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

September 2016 Service Manual
Scheduled Maintenance Procedures
Part No. 115415 Load Lifter 3
Section 3 Sche duled Mai nten ance Pr oced ures
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.
Failure 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.
Machine Configuration:
Unless otherwise specified, perform each
procedure with the machine in the following
configuration:
•Machine parked on a firm, level surface
•Carriage fully lowered
•Legs down and locked
•Load platform down

Service Manual September 2016
Scheduled Maintenance Procedures
4 Load Lifter Part No. 115415
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
an imminently
hazardous situation which, if not
avoided, will result in death or
serious injury.
Indicates a potential
ly 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.
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.
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 t
his procedure.
Indicates that new parts will be required to
perform this procedure.
Indicates that dealer service will be
required to perform this procedure.

September 2016 Service Manual
Scheduled Maintenance Procedures
Part No. 115415 Load Lifter 5
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 Report
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.

Service Manual September 2016
6 Load Lifter Part No. 115415
This page intentionally left blank.

September 2016 Service Manual
Pre-Delivery Preparation Report
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 YNR
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

Service Manual September 2016
8 Load Lifter Part No. 115415
This page intentionally left blank.

September 2016 Service Manual
Maintenance Inspection Report
Part No. 115415 Load Lifter 9
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
A-4 Tires and wheels
A-5 Brake operation
(if equipped)
Comments
Checklist B Y N R
B-1 Inspect welds
B-2 Clean channels
B-3 Inspect and lubricate
winch
Checklist C- Rev A Y N R
C-1 Friction disks and
winch shaft
Comments

Service Manual September 2016
10 Load Lifter Part No. 115415
This page intentionally left blank.

September 2016 Service Manual
Checklist A Procedures
Part No. 115415 Load Lifter 11
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.

Service Manual September 2016
Checklist A Procedures
12 Load Lifter Part No. 115415
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
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.