Genie AL5HT Service Manual 1265482 – PDF DOWNLOAD

Description

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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