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Terex AL4L, Service Manual

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Terex AL4L Service Manual Download Page 60

August 2016

5 - 6 

AL4L • AL5L 

Part No. 229171

Section 5 • Troubleshooting

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Summary of Contents for AL4L

Page 1: ......

Page 2: ...rkshop In these 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...

Page 3: ...August 2016 Part No 229171 AL4L AL5L Serial Number Legend INTRODUCTION iii...

Page 4: ...August 2016 AL4L AL5L Part No 229171 This page intentionally left blank iv...

Page 5: ...ual 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 underst...

Page 6: ...well lit 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 priorit...

Page 7: ...Specifications AL5L 2 1 Performance Specifications 2 2 Marathon Generator AL4L 2 2 Marathon Generator AL5L 2 2 Kubota D1105 D3BG Engine Specifications 2 3 SAE and Metric Fasteners Torque Charts 2 4 Se...

Page 8: ...ipped 3 10 A 12 Perform Engine Maintenance 3 10 A 13 Perform Generator Maintenance 3 11 A 14 Adjust the Brakes if equipped 3 11 A Checklist B Procedures B 1 Inspect the Engine Start Battery or Lightin...

Page 9: ...3 C 5 Perform Engine Maintenance 3 24 A Checklist D Procedures D 1 Perform Engine Maintenance 3 25 D 2 Perform Coupler Maintenance 3 25 A Checklist E Procedures E 1 Replace the Mast Lift Cable 3 26 E...

Page 10: ...hooting Introduction 5 1 A Troubleshooting 5 2 Section 6 Rev Schematics Introduction 6 1 A Electrical Component and Wire Color Legend 6 2 A Trailer Lighting Wiring Diagram 6 3 A Electrical Schematic A...

Page 11: ...ge 4 x 270 watts Fuel capacities Single tank 30 gallons 114 liters Battery Engine Start Standard Heavy duty Type 12V DC 12V DC Group 24 24 Quantity 1 1 Cold cranking ampere 400 650 Reserve capacity 25...

Page 12: ...es 10 hours AL5L 10 hours Marathon Generator AL4L Generator speed full load 60 Hz 1800 rpm Temperature ambient maximum 104 F 40 C Power 6 kw Capacitor disconnected 25 F Marathon Generator AL5L Generat...

Page 13: ...o 0 185 mm Engine coolant capacity 3 3 quarts 3 1 liters Lubrication system Oil pressure 28 to 64psi 1 93to4 41 bar Oil capacity including filter 5 4 quarts 5 1 liters Oil viscosity requirements Units...

Page 14: ...REV B August 2016 2 4 AL4L AL5L Part No 229171 Section 2 Specifications SPECIFICATIONS...

Page 15: ...parked on a firm level 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...

Page 16: ...here are five types of 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 M...

Page 17: ...dels Perform every 160 hours A 11 Battery Perform every 200 hours A 12 Engine maintenance Kubota models A 13 Generator A 14 Brakes Checklist B Rev A Y N R B 1 Battery B 2 Electrical wiring B 3 Battery...

Page 18: ...azard and could result 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 o...

Page 19: ...etermine 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...

Page 20: ...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 and compon...

Page 21: ...amage may also result if 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 N...

Page 22: ...pressure 50 psi 3 4 bar A 9 Inspect the Cable and Cable Pulleys Terex specifications require that this procedure be performed monthly Detection of damage to the cable or pulleys is essential for safe...

Page 23: ...ators Manual Genie part number 131379 5 Visually inspect the winch cable for the following nicks partial strand cut through kinks in the cable permanent bends weld spatter Result Nicks kinks in the ca...

Page 24: ...ily injury hazard Batteries contain acid Avoid spilling or contacting battery acid Neutralize battery acid spills with baking soda and water 1 Open the cabinet doors 2 Check the battery acid level If...

Page 25: ...ipped 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 performance Brake...

Page 26: ...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 27: ...iminate corrosion on the battery terminals 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 perf...

Page 28: ...ce the 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 neutrali...

Page 29: ...s and other jewelry 1 Inspect the line strainer of the pump assembly Clean or replace as necessary 2 Inspect the tubing of the battery watering system ensuring that all parts are in good working condi...

Page 30: ...Repeat this procedure 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...

Page 31: ...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 32: ...washer and castle nut 11 Tighten the castle nut to 50 ft lbs 68 Nm to seat the bearings CHECKLIST B PROCEDURES 12 Fully loosen the castle nut Do not rotate the hub 13 Finger tighten the castle nut un...

Page 33: ...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 the Suspension Axle specifications require that this p...

Page 34: ...ions require that this procedure be performed every 400 hours or semi annually whichever comes first Replace oil filter Replace fuel filter Required maintenance procedures and additional engine inform...

Page 35: ...quire that this procedure be performed every 500 hours or semi annually whichever comes first Maintaining the light assemblies is essential to good machine performance Failure to regularly clean the l...

Page 36: ...d outer bearing should fall loose from the 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 9 I...

Page 37: ...ss and harness connections and repair as required and repeat this procedure beginning with step 2 CHECKLIST C PROCEDURES 3 With the engine running press down on the brake pedal and use a multimeter to...

Page 38: ...if the exposed copper coil is visible in any way and resurface the drake drums 13 Slide the hub onto the yoke spindle NOTICE Component damage hazard Do not apply excessive force or damage to the lip o...

Page 39: ...Perform Coupler Maintenance Coupler specifications require that this procedure be performed annually Maintaining the coupler in good condition is essential to safe operation and good performance Coup...

Page 40: ...eration 1 Replace both mast lift cables Refer to Repair Procedure 1 1 How to Replace the Mast Lift Cable Checklist E Procedures E 2 Perform Engine Maintenance Kubota D1105 D3BG Models Engine specifica...

Page 41: ...ble in the Kubota D1105 Operators Manual Kubota part number 16622 89166 Kubota D1105 Operators Manual Genie part number 131379 E 4 Perform Generator Maintenance Marathon Models Generator specification...

Page 42: ...August 2016 3 LM AL4L AL5L Part No 229171 Section 3 Scheduled Maintenance Procedures This page intentionally left blank...

Page 43: ...onnected to the power 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 Se...

Page 44: ...CAUTION Bodily injury 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...

Page 45: ...one Note During assembly 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 Remov...

Page 46: ...to Replace 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 15 cm Round Tube Base Assembly 2 inch 5 cm Mast Section 3...

Page 47: ...ies 6 Remove the pinion 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 be...

Page 48: ...ase or oil onto the friction 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 ti...

Page 49: ...lock gear and lock gear 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 insta...

Page 50: ...gether using a length 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 Componen...

Page 51: ...achine GENERATOR How to 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...

Page 52: ...harge the capacitor by 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 o...

Page 53: ...over bearing housing to 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...

Page 54: ...uency Hz connect the multimeter leads to one of the outlets at the control box and note the reading Result The reading is 61 5 0 5 Hz The engine RPM is set correctly Result The reading is less than 61...

Page 55: ...f all power when not needed for testing Use extreme caution when working with high voltage electrical components CAUTION Burn hazard Contact with hot engine components may cause severe burns Use cauti...

Page 56: ...and or 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 rad...

Page 57: ...Problem TROUBLESHOOTING 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 syste...

Page 58: ...tions 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 to 1850 rpm no load Generator...

Page 59: ...repair 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...

Page 60: ...August 2016 5 6 AL4L AL5L Part No 229171 Section 5 Troubleshooting This page intentionally left blank...

Page 61: ...operating instructions 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...

Page 62: ...ine Main F9 30 30 amp Engine starter G Gauge G6 Hour meter lights G6A Hour meter engine KS Key switch KS1 Key switch L LED or Light L30 1 Light head top left L30 2 Light head bottom left L30 3 Light h...

Page 63: ...MARKER LIGHT RIGHT REAR MARKER LIGHT LEFT REAR BRAKE LIGHT RIGHT BRAKE LIGHT LEFT LICENSE PLATE LIGHT YL BL BK BK WH L36F L34 L58 L33 L36R L35R L35F U54 ELECTRIC BRAKE LEFT U53 BL GR BR YL WH R T G L...

Page 64: ...1 BN3 WH GR 240V OUTLET RD BK BREAKER 15A 120V 15A GFI RECEPTACLE BREAKER 30A RD BK WH BREAKER 15A 120V 15A GFI RECEPTACLE BREAKER 15A 120V 15A GFI RECEPTACLE BREAKER 15A 120V 15A GFI RECEPTACLE B8 12...

Page 65: ...BR YL WH 1 YL RD WH BR BL GR BK EN12 B A D 2 3 4 GR B A D B A D B A D YL RD BR BL BK WH EMERGENCY STOP OPTION WH RD 30A FUSE BK ENGINE RD FUEL SOLENOID BR HOLD PULL ST B RD OR COOLANT TEMP NO BK OR BK...

Page 66: ...D1 F9 50 B8 120V PLUG FOR BATTERY CHARGER U9 HOUR METER LIGHTS BK BUSS BAR YL YL WH BK G6 85 87 86 30 NC NO COM TIMER 48V DC BK WH GR GR BK WH EN2 CONTROL BOX YL RD BR BL BK WH CR114 U60 ES0528B 1 YL...

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