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Terex AL4 Service Manual Download Page 12

August 2016

Part No. 218567 

AL4 • AL4000 

 

 

2-1 

Winch ............................................................................................................4 - 5

 

 Generator

 

 

3-1 

Generator ......................................................................................................4 - 8

 

 Engine

 

 

4-1 

Engine RPM ................................................................................................4 - 12

Section 5 

 

Troubleshooting

  

Introduction 

.............................................................................................................5 

- 1

 

 

Troubleshooting .......................................................................................................5 - 2

Section 6 

 

Schematics

  

Introduction 

.............................................................................................................6 

- 1

 

 

Wire Color Legend ..................................................................................................6 - 2

 

 

Trailer Lighting Wiring Diagram ...............................................................................6 - 3

 

 

Electrical Schematic, (ANSI / CSA) .........................................................................6 - 4

 

 

Electrical Schematic, (AUS) ....................................................................................6 - 5

 

 

Control Box and Engine Wiring, (Kubota Models) ...................................................6 - 8

 

 

Control Box and Engine Wiring, (Perkins Models) ..................................................6 - 9

 

 

Control Box and Engine Wiring, (AUS) ..................................................................6 - 12

 

 

Trailer Wiring Diagram, (ANSI / CSA) ....................................................................6 - 13

 

 

Trailer Wiring Diagram, (AUS) ...............................................................................6 - 15

xi

TABLE OF CONTENTS

Discount-Equipment.com

Summary of Contents for AL4

Page 1: ...D i s c o u n t E q u i p m e n t c o m...

Page 2: ...ie Terex JLG MultiQuip Mayco Toro Stone Diamond Products Magnum Airman Mustang Power Blanket Nifty Lift Atlas Copco Chicago Pneumatic Allmand Brothers Essick Miller Spreader Skyjack Lull Skytrak Tsuru...

Page 3: ...se instances we strongly recommend that maintenance and repair be performed at an authorized Terex dealer service center Technical Publications Terex has endeavored to deliver the highest degree of ac...

Page 4: ...umber legend REFERENCE EXAMPLES Kubota Engine_Section 2_Specifications A 6 B 3 C 7_Section 3_Maintenance Procedure 3 2 6 4 9 1_Section 4_Repair Procedure Fault Codes_Section 5 6 35 6 56 6 104_Section...

Page 5: ...e_Section 2_Specifications A 6 B 3 C 7_Section 3_Maintenance Procedure 3 2 6 4 9 1_Section 4_Repair Procedure Fault Codes_Section 5 6 35 6 56 6 104_Section 6_Schematic Page Electronic Version Click on...

Page 6: ...August 2016 Part No 218567 AL4 AL4000 Serial Number Legend INTRODUCTION v D i s c o u n t E q u i p m e n t c o m...

Page 7: ...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 haz...

Page 8: ...any forklift overhead crane or other lifting or supporting device is fully capable of supporting and stabilizing the weight to be lifted Use only chains or straps that are in good condition and of amp...

Page 9: ...3D 11 Engine 2 2 Kubota D1105 D3BG Engine Specifications 2 4 SAE and Metric Fasteners Torque Charts 2 5 Section 3 Scheduled Maintenance Procedures Introduction 3 1 Maintenance Inspection Report 3 3 Ch...

Page 10: ...n the Fuel Filter Water Separator Kubota Models 3 14 A 18 Adjust the Brakes if equipped 3 15 Checklist B Procedures B 1 Inspect the Engine Start Battery or Lighting Battery Pack 3 17 B 2 Inspect the E...

Page 11: ...form Generator Maintence Leroy Somer Models 3 30 D 3 Perform Coupler Maintenance 3 31 Checklist E Procedures E 1 Replace the Mast Lift Cable 3 32 E 2 Perform Engine Maintenance 3 32 E 3 Perform Engine...

Page 12: ...uction 6 1 Wire Color Legend 6 2 Trailer Lighting Wiring Diagram 6 3 Electrical Schematic ANSI CSA 6 4 Electrical Schematic AUS 6 5 Control Box and Engine Wiring Kubota Models 6 8 Control Box and Engi...

Page 13: ...August 2016 AL4 AL4000 Part No 218567 This page intentionally left blank xii D i s c o u n t E q u i p m e n t c o m...

Page 14: ...e dry 90 ft lbs 122 Nm Lug nut torque lubricated 67 5 ft lbs 91 5 Nm Tire pressure maximum cold 50 psi 3 4 bar Specifications Performance Specifications Tongue weight maximum With fuel single tank 150...

Page 15: ...Bore and stroke 3 03 x 3 19 inches 77 x 81 mm Horsepower net intermittent 25 3000 rpm 18 6 kW Firing order 1 2 3 Compression ratio 23 1 Compression pressure 425 psi 29 bar Pressure of the lowest cyli...

Page 16: ...ressure 40 to 60psi hot 2000 rpm 3to4 bar Oil capacity including filter 4 6 quarts 4 4 liters Oil viscosity requirements Units ship with 15W 40 Extreme operating temperatures may require the use of al...

Page 17: ...iters Oil viscosity requirements Units ship with 10W 30 Extreme operating temperatures may require the use of alternative engine oils For oil requirements refer to the Engine Operator Handbook on your...

Page 18: ...Section 2 Specifications August 2016 Part No 218567 AL4 AL4000 2 5 SPECIFICATIONS 10 9 12 9 8 8 4 6 D i s c o u n t E q u i p m e n t c o m...

Page 19: ...August 2016 2 6 AL4 AL4000 Part No 218567 Section 2 Specifications This page intentionally left blank D i s c o u n t E q u i p m e n t c o m...

Page 20: ...vel surface Mast in the stowed position Wheels chocked Light switches in the off position No external AC power devices connected to the power outlets at the control box About This Section This section...

Page 21: ...maintenance inspections that must be performed according to a schedule daily quarterly semi annually annually and two year The Scheduled Maintenance Procedures Section and the Maintenance Inspection R...

Page 22: ...orm after 50 hours A 12 Engine maintenance Kubota models Perform every month A 13 Cable and Pulleys Perform every 100 hours A 14 Engine maintenance Kubota models Perform every 200 hours A 15 Engine ma...

Page 23: ...ct the appropriate checklist s for the type of inspection to be performed Daily or 8 hours Inspection A Quarterly or 250 hours Inspection A B Semi annually or 500 hours Inspection A B C Annually or 10...

Page 24: ...esult in unsafe operating conditions 1 Check to make sure that the operator s and safety manuals are present and complete in the storage container in the cabinet 2 Examine the pages of each manual to...

Page 25: ...intenance 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 T...

Page 26: ...procedure be performed before towing Maintaining the coupler in good condition is essential to safe operation and good performance Coupler failure could result in a machine tip over during transport a...

Page 27: ...f problems are not discovered and repaired in a timely fashion 1 Test the brakes for proper function Repair or replace any faulty components as needed A 7 Torque the Wheel Lug Nuts Axle specifications...

Page 28: ...ure 50 psi 3 4 bar A 9 Inspect the Engine Air Filter Genie specifications require that this procedure be performed every 40 hours or weekly whichever comes first Maintaining the engine air filter in g...

Page 29: ...intenance Leroy Somer Models Generator specifications require that this procedure be performed every 40 hours or weekly whichever comes first Maintaining the generator in good condition is essential t...

Page 30: ...orking condition exists if these components are damaged and do not operate smoothly Regular inspection of this system allows the inspector to identify changes in the operating condition that may indic...

Page 31: ...meter or more is found OR there is a broken wire at the crush point The cable must immediately be replaced 7 Wind the cable onto the winch ensuring that the cable is correctly installed onto each of t...

Page 32: ...he generator exterior Clean and inspect the inside of the capacitor box Check for loose or damaged wires and components Electrocution burn hazard Contact with electrically charged circuits could resul...

Page 33: ...hted tobacco Always have an approved fire extinguisher within easy reach 1 Locate the fuel filter water separator and loosen the vent plug located on the fuel filter water separator head 2 Loosen the...

Page 34: ...Brakes if equipped Axle specifications require that this procedure be performed initially at 250 miles of use Maintaining the axle brakes in good condition is essential to safe operation and good per...

Page 35: ...l the wheel spins freely with little drag 7 Securely install the small rubber plug into the brake backing plate 8 Check for wheel bearing wear by attempting to move wheel hub side to side then up and...

Page 36: ...and cables 3 Be sure that the battery retainers and cable connections are tight 4 Fully charge the batteries Allow the batteries to rest 24 hours before performing this procedure to allow the battery...

Page 37: ...he battery 11 Check the battery acid level If needed replenish with distilled water to 1 8 inch 3 mm below the bottom of the battery fill tube Do not overfill 12 Install the vent caps and neutralize a...

Page 38: ...ut for proper torque Specification Lug nut torque dry 90 ft lbs 122 Nm Lug nut torque lubricated 67 5 ft lbs 91 5 Nm CHECKLIST B PROCEDURES B 4 Perform Engine Maintenance Perkins Models Engine specifi...

Page 39: ...ure beginning with step 1 for the other jacks on the machine CHECKLIST B PROCEDURES B 6 Inspect and Lubricate the Winch Terex specifications require that this procedure be performed every 250 hours or...

Page 40: ...equire that this procedure be performed every 3000 miles or quarterly whichever comes first Maintaining the axle brakes in good condition is essential to safe operation and good performance Brakes whi...

Page 41: ...nger turn Note This centers the brake shoes on the brake drum ensuring the shoes are positioned correctly 6 Pull the hub off of the spindle The washer and outer bearing should fall loose from the hub...

Page 42: ...Remove the jack stand and lower the machine to the ground Chock the front and rear of the tire 23 Repeat this procedure beginning with step 2 for the other wheel CHECKLIST B PROCEDURES B 9 Inspect th...

Page 43: ...dure be performed every 400 hours or semi annually whichever comes first Replace oil filter Replace fuel filter Required maintenance procedures and additional engine information is available in the Ku...

Page 44: ...book Genie part number 131661 C 2 Clean the Light Assemblies Terex specifications require that this procedure be performed every 500 hours or semi annually whichever comes first Maintaining the light...

Page 45: ...hub 7 Place the hub on a flat surface and gently pry the bearing seal out of the hub Remove the rear bearing 8 Pack both bearings with clean fresh grease CHECKLIST C PROCEDURES 9 Inspect the hub for...

Page 46: ...ons and repair as required and repeat this procedure beginning with step 2 3 With the engine running press down on the brake pedal and use a multimeter to measure the total amp draw of the brake circu...

Page 47: ...t until snug 19 Install a new cotter pin Bend the cotter pin to lock it in place Note Always replace the cotter pin with a new one when removing the castle nut 20 Install the dust cap then the tire an...

Page 48: ...ly Loose or damaged connections or components may result in a generator to lose efficiency and reduce the life of the generator Inspect stator output leads and insulation for cracking and damage Inspe...

Page 49: ...enerator Maintenance Leroy Somer Models Generator specifications require that this procedure be performed every 8000 hours or annually whichever comes first Maintaining the generator in good condition...

Page 50: ...ld result in a machine tip over during transport and component damage may also result if problems are not discovered and repaired in a timely fashion 1 Check coupler welds and mounting bolt torque Tor...

Page 51: ...ications require that this procedure be performed every 2000 hours or bi annually whichever comes first Kubota D1105 Replace coolant Replace radiator hoses and clamps Replace fuel hoses and clamps Rep...

Page 52: ...Perkins 403D 11 User s Handbook Perkins part number SEBU8311 01 Kubota D1105 Operator s Manual Genie part number 131379 Perkins 403D 11 User s Handbook Genie part number 131661 E 4 Perform Generator M...

Page 53: ...18 E 6 Perform Generator Maintenance Leroy Somer Models Generator specifications require that this procedure be performed every 30 000 hours or 5 years whichever comes first Maintaining the generator...

Page 54: ...outlets at the control box About This Section Most of the procedures in this section should only be performed by a trained service professional in a suitably equipped workshop Select the appropriate r...

Page 55: ...hazard Cables can fray Always wear adequate hand protection when handling the cable 3 Remove the fasteners securing the coil cable cover onto the side of the mast Set the cover and fasteners to the si...

Page 56: ...ly carefully install the mast cable Refer to the illustration on the following page for cable routing How to Disassemble the Mast 1 Remove the mast assembly See 1 1 How to Remove the Mast Assembly 2 R...

Page 57: ...the Mast Lift Cable See 1 1 How to Disassemble the Mast Note Refer to the illustration below for cable routing detail Winch 6 inch Round Tube Base Assembly 2 inch Mast Section 3 inch Mast Section 4 i...

Page 58: ...shaft bushings Use a soft metal drift equal to the outside diameter of the bushing and tap with a rubber mallet Note Carefully observe the quantity and location of the shims between the winch drum an...

Page 59: ...iction disk 5 Install the retaining ring into the small groove at the non threaded end of the pinion shaft 6 Install the ratchet pawl kit as shown in the illustration Securely tighten the fasteners 7...

Page 60: ...ar nut onto the pinion shaft and tighten 11 Install the winch onto the machine Securely tighten the fasteners Do not over tighten 12 Route the cable onto the winch drum and install the cable retaining...

Page 61: ...of rope or elastic cord 5 Attach a lifting strap from an overhead crane to the top panel and doors assembly Support the assembly Do not apply any lifting pressure Notice Component damage hazard The ca...

Page 62: ...Install the Generator 1 Using a liquid threadlocker on the fastener threads install the fasteners securing the generator rotor to the engine flywheel Tighten to finger tight 2 In a star pattern torqu...

Page 63: ...shorting across the capacitor terminals Repeat for the second capacitor if equipped DANGER High voltage Exposure to electrical wires or electrical current will result in death or serious injury Remove...

Page 64: ...o the generator Remove the cover 2 Locate the diode at the end of the generator 3 Tag and disconnect the positive wire lead from the diode 4 With a multimeter set to test diodes connect one multimeter...

Page 65: ...y Result The reading is less than 60 Hz OR the reading is greater than 62 Hz The engine RPM is not set correctly and should be adjusted Proceed to step 3 7 kw Result The reading is 61 5 0 5 Hz The eng...

Page 66: ...ry Remove all rings watches and other jewelry Turn off all power when not needed for testing Use extreme caution when working with high voltage electrical components CAUTION Burn hazard Contact with h...

Page 67: ...r switch wiring as needed Engine overheats Low coolant level Top off radiator and coolant overflow tank with correct coolant mixture per engine Operator s Manual Radiator is blocked Clear the radiator...

Page 68: ...Faulty glow plug Inspect and repair as needed Battery is discharged or low Charge or replace battery Air cleaner is dirty Clean or replace more frequently Clogged exhaust system Inspect and repair as...

Page 69: ...ose connections Rotor open or shorted Measure resistance between leads Stator grounded or shorted Contact the Genie Service Dept Generator voltage too high High engine speed Adjust the rpm Refer to Se...

Page 70: ...as needed Faulty capacitor Replace Faulty diode Replace Faulty surge suppressor Replace Generator voltage low Loss of residual magnetism Flash the rotor Low engine speed Adjust idle See Repair Section...

Page 71: ...August 2016 5 6 AL4 AL4000 Part No 218567 Section 5 Troubleshooting This page intentionally left blank D i s c o u n t E q u i p m e n t c o m...

Page 72: ...ns in the appropriate operator s manual on your machine before attempting any maintenance or repair procedure Be sure that all necessary tools and test equipment are available and ready for use About...

Page 73: ...d WIRE COLOR LEGEND Item Description BL Blue BK Black BR Brown GR Green OR Orange VI Violet RD Red WH White YL Yellow OR BK Orange Black WH BK White Black WH RD White Red GR YL Green Yellow RD BK Red...

Page 74: ...Section 6 Schematics August 2016 6 3 Electrical Schematic ANSI CSA models 6 4 D i s c o u n t E q u i p m e n t c o m...

Page 75: ...D RD WH WH WH WH BK BK BK BK A B C C B A C B A C A B 16 3 CONNECTOR PIN A NEUTRAL PIN B 220V AC POWER PIN C GROUND 16 5 CORD SET CONNECTOR PIN 1 NEUTRAL PIN 2 220V AC POWER BALLAST PIN 3 GROUND PIN 4...

Page 76: ...RD RD BL BL BL BL BR BR BR BR A B C C B A C B A C A B 16 3 CONNECTOR PIN A NEUTRAL PIN B 220V AC POWER PIN C GROUND 16 5 CORD SET CONNECTOR PIN 1 NEUTRAL PIN 2 220V AC POWER BALLAST PIN 3 GROUND PIN 4...

Page 77: ...August 2016 Section 6 Schematics 6 6 6 5 Electrical Schematic AS models D i s c o u n t E q u i p m e n t c o m...

Page 78: ...Section 6 Schematics August 2016 6 7 Control Box and Engine Wiring Kubota Models 6 8 D i s c o u n t E q u i p m e n t c o m...

Page 79: ...TERNATOR FAILURE LIGHT YL BK HOUR METER RELAY 12V SPST NC 87 86 BR BR PREHEAT PUSH BUTTON YL 87a BR RD 11 12 11 12 1 2 3 4 5 6 7 8 9 10 BL YL BR BR RD RD GR YL OR 5 6 7 8 9 10 P1 1 2 3 4 6 9 12 3 4 11...

Page 80: ...R METER RELAY 12V SPST NC 87 86 PREHEAT PUSH BUTTON YL 87a 11 12 11 12 1 2 3 4 5 6 7 8 9 10 BL YL BR BR RD RD GR YL OR 5 6 7 8 9 10 P1 1 2 3 4 6 9 12 3 4 11 7 10 2 P1 1 PULL HOLD HIGH COOLANT TEMPERAT...

Page 81: ...August 2016 Section 6 Schematics 6 10 6 9 Control Box and Engine Wiring Perkins Models D i s c o u n t E q u i p m e n t c o m...

Page 82: ...Section 6 Schematics August 2016 6 11 6 12 Control Box and Engine Wiring AS models D i s c o u n t E q u i p m e n t c o m...

Page 83: ...YL BR BK HOUR METER RELAY 12V SPST NC 87 86 BR BR PREHEAT PUSH BUTTON YL 87a BR RD BL WH YL RD RD BK 11 12 11 12 1 2 3 4 5 6 7 8 9 10 BL YL BR BR RD RD GR YL OR 5 6 7 8 9 10 P1 1 2 3 4 6 9 12 3 4 11...

Page 84: ...FRONT MARKER LIGHT LEFT FRONT MARKER LIGHT RIGHT REAR MARKER LIGHT LEFT REAR BRAKE LIGHT RIGHT BRAKE LIGHT LEFT LICENSE PLATE LIGHT YL BL GR BR YL WH R T G L S BL GR BR YL WH 1 2 3 4 6 5 WH BL YL GR B...

Page 85: ...August 2016 Section 6 Schematics 6 14 6 13 Trailer Wiring Diagram ANSI CSA models D i s c o u n t E q u i p m e n t c o m...

Page 86: ...RIGHT BRAKE LIGHT LICENSE MARKER LIGHT LEFT BRAKE LIGHT YL BL RD GR YL RIGHT TURN INDICATOR RUNNING LIGHT RUNNING LIGHT LEFT TURN INDICATOR RED LENSE AMBER LENSE TURN INDICATOR STOP RUNNING VIEW OF A...

Page 87: ...August 2016 Section 6 Schematics 6 16 Trailer Wiring Diagram AS models 6 15 D i s c o u n t E q u i p m e n t c o m...

Page 88: ...www discount equipment com D i s c o u n t E q u i p m e n t c o m...

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