Terex Genie Load Lifter Bedienungsanleitung

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.

Internet: www.genielift.com

E-mail: awp.techpub@terex.com

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.

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

1.70

Height

- Stowed 3 ft 9 i

1.14

Length

- Operating 32 i

81.3 c

Length

- Stowed 15 i

52 c

Width

20.5 i

52 c

Airborne Noise Emissions by machinery

Maximum sound level at normal

operating work stations (A

-weighted)

78 d

*Machine weight will vary depending on options and/or

country standards.

Performance Specifications

Lift capacity

200 l

91 k

Machine weight

58 l

26 k

Load Platform

Length

14 i

36 c

Width

16.8 i

43 c

Load Height

2 i

5 c

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

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