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Summary of Contents for Terex Genie AL5HT
- Page 1 Service Manual AL5HT Part No. 1265482 Rev A May 2015...
- Page 2 Compliance 1255863 Rev A, May 2015 First 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.
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Page 3: Serial Number Legend
May 2015 Service Manual Safety Rules Serial Number Legend Serial Number Legend 1 Model 2 Model year 3 Sequence number 4 Serial label (located on cabinet) 5 Serial number (stamped on chassis) Part No. 1265482 AL5HT... - Page 4 Service Manual May 2015 Safety Rules 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.
- Page 5 May 2015 Service Manual 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.
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Page 6: Table Of Contents
May 2015 Table of Contents Introduction Introduction ......................ii Important Information ....................ii Serial Number Legend ..................3 Serial Number Legend ................... 3 Section 1 Safety Rules ......................iv General Safety Rules ..................... iv Section 2 Specifications ....................... 1 Machine Specifications ..................1 Performance Specifications ................... - Page 7 May 2015 Table of Contents Section 3 Scheduled Maintenance Procedures ..............9 Introduction ......................9 Pre-Delivery Preparation Report ................12 Maintenance Inspection Report................13 Checklist A Procedures ..................15 A-1 Inspect the Manuals and Decals..............15 A-2 Perform Pre-operation Inspection ..............16 A-3 Perform Function Tests .................
- Page 8 May 2015 Table of Contents Checklist C Procedures ..................28 C-1 Inspect the Tower Extend/Retract Cables and Pulleys ........ 28 C-2 Perform Engine Maintenance................ 29 C-3 Perform Axle Maintenance ................29 C-4 Perform Engine Maintenance................ 30 C-5 Perform Engine Maintenance................ 30 Checklist D Procedures ..................
- Page 9 1-1 How to Remove a Lamp ................. 42 1-2 How to Check Line Voltage ................42 1-3 How to Check the Open Circuit Voltage [Terex SM] ........43 Mast ........................44 2-1 How to Remove the Light Bar Assembly ............44 2-2 How to Remove the Light Bar Lift Cylinder ............
- Page 10 May 2015 Table of Contents Isuzu 4LE2-T Engine ..................56 7-1 Timing Adjustment-Isuzu 4LE2-T ..............56 7-2 Glow Plugs-Isuzu 4LE2-T ................56 7-3 Coolant Temperature and Oil Pressure Switches-Isuzu 4LE2-T ....56 Generator ......................57 8-1 Generator ....................... 57 8-2 How to Check a Generator Capacitor ............58 8-3 How to Check a Generator Diode ..............
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Page 11: Specifications
May 2015 Service Manual Specifications Section 2 Specific ati ons Machine Specifications Performance Specifications Total lighting wattage Tongue weight, maximum 4 lights 4000 watts With fuel (single tank) 150 lbs 8 lights 8000 watts 68 kg 4200 lbs With fuel (large tank) 130 lbs Axle load capacity, maximum 1905 kg... -
Page 12: Kubota D1105-E Engine Specifications
Service Manual May 2015 Specifications Kubota D1105-E4BG Engine Injection system Injection pump Bosch MD mini 68.53 cu in Displacement Injection timing 19° BTDC 1.12 liters Injection pump pressure, 1991 psi Number of cylinders maximum 137 bar Bore and Stroke 3.07 x 3.09 inches Fuel requirement 78 x 78.4 mm For fuel requirements, refer to the engine Operator... -
Page 13: Kubota D1505-E Engine Specifications
May 2015 Service Manual Specifications Kubota D1505-E Engine Injection system Injection pump Bosch MD mini 91.41 cu in Displacement Injection timing 19° BTDC 1.5 liters Injection pump pressure, 1991 psi Number of cylinders maximum 137 bar Bore and Stroke 3.07 x 3.09 inches Fuel requirement 78 x 78.4 mm For fuel requirements, refer to the engine Operator... -
Page 14: Isuzu 4Le1 Engine Specifications
Service Manual May 2015 Specifications Isuzu 4LE1 Engine Injection system Injection pump Bosch, PFR type 133 cu in Displacement Injection timing 16° BTDC 2.179 liters Injection pump pressure, 1920 psi Number of cylinders maximum 132.8 bar Bore and Stroke 3.35 x 3.78 inches Fuel requirement 85 x 96 mm For fuel requirements, refer to the engine Operator... -
Page 15: Isuzu 4Le2 Engine Specifications
May 2015 Service Manual Specifications Isuzu 4LE2 Engine Injection system Injection pump Bosch, PFR type 133 cu in Displacement Injection timing 16° BTDC 2.179 liters Injection pump pressure, 1920 psi Number of cylinders maximum 132.8 bar Bore and Stroke 3.35 x 3.78 inches Fuel requirement 85 x 96 mm For fuel requirements, refer to the engine Operator... -
Page 16: Isuzu 4Le2-T Engine Specifications
Service Manual May 2015 Specifications Isuzu 4LE2-T Engine Injection system Injection pump Bosch, PFR type 133 cu in Displacement Injection timing 16° BTDC 2.179 liters Injection pump pressure, 1920 psi Number of cylinders maximum 132.8 bar Bore and Stroke 3.35 x 3.78 inches Fuel requirement 85 x 96 mm For fuel requirements, refer to the engine Operator... -
Page 17: Machine Torque Specifications
May 2015 Service Manual Specifications Machine Torque Specifications Generator Flex plate to flywheel 15 ft-lbs 20 Nm Generator case to bell housing 30 ft-lbs 41 Nm Generator isolators 75 ft-lbs 102 Nm Wheel lugs Lug nut torque, lubricated 67.5 ft-lbs 91.5 Nm Lug nut torque, dry 90 ft-lbs... -
Page 18: Sae And Metric Fasteners Torque Charts
Service Manual May 2015 Specifications AL5HT Part No. 1265482... -
Page 19: Scheduled Maintenance Procedures
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. -
Page 20: About This Section
Service Manual May 2015 Scheduled Maintenance Procedures 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 injury hazards. - Page 21 May 2015 Service Manual Scheduled Maintenance Procedures 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.
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Page 22: Pre-Delivery Preparation Report
Service Manual May 2015 Pre-Delivery Preparation Report Fundamentals Instructions 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. -
Page 23: Maintenance Inspection Report
May 2015 Service Manual Maintenance Inspection Report Model Checklist A Y N R Checklist B Y N R Serial number Inspect the manuals Batteries and decals Date Electrical wiring Pre-operation Hour meter Lug nuts inspection Machine owner Function tests Hydraulic oil analysis Inspected by (print) Perform after 8 hours: Engine maintenance... - Page 24 Service Manual May 2015 Maintenance Inspection Report Model Checklist C Y N R Checklist E Y N R Serial number Inspect tower Hydraulic oil analysis extend/retract cables Date Perform every 3000 hours: Engine maintenance Hour meter Engine maintenance Perform every 6000 miles: Machine owner Perform every 2 years: Axle maintenance...
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Page 25: Checklist A Procedures
Result: The machine is equipped with all required decals, and all decals are legible and Terex specifications require that this procedure be in good condition. performed every 8 hours or daily, whichever comes first. -
Page 26: Perform Pre-Operation Inspection
May 2015 Checklist A Procedures 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. -
Page 27: Perform Engine Maintenance
May 2015 Service Manual Checklist A Procedures Perform Engine Maintenance Perform Generator Maintenance Engine specifications require that this procedure be Generator specifications require that this performed every 8 hours or daily, whichever comes procedure be performed every 40 hours or weekly, first. -
Page 28: Perform Axle Maintenance
Service Manual May 2015 Checklist A Procedures Perform Axle Maintenance Torque the Wheel Lug Nuts Axle specifications require that this procedure be Axle specifications require that this procedure be performed initially and following a wheel change performed initially at 10, 25 and 50 miles of use, or after the first 10, 25 and 50 miles. -
Page 29: Perform Engine Maintenance
May 2015 Service Manual Checklist A Procedures Perform Engine Maintenance Perform Coupler Maintenance Engine specifications require that this procedure be Coupler specifications require that this procedure performed every 50 hours or weekly, whichever be performed weekly. comes first. Maintaining the coupler in good condition is Required maintenance procedures and additional essential to safe operation and good performance. -
Page 30: Grease Turntable Bearing And Rotate Gear
Grease the Turntable Rotation Perform Engine Maintenance - Bearing and Rotate Gear Kubota Terex specifications require that this procedure be Engine specifications require that this procedure be performed every 100 hours of operation. performed every 100 hours. • Check fuel lines and clamps... -
Page 31: Perform Engine Maintenance
May 2015 Service Manual Checklist A Procedures A-12 Perform Engine Maintenance - Kubota Engine specifications require that this procedure be performed every 200 hours. • Change engine oil • Replace oil filter Required maintenance procedures and additional engine information is available in the Kubota D1105-E and V1505-E Operator's Manual (Kubota 16683-89169 part number ) Kubota D-1105 and V-1505 Operator's Manual... -
Page 32: Checklist B Procedures
Put on protective clothing and eye wear. 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 Check the ambient air temperature and adjust comes first. -
Page 33: Inspect The Electrical Wiring
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 performed every 250 hours or quarterly, whichever for every 10° F / 5.5° C below 80° F / 26.7°... -
Page 34: Torque The Wheel Lug Nuts
Torque the Wheel Lug Nuts Perform Hydraulic Oil Analysis Axle specifications require that this procedure be Terex specifications require that this procedure be performed initially at 10, 25 and 50 miles of use, or performed every 250 hours or quarterly, whichever after reinstallation of a tire. -
Page 35: Perform Engine Maintenance
May 2015 Service Manual Checklist B Procedures Perform Engine Maintenance Perform Engine Maintenance Engine specifications require that this procedure be Engine specifications require that this procedure be performed every 250 hours or six months, performed every 250 hours or six months, whichever comes first. -
Page 36: Perform Generator Maintenance
Service Manual May 2015 Checklist B Procedures Perform Generator Maintenance Perform Coupler Maintenance Generator specifications require that this Coupler specifications require that this procedure procedure be performed every 40 hours or weekly, be performed quarterly. whichever comes first. Maintaining the coupler in good condition is •... -
Page 37: Perform Engine Maintenance
May 2015 Service Manual Checklist B Procedures B-10 Perform Engine Maintenance Perform Axle Maintenance Engine specifications require that this procedure be Axle specifications require that this procedure be performed every 400 hours. performed quarterly or every 3,000 miles, whichever comes first. Required maintenance procedures and additional engine information is available in the Kubota Proper axle maintenance, following the axle... -
Page 38: Checklist C Procedures
Cables and Pulleys • kinks in the cable • corrosion • paint or foreign materials Terex specifications require that this procedure be performed every 500 hours or semi-annually, • split or cracked cable ends whichever comes first. • cables are on all pulleys Maintaining the winch is essential to good machine •... -
Page 39: Perform Engine Maintenance
May 2015 Service Manual Checklist C Procedures Perform Engine Maintenance Perform Axle Maintenance Engine specifications require that this procedure be Axle specifications require that this procedure be performed every 50 hours or weekly, whichever performed semi-annually or every 6,000 miles, comes first. -
Page 40: Perform Engine Maintenance
Service Manual May 2015 Checklist C Procedures Perform Engine Maintenance Perform Engine Maintenance Engine specifications require that this procedure be Engine specifications require that this procedure be performed every 750 hours. performed every 800 hours. Required maintenance procedures and additional Required maintenance procedures and additional engine information is available in the Isuzu 4LE1 engine information is available in the Kubota... -
Page 41: Checklist D Procedures
1000 hours or annually, whichever comes first. Required maintenance procedures and additional engine information is available in the Kubota Note: Terex requires that this procedure be D1105-E and V1505-E Operator's Manual (Kubota performed every 1000 hours or annually, 16683-89169 part number ). -
Page 42: Replace The Hydraulic Return Filter
Replace the Hydraulic Return sequence to specification. Refer to Section 2, Specifications. Filter Terex specifications require that this procedure be performed every 1000 hours or quarterly, whichever comes first. Replacement of the hydraulic filters is essential for good machine performance and service life. A dirty... -
Page 43: Perform Engine Maintenance
May 2015 Service Manual Checklist D Procedures Perform Engine Maintenance Perform Engine Maintenance Engine specifications require that this procedure be Engine specifications require that this procedure be performed every 1000 hours or annually, performed every 1250 hours or annually, whichever comes first. whichever comes first. -
Page 44: Perform Engine Maintenance
Service Manual May 2015 Checklist D Procedures Perform Engine Maintenance Perform Generator Maintenance Engine specifications require that this procedure be Generator specifications require that this performed every 1500 hours. procedure be performed every 1500 hours or annually, whichever comes first. Required maintenance procedures and additional engine information is available in the Kubota Maintaining the generator in good condition is... -
Page 45: Perform Tongue Jack And Outrigger Jack Maintenance
May 2015 Service Manual Checklist D Procedures Perform Tongue Jack and Perform Axle Maintenance Outrigger Jack Maintenance Axle specifications require that this procedure be performed annually or every 12,000 miles, Tongue and outrigger jack specifications require whichever comes first. that this procedure be performed annually. Proper axle maintenance, following the axle Required maintenance procedures and additional manufacturer's maintenance schedule, is essential... -
Page 46: Checklist E Procedures
Bodily injury hazard. Spraying hydraulic oil can penetrate and burn skin. Loosen hydraulic connections very slowly to allow Terex requires that this procedure be performed the oil pressure to dissipate every 2000 hours or every two years,whichever gradually. Do not allow oil to comes first. -
Page 47: Perform Engine Maintenance
May 2015 Service Manual Checklist E Procedures 10 Rinse out the inside of the reservoir using a mild solvent. Perform Engine Maintenance 11 Install the suction strainer. 12 Install the hydraulic reservoir onto the power unit. Engine specifications require that this procedure be 13 Install the hydraulic reservoir retaining performed every 3000 hours. -
Page 48: Perform Engine Maintenance
Service Manual May 2015 Checklist E Procedures Perform Engine Maintenance Perform Generator Maintenance Engine specifications require that this procedure be Generator specifications require that this performed every two years. procedure be performed every 4500 hours or every three years, whichever comes first. Required maintenance procedures and additional engine information is available in the Kubota Maintaining the generator in good condition is... -
Page 49: Perform Generator Maintenance
May 2015 Service Manual Checklist E Procedures Perform Generator Maintenance Generator specifications require that this procedure be performed every 15,000 hours or every 19 years, whichever comes first. Maintaining the generator in good condition is essential to safe operation and long service life. Storing the generator in a harsh environment may require this procedure be performed more frequently. -
Page 50: Repair Procedures
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. - Page 51 May 2015 Service Manual 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.
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Page 52: Lighting
Service Manual May 2015 Lighting How to Check Line Voltage How to Remove a Lamp Correct line voltage at the lamp socket is essential Electrocution/burn hazard. for proper operation of the lighting system. Contact with electrically charged circuits could result in death or Electrocution/burn hazard. -
Page 53: How To Check The Open Circuit Voltage [Terex Sm]
May 2015 Service Manual Lighting 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. Contact with electrically charged circuits could result in death or serious injury. -
Page 54: Mast
Service Manual May 2015 Mast Remove the pin retaining fasteners from the light bar pivot pin "B" and the light bar lever How to Remove the Light Bar pivot pin "A". Place a rod through the pins and twist to remove the pins. Assembly Note: Perform this procedure with the tower in the stowed position. - Page 55 May 2015 Service Manual Mast How to Remove the Light Bar Lift Cylinder The light bar lift cylinder raises and lowers the light bar assembly. The light bar lift cylinder is equipped with counterbalance valves to prevent movement in the event of a hydraulic line failure. Note: Perform this procedure with the tower in the stowed position.
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Page 56: Tower Components
Service Manual May 2015 Tower Components Tower Component a tower extension cylinder b light bar c light bar cylinder d light bar lever e light bar link f tower tube number 3 g tower tube number 2 h tower tube number 1 i tower lift cylinder j tower rotation riser AL5HT... -
Page 57: How To Remove The Cable Track
May 2015 Service Manual Tower Components How to Remove the Cable Track How to Remove the Tower Assembly The tower cable track guides the cables and hoses running up the tower. It can be repaired link by link Bodily injury hazard. The without removing the cables and hoses that run procedures in this section through it. -
Page 58: How To Disassemble The Tower
Service Manual May 2015 Tower Components Remove the pin retaining fasteners from the tower lift cylinder rod-end pivot pin. How to Disassemble the Tower Use a soft metal drift to remove the pin. Rest Note: When removing a hose assembly or fitting, the tower lift cylinder on the block. - Page 59 May 2015 Service Manual Tower Components Attach a lifting strap from an overhead crane 12 Support and slide the number 2 and 3 tower to the tower extension cylinder. tubes out of the number 1 tower tube and place them on a structure capable of Remove the external snap rings from the supporting them.
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Page 60: How To Remove The Tower Lift Cylinder
Service Manual May 2015 Tower Components 14 Pull the extend cable free of the pulley mount and lay it flat on top of the number 3 tower How to Remove the Tower Lift tube. Cylinder Bodily injury hazard. Cables can fray. Always wear adequate The tower lift cylinder raises and lowers the tower hand protection when handling assembly. -
Page 61: How To Remove The Tower Extension Cylinder
May 2015 Service Manual Tower Components Remove the external snap rings from the tower extension cylinder barrel-end pivot pin. How to Remove the Tower Use a soft metal drift to remove the pin. Extension Cylinder Slide the extension cylinder towards the tongue end of the machine slightly and The tower extension cylinder extends and retracts carefully... -
Page 62: How To Remove The Tower Rotation Motor
Service Manual May 2015 Tower Components How to Remove the Tower How to Adjust the Tower Rotation Rotation Motor Gear Backlash Note: When removing a hose assembly or fitting, The rotation motor mounting fasteners are located the O-ring on the fitting and/or hose end must be in slotted holes to allow the adjustment of gear replaced and then torqued to specification during backlash between the motor pinion gear and the... -
Page 63: Kubota D1105-E / V1505-E Engine
May 2015 Service Manual Kubota D1105-E / V1505-E Engine Coolant Temperature and Oil Timing Adjustment-Kubota Pressure Switches-Kubota Engines 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). -
Page 64: Isuzu 4Le1 Engine
Service Manual May 2015 Isuzu 4LE1 Engine Coolant Temperature and Oil Timing Adjustment-Isuzu 4LE1 Pressure Switches-Isuzu 4LE1 Complete information to perform this procedure is available in the Isuzu 4LE1 Workshop Manual The engine coolant temperature switch is a (Isuzu part number: IDE-2270). normally open switch. -
Page 65: Isuzu 4Le2 Engine
May 2015 Service Manual Isuzu 4LE2 Engine Coolant Temperature and Oil Timing Adjustment-Isuzu 4LE2 Pressure Switches-Isuzu 4LE2 Complete information to perform this procedure is available in the Isuzu 4LE2 Workshop Manual The engine coolant temperature switch is a (Isuzu part number: IDE-2270). normally open switch. -
Page 66: Isuzu 4Le2-T Engine
Service Manual May 2015 Isuzu 4LE2-T Engine Coolant Temperature and Oil Timing Adjustment-Isuzu 4LE2-T Pressure Switches-Isuzu 4LE2-T Complete information to perform this procedure is available in the Isuzu 4LE2 Workshop Manual The engine coolant temperature switch is a (Isuzu part number: IDE-2270). normally open switch. -
Page 67: Generator
May 2015 Service Manual Generator 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. -
Page 68: How To Check A Generator Capacitor
Service Manual May 2015 Generator With an ohmmeter set to its highest resistance scale, connect the ohmmeter leads to the How to Check a Generator capacitor terminals and observe the reading Capacitor on the meter. Then, reverse the connections and observe the reading on the meter. High voltage. -
Page 69: How To Check A Generator Diode
May 2015 Service Manual Generator Reverse the multimeter lead connections. Note the results. How to Check a Generator Diode Result: The two readings are at a ratio of 3000:1 or higher. The diode is good. High voltage. Exposure to electrical wires or electrical Result: The two readings are at a ratio of less current will result in death or than 3000:1. -
Page 70: Light Ballast
Service Manual May 2015 Light Ballast Move the Set switch to the program position (P) to set the desired stop and start time. A Ground Controls default time of AM 12:00 will appear. A small 1 will appear to the right of the time with a The timer is used to automatically start the engine lamp symbol above it. -
Page 71: Light Ballast
May 2015 Service Manual Light Ballast Using an insulated conductor or a screwdriver with an insulated handle, discharge the Light Ballast capacitor by shorting across the capacitor terminals. High voltage. Exposure to Note: Refer to the instructions which are provided electrical wires or electrical for your multimeter to ensure the diode is current will result in death or... -
Page 72: Fuel Tank
Service Manual May 2015 Fuel Tank 10-1 Models without fuel containment option: Fuel Tank Support the fuel tank support weldment at each end using lifting jacks and blocks. Do not Open both cabinet doors. apply any lifting pressure. Do not directly Remove the fuel filler cap from the tank. - Page 73 May 2015 Service Manual Fuel Tank Models with fuel containment option: Support the fuel tank containment weldment at each end using lifting jacks and blocks. Do not apply any lifting pressure. Component damage hazard. The fuel tank is plastic and may become damaged if the lifting jacks are in direct contact with the plastic tank.
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Page 74: Diagnostics
Service Manual May 2015 Diagnostics Section 5 Diagnostics Before Troubleshooting: Read, understand and obey the safety rules and operating instructions in the appropriate operator's manual on your machine. Be sure that all necessary tools and test equipment are available and ready for use. Observe and Obey: ... -
Page 75: Diagnostic Charts
May 2015 Service Manual Diagnostic Charts Problem Possible Cause Solution Mast will not rise to the Mast retention pin is in place Retract the mast retention pin. operating position Faulty cable or pulley Inspect and repair as needed. Faulty winch Inspect and repair as needed. - Page 76 Service Manual May 2015 Diagnostic Charts 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.
- Page 77 May 2015 Service Manual Diagnostic Charts 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.
- Page 78 Service Manual May 2015 Diagnostic Charts 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.
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Page 79: Schematics
May 2015 Service Manual Schematics Section 6 Schem atics About This Section There are two groups of schematics in this section. Electrical Schematics Electrocution/burn hazard. Contact with electrically charged Observe and Obey: circuits could result in death or serious injury. Remove all rings, ... -
Page 80: Wire Color Legend
Service Manual May 2015 Wire Color Legend Wire Color Legend 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 AL5HT Part No. 1265482... - Page 81 May 2015 Service Manual Electrical Wiring Schematic ANSI / CSA...
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Page 82: Electrical Wiring Schematic Ansi / Csa
Service Manual May 2015 Electrical Wiring Schematic ANSI / CSA Models AL5HT Part No. 1265482... -
Page 83: Electrical Wiring Schematic Aus
May 2015 Service Manual Electrical Wiring Schematic AUS Models Part No. 1265482 AL5HT... - Page 84 Service Manual May 2015 Electrical Wiring Schematic AUS...
- Page 85 May 2015 Service Manual Control Box Wiring - Kubota Models...
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Page 86: Control Box And Engine Wiring - Kubota Models
Service Manual May 2015 Control Box and Engine Wiring - Kubota Models AL5HT Part No. 1265482... -
Page 87: Control Box And Engine Wiring - Aus Models
May 2015 Service Manual Control Box and Engine Wiring - AUS Models Part No. 1265482 AL5HT... - Page 88 Service Manual May 2015 Control Box Wiring - AUS Models...
- Page 89 May 2015 Service Manual Trailer Wiring Diagram - ANSI / CSA Models...
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Page 90: Trailer Wiring Diagram - Ansi / Csa Models
Service Manual May 2015 Trailer Wiring Diagram - ANSI / CSA Models AL5HT Part No. 1265482... -
Page 91: Trailer Wiring Diagram - Aus Models
May 2015 Service Manual Trailer Wiring Diagram - AUS Models Part No. 1265482 AL5HT... - Page 92 Service Manual May 2015 Trailer Wiring Diagram - AUS Models...
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Page 93: Al5Ht Part No
May 2015 Service Manual This page intentionally left blank. AL5HT Part No. 1265482 Servic e M anual May 2015 Part No. 1265482 AL5HT...