Terex Genie AL5HT Service Manual

Service Manual

AL5HT

Part No. 1265482 Rev A May 2015

Service Manual May 2015

Introduction

Introducti on Introducti on

Important

Read, understand and obey the safety rules and operating instructions in the appropriate Operator's Manual on your machine before attempting any maintenance procedure.

This manual provides detailed scheduled maintenance information for the machine owner and user. It also provides troubleshooting and repair procedures for qualified service professionals.

Basic mechanical, hydraulic and electrical skills are required to perform most procedures. However, several procedures require specialized skills, tools, lifting equipment and a suitable workshop. In these instances, we strongly recommend that maintenance and repair be performed at an authorized Terex dealer service center.

Technical Publications

Terex has endeavored to deliver the highest degree of accuracy possible. However, continuous improvement of our products is a Terex policy. Therefore, product specifications are subject to change without notice.

Readers are encouraged to notify Terex of errors and send in suggestions for improvement. All communications will be carefully considered for future printings of this and all other manuals.

Internet: www.genielift.com E-mail: awp.techpub@tere x .c om

Compliance

Machine Classification

Group A/Type 1 as defined by ISO 16368

Machine Design Life

Unrestricted with proper operatio n, inspec t ion and scheduled maintenance.

in the U.S.A. and many other countries.

ii AL5HT Part No. 1265482

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)

Part No. 1265482 AL5HT 3

5 Serial number (stamped on chassis)

Service Manual May 2015

Safety Rules

Section 1 Safety Rules

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 performe d.

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 hav e the appr o priat e tools , lift ing

equipment and a suitable workshop.

iv AL5HT Part No. 1265482

May 2015 Service Manual

Read each procedure thoroughly. This manual and the decals on the machine, use signal words to identify the following:

Safety alert symbol—used to alert personnel to potential personal injury hazards. Obey all safety messages that to avoid possible injury or death.

Indicates a imminently hazardous situation which, if not avoided, will result in death or serious injury.

Indicates a potentially hazardous situation which, if not avoided, could result in death o injury.

Indicates a potentially hazardous situation which, if not avoided, may cause minor or moderate injury.

Indicates a potentially hazardous situation which, if not avoided, may result in property damage.

Be sure to wear protective 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

Be sure to keep sparks, flames and lighted tobacco away from flammable and combustible materials like battery gases and engine fuels. Always have an approved fire extinguisher within easy reach.

Be sure that all tools and working areas are properly maintained and ready for use. Keep work surfaces clean and free of debris components and cause damage.

Be sure any forklift, overhead crane or other lifting or supporting device is fully capable of supporting and stabilizing the weight to be lifted. Use only chains or straps that are in good condi ample capacity.

Be sure that fasteners intended for one time use (i.e., cotter pins and self nuts) are not reused. These components may fail if they are used a second time.

Be sure to properly dispose of old oil or other fluids. Please be environmentally safe.

Be sure that your workshop or work area is properly ventilated and well lit.

Safety Rules

Personal Safety

Any person working on or around a machine must be aware of all known safety hazards. Personal safety and the continued safe operation of the machine should be your top priority.

follow this symbol

r serious

Workplace Safety

Any person working on or around a machine must be aware of all known safety hazards. Personal safety and the continued safe operation of the machine should be your top priority.

that could get into machine

tion and of

-toed shoes.

eye wear and

-locking

Use an approved container.

Part No. 1265482 AL5HT v

May 2015

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 Specificatio ns ................................................................................... 1

Generator Options ................................................................................................. 1

Kubota D1105-E Engine Specifications ................................................................. 2

Kubota D1505-E Engine Specifications ................................................................. 3

Isuzu 4LE1 Engine Specifications .......................................................................... 4

Isuzu 4LE2 Engine Specifications .......................................................................... 5

Isuzu 4LE2-T Engine Specifications ...................................................................... 6

Machine Torque Specifications .............................................................................. 7

SAE and Metric Fasteners Torque Charts ............................................................. 8

vi AL5HT Part No. 1265482

May 2015

Table of Contents

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

Introduction ............................................................................................................. 9

Pre-Delivery Prepar at ion R eport .......................................................................... 12

Maintenance Inspection Report............................................................................ 13

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

A-1 Inspect the Manuals and Decals.................................................................... 15

A-2 Perform Pre-operat ion Ins pec ti on .................................................................. 16

A-3 Perform Function Tests ................................................................................. 16

A-4 Perform Engine Maintenance ........................................................................ 17

A-5 Perform Generator Maintenance ................................................................... 17

A-6 Perform Axle Maintenance ............................................................................ 18

A-7 Torque the Wheel Lug Nuts ........................................................................... 18

A-8 Perform Engine Maintenance ........................................................................ 19

A-9 Perform Coupler Maintenance ....................................................................... 19

A-10 Grease turntable bearing and rotate gear ................................................... 20

A-11 Perform Engine Maintenance ...................................................................... 20

A-12 Perform Engine Maintenance ...................................................................... 21

Checklist B Procedures ..................................................................................... 22

B-1 Inspect the Engine Start Battery .................................................................... 22

B-2 Inspect the Electrical Wiring .......................................................................... 23

B-3 Torque the Wheel Lug Nuts ........................................................................... 24

B-4 Perform Hydraulic Oil Analysis ...................................................................... 24

B-5 Perform Engine Maintenance ........................................................................ 25

B-6 Perform Engine Maintenance ........................................................................ 25

B-7 Perform Generator Maintenance ................................................................... 26

B-8 Perform Coupler Maintenance ....................................................................... 26

B-9 Perform Engine Maintenance ........................................................................ 27

B-10 Perform Axle Maintenance .......................................................................... 27

Part No. 1265482 AL5HT vii

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 ..................................................................................... 31

D-1 Perform Engine Maintenance........................................................................ 31

D-2 Check the Tower Rotation Bearing Bolts ..................................................... 31

D-3 Replace the Hydraulic Return Filter .............................................................. 32

D-4 Perform Engine Maintenance........................................................................ 33

D-5 Perform Engine Maintenance........................................................................ 33

D-6 Perform Engine Maintenance........................................................................ 34

D-7 Perform Generator Maintenance .................................................................. 34

D-8 Perform Tongue Jack and Outrigger Jack Maintenance .............................. 35

D-9 Perform Axle Maintenance ............................................................................ 35

Checklist E Procedures ..................................................................................... 36

E-1 Perform Hydraulic Oil Analysis ...................................................................... 36

E-2 Perform Engine Maintenance ........................................................................ 37

E-3 Perform Engine Maintenance ........................................................................ 38

E-4 Perform Generator Maintenance ................................................................... 38

E-5 Perform Generator Maintenance ................................................................... 39

viii AL5HT Part No. 1265482

May 2015

Table of Contents

Section 4 Repair Procedures ............................................................................................. 40

Introduction ........................................................................................................... 40

Lighting ............................................................................................................... 42

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 .................................................... 44

Tower Components ............................................................................................ 46

3-1 Tower Component ......................................................................................... 46

3-2 How to Remove the Cable Track .................................................................. 47

3-3 How to Remove the Tower Assembly ........................................................... 47

3-4 How to Disassemble the Tower .................................................................... 48

3-5 How to Remove the Tower Lift Cylinder ....................................................... 50

3-6 How to Remove the Tower Extension Cylinder ............................................ 51

3-7 How to Remove the Tower Rotation Motor ................................................... 52

3-8 How to Adjust the Tower Rotation Gear Backlash ........................................ 52

Kubota D1105-E / V1505-E Engine .................................................................... 53

4-1 Timing Adjustment-Kubota Engines ............................................................... 53

4-2 Glow Plugs-Kubota En gines .......................................................................... 53

4-3 Coolant Temperature and Oil Pressure Switches-Kubota Engines ............... 53

Isuzu 4LE1 Engine .............................................................................................. 54

5-1 Timing Adjustment-Isuzu 4LE1 ...................................................................... 54

5-2 Glow Plugs-Isuzu 4LE1 .................................................................................. 54

5-3 Coolant Temperature and Oil Pressure Switches-Isuzu 4LE1 ...................... 54

Isuzu 4LE2 Engine .............................................................................................. 55

6-1 Timing Adjustment-Isuzu 4LE2 ...................................................................... 55

6-2 Glow Plugs-Isuzu 4LE2 .................................................................................. 55

6-3 Coolant Temperature and Oil Pressure Switches-Isuzu 4LE2 ...................... 55

Part No. 1265482 AL5HT ix

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 .................................................................. 59

Light Ballast ........................................................................................................ 60

9-1 Ground Controls ............................................................................................ 60

9-2 Light Ballast ................................................................................................... 61

Fuel Tank ............................................................................................................ 62

10-1 Fuel Tank ..................................................................................................... 62

Section 5 Diagnostics ......................................................................................................... 64

Introduction .......................................................................................................... 64

Diagnostic Charts .............................................................................................. 65

Section 6 Schematics ......................................................................................................... 69

Introduction .......................................................................................................... 69

Wire Color Legend ............................................................................................... 70

Electrical Wiring Schematic ANSI / CSA ............................................................. 72

Electrical Wiring Schematic AUS ......................................................................... 73

Control Box and Engine Wiring - Kubota Models ................................................ 76

Control Box and Engine Wiring - AUS Models .................................................... 77

Trailer Wiring Diagram - ANSI / CSA Models ...................................................... 80

Trailer Wiring Diagram - AUS Models .................................................................. 81

x AL5HT Part No. 1265482

May 2015 Service Manual

Total lighting wattage

4 8

atts atts

Axle load capacity, maximum

Fluid capacities

Hydraulic tank capacity

allons

iters

Hydraulic system capacity (including tank)

allons

iters

Fuel capacities

Single tank

allons

iters

Large tank (option)

allons

iters

Tires and wheels (U.S. models)

Tire size ST205/75D15

Load range

Lug nut torque, dry

lbs

122 Nm

Lug nut torque, lubricated

lbs

91.5 Nm

Tires and

Tire size

7.5R16 C 112/110L

Lug nut torque, dry

lbs

108 Nm

Lug nut torque, lubricated

Tongue weight, maximum

With fuel (single tank)

With fuel (large tank)

Run time

Single tank

ours

Large tank

ours

Marathon

Generator rpm @ full load

Temperature, ambient maxi mum

104° F

40° C

Power

Marathon

Generator rpm @ full load

Temperature, ambient maxi mum

104° F

40° C

Power

Marathon 12 kW 281CSL1513

Generator rpm @ full load

Temperature, ambient maxi mum

104° F

40° C

Power

Marathon 2

Generator rpm @ full load

Temperature, ambient maxi mum

104° F

40° C

Power

Specifications

Section 2 Specificati ons

Machine Specifications

lights lights

1.4 g

30 g

60 g

90 ft-

67.5 ft-

4000 w 8000 w

4200 l

1905 k

5.3 l

2 g

7.6 l

114 l

227 l

Performance Specifications

150 l

68 k

130 l

59 k

50 h

100 h

Generator Options

8 kW 201CSA5412

60Hz, 1800 r

8 k

8 kW 201CSA5420

60 Hz, 1800 r

8 k

wheels (Australia models)

80 ft-

75 p

5.2 b

60 Hz, 1800 r

12 k

0 kW 334CSA3028

60 Hz, 1800 r

20 k

For operational specifications, refer to the Operator's Manual.

Continuous improvement of our produ cts is a Genie policy. Product specifications are subject to change without notice or obligation.

Part No. 1265482 AL5HT 1

Service Manual May 2015

Displacement

u in

iters

Number of cylinders

Bore and Stroke

nches

Horsepower

@ 1800

Firing order

Compression ratio

23:1

Compression pressure

Engine speed

Governor

centrifugal

mechanical

Valve Clearance, cold

Engine coolant

Capacity

uarts

iters

Lubrication system

Oil pressure

Oil capacity (including filter)

uarts

iters

Oil pressure switch (engine shutoff pressure)

Oil viscosity requirements

Unit ships with temperatures may require the use of alternative engine oils. For oil requirements, refer to the Engine Operator Manual for your engine.

Injection system

Injection pump

Bosch MD mini

Injection timing 19° BTDC

Injection pump maximum

Fuel requirement

For fuel requirements, refer to the engine Operator Manual for your engine.

Battery

Type

12V DC

Group

27TM

Quantity

Cold cranking ampere 500

Reserve capacity @ 75A rate

inutes

Alternator

Alternator output

40A, 12V DC

Fan belt deflection

Specifications

Kubota D1105-E4BG Engine

0.0057 to 0.0072 i

0.145 to 0.185 m

3.27 q

28 to 64 p

5.4 q

10W-30. Extreme operating

68.53 c

3.07 x 3.09 i 78 x 78.4 m

13.6

412 to 469 p

28.4 to 32.3 b

1.93 to 4.41 b

1.12 l

10.1 k 1 - 2 -

1800 r

3.1 l

5.1 l 7 p

pressure,

1991 p

137 b

105 m

1/4 to 3/8 inch

7 to 9 m

2 AL5HT Part No. 1265482

May 2015 Service Manual

Displacement

u in

iters

Number of cylinders

Bore and Stroke

nches

Horsepower

17.9 @ 1800 W

Firing order

Compression ratio

22:1

Compression pressure

Engine speed

Governor

centrifugal

mechanical

Valve Clearance, cold

Engine coolant

Capacity

uarts

iters

Lubrication system

Oil pressure

Oil capacity (including filter)

uarts

iters

Oil pressure switch (engine shutoff pressure)

Oil viscosity requirements

Unit temperatures may require the use of alternative engine oils. For oil requirements, refer to the Engine Operator Manual for your engine.

Injection system

Injection pump

Bosch MD mini

Injection timing 19° BTDC

Injection pump pressure, maximum

Fuel requirement

For fuel requirements, refer to the engine Operator Manual for your engine.

Battery

Type

12V DC

Group

27TM

Quantity

Cold cranking ampere 630

Reserve capacity @ 75A rate

inutes

Alternator

Alternator output

30A, 12V DC

Fan belt deflection

nch

Specifications

Kubota D1505-E Engine

4.23 q

28 to 64 p

7.08 q

ships with 10W-30. Extreme operating

3.07 x 3.09 i

0.0057 to 0.0072 i

0.145 to 0.185 m

91.41 c

1.5 l

78 x 78.4 m

13.4 k

1 - 3 - 4 -

412 to 469 p

28.4 to 32.3 b 1800 r

4 l

1.93 to 4.41 b

6.7 l 7 p

1991 p

137 b

105 m

1/4 to 3/8 i

7 to 9 m

Part No. 1265482 AL5HT 3

Service Manual May 2015

Displacement

u in

iters

Number of cylinders

Bore and Stroke

nches

Horsepower

31.4 @ 1800 W

Firing order

Compression ratio

21.5:1

Compression pressure

Engine speed

Governor

variable speed,

mechanical

Valve Clearance, cold

Intake

Exhaust

Engine coolant

Capacity

uarts

iters

Coolant temperature switch (engine shut

221°± 7°F

105° ± 4°C

Lubrication system

Oil pressure (hot @ 180

Oil capacity (including filter)

uarts

iters

Oil pressure switch (engine shutoff pressure)

Oil viscosity requirements

Unit ships with 10W temperatures may require the use of alternative engine oils. For oil requirements, refer to the Engine Manual for your engine.

Injection system

Injection pump

Bosch, PFR type

Injection timing 16° BTDC

Injection pump pressure, maximum

Fuel requirement

For fuel requirements, refer to the engine Operator Manual for your

Battery

Type

12V DC

Group

27TM

Quantity

Cold cranking ampere 630

Reserve capacity @ 75A rate

inutes

Alternator

Alternator output

35A, 12V DC

Fan belt deflection

Specifications

Isuzu 4LE1 Engine

0.0157 i

4 q

-off temperature)

0 rpm) 64 p

7.08 q

-30. Extreme operating

3.35 x 3.78 i

28.4 to 32.3 b

133 c

2.179 l

85 x 96 m

23.4 k

1 - 3 - 4 -

412 to 469 p

1800 r

0.4 m

3.8 l

4.4 b

6.7 l 14 p

0.96 b

1920 p

132.8 b

engine.

105 m

1/4 to 3/8 inch

7 to 9 m

4 AL5HT Part No. 1265482

Operator

May 2015 Service Manual

Displacement

u in

iters

Number of cylinders

Bore and Stroke

nches

Horsepower

31.4 @ 1800 W

Firing order

Compression ratio

21.5:1

Compression pressure

Engine speed

Governor

variable speed,

mechanical

Valve Clearance, cold

Intake

Exhaust

Engine coolant

Capacity

uarts

iters

Coolant temperature switch (engine shut

221°± 7°F

105° ± 4°C

Lubrication system

Oil pressure (hot @ 180

Oil capacity (including filter)

uarts

iters

Oil pressure switch (engine shutoff pressure)

Oil viscosity requirements

Unit ships with 10W temperatures may require the use of alternative engine oils. For oil requirements, refer to the Engine Operator Manual for your engine.

Injection system

Injection pump

Bosch, PFR type

Injection timing 16° BTDC

Injection pump maximum

Fuel requirement

For fuel requirements, refer to the engine Operator Manual for your engine.

Battery

Type

12V DC

Group

27TM

Quantity

Cold cranking ampere 630

Reserve capacity @ 75A rate

inutes

Alternator

Alternator output

35A, 12V DC

Fan belt deflection

nch

Specifications

Isuzu 4LE2 Engine

0.0157 i

4 q

-off temperature)

0 rpm) 64 p

7.08 q

-30. Extreme operating

3.35 x 3.78 i

28.4 to 32.3 b

133 c

2.179 l

85 x 96 m

23.4 k

1 - 3 - 4 -

412 to 469 p

1800 r

0.4 m

3.8 l

4.4 b

6.7 l 14 p

0.96 b

pressure,

1920 p

132.8 b

105 m

1/4 to 3/8 i

7 to 9 m

Part No. 1265482 AL5HT 5

Service Manual May 2015

Displacement

u in

iters

Number of cylinders

Bore and Stroke

nches

Horsepower

31.4 @ 1800 W

Firing order

Compression ratio

21.5:1

Compression pressure

Engine speed

Governor

variable speed,

mechanical

Valve Clearance, cold

Intake

Exhaust

Engine coolant

Capacity

uarts

iters

Coolant temperature switch (engine shut

221°± 7°F

105° ± 4°C

Lubrication system

Oil pressure (hot @ 180

Oil capacity (including filter)

uarts

iters

Oil pressure switch (engine shutoff pressure)

Oil viscosity requirements

Unit ships with 10W temperatures may require the use of alternative engine oils. For oil requirements, refer to the Engine Manual for your engine.

Injection system

Injection pump

Bosch, PFR type

Injection timing 16° BTDC

Injection pump pressure, maximum

Fuel requirement

For fuel requirements, refer to the engine Operator Manual for your

Battery

Type

12V DC

Group

27TM

Quantity

Cold cranking ampere 630

Reserve capacity @ 75A rate

inutes

Alternator

Alternator output

35A, 12V DC

Fan belt deflection

Specifications

Isuzu 4LE2-T Engine

0.0157 i

4 q

-off temperature)

0 rpm) 64 p

7.08 q

-30. Extreme operating

3.35 x 3.78 i

28.4 to 32.3 b

133 c

2.179 l

85 x 96 m

23.4 k

1 - 3 - 4 -

412 to 469 p

1800 r

0.4 m

3.8 l

4.4 b

6.7 l 14 p

0.96 b

1920 p

132.8 b

engine.

105 m

1/4 to 3/8 inch

7 to 9 m

6 AL5HT Part No. 1265482

Operator

May 2015 Service Manual

Generator

Flex plate to flywheel

lbs

20 Nm

Generator case to bell housing

lbs

41 Nm

Generator isolators

lbs

102 Nm

Wheel lugs

Lug nut torque, lubricated

lbs

91.5 Nm

Lug nut torque, dry

lbs

122 Nm

Engine vibration isolators

Mounting bolts, dry

lbs

81 Nm

Mounting bolts, lubricated

lbs

61 Nm

Specifications

Machine Torque Specif ications

15 ft-

67.5 ft-

90 ft-

60 ft-

45 ft-

30 ft-

75 ft-

Continuous improvement of our produ cts is a Genie policy. Product specifications are subject to change without notice or obligation.

Part No. 1265482 AL5HT 7

Service Manual May 2015

Specifications

8 AL5HT Part No. 1265482

May 2015 Service Manual

Failure to perform each procedure as presented and scheduled may cause death, serious injury or sub damage.

Scheduled Maint enance Procedures

Section 3 Scheduled M aintenanc e Procedur es

Observe and Obey:

 Maintenance inspections shall be completed

by a person trained and qualified on the maintenance of this machine.

 Scheduled maintenance inspections shall be

completed daily, quarterly, s emi-annually, annually and every 2 years as specified of the Maintenance inspection Report. The frequency and extent of periodic examinations and tests may also depend on national regulations.

stantial

Machine Configuration:

 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

• Key switch in the off position with the key

removed

• The red Emergency Stop button in the off position on the electrical control box

• Wheels chocked

• Light switches in the off position

• All external AC power supply disconnected

from the machine

 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. 1265482 AL5HT 9

Service Manual May 2015

Safety alert symbol—used to alert personnel to potenti injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death.

Indicates a imminently hazardous situation which, if not avoided, will result in death or serious injury.

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

Indicates a potentially hazardous situation which, if not avoided, may cause minor or moderate injury.

Indicates a potentially hazardous situation which, if not may result in property damage.

Scheduled Maint enance Procedures

About This Section

This section contains detailed procedures for each scheduled maintenance inspection.

Each procedure includes a descr iption, safety warnings and step-by-s tep i ns truc tions .

Symbols Legend

al personal

hazardous

avoided,

Indicates that a specific result is expected

after performing a series of steps.

Indicates that an incorrect result has occurred

after performing a series of steps.

10 AL5HT Part No. 1265482

May 2015 Service Manual

Indicates that tools will be required to perform

Indicates that new parts will be required to perform this procedure.

Indicates that dealer service will be required to perform this procedure.

Indicates that a cold engine will be required to perform this procedure.

Indicates that a warm engine will be required to perform this procedure.

Inspection Checklist

Daily or every

Quarterly or every 25

A + B

Semi

A + B + C

Annually or every 100

A + B + C + D

Two

A + B + C + D + E

Scheduled Maint enance Procedures

Maintenance Symbols Legend

Pre-delivery Preparation Report

Note: The following symbols have been used in this manual to help communicate the intent of the instructions. When one or more of the symbols appear at the beginning of a maintenance procedure, it conveys the meaning below.

this procedure.

The pre-delivery preparation report contains checklists for each type of scheduled inspection.

Make copies for each inspection. Store completed forms as required.

Maintenance Schedule

The Scheduled Maintenance Procedures section and the Maintenance Inspection Report hav e bee n divided into subsections. Use the following chart to determine which group(s) of procedures are required to perform a scheduled inspection.

8 hours

0 hours

-annually or every 500 hours 0 hours

-year or every 2000 hours

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. 1265482 AL5HT 11

Service Manual May 2015

Legend

Comments

Pre

Maintenance items completed

Function tests completed

Model

Serial number

Date

Machine owner

Inspected by (print)

Inspector signature

Inspector title

Inspector company

Pre-Delivery Preparation Report

Fundamentals

It is the responsibility of the owner or dealer to perform the Pre-deliver y Pr eparation.

The Pre-delivery Preparation is performed prior to each delivery. The inspection is designed to discover if anything is apparently wrong with a machine before it is put into service.

A damaged or modified machine must never be used. If damage or any variation from factory delivered condition is discovered, the machine must be tagged and removed from service.

Repairs to the machine may only be made by a qualified service technician, according to the manufacturer's specifications.

Scheduled maintenance inspections shall be performed by qualified service technicians, according to the manufacturer's specifications and the requirements listed in the responsibilities manual.

Instructions

Use the operator’s manual on your machine. The Pre-delivery Preparation consists of

completing the Pre-operation Inspection, the Maintenance items and the Function Tests.

Use this form to record the results. Place a check in the appropriate box after each part is completed. Follow the instructions in the operator’s manual.

If any inspection receives an N, remove the machine from service, repair and re-inspect it. After repair, place a check in the R box.

Y = yes, acceptable N = no, remove from service R = repaired

-delivery Preparation

-operation inspection c om plete d

Y N R

May 2015 Service Manual

Model

Serial number

Date

Hour meter

Machine owner

Inspected by (print)

Inspector signature

Inspector title

Inspector company

Daily or every

Quarterly or every 25

Semi every 50

Annually or every 100

Two every 200

Legend

Comments

Maintenance Inspection Report

Instructions

• Make copies of this report to use for each inspection.

• Select the appropriate checklist(s) for the type of inspection(s) to perform.

0 hours

-annually or

0 hours

-year or

0 hours

• Place a check in the appropriate box after each inspection procedure is completed.

• Us e t he step-by-step procedures in this section to learn how to perform these inspections.

• I f any inspect i on receives an "N," tag and remove the machine from service, repair and re-inspect it. After repair, place a check in the "R" box.

Y = yes, acceptable N = no, remove from service R = repaired

8 hours A

A + B

A + B + C

0 hours

A + B + C + D

A + B + C + D + E

Checklist A Y N R

A-1 Inspect the manuals

and decals

A-2 Pre-operation

inspection

A-3 Function tests Perform after 8 hours: A-4 Engine maintenance A-5 Generator

maintenance

Perform after 10 miles: A-6 Axle maintenance Perform after 25 miles: A-6 Axle maintenance Perform after 50 miles: A-6 Axle maintenance Perform after 40 hours: A-7 30-day service Perform after 50 hours: A-8 Engine maintenance Perform weekly: A-9 Coupler Perform after 100 hours: A-10 Grease turntable

bearing

A-11 Engine maintenance

- Kubota models

Perform after 200 hours: A-12 Engine maintenance

- Kubota models

Checklist B Y N R

B-1 Batteries B-2 Electrical wiring B-3 Lug nuts B-4 Hydraulic oil analysis B-5 Engine maintenance B-6 Engine maintenance

- Kubota models

B-7 Generator

maintenance

Perform quarterly: B-8 Coupler Perform every 400 hours: B-9 Engine maintenance

- Kubota models

Perform every 3000 miles: B-10 Axle maintenance

Part No. 1265482 AL5HT 13

Service Manual May 2015

Model

Serial number

Date

Hour meter

Machine owner

Inspected by (print)

Inspector signature

Inspector title

Inspector company

Daily or every

Quarterly or every 25

Semi every 50

Annually or every 100

Two every 200

Legend

Checklist D

Y N R

Checklist E

Comments

Maintenance Inspection Report

Instructions

• Make copies of this report to use for each inspection.

• Select the appropriate checklist(s) for the type of inspection(s) to perform.

0 hours

-annually or

0 hours

-year or

0 hours

• Place a check in the appropriate box after each inspection procedure is completed.

• Us e t he step-by-step procedures in this section to learn how to perform these inspections.

• I f any inspect i on receives an "N," tag and remove the machine from service, repair and re-inspect it. After repair, place a check in the "R" box.

Y = yes, acceptable N = no, remove from service R = repaired

8 hours A

A + B

A + B + C

0 hours

A + B + C + D

A + B + C + D + E

Checklist C Y N R

C-1 Inspect tower

extend/retract cables

C-2 Engine maintenance Perform every 6000 miles: C-3 Axle maintenance Perform after 750 hours: C-4 Engine maintenance -

Isuzu models

Perform every 800 hours: C-5 Engine maintenance -

Kubota models

D-1 Engine maintenance

- Kubota models

D-2 Generator

maintenance

D-3 Hydraulic filters D-4 Engine maintenance

- Isuzu models

Perform every 1250 hours: D-5 Engine maintenance

- Isuzu models

Perform every 1500 hours: D-6 Engine maintenance D-7 Generator

maintenance

Perform annually: D-8 Tongue jack and

outrigger jack maintenance

Perform every 12,000 hours: D-9 Axle maintenance

Y N R

E-1 Hydraulic oil analysis Perform every 3000 hours: E-2 Engine maintenance Perform every 2 years: E-3 Engine maintenance Perform every 4500 hours: E-4 Generator

maintenance

Perform every 15,000 hours: E-5 Generator

maintenance

14 AL5HT Part No. 1265482

May 2015 Service Manual

Checklist A Procedures

A-1 Inspect the Manuals and Decal s

Terex specifications require that this procedure be performed every 8 hours or daily, whichever comes first.

Maintaining the operator’s and safety manuals in good condition is essential to safe machine operation. Manuals are included with each machine and should be stored in the container provided in the platform. An illegible or missing manual will not provide safety and operational information necessary for a safe operating condition.

In addition, maintaining all of the safety and 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.

3 Open the operator's manual to the decals

inspection section. Carefully and thoroughly inspect all decals on the machine for legibility and damage.

Result: The machine is equipped with all

required decals, and all decals are legible and in good condition.

Result: The machine is not equi ppe d with al l

required decals, or one or more decals are illegible or in poor condition. Remove the machine from service until the decals are replaced.

4 Always return the manuals to the storage

container after use.

Note: Contact your authorized Terex distributor or Terex if replacement manuals or decals are needed.

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. 1265482 AL5HT 15

Service Manual May 2015

Checklist A Procedures

A-2 Perform Pre-operation Inspection

Terex specifications require that this procedure be performed every 8 hours or daily, whichever comes first.

Completing a Pre-operation Inspection is essential to safe machine operation. The Pre-operation Inspection is a visual inspection performed by the operator prior to each work shift. The inspection is designed to discover if anything is apparently wrong with a machine before the operator performs the function tests. The Pre-operation Inspection also serves to determine if routine maintenance procedures are required.

Complete information to perform this procedure is available in the appropriate operator's manual. Refer to the Operator's Manual on your machine.

A-3 Perform Function Tests

Terex specifications require that this procedure be performed every 8 hours or daily, whichever comes first.

Completing the function tests is essential to safe machine operation. Function tests are designed to discover any malfunctions before the machine is put into service. A malfunctioning machine must never be used. If malfunctions are discovered, the machine must be tagged and removed from service.

Complete information to perform this procedure is available in the appropriate operator's manual. Refer to the Operator's Manual on your machine.

16 AL5HT Part No. 1265482

May 2015 Service Manual

Isuzu 4LE1 Diesel Engine Owner's Manual

Genie part number 116133

Isuzu 4LE2 Diesel Engine Owner's Manual

Genie part number 1264609

Kubota D-1105 and V-1505 Operator's Manual

Genie part number 893020

Marathon Manual

Genie part number 116188

Checklist A Procedures

A-4 Perform Engine Maintenance

Engine specifications require that this procedure be performed every 8 hours or daily, whichever comes first.

• Engine oil level – check

• Coolant level – check/add

• Fuel system filter/water separator – drain

• Engine tightness – check for leaks

• Exhaust system – check for leaks

• Loose or missing fasteners

Required maintenance procedures and additional engine information is available in the Ku bota D1105-E and V1505-E Operator's Manual (Kubota 16683-89169 part number ) OR the Isuzu 4LE1 Diesel Engine Owner's Manual (Isuzu part number IDE-6033) OR the Isuzu 4LE2 Diesel Engine Owner's Manual (Isuzu part number IDE-6450).

A-5 Perform Generator Maintenance

Generator specifications require that this procedure be performed every 40 hours or weekly, whichever comes first.

• Clean and inspect the generator exterior

• Clean and replace the generator air filters -

(if equipped)

Part No. 1265482 AL5HT 17

Service Manual May 2015

Checklist A Procedures

A-6 Perform Axle Maintenance

Axle specifications require that this procedure be performed initially and following a wheel change after the first 10, 25 and 50 miles.

Proper axle maintenance, following the axle manufacturer's maintenance schedule, is essential to good axle performance and service life. Failure to perform the maintenance procedures can lead to poor axle performance and component damage.

Required maintenance procedures and additional axle information is available in the Axis Axle Operator Maintenance Manual included with your machine.

A-7 Torque the Wheel Lug Nuts

Axle specifications require that this procedure be performed initially at 10, 25 and 50 miles of use, or after reinstallation of a tire.

Maintaining the wheel lug nuts at proper torque is essential to safe operation and good service life of the tires, wheel and axle.

1 Check each lug nut for proper torque. Refer to

Specifications, Machine Specifications.

18 AL5HT Part No. 1265482

May 2015 Service Manual

Isuzu 4LE1 Diesel Engine Owner's Manual

Genie part number 116133

Isuzu 4LE2 Diesel Engine Owner's Manual

Genie part number 1264609

Kubota D-1105 and V-1505 Operator's Manual

Genie part number 893020

Checklist A Procedures

A-8 Perform Engine Maintenance

Engine specifications require that this procedure be performed every 50 hours or weekly, whichever comes first.

A-9 Perform Coupler Maintenance

Coupler specifications require that this procedure be performed weekly.

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. 1265482 AL5HT 19

+ 65 hidden pages

Terex Genie AL5HT Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Table of Contents

Specifications

Machine Specifications

Performance Specifications

Generator Options

Machine Torque Specif ications

Scheduled Maint enance Procedures

Pre-Delivery Preparation Report

Maintenance Inspection Report

Checklist A Procedures

A-1 Inspect the Manuals and Decal s

A-2 Perform Pre-operation Inspection

A-3 Perform Function Tests

A-4 Perform Engine Maintenance

A-5 Perform Generator Maintenance

A-6 Perform Axle Maintenance

A-7 Torque the Wheel Lug Nuts

A-8 Perform Engine Maintenance

A-9 Perform Coupler Maintenance