Genie AL5 Vertical Mast with Tier 4 Service Manual – PDF DOWNLOAD
Language : English
Pages : 98
Downloadable : Yes
File Type : PDF
Table of Contents:
Genie AL5 Vertical Mast with Tier 4 Service Manual – PDF DOWNLOAD
Introduction Introduction ii
Important Information ii
Serial Number Legend iii
Serial Number Legend iii
Section 1 Safety Rules iv
General Safety Rules iv
Section 2 Specifications 1
Machine Specifications 1
Performance Specifications 1
Performance Specifications 1
Machine Specifications 1
Machine Specifications 2
Machine Specifications 3
Machine Specifications 4
Machine Specifications 5
Machine Torque Specifications 7
SAE and Metric Fasteners Torque Charts 8
Section 3 Scheduled Maintenance Procedures 9
Introduction 9
Pre-Delivery Preparation Report 12
Maintenance Inspection Report 13
Checklist A Procedures 15
A-1 Inspect the Manuals and Decals 15
A-2 Perform Pre-operation Inspection 16
A-3 Perform Function Tests 16
A-4 Perform Engine Maintenance 17
A-5 Perform Coupler Maintenance 17
A-6 Test the Brakes (if equipped) 18
A-7 Torque the Wheel Lug Nuts 18
A-8 Check the Tires and Wheels 19
A-9 Inspect the Engine Air Filter 19
A-10 Perform Generator Maintenance 20
A-11 Perform Engine Maintenance 21
A-12 Perform Engine Maintenance 21
A-13 Inspect the Cable and Cable Pulleys 22
A-14 Perform Engine Maintenance 23
A-15 Perform Engine Maintenance 23
A-16 Perform Generator Maintenance 24
A-17 Drain the Fuel Filter/Water Separator 24
A-18 Adjust the Brakes (if equipped) 26
Checklist B Procedures 27
B-1 Inspect the Engine Start Battery 27
B-2 Inspect the Electrical Wiring 28
B-3 Torque the Wheel Lug Nuts 29
B-5 Perform Engine Maintenance 29
B-5 Perform Jack Maintenance 30
B-6 Inspect and Lubricate the Winch 30
B-7 Lubricate the T-bolt 31
B-8 Inspect and Adjust the Brakes (if equipped) 31
B-9 Inspect the Suspension 33
B-10 Perform Engine Maintenance 34
Checklist C Procedures 35
C-1 Perform Engine Maintenance 35
C-2 Clean the Light Assemblies 36
C-3 Grease the Wheel Bearings 36
C-4 Inspect the Electric Brake Magnets 38
C-5 Perform Engine Maintenance 39
C-6 Perform Generator Maintenance 40
Checklist D Procedures 41
D-1 Perform Engine Maintenance 41
D-2 Perform Generator Maintenance 42
D-3 Perform Coupler Maintenance 42
Checklist E Procedures 43
E-1 Inspect the Cable and Cable Pulleys 43
E-2 Perform Engine Maintenance 44
E-3 Perform Engine Maintenance 45
E-4 Perform Generator Maintenance 45
E-5 Perform Generator Maintenance 46
E-6 Perform Generator Maintenance 46
Section 4 Repair Procedures 47
Introduction 47
Lighting 49
1-1 How to Remove a Lamp 49
1-2 How to Check Line Voltage 49
1-3 How to Check the Open Circuit Voltage 50
Mast 51
2-1 How to Remove the Mast Assembly 51
2-2 How to Disassemble the Mast Assembly 51
2-3 How to Replace the Mast Lift Cables 53
2-4 How to Remove the Electric Winch 54
Kubota D1105-E / V1505-E Engine 55
3-1 Timing Adjustment-Kubota Engines 55
3-2 Glow Plugs-Kubota Engines 55
3-3 Coolant Temperature and Oil Pressure Switches-Kubota Engines 55
Isuzu 4LE1 Engine 56
4-1 Timing Adjustment-Isuzu 4LE1 56
4-2 Glow Plugs-Isuzu 4LE1 56
4-3 Coolant Temperature and Oil Pressure Switches-Isuzu 4LE1 56
Isuzu 4LE2 Engine 57
5-1 Timing Adjustment-Isuzu 4LE2 57
5-2 Glow Plugs-Isuzu 4LE2 57
5-3 Coolant Temperature and Oil Pressure Switches-Isuzu 4LE2 57
Isuzu 4LE2-T Engine 58
6-1 Timing Adjustment-Isuzu 4LE2-T 58
6-2 Glow Plugs-Isuzu 4LE2-T 58
6-3 Coolant Temperature and Oil Pressure Switches-Isuzu 4LE2-T 58
Generator 59
7-1 Generator 59
7-2 How to Check a Generator Capacitor 60
7-3 How to Check a Generator Diode 61
Light Ballast 63
8-1 Ground Controls 63
8-2 Light Ballast 64
Fuel Tank 65
9-1 Fuel Tank 65
Section 5 Diagnostics 67
Introduction 67
Section 6 Schematics 73
Introduction 73
Wire Color Legend 74
Electrical Wiring Schematic ANSI / CSA 75
Electrical Wiring Schematic ANSI / CSA 75
Electrical Wiring Schematic AUS 77
Electrical Wiring Schematic AUS 78
Control Box Wiring – Kubota Models 79
Control Box and Engine Wiring – Kubota Models 80
Control Box Wiring – AUS Models 81
Control Box and Engine Wiring – AUS Models 82
Trailer Wiring Diagram – ANSI / CSA Models 83
Trailer Wiring Diagram – ANSI / CSA Models 84
Trailer Wiring Diagram – AUS Models 85
Trailer Wiring Diagram – AUS Models 86
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