Service Manual: AL5 AL5 With Tier 4 AL5000

Service Manual
AL5
AL5 with Tier 4
AL5000
Part No. 116476

Rev B
April 2015
Service Manual April 2015
Introduction
Intr oducti on Intr oducti on
Important Inform ati on
Important Technical Publications

Read, understand and obey the safety rules and Terex has endeavored to deliver the highest
operating instructions in the appropriate Operator's degree of accuracy possible. However, continuous
Manual on your machine before attempting any improvement of our products is a Terex policy.
maintenance procedure. Therefore, product specifications are subject to
change without notice.
This manual provides detailed scheduled
maintenance information for the machine owner Readers are encouraged to notify Terex of errors
and user. It also provides troubleshooting and and send in suggestions for improvement. All
repair procedures for qualified service communications will be carefully considered for
professionals. future printings of this and all other manuals.
Basic mechanical, hydraulic and electrical skills are

required to perform most procedures. However, Contact Us:
several procedures require specialized skills, tools,
lifting equipment and a suitable workshop. In these Internet: www.genielift.com
instances, we strongly recommend that E-mail: awp.techpub@terex.com
maintenance and repair be performed at an
authorized Terex dealer service center.
Copyright © 2014 by Terex Corporation

Compliance 116476 Rev B, April 2015
Second Edition, First Printing
Machine Classification
'Terex' and 'AWP' are registered trademarks of Terex USA, LLC
Group A/Type 1 as defined by ISO 16368 in the U.S.A. and many other countries.
Machine Design Life

Unrestricted with proper operation, inspection and
scheduled maintenance.
ii AL5 Part No. 116476

April 2015 Service Manual
Safety Rules
Serial Number Legend

To August 31, 2016
1 Model 1 Sequence number

2 Model year 2 Serial number (stamped on chassis)
3 Facility code 3 Serial label
From September 1, 2016
1 Model 1 Sequence number

2 Facility code 2 Serial number (stamped on chassis)
3 Serial label
Part No. 116476 AL5 3

Safety Rules
Gener al Safety R ules
Section 1 Safety 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.
iv AL5 Part No. 116476

Safety Rules
Personal Safety Workplace Safety

Any person working on or around a machine must Any person working on or around a machine must
be aware of all known safety hazards. Personal be aware of all known safety hazards. Personal
safety and the continued safe operation of the safety and the continued safe operation of the
machine should be your top priority. machine should be your top priority.
Read each procedure thoroughly. This Be sure to keep sparks, flames and
manual and the decals on the machine, lighted tobacco away from flammable and
use signal words to identify the following: combustible materials like battery gases
and engine fuels. Always have an
Safety alert symbol—used to alert approved fire extinguisher within easy
personnel to potential personal reach.
injury hazards. Obey all safety
messages that follow this symbol Be sure that all tools and working areas
to avoid possible injury or death. are properly maintained and ready for
use. Keep work surfaces clean and free of
Indicates a imminently hazardous debris that could get into machine
situation which, if not avoided, will components and cause damage.
result in death or serious injury.
Be sure any forklift, overhead crane or
Indicates a potentially hazardous other lifting or supporting device is fully
situation which, if not avoided, capable of supporting and stabilizing the
could result in death or serious weight to be lifted. Use only chains or
injury. straps that are in good condition and of
ample capacity.
Indicates a potentially hazardous
situation which, if not avoided, Be sure that fasteners intended for one
may cause minor or moderate time use (i.e., cotter pins and self-locking
injury. nuts) are not reused. These components
may fail if they are used a second time.
situation which, if not avoided, Be sure to properly dispose of old oil or
may result in property damage. other fluids. Use an approved container.
Please be environmentally safe.
Be sure to wear protective eye wear and
other protective clothing if the situation Be sure that your workshop or work area
warrants it. is properly ventilated and well lit.
Be aware of potential crushing hazards
such as moving parts, free swinging or
unsecured components when lifting or
placing loads. Always wear approved
steel-toed shoes.
Part No. 116476 AL5 v

April 2015
Table of Contents
Introduction Introduction .......................................................................................................... ii

Important Information ..............................................................................................ii
Serial Number Legend ........................................................................................... 3
Section 1 Safety Rules......................................................................................................... iv

General Safety Rules .............................................................................................iv
Section 2 Specifications ....................................................................................................... 1

Machine Specifications .......................................................................................... 1
Performance Specifications ................................................................................... 1
Performance Specifications ................................................................................... 1
Isuzu 4LE2 Engine ................................................................................................. 5
Isuzu 4LE2-T Engine ............................................................................................. 6
Machine Torque Specifications .............................................................................. 7
SAE and Metric Fasteners Torque Charts ............................................................. 8
Section 3 Scheduled Maintenance Procedures ................................................................. 9

Introduction ............................................................................................................ 9
Pre-Delivery Preparation Report .......................................................................... 12
Maintenance Inspection Report ........................................................................... 13
vi AL5 Part No. 116476

April 2015
Table of Contents
Checklist A Procedures ..................................................................................... 15

A-1 Inspect the Manuals and Decals.................................................................... 15
A-2 Perform Pre-operation Inspection .................................................................. 16
A-3 Perform Function Tests ................................................................................. 16
A-4 Perform Engine Maintenance ........................................................................ 17
A-5 Perform Coupler Maintenance ....................................................................... 17
A-6 Test the Brakes (if equipped)......................................................................... 18
A-7 Torque the Wheel Lug Nuts ........................................................................... 18
A-8 Check the Tires and Wheels .......................................................................... 19
A-9 Inspect the Engine Air Filter ........................................................................... 19
A-10 Perform Generator Maintenance ................................................................. 20
A-11 Perform Engine Maintenance ...................................................................... 21
A-13 Inspect the Cable and Cable Pulleys ........................................................... 22
A-16 Perform Generator Maintenance ................................................................. 24
A-17 Drain the Fuel Filter/Water Separator .......................................................... 24
A-18 Adjust the Brakes (if equipped).................................................................... 26
Checklist B Procedures ..................................................................................... 27

B-1 Inspect the Engine Start Battery .................................................................... 27
B-2 Inspect the Electrical Wiring .......................................................................... 28
B-3 Torque the Wheel Lug Nuts ........................................................................... 29
B-5 Perform Engine Maintenance ........................................................................ 29
B-5 Perform Jack Maintenance ............................................................................ 30
B-6 Inspect and Lubricate the Winch ................................................................... 30
B-7 Lubricate the T-bolt ........................................................................................ 31
B-8 Inspect and Adjust the Brakes (if equipped) .................................................. 31
B-9 Inspect the Suspension ................................................................................. 33
B-10 Perform Engine Maintenance ...................................................................... 34
Part No. 116476 AL5 vii

April 2015
Table of Contents
Checklist C Procedures ..................................................................................... 35

C-1 Perform Engine Maintenance........................................................................ 35
C-2 Clean the Light Assemblies........................................................................... 35
C-3 Grease the Wheel Bearings .......................................................................... 36
C-4 Inspect the Electric Brake Magnets .............................................................. 37
C-5 Perform Engine Maintenance........................................................................ 39
C-6 Perform Generator Maintenance .................................................................. 39
Checklist D Procedures ..................................................................................... 40

D-1 Perform Engine Maintenance........................................................................ 40
D-2 Perform Generator Maintenance .................................................................. 40
D-3 Perform Coupler Maintenance ...................................................................... 41
Checklist E Procedures ..................................................................................... 42

E-1 Inspect the Cable and Cable Pulleys ............................................................ 42
E-2 Perform Engine Maintenance ........................................................................ 43
E-3 Perform Engine Maintenance ........................................................................ 43
E-4 Perform Generator Maintenance ................................................................... 44
Section 4 Repair Procedures ............................................................................................. 46

Introduction .......................................................................................................... 46
Lighting ............................................................................................................... 48
1-1 How to Remove a Lamp ................................................................................ 48
1-2 How to Check Line Voltage ........................................................................... 48
1-3 How to Check the Open Circuit Voltage [Terex SM] ..................................... 49
viii AL5 Part No. 116476

April 2015
Table of Contents
Mast ..................................................................................................................... 50
2-1 How to Remove the Mast Assembly .............................................................. 50
2-2 How to Disassemble the Mast Assembly ....................................................... 50
2-3 How to Replace the Mast Lift Cables ............................................................. 51
2-4 How to Remove the Electric Winch ................................................................ 53
2-5 How to Disassemble the Manual Winch ........................................................ 53
2-6 How to Assemble the Manual Winch ............................................................. 54
2-7 How to Remove the Electric Winch ................................................................ 55
Kubota D1105-E / V1505-E Engine .................................................................... 56

3-1 Timing Adjustment-Kubota Engines ............................................................... 56
3-2 Glow Plugs-Kubota Engines .......................................................................... 56
3-3 Coolant Temperature and Oil Pressure Switches-Kubota Engines ............... 56
Isuzu 4LE1 Engine .............................................................................................. 57

4-1 Timing Adjustment-Isuzu 4LE1 ...................................................................... 57
4-2 Glow Plugs-Isuzu 4LE1 .................................................................................. 57
4-3 Coolant Temperature and Oil Pressure Switches-Isuzu 4LE1 ...................... 57
Isuzu 4LE2 Engine .............................................................................................. 58

5-1 Timing Adjustment-Isuzu 4LE2 ...................................................................... 58
5-2 Glow Plugs-Isuzu 4LE2 .................................................................................. 58
5-3 Coolant Temperature and Oil Pressure Switches-Isuzu 4LE2 ...................... 58
Isuzu 4LE2-T Engine .......................................................................................... 59

6-1 Timing Adjustment-Isuzu 4LE2-T ................................................................... 59
6-2 Glow Plugs-Isuzu 4LE2-T .............................................................................. 59
6-3 Coolant Temperature and Oil Pressure Switches-Isuzu 4LE2-T ................... 59
Part No. 116476 AL5 ix

April 2015
Table of Contents
Generator ............................................................................................................ 60
7-1 Generator ....................................................................................................... 60
7-2 How to Check a Generator Capacitor ............................................................ 61
7-3 How to Check a Generator Diode .................................................................. 62
Light Ballast ........................................................................................................ 63

8-1 Ground Controls ............................................................................................ 63
8-2 Light Ballast ................................................................................................... 63
Fuel Tank ............................................................................................................ 65

9-1 Fuel Tank ....................................................................................................... 65
Section 5 Diagnostics ......................................................................................................... 67

Introduction .......................................................................................................... 67
Diagnostic Charts .............................................................................................. 68
Section 6 Schematics ......................................................................................................... 73

Introduction .......................................................................................................... 73
Wire Color Legend ............................................................................................... 74
Electrical Wiring Schematic ANSI / CSA ............................................................. 76
Electrical Wiring Schematic AUS ......................................................................... 77
Control Box and Engine Wiring - Kubota Models ................................................ 80
Control Box and Engine Wiring - AUS Models .................................................... 81
Trailer Wiring Diagram - ANSI / CSA Models ...................................................... 84
Trailer Wiring Diagram - AUS Models .................................................................. 85
x AL5 Part No. 116476

Specifications
Section 2 Specific ati ons
Machine Specifications Generator Options

Machi ne Specific ations Performanc e Specific ati ons
Total lighting wattage 4 x 1000 watts Marathon 8 kW 201CSA5412

Fuel capacities Generator rpm @ full load 60Hz, 1800 rpm
Single tank 30 gallons Temperature, ambient maximum 104° F
114 liters 40° C
Large tank (option) 60 gallons Power 8 kW
227 liters Marathon 8 kW 201CSA5420
Tires and wheels
Generator rpm @ full load 60 Hz, 1800 rpm
Tire size ST205/75D15 Temperature, ambient maximum 104° F
Load range C 40° C
Lug nut torque, dry 90 ft-lbs Power 8 kW
122 Nm Marathon 12 kW 281CSL1513
Lug nut torque, lubricated 67.5 ft-lbs Generator rpm @ full load 60 Hz, 1800 rpm
91.5 Nm
Temperature, ambient maximum 104° F
Performance Specifications
Performanc e Specific ati ons
40° C
Tongue weight, maximum Power 12 kW

Marathon 20 kW 334CSA3028
With fuel (single tank) 150 lbs
68 kg Generator rpm @ full load 60 Hz, 1800 rpm
With fuel (large tank) 130 lbs Temperature, ambient maximum 104° F
59 kg 40° C
Run time Power 20 kW
Single tank 50 hours For operational specifications, refer to the
Large tank 100 hours Operator's Manual.
For operational specifications, refer to the Continuous improvement of our products is a
Operator's Manual. Genie policy. Product specifications are
subject to change without notice or obligation.
Continuous improvement of our products is a
Genie policy. Product specifications are
Part No. 116476 AL5 1

Specifications
Kubota D1105-E4BG Engine

Machi ne Specific ations
Injection system
Injection pump Bosch MD mini
Displacement 68.53 cu in
1.12 liters Injection timing 19° BTDC
Number of cylinders 3 Injection pump pressure, 1991 psi
maximum 137 bar
Bore and Stroke 3.07 x 3.09 inches
78 x 78.4 mm Fuel requirement
Horsepower 13.6 @ 1800 For fuel requirements, refer to the engine Operator
10.1 kW Manual for your engine.
Firing order 1-2-3 Battery
Compression ratio 23:1 Type 12V DC
Compression pressure 412 to 469 psi Group 27TM
28.4 to 32.3 bar Quantity 1
Engine speed 1800 rpm Cold cranking ampere 500
Governor centrifugal Reserve capacity @ 75A rate 105 minutes
mechanical
Alternator
Valve Clearance, cold 0.0057 to 0.0072 in
0.145 to 0.185 mm Alternator output 40A, 12V DC
Engine coolant Fan belt deflection 1/4 to 3/8 inch

7 to 9 mm
Capacity 3.27 quarts
3.1 liters
Lubrication system
Oil pressure 28 to 64 psi
1.93 to 4.41 bar
Oil capacity (including filter) 5.4 quarts
5.1 liters
Oil pressure switch (engine 7 psi
shutoff pressure)
Oil viscosity requirements
Unit ships with 10W-30. Extreme operating
temperatures may require the use of alternative engine
oils. For oil requirements, refer to the Engine Operator
Manual for your engine.
2 AL5 Part No. 116476

Specifications
Kubota D1505-E Engine

Injection system
Injection pump Bosch MD mini
Displacement 91.41 cu in
maximum 137 bar
78 x 78.4 mm Fuel requirement
Firing order 1-3-4-2 Battery
Compression ratio 22:1 Type 12V DC
Governor centrifugal Reserve capacity @ 75A rate 105 minutes
mechanical
Alternator
Valve Clearance, cold 0.0057 to 0.0072 in
0.145 to 0.185 mm Alternator output 30A, 12V DC
Engine coolant Fan belt deflection 1/4 to 3/8 inch

7 to 9 mm
Capacity 4.23 quarts
4 liters
Lubrication system
Oil pressure 28 to 64 psi
1.93 to 4.41 bar
6.7 liters
shutoff pressure)
Part No. 116476 AL5 3

Specifications
Isuzu 4LE1 Engine

Injection system
Injection pump Bosch, PFR type
Displacement 133 cu in
maximum 132.8 bar
85 x 96 mm Fuel requirement
Compression ratio 21.5:1 Type 12V DC
Governor variable speed, Reserve capacity @ 75A rate 105 minutes
mechanical
Alternator
Valve Clearance, cold
Alternator output 35A, 12V DC
Intake 0.0157 in
0.4 mm Fan belt deflection 1/4 to 3/8 inch
7 to 9 mm
Exhaust 0.0157 in
0.4 mm
Engine coolant
Capacity 4 quarts
3.8 liters
Coolant temperature switch 221°± 7°F
(engine shut-off temperature) 105° ± 4°C
Lubrication system
Oil pressure (hot @ 1800 rpm) 64 psi
4.4 bar
6.7 liters
shutoff pressure) 0.96 bar
4 AL5 Part No. 116476

Specifications
Isuzu 4LE2 Engine

Isuz u 4LE2 Engine
Injection system
maximum 132.8 bar
mechanical
Alternator
Intake 0.0157 in
7 to 9 mm
Exhaust 0.0157 in
0.4 mm
Engine coolant
Capacity 4 quarts
3.8 liters
Lubrication system
4.4 bar
6.7 liters
Part No. 116476 AL5 5

Specifications
Isuzu 4LE2-T Engine

Isuz u 4LE2-T Engine
Injection system
maximum 132.8 bar
mechanical
Alternator
Intake 0.0157 in
7 to 9 mm
Exhaust 0.0157 in
0.4 mm
Engine coolant
Capacity 4 quarts
3.8 liters
Lubrication system
4.4 bar
6.7 liters
6 AL5 Part No. 116476

Specifications
Machine Torque Specifications

Machi ne T orque Specifications
Wheel lugs
Lug nut torque, lubricated 67.5 ft-lbs
Generator 91.5 Nm
Flex plate to flywheel 15 ft-lbs Lug nut torque, dry 90 ft-lbs
20 Nm 122 Nm
Generator case to bell housing 30 ft-lbs Engine vibration isolators
41 Nm
Mounting bolts, dry 60 ft-lbs
Generator isolators 75 ft-lbs 81 Nm
102 Nm
Mounting bolts, lubricated 45 ft-lbs
61 Nm
Continuous improvement of our products is a

Genie policy. Product specifications are
Part No. 116476 AL5 7

Specifications
SAE and M etric F asteners Tor que C harts
8 AL5 Part No. 116476

Scheduled Maintenance Procedures
Machine Configuration:
Section 3 Schedul ed Mai ntenance Pr ocedures
Intr oducti on
 Unless otherwise specified, perform each

procedure with the machine in the following
configuration:
• Machine parked on a firm, level surface
• Mast in the stowed position
Observe and Obey:
• Key switch in the off position with the key
 Maintenance inspections shall be completed removed
by a person trained and qualified on the
maintenance of this machine. • The red Emergency Stop button in the off
position on the electrical control box
 Scheduled maintenance inspections shall be
completed daily, quarterly, semi-annually, • Wheels chocked
annually and every 2 years as specified of the • Light switches in the off position
Maintenance inspection Report. The frequency
and extent of periodic examinations and tests • All external AC power supply disconnected
may also depend on national regulations. from the machine
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 Terex approved replacement parts.
 Machines that have been out of service for a
period longer than 3 months must complete the
quarterly inspection.
Part No. 116476 AL5 9

About This Section

This section contains detailed procedures for each
scheduled maintenance inspection.
Each procedure includes a description, safety
warnings and step-by-step instructions.
Symbols Legend
Safety alert symbol—used to alert
personnel to potential personal
messages that follow this symbol
to avoid possible injury or death.
Indicates a imminently hazardous

situation which, if not avoided, will

situation which, if not avoided,
could result in death or serious
injury.

may cause minor or moderate
injury.

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
10 AL5 Part No. 116476

Maintenance Symbols Legend Pre-delivery Preparation Report

Note: The following symbols have been used in this The pre-delivery preparation report contains
manual to help communicate the intent of the checklists for each type of scheduled inspection.
instructions. When one or more of the symbols
appear at the beginning of a maintenance Make copies for each inspection. Store completed
procedure, it conveys the meaning below. forms as required.
Indicates that tools will be required to Maintenance Schedule

perform this procedure.
The Scheduled Maintenance Procedures section
and the Maintenance Inspection Report have been
Indicates that new parts will be required to divided into subsections. Use the following chart to
perform this procedure. determine which group(s) of procedures are
required to perform a scheduled inspection.
Indicates that dealer service will be Inspection Checklist

required to perform this procedure. Daily or every 8 hours A
Quarterly or every 250 hours A+B
Indicates that a cold engine will be Semi-annually or every 500 hours A+B+C
required to perform this procedure. Annually or every 1000 hours A+B+C+D
Two-year or every 2000 hours A+B+C+D+E
Indicates that a warm engine will be

required to perform this procedure. Maintenance Inspection Report
The maintenance inspection report contains
checklists for each type of scheduled inspection.
Make copies of the Maintenance Inspection Report
to use for each inspection. Maintain completed
forms for a minimum of 4 years or in compliance
with your employer, jobsite and governmental
regulations and requirements.
Part No. 116476 AL5 11

Pre-Delivery Preparation Report
Fundamentals Instructions
Pre-Deliv ery Prepar ati on Repor t
It is the responsibility of the owner or dealer to Use the operator’s manual on your machine.
perform the Pre-delivery Preparation.
The Pre-delivery Preparation consists of
The Pre-delivery Preparation is performed prior to completing the Pre-operation Inspection, the
each delivery. The inspection is designed to Maintenance items and the Function Tests.
discover if anything is apparently wrong with a
machine before it is put into service. Use this form to record the results. Place a check in
the appropriate box after each part is completed.
A damaged or modified machine must never be Follow the instructions in the operator’s manual.
used. If damage or any variation from factory
delivered condition is discovered, the machine If any inspection receives an N, remove the
must be tagged and removed from service. machine from service, repair and re-inspect it. After
repair, place a check in the R box.
Repairs to the machine may only be made by a
qualified service technician, according to the Legend
manufacturer's specifications. Y = yes, acceptable
N = no, remove from service
Scheduled maintenance inspections shall be R = repaired
performed by qualified service technicians, Comments
according to the manufacturer's specifications and
the requirements listed in the responsibilities
manual.
Pre-delivery Preparation Y N R
Pre-operation inspection completed
Maintenance items completed
Function tests completed
Model
Serial number
Date
Machine owner
Inspected by (print)
Inspector signature
Inspector title
Inspector company
Maintenance Inspection Report

Maintenanc e Ins pection R eport
Model Checklist A Y N R Checklist B Y N R

Serial number A-1 Inspect the manuals B-1 Batteries
Date and decals
B-2 Electrical wiring
Hour meter A-2 Pre-operation
inspection B-3 Lug nuts
Machine owner
A-3 Function tests B-4 Engine maintenance
- Isuzu models
Perform after 8 hours:
Inspector signature
B-5 Jack
Inspector title A-4 Engine maintenance
- Isuzu models B-6 Winch
Inspector company
Perform before towing: B-7 T-bolt
Instructions A-5 Coupler Perform every 3000 miles:
• Make copies of this report to use for A-6 Brakes (if equipped) B-8 Brakes (if equipped)
each inspection. Perform after 10 miles: B-9 Suspension
• Select the appropriate checklist(s) for
the type of inspection(s) to perform. A-7 Lug nuts Perform every 400 hours:
Daily or every 8 hours A Perform weekly: B-10 Engine maintenance
A+B - Kubota models
Quarterly or every A-8 Tires and wheels
250 hours
A-9 Engine air filter
Semi-annually or A+B+C
every 500 hours A-10 Generator
Annually or A+B+C+D maintenance
every A-11 Engine maintenance
1000 hours - Kubota models
Two-year or A+B+C+D+E Perform after 50 hours:
every
2000 hours A-12 Engine maintenance
- Kubota models
• Place a check in the appropriate box
after each inspection procedure is Perform monthly:
completed. A-13 Cables and pulleys
• Use the step-by-step procedures in
this section to learn how to perform Perform every 100 hours:
these inspections.
A-14 Engine maintenance
• If any inspection receives an "N," tag - Kubota models
and remove the machine from service,
repair and re-inspect it. After repair, Perform every 200 hours:
place a check in the "R" box.
A-15 Engine maintenance
- Kubota models
Legend A-16 Generator
Y = yes, acceptable maintenance
N = no, remove from service A-17 Fuel/Water
R = repaired separator
A-18 Brakes (if equipped)
Part No. 116476 AL5 13

Maintenance Inspection Report
Model Checklist C Y N R Checklist E Y N R

Serial number C-1 Engine maintenance E-1 Cable
Date C-2 Lights Perform every 2000 hours:
Hour meter
Perform every 6000 miles: E-2 Engine maintenance
Machine owner
C-3 Wheel bearings Perform every 3000 hours:
C-4 Brakes (if equipped) E-3 Engine maintenance
Inspector signature
Inspector title Perform every 800 hours: Perform every 10,000 hours:
Inspector company C-5 Engine maintenance - E-4 Generator

Kubota models maintenance
Perform every 2000 hours: Perform every 20,000 hours:
Instructions
C-6 Generator E-5 Generator
• Make copies of this report to use for
maintenance maintenance
each inspection.
• Select the appropriate checklist(s) for Checklist D Y N R Perform every 30,000 hours:
the type of inspection(s) to perform. Perform every 1500 hours: E-6 Generator
Daily or every 8 hours A maintenance
D-1 Engine maintenance
Quarterly or every A+B - Kubota models
250 hours Perform every 8000 hours: Comments
Semi-annually or A+B+C
every 500 hours D-2 Generator
maintenance
Annually or A+B+C+D
every Perform annually:
1000 hours D-3 Coupler
Two-year or A+B+C+D+E
every
2000 hours
• Place a check in the appropriate 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
14 AL5 Part No. 116476

Checklist A Procedures
Checklist A Procedur es
A-1
A-1 Ins pect the M anuals and D ec als
3 Open the operator's manual to the decals

inspection section. Carefully and thoroughly
Inspect the Manuals and Decals inspect all decals on the machine for legibility
and damage.
Result: The machine is equipped with all
Terex specifications require that this procedure be required decals, and all decals are legible and
performed every 8 hours or daily, whichever comes in good condition.
first. Result: The machine is not equipped with all
Maintaining the operator’s and safety manuals in required decals, or one or more decals are
good condition is essential to safe machine illegible or in poor condition. Remove the
operation. Manuals are included with each machine from service until the decals are
machine and should be stored in the container replaced.
provided in the platform. An illegible or missing 4 Always return the manuals to the storage
manual will not provide safety and operational container after use.
information necessary for a safe operating
condition. Note: Contact your authorized Terex distributor or
Terex if replacement manuals or decals are
In addition, maintaining all of the safety and needed.
instructional decals in good condition is mandatory
for safe machine operation. Decals alert operators
and personnel to the many possible hazards
associated with using this machine. They also
provide users with operation and maintenance
information. An illegible decal will fail to alert
personnel of a procedure or hazard 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 inside the cabinet.
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 not
appropriate for the machine or all manuals are
not in good condition or is illegible. Remove
the machine from service until the manual is
replaced.
Part No. 116476 AL5 15

A-2 A-3
A-2 Per form Pre- operation Ins pection A-3 Per form F uncti on Tes ts
Perform Pre-operation Inspection Perform Function Tests
Terex specifications require that this procedure be Terex specifications require that this procedure be
performed every 8 hours or daily, whichever comes performed every 8 hours or daily, whichever comes
first. first.
Completing a Pre-operation Inspection is essential Completing the function tests is essential to safe
to safe machine operation. The Pre-operation machine operation. Function tests are designed to
Inspection is a visual inspection performed by the discover any malfunctions before the machine is
operator prior to each work shift. The inspection is put into service. A malfunctioning machine must
designed to discover if anything is apparently never be used. If malfunctions are discovered, the
wrong with a machine before the operator performs machine must be tagged and removed from
the function tests. The Pre-operation Inspection service.
also serves to determine if routine maintenance
procedures are required. Complete information to perform this procedure is
available in the appropriate operator's manual.
Complete information to perform this procedure is Refer to the Operator's Manual on your machine.
available in the appropriate operator's manual.
Refer to the Operator's Manual on your machine.
16 AL5 Part No. 116476

A-4 A-5
A-4 Per form Engi ne M ai ntenance A-5 Per form C oupl er Mai ntenance
Perform Engine Maintenance Perform Coupler Maintenance
Engine specifications require that this procedure be Coupler specifications require that this procedure
performed every 8 hours or daily, whichever comes be performed before towing.
first.
Maintaining the coupler in good condition is
• Engine oil level – check essential to safe operation and good performance.
Coupler failure could result in a machine tip-over
• Coolant level – check/add during transport, and component damage may also
• Fuel system filter/water separator – drain result if problems are not discovered and repaired
in a timely fashion.
• Engine tightness – check for leaks
1 Check vehicle, mounting bracket, hitch ball
• Exhaust system – check for leaks and coupler for signs of wear or damage and
• Loose or missing fasteners that the coupler handle opens and closes
freely.
Required maintenance procedures and additional
engine information is available in the Kubota Result: if coupler and/or mounting bracket is
D1105-E and V1505-E Operator's Manual (Kubota deformed or damaged, replace complete
16683-89169 part number ) OR the Isuzu 4LE1 coupler and mounting bracket. Replace bent,
Diesel Engine Owner's Manual (Isuzu part number broken or worn parts before use.
IDE-6033) OR the Isuzu 4LE2 Diesel Engine 2 Close coupler securely by ensuring that the
Owner's Manual (Isuzu part number IDE-6450). hitch ball is fully seated in the coupler ball
pocket and the pin is inserted behind the collar
Isuzu 4LE1 Diesel Engine Owner's Manual
or latch.
Genie part number 116133
3 Check mounting bracket hardware for wear
and proper tightness.
Result: Replace bent, broken or worn
Kubota D-1105 and V-1505 Operator's Manual
hardware.
Part No. 116476 AL5 17

A-6 A-7
A-6 T est the Br akes (if equi pped) A-7 T orque the Wheel Lug N uts
Test the Brakes (if equipped) Torque the Wheel Lug Nuts
Axle specifications require that this procedure be Axle specifications require that this procedure be
performed before towing. performed initially at 10, 25 and 50 miles of use, or
after reinstallation of a tire.
Maintaining the axle brakes in good condition is
essential to safe operation and good performance. Maintaining the wheel lug nuts at proper torque is
Brakes which are out of adjustment can result in essential to safe operation and good service life of
longer stopping distances and excessive brake the tires, wheel and axle.
wear on the towing vehicle. Component damage
may also result if problems are not discovered and 1 Check each lug nut for proper torque. Refer to
repaired in a timely fashion. Specifications, Machine Specifications.
Test the brakes for proper function. Repair or

replace any faulty components as needed.
18 AL5 Part No. 116476

A-8 A-9
A-8 C heck the Tires and W heels A-9 Ins pect the Engi ne Air Filter
Check the Tires and Wheels Inspect the Engine Air Filter
Terex specifications require that this procedure be

Axle specifications require that this procedure be performed every 40 hours or weekly, whichever
performed weekly. comes first.
Maintaining the tires and wheels in good condition Maintaining the engine air filter in good condition is
and the tires at the correct pressure is essential to essential to good engine performance and service
safe operation and good performance. Tire and/or life. Failure to perform this procedure can lead to
wheel failure could result in a machine tip-over. poor engine performance and component damage.
Component damage may also result if problems
are not discovered and repaired in a timely fashion. Note: Perform this procedure with the engine off.
Bodily injury hazard. An 1 Open the engine side cover. Empty the dust
over-inflated tire can explode discharge valve by pressing together the sides
and could cause death or serious of the discharge slot. Clean the discharge slot
injury. as needed.
Tip-over hazard. Do not use

temporary flat tire repair
products.
1 Check all tire treads and sidewalls for cuts,

cracks, punctures and unusual wear.
2 Check each wheel for damage, bends and
cracked welds.
3 Check each lug nut for proper torque. Refer to
Specifications, Machine Specifications.
4 Check the pressure in each air-filled tire.
1 clamp
2 cannister end cap
3 dust discharge valve
Part No. 116476 AL5 19

A-10
A-10 Perform Gener ator Mai ntenance
2 Release the latches on the air cleaner cap.

Remove the end cap from the air cleaner Perform Generator Maintenance
canister.
3 Remove the filter element.
4 Use a damp cloth to wipe the filter sealing
Generator specifications require that this
surface and the inside of the outlet tube. Make
procedure be performed every 40 hours or weekly,
sure that all contaminant is removed before
whichever comes first.
the filter is inserted.
5 Check new filter element gasket for damage • Clean and inspect the generator exterior
before installing. • Clean and replace the generator air filters -
6 Install the new filter element. (if equipped)
7 Install the end cap on the canister and secure. Marathon Manual
Note: Be sure the discharge slot is pointing down.
20 AL5 Part No. 116476

A-11 A-12
A-11 Perform Engine M aintenanc e A-12 Perform Engine M aintenanc e
Perform Engine Maintenance - Perform Engine Maintenance -

Kubota Kubota
Engine specifications require that this procedure be Engine specifications require that this procedure be
performed every 100 hours. performed every 200 hours.
• Check fuel lines and clamps • Change engine oil

Required maintenance procedures and additional • Replace oil filter
engine information is available in the Kubota
D1105-E and V1505-E Operator's Manual (Kubota Required maintenance procedures and additional
16683-89169 part number ) engine information is available in the Kubota
D1105-E and V1505-E Operator's Manual (Kubota
Kubota D-1105 and V-1505 Operator's Manual 16683-89169 part number )
Genie part number 893020 Kubota D-1105 and V-1505 Operator's Manual
Part No. 116476 AL5 21

A-13
A-13 Ins pec t the C abl e and C able Pulleys
5 Visually inspect the winch cable for the

Inspect the Cables and Cable following:
Pulleys • nicks (partial strand cut through)

• kinks in the cable (permanent bends)
• weld splatter
Terex specifications require that this procedure be Result: Nicks, kinks in the cable or weld
performed monthly. splatter are. The cable must immediately be
Detection of damage to the cables or pulleys is replaced.
essential for safe machine operation. An unsafe 6 Visually inspect the winch cable for the
working condition exists if these components are following:
damaged and do not operate smoothly. Regular
inspection of this system allows the inspector to • crushed spot on the cable
identify changes in the operating condition that may Result: A crushed spot on the cable
indicate damage. measuring 125% of the cable diameter or
more is found OR there is a broken wire at the
1 Visually inspect the electric winch and cable
crush point. The cable must immediately be
pulleys for the following:
replaced.
• broken or damaged pulleys
7 Wind cable onto the winch, ensuring that the
• unusual or excessive pulley wear cable is correctly installed onto each of the
pulleys.
Result: A pulley is broken or damaged, or
shows unusual or excessive pulley wear. The
pulley must immediately be replaced.
2 Put on protective leather gloves and eye wear.
3 Fully unwind the cable from the winch.
4 Wearing leather gloves, run a hand up and
down a length of the cable, inspecting the
cable and components for the following:
• frayed or broken wire strands
Result: In any given one-foot of cable length
there are 4 or more broken wires on any 2 or
more strands. The cable must immediately be
replaced.
22 AL5 Part No. 116476

A-14 A-15
A-14 Perform Engine M aintenanc e A-15 Perform Engine M aintenanc e

Kubota Kubota
performed every 100 hours. performed every 200 hours.
• Clean air filter • Change engine oil

• Clean the fuel filter • Replace oil filter
• Inspect fan belt • Inspect radiator hoses and clamps
Required maintenance procedures and additional • Inspect air intake hose
D1105-E and V1505-E Operator's Manual (Kubota Required maintenance procedures and additional
16683-89169 part number ) engine information is available in the Kubota
Kubota D-1105 and V-1505 Operator's Manual 16683-89169 part number )
Genie part number 893020 Kubota D-1105 and V-1505 Operator's Manual
Part No. 116476 AL5 23

A-16 A-17
A-16 Perform Gener ator Mai ntenance A-17 Drai n the F uel Filter/W ater Separ ator
Perform Generator Maintenance Drain the Fuel Filter/Water

Separator
Generator specifications require that this performed every 200 hours or monthly, whichever
procedure be performed every 200 hours or comes first.
quarterly, whichever comes first.
Proper maintenance of the fuel filter/water
• Clean and inspect the generator exterior separator is essential for good engine performance.
Failure to perform this procedure can lead to poor
• Clean and replace the inside of the engine performance and component damage.
capacitor box. Check for loose or damaged
wires and components. Explosion and fire hazard.
Engine fuels are combustible.
Electrocution/burn hazard. Perform this procedure in an
Contact with electrically charged open, well-ventilated area away
circuits could result in death or from heaters, sparks, flames and
serious injury. Remove all rings, lighted tobacco. Always have an
watches and other jewelry. approved fire extinguisher within
easy reach.
Marathon Manual
Genie part number 116188 1 Locate the fuel filter/water separator and
loosen the vent plug located on the fuel
filter/water separator head.
2 Loosen the drain plug located at the bottom of
the bowl. Allow the water to drain into a
suitable container until fuel starts to come out.
Immediately tighten the drain plug.
a capacitor box
b generator
24 AL5 Part No. 116476

Bleed the fuel system:

5 Loosen the vent plug/screw located on the
filter head.
6 Operate the hand primer until fuel, free of air,
flows from the vent plug/screw. Tighten the
vent plug/screw on the filter head.
7 Loosen the vent screw, located on top of the
fuel injection pump.
8 Operate the hand primer until fuel, free of air,
flows from the vent plug/screw. Tighten the
vent plug/screw on the injection pump.
9 Clean up any fuel that may have spilled.
10 Attempt to start the engine using the starter
motor for a maximum of 15 seconds, resting
the starter for 30 seconds before trying again.
11 Inspect the fuel filter/water separator for leaks.
a head bolt Explosion and fire hazard. If a
b vent plug fuel leak is discovered, keep any
c separator head additional personnel from
d filter bowl entering the area and do not
e drain plug operate the machine. Repair the
3 Tighten the vent plug and clean up any spills leak immediately.
or wet surfaces.
Note: Information to perform this procedure is also
Note: If the fuel bowl is completely drained, available in the Kubota D1105-E and V1505-E
you must prime, or bleed, the fuel filter/water Operator's Manual (Kubota 16683-89169 part
separator before starting the engine. See step number)
5.
4 Start the engine from the electrical control
panel and check the fuel filter/water separator
for leaks.
Part No. 116476 AL5 25

A-18
A-18 Adj ust the Brak es (if equipped)
4 Insert a brake adjuster tool into the opening of

Test the Brakes (if equipped) the brake backing plate, engaging it with the
teeth of the brake adjuster wheel. Move the tip
of the adjuster tool in an upwards direction to
tighten the brakes.
Axle specifications require that this procedure be Note: It may be helpful to use a flashlight when
performed initially at 250 miles of use. locating the brake adjuster wheel.
Maintaining the axle brakes in good condition is 5 Repeatedly move the tip of the adjuster tool in
essential to safe operation and good performance. an upwards direction to tighten the brakes until
Brakes which are out of adjustment can result in the wheel locks up and will no longer turn.
longer stopping distances and excessive brake
Note: This centers the brake shoes on the brake
wear on the towing vehicle. Component damage
drum, ensuring the shoes are positioned correctly.
may also result if problems are not discovered and
repaired in a timely fashion. 6 Move the tip of the adjuster tool in a
downwards direction 3 to 5 clicks to loosen the
Note: Perform this procedure with the machine on
brakes only until the wheel spins freely with
a firm, level surface with the machine in the stowed
little drag.
position.
7 Securely install the small rubber plaug into the
1 Select a wheel. Chock the front and rear of the brake backing plate.
tire at the opposite side of the machine.
8 Check the wheel bearing wear by attempting
2 Place a lifting jack under the axle near the to move wheel hub side to side, then up and
brake to be adjusted. Lift the axle until the down.
wheel is off the ground and place a jack stand
under the axle. Lower the axle onto the jack There is no side to side or up and down
stand. movement. The bearing is good.
3 Working from the back side of the wheel at the There is side to side or up and down
brake backing plate, locate and remove the movement. The bearing must be adjusted or
small rubber plug from the lower side of the replaced. See B-8, Inspect and Adjust the
backing plate to access the star-shaped brake Brakes (if equipped).
adjuster wheel. Set the plug to the side. 9 Lift the axle slightly. Remove the jack stand
and lower the machine to the ground. Chock
the front and rear of the tire.
10 Repeat this procedure, beginning with step 2,
for the other wheel.
26 AL5 Part No. 116476

Checklist B Procedures
Models without maintenance-free or sealed
Checklist B Procedur es
B-1
B-1 Ins pect the Engi ne Start Battery
batteries:
Inspect the Engine Start Battery
5 Put on protective clothing and eye wear.
6 Remove the battery vent caps and check the
specific gravity of each battery cell with a
Terex specifications require that this procedure be hydrometer. Note the results.
performed every 250 hours or quarterly, whichever
comes first. 7 Check the ambient air temperature and adjust
the specific gravity reading for each cell as
Proper battery condition is essential to good engine follows:
performance and operational safety. Improper fluid
levels or damaged cables and connections can • Add 0.004 to the reading of each cell for
result in engine component damage and every 10° F / 5.5° C above 80° F / 26.7° C.
hazardous conditions. • Subtract 0.004 from the reading of each cell
for every 10° F / 5.5° C below 80° F / 26.7°
Electrocution/burn hazard. C.
Contact with electrically charged
circuits could result in death or Result: All battery cells display an adjusted
serious injury. Remove all rings, specific gravity of 1.277 or higher. The battery
watches and other jewelry. is fully charged. Proceed to step 11.
Result: One or more battery cells display a
Bodily injury hazard. Batteries specific gravity of 1.276 or below. Proceed to
contain acid. Avoid spilling or step 8.
contacting battery acid.
Neutralize battery acid spills with 8 Perform an equalizing charge OR fully charge
baking soda and water. the battery(s) and allow the battery(s) to rest at
least 6 hours.
Note: Fully charge the batteries and allow the 9 Remove the battery vent caps and check the
batteries to rest 24 hours before performing this specific gravity of each battery cell with a
procedure to allow the battery cells to equalize. hydrometer. Note the results.
1 Open the side covers.
2 Be sure that the battery cable connections are
free of corrosion.
Note: Adding terminal protectors 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 battery separator wire
connections are tight (if equipped).
Part No. 116476 AL5 27

10 Check the ambient air temperature and adjust B-2

B-2 Ins pect the Electrical Wiring
the specific gravity reading for each cell as

follows: Inspect the Electrical Wiring
• Add 0.004 to the reading of each cell for
every 10° F / 5.5° C above 80° F / 26.7° C.
• Subtract 0.004 from the reading of each cell Terex specifications require that this procedure be
for every 10° F / 5.5° C below 80° F / 26.7° performed every 250 hours or quarterly, whichever
C. comes first.
Result: All battery cells display a specific Maintaining electrical wiring in good condition is
gravity of 1.277 or greater. The battery is fully essential to safe operation and good machine
charged. Proceed to step 11. performance. Failure to find and replace burnt,
chafed, corroded or pinched wires could result in
Result: One or more battery cells display a
unsafe operating conditions and may cause
specific gravity from 1.218 to 1.269. The
component damage.
battery is still usable, but at a lower
performance. The battery will need to be Electrocution/burn hazard.
recharged more often. Proceed to step 11. Contact with electrically charged
Result: One or more battery cells display a circuits could result in death or
specific gravity from 1.217 to 1.173. The serious injury. Remove all rings,
battery is approaching the end of its life. watches and other jewelry.
Proceed to step 11.
1 Inspect the following areas for burnt, chafed,
Result: The difference in specific gravity corroded pinched and loose wires:
readings between cells is greater than 0.1 OR
the specific gravity of one or more cells is less • Ground controls
than 1.177. Replace the battery.
• Battery
11 Check the battery acid level. If needed,
• Engine
replenish with distilled water to 1/8 inch / 3 mm
below the bottom of the battery fill tube. Do not • Mast
overfill.
• Lighting junction box
12 Install the vent caps and neutralize any • Trailer lighting wire harness
electrolyte that may have spilled.
2 Inspect for a lite, even coating of dielectric
13 Close the side covers. grease in the following locations:
• Lighting junction box
• Ground controls
• All wire harness connectors
Note: Do not apply excessive amounts of dielectric
grease to harness connectors, pins or sockets.
• Note: Do not apply dielectric grease to a

engine ECU/ECM or engine harness
connectors.
28 AL5 Part No. 116476

B-3 B-4
B-3 T orque the Wheel Lug N uts B-5 Per form Engi ne M ai ntenance
Torque the Wheel Lug Nuts Perform Engine Maintenance
Axle specifications require that this procedure be Engine specifications require that this procedure be
performed initially at 10, 25 and 50 miles of use, or performed every 250 hours or six months,
after reinstallation of a tire. whichever comes first.
Maintaining the wheel lug nuts at proper torque is • Inspect alternator and fan belts
essential to safe operation and good service life of
the tires, wheel and axle. Required maintenance procedures and additional
1 Check each lug nut for proper torque. Refer to D1105-E and V1505-E Operator's Manual (Kubota
Specifications, Machine Specifications. 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 IDE-6450).

Part No. 116476 AL5 29

B-5 B-6
B-5 Per form J ack Mai ntenance B-6 Ins pect and Lubricate the Wi nch
Perform Jack Maintenance Inspect and Lubricate the Winch
Jack specifications require that this procedure be Terex specifications require that this procedure be
performed every 250 hours or quarterly, whichever performed every 250 hours or quarterly, whichever
comes first. comes first.
Maintaining the jack is essential to good machine Maintaining the winch is essential to good machine
performance and safe operation. An unsafe performance and safe operation. An unsafe
working condition exists if the jack has excessive working condition exists if the winch has excessive
wear and/or does not operate smoothly, free of wear and/or does not operate smoothly, free of
hesitation and binding. hesitation and binding.
1 Select a jack. 1 Carefully lubricate the winch.

2 Remove the cover from the top of the jack.
3 Apply a small amount of automotive grease to
the internal gearing, and rotate the handle
several times to evenly distribute the grease.
4 Apply a few drops of light oil to the jack handle
where it makes contact with the outside of the
jack tube.
5 Securely install the cover onto the jack.
for the other jackson the machine.
30 AL5 Part No. 116476

B-7 B-8
B-7 Lubric ate the T-bolt B-8 Ins pect and Adjust the Brak es (if equi pped)
Lubricate the T-bolt Inspect and Adjust the Brakes (if

equipped)

performed every 250 hours or quarterly, whichever Axle specifications require that this procedure be
comes first. performed every 3000 miles or quarterly,
Maintaining the T-bolt is essential to good machine whichever comes first.
performance and safe operation. An unsafe Maintaining the axle brakes in good condition is
working condition exists if the T-bolt has excessive essential to safe operation and good performance.
wear and/or does not operate smoothly, free of Brakes which are out of adjustment can result in
hesitation and binding. longer stopping distances and excessive brake
1 Using the illustration as a guide, locate the wear on the towing vehicle. Component damage
T-bolt at the bottom of the mast assembly. may also result if problems are not discovered and
Remove the T-bolt from the mast. repaired in a timely fashion.
2 Remove all dust, dirt and copper anti-seize Note: Perform this procedure with the machine on
from the threaded surfaces of the T-bolt, and a firm, level surface with the machine in the stowed
apply a few drops of light oil or copper position.
anti-seize lubricant onto the threaded
1 Select a wheel. Chock the front and rear of the
surfaces.
3 Fully install the T-bolt into the mast.
2 Loosen the wheel lug nuts. Do not remove
them.
3 Place a lifting jack under the axle near the
wheel to be removed. Lift the axle until the
under the axle. Lower the axle onto the jack
stand and remove the wheel.
4 Remove the dust cap from the hub. Remove
the cotter pin from the castle nut.
a T-bolt
5 Remove the castle nut and washer.
6 Pull the hub off of the spindle. The washer and
outer bearing should fall loose from the hub.
Part No. 116476 AL5 31

7 Inspect the brake lining for wear (if equipped). 14 Install a new cotter pin. Bend the cotter pin to
lock it in place.
Result: the thickness of the brake lining is
greater than 1/16 inch / 1.6 mm. The brake Note: Always replace the cotter pin with a new one
shoes are good. when removing the castle nut.
Result: the thickness of the brake lining is 15 Install the dust cap, then the tire and wheel
1/16 inch / 1.6 mm or less. The brake shoes assembly. Torque the wheel lug nuts to
must be replaced and the brake drums must specification. Refer to Section 2,
be inspected for wear, scoring and other Specifications.
damage.
16 Working from the back side of the wheel at the
Note: The maximum bore of a good brake drum brake backing plate, locate and remove the
shall not be greater than 0.090 inch / 2.29 mm in small rubber plug from the lower side of the
excess of the drum diameter. backing plate to access the star-shaped brake
Note: If drum resurfacing is required, the brake adjuster wheel. Set the plug to the side.
drum should be resurfaced to a 120 micron finish. 17 Insert a brake adjuster tool into the opening of
the brake backing plate, engaging it with the
Note: If replacing the brake shoes, apply a light
teeth of the brake adjuster wheel. Move the tip
coat of grease or anti-seize compound to the
of the adjuster tool in an upwards direction to
anchor pin, arm bushing and pin, and areas of the
tighten the brakes.
backing plate which contact the magnet arm and
brake shoes frame. Apply a small amount of lube to Note: It may be helpful to use a flashlight when
the actuating cam at the top of the magnet arm. Do locating the brake adjuster wheel.
not allow grease or oil to contact the brakes shoes
or the inside of the drum. 18 Repeatedly move the tip of the adjuster tool in
an upwards direction to tighten the brakes until
8 Slide the hub onto the yoke spindle. the wheel locks up and will no longer turn.
Component damage hazard. Do Note: This centers the brake shoes on the brake
not apply excessive force or drum, ensuring the shoes are positioned correctly.
damage to the lip of the seal may
19 Move the tip of the adjuster tool in a
occur.
downwards direction 3 to 5 clicks to loosen the
brakes only until the wheel spins freely with
9 Place the outer bearing into the hub.
little drag.
10 Install the washer and the castle nut.
11 Tighten the castle nut to 50 ft-lbs / 68 Nm to
seat the bearings.
12 Fully loosen the castle nut. Do not rotate the
hub.
13 Finger tighten the castle nut until snug.
32 AL5 Part No. 116476

B-9
B-9 Ins pect the Suspension
20 Securely install the small rubber plug into the

brake backing plate. Inspect the Suspension
21 Check the wheel bearing wear by attempting
to move wheel hub side to side, then up and
down.
Axle specifications require that this procedure be
There is no side to side or up and down
performed every 3000 miles or quarterly,
movement. The bearing is good.
There is side to side or up and down
movement. The bearing must be adjusted or Maintaining the axle suspension in good condition
replaced. See B-8, Inspect and Adjust the is essential to safe operation and good
Brakes (if equipped). performance. Towing the machine with worn or
damaged suspension components could result in a
22 Lift the axle slightly. Remove the jack stand tip-over. Component damage may also result if
and lower the machine to the ground. Chock problems are not discovered and repaired in a
the front and rear of the tire. timely fashion.
23 Repeat this procedure, beginning with step 2, 1 Working with a flashlight or in a well lit shop,
for the other wheel. carefully inspect all suspension components
and fasteners. Replace as necessary.
Part No. 116476 AL5 33

B-10
B-10 Perform Engine M aintenanc e
Perform Engine Maintenance -

Kubota
Engine specifications require that this procedure be

performed every 400 hours or semi-annually,
• Replace oil filter

• Replace fuel filter
16683-89169 part number )

34 AL5 Part No. 116476

Checklist C Procedures
C-2
Checklist C Procedur es C-2 Clean the Li ght Ass embli es
C-1
C-1 Perform Engine M aintenanc e
Perform Engine Maintenance - Clean the Light Assemblies

Kubota

performed every 500 hours or semi-annually,
performed every 500 hours.
Maintaining the light assemblies is essential to
• Replace fan belts
good machine performance. Failure to regularly
• Flush coolant system clean the light assemblies may result in less light
than expected and, over time, could result in
• Clean fuel tank damage to the machine.
Note: Perform this procedure with the light
assemblies out of direct sunlight and cool to the
touch.
1 Use clean, cool water to rinse the surface of
each light assembly.
2 Clean each light assembly using a soft cloth,
water and a mild dishwashing detergent.
Component damage hazard.
Harsh checmcals and cleaning
agents will damage the surface
of the light assembly. Do not
allow harsh cleaning agents to
make contact with the light
surface..
3 Thoroughly rinse, then dry with a soft cloth.
Part No. 116476 AL5 35

C-3
C-3 Gr eas e the W heel Bearings
5 Remove the castle nut and washer.

Grease the Wheel Bearings 6 Pull the hub off of the spindle. The washer and
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
Axle specifications require that this procedure be
rear bearing.
performed every 6,000 hours or semi-annually,
whichever comes first. 8 Pack both bearings with clean, fresh grease.
Maintaining the axle wheel bearings is essential to 9 Inspect the hub for wear. Replace if
safe machine operation and service life. Operating necessary.
a machine with loose or worn wheel bearings may
10 Place the large inner bearing into the rear of
cause an unsafe operating condition and continued
the hub.
use may result in component damage. Extremely
wet or dry conditions or regular steam cleaning and 11 Install a new bearing grease seal into the hub
pressure washing of the machine may require that by pressing it evenly into the hub until it is
this procedure be performed more often. flush.
Note: Perform this procedure with the machine on Note: Always replace the bearing grease seal when
a firm, level surface with the machine in the stowed removing the hub.
position.
12 Inspect the brake lining for wear (if equipped).
1 Select a wheel. Chock the front and rear of the
13 Inspect the brake cylinder for leaks (if
equipped).
2 Loosen the wheel lug nuts. Do not remove
14 Inspect the brake springs for wear or loss of
them.
arch (if equipped).
15 Inspect the brake wiring/hoses for wear (if
wheel to be removed. Lift the axle until the
equipped).
under the axle. Lower the axle onto the jack
stand and remove the wheel.
4 Remove the dust cap from the hub. Remove
the cotter pin from the castle nut.
36 AL5 Part No. 116476

C-4
C-4 Inspec t the El ectric Brake Magnets
16 Slide the hub onto the yoke spindle.

Component damage hazard. Do Inspect the Electric Brake
not apply excessive force or Magnets (if equipped)
occur.
17 Place the outer bearing into the hub. Axle specifications require that this procedure be
18 Install the washer and the castle nut. performed every 6,000 hours or semi-annually,
19 Tighten the castle nut to 50 ft-lbs / 68 Nm to
seat the bearings. Maintaining the axle brakes in good condition is
essential to safe operation and good performance.
20 Fully loosen the castle nut. Do not rotate the A faulty brake magnet can severely impact the
hub. stopping power of a trailer. While some magnet
21 Finger tighten the castle nut until snug. problems will be apparent upon visual inspection,
there may also be electrical problems that can
22 Install a new cotter pin. Bend the cotter pin to impact performance. A failing or faulty brake
lock it in place. magnet can lead to weak or surging brakes, or
Note: Always replace the cotter pin with a new one cause the brakes to pull to one side. It is important
when removing the castle nut. to inspect and test the magnets at regular intervals
to ensure maximum effectiveness.
23 Install the dust cap, then the tire and wheel
assembly. Torque the wheel lug nuts to 1 Connect the electric brake wire harness to a
specification. Refer to Section 2, tow vehicle capable of towing the machine.
Specifications. 2 Start the engine of the tow vehicle, and press
down on the brake pedal.
Result: An audible 'click' is noted at each
brake when the brake magnet is activated and
pulls itself into contact with the brake drum.
The brake circuit is functioning correctly.
Result: An audible 'click' is not noted at each
brake because the brake magnet is not
activated and does not make contact with the
brake drum. The brake circuit is faulty. Inspect
the wire harness and harness connections
and repair as required, and repeat this
procedure beginning with step 2.
Part No. 116476 AL5 37

3 With the engine running, press down on the 11 Locate the brake magnet. Inspect the surface
brake pedal and use a multimeter to measure of the magnet for pitting and any irregular
the total amp draw of the brake circuit by surface wear.
positioning an amp clamp around the brake
Result: Replace the magnets and magnet
wire lead near the trailer connector. Note the
springs on both sides of the axle if pitting or
reading.
any irregular surface wear is detected, and
Result: The total amp draw measures 5.5 to resurface the brake drums.
6.0 amps. The brake circuit is functioning
12 Inspect the copper coil at the center of the
correctly.
magnet.
Result: The total amp draw measures less
Result: Replace the magnets and magnet
than 5.5 amps. Replace the magnets and
springs on both sides of the axle if the
magnet springs on both sides of the axle, and
resurface the brake drums. Repeat this exposed copper coil is visible in any way, and
resurface the brake drums.
procedure beginning with step 4.
4 Stop the engine of the tow vehicle. 13 Slide the hub onto the yoke spindle.
5 Select a wheel. Chock the front and rear of the Component damage hazard. Do
tire at the opposite side of the machine. not apply excessive force or
6 Loosen the wheel lug nuts. Do not remove occur.
them.
14 Place the outer bearing into the hub.
wheel to be removed. Lift the axle until the 15 Install the washer and the castle nut.
under the axle. Lower the axle onto the jack 16 Tighten the castle nut to 50 ft-lbs / 68 Nm to
stand and remove the wheel. seat the bearings.
8 Remove the dust cap from the hub. Remove 17 Fully loosen the castle nut. Do not rotate the
the cotter pin from the castle nut. hub.
9 Remove the castle nut and washer. 18 Finger tighten the castle nut until snug.
10 Pull the hub off of the spindle. The washer and 19 Install a new cotter pin. Bend the cotter pin to
outer bearing should fall loose from the hub. 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 and wheel

assembly. Torque the wheel lug nuts to
specification. Refer to Section 2,
Specifications.
for the other side of the machine.
38 AL5 Part No. 116476

C-5 C-6
C-5 Perform Engine M aintenanc e C-6 Perform Generator Mai ntenance
Perform Engine Maintenance - Perform Generator Maintenance

Kubota

Engine specifications require that this procedure be procedure be performed every 2000 hours or
performed every 800 hours or annually, whichever semi-annually, whichever comes first.
comes first. Maintaining the generator in good condition is
essential to safe operation and long service life.
• Replace air filter
Storing the generator in a harsh environment may
• Inspect wiring require this procedure be performed more
frequently. Loose or damaged connections or
• Check valve clearance components may result in a generator to lose
Required maintenance procedures and additional efficiency, and reduce the life of the generator.
D1105-E and V1505-E Operator's Manual (Kubota • Inspect stator output leads and insulation
16683-89169 part number ) for cracking and damage.
• Inspect exposed electrical for loose or
damaged connections.
• Inspect transformers, fuses, capacitors and
lighting arrestors for loose or damaged
component connections.
• Inspect all wire and electrical connections
for proper clearance..
• Inspect and clean inside of outlet box, air
screens and air baffles with compressed air.
• Inspect for machine vibration and bearing
wear.
Marathon Manual
Part No. 116476 AL5 39

Checklist D Procedures
D-2
Checklist D Procedur es D-2 Perform Generator Mai ntenance
D-1
D-1 Perform Engine M aintenanc e
Perform Engine Maintenance - Perform Generator Maintenance

Kubota

procedure be performed every 8000 hours or
annually, whichever comes first.
performed every 1500 hours or bi-annually,
whichever comes first. Maintaining the generator in good condition is
• Injectors
Required maintenance procedures and additional require this procedure be performed more
engine information is available in the Kubota frequently. Poor resistance may result in a
D1105-E and V1505-E Operator's Manual (Kubota generator to lose efficiency, and reduce the life of
16683-89169 part number ) the generator.
Kubota D-1105 and V-1505 Operator's Manual • Check resistance to ground on generator
Genie part number 893020 windings, main rotating assembly, stator,
exciter field and armature.
Marathon Manual
40 AL5 Part No. 116476

Checklist D Procedures
D-3
D-3 Perform Coupler M aintenanc e
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.
Coupler failure could 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. Torque the fasteners to 35 ft-lbs / 48
Nm.
Result: 1.5 full threads of the locking bolt must
be exposed beyond the lock nut after the
adjustment.
2 Apply automotive grease to the coupler ball
pocket.
3 Oil coupler pivot points using SAE 30 motor
oil.
Part No. 116476 AL5 41

Checklist E Procedures
Checklist E Pro ced ures
E-1
E-1 Ins pect the C able and Cable Pulley s
5 Visually inspect the winch cable for the

following:
Inspect the Cables and Cable
Pulleys • nicks (partial strand cut through)
• kinks in the cable (permanent bends)
• weld splatter
Terex specifications require that this procedure be Result: Nicks, kinks in the cable or weld
performed every two years. splatter are. The cable must immediately be
replaced.
Detection of damage to the cables or pulleys is
essential for safe machine operation. An unsafe 6 Visually inspect the winch cable for the
working condition exists if these components are following:
damaged and do not operate smoothly. Regular
inspection of this system allows the inspector to • crushed spot on the cable
identify changes in the operating condition that may Result: A crushed spot on the cable
indicate damage. measuring 125% of the cable diameter or
more is found OR there is a broken wire at the
1 Visually inspect the electric winch and cable crush point. The cable must immediately be
pulleys for the following: replaced.
• broken or damaged pulleys 7 Wind cable onto the winch, ensuring that the
• unusual or excessive pulley wear cable is correctly installed onto each of the
pulleys.
Result: A pulley is broken or damaged, or
shows unusual or excessive pulley wear. The If the mast cables need replacing, refer to Repair
pulley must immediately be replaced. Procedure 2-3, How to Replace the Mast Lift
Cables.
2 Put on protective leather gloves and eye wear.
3 Fully unwind the cable from the winch.
4 Wearing leather gloves, run a hand up and
down a length of the cable, inspecting the
cable and components for the following:
• frayed or broken wire strands
Result: In any given one-foot of cable length
there are 4 or more broken wires on any 2 or
more strands. The cable must immediately be
replaced.
42 AL5 Part No. 116476

E-2 E-3
E-2 Per form Engi ne M ai ntenance E-3 Per form Engi ne M ai ntenance

Kubota Kubota
performed every 2000 hours or bi-annually, performed every 3000 hours.
• Inspect injection pump
• Replace coolant
• Inspect injection timing
• Replace radiator hoses and clamps
• Replace fuel hoses and clamps engine information is available in the Kubota
• Replace air intake hose and clamps 16683-89169 part number )
engine information is available in the Kubota Kubota D-1105 and V-1505 Operator's Manual
D1105-E and V1505-E Operator's Manual (Kubota Genie part number 893020

Part No. 116476 AL5 43

E-4 E-5
E-4 Per form Generator M aintenanc e E-5 Per form Generator M aintenanc e
Perform Generator Maintenance Perform Generator Maintenance
Generator specifications require that this Generator specifications require that this
procedure be performed every 10,000 hours. procedure be performed every 20,000 hours or
3 years, whichever comes first.
Maintaining the generator in good condition is
essential to safe operation and long service life. Maintaining the generator in good condition is
Regular replacement of the shaft bearing will essential to safe operation and long service life.
extend the life of the generator. Storing the generator in a harsh environment may
require this procedure be performed more
• Replace the generator shaft bearing. frequently. Allowing dirt and grease to build up on
Consult a trained Marathon service the generator may result in a generator which will
professional. run hotter, lose efficiency, and reduce the life of the
Marathon Manual generator.
Genie part number 116188 • Inspect and clean the generator and
windings for oil or dirt contamination.
Marathon Manual
44 AL5 Part No. 116476

E-6
E-6 Per form Generator M aintenanc e
Perform Generator Maintenance

procedure be performed every 30,000 hours or
5 years, whichever comes first.
Maintaining the generator in good condition is
require this procedure be performed more
frequently. Allowing dirt and grease to build up on
the generator may result in a generator which will
run hotter, lose efficiency, and reduce the life of the
generator. Regular replacement of the shaft
bearing will extend the service life of the generator.
• Disassemble the generator, including rotor

removal.
• Inspect and clean generator components
including generator windings.
• Replace the generator shaft bearings.
Consult a trained Marathon service
professional.
Marathon Manual
Part No. 116476 AL5 45

Repair Procedures
Machine Configuration:
Section 4 Repair Pr oc edures
Intr oducti on
 Unless otherwise specified, perform each

repair procedure with the machine in the
following configuration:
• Machine parked on a firm, level surface
• Mast in the stowed position
Observe and Obey:
• Key switch in the off position with the key
 Repair procedures shall be completed by a removed
person trained and qualified on the repair of
this machine. • The red Emergency Stop button in the off
damaged or malfunctioning machine. • Wheels chocked
 Repair any machine damage or malfunction • Light switches in the off position
before operating the machine. • All external AC power supply disconnected
from the machine
Before Repairs Start:
 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 Terex approved replacement parts.
 Read each procedure completely and adhere
to the instructions. Attempting shortcuts may
produce hazardous conditions.
46 AL5 Part No. 116476

Repair Procedures
About This Section

Most of the procedures in this section should only
be performed by trained service professional in a
suitably equipped workshop. Select the appropriate
repair procedure after troubleshooting the problem.
Perform disassembly procedures to the point
where repairs can be completed. Then to
re-assemble, perform the disassembly steps in
reverse order.
Symbols Legend
Safety alert symbol—used to alert
personnel to potential personal
messages that follow this symbol
to avoid possible injury or death.
Indicates a imminently hazardous

situation which, if not avoided, will

could result in death or serious
injury.

may cause minor or moderate
injury.

may result in property damage.
Indicates that a specific result is expected

Indicates that an incorrect result has occurred
Part No. 116476 AL5 47

Lighting
1-2
Lighting 1-2 H ow to Check Li ne Voltage
1-1
1-1 H ow to Rem ov e a Lam p
How to Remove a Lamp How to Check Line Voltage

Electrocution/burn hazard. Correct line voltage at the lamp socket is essential
Contact with electrically charged for proper operation of the lighting system.
circuits could result in death or
serious injury. Remove all rings, Electrocution/burn hazard.
watches and other jewelry. Contact with electrically charged
Burn hazard. Beware of hot lamp serious injury. Remove all rings,
components. Contact with hot watches and other jewelry.
lamp components may result in
severe burns. 1 Turn off all machine power.
2 Remove the cover from the lamp junction box.
1 Turn off all machine power.
Note: The junction box is located between the light
2 Remove the light lens mounting fasteners and housings at the top of the mast.
remove the lens.
1 Locate the correct wiring for the lamp to be
3 Remove the spring securing the lamp to the tested.
lamp retainer.
2 Connect a voltmeter to the lamp wires.
Contacting the lamp with bare 3 Start the engine.
skin can cause damage to the
4 Turn the appropriate circuit breaker light
lamp. Do not allow bare skin
switch to the "ON" position.
contact with the lamps.
5 Observe the voltage as the lamps warm up.
4 Wrap a clean cloth around the lamp and Refer to the following chart.
remove it from the socket.
Note: It can take up to 5 minutes for the lights to
Note: Be sure to wrap a clean cloth around the reach full intensity. If the lights are turned off and
lamp when installing it into the lamp socket. then turned back on while they are still warm, they
may not light up again for 10 to 20 minutes.
Time Line Voltage

Initial ignition 415V AC
30 seconds 412V AC
1 minute 413V AC
2 minutes 416V AC
5 minutes 246V AC
10 minutes 251V AC
Note: If voltage reading remains high during warm
up, check for loose or broken wire connections or
the lamp may be faulty.
Note: The voltage readings provided in the chart
are averages, voltage on your machine may vary.
48 AL5 Part No. 116476

Lighting
1-3
1-3 H ow to Check the Open Circ uit Voltage [T erex SM]
How to Check the Open Circuit

Voltage
Correct line voltage at the lamp socket is essential
for proper operation of the lighting system.
Electrocution/burn hazard.
serious injury. Remove all rings,
watches and other jewelry.
1 Turn off all machine power.

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 into pins A and B of
the electrical connector socket at the junction
box.
4 Start the engine.

5 Turn the appropriate circuit breaker light
switch to the "ON" position and observe the
reading on the voltmeter. Refer to the
following chart.
Open Circuit Voltage 375V AC to 465V AC
Specification
Note: If there is no reading on the meter. Repair or
replace the capacitor, ballast or wiring.
Part No. 116476 AL5 49

Mast
Mast
2-1
2-1 H ow to Rem ov e the Mast Ass embly
5 Remove the junction box from the light bar.

Lay the coil cord and junction box to the side.
How to Remove the Mast
Assembly 6 Remove the fasteners securing the mast base
to the chassis.
Bodily injury hazard. The 7 Attach a lifting strap from an overhead crane
procedures in this section to the mast base beneath the rotating section
require specific repair skills, and T-bolt. Remove the mast from the
lifting equipment and a suitable machine.
workshop. Attempting this
procedure without these skills 8 Unlock the mast hold-down pin at the mast
and tools could result in death or cradle.
serious injury and significant 9 Remove the mast pivot fasteners, securing the
component damage. Dealer lower end of the mast to the machine, and
service is required. remove the mast from the machine.
Bodily injury hazard. Cables
can fray. Always wear adequate
hand protection when handling
the cable.
1 Turn the handle of the mast winch and fully

loosen the mast cable.
2 Open the cabinet doors and locate the winch.
Remove the cable retaining fastener securing
the cable to the winch drum. Unwind the cable
from the winch drum.
3 Remove the fasteners securing the coil cable
cover onto the side of the mast. Set the cover
and fasteners to the side, and lay the coil
cable to the side.
4 Tag and disconnect the light heads from the
mast junction box, and remove the light heads
from the mast.
50 AL5 Part No. 116476

Mast
2-2
2-2 H ow to Disas sem ble the Mas t Assem bly
7 Working at the top of the 4 inch / 10 cm and

How to Disassemble the Mast 3 inch / 7.5 cm sections, use a drill to remove
the rivets securing the wear pads in position.
Assembly
1 Remove the mast assembly. See 2-1, How to The mast can be damaged if the
Remove the Mast Assembly. drill bit used is too large. Select
a drill bit only large enough to
2 Remove the T-bolt from the 6 inch / 15 cm remove the mandrel from the
round tube assembly. center of the rivet.
3 Remove the nut from the bottom of the mast.
Gently twist and pull the 6 inch / 15 cm round 8 Remove the fasteners securing the pulley and
tube assembly from the mast while pulling the shim to the 3 inch / 7.5 cm mast section. Set
cable free. the components to the side.
Bodily injury hazard. Cables 9 Remove the 2 inch / 5 cm mast section from
can fray. Always wear adequate the 3 inch / 7.5 cm mast section.
hand protection when handling 10 Remove the 3 inch / 7.5 cm mast section from
the cable. the 4 inch / 10 cm mast section.
Component damage hazard. Note: For ease of assembly, note the location
Cables can be damaged if they where each wear pad is removed.
are kinked or pinched.
Note: To ensure that the mast extends properly
Remove the large round plastic bushing from the after assembly, carefully measure the cable to
bottom of the 4 inch / 10 cm mast section. confirm that the new cable is the same length as
the old one.
4 Remove the 2.5 inch / 6 cm washer from the
bottom of the mast assembly. Note: During assembly, carefully install the mast
cable. Refer to the illustration on the following page
5 Pull the mast lock handle fully away from the for cable routing.
mast, then immediately secure the mast lock
in position using locking pliers or a clamp on
the lock handle to restrain it in position.
6 Remove the fasteners securing the pulley and
mast lock to the 4 inch / 10 cm mast section.
Set the components to the side.
Part No. 116476 AL5 51

Mast
2-3 Note: Refer to the illustration below for cable

2-3 H ow to Replace the M ast Li ft C abl es
routing detail.
How to Replace the Mast Lift
Cables
See 2-2, How to Disassemble the Mast Assembly.
52 AL5 Part No. 116476

Mast
2-4 2-5
2-4 H ow to Rem ov e the El ectric Wi nc h 2-5 H ow to Disas sem ble the Manual Wi nch
How to Remove the Electric How to Disassemble the Manual

Winch Winch
1 Turn the handle of the mast pivot winch and Note: For ease of disassembly, refer to the
fully loosen the mast pivot cable. Remove the illustration on the next page.
handle from the winch.
1 Remove the winch. See Repair Procedure,
2 Open the cabinet doors and locate the winch. How to Remove the Winch.
Remove the fasteners securing the handle to
the winch, and remove the handle. 2 On a workbench, remove the cable drum and
lock arm.
3 Remove the cable retaining fastener securing
the cable to the winch drum. Unwind the cable 3 Remove the lock gear and two jam nuts from
from the winch drum. the pinion shaft.
4 Remove the retaining ring from the small
Bodily injury hazard. Cables
groove at the non-threaded end of the pinion
can fray. Always wear adequate
hand protection when handling shaft. Rotate the pinion shaft until the shaft is
the cable. removed. Hold the winch components in place
while removing the pinion shaft.
4 Remove the winch from the machine. 5 Remove the ratchet pawl assemblies.
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 between the winch drum and the bushing
before disassembling.the winch from the machine.
Part No. 116476 AL5 53

Mast
2-6
2-6 H ow to As sem ble the M anual Winch
How to Assemble the Manual

Winch
1 Clean and inspect the winch components
before installing.
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 pinion shaft.
4 Insert the pinion shaft through the small
bushing in the winch frame, the pinion gear,
friction disc ratchet gear, friction disc, pinion
plate, spacer and finally through the large
bushing at the other side of the frame. Refer to
the illustration below.
a pinion shaft bushing - large
Component damage hazard. b spacer
Grease or oil on the friction disc c pinion plate
will result in poor winch
d friction disc
performance. Do not allow
e ratchet gear
grease or oil onto the friction
disk. f pinion gear
g pinion shaft
5 Install the retaining ring into the small groove h retaining ring
at the non-threaded end of the pinion shaft. i pinion shaft bushing - small
j ratchet pawl kit
6 Install the ratchet pawl kit as shown in the
k frame spacer
illustration. Securely tighten the fasteners.
l frame spacer nut
7 Insert the drum bolt through the drum bolt lock, m frame spacer bolt
winch frame, drum spacer, cable drum, frame, n drum bolt
lock arm spacer, lock arm and lock arm o drum bolt lock
bushing. Install and securely tighten the p drum spacer
locknut. q cable fasteners
8 Working from the threaded end of the pinion r cable
shaft, turn the shaft in a clockwise direction s cable drum
until the retaining ring, installed in step 5, is t lock arm spacer
against the winch frame. u lock arm bushing
v lock arm nut
w lock arm
x cable roller
y cable roller washer
z winch lock gear nut
aa winch lock gear
bb pinion shaft nuts
54 AL5 Part No. 116476

Mast
2-7
2-7 H ow to Rem ov e the El ectric Wi nc h
9 Install the two jam nuts onto the pinion shaft

and tighten. How to Remove the Electric
Component damage hazard. Be Winch
sure the pinion shaft is threaded
all the way into the winch drum 1 Lower the mast assembly to the stowed
before tightening the two jam position.
nuts.
2 Remove the fasteners and winch covers from
10 Install the lock gear and lock gear nut onto the the 6 inch / 15 cm mast assembly and set
pinion shaft and tighten. aside. Refer to the illustration below.
11 Install the winch onto the machine. Securely 3 On the electric winch, turn the yellow cap to
tighten the fasteners. Do not over tighten. the free spool position.
12 Route the cable onto the winch drum and Bodily injury hazard. Cables
install the cable retaining fasteners. Install the can fray. Always wear adequate
winch handle and wind the cable onto the hand protection when handling
drum. the cable.
Bodily injury hazard. Cables 4 Pull the cable to unwind it from the winch
can fray. Always wear adequate drum.
hand protection when handling
the cable. 5 Loosen the set screw securing the cable.
Note: Before removing the cable from the winch
Note: Be sure the end of the cable does not extend drum, make note of the cable routing. The cable
past the edge of the winch drum. must be routed the same way when installing the
electric winch.
6 Remove the fasteners securing the electric

winch to the 6 inch / 15 cm mast assembly.
a winch covers
b electric winch
c engaged/free spool lock
d 6 inch / 15 cm mast assembly
Part No. 116476 AL5 55

Kubota D1105-E / V1505-E Engine
3-3
Kubota D 1105-E / V1505-E Eng ine 3-3 C oolant T em per ature and Oil Press ure Swi tches-Kubota Engi nes
3-1
3-1 Timi ng Adjustment- Kubota Engines
Timing Adjustment-Kubota Coolant Temperature and Oil

Engines Pressure Switches-Kubota
Engines
Complete information to perform this procedure is
available in the Kubota 05 Series Workshop The engine coolant temperature switch is a
Manual (Kubota part number: 97897-02432). normally open switch. The switch contacts close at
approximately 225°F / 107°C. If the coolant
Kubota 05 Series Workshop Manual
temperature rises above the switch point, the
Genie part number 31742 switch contacts close and the engine will shut off to
prevent damage. The engine will not start until the
temperature drops below the switch point.
3-2
3-2 Glow Pl ugs-Kubota Engines
Additionally a low coolant level can cause the

Glow Plugs-Kubota Engines coolant temperature switch to not work properly.
Make sure that the coolant system is at proper
1 Disconnect the wiring and buss bar from the level.
glow plugs.
The engine oil pressure switch is a normally closed
2 Connect the leads from an ohmmeter between switch. The switch contacts open at approximately
each glow plug terminal and ground. 7 psi / 0.48 bar. If the oil pressure drops below the
Result: The resistance should be switch point, the contacts open and the engine will
approximately 1 ohm. shut off to prevent damage.
Result: The resistance is 0 ohm or greater

than 1 ohm. The glow plug is faulty.
56 AL5 Part No. 116476

Isuzu 4LE1 Engine
4-3
Isuzu 4L E1 En gin e 4-3 C oolant T em per ature and Oil Press ure Swi tches-Is uz u 4LE1
4-1
4-1 Timi ng Adjustment-Isuz u 4LE1
Timing Adjustment-Isuzu 4LE1 Coolant Temperature and Oil

Pressure Switches-Isuzu 4LE1
available in the Isuzu 4LE1 Workshop Manual The engine coolant temperature switch is a
(Isuzu part number: IDE-2270). normally open switch. The switch contacts close at
Isuzu Workshop Manual
4-2
4-2 Glow Pl ugs-Isuzu 4LE1

Glow Plugs-Isuzu 4LE1 coolant temperature switch to not work properly.
glow plugs.

Part No. 116476 AL5 57

Isuzu 4LE2 Engine
5-3
Isuzu 4L E2 En gin e 5-3 C oolant T em per ature and Oil Press ure Swi tches-Is uz u 4LE2
5-1
5-1 Timi ng Adjustment-Isuz u 4LE2
Timing Adjustment-Isuzu 4LE2 Coolant Temperature and Oil

Pressure Switches-Isuzu 4LE2
5-2
5-2 Glow Pl ugs-Isuzu 4LE2

Glow Plugs-Isuzu 4LE2 coolant temperature switch to not work properly.
glow plugs.

58 AL5 Part No. 116476

Isuzu 4LE2-T Engine
6-3
Isuzu 4L E2-T Eng ine 6-3 C oolant T em per ature and Oil Press ure Swi tches-Is uz u 4LE2-T
6-1 Timing Adjustment-Isuzu

6-1 Timi ng Adjustment-Isuz u 4LE2-T
4LE2-T Coolant Temperature and Oil

Pressure Switches-Isuzu 4LE2-T
6-2
6-2 Glow Pl ugs-Isuzu 4LE2-T

Glow Plugs-Isuzu 4LE2-T coolant temperature switch to not work properly.
glow plugs.

Part No. 116476 AL5 59

Generator
Gen er ator
7-1
7-1 Generator
6 Remove the fasteners securing the top

cabinet panel to the front and rear cabinet end
Generator panels. Remove the top cabinet panel and
doors from the machine and place it on a
High voltage. Exposure to support of adequate capacity.
electrical wires or electrical
current will result in death or 7 Pull the cover off the top of the capacitor box
serious injury. Turn off all power to access the wire harness where it connects
when not needed for testing. Use to the generator.
extreme caution when working
with high voltage electrical Burn hazard. Beware of hot
components. engine components. Contact
with hot engine components
Electrocution/burn hazard. may result in severe burns.
Attempting to service the
machine before the capacitor is 8 Using an insulated conductor or a screwdriver
fully discharged will result in with an insulated handle, discharge the
death or serious injury. capacitor by shorting across the capacitor
terminals. Repeat for the second capacitor, if
Note: Be sure the engine has been turned off for at equipped.
least 15 minutes before servicing the machine. Use
a voltmeter to confirm there is no residual voltage High voltage. Exposure to
in the capacitor. electrical wires or electrical
current will result in death or
1 Deploy the outriggers and level the machine. serious injury. Use extreme
caution when working with high
2 Remove the fasteners and the lifting bar from voltage electrical components.
the top of the cabinet and mast.
3 Select and open a cabinet door. Tag and 9 Tag and disconnect all external wires from the
disconnect the gas strut, then continue to generator.
open the door until it comes to rest above the 10 Use a lifting jack to support the rear of the
top panel of the cabinet. Repeat for the other engine. Do not apply any lifting pressure.
side of the machine.
11 Remove the fasteners securing the generator
4 With both cabinet doors fully opened and to the chassis.
above the top panel of the cabinet, secure the
doors together using a length of rope or elastic 12 Remove the fasteners securing the generator
cord. to the engine bellhousing.
5 Attach a lifting strap from an overhead crane 13 Pull the generator away from the engine just
to the top panel and doors assembly. Support enough to reach the fasteners securing the
the assembly. Do not apply any lifting generator rotor to the engine flywheel.
pressure. Remove the fasteners.
Notice: Component damage hazard. The cabinet 14 Remove the generator from the machine.
doors and/or hinges can become damaged if
excessive pressure is placed on the components. Crushing hazard. The generator
Use a spreader bar to ensure the lifting strap does may become unbalanced and fall
not make contact with any portion of the doors. if not properly supported when
removed from the machine.
60 AL5 Part No. 116476

Generator
7-2
7-2 H ow to Check a Generator C apaci tor
4 With an ohmmeter set to its highest resistance

How to Check a Generator scale, connect the ohmmeter leads to the
capacitor terminals and observe the reading
Capacitor on the meter. Then, reverse the connections
and observe the reading on the meter.
High voltage. Exposure to
electrical wires or electrical Result: The meter indicates a very low
current will result in death or resistance which then gradually increases
serious injury. Turn off all power AND a very high resistance which then
when not needed for testing. Use gradually decreases. The capacitor is working.
extreme caution when working Result: The meter indicates a very high
with high voltage electrical resistance which does not decrease. The
components. capacitor is faulty and should be replaced.
Electrocution/burn hazard. Result: The meter indicates a very low resistance
Attempting to service the which does not increase. The capacitor is faulty
machine before the capacitor is and should be replaced.
fully discharged will result in
death or serious injury.
Note: Be sure the engine has been turned off for at

a voltmeter to confirm there is no residual voltage
in the capacitor.
1 Remove the generator capacitor cover.

2 Using an insulated conductor or a screwdriver
with an insulated handle, discharge the
capacitor by shorting across the capacitor
terminals. Repeat for the second capacitor, if
equipped.
High voltage. Exposure to
serious injury. Use extreme
caution when working with high
voltage electrical components.
3 Tag and disconnect the wires attached to the

capacitor(s).
Part No. 116476 AL5 61

Generator
7-3
7-3 H ow to Check a Generator Di ode
5 Reverse the multimeter lead connections.

How to Check a Generator Diode Note the results.
Result: The two readings are at a ratio of
High voltage. Exposure to 3000:1 or higher. The diode is good.
Result: The two readings are at a ratio of less
than 3000:1. The diode is faulty and should be
serious injury. Turn off all power
replaced.
when not needed for testing. Use
extreme caution when working Note: Before installing a new diode, clean the
with high voltage electrical surface of the exciter rotor core, and run a bead of
components. a thermal-electrical compound around the base of
the diode (the threads of the diode should not be
Electrocution/burn hazard. coated). Torque to 20 to 30 in-lbs / 2.2 to 3.4 Nm.
Attempting to service the
machine before the capacitor is
fully discharged will result in
death or serious injury.

in the capacitor.
1 Remove the fasteners securing the end

cover/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, connect
one multimeter lead to the diode terminal and
the other multimeter lead to the 'Q' lead
terminal of the generator. Note the results.
Note: Refer to the instructions which are provided
for your multimeter to ensure the diode is
accurately tested.
62 AL5 Part No. 116476

Light Ballast
Light Ballast
8-1
8-1 Ground C ontrols
10 Use the day, hour and minute buttons to set

the timer to the desired start day and time.
Ground Controls
11 Press the program button (P) to set the timer
The timer is used to automatically start the engine for the desired shut-off time. AM 12:00 will
and turn on the lights at a preset time. appear in the display with a small 2 to the
right.
1 Move the engine start switch to timed start.
Note: The lamp symbol will not appear above the 2.
2 On the timer, move the mode switch (upper
left switch) to AUTO and the set switch (upper 12 Use the day, hour and minute buttons to set
right switch) to RUN. the timer to the desired shut-off day and time.
3 Using the tip of a pencil or pen, press the 13 Move the set switch to RUN.
Reset button (R). A blinking display will show
0:00 for the time and an arrow under the day 7
(for Sunday).
4 Move the set switch to the left (clock icon) to
set the present day and time.
5 A default time of AM 12:00 will appear on the
display screen.
6 Press the day button (1..7) 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 minute of the present hour is displayed.
9 Move the Set switch to the program position
(P) to set the desired stop and start time. A
default time of AM 12:00 will appear. A small
1 will appear to the right of the time with a
lamp symbol above it.
Part No. 116476 AL5 63

Light Ballast
8-2 Light Ballast

8-2 Light Ballas t
4 Using an insulated conductor or a screwdriver

with an insulated handle, discharge the
High voltage. Exposure to capacitor by shorting across the capacitor
electrical wires or electrical terminals.
current will result in death or Note: Refer to the instructions which are provided
serious injury. Turn off all power for your multimeter to ensure the diode is
when not needed for testing. Use accurately tested.
extreme caution when working
with high voltage electrical High voltage. Exposure to
components. electrical wires or electrical
Electrocution/burn hazard. serious injury. Turn off all power
Attempting to service the when not needed for testing. Use
machine before the capacitor is extreme caution when working
fully discharged will result in with high voltage electrical
death or serious injury. components.
5 With an ohmmeter set to its highest resistance
scale, connect the ohmmeter leads to the
capacitor terminals and observe the reading
in the capacitor.
on the meter. Then, reverse the connections
Note: This procedure is only for the capacitors and observe the reading on the meter.
which are attached to the lighting ballasts. To test a Result: The meter indicates a resistance
generator capacitor, see 5-2, How to Check a which then gradually decreases. The capacitor
Generator Capacitor. is working.
1 Open both cabinet doors and locate the light Result: The meter indicates a very high
ballast boxes on each side of the machine. resistance which does not decrease. The
2 Choose a ballast box. Tag and disconnect the capacitor is faulty and should be replaced.
wire harness connector from the ballast box. Result: The meter indicates a very low
Note: If the ballast capacitor to be tested is located resistance which does not increase. The
under another ballast box, the top ballast box will capacitor is faulty and should be replaced.
need to be removed first.
Probable causes of capacitor failure:
3 Remove the ballast box cover fasteners.
• Normal end-of-life failure.
• Overheated due to light fixture heat or high
ambient temperature.
• Incorrect capacitor voltage rating.
Capacitor becomes loose in ballast box.
64 AL5 Part No. 116476

Fuel Tank
Models without fuel containment option:

Fuel Tan k
9-1 Fuel Tank

9-1 F uel T ank
4 Support the fuel tank support weldment at

1 Open both cabinet doors. each end using lifting jacks and blocks. Do not
2 Remove the fuel filler cap from the tank. Using apply any lifting pressure. Do not directly
an approved hand-operated pump, drain the support the fuel tank.
fuel tank into a container of suitable capacity. Component damage hazard.
Refer to Section 2, Specifications. The fuel tank is plastic and may
Explosion and fire hazard. become damaged if the lifting
Engine fuels are combustible. jacks are in direct contact with
Perform this procedure in an the plastic tank.
open, well-ventilated area away
from heaters, sparks, flames 5 Remove the fasteners securing the fuel tank
and lighted tobacco. Always support weldment to the chassis.
have an approved fire 6 Carefully lower the fuel tank out of the chassis
extinguisher within easy reach. and remove it from the machine.
Explosion and fire hazard. When Component damage hazard. The
transferring fuel, connect a fuel tank is plastic and may
grounding wire between the become damaged if allowed to
machine and pump or container. fall.
Be sure to only use a hand Note: It may be necessary to lower the outriggers
operated pump suitable for use to the ground and raise the machine using the
with diesel fuel.damage hazard. outriggers to obtain adequate clearance to
Be sure not to cut the power to completely remove the fuel tank from the machine.
the platform wiring.
Note: Clean the fuel tank and inspect for cracks
3 Tag, disconnect and plug the fuel hoses from and other damage before installing it onto the
the fuel tank. Clean up any fuel that may have machine.
spilled.
Part No. 116476 AL5 65

Fuel Tank
Models with fuel containment option:

7 Support the fuel tank containment weldment at
each end using lifting jacks and blocks. Do not
apply any lifting pressure.
The fuel tank is plastic and may
become damaged if the lifting
jacks are in direct contact with
the plastic tank.
8 Remove the fasteners 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.
Component damage hazard. The
fuel tank is plastic and may
become damaged if allowed to
fall.
Note: It may be necessary to lower the outriggers

to the ground and raise the machine using the
outriggers to obtain adequate clearance to
completely remove the fuel tank from the machine.
Note: Clean the fuel tank and inspect for cracks
and other damage before installing it onto the
machine.
66 AL5 Part No. 116476

Diagnostics
Before Troubleshooting:
Section 5 Diagnostics
Intr oducti on
 Read, understand and obey the safety rules

 Be sure that all necessary tools and test
equipment are available and ready for use.
Observe and Obey:  Read each appropriate fault code thoroughly.
 Troubleshooting and repair procedures shall Attempting short cuts may produce hazardous
be completed by a person trained and qualified conditions.
on the repair of this machine  Be aware of the following hazards and follow
generally accepted safe workshop practices.
damaged or malfunctioning machine. Electrocution/burn hazard.
 Repair any machine damage or malfunction Contact with electrically charged
before operating the machine. circuits could result in death or
 Unless otherwise specified, perform each watches and other jewelry.
procedure with the machine in the following
configuration: High voltage. Exposure to
• Machine parked on a firm, level surface current will result in death or
• Mast in the stowed position serious injury. Turn off all power
when not needed for testing. Use
• Key switch in the off position with the key extreme caution when working
removed with high voltage electrical
• The red Emergency Stop button in the off components.
Burn hazard. Beware of hot
• Wheels chocked engine components. Contact
with hot engine components
• Light switches in the off position may cause severe burns. Use
• All external AC power supply disconnected caution when working around
from the machine lamps or a hot engine.
Part No. 116476 AL5 67

Diagnostic Charts
Diagno stic Ch arts
Problem Possible Cause Solution

Boom will not rise to the Yoke pin is in place Remove yoke pin.
operating position
Faulty cable or pulley Inspect and repair as needed.
Faulty winch Inspect and repair as needed.
Boom will not telescope Telescope lock pin closed Open telescope lock 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 Inspect and repair as needed.

corroded
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 Crankcase oil level is too high Drain oil to the proper level.
dense smoke
Low compression Inspect for broken/seized piston rings
or inspect valve clearance.
Injector nozzle faulty Replace injector.
Combustion incomplete due to faulty timing, Inspect and repair as needed.

poor valve adjustment or poor compression
68 AL5 Part No. 116476

Diagnostic Charts
Problem Possible Cause Solution

Engine runs rough Air or contaminated fuel in fuel system Inspect and repair as needed.
Clogged or leaking fuel system Replace fuel lines, tighten all
connections, inspect the fuel pickup
tube and inspect the fuel filter.
Clogged exhaust system Inspect and repair as needed.
Clogged air filter Inspect and repair or replace as

needed.
Clogged or stuck fuel injectors Inspect and repair as needed.
Faulty governor or fuel pump Inspect and repair as needed.
Engine turns over but will not Empty fuel tank Add fuel to tank.
start or is difficult to start
Leaking or pinched fuel lines Inspect and repair as needed.
Clogged fuel filter 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 injection nozzle clogged Inspect and repair as needed.
Fuel injection pump faulty Inspect and repair as needed.
Fuel solenoid valve faulty Inspect and repair as needed.
Faulty glow plug Inspect and repair as needed.
Faulty relay or wiring connection in control Inspect and repair as needed.

box
Battery is discharged or low Charge or replace battery.
Air cleaner is dirty Clean or replace more frequently.
Part No. 116476 AL5 69

Diagnostic Charts
Engine battery quickly Battery electrolyte low Add distilled water and charge.
discharged
Fan belt slips Inspect and repair as needed.
Wiring loose or disconnected Inspect and repair as needed.
Faulty alternator, rectifier or diode Inspect and repair as needed.
Faulty battery Replace battery.
Engine runs but battery voltage Faulty alternator Inspect and repair as needed.
is low
Engine runs but lights will not Circuit breaker has tripped Reset circuit breaker.
operate
Loose wiring connections Inspect and repair as needed.
Faulty generator Inspect and repair as needed.
Lamp light output low Dirty light fixture Clean light fixture.
Light heads are flashing on-off Batteries low Charge batteries.
Short in power supply cable Inspect and repair as needed.
Power supply cable connector faulty Inspect and repair as needed.
Light head will not illuminate End of life Replace lamp or light head.
Short in power supply cable Inspect and repair as needed.
Power supply cable connector faulty or poor Inspect and repair as needed.
connection
Unusual noise from the Generator has a faulty bearing or faulty fan Inspect and repair as needed.
generator blade
70 AL5 Part No. 116476

Diagnostic Charts
Generator produces full voltage Loose or broken lead wires Inspect lead wires and connections for
at no load or voltage drops at broken wires and loose connections.
full load
Rotor open or shorted Measure resistance between leads..
Stator grounded or shorted Contact the Genie Service

Department.
Generator voltage too high HIgh engine speed Adjust the rpm
Refer to Section 2, Specifications
Generator produces no voltage Faulty surge suppressor Disconnect suppressor from circuit. If
at no load or at full load there is an obvious increase in
voltage, replace the suppressor.
Faulty capacitor Replace capacitor.
Loss of residual magnetism Flash the rotor.
Open winding Replace the generator.
Generator will not hold voltage Machine has been unused for a significant Flash the rotor.
(loss of residual magnetism) length of time
Rotor shorting out when the unit gets hot Inspect rotor windings for broken
and/or burned wires.
Pinched leads Inspect and repair as needed.
Faulty capacitor Replace the capacitor.
Faulty diode Replace the diode.
Faulty surge suppressor Replace the surge suppressor.
Part No. 116476 AL5 71

Diagnostic Charts
Generator voltage spikes Incorrect engine adjustment, fuel line or Change fuel filter and check engine
faulty fuel speed.
Loose connection Inspect all connections and repair as
needed.
Faulty ground connection Inspect all ground connections and
repair as needed.
Load induced Filter load.
Generator voltage low Loss of residual magnetism Flash the rotor.

Low engine speed Adjust idle. See Repair Section.
Faulty capacitor Replace the capacitor.
Faulty diode Replace the diode.
72 AL5 Part No. 116476

Schematics
About This Section

Section 6 Schem atics
Intr oducti on
There are two groups of schematics in this section.
Electrical Schematics
Electrocution/burn hazard.
Observe and Obey: circuits could result in death or
 Troubleshooting and repair procedures shall watches and other jewelry.
be completed by a person trained and qualified
on the repair of this machine
Hydraulic Schematics
damaged or malfunctioning machine. Bodily injury hazard. Spraying
hydraulic oil can penetrate and
 Repair any machine damage or malfunction burn skin. Loosen hydraulic
before operating the machine.
connections very slowly to allow
Before Troubleshooting: the oil pressure to dissipate
gradually. Do not allow oil to
 Read, understand and obey the safety rules squirt or spray.
 Be sure that all necessary tools and test
equipment are available and ready for use.
Part No. 116476 AL5 73

Wire Color Legend
Wire Color Legend

Wire Col or 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 Red/Black
YL/RD Yellow/Red
BL/WH Blue/White
74 AL5 Part No. 116476

Electrical Wiring Schematic ANSI / CSA
75
Electrical Wiring Schematic ANSI / CSA Models

Elec trical Wiring Schem atic ANSI / CSA
76 AL5 Part No. 116476

Electrical Wiring Schematic AUS Models

Elec trical Wiring Schem atic AUS
Part No. 116476 AL5 77

Electrical Wiring Schematic AUS
78
Control Box Wiring - Kubota Models
79
Control Box and Engine Wiring - Kubota Models

Control Box and Engine Wiring - Kubota M odels
80 AL5 Part No. 116476

Control Box and Engine Wiring - AUS Models

Control Box and Engine Wiring - AUS Models
Part No. 116476 AL5 81

Control Box Wiring - AUS Models
82
Trailer Wiring Diagram - ANSI / CSA Models
83
Trailer Wiring Diagram - ANSI / CSA Models

Trailer Wiring Diagram - AN SI / C SA Models
84 AL5 Part No. 116476

Trailer Wiring Diagram - AUS Models

Trailer Wiring Diagram - AU S M odels
Part No. 116476 AL5 85

Trailer Wiring Diagram - AUS Models
86
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AL5 Part No. 116476 Servic e M anual April 2015
Part No. 116476 AL5 87

Service Manual: AL5 AL5 With Tier 4 AL5000

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Service Manual: AL5 AL5 With Tier 4 AL5000

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Service Manual

Part No. 116476

Important Technical Publications

Basic mechanical, hydraulic and electrical skills are

Copyright © 2014 by Terex Corporation

Machine Design Life

ii AL5 Part No. 116476

Serial Number Legend

1 Model 1 Sequence number

1 Model 1 Sequence number

Part No. 116476 AL5 3

Do Not Perform Maintenance

iv AL5 Part No. 116476

Personal Safety Workplace Safety

Part No. 116476 AL5 v

Introduction Introduction .......................................................................................................... ii

Section 1 Safety Rules......................................................................................................... iv

Section 2 Specifications ....................................................................................................... 1

Section 3 Scheduled Maintenance Procedures ................................................................. 9

vi AL5 Part No. 116476

Checklist A Procedures ..................................................................................... 15

Checklist B Procedures ..................................................................................... 27

Part No. 116476 AL5 vii

Checklist C Procedures ..................................................................................... 35

Checklist D Procedures ..................................................................................... 40

Checklist E Procedures ..................................................................................... 42

Section 4 Repair Procedures ............................................................................................. 46

viii AL5 Part No. 116476

Kubota D1105-E / V1505-E Engine .................................................................... 56

Isuzu 4LE1 Engine .............................................................................................. 57

Isuzu 4LE2 Engine .............................................................................................. 58

Isuzu 4LE2-T Engine .......................................................................................... 59

Part No. 116476 AL5 ix

Light Ballast ........................................................................................................ 63

Fuel Tank ............................................................................................................ 65

Section 5 Diagnostics ......................................................................................................... 67

Diagnostic Charts .............................................................................................. 68

Section 6 Schematics ......................................................................................................... 73

x AL5 Part No. 116476

Machine Specifications Generator Options

Total lighting wattage 4 x 1000 watts Marathon 8 kW 201CSA5412

Tongue weight, maximum Power 12 kW

Part No. 116476 AL5 1

Kubota D1105-E4BG Engine

Engine coolant Fan belt deflection 1/4 to 3/8 inch

2 AL5 Part No. 116476

Kubota D1505-E Engine

Engine coolant Fan belt deflection 1/4 to 3/8 inch

Part No. 116476 AL5 3

Isuzu 4LE1 Engine

4 AL5 Part No. 116476

Isuzu 4LE2 Engine

Part No. 116476 AL5 5

Isuzu 4LE2-T Engine

6 AL5 Part No. 116476

Machine Torque Specifications

Continuous improvement of our products is a

Part No. 116476 AL5 7

8 AL5 Part No. 116476