Terex Genie AL5HT, Service Manual

Page: 75 / 94

May 2015 Service Manual
Diagnostic Charts
Part No. 1265482 AL5HT 65
Problem Possible Cause Solution
Mast will not rise to the
operating position Mast retention pin is in place Retract the mast retention pin.
Faulty cable or pulley Inspect and repair as needed.
Faulty winch Inspect and repair as needed.
Engine will not turn over No power Inspect and repair battery cables and
connections as needed. Inspect and
charge or replace battery as needed.
Inspect and replace fuse.
Faulty starter Inspect and repair as needed.
Faulty starter switch Inspect and repair switch 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 blocked Clear the radiator fins.
Radiator or cooling system clogged or
corroded Inspect and repair as needed.
Fan or radiator cap faulty Inspect and repair as needed.
Thermostat faulty Inspect and repair as needed.
Head gasket faulty Inspect and repair as needed.
Fan belt is loose Tighten or replace fan belt.
Unsuitable fuel used Drain fuel system and replace with
specified fuel.
Engine runs but produces a
dense smoke Crankcase oil level is too high Drain oil to the proper level.
Low compression Inspect for broken/seized piston rings
or inspect valve clearance.
Injector nozzle faulty Replace injector.
Combustion incomplete due to faulty timing,
poor valve adjustment or poor compression Inspect and repair as needed.