Genie Super Tower User manual

Service Manual
Serial Number Range
Super Tower
from 7794-101 to 7702-1600
from ST02-
1601 to
ST16-
4786
from ST16G-4787 to
ST16G-
6899
from STG-6900
Part No. 115411
Rev A1
September 2016

Service Manual September 2016
Introduction
ii Super Tower Part No. 115411
Intr oduct io n Intr oduct io n
Impor tant Inf ormati on
Important
Read, understand and obey the safety rules and
operating instructions in the appropriate Operator's
Manual on your machine before attempting any
maintenance procedure.
This manual provides detailed scheduled
maintenance information for the machine owner
and user. It also provides troubleshooting and
repair procedures for qualified service
professionals.
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 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.
Contact Us:
Internet: www.genielift.com
E-mail: [e-mail]
Serial Number Information
Genie Industries offers the following Service
Manuals for this model:
Title
Part No.
Genie Super Tower Parts and Service Manual,
First Edition (from serial number 7794-00101 to
7702 to 01600) and (from
ST02-1601............................................32951
*Note: Genie Super Tower Service Manual
115411 and Genie Super Tower Part's Manual
115412 replaces Genie Super Tower Parts and
Service Manual 32951.
Find a Manual for this Model
Go to http://www.genielift.com
Use the links to locate Service Manuals,
Maintenance Manuals, Service and Repair
Manuals, Parts Manuals and Operator's Manuals.
Copyright © 1994 by Genie Industries
115411 Rev A, February 2009
Second Edition, First Printing
'Genie'' and "Super Tower" are registered trademarks of Terex
South Dakota. in the U.S.A. and many other countries.

September 2016 Service Manual
Introduction
Part No. 115411 Super Tower iii
RevisionHistory
Revision History
Revision
Date
Section
Procedure / Page / Description
A 2/2009 Initial Release
A1 9/2016 Introduction Serial Number Legend
Reference Examples:
Section – Maintenance, B-3 Electronic Version
Click on any content or procedure in the Table of Contents to view
the update.
Section – Repair Procedure, 4-2
Section – Fault Codes, All charts
Section – Schematics, Legends and schematics

Service Manual September 2016
Introduction
iv Super Tower Part No. 115411
Serial Number Legend
To August 31,
2016
1 Model
2 Model year
3 Facility code
4 Sequence number
5 Serial number (stamped on base)
6 Serial label (located on base)
From September 1, 2016
1 Model
2 Facility code
3 Sequence number
4 Serial number (stamped on base)
5 Serial label (located on base)

September 2016 Service Manual
Safety Rules
Part No. 115411 Super Tower v
Section 1 Safet y Rul es
Gener al Safety R ules
Gener al Safet y Rul es
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.
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.

Service Manual September 2016
Safety Rules
vi Super Tower Part No. 115411
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.
Indicates a imminently hazardous
situation which, if not avoided, will
result in death or serious injury.
Indicates a potentially hazardous
situation which, if not
avoided,
could result in death or serious
injury.
Indicates a potentially hazardous
situation which, if not avoided,
may cause minor or moderate
injury.
Indicates a potentially hazardous
situation which, if not avoided,
may result in property damage.
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
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.
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 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 o
r
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.
Be sure that your workshop or work area
is properly ventilated and well lit.

September 2016
Table of Contents
Part No. 115411 Super Tower vii
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
General Safety Rules.............................................................................................v
Section 2 Specifications.......................................................................................................1
Specifications .........................................................................................................1
SAE and Metric Fasteners Torque Charts.............................................................2
Section 3 Scheduled Maintenance Procedures .................................................................3
Introduction.............................................................................................................3
Pre-Delivery Preparation Report............................................................................6
Maintenance Inspection Report .............................................................................8
Checklist A Procedures.....................................................................................10
A-1 Inspect the Manuals and Decals ...................................................................10
A-2 Perform Pre-operation Inspection..................................................................11
A-3 Perform Function Tests .................................................................................11
Checklist B Procedures.....................................................................................12
B-1 Inspect All Welds...........................................................................................12
B-2 Clean the Columns........................................................................................12
B-3 Check the Winch Operation...........................................................................13
B-4 Inspect the Carriage Hold-down Bar .............................................................13
B-5 Inspect and Lubricate the Winch...................................................................14

September 2016
Table of Contents
viii Super Tower Part No. 115411
Checklist C Procedures..................................................................................... 15
C-1 Inspect the Mast Assembly for Wear ...........................................................15
C-2 Inspect the Safety Brake System (if equipped).............................................16
C-3 Replace the Winch Friction Disks .................................................................18
C-4 Replace the Winch Friction Disks .................................................................18
C-5 Lubricate the Casters and Wheels................................................................19
C-6 Inspect the Painted Surfaces........................................................................19
Section 4 Repair Procedures............................................................................................. 20
Base Assembly...................................................................................................21
1-1 How to Remove the Base..............................................................................21
Mast Assembly................................................................................................... 22
2-1 How to Disassemble the Mast Assembly ......................................................22
Cable Routing ......................................................................................................25
2-2 Lifting Cable...................................................................................................26
2-3 Lifting Pulley...................................................................................................28
Winches .............................................................................................................. 29
3-1 One-speed Winch..........................................................................................29
3-1 One-speed Winch..........................................................................................29
One-speed Winch Assembly - ANSI....................................................................31
3-1 Two-speed Winch..........................................................................................33
Two-speed Winch Assembly................................................................................35

September 2016 Service Manual
Specifications
Part No. 115411 Super Tower 1
Section 2 Speci ficati ons
Speci ficati ons
Model
ST-20 ST-25
Height
-Stowed 78.8 in 78.8 in
200 cm 200 cm
Width
-Stowed 22 in 22 in
56 cm 56 cm
Length
-Stowed 25.3 in 25.3 in
64 cm 64 cm
Length
-Operating 81.1 in 81.8 in
208 cm 208 cm
Ground Clearance
2 in 2 in
5.1 cm 5.1 cm
Outrigger Footprint
81.8 in 81.8 in
208 cm 208 cm
Load Capacity
800 lbs 650 lbs
at 18" load center
363 kg 295 kg
Load Capacity
733 lbs 583 lbs
at 20" load
center 332 kg 264 kg
Load Capacity
667 lbs 517 lbs
at 22" load center
303 kg 235 kg
Load Capacity
600 lbs 450 lbs
at 24" load center
272 kg 204 kg
Net Weight
507 lbs 555 lbs
230 kg 252 kg
Dimensions
ST-20 ST-25
Standard Forks
forks down
19 ft 6 in 24 ft 4 in
5.9 m 7.4 m
forks up
21 ft 2.5 in 26 ft 0.5 in
6.5 m 7.9 m
Adjustable Forks
forks down
24 ft 4 in 24 ft 4 in
7.4 m 7.4 m
forks up
26 ft 0.5 in 26 ft 0.5 in
7.9 m 7.9 m
Load Handling
Attachment
L x W x D Net Weight
Adjustable
Forks
27.
5 x 11.5 to 30
x
2.5 in 52.5 lbs
70 x 29 to 76 x
6.4 cm 23.8 kg
Standard Forks
30 x 2 x 3 in 4.5 lbs
76.2 x 5.1 x
7.6 cm 2 kg
76.2 x 5.1 x
7.6 cm 2 kg
Continuous improvement of our products is a
Genie policy. Product specifications are
subject to change without notice.

Service Manual September 2016
Specifications
2 Super Tower Part No. 115411
SAE and M etr ic F as te ners Tor qu e C har ts

September 2016 Service Manual
Scheduled Maintenance Procedures
Part No. 115411 Super Tower 3
Section 3 Sche duled Mai nten ance Pr oced ures
Intr oduct io n
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
. The frequency and extent of periodic
examinations and tests may also depend on
national regulations.
Fail
ure to perform each
procedure as presented and
scheduled may cause death,
serious injury or substantial
damage.
Immediately tag and remove from service a
damaged or malfunctioning machine.
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.
Unless otherwise specified, perform each
procedure with the machine in the following
configuration:
•Machine parked on a firm, level surface
•Carriage fully lowered
•Casters locked
•Load handling attachment installed
About This Section
This section contains detailed procedures for each
scheduled maintenance inspection.
Each procedure includes a description, safety
warnings and step-by-step instructions.
Symbols Legend
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.
Indicates a imminently hazardous
situation which, if not avoided, will
result in death or serious injury.
Indicates a potentially hazardous
situation which, if not avoided,
could result in death or serious
injury.
Indicates a potentially hazardous
situation whic
h, if not avoided,
may cause minor or moderate
injury.
Indicates a potentially hazardous
situation which, if not avoided,
may result in property damage.
Indicates that a specific result is expected
after performing a series of steps.
Indicates that an incorrect result has occurred
after performing a series of steps.

Service Manual September 2016
Scheduled Maintenance Procedures
4 Super Tower Part No. 115411
Maintenance Symbols Legend
Note: The following symbols have been used in this
manual to help communicate the intent of the
instructions. When one or more of the symbols
appear at the beginning of a maintenance
procedure, it conveys the meaning below.
Indicates that tools will be required to
perform this procedure.
Indicates that new parts will be required to
perform this procedure.
Indicates that dealer service will be
required
to perform this procedure.
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. Use the following chart to
determine which group(s) of procedures are
required to perform a scheduled inspection.
Inspection
Checklist
Daily or
every 8 hours
A
Quarterly or every 25
0 hours
A + B
Annually or every 100
0 hours
A + B + C
Maintenance Inspection Report
The maintenance inspection report contains
checklists for each type of scheduled inspection.
Make copies of the
Maintenance Inspection Repor t
to use for each inspection. Maintain completed
forms for a minimum of 4 years or in compliance
with your employer, jobsite and governmental
regulations and requirements.

September 2016 Service Manual
Part No. 115411 Super Tower 5
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Service Manual September 2016
Pre-Delivery Preparation Report
Pre-Deli v ery Pre par ati on R epor t
Fundamentals
It is the responsibility of the owner or dealer to
perform the Pre-delivery Preparation.
The Pre-delivery Preparation is performed prior to
each delivery. The inspection is designed to
discover if anything is apparently wrong with a
machine before it is put into service.
A damaged or modified machine must never be
used. If damage or any variation from factory
delivered condition is discovered, the machine
must be tagged and removed from service.
Repairs to the machine may only be made by a
qualified service technician, according to the
manufacturer's specifications.
Scheduled maintenance inspections shall be
performed by qualified service technicians,
according to the manufacturer's specifications and
the requirements listed in the responsibilities
manual.
Instructions
Use the operator’s manual on your machine.
The Pre-delivery Preparation consists of
completing the Pre-operation Inspection, the
Maintenance items and the Function Tests.
Use this form to record the results. Place a check in
the appropriate box after each part is completed.
Follow the instructions in the operator’s manual.
If any inspection receives an N, remove the
machine from service, repair and re-inspect it. After
repair, place a check in the R box.
Legend
Y = yes, acceptable
N = no, remove from service
R = repaired
Comments
Pre-delivery Preparation
Y
N
R
Pre
-operation inspection completed
Maintenance items completed
Function tests completed
Model
Serial number
Date
Machine owner
Inspected by (print)
Inspector signature
Inspector title
Inspector company

September 2016 Service Manual
Part No. 115411 Super Tower 7
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Service Manual September 2016
Maintenance Inspection Report
8 Super Tower Part No. 115411
Maint ena nc e Ins pec tio n Re port
Model
Serial number
Date
Hour meter
Machine owner
Inspected by (print)
Inspector signature
Inspector title
Inspector company
Instructions
•Make copies of this report to use for
each inspection.
•Select the appropriate checklist(s) for
the type of inspection(s) to perform.
Daily or every
8 hours A
Quarterly or every
25
0 hours A + B
Annually or every
100
0 hours
A + B + C
•Place a check in the appropriate box
after each inspection procedure is
completed.
•Use the step-by-step procedures in
this section to learn how to perform
these inspections.
•If any inspection receives an "N," tag
and remove the machine from service,
repair and re-inspect it. After repair,
place a check in the "R" box.
Legend
Y = yes, acceptable
N = no, remove from service
R = repaired
Checklist A- Rev A Y N R
A-1 Inspect the manuals
and decals
A-2 Pre-operation
inspection
A-3 Function tests
Checklist B Y N R
B-1 Welds
B-2 Clean columns
B-3 Winch operation
B-4 Carriage hold down
bar
B-5 Inspect and lubricate
winch
Comments
Checklist C- Rev A Y N R
C-1 Mast assembly wear
C-2 Safety brake system
(if equipped)
C-3 Replace winch friction
disk
C-4 Inspect cable and
pulleys
C-5 Lubricate the casters
and wheels
C-6 Painted surfaces
Comments

September 2016 Service Manual
Part No. 115411 Super Tower 9
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Service Manual September 2016
Checklist A Procedures
10 Super Tower Part No. 115411
Chec klist A Pro cedur es
A-1 Ins pec t th e M anu als and D ec als
A-1
Inspect the Manuals and Decals
Genie specifications require that this procedure be
performed every 8 hours or daily, whichever comes
first.
Maintaining the operator’s and safety manuals in
good condition is essential to safe machine
operation. Manuals are included with each
machine and should be stored in the container
provided in the platform. An illegible or missing
manual will not provide safety and operational
information necessary for a safe operating
condition.
In addition, maintaining all of the safety and
instructional decals in good condition is mandatory
for safe machine operation. Decals alert operators
and personnel to the many possible hazards
associated with using this machine. They also
provide users with operation and maintenance
information. An illegible decal will fail to alert
personnel of a procedure or hazard and could
result in unsafe operating conditions.
1 Check to make sure that the operator's, safety
and responsibilities manuals are present and
complete in the storage container on the
platform.
2 Examine the pages of each manual to be sure
that they are legible and in good condition.
Result: The operator's manual is appropriate
for the machine and all manuals are legible
and in good condition.
Result: The operator's manual is not
appropriate for the machine or all manuals are
not in good condition or is illegible. Remove
the machine from service until the manual is
replaced.
3 Open the operator's manual to the decals
inspection section. Carefully and thoroughly
inspect all decals on the machine for legibility
and damage.
Result: The machine is equipped with all
required decals, and all decals are legible and
in good condition.
Result: The machine is not equipped with all
required decals, or one or more decals are
illegible or in poor condition. Remove the
machine from service until the decals are
replaced.
4 Always return the manuals to the storage
container after use.
Note: Contact your authorized Genie distributor or
Genie if replacement manuals or decals are
needed.

September 2016 Service Manual
Checklist A Procedures
Part No. 115411 Super Tower 11
A-2 Per for m Pre-oper ati on I ns pecti on
A-2
Perform Pre-operation Inspection
Genie specifications require that this procedure be
performed every 8 hours or daily, whichever comes
first.
Completing a Pre-operation Inspection is essential
to safe machine operation. The Pre-operation
Inspection is a visual inspection performed by the
operator prior to each work shift. The inspection is
designed to discover if anything is apparently
wrong with a machine before the operator performs
the function tests. The Pre-operation Inspection
also serves to determine if routine maintenance
procedures are required.
Complete information to perform this procedure is
available in the appropriate operator's manual.
Refer to the Operator's Manual on your machine.
A-3 Perf orm Fu nction T ests
A-3
Perform Function Tests
Genie specifications require that this procedure be
performed every 8 hours or daily, whichever comes
first.
Completing the function tests is essential to safe
machine operation. Function tests are designed to
discover any malfunctions before the machine is
put into service. A malfunctioning machine must
never be used. If malfunctions are discovered, the
machine must be tagged and removed from
service.
Complete information to perform this procedure is
available in the appropriate operator's manual.
Refer to the Operator's Manual on your machine.

Service Manual September 2016
Checklist B Procedures
12 Super Tower Part No. 115411
Chec klist B P roced ure s
B-1 Insp ect AllW elds
B-1
Inspect All Welds
Genie specifications require that this procedure be
performed every 250 hours or quarterly, whichever
comes first.
Weld inspections are essential to safe machine
operation and good machine performance. Failure
to locate and repair damage may result in an
unsafe operating condition.
1 Visually inspect the welds in the following
locations:
•Winch mounting plate
•Loading wheels/steer handle
•Base
•Legs and stabilizers
•Load handling attachment(s)
B-2C l ean the C olum ns
B-2
Clean the Columns
Genie requires that this procedure be performed
every 250 hours or quarterly, whichever comes
first.
Clean columns are essential to good machine
performance and safe operation. Extremely dirty
conditions may require that the columns be
cleaned more often.
1 Raise all columns to full height.
2 Visually inspect the inner and outer channels
of the columns for debris or foreign material. If
necessary, use a mild cleaning solvent to
clean the columns.
Bodily injury hazard. This
procedure will require the use of
additional access equipment.
Do not place ladders or scaffold
on or against any part of the
machine. Performing this
procedure without the proper
skills and tools could result in
death or serious injury. Dealer
service is strongly
recommended.