Terex Genie Superlift Advantage SL-5 Quick start guide

Parts Manual
Serial Number Range
Parts & Service Manual
Part No. 32283
Rev A6
August 2007
Serial Number Range
Superlift
Advantage
from serial number
9594-101 to 5501-15094
and from SLA02-15095
to SLA04-25258

Parts and Service Manual - First
Part No. 32283 Genie Superlift Advantage
July, 2007
v
Table of Contents
Introduction
Important Information...................................................................................................... ii
Section One Safety Rules
General Safety Rules .................................................................................................... iii
Section Two Specifications
Superlift 5 ................................................................................................................................. 2 - 1
Superlift 10 ................................................................................................................................. 2 - 1
Superlift 15 ................................................................................................................................. 2 - 1
Superlift 20 ................................................................................................................................. 2 - 1
Superlift 25 ................................................................................................................................. 2 - 1
Load Handling Attachments ................................................................................................................... 2 - 1
Bolt Torque Specification ....................................................................................................................... 2 - 3
Section Three Scheduled Maintenance Inspections
Introduction ............................................................................................................... 3 - 1
Table A ................................................................................................................................. 3 - 2
Table B ................................................................................................................................. 3 - 2
Table C ................................................................................................................................. 3 - 2
Maintenance Inspection Report ............................................................................................................. 3 - 3
Section Four Scheduled Maintenance Procedures
Introduction ............................................................................................................... 4 - 1
A-1 Inspect the Operator's Manual .................................................................................. 4 - 2
A-2 Inspect the Decals and Placards .............................................................................. 4 - 2
A-3 Inspect for Damage, Loose or Missing Parts ............................................................ 4 - 2
A-4 Check the Winch Operation ...................................................................................... 4 - 3
A-5 Inspect the Columns for Damage ............................................................................. 4 - 3
A-6 Inspect the Cable and Cable Pulleys ........................................................................ 4 - 3
A-7 Check the Mast for Proper Sequencing .................................................................... 4 - 4
A-8 Inspect the Casters and Wheels ............................................................................... 4 - 4
B-1 Inspect the Column Hold Down System ................................................................... 4 - 5

Parts and Service Manual - First Edition
Genie Superlift Advantage Part No. 32283
Section Four Scheduled Maintenance Procedures, cont.
B-2 Inspect All Welds ...................................................................................................... 4 - 5
B-3 Clean the Columns ................................................................................................... 4 - 5
B-4 Inspect and Lubricate the Winch............................................................................... 4 - 6
B-5 Inspect and Lubricate the Rotating Barrel Handler ................................................... 4 - 6
C-1 Lubricate the Casters and Wheels ............................................................................ 4 - 7
C-2 Inspect the Mast Assembly for Wear ........................................................................ 4 - 7
C-3 Replace the Winch Friction Disks ............................................................................. 4 - 8
C-4 Inspect the Safety Brake System.............................................................................. 4 - 8
C-5 Inspect the Painted Surfaces .................................................................................... 4 - 9
Section Five Troubleshooting Flow Charts
Introduction ............................................................................................................... 5 - 1
1 Mast Will Not Sequence Properly ............................................................................. 5 - 2
2 Carriage Will Not Raise, But Winch Will Operate ...................................................... 5 - 3
3 Winch Will Not Operate ............................................................................................ 5 - 4
Section Six Repair Procedures
Introduction ............................................................................................................... 6 - 1
Base Assembly
1-1 How To Remove the Base - Standard Base ............................................................. 6 - 2
1-2 How To Remove the Base - Straddle Base .............................................................. 6 - 3
Mast Assembly
2-1 How to Disassemble the Mast Assembly .................................................................. 6 - 4
2-2 How to Replace the Lifting Cable .............................................................................. 6 - 5
2-3 How to Replace a Lifting Pulley - Mast Installed ....................................................... 6 - 6
Winches
3-1 How To Disassemble the Winch - Single Speed ....................................................... 6 - 7
3-2 How To Disassemble the Winch - Two Speed .......................................................... 6 - 9
vi
TABLE OF CONTENTS

Parts and Service Manual - First
Part No. 32283 Genie Superlift Advantage
August 2007
Section Seven Service Parts
How To Order Parts .................................................................................................. 7 - 1
Figure 7-A Decals and Paint (Rev A; August 2007) ................................................................... 7 - 2
Figure 7-B Number 1 Mast Attached Parts (Rev A; August 2007) .............................................. 7 - 6
Figure 7-C Standard Base Components (Rev A; August 2007) .................................................. 7 - 8
Figure 7-D Straddle Base Components (Rev A; August 2007) ................................................. 7 - 12
Figure 7-E Mast Components - View 1 (Rev C; October 2006) ................................................ 7 - 14
Figure 7-F Mast Components - View 2 (Rev B; August 2007) .................................................. 7 - 16
Figure 7-G Mast Components - Pulleys and Cable (Rev C; August 2007)................................ 7 - 18
Figure 7-H Load Handling Attachments - Forks ........................................................................ 7 - 22
Figure 7-I Load Handling Attachments - Boom, Pipe Cradle and Load Platform ..................... 7 - 24
Figure 7-J Load Handling Attachments - Vertical Barrel Stacker ............................................. 7 - 26
Figure 7-K Load Handling Attachments - Rotating Barrel Handler ............................................ 7 - 28
Figure 7-L Single Speed Winch (Rev B; July 2007) ................................................................. 7 - 32
Figure 7-M Two Speed Winch (Rev B; July 2007) .................................................................... 7 - 34
vii
TABLE OF CONTENTS

Parts and Service Manual - First Edition
Genie Superlift Advantage Part No. 32283
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Part No.32283 Genie Superlift Advantage 2 - 1
Section 2 - Specifications
Part and Service Manual - First Edition
Model SL-5 SL-10 SL-15 SL-20 SL-25
Height-Stowed 781/2in 781/2in 781/2in 781/2in 781/2in
199 cm 199 cm 199 cm 199 cm 199 cm
Width 311/2in 311/2in 311/2in 311/2in 311/2in
Standard Base 80 cm 80 cm 80 cm 80 cm 80 cm
Width - stabilizers lowered 785/8in 785/8in 785/8in 785/8in 785/8in
Standard Base 185 cm 185 cm 185 cm 185 cm 185 cm
Width-Min 311/2in 311/2in 311/2in NA NA
Straddle Base 80 cm 80 cm 80 cm
Width-Max 58 in 58 in 58 in NA NA
Straddle Base 147 cm 147 cm 147 cm
Length-Stowed 29 in 29 in 29 in 29 in 31 in
74 cm 74 cm 74 cm 74 cm 79 cm
Length - Operating 571/2in 571/2in 721/2in 801/2in 801/2in
146 cm 146 cm 184 cm 204 cm 204 cm
Ground 2 in 2 in 2 in 2 in 2 in
Clearance 50.8 mm 50.8 mm 50.8 mm 50.8 mm 50.8 mm
Load Capacity 1000 lbs 1000 lbs 800 lbs 800 lbs 650 lbs
at 18" load center 454 kg 454 kg 363 kg 363 kg 295 kg
Net Weight - Standard Base 215 lbs 260 lbs 317 lbs 405 lbs 450 lbs
(no load handling attachment) 97.5 kg 117.9 kg 143.8 kg 183.7 kg 204.1 kg
Net Weight - Straddle Base 258 lbs 303 lbs 360 lbs NA NA
(no load handling attachment) 117.0 kg 137.4 kg 163.3 kg
Load Handling Attachments Length Width Depth Net Weight
Standard Forks 271/2in 231/2in 21/2 in 38 lbs
70 cm 60 cm 6.5 cm 17.2 kg
Adjustable Forks 271/2in 111/2 in to 30 in 21/2 in 52.5 lbs
70 cm 29 cm to 76 cm 6.5 cm 23.8 kg
Flat Forks 32 in 16 in to 31 in 11/2in 73 lbs
81 cm 41 cm to 79 cm 4 cm 33.1 kg
Boom 18 in to 42 in 11/2in 61/2in 34.5 lbs
46 cm to 107 cm 4 cm 16 cm 15.6 kg
Vertical Barrel Stacker 21 in 29 in NA 50.5 lbs
53 cm 74 cm 22.9 kg
Rotating Barrel Handler 29 in 31 in NA 85 lbs
74 cm 79 cm 38.6 kg
Pipe Cradle 271/2in 24 1/2in 6 in 10 lbs
70 cm 63 cm 11.5 cm 4.5 kg
Load Platform 271/2in 231/2in 21/2in 26.5 lbs
70 cm 60 cm 6.5 cm 12.0 kg
Specifications

2 - 2 Genie Superlift Advantage Part No.32283
Section 2 - Specifications Part and Service Manual - First Edition
SPECIFICATIONS
Dimensions - Operating SL-5 SL-10 SL-15 SL-20 SL-25
Standard Forks forks down 4 ft 101/2in 9 ft 9 in 14 ft 71/2in 19 ft 6 in 24 ft 4 in
1.5 m 3 m 4.5 m 6 m 7.4 m
forks up 6 ft 7 in 11 ft 51/2in 16 ft 4 in 21 ft 21/2in 26 ft 1/2in
2 m 3.5 m 5 m 6.5 m 7.9 m
Adjustable Forks forks down 4 ft 101/2in 9 ft 9 in 14 ft 71/2in 19 ft 6 in 24 ft 4 in
1.5 m 3 m 4.5 m 6 m 7.4 m
forks up 6 ft 7 in 11 ft 51/2in 16 ft 4 in 21 ft 21/2in 26 ft 1/2in
2 m 3.5 m 5 m 6.5 m 7.9 m
Flat Forks 4 ft 101/2in 9 ft 9 in 14 ft 71/2in NA NA
1.5 m 3 m 4.5 m
Boom 5 ft 101/2in 10 ft 9 in 15 ft 71/2in 20 ft 6 in 25 ft 4 in
1.8 m 3.3 m 4.8 m 6.3 m 7.7 m
Note: measured from ground to bottom of shackle
Vertical Barrel Stacker 30 gallon 4 ft 8 ft 10 in 13 ft 9 in NA NA
(24 Load Center) 1.2 m 2.7 m 4.2 m
55 gallon 3 ft 10 in 8 ft 8 in 13 ft 7 in
1.2 m 2.6 m 4.1 m
Note: measured from ground to bottom of barrel
Rotating Barrel Handler 55 gallon 3 ft 10 in 8 ft 8 in 13 ft 7 in NA NA
(24 inch Load Center) 1.2 m 2.6 m 4.1 m
Note: measured from ground to bottom of barrel
Load Platform forks down 4 ft 101/2in 9 ft 9 in 14 ft 71/2in 19 ft 6 in 24 ft 4 in
1.5 m 3 m 4.5 m 6 m 7.4 m
forks up 6 ft 7 in 11 ft 51/2in 16 ft 4 in 21 ft 21/2in 26 ft 1/2in
2 m 3.5 m 5 m 6.5 m 7.9 m
Note: can be used with standard forks and adjustable forks only
Pipe Cradle:handles round objects up to 30 in (76 cm) in diameter
Note: can be used with standard forks and adjustable forks only (see above for working heights)
Non-marking Fork Option
Note: can be used with standard forks and adjustable forks only (see above for working heights)
Fork Extension Option
Note: can be used with standard forks and adjustable forks only (see above for working heights)

Part No.32283 Genie Superlift Advantage 2 - 3
Section 2 - Specifications
Part and Service Manual - First Edition
13
20
12
18
11
18
10
16
9
14
8
12
24
32
20
28
18
24
16
24
14
20
Torque - Dry
inch-pounds
Torque - Dry
foot-pounds
Torque - Dry
Newton meters
Torque - Dry
inch-pounds
Torque - Dry
foot-pounds
Torque - Dry
Newton meters
43
49
96
120
17
19
30
35
50
55
75
90
110
120
150
170
260
300
430
470
640
700
5
6
11
14
23
28
41
48
68
75
102
122
149
163
204
231
353
407
583
637
868
949
60
68
144
168
25
25
45
50
70
80
110
120
150
170
220
240
380
420
600
660
900
1000
7
8
16
19
34
34
61
68
95
109
149
163
204
231
298
326
515
570
814
895
1221
1356
10
1/4
5/16
3/8
7/16
1/2
9/16
5/8
3/4
7/8
1
Torque specifications for lubricated bolts are 25% less than dry torque specifications for each bolt size.
These bolt torque specifications are for general use only. Specification may vary depending on application of bolt.
Size Threads SAE Grade 5 Bolts SAE Grade 8 Bolts
Bolt Torque Specifications
SPECIFICATIONS

2 - 4 Genie Superlift Advantage Part No.32283
Section 2 - Specifications Part and Service Manual - First Edition
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Part No.32283 Genie Superlift Advantage 3 - 1
Section 3 - Scheduled Maintenance InspectionsParts and Service Manual - First Edition
Dealer
service
suggested
New parts
required
Tools are
required
Scheduled Maintenance Inspections
Observe and Obey:
Maintenance inspections shall be completed by
a person trained and qualified on the
maintenance of this machine.
Scheduled maintenance inspections shall be
completed daily, quarterly and annually as
specified on the maintenance inspection report.
Failure to properly complete each
inspection when required may
result in death, serious injury or
substantial machine damage.
Immediately tag and remove from service a
damaged or malfunctioning machine.
Repair any machine damage or malfunction
before operating machine.
Keep records on all inspections for three years.
Machines that have been out of service for a
period longer than 3 months must complete the
quarterly inspection.
About This Section
Schedule
There are three types of maintenance inspections
that must be performed according to a schedule—
daily, quarterly and annually. To account for
repeated procedures, the Maintenance Tables and
the Maintenance Inspection Report have been
divided into three subsections—A, B, C. Use the
following chart to determine which group(s) of
procedures are required to perform a scheduled
inspection.
Inspection Table or Checklist
Daily A
Quarterly (every 150 hours or three months) A + B
Annual A + B + C
Maintenance Tables
The maintenance tables contained in this section
provide summary information on the specific
physical requirements for each inspection.
Complete step-by-step instructions for each
scheduled maintenance procedure are provided in
section 4, Scheduled Maintenance Procedures .
Maintenance Inspection Report
The maintenance inspection report contains
checklists for each type of scheduled inspection.
Make copies of the Maintenance Inspection Report
to use for each inspection. Keep records on all
inspections for three years.