Terex AL4L User manual

August 2016
AL4L • AL5L Part No. 229171
ii
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.
Contact Us:
e-mail: [e-mail]
Introduction
Copyright © 2011 by Terex Corporation
229171 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.

August 2016
Part No. 229171 AL4L • AL5L
Serial Number Legend
INTRODUCTION
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August 2016
AL4L • AL5L Part No. 229171
This page intentionally left blank.
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August 2016
Part No. 229171 AL4L • AL5L
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
v

August 2016
AL4L • AL5L Part No. 229171
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.
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.
SAFETY RULES
Section 1 • Safety Rules
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August 2016
Part No. 229171 AL4L • AL5L
Table of Contents
Introduction
Important Information................................................................................................... ii
Serial Number Legend ................................................................................................ iii
Section 1 Safety Rules
General Safety Rules ................................................................................................... v
Section 2 Rev Specifications
A Machine Specifications, AL4L .................................................................................2 - 1
Machine Specifications, AL5L .................................................................................2 - 1
Performance Specifications.....................................................................................2 - 2
Marathon Generator, AL4L......................................................................................2 - 2
Marathon Generator, AL5L......................................................................................2 - 2
Kubota D1105-D3BG Engine Specifications...........................................................2 - 3
SAE and Metric Fasteners Torque Charts...............................................................2 - 4
Section 3 Rev Scheduled Maintenance Procedures
Introduction .............................................................................................................3 - 1
Maintenance Inspection Report ..............................................................................3 - 3
A Checklist A Procedures
A-1 Inspect the Manuals and Decals ...................................................................3 - 4
A-2 Perform Pre-operation Inspection..................................................................3 - 5
A-3 Perform Function Tests..................................................................................3 - 5
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AL4L • AL5L Part No. 229171
Section 3 Rev Scheduled Maintenance Procedures,continued
A-4 Perform Engine Maintenance ........................................................................3 - 6
A-5 Perform Coupler Maintenance.......................................................................3 - 6
A-6 Test the Brakes (if equipped).........................................................................3 - 7
A-7 Torque the Wheel Lug Nuts ...........................................................................3 - 7
A-8 Check the Tires and Wheels..........................................................................3 - 8
A-9 Inspect the Cable and Cable Pulleys.............................................................3 - 8
A-10 Perform Engine Maintenance ........................................................................3 - 9
A-11 Perform Lighting-battery Maintenance (if equipped) ...................................3 - 10
A-12 Perform Engine Maintenance ......................................................................3 - 10
A-13 Perform Generator Maintenance .................................................................3 - 11
A-14 Adjust the Brakes (if equipped) ...................................................................3 - 11
A Checklist B Procedures
B-1 Inspect the Engine Start Battery or Lighting Battery Pack ..........................3 - 13
B-2 Inspect the Electrical Wiring ........................................................................3 - 14
B-3 Inspect the Battery Watering System (if equipped) .....................................3 - 15
B-4 Torque the Wheel Lug Nuts .........................................................................3 - 15
B-5 Perform Jack Maintenance ..........................................................................3 - 16
B-6 Inspect and Lubricate the Winch .................................................................3 - 16
B-7 Lubricate the T-bolt ......................................................................................3 - 17
B-8 Inspect and Adjust the Brakes (if equipped)................................................3 - 17
B-9 Inspect the Suspension ...............................................................................3 - 19
B-10 Perform Engine Maintenance ......................................................................3 - 20
TABLE OF CONTENTS
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Part No. 229171 AL4L • AL5L
Section 3 Rev Scheduled Maintenance Procedures,continued
A Checklist C Procedures
C-1 Perform Engine Maintenance ......................................................................3 - 21
C-2 Clean the Light Assemblies .........................................................................3 - 21
C-3 Grease the Wheel Bearings ........................................................................3 - 22
C-4 Inspect the Electric Brake Magnets (if equipped)........................................3 - 23
C-5 Perform Engine Maintenance ......................................................................3 - 24
A Checklist D Procedures
D-1 Perform Engine Maintenance ......................................................................3 - 25
D-2 Perform Coupler Maintenance.....................................................................3 - 25
A Checklist E Procedures
E-1 Replace the Mast Lift Cable ........................................................................3 - 26
E-2 Perform Engine Maintenance ......................................................................3 - 26
E-3 Perform Engine Maintenance ......................................................................3 - 27
E-4 Perform Generator Maintenance .................................................................3 - 27
Section 4 Rev Repair Procedures
Introduction .............................................................................................................4 - 1
AMast
1-1 Mast...............................................................................................................4 - 2
AWinch
2-1 Winch ............................................................................................................4 - 5
AGenerator
3-1 Generator ......................................................................................................4 - 8
AEngine
4-1 Engine RPM ................................................................................................4 - 12
TABLE OF CONTENTS
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August 2016
AL4L • AL5L Part No. 229171
Section 5 Rev Troubleshooting
Introduction .............................................................................................................5 - 1
A Troubleshooting.......................................................................................................5 - 2
Section 6 Rev Schematics
Introduction .............................................................................................................6 - 1
A Electrical Component and Wire Color Legend ........................................................6 - 2
A Trailer Lighting Wiring Diagram ...............................................................................6 - 3
A Electrical Schematic, AL5L .....................................................................................6 - 4
A Electrical Schematic, AL4L .....................................................................................6 - 6
x
TABLE OF CONTENTS

Section 2 • Specifications
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August 2016
Part No. 229171 AL4L • AL5L 2 - 1
Machine Specifications, AL4L
Total lighting wattage 4 x 270 watts
Batteries - Lighting
Type 6V DC
Group 902 (J305G-AC)
Quantity 8
Reserve capacity @ 25A rate 678 minutes
Weight 88 lbs
40 kg
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
Machine Specifications, AL5L
Total lighting wattage 4 x 270 watts
Fuel capacities
Single tank 30 gallons
114 liters
Battery - Engine Start Standard Heavy-duty
Type 12V DC 12V DC
Group 24 24
Quantity 1 1
Cold cranking ampere 400 650
Reserve capacity @ 25A rate 60 min 90 min
Batteries - Lighting
Type 6V DC
Group 902 (J305G-AC)
Quantity 8
Reserve capacity @ 25A rate 678 minutes
Weight 88 lbs
40 kg
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
Continuous improvement of our products
is a Genie policy. Product specifications are
subject to change without notice.
For operational specifications, refer to the
Operator's Manual.

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2 - 2 AL4L • AL5L Part No. 229171
Section 2 • Specifications
SPECIFICATIONS
Performance Specifications
Tongue weight, maximum
AL4L with batteries 110 lbs
50 kg
AL5L with no fuel 146 lbs
66 kg
Run time
AL4L with batteries 10 hours
AL5L 10 hours
Marathon Generator, AL4L
Generator speed @ full load 60 Hz 1800 rpm
Temperature, ambient maximum 104°F
40°C
Power 6 kw
Capacitor (disconnected) 25 µF
Marathon Generator, AL5L
Generator speed @ full load 60 Hz 1800 rpm
Temperature, ambient maximum 104°F
40°C
Power 8 kw
Capacitor (disconnected) 25 µF
Continuous improvement of our products
is a Genie policy. Product specifications are
subject to change without notice.

Section 2 • Specifications
REV B
August 2016
Part No. 229171 AL4L • AL5L 2 - 3
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 1850 rpm
Frequency 61.5 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 64 psi
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.
Continuous improvement of our products
is a Genie policy. Product specifications are
subject to change without notice.

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Section 2 • Specifications
SPECIFICATIONS

Section 3 • Scheduled Maintenance ProceduresAugust 2016
Part No. 229171 AL4L • AL5L 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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Section 3 • Scheduled Maintenance Procedures
SCHEDULED MAINTENANCE PROCEDURES
Maintenance Symbols Legend
Note: The following symbols have been used in
this manual to help communicate the intent of the
instructions. When one or more of the symbols
appears at the beginning of a maintenance
procedure, it conveys the meaning below.
Indicates that tools will be required to
perform this procedure.
Indicates that new parts will be required
to perform this procedure.
Indicates that a cold motor or pump will
be required to perform this procedure.
Indicates that dealer service will be
required to perform this procedure.
Maintenance Schedule
There are five types of maintenance inspections
that must be performed according to a schedule—
daily, quarterly, semi-annually, annually, and
two year. The Scheduled Maintenance Procedures
Section and the Maintenance Inspection Report
have been divided into five subsections—A, B,
C, D, and E. Use the following chart to determine
which group(s) of procedures are required to
perform a scheduled inspection.
Inspection Checklist
Daily or every 8 hours A
Quarterly or every 250 hours A + B
Semi-annually or every 500 hours A + B + C
Annually or every 1000 hours A + B + C + D
Two year or every 2000 hours A + B + C + D + E
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 in compliance with employer, job site and
governmental regulations.

Section 3 • Scheduled Maintenance ProceduresAugust 2016
Part No. 229171 AL4L • AL5L 3 - 3
Maintenance Inspection Report
Checklist C - Rev A Y N R
C-1 Engine maintenance -
Kubota models
C-2 Lights
Perform every 6000 miles:
C-3 Wheel bearings
C-4 Electric brake
Perform every 800 hours:
C-5 Engine maintenance -
Kubota models
Checklist D - Rev A Y N R
Perform every 12000 miles:
D-1 Engine maintenance -
Kubota models
Perform annually:
D-2 Coupler
Checklist E - Rev A Y N R
Perform every 2000 hours:
E-1 Cable
E-2 Engine maintenance -
Kubota models
Perform every 3000 hours:
E-3 Engine maintenance -
Kubota models
Perform every 10000 hours:
E-4 Generator
Comments
Checklist A - Rev A Y N R
A-1 Manuals and decals
A-2 Pre-operation inspect
A-3 Function tests
Perform every 8 hours:
A-4 Engine maintenance -
Kubota models
Perform before towing:
A-5 Coupler
A-6 Brakes
Perform at 10 miles:
A-7 Lug nuts
Perform every week:
A-8 Tires and wheels
Perform every month:
A-9 Cable and Pulleys
Perform every 100 hours:
A-10 Engine maintenance -
Kubota models
Perform every 160 hours:
A-11 Battery
Perform every 200 hours:
A-12 Engine maintenance -
Kubota models
A-13 Generator
A-14 Brakes
Checklist B - Rev A Y N R
B-1 Battery
B-2 Electrical wiring
B-3 Battery watering
B-4 Lug nuts
B-5 Jack
B-6 Winch
B-7 T-bolt
Perform every 3000 miles:
B-8 Brakes
B-9 Suspension
Perform every 400 hours:
B-10 Engine maintenance -
Kubota models
Instructions
· Make copies of this report to use for
each inspection.
· Select the appropriate checklist(s) for
the type of inspection to be performed.
Daily or 8 hours
Inspection: A
Quarterly or 250 hours
Inspection: A+B
Semi-annually or
500 hours
Inspection: A+B+C
Annually or
1000 hours
Inspection: A+B+C+D
Two year or
2000 hours
Inspection: A+B+C+D+E
· Place a check in the appropriate box
after each inspection procedure is
completed.
· Use the step-by-step procedures in
this section to learn how to perform
these inspections.
· If any inspection receives an “N”, tag
and remove the machine from service,
repair and re-inspect it. After repair,
place a check in the “R” box.
Legend
Y = yes, acceptable
N = no, remove from service
R = repaired
Model
Serial number
Date
Hour meter
Machine owner
Inspected by (print)
Inspector signature
Inspector title
Inspector company

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Section 3 • Scheduled Maintenance Procedures
Checklist A Procedures
A-1
Inspect the Manuals and Decals
Terex specifications require that this procedure be
performed at the beginning of every work shift or
daily, whichever comes first.
Maintaining the operator’s and safety manuals
in good condition is essential to safe machine
operation. Manuals are included with each
machine and should be stored in the container
provided in the cabinet. An illegible or missing
manual will not provide safety and operational
information necessary for a safe operating
condition.
In addition, maintaining all of the safety and
instructional decals in good condition is mandatory
for safe machine operation. Decals alert operators
and personnel to the many possible hazards
associated with using this machine. They also
provide users with operation and maintenance
information. An illegible decal will fail to alert
personnel of a procedure or hazard and could
result in unsafe operating conditions.
1 Check to make sure that the operator's and
safety manuals are present and complete in the
storage container in the cabinet.
2 Examine the pages of each manual to be sure
that they are legible and in good condition.
Result: The operator's manual is appropriate for
the machine and all manuals are legible and in
good condition.
Result: The operator's manual is not
appropriate for the machine or all manuals are
not in good condition or is illegible. Remove
the machine from service until the manual is
replaced.
3 Open the operator's manual to the decals
inspection section. Carefully and thoroughly
inspect all decals on the machine for legibility
and damage.
Result: The machine is equipped with all
required decals, and all decals are legible and
in good condition.
Result: The machine is not equipped with all
required decals, or one or more decals are
illegible or in poor condition. Remove the
machine from service until the decals are
replaced.
4 Always return the manuals to the storage
container after use.
Note: Contact your authorized Genie distributor or
Genie Industries if replacement manuals or decals
are needed.

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Section 3 • Scheduled Maintenance ProceduresAugust 2016
Part No. 229171 AL4L • AL5L 3 - 5
A-2
Perform Pre-operation Inspection
Terex specifications require that this procedure be
performed at the beginning of every work shift or
daily, whichever comes first.
Completing a Pre-operation Inspection is essential
to safe machine operation. The Pre-operation
Inspection is a visual inspection performed by the
operator prior to each work shift. The inspection
is designed to discover if anything is apparently
wrong with a machine before the operator
performs the function tests. The Pre-operation
Inspection also serves to determine if routine
maintenance procedures are required.
Complete information to perform this procedure
is available in the appropriate operator's manual.
Refer to the Operator's Manual on your machine.
A-3
Perform Function Tests
Terex specifications require that this procedure be
performed at the beginning of every work shift or
daily, whichever comes first.
Completing the function tests is essential to safe
machine operation. Function tests are designed to
discover any malfunctions before the machine is
put into service. A malfunctioning machine must
never be used. If malfunctions are discovered,
the machine must be tagged and removed from
service.
Complete information to perform this procedure
is available in the appropriate operator's manual.
Refer to the Operator's Manual on your machine.
CHECKLIST A PROCEDURES

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Section 3 • Scheduled Maintenance Procedures
A-4
Perform Engine Maintenance -
Kubota D1105-D3BG Models
Terex specifications require that this procedure be
performed at the beginning of every work shift or
daily, whichever comes first.
• Oil level and leaks
• Coolant level and leaks
• Damaged or loose parts
• Color of exhaust
• Unusual engine noise
Required maintenance procedures and additional
engine information is available in the Kubota
D1105 Operators Manual (Kubota part number
16622-89166)
Kubota D1105 Operators Manual
Genie part number 131379
A-5
Perform Coupler Maintenance
Coupler specifications require that this procedure
be performed before towing.
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 vehicle, mounting bracket, hitch ball and
coupler for signs of wear or damage and that
the coupler handle opens and closes freely.
Result: If coupler and/or mounting bracket
is deformed or damaged, replace complete
coupler and mounting bracket. Replace bent,
broken or worn parts before use.
2 Close coupler securely by ensuring that the
hitch ball is fully seated in the coupler ball
pocket and the pin is inserted behind the collar
or latch.
3 Check mounting bracket hardware for wear and
proper tightness.
Result: Replace bent, broken or worn hardware.
CHECKLIST A PROCEDURES