Genie Super Tower ST-20 Parts & Service Manual
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Genie Super Tower ST-20 Parts & Service Manual

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See also: Operator's Manual
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)

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Summary of Contents for Genie Super Tower ST-20

  • Page 1 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)
  • Page 2 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.

  • Page 3: How To Read Your Serial Number

    Model year Country of manufacture: USA Facility code This machine complies with: used only for model manufactured ANSI A92.6-1999 in multiple facilities B354.2-01 Genie Industries 18340 NE 76th Street Redmond, WA 98052 PN - 77055 Part No. 32951 Genie Super Tower...
  • Page 4 November 2005 Safety Rules 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.
  • Page 5 Green—used to indicate operation may fail if they are used a second time. or maintenance information. Be sure to properly dispose of old oil or other fluids. Use an approved container. Please be environmentally safe . Part No. 32951 Genie Super Tower...
  • Page 6 November 2005 This page intentionally left blank. Genie Super Tower Part No. 32951...

  • Page 7: Table Of Contents

    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 Part No. 32951 Genie Super Tower...
  • Page 8 Mast Components, Pulleys and Cables ..............8 - 8 Figure 8-E Winch Components, One-speed ................. 8 - 10 Figure 8-F Winch Components, Two-speed ................. 8 - 12 Section 9 Accessories Figure 9-A Adjustable Forks ....................9 - 2 viii Genie Super Tower Part No. 32951...
  • Page 9 The following parts are required to perform maintenance procedures as outlined in the Genie Genie Gray Paint, 12 Ounce / 355 ml Aerosol ..1268 Super Tower Parts and Service Manual. Genie Blue Paint, 12 Ounce / 355 ml Aerosol ..1484 Description Part No.

  • Page 10: How To Order Parts

    November 2005 How To Order Parts Please be prepared with the following information Genie North America when ordering replacement parts for your Genie Telephone (425) 556-6551 product: Toll Free (877) 367-5606 in U.S.A. and Canada Machine model number Fax (425) 556-8659...

  • Page 11: Service Parts Fax Order Form

    Ship all available parts and contact customer on disposition of back-ordered parts Other (please specify) ENIE NDUSTRIES Order Number ______________ Origin Code ________________ Comments _________________________ Date Scheduled ____________ Ship Condition ______________ __________________________________ Part No. 32951 Genie Super Tower Order Total ________________ Terms Code ________________ __________________________________...

  • Page 12: Genie Super Tower Part

    November 2005 Genie Super Tower Part No. 32951...

  • Page 13: Adjustable Forks

    23.8 kg Outrigger 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 Part No. 32951 Genie Super Tower 2 - 1...
  • Page 14 Section 2 • Specifications November 2005 This page intentionally left blank. 2 - 2 Genie Super Tower Part No. 32951...
  • Page 15 Indicates that a specific result is expected after · Machine positioned on a firm, level surface performing a series of steps. · Carriage fully lowered · Casters locked · Load handling attachment installed Part No. 32951 Genie Super Tower 3 - 1...

  • Page 16: Pre-Delivery Preparation Report

    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. 3 - 2 Genie Super Tower Part No. 32951...
  • Page 17 PO Box 97030 Grantham, Lincolnshire Redmond, WA 98073-9730 NG31- 6BH England Part No. 32951 Genie Super Tower 3 - 3 (425) 881-1800 (44) 1476-584333 Copyright © 2002 by Genie Industries. Genie® is a registered trademark of Genie Industries. Rev A...
  • Page 18 Section 3 • Scheduled Maintenance Procedures November 2005 This page intentionally left blank. 3 - 4 Genie Super Tower Part No. 32951...

  • Page 19: Maintenance Inspection Report

    After repair, place a check in the “R” box. Legend Y = yes, acceptable N = no, remove from service R = repaired Comments Part No. 32951 Genie Super Tower 3 - 5...

  • Page 20: B Checklist A Procedures

    Complete information to perform this procedure is Refer to the Operator's Manual on your machine. available in the appropriate operator's manual. Refer to the Operator's Manual on your machine. 3 - 6 Genie Super Tower Part No. 32951...

  • Page 21: Checklist B Procedures

    Performing this procedure without the proper skills and tools could result in death or serious injury. Dealer service is strongly recommended. Part No. 32951 Genie Super Tower 3 - 7...

  • Page 22: Check The Winch Operation

    Do not apply grease to brake friction disks or rachet gear. 2 Carefully lubricate both pivot points on each ratchet pawl with 30W oil. 3 - 8 Genie Super Tower Part No. 32951...
  • Page 23 3.1 mm 5 Lubricate the surface of the frame drum spacer with a thin layer of lithium grease. Tighten the drum bolt to 20 ft-lbs / 27 Nm. Do not overtighten. Part No. 32951 Genie Super Tower 3 - 9...
  • Page 24 Section 3 • Scheduled Maintenance Procedures November 2005 This page intentionally left blank. 3 - 10 Genie Super Tower Part No. 32951...

  • Page 25: Checklist C Procedures

    0.062 inch / 1.57 mm between the roller wheel and the column. If mast inspection results in a measurement that is not within specification, refer to Repair procedure 2-1, How to Disassemble the Mast Assembly. Part No. 32951 Genie Super Tower 3 - 11...

  • Page 26: Replace The Winch Friction Disks

    1 Replace the winch friction disks. Refer to Repair specification, refer to Repair Procedures 3-1, How to Disassemble the One- Procedure 2-1, How to speed Winch and 3-2, How to Disassemble the Disassemble the Mast Assembly. Two-speed Winch. 3 - 12 Genie Super Tower Part No. 32951...

  • Page 27: Inspect The Safety Brake System

    4 Raise the carriage 6 inches / 15.2 cm to unlock have a safety brake and will not the safety brake. need to be tested. Part No. 32951 Genie Super Tower 3 - 13...

  • Page 28: Inspect The Painted Surfaces

    1 Visually inspect the welds in the following locations: · Blistering · Rust · Peeling · Fading ·Corrosion Replace any component if it is damaged. 3 - 14 Genie Super Tower Part No. 32951...
  • Page 29 Section 4 • Troubleshooting Flow Charts Troubleshooting Flow Charts Before Troubleshooting: Read, understand and obey the safety rules and operating instructions printed in the Genie Super Tower Operator's Manual . Be sure that all necessary tools and test equipment are available and ready for use.
  • Page 30 The forks will not change position if Replace the damaged the columns shift Check each Mast for column OR consult damage. position. The Genie Inustries Service Departmet. carriage should always raise first, Consult the Genie and lower last. Industries Service Department.
  • Page 31 Re-install cable (if removed during inspection). Replace damaged Inspect winch drum and column OR consult the pinion gear for damage. Genie Industries Service Department. good Consult the Genie Industries Service Department. Part No. 32951 Genie Super Tower 4 - 3...
  • Page 32 Repair the One-speed Operation. Winch. good Check carriage and Replace damaged mast for damaged column OR consult the column(s). Genie Industries Service Department. good Consult the Genie Industries Service Department. 4 - 4 Genie Super Tower Part No. 32951...
  • Page 33 Red—used to indicate the presence of an imminently Read, understand and obey the safety rules hazardous situation which, if not and operating instructions in the Genie Super avoided, will result in death or Tower Operator's Manual . serious injury. Be sure that all necessary tools and parts are Orange—used to indicate the...

  • Page 34: How To Remove The Base

    9 Remove the mounting fasteners from the mast brace to the base. Repeat for other side. 10 Remove the base mounting fasteners. Then remove the base from the machine. 5 - 2 Genie Super Tower Part No. 32951...

  • Page 35: How To Disassemble The Mast Assembly

    7 Remove the carriage by sliding it out the bottom of the mast towards the base while holding the safety brake rollers in position with the hex key wrench. 8 Repeat steps 5 through 7 for each remaining column. Part No. 32951 Genie Super Tower 5 - 3...
  • Page 36 Bodily injury hazard. Cables can fray. Always wear adequate hand protection when handling cable. Refer to Section Eight, Figure 8-D, Mast Components, Pulleys and Cables , to identify the cable routing. 5 - 4 Genie Super Tower Part No. 32951...

  • Page 37: How To Replace The Lifting Cable

    MAST ASSEMBLY How to Replace the Lifting Cable How to Replace a Lifting Pulley - Mast Installed All Genie replacement cables come with one preswaged end 1 Fully lower the carriage. that terminates to the last column 2 Unwind 1 to 2 feet / 0.30 to 0.60 cm of cable and one taped end that terminates from the winch drum.

  • Page 38: How To Disassemble The One-Speed Winch

    Place a block in between the walls of the winch housing to prevent the housing from bending while removing the bushings. 10 Remove the winch housing from the machine. 5 - 6 Genie Super Tower Part No. 32951...
  • Page 39 Do not allow grease or oil onto the friction disks or the ratchet gear. Part No. 32951 Genie Super Tower 5 - 7...

  • Page 40: How To Disassemble The Two-Speed Winch

    Turn the pinion gear winch drum evenly. counterclockwise and slide it off the left side of the shaft. 5 - 8 Genie Super Tower Part No. 32951...
  • Page 41 5 Install the winch housing on the mast. Be sure the winch drum is toward the top. 6 Insert the longer threaded end of the pinion shaft approximately halfway through the right side bushing. Part No. 32951 Genie Super Tower 5 - 9...
  • Page 42 Do not tighten the nut. 12 Slide the left side bushing, spring and ball housing, spacer, input shaft gears and right side bushing onto the input shaft. 5 - 10 Genie Super Tower Part No. 32951...
  • Page 43 24 While holding the cable tight on the drum, rotate the drum with a handle and spool the cable onto the drum evenly. Component damage hazard. Be sure the cable winds onto the winch drum evenly. Part No. 32951 Genie Super Tower 5 - 11...
  • Page 44 Section 5 • Repair Procedures November 2005 5 - 12 Genie Super Tower Part No. 32951...
  • Page 45 November 2005 Section 6 • Decals Decals Part No. 32951 Genie Super Tower 6 - 1...

  • Page 46: Decals

    Section 6 • Decals November 2005 Figure 6-A REV B Decals with Words (before serial number 7794-101) 6 - 2 Genie Super Tower Part No. 32951...
  • Page 47 Label - Use This Winch ....1 32885 Warning - Silent Winch ....1 32929 Warning - Machine Safety and Setup ........1 32926 Genie Super Tower Logo .... 2 32931 Warning - Adjustable Fork Safety and Setup ......1 6724 Serial Plate ........1 33468 Warning - No Riders ....

  • Page 48: Decals With Words

    November 2005 Figure 6-B REV C Decals with Words (after serial number 7794-100) 52985 97529 32929 32885 32938 32770 32939 33493 33498 33498 32934 31072 33468 33498 32927 27865 or 32928 82959 6 - 4 Genie Super Tower Part No. 32951...
  • Page 49 Warning - No Riders ....1 33498 Label - Serial Plate ...... 2 32934 Label - Outrigger Storage Socket .......... 1 52985 Cosmetic - Genie Super Tower ........... 2 82959 Danger - Electrocution Hazard ......... 2 97529 Caution - Bodily Injury Hazard .........

  • Page 50: Decals With Symbols

    Section 6 • Decals November 2005 Figure 6-C REV B Decals with Symbols 52985 97532 82487 97544 97545 82487 97541 82964 97546 33498 33498 33498 97539 32927 or 32928 97539 6 - 6 Genie Super Tower Part No. 32951...
  • Page 51 Cosmetic, ST-20 ......2 32928 Cosmetic, ST-25 ......2 33498 Label - Serial Plate ...... 3 52985 Cosmetic - Genie Super Tower ........... 2 82487 Label - Read the Manual ..... 2 82964 Warning - No Riders ....1 97532 Caution - Bodily Injury Hazard .........
  • Page 52 Section 6 • Decals November 2005 Notes 6 - 8 Genie Super Tower Part No. 32951...

  • Page 53: Base Components

    November 2005 Section 7 • Base Components Base Components Part No. 32951 Genie Super Tower 7 - 1...
  • Page 54 Section 7 • Base Components November 2005 Figure 7-A REV C Base Components 7 - 2 Genie Super Tower Part No. 32951...
  • Page 55 Low Profile Nylock Nut, Decals (includes item 7) (ST-25) (Asia, South America and Europe models) (after 33673 Leveling Jack Casting ....4 serial number 7794-101) 14538 Leveling Jack Foot Pad .... 4 Part No. 32951 Genie Super Tower 7 - 3...
  • Page 56 Section 7 • Base Components November 2005 Notes 7 - 4 Genie Super Tower Part No. 32951...
  • Page 57 November 2005 Section 8 • Mast and Winch Components Mast and Winch Components Part No. 32951 Genie Super Tower 8 - 1...

  • Page 58: Number 1 Mast Attached Parts

    Section 8 • Mast and Winch Components November 2005 Figure 8-A REV C Number 1 Mast Attached Parts 8 - 2 Genie Super Tower Part No. 32951...

  • Page 59: Nylatron Roller, 1.75 X 0.72 Inch

    Flange Bearing, 8 ......7713 Low Profile Nylock Nut, 33674 Lock Pin Assembly ....1 32483 Roll Pin, 0.25 x 0.5 inch .... 1 33663P Carriage Hold Down Latch Bracket ......1 Part No. 32951 Genie Super Tower 8 - 3...

  • Page 60: Mast Components, View 1

    Section 8 • Mast and Winch Components November 2005 Figure 8-B REV C Mast Components, View 1 8 - 4 Genie Super Tower Part No. 32951...
  • Page 61 -16 x 1.75 inches 35100 Safety Brake Ramp (before serial number 7795-00359) ..2 — 35101 Safety Brake Ramp (after serial number 7795-00358) 33541 Shim - 0.75 x 0.10 inch ..... 3 Part No. 32951 Genie Super Tower 8 - 5...

  • Page 62: Mast Components, View 2

    Section 8 • Mast and Winch Components November 2005 Figure 8-C REV C Mast Components, View 2 8 - 6 Genie Super Tower Part No. 32951...
  • Page 63 7794-00001 to 7794-00358) ..2 — 35480 Column Assembly, Numbers 2 - 5 (all models) (from serial number 7794-00357 to 7799-00001) — 57036 Column Assembly, Numbers 2-5 (all models) (after serial number 7799-00000) Part No. 32951 Genie Super Tower 8 - 7...

  • Page 64: Mast Components, Pulleys And Cables

    Section 8 • Mast and Winch Components November 2005 Figure 8-D REV C Mast Components, Pulleys and Cables 8 - 8 Genie Super Tower Part No. 32951...
  • Page 65 7794-00001 to 7794-00358) ..2 — 35480 Column Assembly, Numbers 2 - 5 (all models) (from serial number 7794-00357 to 7799-00001) — 57036 Column Assembly, Numbers 2-5 (all models) (after serial number 7799-00000) ....2 Part No. 32951 Genie Super Tower 8 - 9...

  • Page 66: Winch Components, One-Speed

    Section 8 • Mast and Winch Components November 2005 Figure 8-E REV C Winch Components, One-speed 15 16 8 - 10 Genie Super Tower Part No. 32951...
  • Page 67 Drum Spacer ......1 31946 Drum Lock Bolt ......1 6770 Winch Gear Cover ....1 7256 Screw - HHC, -18 x 6 inches, GR 2 6782 Lock Nut, 6185 Drum Bolt ........1 Part No. 32951 Genie Super Tower 8 - 11...

  • Page 68: Winch Components, Two-Speed

    Section 8 • Mast and Winch Components November 2005 Figure 8-F REV C Winch Components, Two-speed 30 22 8 - 12 Genie Super Tower Part No. 32951...
  • Page 69 — 80153 Ratchet Spring — 80152 Ratchet Spacer — 4828 Nylock Nut, 40116 Retaining Ring, 0.75 inch ..1 40126 Sintered Iron Bearing, 0.75 inch 80155 Pinion Shaft Assembly ....1 Part No. 32951 Genie Super Tower 8 - 13...
  • Page 70 Section 8 • Mast and Winch Components November 2005 Notes 8 - 14 Genie Super Tower Part No. 32951...
  • Page 71 November 2005 Section 9 • Accessories Accessories Part No. 32951 Genie Super Tower 9 - 1...
  • Page 72 Section 9 • Accessories November 2005 Figure 9-A REV B Adjustable Forks 9 - 2 Genie Super Tower Part No. 32951...
  • Page 73 7794-100) ... 1 — 107221 Adjustable Fork Carrier with Symbol Decals (Asia, South America and Europe models) (after serial number 7794-100) 33707-S Adjustable Fork ......2 32375 Fork Lock Pin ......2 Part No. 32951 Genie Super Tower 9 - 3...
  • Page 74 Section 9 • Accessories November 2005 Notes 9 - 4 Genie Super Tower Part No. 32951...
  • Page 75 Genie North America Phone 425.881.1800 Toll Free USA and Canada 800.536.1800 Fax 425.883.3475 Genie Australia Pty Ltd. Phone +61 7 3375 1660 Fax +61 7 3375 1002 Genie China Genie Scandinavia Phone +86 21 53852570 Phone +46 31 3409612 Fax +86 21 53852569...

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Super tower st-25

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