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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

Содержание Genie Load Lifter

Страница 1: ...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 ...

Страница 2: ...couraged 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 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 ...

Страница 3: ...age 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 ...

Страница 4: ...15 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 ...

Страница 5: ...ny 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 hav...

Страница 6: ...ing hazards such as moving parts free swinging or unsecured components when lifting 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 flammabl...

Страница 7: ...aintenance 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 Cle...

Страница 8: ...ir 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 ...

Страница 9: ... in 52 cm Airborne Noise Emissions by machinery Maximum sound level at normal operating work stations A weighted 78 dB Machine weight will vary depending on options and or country standards Performance Specifications Lift capacity 200 lbs 91 kg Machine weight 58 lbs 26 kg Load Platform Length 14 in 36 cm Width 16 8 in 43 cm Load Height 2 in 5 cm Continuous improvement of our products is a Genie po...

Страница 10: ...Service Manual September 2016 Specifications 2 Load Lifter Part No 115415 ...

Страница 11: ...o 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...

Страница 12: ...lt 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 ...

Страница 13: ... 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 250 hours A B Annually 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 Ma...

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Страница 15: ... 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 eac...

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Страница 17: ...ppropriate 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 d...

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Страница 19: ...safe 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...

Страница 20: ...rves 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 machin...

Страница 21: ...ace and check that the wheels roll smoothly free of hesitation and binding 3 Check the tire pressure with an air pressure gauge and add air as needed Air pressure 50 psi 3 4 bar A 5 Check the Brake Operation if equipped Genie specifications require that this procedure be performed every 8 hours or daily whichever comes first Detection of damage to the brake system is essential to safe machine oper...

Страница 22: ... frame Load platform B 2 Clean the Channels Genie requires that this procedure be performed every 250 hours or quarterly whichever comes first Clean inner and outer frame channels are essential to good machine performance and safe operation Extremely dirty conditions may require that the channels be cleaned more often 1 Raise the load platform to the maximum height 2 Visually inspect the inner and...

Страница 23: ...essive wear and or does not operate smoothly free of hesitation and binding 1 Carefully lubricate the pivot point on the ratchet pawl with 30W oil Component damage hazard Do not allow oil onto the brake disk 2 Inspect the brake disks for excessive wear Replace if the pad is less than1 16 inch 1 5 mm thick Refer to Repair procedure How to Disassemble the Winch if necessary 3 Inspect the pinion shaf...

Страница 24: ...e be performed every 1000 hours or annually whichever comes first Maintaining the winch is essential to good machine performance and safe operation An unsafe working condition exists if the winch has excessive wear and or does not operate smoothly free of hesitation and binding 1 Replace the winch brake disks and lubricate the winch shaft Refer to Repair procedure How to Disassemble the Winch ...

Страница 25: ...tart Read understand and obey the safety rules and operating instructions in the appropriate operator s manual on your machine Be sure that all necessary tools and parts are available and ready for use Use only Genie approved replacement parts Read each procedure completely and adhere to the instructions Attempting shortcuts may produce hazardous conditions Machine Configuration Unless otherwise s...

Страница 26: ...rsonnel to potential personal injury hazards Obey all safety messages that follow this symbol to avoid possible injury or death Indicates a 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...

Страница 27: ... fray Always wear adequate hand protection when handling cable 9 Remove the inner frame stop angle mounting fasteners from the outer frame channels and remove the inner frame stop angle from the outer frame channels 10 Remove the winch plate mounting fasteners from the outer frame channels and remove the winch plate from the outer frame channels 11 Pull the cable through the pulley located in the ...

Страница 28: ... rubber mallet How to Assemble the Winch 1 Clean and inspect the winch components before installing Note Refer to the illustration Winch Assembly for an exploded view 2 Install the pinion shaft bushings Use a soft metal drift equal to the outside diameter of the bushing and tap with a rubber mallet until fully seated 3 Apply a small amount of lithium grease to the large threaded section of the pin...

Страница 29: ...September 2016 Service Manual Repair Procedures Part No 115415 Load Lifter 21 Winch Assembly ...

Страница 30: ...rake Disk 5 Roll Pin 21 Ratchet Gear 6 Handle Assembly 22 Brake Disk 7 Screw 23 Pinion Plate 8 Nylock nut 24 Pinion Shaft Spacer 9 Outer Frame Pulley 25 Winch Mounting Bracket Spacer 10 Glide Button 26 Screw 11 Outer Frame Channel Left Side 27 Nylock nut 12 Outer Frame Channel Right Side 28 Winch Handle 13 Retainer Ring 29 Wing nut 14 Direct Drive Pinion Shaft 30 Star Washer 15 Rubber Bumper 31 Ja...

Страница 31: ...n installing the new pulley and pulley bracket Carriage Pulley 10 Remove the pulley mounting fastener and remove the pulley 11 Wrap the cable around the new pulley and re install the pulley into the handle Note Be sure not to twist the cable when installing the new pulley 1 4 How to Replace the Lifting Cable Bodily injury hazard Cables can fray Always wear adequate hand protection when handling ca...

Страница 32: ...least 4 wraps of cable on the winch drum Cable Routing Note The numbers on the illustration correspond to the steps in procedure 1 4 Platform is raised for illustrative purposes only 1 5 How to Adjust the Glide Buttons 1 Using proper lifting techniques lay the machine on a table or other suitable work station 2 Remove the inner frame stop angle mounting fasteners Remove the inner frame stop angle ...

Страница 33: ...el brake cams until they contact the tires Tighten the brake cam clamping bolts 4 With the pedal up rotate the brake cam rod until there is approximately 1 4 inch 63 mm of gap between the wheel and the wheel brake cam Tighten the center brake cam clamping bolt 5 Check the brake for proper activation Note The brake should lock easily in place Avoid using too much force on the brake pedal Load Li ft...

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