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Terex AL4 Service Manual

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  • Page 2 One of our experienced staff members will get back to you with a quote for the right part that your machine needs. We sell worldwide for the brands: Genie, Terex, JLG, MultiQuip, Mayco, Toro/Stone, Diamond Products, Magnum, Airman, Mustang, Power Blanket, Nifty Lift, Atlas Copco,...
  • Page 3 Copyright © 2012 by Terex Corporation 218567 Rev B August 2016 First Edition, Second Printing Terex is a registered trademarks of Terex USA, LLC in the USA and many other countries. Printed on recycled paper Printed in U.S.A. AL4 • AL4000 Part No.

  • Page 4: Revision History

    Kubota Engine_Section 2_Specifi cations. A-6,B-3,C-7_Section 3_Maintenance Procedure. Click on any procedure or page number 3-2, 6-4, 9-1_Section 4_Repair Procedure. highlighted in blue to view the update. Fault Codes_Section 5. 6-35, 6-56, 6-104_Section 6_Schematic Page #. Part No. 218567 AL4 • AL4000...
  • Page 5 Kubota Engine_Section 2_Specifi cations. Electronic Version A-6,B-3,C-7_Section 3_Maintenance Procedure. Click on any procedure or page number 3-2, 6-4, 9-1_Section 4_Repair Procedure. highlighted in blue to view the update. Fault Codes_Section 5. 6-35, 6-56, 6-104_Section 6_Schematic Page #. AL4 • AL4000 Part No. 218567...

  • Page 6: Serial Number Legend

    August 2016 INTRODUCTION Serial Number Legend Part No. 218567 AL4 • AL4000...

  • Page 7: Safety Rules

    Be sure to wear protective eye wear and other protective clothing if the situation warrants it. 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. AL4 • AL4000 Part No. 218567...
  • Page 8 Be sure to properly dispose of old oil or other fl uids. Use an approved container. Please be environmentally safe. Be sure that your workshop or work area is properly ventilated and well lit. Part No. 218567 AL4 • AL4000...

  • Page 9: Table Of Contents

    Inspect the Manuals and Decals ..............3 - 5 Perform Pre-operation Inspection ..............3 - 6 Perform Function Tests ..................3 - 6 Section 3 Scheduled Maintenance Procedures, continued Perform Engine Maintenance ................3 - 7 Perform Coupler Maintenance ...............3 - 7 AL4 • AL4000 Part No. 218567 viii...
  • Page 10 Inspect the Suspension ................3 - 23 B-10 Perform Engine Maintenance - Kubota Models ...........3 - 24 Section 3 Scheduled Maintenance Procedures, continued Checklist C Procedures Perform Engine Maintenance ..............3 - 25 Clean the Light Assemblies .................3 - 25 Part No. 218567 AL4 • AL4000...
  • Page 11 Perform Generator Maintenance - Leroy Somer Models ......3 - 34 Perform Generator Maintenance - Leroy Somer Models ......3 - 34 Section 4 Repair Procedures Introduction ......................4 - 1 Mast Mast .......................4 - 2 Winch AL4 • AL4000 Part No. 218567...
  • Page 12 Control Box and Engine Wiring, (Perkins Models) ..........6 - 9 Control Box and Engine Wiring, (AUS) ..............6 - 12 Trailer Wiring Diagram, (ANSI / CSA) ..............6 - 13 Trailer Wiring Diagram, (AUS) ................6 - 15 Part No. 218567 AL4 • AL4000...

  • Page 13: Al4 • Al4000 Part

    August 2016 This page intentionally left blank. AL4 • AL4000 Part No. 218567...

  • Page 14: Specifi Cations

    50 psi 3.4 bar Continuous improvement of our products For operational specifi cations, refer to the is a Genie policy. Product specifi cations are Operator's Manual. subject to change without notice. Part No. 218567 AL4 • AL4000 2 - 1...

  • Page 15: Generator Options

    BS 6580:1992 or ASTMD 3306-89 or AS 2108-1977 Continuous improvement of our products is a Genie policy. Product specifi cations are subject to change without notice. 2 - 2 AL4 • AL4000 Part No. 218567...
  • Page 16 Ampere hour 75 A Cold cranking ampere Reserve capacity @ 25A rate 65 minutes Continuous improvement of our products is a Genie policy. Product specifi cations are subject to change without notice. Part No. 218567 AL4 • AL4000 2 - 3...
  • Page 17 Engine Operator Handbook on your machine. Injection system Injection pump make Bosch MD Continuous improvement of our products is a Genie policy. Product specifi cations are subject to change without notice. 2 - 4 AL4 • AL4000 Part No. 218567...
  • Page 18 August 2016 Section 2 • Specifi cations SPECIFICATIONS 10.9 12.9 Part No. 218567 AL4 • AL4000 2 - 5...
  • Page 19 Section 2 • Specifi cations August 2016 This page intentionally left blank. 2 - 6 AL4 • AL4000 Part No. 218567...

  • Page 20: Scheduled Maintenance Procedures

    Use only Terex approved replacement parts. Indicates a potentially hazardous NOTICE Machines that have been out of service for a situation which, if not avoided, period longer than 3 months must complete the may result in property damage.
  • Page 21 Make copies of the Maintenance Inspection Report to use for each inspection. Maintain completed forms in compliance with employer, job site and governmental regulations. 3 - 2 AL4 • AL4000 Part No. 218567...

  • Page 22: Maintenance Inspection Report

    After repair, place a check in the “R” box. Legend Y = yes, acceptable N = no, remove from service R = repaired Part No. 218567 AL4 • AL4000 3 - 3...
  • Page 23 After repair, place a check in the “R” box. Legend Y = yes, acceptable N = no, remove from service R = repaired 3 - 4 AL4 • AL4000 Part No. 218567...

  • Page 24: Checklist A Procedures

    Carefully and thoroughly inspect all decals on the machine for legibility and damage. Terex specifi cations require that this procedure be Result: The machine is equipped with all performed at the beginning of every work shift or required decals, and all decals are legible and daily, whichever comes fi...

  • Page 25: Perform Pre-Operation Inspection

    CHECKLIST A PROCEDURES Perform Pre-operation Inspection Perform Function Tests Terex specifi cations require that this procedure be Terex specifi cations require that this procedure be performed at the beginning of every work shift or performed at the beginning of every work shift or daily, whichever comes fi...

  • Page 26: Perform Engine Maintenance

    3 Check mounting bracket hardware for wear and proper tightness. Result: Replace bent, broken or worn hardware. Part No. 218567 AL4 • AL4000 3 - 7...

  • Page 27: Test The Brakes (If Equipped)

    Lug nut torque, dry 90 ft-lbs 1 Test the brakes for proper function. Repair or 122 Nm replace any faulty components as needed. Lug nut torque, lubricated 67.5 ft-lbs 91.5 Nm 3 - 8 AL4 • AL4000 Part No. 218567...

  • Page 28: Check The Tires And Wheels

    Note: Be sure the dust discharge valve is facing Air pressure 50 psi down when installed. 3.4 bar 8 Secure the end cap to the air cleaner cannister with the retaining clamps. Part No. 218567 AL4 • AL4000 3 - 9...

  • Page 29: Perform Generator Maintenance Leroy Somer Models

    Genie part number 131379 • Clean and inspect the generator exterior • Clean or replace the generator air fi lters - (if equipped) Leroy Somer Manual Genie part number 116118 3 - 10 AL4 • AL4000 Part No. 218567...

  • Page 30: Inspect The Cable And Cable Pulleys

    Inspect the Cable and Kubota Models Cable Pulleys Engine specifi cations require that this one time Terex specifi cations require that this procedure be procedure be performed after the fi rst 50 hours of performed monthly. operation. Detection of damage to the cable or pulleys is •...

  • Page 31: Perform Engine Maintenance - Kubota Models

    The cable must immediately be replaced. 7 Wind the cable onto the winch, ensuring that Kubota D1105 Operator's Manual Genie part number 131379 the cable is correctly installed onto each of the pulleys. 3 - 12 AL4 • AL4000 Part No. 218567...

  • Page 32: Perform Engine Maintenance - Kubota Models

    Electrocution/burn hazard. Contact with electrically charged circuits could result in death or serious injury. Remove all rings, watches and other jewelry. Marathon Manual Genie part number 116188 capacitor box generator Part No. 218567 AL4 • AL4000 3 - 13...

  • Page 33: Drain The Fuel Filter/Water Separator - Kubota Models

    fi lter/water separator before starting the engine. See step 5. 4 Start the engine from the ground controls and check the fuel fi lter/water separator for leaks. 3 - 14 AL4 • AL4000 Part No. 218567...

  • Page 34: Adjust The Brakes (If Equipped)

    Move the tip of the adjuster tool in an upwards direction to tighten the brakes. Note: It may be helpful to use a fl ashlight when locating the brake adjuster wheel. Part No. 218567 AL4 • AL4000 3 - 15...
  • Page 35 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. 3 - 16 AL4 • AL4000 Part No. 218567...

  • Page 36: Checklist B Procedures

    4 Fully charge the batteries. Allow the batteries to rest 24 hours before performing this procedure to allow the battery cells to equalize. Terex specifi cations requires that this procedure be 5 Put on protective clothing and eye wear. performed every 250 hours or quarterly, whichever 6 Remove the battery vent caps and check the comes fi...

  • Page 37: Inspect The Electrical Wiring

    • Add 0.004 to the reading of each cell for every 10° / 5.5° C above 80° F / 26.7° C. Terex specifi cations requires that this procedure be • Subtract 0.004 from the reading of each cell for performed every 250 hours or quarterly, whichever every 10°...

  • Page 38: Torque The Wheel Lug Nuts

    Torque the Wheel Lug Nuts Perform Engine Maintenance - Perkins Models Terex specifi cations requires that this procedure be Engine specifi cations require that this procedure performed every 250 hours or quarterly, whichever be performed every 250 hours or six months, comes fi...

  • Page 39: Perform Jack Maintenance

    Perform Jack Maintenance Inspect and Lubricate the Winch Jack specifi cations require that this procedure be Terex specifi cations require that this procedure be performed every 250 hours or quarterly, whichever performed every 250 hours or quarterly, whichever comes fi rst.

  • Page 40: Lubricate The T-Bolt

    CHECKLIST B PROCEDURES Lubricate the T-bolt Inspect and Adjust the Brakes (if equipped) Terex specifi cations require that this procedure be performed every 250 hours or quarterly, whichever Axle specifi cations require that this procedure comes fi rst. be performed every 3000 miles or quarterly, whichever comes fi...
  • Page 41 Note: This centers the brake shoes on the brake 9 Place the outer bearing into the hub. drum, ensuring the shoes are positioned correctly. 10 Install the washer and castle nut. 3 - 22 AL4 • AL4000 Part No. 218567...

  • Page 42: Inspect The Suspension

    1 Working with a fl ashlight or in a well lit shop, carefully inspect all suspension components 23 Repeat this procedure, beginning with step 2, and fasteners. Replace as necessary. for the other wheel. Part No. 218567 AL4 • AL4000 3 - 23...

  • Page 43: Perform Engine Maintenance - Kubota Models

    • Replace fuel fi lter Required maintenance procedures and additional engine information is available in the Kubota D1105 Operators Manual (Kubota part number 16622-89166) Kubota D1105 Operators Manual Genie part number 131379 3 - 24 AL4 • AL4000 Part No. 218567...

  • Page 44: Clean The Light Assemblies

    Section 3 • Scheduled Maintenance Procedures Checklist C Procedures Perform Engine Maintenance Clean the Light Assemblies Terex specifi cations require that this procedure Engine specifi cations require that this procedure be performed every 500 hours or semi-annually, be performed every 500 hours.

  • Page 45: Grease The Wheel Bearings

    23 Install the dust cap, then the tire and wheel 8 Pack both bearings with clean, fresh grease. assembly. Torque the wheel lug nuts to specifi cation. Refer to Section 2, Specifi cations. 3 - 26 AL4 • AL4000 Part No. 218567...

  • Page 46: Inspect The Electric Brake Magnets (If Equipped)

    2. springs on both sides of the axle if pitting or 3 With the engine running, press down on the any irregular surface wear is detected, and resurface the drake drums. Part No. 218567 AL4 • AL4000 3 - 27...

  • Page 47: Perform Engine Maintenance - Kubota Models

    20 Install the dust cap, then the tire and wheel assembly. Torque the wheel lug nuts to specifi cation. Refer to Section 2, Specifi cations. 21 Repeat this procedure, beginning with step 6, for the other side of the machine. 3 - 28 AL4 • AL4000 Part No. 218567...

  • Page 48: Perform Generator Maintenance Leroy Somer Models

    • Inspect and clean inside of outlet box, air screens and air baffl es with compressed air • Inspect for machine vibration and bearing wear Leroy Somer Manual Genie part number 116118 Part No. 218567 AL4 • AL4000 3 - 29...

  • Page 49: Checklist D Procedures

    Kubota D1105 Operators Manual Genie part number 131379 • Check resistance to ground on generator windings, main rotating assembly, stator, exciter fi eld and armature Leroy Somer Manual Genie part number 116118 3 - 30 AL4 • AL4000 Part No. 218567...

  • Page 50: Perform Coupler Maintenance

    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. 218567 AL4 • AL4000 3 - 31...

  • Page 51: Checklist E Procedures

    August 2016 Checklist E Procedures Replace the Mast Lift Cable Perform Engine Maintenance Terex specifi cations require that this procedure be Engine specifi cations require that this procedure performed every two years. be performed every 2000 hours or bi-annually, whichever comes fi rst.

  • Page 52: Perform Engine Maintenance

    Kubota D1105 Operator's Manual (Kubota part number 16622-89166) OR the Perkins 403D-11 User's Handbook (Perkins part number SEBU8311-01). Kubota D1105 Operator's Manual Genie part number 131379 Perkins 403D-11 User's Handbook Genie part number 131661 Part No. 218567 AL4 • AL4000 3 - 33...

  • Page 53: Perform Generator Maintenance Leroy Somer Models

    Genie part number 116118 • Inspect and clean generator components including generator windings • Replace the generator shaft bearings. Consult a trained Leroy Somer service professional. Leroy Somer Manual Genie part number 116118 3 - 34 AL4 • AL4000 Part No. 218567...

  • Page 54: Repair Procedures

    Indicates a potentially hazardous WARNING available and ready for use. situation which, if not avoided, Use only Terex approved replacement parts. could result in death or serious injury. Read each procedure completely and adhere to the instructions. Attempting shortcuts may...

  • Page 55: Mast

    4 Tag and disconnect the light heads from the mast junction box, and remove the light heads from the mast. 4 - 2 AL4 • AL4000 Part No. 218567...
  • Page 56 Refer to the illustration on the following page for cable routing. 7 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. 218567 AL4 • AL4000 4 - 3...
  • Page 57 Note: Refer to the illustration below for cable routing detail. 2 inch 4 inch 3 inch Mast Mast Mast Section Section Section Detail A Detail B Detail C 6 inch Winch Round Tube Base Assembly 4 - 4 AL4 • AL4000 Part No. 218567...

  • Page 58: Winch

    4 Remove the winch from the machine. 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. Part No. 218567 AL4 • AL4000 4 - 5...
  • Page 59 4 - 6 AL4 • AL4000 Part No. 218567...
  • Page 60 Bodily injury hazard. Cables can fray. Always wear adequate hand protection when handling the cable. Note: Be sure the end of the cable does not extend past the edge of the winch drum. Part No. 218567 AL4 • AL4000 4 - 7...

  • Page 61: Generator

    4 With both cabinet doors fully opened and above with high voltage electrical the top panel of the cabinet, secure the doors components. together using a length of rope or elastic cord. 4 - 8 AL4 • AL4000 Part No. 218567...
  • Page 62 6 Install the external wires onto the terminal block at the top of the generator. Securely tighten the fasteners. 7 Install the capacitor cover onto the generator. Install and securely tighten the fasteners. Part No. 218567 AL4 • AL4000 4 - 9...
  • Page 63 High voltage. Exposure to DANGER electrical wires or electrical current will result in death or serious injury. Remove all rings, watches and other jewelry. Use extreme caution when working with high voltage electrical components. 4 - 10 AL4 • AL4000 Part No. 218567...
  • Page 64 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. Part No. 218567 AL4 • AL4000 4 - 11...

  • Page 65: Engine

    RPM or counterclockwise to decrease the engine RPM. Tighten the locknut and repeat this procedure beginning with step 2. Perkins 403D-11 jamb nut adjustment screw 4 - 12 AL4 • AL4000 Part No. 218567...

  • Page 66: Troubleshooting

    • Light switches in the off position electrical components. • Wheels chocked Burn hazard. Contact with hot CAUTION engine components may cause severe burns. Use caution when working around lamps or a hot engine. General Repair Process Part No. 218567 AL4 • AL4000 5 - 1...
  • Page 67 Inspect for broken/seized piston rings OR inspect valve clearance Injector nozzle faulty Replace injector Combustion incomplete due to Inspect and repair as needed faulty injector timing, poor valve adjustment or poor compression 5 - 2 AL4 • AL4000 Part No. 218567...
  • Page 68 Fan belt slips Inspect and repair as needed Wiring loose or disconnected Inspect and repair as needed Faulty alternator, rectifi er or diode Inspect and repair as needed Faulty battery Replace Part No. 218567 AL4 • AL4000 5 - 3...
  • Page 69 If there is an obvious increase in voltage, replace the suppressor. Faulty capacitor Replace Loss of residual magnetism Flash the rotor Replace the generator Open winding 5 - 4 AL4 • AL4000 Part No. 218567...
  • Page 70 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 Faulty diode Replace Part No. 218567 AL4 • AL4000 5 - 5...
  • Page 71 Section 5 • Troubleshooting August 2016 This page intentionally left blank. 5 - 6 AL4 • AL4000 Part No. 218567...

  • Page 72: Schematics

    Be sure that all necessary tools and test equipment are available and ready for use. Part No. 218567 AL4 • AL4000 6 - 1...

  • Page 73: Wire Color Legend

    August 2016 Wire Colors Legend WIRE COLOR LEGEND Item Description Blue Black Brown Green Orange Violet White 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 6 - 2 AL4 • AL4000 Part No. 218567...

  • Page 74: Electrical Schematic, (Ansi / Csa)

    Section 6 • Schematics August 2016 Electrical Schematic (ANSI / CSA models) 6 - 3 6 - 4...
  • Page 75 16/5 CORD SET & CONNECTOR PIN 1 = NEUTRAL RECEPTACLE PIN 2 = 220V AC POWER (BALLAST) 5 POLE, TYP.4 PIN 3 = GROUND PIN 4 = GENERATOR NEUTRAL PIN 5 = FROM GENERATOR BREAKER 6 - 4 AL4 • AL4000 Part No. 218567...

  • Page 76: Electrical Schematic, (Aus)

    PIN 1 = NEUTRAL RECEPTACLE PIN 2 = 220V AC POWER (BALLAST) 5 POLE, TYP. 4 PIN 3 = GROUND PIN 4 = GENERATOR NEUTRAL PIN 5 = FROM GENERATOR BREAKER Part No. 218567 AL4 • AL4000 6 - 5...
  • Page 77 August 2016 Section 6 • Schematics Electrical Schematic (AS models) 6 - 5 6 - 6...

  • Page 78: Control Box And Engine Wiring (Kubota Models)

    Section 6 • Schematics August 2016 Control Box and Engine Wiring (Kubota Models) 6 - 7 6 - 8...
  • Page 79 SPST, NC SOLENIOD ALTERNATOR WH/BK STARTER PULL HOLD RD/BK GR/YL LOW OIL PRESSURE (NC) SWITCH TERMINAL HIGH COOLANT HOUR TEMPERATURE KEY POSITION METER (NO) GLOW PLUGS FUEL PUMP START WH/BK PRE-HEAT START 6 - 8 AL4 • AL4000 Part No. 218567...
  • Page 80 PULL HOLD GR/YL HIGH COOLANT TEMPERATURE (NO) LOW OIL PRESSURE (NC) SWITCH TERMINAL GLOW PLUGS HOUR KEY POSITION METER VOLTAGE REGULATOR START PRE-HEAT START VOLTAGE REGULATOR CONNECTOR (VIEW FROM WIRE SIDE) Part No. 218567 AL4 • AL4000 6 - 9...
  • Page 81 August 2016 Section 6 • Schematics Control Box and Engine Wiring (Perkins Models) 6 - 9 6 - 10...
  • Page 82 Section 6 • Schematics August 2016 Control Box and Engine Wiring (AS models) 6 - 11 6 - 12...
  • Page 83 HIGH COOLANT RD/BK HOUR TEMPERATURE BL/WH METER (NO) GLOW PLUGS FUEL PUMP YL/RD TO WINCH SOLENOID (TOWER DOWN) RD/BK TO WINCH BATTERY + WH/BK BL/WH TO WINCH SOLENOID (TOWER UP) START 6 - 12 AL4 • AL4000 Part No. 218567...

  • Page 84: Trailer Wiring Diagram, (Ansi / Csa)

    BRAKE LIGHT RIGHT LICENSE PLATE LIGHT BRAKE LIGHT 4-Way LEFT Connector Wiring MARKER LIGHT MARKER LIGHT LEFT FRONT LEFT REAR 6-Way 7-Way ‘Round Pin’ 7-Way ‘Blade’ Connector Wiring Connector Wiring Connector Wiring Part No. 218567 AL4 • AL4000 6 - 13...
  • Page 85 August 2016 Section 6 • Schematics Trailer Wiring Diagram (ANSI / CSA models) 6 - 13 6 - 14...
  • Page 86 RUNNING LIGHT GROUND GR/YL BUTT SPLICE LICENSE MARKER LIGHT GROUND BR/YL RUNNING LIGHT LEFT BRAKE LIGHT LEFT TURN INDICATOR VIEW OF ACTUAL LIGHT PRIENTATION RUNNING RED LENSE STOP TURN INDICATOR AMBER LENSE Part No. 218567 AL4 • AL4000 6 - 15...
  • Page 87 August 2016 Section 6 • Schematics Trailer Wiring Diagram (AS models) 6 - 15 6 - 16...
  • Page 88 www.discount-equipment.com...

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