Terex AL4 User manual

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August 2016
AL4 • AL4000 Part No. 218567
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ii
Introduction
Important
Read, understand and obey the safety rules and
operating instructions in the appropriate operator's
manual on your machine before attempting any
maintenance or repair procedure.
This manual provides detailed scheduled
maintenance information for the machine owner
and user. It also provides troubleshooting fault
codes 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.
Introduction
Copyright © 2012 by Terex Corporation
218567 Rev B August 2016
First Edition, Second Printing
Terex is a registered trademarks of
Terex USA, LLC in the USA and many other
countries.
Printed on recycled paper
Printed in U.S.A.
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August 2016
Part No. 218567 AL4 • AL4000
Revision Date Section Procedure / Schematic Page / Description
A 8/2012 New release
B 8/2016 Section 1 Updated revision history and serial number legend
REFERENCE EXAMPLES:
Kubota Engine_Section 2_Specifications.
A-6,B-3,C-7_Section 3_Maintenance Procedure.
3-2, 6-4, 9-1_Section 4_Repair Procedure.
Fault Codes_Section 5.
6-35, 6-56, 6-104_Section 6_Schematic Page #.
Electronic Version
Click on any procedure or page number
highlighted in blue to view the update.
iii
Revision History
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August 2016
AL4 • AL4000 Part No. 218567
Revision Date Section Procedure / Schematic Page / Description
REFERENCE EXAMPLES:
Kubota Engine_Section 2_Specifications.
A-6,B-3,C-7_Section 3_Maintenance Procedure.
3-2, 6-4, 9-1_Section 4_Repair Procedure.
Fault Codes_Section 5.
6-35, 6-56, 6-104_Section 6_Schematic Page #.
Electronic Version
Click on any procedure or page number
highlighted in blue to view the update.
REVISION HISTORY
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August 2016
Part No. 218567 AL4 • AL4000
Serial Number Legend
INTRODUCTION
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August 2016
AL4 • AL4000 Part No. 218567
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.
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 follow this
symbol to avoid possible injury or
death.
Indicates an 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 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 avoided,
may result in property damage.
Be sure to wear protective eye wear and
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-toed
shoes.
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 performed.
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 have the appropriate tools, lifting
equipment and a suitable workshop.
Safety Rules
Section 1 • Safety Rules
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August 2016
Part No. 218567 AL4 • AL4000
Workplace Safety
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 that could get into machine
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 condition and of ample
capacity.
Be sure that fasteners intended for one
time use (i.e., cotter pins and self-locking
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. Use an approved container.
Please be environmentally safe.
Be sure that your workshop or work area
is properly ventilated and well lit.
SAFETY RULES
Section 1 • Safety Rules
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August 2016
AL4 • AL4000 Part No. 218567
Table of Contents
Introduction
Important Information................................................................................................... ii
Revision History .......................................................................................................... iii
Serial Number Legend ................................................................................................. v
Section 1 Safety Rules
General Safety Rules .................................................................................................. vi
Section 2 Specifications
Machine Specifications ...........................................................................................2 - 1
Performance Specifications.....................................................................................2 - 1
Generator Options...................................................................................................2 - 2
Perkins 403D-11 Engine .........................................................................................2 - 2
Kubota D1105-D3BG Engine Specifications...........................................................2 - 4
SAE and Metric Fasteners Torque Charts...............................................................2 - 5
Section 3 Scheduled Maintenance Procedures
Introduction .............................................................................................................3 - 1
Maintenance Inspection Report ..............................................................................3 - 3
Checklist A Procedures
A-1 Inspect the Manuals and Decals ...................................................................3 - 5
A-2 Perform Pre-operation Inspection..................................................................3 - 6
A-3 Perform Function Tests..................................................................................3 - 6
Section 3 Scheduled Maintenance Procedures,continued
A-4 Perform Engine Maintenance ........................................................................3 - 7
A-5 Perform Coupler Maintenance.......................................................................3 - 7
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August 2016
Part No. 218567 AL4 • AL4000
A-6 Test the Brakes (if equipped).........................................................................3 - 8
A-7 Torque the Wheel Lug Nuts ...........................................................................3 - 8
A-8 Check the Tires and Wheels..........................................................................3 - 9
A-9 Inspect the Engine Air Filter ..........................................................................3 - 9
A-10 Perform Generator Maintenance - Leroy Somer Models.............................3 - 10
A-11 Perform Engine Maintenance - Kubota Models ...........................................3 - 10
A-12 Perform Engine Maintenance - Kubota Models ...........................................3 - 11
A-13 Inspect the Cable and Cable Pulleys...........................................................3 - 11
A-14 Perform Engine Maintenance - Kubota Models ...........................................3 - 12
A-15 Perform Engine Maintenance - Kubota Models ...........................................3 - 13
A-16 Perform Generator Maintenance - Marathon Models ..................................3 - 13
A-17 Drain the Fuel Filter/Water Separator - Kubota Models...............................3 - 14
A-18 Adjust the Brakes (if equipped) ...................................................................3 - 15
Checklist B Procedures
B-1 Inspect the Engine Start Battery or Lighting Battery Pack ..........................3 - 17
B-2 Inspect the Electrical Wiring ........................................................................3 - 18
B-3 Torque the Wheel Lug Nuts .........................................................................3 - 19
B-4 Perform Engine Maintenance - Perkins Models ..........................................3 - 19
B-5 Perform Jack Maintenance ..........................................................................3 - 20
B-6 Inspect and Lubricate the Winch .................................................................3 - 20
B-7 Lubricate the T-bolt ......................................................................................3 - 21
B-8 Inspect and Adjust the Brakes (if equipped)................................................3 - 21
B-9 Inspect the Suspension ...............................................................................3 - 23
B-10 Perform Engine Maintenance - Kubota Models ...........................................3 - 24
Section 3 Scheduled Maintenance Procedures,continued
Checklist C Procedures
C-1 Perform Engine Maintenance ......................................................................3 - 25
C-2 Clean the Light Assemblies.........................................................................3 - 25
TABLE OF CONTENTS
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August 2016
AL4 • AL4000 Part No. 218567
C-3 Grease the Wheel Bearings ........................................................................3 - 26
C-4 Inspect the Electric Brake Magnets (if equipped)........................................3 - 27
C-5 Perform Engine Maintenance - Kubota Models ...........................................3 - 28
C-6 Perform Generator Maintenance - Leroy Somer Models.............................3 - 29
Checklist D Procedures
D-1 Perform Engine Maintenance - Kubota Models ...........................................3 - 30
D-2 Perform Generator Maintence - Leroy Somer Models.................................3 - 30
D-3 Perform Coupler Maintenance.....................................................................3 - 31
Checklist E Procedures
E-1 Replace the Mast Lift Cable ........................................................................3 - 32
E-2 Perform Engine Maintenance ......................................................................3 - 32
E-3 Perform Engine Maintenance ......................................................................3 - 33
E-4 Perform Generator Maintenance - Marathon Models ..................................3 - 33
E-5 Perform Generator Maintenance - Leroy Somer Models.............................3 - 34
E-6 Perform Generator Maintenance - Leroy Somer Models.............................3 - 34
Section 4 Repair Procedures
Introduction .............................................................................................................4 - 1
Mast
1-1 Mast...............................................................................................................4 - 2
Winch
TABLE OF CONTENTS
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August 2016
Part No. 218567 AL4 • AL4000
2-1 Winch ............................................................................................................4 - 5
Generator
3-1 Generator ......................................................................................................4 - 8
Engine
4-1 Engine RPM ................................................................................................4 - 12
Section 5 Troubleshooting
Introduction .............................................................................................................5 - 1
Troubleshooting.......................................................................................................5 - 2
Section 6 Schematics
Introduction .............................................................................................................6 - 1
Wire Color Legend ..................................................................................................6 - 2
Trailer Lighting Wiring Diagram ...............................................................................6 - 3
Electrical Schematic, (ANSI / CSA).........................................................................6 - 4
Electrical Schematic, (AUS) ....................................................................................6 - 5
Control Box and Engine Wiring, (Kubota Models)...................................................6 - 8
Control Box and Engine Wiring, (Perkins Models) ..................................................6 - 9
Control Box and Engine Wiring, (AUS)..................................................................6 - 12
Trailer Wiring Diagram, (ANSI / CSA)....................................................................6 - 13
Trailer Wiring Diagram, (AUS) ...............................................................................6 - 15
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TABLE OF CONTENTS
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AL4 • AL4000 Part No. 218567
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Section 2 • SpecificationsAugust 2016
Part No. 218567 AL4 • AL4000 2 - 1
Machine Specifications
Total lighting wattage 4 x 1000 watts
Fuel capacities
Single tank 30 gallons
114 liters
Dual tanks (option) 60 gallons
227 liters
Tires and wheels
Tire size ST205/75D15
Load range C
Lug nut torque, dry 90 ft-lbs
122 Nm
Lug nut torque, lubricated 67.5 ft-lbs
91.5 Nm
Tire pressure, maximum (cold) 50 psi
3.4 bar
Specifications
Performance Specifications
Tongue weight, maximum
With fuel (single tank) 150 lbs
68 kg
(dual tank) 130 lbs
59 kg
Run time
Single tank 50 hours
For operational specifications, refer to the
Operator's Manual.
Continuous improvement of our products
is a Genie policy. Product specifications are
subject to change without notice.
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August 2016
2 - 2 AL4 • AL4000 Part No. 218567
Section 2 • Specifications
SPECIFICATIONS
Generator Options
6 kw and 8 kw
Generator speed @ full load 60 Hz 1800 rpm
Temperature, ambient maximum 104°F
40°C
Capacitor (disconnected) 25 µF
7 kw
Generator speed @ full load 50 Hz 1500 rpm
Temperature, ambient maximum 104°F
40°C
Capacitor (disconnected) 25 µF
Continuous improvement of our products
is a Genie policy. Product specifications are
subject to change without notice.
Perkins 403D-11 Engine
Displacement 68.9 cu in
1.1 liters
Number of cylinders 3
Bore and stroke 3.03 x 3.19 inches
77 x 81 mm
Horsepower, net intermittent 25 @ 3000 rpm
18.6 kW
Firing order 1 - 2 - 3
Compression ratio 23:1
Compression pressure 425 psi
29 bar
Pressure of the lowest cylinder must be within
50 psi / 3.5 bar of the highest cylinder, though
at no time less than 360 psi / 25 bar
Idle speed @ no load 1500 rpm
(with 7kw generator)
Frequency 50 hz
Idle speed @ no load 1800 rpm
(with 6kw or 8kw generator)
Frequency 60 hz
Governor centrifugal mechanical
Valve clearance, cold 0.0078 in
0.2 mm
Engine coolant capacity 2.0 quarts
1.9 liters
Engine coolant should be clean soft water with 50% anti
freeze concentration ethylene glycol to BS 6580:1992 or
ASTMD 3306-89 or AS 2108-1977
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Section 2 • SpecificationsAugust 2016
Part No. 218567 AL4 • AL4000 2 - 3
SPECIFICATIONS
Continuous improvement of our products
is a Genie policy. Product specifications are
subject to change without notice.
Heavy duty battery
Type 12V DC
Group 24
Quantity 1
Ampere hour 75 A
Cold cranking ampere 700
Reserve capacity @ 25A rate 125 minutes
Alternator
Output 40A, 12V DC
Fan belt deflection 3/16 inch
5 mm
Lubrication system
Oil pressure 40 to 60psi
(hot @ 2000 rpm) 3 to 4 bar
Oil capacity (including filter) 4.6 quarts
4.4 liters
Oil viscosity requirements
Units ship with 15W-40.
Extreme operating temperatures may require the use of
alternative engine oils. For oil requirements, refer to the
Engine Operator Handbook on your machine.
Injection system
Injection pump make Bosch
Injection timing 23° BTDC @ 3000 rpm
Injection pump pressure 2133 psi
150 bar
Fuel requirement diesel number 2-D
Standard battery
Type 12V DC
Group 24
Quantity 1
Ampere hour 75 A
Cold cranking ampere 500
Reserve capacity @ 25A rate 65 minutes
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August 2016
2 - 4 AL4 • AL4000 Part No. 218567
Section 2 • Specifications
Kubota D1105-D3BG Engine
Displacement 68.53 cu in
1.123 liters
Number of cylinders 3
Bore and stroke 3.07 x 3.09 inches
78 x 78.4 mm
Horsepower, gross intermittent 13.6 @ 1800 rpm
10.1 kW
Firing order 1 - 2 - 3
Compression ratio 24:1
Compression pressure 412 to 469 psi
28.4 to 32.3 bar
Idle speed @ no load 1500 rpm
(with 7kw generator)
Frequency 50 hz
Idle speed @ no load 1800 rpm
(with 6kw or 8kw generator)
Frequency 60 hz
Governor centrifugal mechanical
Valve clearance, cold 0.0057 to 0.0072 in
0.145 to 0.185 mm
Engine coolant capacity 3.3 quarts
3.1 liters
Lubrication system
Oil pressure 28 to 64psi
1.93 to 4.41 bar
Oil capacity (including filter) 5.4 quarts
5.1 liters
Oil viscosity requirements
Units ship with 10W-30.
Extreme operating temperatures may require the use of
alternative engine oils. For oil requirements, refer to the
Engine Operator Handbook on your machine.
Injection system
Injection pump make Bosch MD
Injection timing 18° BTDC
Injection pump pressure 1991 psi
137 bar
Fuel requirement
For fuel requirements, refer to the engine Operator's
Manual on your machine.
Standard battery
Type 12V DC
Group 24
Quantity 1
Ampere hour 75 A
Cold cranking ampere 500
Reserve capacity @ 25A rate 65 minutes
Heavy duty battery
Type 12V DC
Group 24
Quantity 1
Ampere hour 75 A
Cold cranking ampere 700
Reserve capacity @ 25A rate 125 minutes
Alternator
Output 40A, 14V DC
Fan belt deflection 0.28 to 0.35 inch
7 to 9 mm
SPECIFICATIONS
Continuous improvement of our products
is a Genie policy. Product specifications are
subject to change without notice.
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Section 2 • SpecificationsAugust 2016
Part No. 218567 AL4 • AL4000 2 - 5
SPECIFICATIONS
10.9 12.98.8
4.6
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2 - 6 AL4 • AL4000 Part No. 218567
Section 2 • Specifications
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Section 3 • Scheduled Maintenance ProceduresAugust 2016
Part No. 218567 AL4 • AL4000 3 - 1
Scheduled Maintenance Procedures
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, semi-annually,
annually and every 2 years as specified on the
Maintenance Inspection Report.
WARNING
Failure to perform each procedure
as presented and scheduled could
result in death, serious injury or
substantial damage.
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.
Unless otherwise specified, perform each
maintenance procedure with the machine in the
following configuration:
• Machine parked on a firm, level surface
• Mast in the stowed position
• Wheels chocked
• Light switches in the off position
• No external AC power devices connected to
the power outlets at the control box.
About This Section
This section contains detailed procedures for each
scheduled maintenance inspection.
Each procedure includes a description, safety
warnings and step-by-step instructions.
Symbols Legend
Safety alert symbol—used to alert
personnel to potential personal
injury hazards. Obey all safety
messages that follow this symbol
to avoid possible injury or death.
DANGER
Indicates an imminently
hazardous situation which, if not
avoided, will result in death or
serious injury.
WARNING
Indicates a potentially hazardous
situation which, if not avoided,
could result in death or serious
injury.
CAUTION
Indicates a potentially hazardous
situation which, if not avoided,
may cause minor or moderate
injury.
NOTICE
Indicates a potentially hazardous
situation which, if not avoided,
may result in property damage.
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.
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