Terex AL4 Bedienungsanleitung

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August 2016

AL4 • AL4000 Part No. 218567

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

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

Discount-Equipment.com

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

Discount-Equipment.com

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

vii

Discount-Equipment.com

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

viii

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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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