PDF Service Manual Terex AL5 AL5000 Light Tower - 558 KB
Keep your Terex AL5 and AL5000 series light towers in perfect working order with this complete service manual.
This guide covers models with Tier 4 engines and provides detailed instructions for troubleshooting, repair, and maintenance.
It includes electrical and hydraulic schematics, making it an essential resource for technicians.
Proper servicing using this manual will ensure reliable performance on any job site.
PDF Viewer
Viewer loads when you scroll here
SHARE THIS MANUAL
Download the PDF Manual
PDF viewer loading area
Text Preview from This Manual
The text below was extracted from the visible preview pages to help you confirm the manual contents before download.
--- Page 1 ---
Service Manual
AL5
AL5 with Tier 4
AL5000
Part No. 116476
Rev B
April 2015
--- Page 3 ---
April 2015 Service Manual
Specifications
Section 2 Specific ati ons
Machine Specifications Generator Options
Machi ne Specific ations Performanc e Specific ati ons
Total lighting wattage 4 x 1000 watts Marathon 8 kW 201CSA5412
Fuel capacities Generator rpm @ full load 60Hz, 1800 rpm
Single tank 30 gallons Temperature, ambient maximum 104° F
114 liters 40° C
Large tank (option) 60 gallons Power 8 kW
227 liters Marathon 8 kW 201CSA5420
Tires and wheels
Generator rpm @ full load 60 Hz, 1800 rpm
Tire size ST205/75D15 Temperature, ambient maximum 104° F
Load range C 40° C
Lug nut torque, dry 90 ft-lbs Power 8 kW
122 Nm Marathon 12 kW 281CSL1513
Lug nut torque, lubricated 67.5 ft-lbs Generator rpm @ full load 60 Hz, 1800 rpm
91.5 Nm
Temperature, ambient maximum 104° F
Performance Specifications
Performanc e Specific ati ons
40° C
Tongue weight, maximum Power 12 kW
Marathon 20 kW 334CSA3028
With fuel (single tank) 150 lbs
68 kg Generator rpm @ full load 60 Hz, 1800 rpm
With fuel (large tank) 130 lbs Temperature, ambient maximum 104° F
59 kg 40° C
Run time Power 20 kW
Single tank 50 hours For operational specifications, refer to the
Large tank 100 hours Operator's Manual.
For operational specifications, refer to the Continuous improvement of our products is a
Operator's Manual. Genie policy. Product specifications are
subject to change without notice or obligation.
Continuous improvement of our products is a
Genie policy. Product specifications are
subject to change without notice or obligation.
Part No. 116476 AL5 1
--- Page 4 ---
April 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. When one or more of the symbols
appear at the beginning of a maintenance Make copies for each inspection. Store completed
procedure, it conveys the meaning below. forms as required.
Indicates that tools will be required to Maintenance Schedule
perform this procedure.
The Scheduled Maintenance Procedures section
and the Maintenance Inspection Report have been
Indicates that new parts will be required to divided into subsections. Use the following chart to
perform this procedure. determine which group(s) of procedures are
required to perform a scheduled inspection.
Indicates that dealer service will be Inspection Checklist
required to perform this procedure. Daily or every 8 hours A
Quarterly or every 250 hours A+B
Indicates that a cold engine will be Semi-annually or every 500 hours A+B+C
required to perform this procedure. Annually or every 1000 hours A+B+C+D
Two-year or every 2000 hours A+B+C+D+E
Indicates that a warm engine will be
required to perform this procedure. 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. 116476 AL5 11
--- Page 5 ---
April 2015 Service Manual
Checklist A Procedures
A-11 A-12
A-11 Perform Engine M aintenanc e A-12 Perform Engine M aintenanc e
Perform Engine Maintenance - Perform Engine Maintenance -
Kubota Kubota
Engine specifications require that this procedure be Engine specifications require that this procedure be
performed every 100 hours. performed every 200 hours.
• Check fuel lines and clamps • Change engine oil
Required maintenance procedures and additional • Replace oil filter
engine information is available in the Kubota
D1105-E and V1505-E Operator's Manual (Kubota Required maintenance procedures and additional
16683-89169 part number ) engine information is available in the Kubota
D1105-E and V1505-E Operator's Manual (Kubota
Kubota D-1105 and V-1505 Operator's Manual 16683-89169 part number )
Genie part number 893020 Kubota D-1105 and V-1505 Operator's Manual
Genie part number 893020
Part No. 116476 AL5 21
--- Page 6 ---
April 2015 Service Manual
Checklist B Procedures
B-7 B-8
B-7 Lubric ate the T-bolt B-8 Ins pect and Adjust the Brak es (if equi pped)
Lubricate the T-bolt Inspect and Adjust the Brakes (if
equipped)
Terex specifications require that this procedure be
performed every 250 hours or quarterly, whichever Axle specifications require that this procedure be
comes first. performed every 3000 miles or quarterly,
Maintaining the T-bolt is essential to good machine whichever comes first.
performance and safe operation. An unsafe Maintaining the axle brakes in good condition is
working condition exists if the T-bolt has excessive essential to safe operation and good performance.
wear and/or does not operate smoothly, free of Brakes which are out of adjustment can result in
hesitation and binding. longer stopping distances and excessive brake
1 Using the illustration as a guide, locate the wear on the towing vehicle. Component damage
T-bolt at the bottom of the mast assembly. may also result if problems are not discovered and
Remove the T-bolt from the mast. repaired in a timely fashion.
2 Remove all dust, dirt and copper anti-seize Note: Perform this procedure with the machine on
from the threaded surfaces of the T-bolt, and a firm, level surface with the machine in the stowed
apply a few drops of light oil or copper position.
anti-seize lubricant onto the threaded
1 Select a wheel. Chock the front and rear of the
surfaces.
tire at the opposite side of the machine.
3 Fully install the T-bolt into the mast.
2 Loosen the wheel lug nuts. Do not remove
them.
3 Place a lifting jack under the axle near the
wheel to be removed. Lift the axle until the
wheel is off the ground and place a jack stand
under the axle. Lower the axle onto the jack
stand and remove the wheel.
4 Remove the dust cap from the hub. Remove
the cotter pin from the castle nut.
a T-bolt
5 Remove the castle nut and washer.
6 Pull the hub off of the spindle. The washer and
outer bearing should fall loose from the hub.
Part No. 116476 AL5 31
--- Page 7 ---
April 2015 Service Manual
Checklist D Procedures
D-3
D-3 Perform Coupler M aintenanc e
Perform Coupler Maintenance
Coupler specifications require that this procedure
be performed annually.
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. 116476 AL5 41
--- Page 8 ---
April 2015 Service Manual
Mast
2-2
2-2 H ow to Disas sem ble the Mas t Assem bly
7 Working at the top of the 4 inch / 10 cm and
How to Disassemble the Mast 3 inch / 7.5 cm sections, use a drill to remove
the rivets securing the wear pads in position.
Assembly
Component damage hazard.
1 Remove the mast assembly. See 2-1, How to The mast can be damaged if the
Remove the Mast Assembly. drill bit used is too large. Select
a drill bit only large enough to
2 Remove the T-bolt from the 6 inch / 15 cm remove the mandrel from the
round tube assembly. center of the rivet.
3 Remove the nut from the bottom of the mast.
Gently twist and pull the 6 inch / 15 cm round 8 Remove the fasteners securing the pulley and
tube assembly from the mast while pulling the shim to the 3 inch / 7.5 cm mast section. Set
cable free. the components to the side.
Bodily injury hazard. Cables 9 Remove the 2 inch / 5 cm mast section from
can fray. Always wear adequate the 3 inch / 7.5 cm mast section.
hand protection when handling 10 Remove the 3 inch / 7.5 cm mast section from
the cable. the 4 inch / 10 cm mast section.
Component damage hazard. Note: For ease of assembly, note the location
Cables can be damaged if they where each wear pad is removed.
are kinked or pinched.
Note: To ensure that the mast extends properly
Remove the large round plastic bushing from the after assembly, carefully measure the cable to
bottom of the 4 inch / 10 cm mast section. confirm that the new cable is the same length as
the old one.
4 Remove the 2.5 inch / 6 cm washer from the
bottom of the mast assembly. Note: During assembly, carefully install the mast
cable. Refer to the illustration on the following page
5 Pull the mast lock handle fully away from the for cable routing.
mast, then immediately secure the mast lock
in position using locking pliers or a clamp on
the lock handle to restrain it in position.
6 Remove the fasteners securing the pulley and
mast lock to the 4 inch / 10 cm mast section.
Set the components to the side.
Part No. 116476 AL5 51
--- Page 9 ---
April 2015 Service Manual
Generator
7-2
7-2 H ow to Check a Generator C apaci tor
4 With an ohmmeter set to its highest resistance
How to Check a Generator scale, connect the ohmmeter leads to the
capacitor terminals and observe the reading
Capacitor on the meter. Then, reverse the connections
and observe the reading on the meter.
High voltage. Exposure to
electrical wires or electrical Result: The meter indicates a very low
current will result in death or resistance which then gradually increases
serious injury. Turn off all power AND a very high resistance which then
when not needed for testing. Use gradually decreases. The capacitor is working.
extreme caution when working Result: The meter indicates a very high
with high voltage electrical resistance which does not decrease. The
components. capacitor is faulty and should be replaced.
Electrocution/burn hazard. Result: The meter indicates a very low resistance
Attempting to service the which does not increase. The capacitor is faulty
machine before the capacitor is and should be replaced.
fully discharged will result in
death or serious injury.
Note: Be sure the engine has been turned off for at
least 15 minutes before servicing the machine. Use
a voltmeter to confirm there is no residual voltage
in the capacitor.
1 Remove the generator capacitor cover.
2 Using an insulated conductor or a screwdriver
with an insulated handle, discharge the
capacitor by shorting across the capacitor
terminals. Repeat for the second capacitor, if
equipped.
High voltage. Exposure to
electrical wires or electrical
current will result in death or
serious injury. Use extreme
caution when working with high
voltage electrical components.
3 Tag and disconnect the wires attached to the
capacitor(s).
Part No. 116476 AL5 61
--- Page 10 ---
April 2015 Service Manual
Diagnostic Charts
Generator produces full voltage Loose or broken lead wires Inspect lead wires and connections for
at no load or voltage drops at broken wires and loose connections.
full load
Rotor open or shorted Measure resistance between leads..
Stator grounded or shorted Contact the Genie Service
Department.
Generator voltage too high HIgh engine speed Adjust the rpm
Refer to Section 2, Specifications
Generator produces no voltage Faulty surge suppressor Disconnect suppressor from circuit. If
at no load or at full load there is an obvious increase in
voltage, replace the suppressor.
Faulty capacitor Replace capacitor.
Loss of residual magnetism Flash the rotor.
Open winding Replace the generator.
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.
Pinched leads Inspect and repair as needed.
Faulty capacitor Replace the capacitor.
Faulty diode Replace the diode.
Faulty surge suppressor Replace the surge suppressor.
Part No. 116476 AL5 71