Terex Genie Load Lifter User manual

Service Manual
Serial Number Range
Load Lifter
from 3395-100 to 3301-4263
from LL02-
4264 to
LL16G-
12199
from LLG-
12200
Part No. 115415
Rev A1
September 2016

Service Manual September 2016
Introduction
ii Load Lifter Part No. 115415
Intr oduct io n Intr oduct io n
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 Load Lifter Parts Manual, First Edition
(from serial number 2584-102 to
2595-11321).................................................20950
Genie Load Lifter Parts, Service and Operator's
Manual, First Edition (before serial number
3395-100).....................................................35523
Genie Load Lifter Parts and Service Manual, Third
Edition (from serial number 3395-100 to 3301-4263,
and from
LL02-4264)..................................................*82300
*Note: Genie Load Lifter Service Manual
115415 and Genie Load Lifter Part's Manual
115416 replaces Genie Load Lifter Parts and
Service Manual 82300.
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 © 1998 by Terex Corporation
115415 Rev A, April 2009
Fourth Edition, First Printing
'Genie'' is a registered trademark of Terex South Dakota. in the
U.S.A. and many other countries. “Super Series” is a trademark
of Terex South Dakota.

September 2016 Service Manual
Introduction
Part No. 115415 Load Lifter iii
Revision History
Revision Date Section Procedure / Page / Description
A 4/2009 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 Load Lifter Part No. 115415
Serial Number Legend
To August 31, 2016
1 Model
2 Model year
3 Facility code
4 Sequence number
5 Serial label
6 Serial number (stamped on winch bracket)
From September 1, 2016
1 Model
2 Facility code
3 Sequence number
4 Serial label
5 Serial number (stamped on winch bracket)

September 2016 Service Manual
Safety Rules
Part No. 115415 Load Lifter v
Section 1 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 Load Lifter Part No. 115415
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
an 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 li
fting 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 p
roperly 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 stab
ilizing 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.
Be sure that your workshop or work area
is properly ventilated and well lit.

September 2016
Table of Contents
Part No. 115415 Load Lifter 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
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............................................................................7
Maintenance Inspection Report..............................................................................9
Checklist A Procedures ..................................................................................... 11
A-1 Inspect the Manuals and Decals....................................................................11
A-2 Perform Pre-operation Inspection..................................................................12
A-3 Perform Function Tests .................................................................................12
A-4 Inspect the Pneumatic Tires and Wheels (if equipped).................................13
A-5 Check the Brake Operation (if equipped) ......................................................13
Checklist B Procedures ..................................................................................... 14
B-1 Inspect All Welds ...........................................................................................14
B-2 Clean the Channels .......................................................................................14
B-3 Inspect and Lubricate the Winch ...................................................................15
Checklist C Procedures ..................................................................................... 16
C-1 Replace the Winch Brake Disks and Lubricate the Winch Shaft...................16

September 2016
Table of Contents
viii Load Lifter Part No. 115415
Section 4 Repair Procedures ............................................................................................. 17
Base Assembly................................................................................................... 19
1-1 How to Disassemble the Machine .................................................................19
1-2 How to Disassemble the Winch.....................................................................19
Winch ssembly ................................................................................................... 21
1-3 How to Replace the Pulley.............................................................................23
1-4 How to Replace the Lifting Cable ..................................................................23
1-5 How to Replace the Glide Buttons.................................................................24
1-6 How to Adjust the Brake (if equipped)...........................................................24

September 2016 Service Manual
Specifications
Part No. 115415 Load Lifter 1
Section 2 Specif icati ons
Machine Specifications
Height, maximum platform
5 ft 7 i
n
1.70
m
Height
- Stowed 3 ft 9 i
n
1.14
m
Length
- Operating 32 i
n
81.3 c
m
Length
- Stowed 15 i
n
52 c
m
Width
20.5 i
n
52 c
m
Airborne Noise Emissions by machinery
Maximum sound level at normal
operating work stations (A
-weighted)
78 d
B
*Machine weight will vary depending on options and/or
country standards.
Performance Specifications
Lift capacity
200 l
bs
91 k
g
Machine weight
58 l
bs
26 k
g
Load Platform
Length
14 i
n
36 c
m
Width
16.8 i
n
43 c
m
Load Height
2 i
n
5 c
m
Continuous improvement of our products is a Genie
policy. Product specifications are subject to change
without notice.

Service Manual September 2016
Specifications
2 Load Lifter Part No. 115415