Professional Documents
Culture Documents
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: awp.techpub@terex.com Copyright © 2011 by Terex Corporation
Printed in U.S.A.
INTRODUCTION
Safety Rules
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.
SAFETY RULES
Table of Contents
Introduction
Important Information ................................................................................................... ii
Serial Number Legend ................................................................................................ iii
TABLE OF CONTENTS
TABLE OF CONTENTS
TABLE OF CONTENTS
REV B
Specifications
Machine Specifications, AL4L Machine Specifications, AL5L
Total lighting wattage 4 x 270 watts Total lighting wattage 4 x 270 watts
Batteries - Lighting Fuel capacities
Type 6V DC Single tank 30 gallons
Group 902 (J305G-AC) 114 liters
SPECIFICATIONS REV B
REV B SPECIFICATIONS
SPECIFICATIONS REV B
Unless otherwise specified, perform each Indicates that a specific result is expected after
maintenance procedure with the machine in the performing a series of steps.
following configuration: Indicates that an incorrect result has occurred
· Machine parked on a firm, level surface after performing a series of steps.
· 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.
Note: The following symbols have been used in There are five types of maintenance inspections
this manual to help communicate the intent of the that must be performed according to a schedule—
instructions. When one or more of the symbols daily, quarterly, semi-annually, annually, and
appears at the beginning of a maintenance two year. The Scheduled Maintenance Procedures
procedure, it conveys the meaning below. Section and the Maintenance Inspection Report
have been divided into five subsections—A, B,
C, D, and E. Use the following chart to determine
Indicates that tools will be required to which group(s) of procedures are required to
perform this procedure. perform a scheduled inspection.
Inspection Checklist
Daily or every 8 hours A
Indicates that new parts will be required
Quarterly or every 250 hours A+B
to perform this procedure.
Semi-annually or every 500 hours A+B+C
Annually or every 1000 hours A+B+C+D
Indicates that a cold motor or pump will Two year or every 2000 hours A+B+C+D+E
be required to perform this procedure.
Maintenance Inspection Report
Indicates that dealer service will be The maintenance inspection report contains
required to perform this procedure. checklists for each type of scheduled inspection.
A-2 A-3
Perform Pre-operation Inspection Perform Function Tests
Terex specifications require that this procedure be Terex specifications require that this procedure be
performed at the beginning of every work shift or performed at the beginning of every work shift or
daily, whichever comes first. daily, whichever comes first.
Completing a Pre-operation Inspection is essential Completing the function tests is essential to safe
to safe machine operation. The Pre-operation machine operation. Function tests are designed to
Inspection is a visual inspection performed by the discover any malfunctions before the machine is
operator prior to each work shift. The inspection put into service. A malfunctioning machine must
is designed to discover if anything is apparently never be used. If malfunctions are discovered,
wrong with a machine before the operator the machine must be tagged and removed from
performs the function tests. The Pre-operation service.
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.
Complete information to perform this procedure Refer to the Operator's Manual on your machine.
is available in the appropriate operator's manual.
Refer to the Operator's Manual on your machine.
A-4 A-5
Perform Engine Maintenance - Perform Coupler Maintenance
Kubota D1105-D3BG Models
A-6 A-7
Test the Brakes (if equipped) Torque the Wheel Lug Nuts
Axle specifications require that this procedure be Axle specifications require that this procedure be
performed before towing. performed initially at 10, 25 and 50 miles of use, or
after reinstallation of a tire.
Maintaining the axle brakes in good condition is
essential to safe operation and good performance. Maintaining the wheel lug nuts at the proper torque
Brakes which are out of adjustment can result in is essential to safe operation and good service life
longer stopping distances and excessive brake of the tires, wheel and axle.
wear on the towing vehicle. Component damage
may also result if problems are not discovered and 1 Check each lug nut for proper torque.
repaired in a timely fashion. Specification
1 Test the brakes for proper function. Repair or Lug nut torque, dry 90 ft-lbs
122 Nm
replace any faulty components as needed.
Lug nut torque, lubricated 67.5 ft-lbs
91.5 Nm
A-8 A-9
Check the Tires and Wheels Inspect the Cable and
Cable Pulleys
A-11 A-12
Perform Lighting-battery Perform Engine Maintenance -
Maintenance (if equipped) Kubota D1105-D3BG Models
Terex specifications require that this procedure be Engine specifications require that this procedure
performed for the batteries which supply power to be performed every 200 hours or quarterly,
the lighting every 160 hours or monthly, whichever whichever comes first.
comes first.
• Radiator hoses and clamps
Proper battery condition is essential to good • Intake air piping
machine performance and operational safety. • Change engine oil
Improper fluid levels can result in component
damage and hazardous conditions. Required maintenance procedures and additional
engine information is available in the Kubota
Electrocution/burn hazard. D1105 Operators Manual (Kubota part number
WARNING Contact with electrically charged 16622-89166)
circuits could result in death or
Kubota D1105 Operators Manual
serious injury. Remove all rings,
Genie part number 131379
watches and other jewelry.
Bodily injury hazard. Batteries
WARNING contain acid. Avoid spilling or
contacting battery acid. Neutralize
battery acid spills with baking
soda and water.
1 Open the cabinet doors.
2 Check the battery acid level. If needed,
replenish with distilled water to 1/8 inch / 3 mm
below the bottom of the battery fill tube. Do not
overfill.
3 Install the vent caps and neutralize any
electrolyte that may have spilled.
A-13 A-14
Perform Generator Maintenance- Adjust the Brakes (if equipped)
Marathon Models
REV B
Checklist B Procedures
B-1 3 Be sure that the battery retainers and cable
connections are tight.
Inspect the Engine Start Battery
4 Fully charge the batteries. Allow the batteries to
or Lighting Battery Pack rest 24 hours before performing this procedure
to allow the battery cells to equalize.
5 Put on protective clothing and eye wear.
Terex specifications requires that this procedure be
6 Remove the battery vent caps and check the
performed every 250 hours or quarterly, whichever
specific gravity of each battery cell with a
comes first.
hydrometer. Note the results.
Proper battery condition is essential to good 7 Check the ambient air temperature and adjust
machine performance and operational safety. the specific gravity reading for each cell as
Improper fluid levels or damaged cables and follows:
connections can result in component damage and
hazardous conditions. • Add 0.004 to the reading of each cell for
every 10° / 5.5° C above 80° F / 26.7° C.
Electrocution/burn hazard.
WARNING Contact with electrically charged • Subtract 0.004 from the reading of each cell for
circuits could result in death or every 10° / 5.5° C below 80° F / 26.7° C.
serious injury. Remove all rings, Result: All battery cells display an adjusted
watches and other jewelry. specific gravity of 1.277 +/- 0.007. The battery
Bodily injury hazard. Batteries is fully charged. Proceed to step 11.
WARNING contain acid. Avoid spilling or Result: One or more battery cells display a
contacting battery acid. Neutralize specific gravity of 1.269 or below. Proceed to
battery acid spills with baking step 8.
soda and water.
8 Perform an equalizing charge OR fully charge
1 Open the side covers. the batteries and allow the batteries to rest at
2 Be sure that the battery cable connections are least 6 hours.
free of corrosion. 9 Remove the battery vent caps and check the
Note: Adding terminal protectors and a corrosion specific gravity of each battery cell with a
preventative sealant will help eliminate corrosion hydrometer. Note the results.
on the battery terminals and cables.
12 Install the vent caps and neutralize any • Trailer lighting wire harness
electrolyte that may have spilled. 2 Inspect for a liberal coating of dielectric grease
in the following locations:
• Lighting junction box
• Ground controls
• All wire harness connectors
B-3 B-4
Inspect the Battery Watering Torque the Wheel Lug Nuts
System (if equipped)
B-5 B-6
Perform Jack Maintenance Inspect and Lubricate the Winch
Jack specifications require that this procedure be Terex specifications require that this procedure be
performed every 250 hours or quarterly, whichever performed every 250 hours or quarterly, whichever
comes first. comes first.
Maintaining the jack is essential to good machine Maintaining the winch is essential to good machine
performance and safe operation. An unsafe performance and safe operation. An unsafe
working condition exists if the jack has excessive working condition exists if the winch has excessive
wear wear and/or does not operate smoothly, free of
and/or does not operate smoothly, free of hesitation and binding.
hesitation and binding.
1 Carefully lubricate the pivot point on the ratchet
1 Select a jack. pawl and winch shaft with 30W oil.
2 Remove the cover from the top of the jack. Component damage hazard. Do
NOTICE not allow oil onto the brake disk.
3 Apply a small amount of automotive grease
to the internal gearing, and rotate the handle 2 Inspect the brake disks for excessive wear.
several times to evenly distribute the grease. Replace if the pad is less than
1
4 Apply a few drops of light oil to the jack handle /16 inch / 1.5 mm thick. If necessary, refer to
where it makes contact with the outside of the Repair procedure 2-1, How to Disassemble the
jack tube. Winch.
5 Securely install the cover onto the jack. 3 Inspect the pinion shaft bushings for excessive
wear. Replace if the wall thickness of the
6 Repeat this procedure, beginning with step 1,
bushing is less than 1/8 inch / 3.1 mm. If
for the other jacks on the machine.
necessary, refer to Repair procedure 2-1, How
to Disassemble the Winch.
B-7 B-8
Lubricate the T-bolt Inspect and Adjust the Brakes
(if equipped)
2 Remove all dust, dirt and oil residue from the Note: Perform this procedure with the machine
threaded surfaces of the T-bolt, and apply a few on a firm, level surface with the machine in the
drops of light oil or thread lubricant onto the stowed position.
threaded surfaces.
1 Select a wheel. Chock the front and rear of the
3 Fully install the T-bolt into the mast. tire at the opposite side of the machine.
2 Loosen the wheel lug nuts. Do not remove
a 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.
a T-bolt 4 Remove the dust cap from the hub. Remove the
cotter pin from the castle nut.
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.
7 Inspect the brake lining for wear (if equipped). 12 Fully loosen the castle nut. Do not rotate the
hub.
Result: The thickness of the brake lining is
greater than 1/16 inch / 1.6 mm. The brake shoes 13 Finger tighten the castle nut until snug.
are good.
14 Install a new cotter pin. Bend the cotter pin
Result: The thickness of the brake lining is to lock it in place.
1
/16 inch / 1.6 mm or less. The brake shoes
Note: Always replace the cotter pin with a new one
must be replaced and the brake drums must
when removing the castle nut.
inspected for wear, scoring and other damage.
Note: The maximum bore of a good brake drum 15 Install the dust cap, then the tire and wheel
shall not be greater than 0.090 inch / 2.29 mm in assembly. Torque the wheel lug nuts to
excess of the drum diameter. specification. Refer to Section 2, Specifications
16 Working from the back side of the wheel at the
Note: If drum resurfacing is required, the brake
brake backing plate, locate and remove the
drum should be resurfaced to a 120 micron finish.
small rubber plug from the lower side of the
Note: If replacing the brake shoes, apply a light backing plate to access the star-shaped brake
coating of grease or anti-seize compound to the adjuster wheel. Set the plug to the side.
brake anchor pin, arm bushing and pin, and areas 17 Insert a brake adjuster tool into the opening of
of the backing plate which contact the magnet arm the brake backing plate, engaging it with the
and brake shoes frame. Apply a small amount of teeth of the brake adjuster wheel. Move the tip
lube to the actuating cam at the top of the magnet of the adjuster tool in an upwards direction to
arm. Do not allow grease or oil to contact the tighten the brakes.
brake shoes or the inside of the drum.
Note: It may be helpful to use a flashlight when
8 Slide the hub onto the yoke spindle. locating the brake adjuster wheel.
Component damage hazard.
NOTICE Do not apply excessive force or
18 Repeatedly move the tip of the adjuster tool in
an upwards direction to tighten the brakes until
damage to the lip of the seal may the wheel locks up and will no longer turn.
occur.
Note: This centers the brake shoes on the brake
9 Place the outer bearing into the hub. drum, ensuring the shoes are positioned correctly.
10 Install the washer and castle nut.
19 Move the tip of the adjuster tool in a downwards
11 Tighten the castle nut to 50 ft-lbs / 68 Nm to direction 3 to 5 clicks to loosen the brakes only
seat the bearings. until the wheel spins freely with little drag.
B-10
Perform Engine Maintenance -
Kubota D1105-D3BG Models
REV B
Checklist C Procedures
C-1 C-2
Perform Engine Maintenance - Clean the Light Assemblies
Kubota D1105-D3BG Models
Kubota D1105 Operators Manual 1 Use clean, cool water to rinse the surface of
Genie part number 131379 each light assembly.
2 Clean each light assembly using a soft cloth,
water and a mild dishwashing detergent.
Component damage hazard.
NOTICE Harsh chemicals and cleaning
agents will damage the surface of
the light assembly. Do not allow
harsh cleaning agents to make
contact with the light surface.
3 Thoroughly rinse, then dry with a soft cloth.
15 Install the washer and castle nut. Required maintenance procedures and additional
engine information is available in the Kubota
16 Tighten the castle nut to 50 ft-lbs / 68 Nm to D1105 Operators Manual (Kubota part number
seat the bearings. 16622-89166)
17 Fully loosen the castle nut. Do not rotate the Kubota D1105 Operators Manual
hub. Genie part number 131379
18 Finger tighten the castle nut until snug.
19 Install a new cotter pin. Bend the cotter pin
to lock it in place.
Note: Always replace the cotter pin with a new one
when removing the castle nut.
REV B
Checklist D Procedures
D-1 D-2
Perform Engine Maintenance - Perform Coupler Maintenance
Kubota D1105-D3BG Models
E-1 E-2
Replace the Mast Lift Cable Perform Engine Maintenance -
Kubota D1105-D3BG Models
E-3 E-4
Perform Engine Maintenance - Perform Generator Maintenance-
Kubota D1105-D3BG Models Marathon Models
Engine specifications require that this procedure Generator specifications require that this
be performed every 3000 hours. procedure be performed every 10,000 hours.
REV B
Repair Procedures
About This Section
Most of the procedures in this section should only
be performed by a trained service professional
in a suitably equipped workshop. Select the
appropriate repair procedure after troubleshooting
the problem.
Observe and Obey: Perform disassembly procedures to the point
where repairs can be completed. Then to
Repair procedures shall be completed by a
re-assemble, perform the disassembly steps in
person trained and qualified on the repair of
reverse order.
this machine.
Immediately tag and remove from service a Symbols Legend
damaged or malfunctioning machine. Safety alert symbol—used to alert
Repair any machine damage or malfunction personnel to potential personal
before operating the machine. injury hazards. Obey all safety
messages that follow this symbol
Before Repairs Start: to avoid possible injury or death.
Indicates an imminently
Read, understand and obey the safety rules DANGER hazardous situation which, if not
and operating instructions in the appropriate
Operator's Manual on your machine. avoided, will result in death or
serious injury.
Be sure that all necessary tools and parts are
Indicates a potentially hazardous
available and ready for use.
WARNING situation which, if not avoided,
Use only Terex approved replacement parts. could result in death or serious
Read each procedure completely and adhere injury.
to the instructions. Attempting shortcuts may Indicates a potentially hazardous
produce hazardous conditions. CAUTION situation which, if not avoided,
Unless otherwise specified, perform each may cause minor or moderate
maintenance procedure with the machine in the injury.
following configuration: Indicates a potentially hazardous
· Machine parked on a firm, level surface
NOTICE situation which, if not avoided,
may result in property damage.
· Mast in the stowed position
· Wheels chocked Indicates that a specific result is expected after
performing a series of steps.
· Light switches in the off position
Indicates that an incorrect result has occurred
· No external AC power devices connected to
after performing a series of steps.
the power outlets at the control box.
Mast REV B
REV B MAST
How to Disassemble the Mast 8 Working at the top of the 4 inch / 10 cm and
3 inch / 7.5 cm mast sections, use a drill to
1 Remove the mast assembly. See 1-1, How to remove the rivets securing the wear pads in
Remove the Mast Assembly. position.
2 Remove the T-bolt from the 6 inch / 15 cm Component damage hazard. The
round tube assembly. NOTICE mast can be damaged if the drill
3 Remove the nut from the bottom of the mast. bit used is too large. Select a drill
Gently twist and pull the 6 inch / 15 cm round bit only large enough to remove
tube assembly from the mast while pulling the the mandrel from the center of the
cable free. rivet.
9 Remove the fasteners securing the pulley and
CAUTION Bodily injury hazard. Cables can
fray. Always wear adequate hand shim to the 3 inch / 7.5 cm mast section. Set
protection when handling the the components to the side.
cable. 10 Remove the 2 inch / 5 cm mast section from the
Component damage hazard. 3 inch / 7.5 cm mast section.
NOTICE Cables can be damaged if they 11 Remove the 3 inch / 7.5 cm mast section from
are kinked or pinched. the 4 inch / 10 cm mast section.
4 Remove the large round plastic bushing from Note: For ease of assembly, note the location
the bottom of the 4 inch / 10 cm mast section. where each wear pad is removed.
5 Remove the 2.5 inch / 6 cm washer from the Note: To ensure that the mast extends properly
bottom of the mast assembly. after assembly, carefully measure the cable to
6 Pull the mast lock handle fully away from the confirm that the new cable is the same length as
mast, then immediately secure the mast lock in the old one.
position using locking pliers or a clamp on the
Note: During assembly, carefully install the mast
lock handle to restrain it in position.
cable. Refer to the illustration on the following page
7 Remove the fasteners securing the pulley and for cable routing.
mast lock to the 4 inch / 10 cm mast section.
Set the components to the side.
MAST REV B
Detail B
Detail C
6 inch
Winch
(15 cm)
Round Tube Base
Assembly
REV B
Winch
2-1 How to Disassemble the Winch
Winch Note: For ease of disassembly, refer to the
illustration on the next page.
How to Remove the Winch
1 Remove the winch. See 2-1, How to Remove
1 Turn the handle of the mast pivot winch and the Winch.
fully loosen the mast pivot cable. Remove the
handle from the winch. 2 On a workbench, remove the cable drum and
lock arm.
2 Open the cabinet doors and locate the winch.
Remove the fasteners securing the handle to 3 Remove the lock gear and two jam nuts from
the winch, and remove the handle. the pinion shaft.
3 Remove the cable retaining fastener securing 4 Remove the retaining ring from the small
the cable to the winch drum. Unwind the cable groove at the non-threaded end of the pinion
from the winch drum. shaft. Rotate the pinion shaft until the shaft is
removed. Hold the winch components in place
CAUTION Bodily injury hazard. Cables can
fray. Always wear adequate hand
while removing the pinion shaft.
WINCH REV B
REV B WINCH
Generator REV B
REV B GENERATOR
9 Tag and disconnect all external wires from the How to Install the Generator
generator.
1 Using a liquid threadlocker on the fastener
10 Use a lifting jack to support the rear of the threads, install the fasteners securing the
engine. Do not apply any lifting pressure. generator rotor to the engine flywheel. Tighten
11 Remove the fasteners securing the generator to to finger tight.
the chassis. 2 In a star pattern, torque the flywheel fasteners
12 Remove the fasteners securing the generator to to 15 ft-lbs / 20 Nm.
the engine bellhousing. 3 With the engine supported, install the generator
13 Pull the generator away from the engine just onto the engine. Using a liquid threadlocker
enough to reach the fasteners securing the on the fastener threads, install the fasteners
generator rotor to the engine flywheel. Remove securing the generator to the engine
the fasteners. bellhousing. Tighten to finger tight.
14 Remove the generator from the machine. 4 In a star pattern, torque the bellhousing
fasteners to 30 ft-lbs / 41 Nm.
Crushing hazard. The generator
CAUTION will fall if not properly supported 5 Install the fasteners securing the generator to
when removed from the machine. the chassis. Securely tighten the fasteners.
6 Install the external wires onto the terminal block
at the top of the generator. Securely tighten the
fasteners.
7 Install the capacitor cover onto the generator.
Install and securely tighten the fasteners.
GENERATOR REV B
REV B GENERATOR
How to Check a Generator Diode 4 With a multimeter set to test diodes, connect
one multimeter lead to the diode terminal
DANGER High voltage. Exposure to and the other multimeter lead to the 'Q' lead
electrical wires or electrical terminal of the generator. Note the results.
current will result in death or
serious injury. Remove all rings, Note: Refer to the instructions which are provided
watches and other jewelry. Turn for your multimeter to ensure the diode is
off all power when not needed accurately tested.
for testing. Use extreme caution 5 Reverse the multimeter lead connections. Note
when working with high voltage the results.
electrical components.
Result: The two readings are at a ratio of
Electrocution/burn hazard.
DANGER 3000:1 or higher. The diode is good.
Attempting to service the machine
before the capacitor is fully Result: The two readings are at a ratio of less
discharged will result in death or than 3000:1. The diode is faulty and should be
serious injury. replaced.
Note: Be sure the engine has been turned off for Note: Before installing a new diode, clean the
at least 15 minutes before servicing the machine. surface of the exciter rotor core, and run a bead of
Use a voltmeter to confirm there is no residual a thermal-electrical compound around the base of
voltage in the capacitor. the diode (the threads of the diode should not be
coated). Torque to 20 to 30 in-lbs / 2.2 to 3.4 Nm.
1 Remove the fasteners securing the end
cover/bearing housing to the generator.
Remove the cover.
2 Locate the diode at the end of the generator.
3 Tag and disconnect the positive wire lead from
the diode.
Engine REV B
4-1
Engine RPM
How to Adjust the Engine RPM
Note: Perform this procedure with the light
switches in the off position and with no external AC
power devices connected to the power outlets at
the control box.
Troubleshooting
Before Troubleshooting:
Read, understand and obey the safety rules
and operating instructions in the appropriate
operator's manual on your machine.
Be sure that all necessary tools and test
equipment are available and ready for use.
Observe and Obey: Be aware of the following hazards and follow
Troubleshooting and repair procedures shall be generally accepted safe workshop practices.
completed by a person trained and qualified on
Electrocution hazard. Exposure to
the repair of this machine. DANGER
electrically charged circuits could
Immediately tag and remove from service a result in death or serious injury.
damaged or malfunctioning machine. Remove all rings, watches and
other jewelry.
Repair any machine damage or malfunction
High voltage. Exposure to
before operating the machine. DANGER
electrical wires or electrical
Unless otherwise specified, perform each current will result in death or
repair procedure with the machine in the serious injury. Remove all rings,
following configuration: watches and other jewelry. Turn
· Machine parked on a firm, level surface off all power when not needed
· Mast in the stowed position for testing. Use extreme caution
when working with high voltage
· Light switches in the off position electrical components.
· Wheels chocked
CAUTION Burn hazard. Contact with hot
engine components may cause
severe burns. Use caution when
working around lamps or a hot
engine.
problem
still exists
Troubleshooting REV B
Engine runs but produces a Crankcase oil level is too high Drain oil to the proper level
dense smoke
Low compression Inspect for broken/siezed piston
rings OR inspect valve clearances
Injector nozzle faulty Replace injector
Combustion incomplete due to Inspect and repair as needed
faulty injector timing, poor valve
adjustment or lack of compression
REV B TROUBLESHOOTING
Engine battery quickly discharged Battery electrolyte low Add distilled water and charge
Fan belt slips Inspect and repair as needed
Wiring loose or disconnected Inspect and repair as needed
Faulty alternator, rectifier or diode Inspect and repair as needed
Faulty battery Replace
TROUBLESHOOTING REV B
Engine runs but lights will not Circuit breaker has tripped Reset circuit breaker
operate
Loose wiring connections Inspect and repair as needed
Faulty generator Inspect and repair as needed
Lamp light output low Dirty light fixture Clean light fixture
Single LED burned out End of life Continue to use until light head
failure OR replace
Generator voltage too high High engine speed Adjust to 1850 rpm (no load)
REV B TROUBLESHOOTING
Generator voltage spikes Incorrect engine adjustment, fuel Change fuel filter and check
line or faulty fuel engine speed
Loose connection Inspect all connections and repair
as needed
Faulty ground connection Inspect all ground connections
and repair as needed
Load induced Filter load
Generator voltage low Loss of residual magnetism Flash the rotor
Low engine speed Adjust idle. See Repair Section.
Faulty capacitor Replace
Faulty diode Replace
Schematics
About This Section
There is one group of schematics in this section.
Electrical Schematics
Electrocution/burn hazard.
WARNING Contact with electrically charged
Observe and Obey: circuits could result in death or
serious injury. Remove all rings,
Troubleshooting and repair procedures shall be watches and other jewelry.
completed by a person trained and qualified on
the repair of this machine. General Repair Process
Read, understand and obey the safety rules Return to Inspect Perform
and operating instructions in the appropriate service and test repair
problem
operator's manual on your machine before solved
attempting any maintenance or repair
procedure.
Be sure that all necessary tools and test
equipment are available and ready for use.
KS Key switch
KS1 = Key switch
L LED or Light
L30-1 = Light head, top left
L30-2 = Light head, bottom left
L30-3 = Light head, top right
L30-4 = Light head, bottom right
L33 = Brake, right
L34 = Brake, left
L35F = Marker, right front
L35R = Marker, right rear
L36F = Marker, left front
L36R = Marker, left rear
L52 = Alternator failure
L58 = License plate
M Motor or Pump
M3 = Starter
M4 = Fuel pump
P Red emergency stop button
P1 = Ground control
Q Solenoid
Q8 = Fuel shut off
QD Quick disconnect
QD1 = Battery pack disconnect
SW Switch
SW1 = Engine coolant temperature
SW2 = Engine oil pressure
SW45 = Lights, 5A
U Electronic Component
U9 = Battery charger
U32 = Glow plug
U53 = Electric brake, left
U54 = Electric brake, right
U60 = Timer
U61 = Power outlet, 120V
U62 = Power ouitlet, 240V
U63 = Generator
L33
BRAKE LIGHT
RIGHT
GR
WH
L58
BR LICENSE PLATE
LIGHT
BL
BK
YL BL
WH
BK L34
BRAKE LIGHT
LEFT
GR
YL
BR
WH
BL
T
G
GR
YL
S
BR
L
WH
R
BR WH
GR YL
YL BR
WH GR
BL BL
1
6 3 4
5 6
2
5
7
1 2
3
4
116097B
BREAKER, 30A
CB11
RD RD RD
BK BK BK
GR GR
CB12A CB12B CB12C CB12D WH
BREAKER BREAKER BREAKER BREAKER
15A 15A 15A 15A
CR114 NO
YL
+ RD
30 86 U60
TIMER YL WH
87 85
- 48V DC
HOUR BK
NC COM
G6 METER
(LIGHTS) BL
YL
BR
BK
WH WH
GR
U9 BK
WH
GR
BK
BUSS BAR
ALTERNATOR L52
-
120V PLUG FAILURE BN3 GLOW PLUG
+ FOR
BATTERY
LIGHT GR GR
YL
CHARGER
YL RD
YL
BR OR
30 86
CR2
30
RD
87a 87 85
OR OR
BR GR
WH
B8 YL
ACC IGN YL YL YL
WH BR BR
ST
KS1 WH
BAT RD
HOUR
G6A METER
(ENGINE)
EN2
CONTROL BOX
U63
GENERATOR
RD
RD
GENERATOR 120V
BK BK GENERATOR 120V
GR GR GENERATOR GROUND
WH GENERATOR NEUTRAL
WH
D D
L30-2 L30-4
2 4 A
B A B
D D
WH
GR
RD
BR
BK
YL
BL
GR
YL
RD
WH
BK
BL
BR
F9-30 B1 BATTERY
30A FUSE + -
P1 N.C. RD
RD BK
WH/RD
EMERGENCY
STOP WH
(OPTION) ST
B+
M3
ALTERNATOR STARTER
D1 WH/BK PULL
BR
HOLD
Q8
L GR FUEL
RD 1 1 RD B IG SOLENOID
OR 2 2 OR OR
GR 3 3 GR
WH WH
4 4
SW1 SW2
BK 5 5 BK COOLANT OIL
TEMP (NO) PRESSURE (NC)
OR/BK
YL 6 6 YL PP
BR 7 7 BR
RD
BR
8 8
BK
9 9
FUEL M4
10 10 PUMP
11 11 U32 WH/BK
GLOW
12 12 PLUGS
ENGINE
D D
L30-2 L30-4
2 4 A
B A B
D D
WH
GR
RD
BR
BK
YL
BL
GR
F9-50
+ RD RD BUSS BAR
CR114 NO
YL
+ RD
30 86 U60
TIMER YL WH
87 85
- 48V DC
HOUR BK
NC COM
G6 METER
(LIGHTS) BL
YL
BR
BK
WH WH
GR
U9 BK
WH
GR
BK
120V PLUG
+ - FOR
BATTERY
CHARGER
B8
ES0528B