Terex AL5 AL5 With Tier 4 AL5000 Service Manual 116476 – PDF DOWNLOAD
Language : English
Pages : 98
Downloadable : Yes
File Type : PDF
Table of Contents:
Terex AL5 AL5 With Tier 4 AL5000 Service Manual 116476 – PDF DOWNLOAD
Cover....................................................................... 1 General Safety Rules........................................................ 4 Serial Number Legend........................................................ 3 Table of Contents........................................................... 6 Specifications..............................................................11 Machine Specifications..................................................11 Performance Specifications..............................................11 Performance Specifications..............................................11 Machine Specifications..................................................12 Machine Specifications..................................................13 Machine Specifications..................................................14 Isuzu 4LE2 Engine.......................................................15 Isuzu 4LE2-T Engine.....................................................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 Coupler Maintenance.....................................27 A-6 Test the Brakes (if equipped)...................................28 A-7 Torque the Wheel Lug Nuts.......................................28 A-8 Check the Tires and Wheels......................................29 A-9 Inspect the Engine Air Filter...................................29 A-10 Perform Generator Maintenance..................................30 A-11 Perform Engine Maintenance.....................................31 A-12 Perform Engine Maintenance.....................................31 A-13 Inspect the Cable and Cable Pulleys............................32 A-14 Perform Engine Maintenance.....................................33 A-15 Perform Engine Maintenance.....................................33 A-16 Perform Generator Maintenance..................................34 A-17 Drain the Fuel Filter/Water Separator..........................34 A-18 Adjust the Brakes (if equipped)................................36 Checklist B Procedures..................................................37 B-1 Inspect the Engine Start Battery................................37 B-2 Inspect the Electrical Wiring...................................38 B-3 Torque the Wheel Lug Nuts.......................................39 B-5 Perform Engine Maintenance......................................39 B-5 Perform Jack Maintenance........................................40 B-6 Inspect and Lubricate the Winch.................................40 B-7 Lubricate the T-bolt............................................41 B-8 Inspect and Adjust the Brakes (if equipped).....................41 B-9 Inspect the Suspension..........................................43 B-10 Perform Engine Maintenance.....................................44 Checklist C Procedures..................................................45 C-1 Perform Engine Maintenance......................................45 C-2 Clean the Light Assemblies......................................45 C-3 Grease the Wheel Bearings.......................................46 C-4 Inspect the Electric Brake Magnets..............................47 C-5 Perform Engine Maintenance......................................49 C-6 Perform Generator Maintenance...................................49 Checklist D Procedures..................................................50 D-1 Perform Engine Maintenance......................................50 D-2 Perform Generator Maintenance...................................50 D-3 Perform Coupler Maintenance.....................................51 Checklist E Procedures..................................................52 E-1 Inspect the Cable and Cable Pulleys.............................52 E-2 Perform Engine Maintenance......................................53 E-3 Perform Engine Maintenance......................................53 E-4 Perform Generator Maintenance...................................54 E-5 Perform Generator Maintenance...................................54 E-6 Perform Generator Maintenance...................................55 Repair Procedures...........................................................56 Introduction............................................................56 Lighting................................................................58 1-1 How to Remove a Lamp............................................58 1-2 How to Check Line Voltage.......................................58 1-3 How to Check the Open Circuit Voltage [Terex SM]................59 Mast....................................................................60 2-1 How to Remove the Mast Assembly.................................60 2-2 How to Disassemble the Mast Assembly............................61 2-3 How to Replace the Mast Lift Cables.............................62 2-4 How to Remove the Electric Winch................................63 2-5 How to Disassemble the Manual Winch.............................63 2-6 How to Assemble the Manual Winch................................64 2-7 How to Remove the Electric Winch................................65 Kubota D1105-E / V1505-E Engine.........................................66 3-1 Timing Adjustment-Kubota Engines................................66 3-2 Glow Plugs-Kubota Engines.......................................66 3-3 Coolant Temperature and Oil Pressure Switches-Kubota Engines....66 Isuzu 4LE1 Engine.......................................................67 4-1 Timing Adjustment-Isuzu 4LE1....................................67 4-2 Glow Plugs-Isuzu 4LE1...........................................67 4-3 Coolant Temperature and Oil Pressure Switches-Isuzu 4LE1........67 Isuzu 4LE2 Engine.......................................................68 5-1 Timing Adjustment-Isuzu 4LE2....................................68 5-2 Glow Plugs-Isuzu 4LE2...........................................68 5-3 Coolant Temperature and Oil Pressure Switches-Isuzu 4LE2........68 Isuzu 4LE2-T Engine.....................................................69 6-1 Timing Adjustment-Isuzu 4LE2-T..................................69 6-2 Glow Plugs-Isuzu 4LE2-T.........................................69 6-3 Coolant Temperature and Oil Pressure Switches-Isuzu 4LE2-T......69 Generator...............................................................70 7-1 Generator.......................................................70 7-2 How to Check a Generator Capacitor..............................71 7-3 How to Check a Generator Diode..................................72 Light Ballast...........................................................73 8-1 Ground Controls.................................................73 8-2 Light Ballast...................................................74 Fuel Tank...............................................................75 9-1 Fuel Tank.......................................................75 Diagnostics.................................................................77 Introduction............................................................77 Diagnostic Charts.......................................................78 Schematics..................................................................83 Introduction............................................................83 Wire Color Legend.......................................................84 Electrical Wiring Schematic ANSI / CSA..................................86 Electrical Wiring Schematic AUS.........................................87 Control Box and Engine Wiring - Kubota Models...........................90 Control Box and Engine Wiring - AUS Models..............................91 Trailer Wiring Diagram - ANSI / CSA Models..............................94 Trailer Wiring Diagram - AUS Models.....................................95 Back Cover .................................................................98
S.S 04/24