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Service Manual

May 2015

Safety Rules

AL5HT

Part No. 1265482

Section 1

Safet y R ules

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.

Summary of Contents for Genie AL5HT

Page 1: ...Service Manual AL5HT Part No 1265482 Rev A May 2015...

Page 2: ...and repair be performed at an authorized Terex dealer service center Compliance Machine Classification Group A Type 1 as defined by ISO 16368 Machine Design Life Unrestricted with proper operation in...

Page 3: ...015 Service Manual Safety Rules Part No 1265482 AL5HT 3 Serial Number Legend Serial Number Legend 1 Model 2 Model year 3 Sequence number 4 Serial label located on cabinet 5 Serial number stamped on ch...

Page 4: ...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...

Page 5: ...rds 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 aw...

Page 6: ...neral Safety Rules iv Section 2 Specifications 1 Machine Specifications 1 Performance Specifications 1 Generator Options 1 Kubota D1105 E Engine Specifications 2 Kubota D1505 E Engine Specifications 3...

Page 7: ...ance 18 A 7 Torque the Wheel Lug Nuts 18 A 8 Perform Engine Maintenance 19 A 9 Perform Coupler Maintenance 19 A 10 Grease turntable bearing and rotate gear 20 A 11 Perform Engine Maintenance 20 A 12 P...

Page 8: ...e 31 D 2 Check the Tower Rotation Bearing Bolts 31 D 3 Replace the Hydraulic Return Filter 32 D 4 Perform Engine Maintenance 33 D 5 Perform Engine Maintenance 33 D 6 Perform Engine Maintenance 34 D 7...

Page 9: ...wer 48 3 5 How to Remove the Tower Lift Cylinder 50 3 6 How to Remove the Tower Extension Cylinder 51 3 7 How to Remove the Tower Rotation Motor 52 3 8 How to Adjust the Tower Rotation Gear Backlash 5...

Page 10: ...to Check a Generator Diode 59 Light Ballast 60 9 1 Ground Controls 60 9 2 Light Ballast 61 Fuel Tank 62 10 1 Fuel Tank 62 Section 5 Diagnostics 64 Introduction 64 Diagnostic Charts 65 Section 6 Schema...

Page 11: ...g nut torque lubricated 75 psi 5 2 bar Performance Specifications Tongue weight maximum With fuel single tank 150 lbs 68 kg With fuel large tank 130 lbs 59 kg Run time Single tank 50 hours Large tank...

Page 12: ...1 93 to 4 41 bar Oil capacity including filter 5 4 quarts 5 1 liters Oil pressure switch engine shutoff pressure 7 psi Oil viscosity requirements Unit ships with 10W 30 Extreme operating temperatures...

Page 13: ...93 to 4 41 bar Oil capacity including filter 7 08 quarts 6 7 liters Oil pressure switch engine shutoff pressure 7 psi Oil viscosity requirements Unit ships with 10W 30 Extreme operating temperatures...

Page 14: ...system Oil pressure hot 1800 rpm 64 psi 4 4 bar Oil capacity including filter 7 08 quarts 6 7 liters Oil pressure switch engine shutoff pressure 14 psi 0 96 bar Oil viscosity requirements Unit ships w...

Page 15: ...system Oil pressure hot 1800 rpm 64 psi 4 4 bar Oil capacity including filter 7 08 quarts 6 7 liters Oil pressure switch engine shutoff pressure 14 psi 0 96 bar Oil viscosity requirements Unit ships w...

Page 16: ...system Oil pressure hot 1800 rpm 64 psi 4 4 bar Oil capacity including filter 7 08 quarts 6 7 liters Oil pressure switch engine shutoff pressure 14 psi 0 96 bar Oil viscosity requirements Unit ships...

Page 17: ...t lbs 41 Nm Generator isolators 75 ft lbs 102 Nm Wheel lugs Lug nut torque lubricated 67 5 ft lbs 91 5 Nm Lug nut torque dry 90 ft lbs 122 Nm Engine vibration isolators Mounting bolts dry 60 ft lbs 81...

Page 18: ...Service Manual May 2015 Specifications 8 AL5HT Part No 1265482...

Page 19: ...y 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...

Page 20: ...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...

Page 21: ...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 Procedure...

Page 22: ...lified 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 deli...

Page 23: ...epair place a check in the R box Legend Y yes acceptable N no remove from service R repaired Checklist A Y N R A 1 Inspect the manuals and decals A 2 Pre operation inspection A 3 Function tests Perfor...

Page 24: ...After repair place a check in the R box Legend Y yes acceptable N no remove from service R repaired Checklist C Y N R C 1 Inspect tower extend retract cables C 2 Engine maintenance Perform every 6000...

Page 25: ...safe operating conditions 1 Check to make sure that the operator s and safety manuals are present and complete in the storage container inside the cabinet 2 Examine the pages of each manual to be sure...

Page 26: ...o 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 machi...

Page 27: ...nd V1505 E Operator s Manual Kubota 16683 89169 part number OR the Isuzu 4LE1 Diesel Engine Owner s Manual Isuzu part number IDE 6033 OR the Isuzu 4LE2 Diesel Engine Owner s Manual Isuzu part number I...

Page 28: ...nance procedures can lead to poor axle performance and component damage Required maintenance procedures and additional axle information is available in the Axis Axle Operator Maintenance Manual includ...

Page 29: ...suzu 4LE2 Diesel Engine Owner s Manual Genie part number 1264609 Kubota D 1105 and V 1505 Operator s Manual Genie part number 893020 A 9 Perform Coupler Maintenance Coupler specifications require that...

Page 30: ...ches 10 to 13 cm at a time and repeat this step until the entire bearing has been greased 7 Remove retaining fasteners from the the pinion gear guard Remove the guard 8 Apply grease to each tooth of t...

Page 31: ...ions require that this procedure be performed every 200 hours Change engine oil Replace oil filter Required maintenance procedures and additional engine information is available in the Kubota D1105 E...

Page 32: ...otectors and a corrosion preventative sealant will help eliminate corrosion on the battery terminals and cables 3 Be sure that the battery retainers and cable connections are tight 4 Be sure that the...

Page 33: ...illed 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 any electrolyte that may have spilled 13 Close the side covers B 2 Inspec...

Page 34: ...e be performed every 250 hours or quarterly whichever comes first Replacement or testing of the hydraulic oil is essential for good machine performance and service life Dirty oil and a clogged suction...

Page 35: ...50 Isuzu 4LE1 Diesel Engine Owner s Manual Genie part number 116133 Isuzu 4LE2 Diesel Engine Owner s Manual Genie part number 1264609 Kubota D 1105 and V 1505 Operator s Manual Genie part number 89302...

Page 36: ...ons require that this procedure be performed quarterly Maintaining the coupler in good condition is essential to safe operation and good performance Coupler failure could result in a machine tip over...

Page 37: ...ngine Owner s Manual Isuzu part number IDE 6450 Kubota D 1105 and V 1505 Operator s Manual Genie part number 893020 B 10 Perform Axle Maintenance Axle specifications require that this procedure be per...

Page 38: ...ndition 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 indicate damag...

Page 39: ...zu 4LE1 Diesel Engine Owner s Manual Genie part number 116133 Isuzu 4LE2 Diesel Engine Owner s Manual Genie part number 1264609 Kubota D 1105 and V 1505 Operator s Manual Genie part number 893020 C 3...

Page 40: ...e Isuzu 4LE2 Diesel Engine Owner s Manual Isuzu part number IDE 6450 Isuzu 4LE1 Diesel Engine Owner s Manual Genie part number 116133 Isuzu 4LE2 Diesel Engine Owner s Manual Genie part number 1264609...

Page 41: ...Bolts Engine specifications require that this procedure be performed every 1000 hours or annually whichever comes first Note Terex requires that this procedure be performed every 1000 hours or annual...

Page 42: ...eplaced more often Bodily injury hazard Beware of hot oil Contact with hot oil may cause severe burns 1 Open the road side cabinet cover and locate the hydraulic return filter next to the power unit 2...

Page 43: ...6450 Isuzu 4LE1 Diesel Engine Owner s Manual Genie part number 116133 Isuzu 4LE2 Diesel Engine Owner s Manual Genie part number 1264609 D 5 Perform Engine Maintenance Engine specifications require tha...

Page 44: ...number 116133 Isuzu 4LE2 Diesel Engine Owner s Manual Genie part number 1264609 Kubota D 1105 and V 1505 Operator s Manual Genie part number 893020 D 7 Perform Generator Maintenance Generator specifi...

Page 45: ...ngue Jack Use Manual Genie part number 150140 D 9 Perform Axle Maintenance Axle specifications require that this procedure be performed annually or every 12 000 miles whichever comes first Proper axle...

Page 46: ...battery cables from the battery Electrocution burn hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry 3 Tag disconnec...

Page 47: ...ll machine functions through 5 10 full cycles to fully remove air from the system 19 Make sure unit is in a clear area during steps 17 and 18 as air in the cylinders can cause sudden movements of the...

Page 48: ...uzu 4LE1 Diesel Engine Owner s Manual Genie part number 116133 Isuzu 4LE2 Diesel Engine Owner s Manual Genie part number 1264609 Kubota D 1105 and V 1505 Operator s Manual Genie part number 893020 E 4...

Page 49: ...hours or every 19 years whichever comes first Maintaining the generator in good condition is essential to safe operation and long service life Storing the generator in a harsh environment may require...

Page 50: ...l on your machine Be sure that all necessary tools and parts are available and ready for use Use only Terex approved replacement parts Read each procedure completely and adhere to the instructions Att...

Page 51: ...l 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...

Page 52: ...trocution burn hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry 1 Turn off all machine power 2 Remove the cover from...

Page 53: ...r 2 Locate the electrical cable of the lamp to be tested Disconnect the cable from the junction box attached to the light bar 3 Set a voltmeter to read 0 to 750V AC Insert the leads of the voltmeter i...

Page 54: ...Remove the hose and cable clamp retaining fasteners from the light bar and remove the clamp Lay the hydraulic hoses and main power cables with junction boxes attached over the back of the cabinet 4 A...

Page 55: ...be replaced and then torqued to specification during installation Refer to Section 2 Hydraulic Hose and Fitting Torque Specifications 1 Tag disconnect and plug the light bar cylinder hydraulic hoses...

Page 56: ...5HT Part No 1265482 3 1 Tower Component a tower extension cylinder b light bar c light bar cylinder d light bar lever e light bar link f tower tube number 3 g tower tube number 2 h tower tube number 1...

Page 57: ...hop Attempting this procedure without these skills and tools could result in death or serious injury and significant component damage Dealer service is required Note When removing a hose assembly or f...

Page 58: ...lift 3 4 How to Disassemble the Tower Note When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torqued to specification during installation Ref...

Page 59: ...and slide the number 2 and 3 tower tubes out of the number 1 tower tube and place them on a structure capable of supporting them Crushing hazard The number 2 and 3 tower tubes could become unbalanced...

Page 60: ...balancing 3 5 How to Remove the Tower Lift Cylinder The tower lift cylinder raises and lowers the tower assembly The tower lift cylinder is equipped with counterbalance valves to prevent movement in...

Page 61: ...the tower extension cylinder hydraulic hoses Cap the fittings on the cylinder Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow...

Page 62: ...to Adjust the Tower Rotation Gear Backlash The rotation motor mounting fasteners are located in slotted holes to allow the adjustment of gear backlash between the motor pinion gear and the rotation b...

Page 63: ...plug is faulty 4 3 Coolant Temperature and Oil Pressure Switches Kubota Engines The engine coolant temperature switch is a normally open switch The switch contacts close at approximately 225 F 107 C...

Page 64: ...3 Coolant Temperature and Oil Pressure Switches Isuzu 4LE1 The engine coolant temperature switch is a normally open switch The switch contacts close at approximately 221 F 105 C If the coolant tempera...

Page 65: ...3 Coolant Temperature and Oil Pressure Switches Isuzu 4LE2 The engine coolant temperature switch is a normally open switch The switch contacts close at approximately 221 F 105 C If the coolant tempera...

Page 66: ...7 3 Coolant Temperature and Oil Pressure Switches Isuzu 4LE2 T The engine coolant temperature switch is a normally open switch The switch contacts close at approximately 221 F 105 C If the coolant tem...

Page 67: ...pressure is placed on the components Use a spreader bar to ensure the lifting strap does not make contact with any portion of the doors 6 Remove the fasteners securing the top cabinet panel to the fro...

Page 68: ...the capacitor by shorting across the capacitor terminals Repeat for the second capacitor if equipped High voltage Exposure to electrical wires or electrical current will result in death or serious in...

Page 69: ...nerator 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 lead to...

Page 70: ...repeatedly until the arrow points to the actual day of the week 7 Press the hour button h repeatedly until the actual hour of the day is displayed 8 Press the minute button m repeatedly until the min...

Page 71: ...ved first 3 Remove the ballast box cover fasteners 4 Using an insulated conductor or a screwdriver with an insulated handle discharge the capacitor by shorting across the capacitor terminals Note Refe...

Page 72: ...nnect and plug the fuel hoses from the fuel tank Clean up any fuel that may have spilled Models without fuel containment option 4 Support the fuel tank support weldment at each end using lifting jacks...

Page 73: ...securing the fuel tank containment weldment to the chassis 9 Carefully lower the fuel tank out of the chassis and remove it from the machine Remove the fuel tank from the fuel containment weldment Com...

Page 74: ...the machine Before Troubleshooting 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 test...

Page 75: ...l Top off radiator and coolant overflow tank with correct coolant mixture per engine operator s manual Radiator blocked Clear the radiator fins Radiator or cooling system clogged or corroded Inspect a...

Page 76: ...er Replace filter Air or water mixed in fuel Air Tighten fule lines and vent fuel system air at injection pump Water Drain fuel and replace filter inspect and clean or replace injector as needed Fuel...

Page 77: ...d repair as needed Power supply cable connector faulty or poor connection Inspect and repair as needed Unusual noise from the generator Generator has a faulty bearing or faulty fan blade Inspect and r...

Page 78: ...he capacitor Faulty diode Replace the diode Faulty surge suppressor Replace the surge suppressor Generator voltage spikes Incorrect engine adjustment fuel line or faulty fuel Change fuel filter and ch...

Page 79: ...s and operating instructions in the appropriate operator s manual on your machine Be sure that all necessary tools and test equipment are available and ready for use About This Section There are two g...

Page 80: ...AL5HT Part No 1265482 Wire Color Legend 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...

Page 81: ...May 2015 Service Manual 71 Electrical Wiring Schematic ANSI CSA...

Page 82: ...Service Manual May 2015 72 AL5HT Part No 1265482 Electrical Wiring Schematic ANSI CSA Models...

Page 83: ...May 2015 Service Manual Part No 1265482 AL5HT 73 Electrical Wiring Schematic AUS Models...

Page 84: ...Service Manual May 2015 74 Electrical Wiring Schematic AUS...

Page 85: ...May 2015 Service Manual 75 Control Box Wiring Kubota Models...

Page 86: ...Service Manual May 2015 76 AL5HT Part No 1265482 Control Box and Engine Wiring Kubota Models...

Page 87: ...May 2015 Service Manual Part No 1265482 AL5HT 77 Control Box and Engine Wiring AUS Models...

Page 88: ...Service Manual May 2015 78 Control Box Wiring AUS Models...

Page 89: ...May 2015 Service Manual 79 Trailer Wiring Diagram ANSI CSA Models...

Page 90: ...Service Manual May 2015 80 AL5HT Part No 1265482 Trailer Wiring Diagram ANSI CSA Models...

Page 91: ...May 2015 Service Manual Part No 1265482 AL5HT 81 Trailer Wiring Diagram AUS Models...

Page 92: ...Service Manual May 2015 82 Trailer Wiring Diagram AUS Models...

Page 93: ...May 2015 Service Manual Part No 1265482 AL5HT 83 This page intentionally left blank AL5HT Part No 1265482 Service M anual May 2015...

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