straddle on a firm, level surface and apply the brakes to swivel casters at the end frames. Fully lower the straddle frame and remove the retaining pin from the straddle frame.

  • Page 31: Lifting Cable

    September 2016 Service Manual Lifting Cable Lifting Cable While holding the cable tightly on the 3-1 H ow to Replace the Lifting C abl e drum, rotate the winch handle How to Replace the Lifting Cable counterclockwise until the cable is spooled onto the drum.

  • Page 32: Winch

    Service Manual September 2016 Repair Procedures Winch 4-1 One-s peed Winc h Slide the pinion shaft towards the small pinion bushing and remove the pinion plate, thrust One-speed Winch washer, ratchet gear, friction disk and pinion gear. Slide the pinion shaft through and out the large pinion bushing.
  • Page 33 September 2016 Service Manual Repair Procedures Install in order, the friction disk, ratchet gear How to Assemble a One-speed and thrust washer onto the pinion shaft. Winch Component damage hazard. Do Bodily injury hazard. Cables can not allow grease or oil onto the brake disks or the ratchet gear.

  • Page 34: One-Speed Winch Assembly - Ansi

    Service Manual September 2016 Repair Procedures 17 Lubricate the teeth of the drum gear and the 20 Route the end of the cable around the winch pinion nut that meshes with the drum gear with drum and out through the remaining hole on multi-purpose grease.
  • Page 35 September 2016 Service Manual Repair Procedures One-speed Winch assembly - ANSI Index Index Description Description Pinion Bushing, Large Cable Keeper Kit (bracket type) Thrust Washer Drum Spacer Ratchet Gear Cable Keeper Kit (threaded stud) Friction Disc Winch Drum Pinion Gear Drum Gear Cover Pinion Shaft Screw...

  • Page 36: One-Speed Winch Assembly - Ce

    Service Manual September 2016 Repair Procedures One-speed Winc h Ass embly - CE One-speed Winch assembly - CE Index Index Description Description Friction Disc Screw Pinion Gear Nylock Nut Pinion Shaft Drum Bolt Retaining Ring Nylock Nut Pinion Shaft Bushing Winch Handle Ratchet pawl Kit Nylock Nut...

  • Page 37: Schematics

    September 2016 Service Manual Schematics About This Section Section 5 Schem atics Intr oducti on There are two groups of schematics in this section. Electrical Schematics Electrocution/burn hazard. Contact with electrically charged Observe and Obey: circuits could result in death or serious injury.

  • Page 38: Limit Switch Legend

    Service Manual September 2016 Schematics Limit Swi tch Legend Limit Switch Legend Super Straddle Part No. 115429...
  • Page 39 September 2016 Service Manual Schematics ELECTRICAL COMPONENT LEGEND Socket Contact Item Description SC1 = SS frame, front left Enclosure SC2 = SS frame, front right EN11A= Pin switch box, front left SC3 = SS frame, rear right EN11B = Pin switch box, front right SC4 = SS frame, rear left EN11C = Pin switch box, rear right SC5 = AWP, front left...
  • Page 40 Service Manual September 2016 Schematics WIRE COLOR LEGEND Color Description Blue Black GN/YL Green/Yellow Orange White WH/BK White/Black ELECTRICAL SYMBOL LEGEND Limit Switch Wire with description or color Male contact Female contact Circuits crossing no connection Connector Super Straddle Part No. 115429...

  • Page 41: Electrical Schematic

    September 2016 Service Manual Electrical Schematic Elec trical Schem atic Electrical Schematic Part 1 of 2 Part No. 115429 Super Straddle...
  • Page 42 Service Manual September 2016 Electrical Schematic Electrical Schematic Part 2 of 2 Super Str addl e Part No. 115429 Servic e M anual September 2016 Super Straddle Part No. 115429...

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