Genie Super Tower ST-20 Quick start guide

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
ii
Contact Us:
www.genieindustries.com
e-mail:[email protected]
Copyright © 1994 by Genie Industries
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
N/A
100 lb / 445 kg
2
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
iv

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 .
v

November 2005
Genie SuperTower Part No.32951
vi
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November 2005
Part No.32951 Genie Super Tower
Table of Contents
vii
Introduction
ImportantInformation ..................................................................................................
ii
How to Read Your Serial Number .............................................................................. iii
Recommended Parts Stocking List ............................................................................ ix
How To Order Parts ................................................................................................... x
Service Parts Fax Order Form ................................................................................... xi
Section 1 Safety Rules
General Safety Rules ................................................................................................. iv
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
ix
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 [phone]
Toll Free [phone] in U.S.A. and Canada
Fax [phone]
Genie UK
Parts Telephone (44) (0) 1476 584352
Parts Fax (44) (0) 1476 584340
Genie Australia
Parts Telephone [phone]
Parts Fax [phone]
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
x

November 2005
Part No.32951 Genie Super Tower
remove this page and make copies
Part Number Description Quantity Price
All back-ordered parts will be shipped when available via the same ship method as the original order
unless Noted below:
Ship complete order only - No back orders
Ship all available parts and contact customer on disposition of back-ordered parts
Other (please specify)
Please fill out completely
Date _________________________________ Account Number _______________________________
Your Name_______________________________ Your Fax Number ______________________________
_________________________________ Your Phone Number ____________________________
Bill To _________________________________ Ship To ___________________________________
_________________________________ ___________________________________
_________________________________ ___________________________________
_________________________________ ___________________________________
Purchase Order Number ____________________ Ship Via ___________________________________
Model(s) ______________________________________________________ Serial No.(s) _________________
Optional Equipment __________________________________________________________________________
FOR GENIE INDUSTRIES USE ONLY
Order Number ______________ Origin Code ________________ Comments _________________________
Date Scheduled ____________ Ship Condition______________ __________________________________
Order Total ________________ Terms Code________________ __________________________________
Service Parts Fax Order Form
Fax to: [phone] or Toll Free: 888-274-6192
International: [phone]
remove this page and make copies

November 2005
Genie SuperTower Part No.32951

Part No.32951 Genie Super Tower 2 - 1
November 2005 Section 2 • Specifications
Specifications
Model ST-20 ST-25
Height-Stowed 783/4in 783/4in
200 cm 200 cm
Width-Stowed 22 in 22 in
56 cm 56 cm
Length-Stowed 251/4in 251/4in
64 cm 64 cm
Length-Operating 813/4in 813/4in
208 cm 208 cm
Ground 2 in 2 in
Clearance 50.8 mm 50.8 mm
Outrigger 813/4in 813/4in
Footprint 208 cm 208 cm
Load Capacity 800 lbs 650 lbs
at 18" load center 363 kg 295 kg
Net Weight 437 lbs 476 lbs
198 kg 216 kg
Dimensions ST-20 ST-25
Adjustable Forks
forks down 19 ft 6 in 24 ft 4 in
6 m 7.4 m
forks up 21 ft 21/2in 26 ft 1/2in
6.5 m 7.9 m
Load Handling
Attachment L x W x D Net Weight
Adjustable Forks
271/2x 111/2 to 30 x 21/2in 52.5 lbs
70 x 29 to 76 x 6.5 23.8 kg
REV A

2 - 2 Genie SuperTower Part No.32951
November 2005Section 2 • Specifications
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Part No.32951 Genie SuperTower 3 - 1
November 2005 Section 3 • Scheduled Maintenance Procedures
Observe and Obey:
Maintenance procedures shall be completed by
a person trained and qualified on the
maintenance of this machine.
Scheduled maintenance procedures shall be
completed daily, quarterly and annually as
specified on the maintenance inspection report.
Failure to properly complete each
inspection when required could
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.
Be sure the capacities of sawhorses or other
supports are sufficient to withstand machine
weight. See Specifications section for the
machine weight.
Be sure overhead cranes or other lifting devices
are of ample capacity to handle machine
weight. See Specifications section for machine
weight.
Unless otherwise specified, perform each
procedure with the machine in the following
configuration:
· Machine positioned on a firm, level surface
· Carriage fully lowered
· Casters locked
· Load handling attachment installed
Scheduled Maintenance Procedures
AboutThis 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.
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
presence of a potentially
hazardous situation which, if not
avoided, may result in property
damage.
Green—used to indicate operation
or maintenance information.
Indicates that a specific result is expected after
performing a series of steps.

3 - 2 Genie SuperTower Part No.32951
November 2005Section 3 • Scheduled Maintenance Procedures
Maintenance Symbols Legend
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.
SCHEDULED MAINTENANCE PROCEDURES
Pre-delivery Preparation Report
The pre-delivery preparation report contains
checklists for each type of scheduled inspection.
Make copies of the Pre-delivery Preparation
Report to use for each inspection. Store completed
forms as required.
Maintenance Schedule
There are three types of maintenance inspections
that must be performed according to a schedule—
daily, quarterly and annual. The Scheduled
Maintenance Procedures Section and the
Maintenance Inspection Report have been divided
into three subsections—A, B and C. 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 250 hours A + B
Annual or every 1000 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 Report
to use for each inspection. Store completed forms
for three years.

Part No.32951 Genie SuperTower 3 - 3
November 2005 Section 3 • Scheduled Maintenance Procedures
Genie Industries USA
18340 NE 76th Street
PO Box 97030
Redmond, WA 98073-9730
[phone]
Copyright © 2002 by Genie Industries. Genie® is a registered trademark of Genie
Industries. Rev A
Genie UK
The Maltings, Wharf Road
Grantham,Lincolnshire
NG31- 6BH England
(44)1476-584333
Pre-DeliveryPreparation Y N R
Pre-operationinspection
completed
Maintenance items completed
Function tests completed
Model
Serial number
Date
Machine owner
Inspected by (print)
Inspector signature
Inspector title
Inspector company
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, completed
N = no, unable to complete
R = repaired
Comments
Pre-DeliverPre-Deliver
Pre-DeliverPre-Deliver
Pre-Delivery Preparationy Preparation
y Preparationy Preparation
y Preparation
Fundamentals
It is the responsibility of the 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'sspecifications.
Scheduled maintenance inspections shall be
performed by qualified service technicians, according
to the manufacturer's specifications and the
requirements listed in the responsibilities manual.

3 - 4 Genie SuperTower Part No.32951
November 2005Section 3 • Scheduled Maintenance Procedures
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Part No.32951 Genie SuperTower 3 - 5
November 2005 Section 3 • Scheduled Maintenance Procedures
Checklist C - Rev B YNR
C-1 Casters and wheels
C-2 Inspect the Mast
Assembly for Wear
C-3 Friction Disks
C-4 Brake System
C-5 Inspect the
painted surfaces
Maintenance Inspection Report
Model
Serial number
Date
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 to be
performed.
Daily or 8 hour
Inspection: A
Quarterly or 250 hour
Inspection: A+B
Annual or 1000 hour
Inspection: 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
Comments
Checklist A - Rev B Y N R
A-1 Pre-Operation
Inspection
A-2 Function
Tests
Checklist B - Rev B YNR
B-1 Inspect All Welds
B-2 Clean the Columns
B-3 Winch operation
B-4 Inspect / Lubricate
winch

3 - 6 Genie SuperTower Part No.32951
November 2005Section 3 • Scheduled Maintenance Procedures
REV B
A-1
Perform Pre-operation Inspection
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.
Checklist A Procedures
A-2
Perform Function Tests
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.