Genesis

Repair Manual
This Manual covers:
Garaventa Genesis I and Genesis 2006 Models

ITEM #05751 Revision B 1 Garaventa Lift, April 2008

About this manual

This manual covers repair procedures for the Genesis I AND Genesis 2006.
No previous versions of this Manual exist. It may be used for all existing models
as of the date of printing.

Genesis I models were shipped up until September 2006. Models shipped after
that date are Genesis 2006 models. This is as of the print date of this document.

The main visible difference between the two models, aside form the shipping
dates is the shape of the mast. Genesis I Models have an extra angles component
in the mast whereas the Genesis 2006 is rectangular.

For more information, see the “Genesis Quick installation Guide” on our website.

Indicates items related to Genesis Hydraulic Lifts

Indicates items related to Lead Screw Lifts

Safety Related items.

ITEM #05751 Revision B 2 Garaventa Lift, April 2008

TABLE OF CONTENTS :

A B OUT THIS MANUAL .............................................. ....2

TA BLE OF CONTENTS : .................................................3
D RIVE N UT R EPLACEMENT PROCEDURE G ENESIS I (P RE
G E NESIS 2006) ......................................................... 4
G E NESIS L EAD S CREW REMOVAL AND REPLACEMENT
G ENESIS I M ODEL ......................................................6
D R IVE N UT R EPLACEMENT PROCEDURE G ENESIS 2006 . 11
G E NESIS L EAD S CREW REMOVAL AND R EPLACEMENT
G ENESIS 2006 M ODEL .............................................. 12
C Y LINDER H EAD /S EAL REPLACEMENT ......................... 18
G ENESIS 2006 H YRAULIC L OWERING VALVE
R EPLACEMENT:........................................................ 19
G ENESIS I H YRAULIC L OWERING VALVE R EPLAC EMENT: 20
R EPLACING HARDWARE IN AN INTERNAL DOOR CLOSER . 21
L ATCH B LOCK U PGRADE (A PRIL 2008) ....................... 22

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D RIVE N UT R EPLACEMENT PROCEDURE G ENESIS I (P RE
G ENESIS 2006)

Parts required:

• 10596 Nut Assembly (1)

• 12857 Greaser (Recommended) (1)
• 04576 Springs (3)
• 11693 Brass Safety nut. (1)

Procedure:

• Run the lift so that you have access to the drive nut. It is best to run the platform
so that you can work under it. It may be necessary to remove the platform in
some cases where access is restricted. As always, the platform most be properly
shored while working under it.
• Turn off the power and lock it.
• Remove the back wall of the platform
• Undo the Drive nut using an 8 mm Allen wrench. And remove the exposed half
of the Drive nut. The back half cannot be removed without moving it with the
Lead screw.
• Disconnect the greaser hose to the drive nut and remove the safety switch so
that it is not damaged.
• Turn the Lead screw so that the safety nut and drive nut descend below the
cross-member of the carriage. Remember the carriage and platform are shored
so they will not move.
• Note the distance between the Drive nut and safety nuts is around 4.5 mm or one
full turn of the screw. This will have to be checked once the drive nut is back in
place.
• Check the safety nut for play. There must be very little movement up and down.
0.5 mm or more play in the safety nut indicates the safety nut must be replaced.
This is especially important where the Drive nut has failed due to poor lubrication.
If this is necessary, removal of the entire screw is necessary. Refer to the repair
manual for this procedure.
• Remove the back half of the Drive nut
• Install the springs supplied in the kit into the drive nut halves and reinstall the
Drive nut onto the screw checking that it is approximately 4.5 mm gap between it
and the safety nut. Refer to the picture attachment.
• Turn the lead screw so that the safety and Drive nuts ascend to their original
position.

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 • Reassemble the drive nut with the new parts.
• Make sure that the drive nut is tightened to 50 lbs.
• Install a new greaser and turn it on. CAUTION! The old greaser will continue to
produce grease. Be ready to catch the excess grease. Smear it onto the drive
screw.
• Make sure the safety switch is properly positioned so that it will activate if the
drive nut fails.
• Put lots of grease onto the threads of the screw.
• Re-assemble the lift and check its operation.
• Return the lift to service.

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G EN ESIS L EAD S CREW REMOVAL AN D REPLACEMENT
G EN ESIS I M ODEL

Screw removal:

Note: As you disassemble the screw, look carefully at how the various nuts retaining
collars and washers are assembled onto it. You will have to reassemble these parts
onto the new shaft.
Never allow the screw to hang unsupported this will damage it irreparably.

Operate the lift so that the platform is about 18 inches (750 mm) above the lower
landing and remove the platform walls and the platform. Do not stress the drive system.
For units that cannot be operated, find a way to support the carriage and platform so
that they are high enough to allow you to remove the platform walls and the platform.
Remove the mast covers and support the carriage so that you can access the Drive nut
assembly easily.
Disassemble the Drive nut and
Safety nut assembly. See
illustrations below:

Two setscrews fix

the bearing collar
to the shaft. They
have to be
loosened to
remove the screw
from the bearing.

When installing the

new shaft, tension
the new shaft
slightly before
tightening these
screws

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Remove the mast cap look closely at the collar at the very top of the screw. There is a
screw passing through the collar above the upper nut. This must be removed. Back the
Nut below down the screw before trying to remove the collar. That nut is tight against
the collar.
With the collar removed, take the nut off the top end of the screw.
Disassemble the top bearing assembly. There are screw(s) fixing it to the screw.

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Mark the motor mount location at the bottom of the mast and loosen the motor bolts.
Release the tension on the belt. By loosening the mounting bolts for the motor
assembly.
Take the belt off the pulley on the screw. You can remove the belt if you wish to replace
it. Otherwise, leave it in place.

Remove the lower Screw nut and loosen the bottom bearing assembly screws. There
may be two of them t in the collar of the bearing.
Remove the lower nuts on the screw.
If there is not enough room to remove the screw out through the top of the mast,
remove the M10 socket head screws from the slider caps on each stabilizer block to
expose the screw. If necessary, the entire stabilizer assembly may be removed by
detaching the stabilizer T bar from its three mounting points along its length.
The screw may now be removed in the direction away from the motor. There are slots to
allow you to do this.

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In some units, where overhead clearance is not restrictive, it may be possible to extract
the screw up out of the top of the mast without removing the stabilizer. This is preferable
since the stabilizer will not require adjustment later.

Screw installation:

Assemble the unit in reverse order to that shown above.

Caution: Treat the screw with care and only remove it

from its packaging when it is time to install it. Do not
allow the screw to bend by holding it improperly.
When handling it, support it along its length. The
screw is checked for concentricity before shipping. If
it is bent during installation, this will cause vibration,
noise and damage to the lift. A replacement screw will
then be required.
•
•
• It may be preferable to assemble the Drive Nut and Safety Nut assembly onto the
screw before bringing the screw into place. Remember not to allow the screw to
hang. This will damage it and make it useless.
• Make sure the pulley is in the proper position before installing the screw. The
pulley has a keyway and key that is retained by a setscrew. Make sure this is
tight.
• Before fixing the lower bearing screws to the shaft, tighten the lower end nuts
onto the shaft (don’t forget the washers) until it is hand tight. Then make 1 and
1/2 more turns on the nut to leave the screw slightly tensioned.
• Tighten the screws of the lower bearing collar onto the screw.
• Make sure the bearings are greased.
• When tightening the screw retaining nuts, apply a small amount of tension to the
screw.
• Apply a generous amount of grease to the entire threads of the screw, not just
the travel area.
• Check the operation of the safety switch. It must be adjusted as shown below.

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Make sure the greaser in installed properly and turned on and set to the appropriate
dispensing rate. See Technical Bulletin 2000-007-00.

Call Technical Support at Garaventa if you have questions. 1 800 667 7790

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D RIVE N UT R EPLACEMENT PROCEDURE G ENESIS 2006

Parts required:

• 35106 Drive Nut Assembly (1)

• 12857 Greaser (Recommended) (1)
• 35105 Brass Safety nut. (1)

Procedure:

• Run the lift so that you have access to the drive nut. It is best to run the platform
to the bottom. The back wall must then be removed. It may be necessary to
remove the platform as well.
• Turn off the power and lock it.
• Disassemble the upper top and bottom bearings on the screw. The Drive Nut
cannot be removed without raising Lead screw up high enough to “unscrew the
Safety and Drive Nuts off the end.
• Disconnect the greaser hose to the drive nut and remove the safety switch so
that it is not damaged. CAUTION! The old greaser will continue to produce
grease. Be ready to catch the excess grease. Smear it onto the drive screw.
• Turn the Lead screw so that it ascends above the nuts and their supporting
frames in the cross-member of the carriage.
• Note the distance between the Drive nut and safety nuts is around 6 to 5 mm or
one full turn of the screw. This will have to be checked once the drive nut is back
in place.
• When replacing the Drive Nut, we always replace the Safety Nut as well due to
the inherent work involved.
• Make sure the safety switch is properly positioned so that it will activate if the
drive nut fails.
• Turn the lead screw so that it descends down to its original position.
• Install the new Greaser and turn it on and reset the safety switch to its original
position.
• Put lots of grease onto the threads of the screw.
• Re-assemble the lift and check its operation.
• Return the lift to service.

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G ENESIS L EAD S CREW REMOVAL AND REPLACEMENT
G ENESIS 2006 M ODEL

Important Notes:
Drive screw replacement must include replacement of the Drive Nut,
the Safety Nut, the upper and lower bearing assemblies and the
installation of a new grease canister. Contact Garaventa for a list of
parts required.
In units 96” and greater, the stabilizer system must be removed with
the screw. We recommend that the stabilizer bushings be replaced
where a stabilizer is supplied.
Allow at least one full day (8 hours) and a crew of two Technicians to
complete this procedure.
Have the Genesis spare parts kit, a complete tool kit and the Genesis
Service manual at hand before attempting this work.

Caution:
• Do not work under an unsupported platform.
• Turn off the mains and lock it off before starting.
• Do not wear loose clothing, tool belts, long hair or jewelry while working on
a lift.
• Follow the standard safety procedures.
Removal of the Lead screw from a Genesis 2006 requires that it be
“unscrewed” upwards out of the mast. It is therefore necessary to
have clearance above the mast to allow for this. The top mast cap
must also be removed. You will need at least 300 mm of clearance
above the screw to remove it.
Before beginning, lower the carriage and platform, remove the
Platform mast-side wall, and the mast cover panels. Units that are
accessible behind the mast should have those covers removed to
provide easier access to the mast internals.

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Screw removal:

Note: As you disassemble the screw, look carefully at how the various nuts retaining
collars and washers are assembled onto it. You will have to reassemble these parts
onto the new shaft.
Never allow the screw to hang unsupported this will damage it irreparably.
Operate the lift so that the platform is at the bottom of the mast.
For units that cannot be operated, use the lowering device to bring the platform to the
bottom. Remove the platform walls. If it will help, also remove the platform.
Remove the mast covers and support the carriage so that you can access the Drive nut
assembly easily.

Two setscrews fix

the bearing collar
to the shaft. They
have to be
loosened to
remove the screw
from the bearing.

When installing the

new shaft, tension
the new shaft
slightly before
tightening these
screws

Remove the mast cap look closely at the collar at the very top of the screw. There is a
screw passing through the collar above the upper nut. This must be removed. Back the
Nut below down the screw before trying to remove the collar. That nut is tight against
the collar.
With the collar removed, take the nut off the top end of the screw.
Disassemble the top bearing assembly. There are screw(s) fixing it to the screw.

ITEM #05751 Revision B 13 Garaventa Lift, April 2008

Mark the motor mount location at the bottom of the mast and loosen the motor bolts.
Release the tension on the belt by loosening the mounting bolts for the motor assembly.
Take the belt off the pulley on the screw. You can remove the belt if you wish to replace
it. Otherwise, leave it in place.

Remove the lower Screw nut and loosen the bottom bearing assembly screws. There
may be two of them in the collar of the bearing.
Remove the lower nuts on the screw.
Lift the screw up until it clears the carriage at the bottom and then extract it out the front
of the mast.
In units 96” and greater, the stabilizer system must be removed with the screw. Once
the screw is removed, the stabilizer may be detached.

ITEM #05751 Revision B 14 Garaventa Lift, April 2008

Screw installation:

Assemble the unit in reverse order to that shown above.

Caution: Treat the screw with care and only remove it

from its packaging when it is time to install it. Do not
allow the screw to bend by holding it improperly.
When handling it, support it along its length. The
screw is checked for concentricity before shipping. If
it is bent during installation, this will cause vibration,
noise and damage to the lift. A replacement screw will
then be required.

It may be preferable to assemble the Drive Nut and Safety Nut assembly onto the screw
before bringing the screw into place. Remember not to allow the screw to hang. This will
damage it and make it useless.
Make sure the pulley is in the proper position before installing the screw. The pulley has
a keyway and key that is retained by a setscrew. Make sure this is tight.
Before fixing the lower bearing screws to the shaft, tighten the lower end nuts onto the
shaft (don’t forget the washers) until it is hand tight. Then make 1 and 1/2 more turns on
the nut to leave the screw slightly tensioned.
Tighten the screws of the lower bearing collar onto the screw.
Make sure the bearings are greased.
When tightening the screw retaining nuts, apply a small amount of tension to the screw.

Apply a generous amount of grease to the entire threads of the screw, not just the travel
area.
Check the operation of the safety switch. It must be adjusted as shown below.

ITEM #05751 Revision B 15 Garaventa Lift, April 2008

The new Lead screw and related components in place. Notice the gap between the
safety nut and the support brackets above and below it. The gap (arrowed) between the
lower bracket and the Safety nut is about 5-6 mm.

ITEM #05751 Revision B 16 Garaventa Lift, April 2008

Make sure the greaser in installed properly and turned on and set to the appropriate
dispensing rate. See Technical Bulletin 2000-007-00.

Call Technical Support at Garaventa if you have questions. 1 800 667 7790

ITEM #05751 Revision B 17 Garaventa Lift, April 2008

C Y L INDER H EAD /S EAL REPLACEMENT
WARNING! Follow these instructions carefully:
Replacement of Cylinder Head/seal requires removal of the entire cylinder/ram
from the lift and work to be done in a clean environment to prevent dirt and
other contaminants from getting into the hydraulic system. Keep the work
area clean. Damage to the cylinder caused by contamination is not covered by
warranty.
Do not damage the cylinder or ram during the disassemble stage of this
procedure. Damage to the Cylinder or ram due to improper handling is not
covered by warranty.
Replacement of the cylinder Head/Seal:
• Run the platform to the bottom and remove the platform mast-side walls
• Disconnect and lock off the mains and battery supply
• Drain the hydraulic oil. Do not allow it to spill.
• Disconnect the hydraulic fittings to the cylinder.
• Remove entire cylinder and ram assembly from the mast.
• Bring the assembly to a clean area where you can work on the cylinder/ram
assembly.
• Remove the cylinder head and ram from the cylinder.
• Remove the piston from the bottom end of the ram.
• Remove the Head/Seal assembly from the ram. You must pull the seal off the
bottom end of the ram (the end that the piston was attached)
• Install the new Head/Seal onto the ram. Be sure that the threaded end is towards
the piston end.
• Re-install the piston onto the bottom end of the ram. Use a small amount of
serviceable Lock-tite to lock the fastener.
• Re-install the ram and cylinder Head/Seal into the cylinder.
• Re-install the cylinder into the mast.
• Reconnect the hydraulic lines
• Refill the reservoir with clean hydraulic oil.
• Bleed the cylinder.

ITEM #05751 Revision B 18 Garaventa Lift, April 2008

G EN ESIS 2006 H YRAULIC L OWERING VALVE
R EPL ACEMENT:
• Ensure the work area is kept clean
• Ensure you have lots of rags ready to catch any oil spillage.
• Raise the platform above you.
• Install shoring pin into the mast or use some other form of appropriate platform
shoring tool.
• Make sure that you have access to the pump assembly and then turn off the lift.
• Close off the hydraulic system by turning the handle on the valve.
• Remove the emergency lowering cable connection at the valve.
• Remove the bracket for the emergency lowering connection. This bracket is
attached to the mast cross-member and to the pump casting with two 13mm
bolts and is located on the right hand side of the pump.
• Remove the outer retaining collar valve on the valve solenoid by hand. Be
careful to observe the position of the O rings on the valve stem and the
orientation of the retaining collar. There is an O ring under the collar and one at
the base of the coil when it is removed. The collar threads are standard right-
hand threads. You should be able to remove it WITHOUT the use of a tool.
• Once this collar is removed, the Valve solenoid coil (black plastic) can be
removed. Don’t forget to disconnect the wires attached to it.
• Use a 24 mm deep socket (very deep to reach the 65 mm to the nut) or a 24mm
open-end angled wrench to undo and remove the valve body nut. Remove the
valve.
• Insert the magnet supplied with the valve into tank, install the new valve and
complete the reassembly using the reverse procedure.
• We recommend flushing and replacing the oil in the tank before running the lift
with a new valve.
• Test the lift, clean up any oil spillage and return the unit to service.

• Description Part Number Qty

• Magnet 15799 1
• Valve 35376 1

• Recommended oil for the lift is AW 32 weight hydraulic oil.

ITEM #05751 Revision B 19 Garaventa Lift, April 2008

G ENESIS I H YRAULIC L OWERING VALVE R EPL ACEMENT:

• Ensure the area is kept clean

• Have lots of rags ready to catch oil spillage.
• Gain access to the pump assembly and turn off the lift.
• Install shoring pin
• Remove emergency lowering connection at the valve
• Remove bracket for emergency lowering connection
• Use a 16mm wrench to remove the nut holding the valve cover in place and
remove the valve cover (black plastic)
• Use a 22mm deep socket or a 22mm open-end wrench to undo and remove the
valve body nut. Remove the valve.
• Insert magnet into tank, install the new valve and complete using the reverse
procedure.

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R EPLACING HARDWARE IN AN INTERNAL DOOR CLOSER .

• Insert a small screwdriver or nail into the extra hole in the connecting bar
protruding from the door.
• Allow the closer to retract to take the tension off the connection in the frame.
• Release the connecting bolt in the door frame.
• Loop wire through the hole after removing the connecting bolt.
• Put tension on the wire and remove the screwdriver or nail from the extra hole in
the bar.
• Allow the closer to retract until it is no longer in tension. Do not let go of the wire,
it will be used to retrieve the closer once it is disconnected at it’s inner end.
• Undo the one screw on the lower side (front) of the mid-way cross rail.
• Pull the closer out of the side hole.
• Change the hard ware on the end to the new cylinder.
• Reverse the above steps.

ITEM #05751 Revision B 21 Garaventa Lift, April 2008

L ATCH B LOCK U PGRADE (A PRIL 2008)

On a small number of Genesis Vertical Platform Lifts with mechanical locks, the locks
have jammed in a position that allows the platform to move away from a landing even
though the door or gate is not properly locked. Should the platform be moved away
from the upper landing when this occurs, the upper door or gate may be opened
creating a potential falling hazard. Although the likelihood of this problem occurring is
small, the following repair is recommended. This does not pertain to OPAL.

Affected Product
This notice pertains to Genesis lifts equipped with mechanical locks shipped during the
past year - from January 2007 to February 2008 and was a part of a general safety
bulletin. It is added to this manual as a reference document. At the time of release,
each dealers received a list of affected lifts in their territory, along with the appropriate
number of parts kits. This notice does not pertain to OPAL. Subsequent to this notice,
the lock design changed.

The Problem
During normal operation of the Genesis mechanical lock, a vertical pin located inside
the doorframe drops through a horizontal hole in the latch block that is mounted on the
escutcheon plate on the door. As the lift leaves the landing, the pin passes through the
hole in the latch block, thus locking the door. A supervisory switch ensures this pin has
moved into the correct locking position before the lift will operate. As well, a magnetic
proximity switch in the doorframe monitors the position of the door. The lift will not
operate if the door is open.
A problem may occur if the lift starts to travel when the door is slightly open but the
magnetic proximity switch is indicating the door is closed. This slight opening could
occur if the door bounces after closing or if wind affects the closing position. Slight
variations in door spacing and magnetic strength affect the door proximity switch
accuracy range. When these conditions occur together they may allow the lift to travel
away from the station with the latch block slightly out of position. In an extreme case,
the corner of the pin spacer bar snags corner of the locking block, simulating a locked
door even though the pin has not passed through the hole in the bolt. In this case the
platform could travel away from the station with the door closed but not properly locked.
A tug on the door could release the jammed block allowing the door to open.

See photos on next page for further explanation.

ITEM #05751 Revision B 22 Garaventa Lift, April 2008

 Locking Pin
is through
Latch Latch Block
Block Pin
Spacer
Bar

Latch Latch
Block Block

Latch block is mounted
to escutcheon plate on
door. Block moves
inside doorframe when
In this photo, the locking In this photo, the door is
pin has correctly passed slightly open. The latch
through hole in the latch block has jammed on the
block, locking the door. edge of the pin spacer bar
The supervisory switch (red circle). The pin is not
will allow the lift to through the latch block but
operate. is in the correct height

The Solution

This problem can be corrected by replacing the

current latch block with a new block with a
chamfered (rounded) edge. See photo. The new
design eliminates the possibility of jamming. This
changeover process takes only a few minutes for
each door or gate. The new design is being used
on new production units.

Note: This correction will not prevent the lift from New latch block with
stopping after two inches of travel if the platform chamfered (rounded)
moves away from the station without the door edge. This prevents
being properly locked. This is how the safety jamming. The side of
system is designed to operate. While this situation the block with the
may be inconvenient for the user it does not create chamfered edge and
a serious safety hazard. There are ways to chamfered hole must
minimize the likelihood of this occurring. This is not face the end of the
the subject of this safety notice and will be dealt locking pin when
with in a separate technical bulletin in the near future.

ITEM #05751 Revision B 23 Garaventa Lift, April 2008

Lock Upgrade Kits

If required, the lock Upgrade Kit consists of a pair of the new chamfered interlock latch
blocks, a small tube of thread lock liquid and installation instructions. One kit is required
for each unit (if affected).

Dealer Action Required

1. If you are required to complete this repair, please contact Garaventa Technical
Support and inform us so that we can update our records.
Instructions
Tools Required:
9 3 mm Allen key
9 Phillips screwdriver
Upgrade Kit Contents:
9 2 X new chamfered (rounded) latch blocks
9 1 X tube of Loctite
Installation Procedure:
• Open lower door and remove the screws holding the escutcheon plate to the
doorframe, apply Loctite, and reinstall the plate. Tighten securely.
• Remove the latch block from the escutcheon plate. Save the fasteners for
installation of the new block. Discard the old block.
• Apply Loctite to the fasteners and install the new block to the door escutcheon
plate.
• Ensure the rounded edge of the block and funnel-shaped side of the hole are
facing towards the end of the locking pin. This means the rounded edge and
funnel-shaped hole face down at the lower landing and face up at the upper
landing.
• Adjust the position of the block so the locking pin is approximately centered in the
hole in the block and tighten.
• Test the locking function several times by operating the platform away from the
landing. Try operating the lift with the door open slightly to confirm the locking
pin assembly cannot jam on the lock block as the platform leaves the landing.
This should not be possible with the new block design.
• Repeat the process with the upper landing / gate.

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