Genie AL5HT Service Manual 1265482 – PDF DOWNLOAD
Language : English
Pages : 94
Downloadable : Yes
File Type : PDF
Table of Contents:
Genie AL5HT Service Manual 1265482 – PDF DOWNLOAD
Front Cover................................................................. 1 Important Information....................................................... 2 Serial Number Legend........................................................ 3 General Safety Rules........................................................ 4 Table of Contents........................................................... 6 Specifications..............................................................11 Machine Specifications..................................................11 Performance Specifications..............................................11 Generator Options.......................................................11 Kubota D1105-E Engine Specifications....................................12 Kubota D1505-E Engine Specifications....................................13 Isuzu 4LE1 Engine Specifications........................................14 Isuzu 4LE2 Engine Specifications........................................15 Isuzu 4LE2-T Engine Specifications......................................16 Machine Torque Specifications...........................................17 SAE and Metric Fasteners Torque Charts..................................18 Scheduled Maintenance Procedures............................................19 Introduction............................................................19 Pre-Delivery Preparation Report.........................................22 Maintenance Inspection Report...........................................23 Checklist A Procedures..................................................25 A-1 Inspect the Manuals and Decals..................................25 A-2 Perform Pre-operation Inspection................................26 A-3 Perform Function Tests..........................................26 A-4 Perform Engine Maintenance......................................27 A-5 Perform Generator Maintenance...................................27 A-6 Perform Axle Maintenance........................................28 A-7 Torque the Wheel Lug Nuts.......................................28 A-8 Perform Engine Maintenance......................................29 A-9 Perform Coupler Maintenance.....................................29 A-10 Grease turntable bearing and rotate gear.......................30 A-11 Perform Engine Maintenance.....................................30 A-12 Perform Engine Maintenance.....................................31 Checklist B Procedures..................................................32 B-1 Inspect the Engine Start Battery................................32 B-2 Inspect the Electrical Wiring...................................33 B-3 Torque the Wheel Lug Nuts.......................................34 B-4 Perform Hydraulic Oil Analysis..................................34 B-5 Perform Engine Maintenance......................................35 B-6 Perform Engine Maintenance......................................35 B-7 Perform Generator Maintenance...................................36 B-8 Perform Coupler Maintenance.....................................36 B-9 Perform Engine Maintenance......................................37 B-10 Perform Axle Maintenance.......................................37 Checklist C Procedures..................................................38 C-1 Inspect the Tower Extend/Retract Cables and Pulleys............38 C-2 Perform Engine Maintenance......................................39 C-3 Perform Axle Maintenance........................................39 C-4 Perform Engine Maintenance......................................40 C-5 Perform Engine Maintenance......................................40 Checklist D Procedures..................................................41 D-1 Perform Engine Maintenance......................................41 D-2 Check the Tower Rotation Bearing Bolts.........................41 D-3 Replace the Hydraulic Return Filter.............................42 D-4 Perform Engine Maintenance......................................43 D-5 Perform Engine Maintenance......................................43 D-6 Perform Engine Maintenance......................................44 D-7 Perform Generator Maintenance...................................44 D-8 Perform Tongue Jack and Outrigger Jack Maintenance..............45 D-9 Perform Axle Maintenance........................................45 Checklist E Procedures..................................................46 E-1 Perform Hydraulic Oil Analysis..................................46 E-2 Perform Engine Maintenance......................................47 E-3 Perform Engine Maintenance......................................48 E-4 Perform Generator Maintenance...................................48 E-5 Perform Generator Maintenance...................................49 Repair Procedures...........................................................50 Introduction............................................................50 Lighting................................................................52 1-1 How to Remove a Lamp............................................52 1-2 How to Check Line Voltage.......................................52 1-3 How to Check the Open Circuit Voltage [Terex SM]................53 Mast....................................................................54 2-1 How to Remove the Light Bar Assembly............................54 2-2 How to Remove the Light Bar Lift Cylinder.......................54 Tower Components........................................................56 3-1 Tower Component................................................56 3-2 How to Remove the Cable Track..................................57 3-3 How to Remove the Tower Assembly...............................57 3-4 How to Disassemble the Tower...................................58 3-5 How to Remove the Tower Lift Cylinder..........................60 3-6 How to Remove the Tower Extension Cylinder.....................61 3-7 How to Remove the Tower Rotation Motor.........................62 3-8 How to Adjust the Tower Rotation Gear Backlash.................62 Kubota D1105-E / V1505-E Engine.........................................63 4-1 Timing Adjustment-Kubota Engines................................63 4-2 Glow Plugs-Kubota Engines.......................................63 4-3 Coolant Temperature and Oil Pressure Switches-Kubota Engines....63 Isuzu 4LE1 Engine.......................................................64 5-1 Timing Adjustment-Isuzu 4LE1....................................64 5-2 Glow Plugs-Isuzu 4LE1...........................................64 5-3 Coolant Temperature and Oil Pressure Switches-Isuzu 4LE1........64 Isuzu 4LE2 Engine.......................................................65 6-1 Timing Adjustment-Isuzu 4LE2....................................65 6-2 Glow Plugs-Isuzu 4LE2...........................................65 6-3 Coolant Temperature and Oil Pressure Switches-Isuzu 4LE2........65 Isuzu 4LE2-T Engine.....................................................66 7-1 Timing Adjustment-Isuzu 4LE2-T..................................66 7-2 Glow Plugs-Isuzu 4LE2-T.........................................66 7-3 Coolant Temperature and Oil Pressure Switches-Isuzu 4LE2-T......66 Generator...............................................................67 8-1 Generator.......................................................67 8-2 How to Check a Generator Capacitor..............................68 8-3 How to Check a Generator Diode..................................69 Light Ballast...........................................................70 9-1 Ground Controls.................................................70 9-2 Light Ballast...................................................71 Fuel Tank...............................................................72 10-1 Fuel Tank......................................................72 Diagnostics.................................................................74 Introduction............................................................74 Diagnostic Charts.......................................................75 Schematics..................................................................79 Introduction............................................................79 Wire Color Legend.......................................................80 Electrical Wiring Schematic ANSI / CSA..................................82 Electrical Wiring Schematic AUS.........................................83 Control Box and Engine Wiring - Kubota Models...........................86 Control Box and Engine Wiring - AUS Models..............................87 Trailer Wiring Diagram - ANSI / CSA Models..............................90 Trailer Wiring Diagram - AUS Models.....................................91 Back Cover..................................................................94
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