AL5000 Service Manual-116476-11-03-08
Contents
1. L 3 vL gt qQ3AOIN3H 38 LSNW HOLIMSAZSP 9 NZNSI HOLIASA33 vL S IVH LO3N LSVTIVd OL SAIL CYS s170vidagods 149 voz vL 3LIHM AL5000 Light Tower Part No 116476 REVA September 2008 Section 5 Schematics DC Wiring Kubota Drawing 116814 TEREX 02891 SSHNHVH 81891 YAEWNN LYVd SSANYVH L 1 ON T ANV1009 HOIH a ea elle YNOH P 23 e 9 elle ON 6 8 8 34nsS3Hd 5 5 9 9 1 e n ejje z z euo ejje I L ass L 1 GION310S E K NH8 voe 1 i aena i TORE I 5 13A I i HOLVNH3 LTV TE a 1 3NION3 Part No 116476 AL5000 Light Tower TEREX Wire Harness Control Box Euro2. ix Howto Order EE Service Parts Fax Order Form Xii Safety Rules General Safety Specifications SPSCHICATIONS TT 2 1 Specifications 2 2 Specifications 2 3 Fastener Torque Specifications 44444 2 4 Scheduled Maintenance Procedures 10110116 P iu 3 1 Pre delivery Preparation 3 2 Maintenance Schedules Kubota Lubrication and Maintenance Service Intervals 3 3 Isuzu Lubrication and Maintenance Service Intervals 3 4 Leroy Somer Generators Maintenance Schedule 3 5 Newage Generators Maintenance Schedule 3 6 Marathon Generators Maintenance Schedule 3 6 Troubleshooting EE 4 1 Troubleshooting 4 2 Part No 116476 AL5000 Light Tower vli September 2008 TEREX TABLE OF CONTENTS REVA Section 5 Rev Schematics A INMOGUCTION tera 5 1 A AC Eight 6511
3. E 5 M NIS EN ala o ol N ol a 15 elo nol eo v 99 zs ob DN nb R Ir o A N DIN EE 9 2 4 AL5000 Light Tower Part No 116476 September 2008 Section 2 Specifications TEREX REVA GENSET TORQUE SPECIFICATIONS Generator Flex Plate to Flywheel Generator Case to Bellhousing Genset Isolators PartNo 116476 AL5000 Light Tower 2 5 Section 2 Specifications September 2008 TEREX REVA This page intentionally left blank 2 6 AL5000 Light Tower Part No 116476 September 2008 Section 3 Scheduled Maintenance Procedures TEREX Scheduled Maintenance Procedures REVA 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 as specified using the supplied Lubrication and Maintenance Service Interval Charts provided in this section AWARNING 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 mac
4. 116476 First Edition Newage Generator Manual 830001 Leroy Somer Manual 116118 Isuzu Engine Manual 116133 Kubota Engine Manual 893020 Axis rnt ttes 116117 Marathon Manual 116188 Copyright O 2008 by TEREX Corporation 116476 Rev A September 2008 First Edition First Printing TEREX is a registered trademark of TEREX Corporation in the USA and many other countries Super Quiet is a trademark of TEREX Corporation 6 Printed on recycled paper Printed in U S A li AL5000 Light Tower Part No 116476 September 2008 TEREX How to Read Your Serial Number REVA Serial Number Legend The serial number plate on your AL5000 is located on the cabinet next to the light tower mast MANUFACTURED BY FABRIQUE TEREX ROCK HILL 590 Huey Road Rock Hill SC 29732 TEREX DATE FEBRUARY 2008 GVWR PNBV 1 244 KG 2 743 LBS GAWR PNBE 1 244 KG 2 743 LBS TIRES PNEU ST205 75D15 LOAD RANGE C RIMS JANTE 15 0 X 4 5 5H COLD TIRES INFL 35 PSI 250 KPA PRESS DE GONFL A FROID SINGLE THIS VEHICLE CONFORMS TO ALL APPLICABLE U S FEDERAL MOTOR VEHICLE SAFETY STANDARDS IN EFFECT ON THE DATE OF MANUFACTURE SHOWN ABOVE THIS VEHICLE CONFORMS TO ALL APPLICABLE STANDARDS PRESCRIBED UNDER
5. 1 1 YOLVNYS LIV M PA ee Sl AL5000Light Tower Part No 116476 REVA September 2008 LSV11Vd LOH LSVTIVd NONNOO LINDYION MOTISA M HO 102 NALSONNL AWVS AHL SI NOLIVHOOIJNOO ALON Movia ALIHM 3000201 SILSAWOG MOVIE T3A N3S N3389 Section 5 Schematics MH or HPS Light Fixture Drawing 2985A TEREX J 3LIHM Part No 116476 AL5000 Light Tower TEREX 1000 MH Ballast Section 5 Schematics September 2008 Drawing 2986 REVA GQNNOYS N33H9 NOININOO LOH qaq NOININOO 1 dNI ALIHM 1 J10VLld3OdH 31Od S 1SvTIV8 3anvH TV13N M0001 W3INHOJSNVHL AL5000 Light Tower Part No 116476 September 2008 Section 5 Schematics TEREX 1000 HPS Ballast Drawing 2987 REVA 15 WNIGOS SYNSS3Yd H IH M0001 H3NHOJSNVMHLE N33H9 NOINWOO dAV1 LOH NONINOO LAdNI A LIHM LNdNI 1 J19VId3O3H 3
6. dH X18 2HO gay NHO TBA 980 GION31OS x t te 1545 AZL IAE JV3H3Hd NHO syn v4 gt 134 134 YOLVNYALIV SLN3NOdMWOO 3NION3 Part No 116476 AL5000LIght Tower Section 5 Schematics September 2008 TEREX DC Wiring Isuzu Drawing 116818 REVA dnd ON LNV1009 HOIH dunssadsud 18 9HO Lc89LL H38IACN Le Vd SSANYVH somd a LHM NHO GION31OS WHT BLK EE YOLVNYALIV I 1 I L 1 1 I 1E I L I L L 3snd 1 3NION3 NOILdO 9015 3 T ol of nyo o 91891 H38IATIN Le Vd SS3NHVH A 1545 4 T 2 o d 134
7. Replace the bearing Refer to the manufacturers manuals for detailed maintence intervals and instructions If the information in the manufacturer s manual differs from that in this manual the manufacturer s manual should take precedence 3 6 AL5000 Light Tower Part No 116476 September 2008 REVA Observe and Obey Troubleshooting and repair procedures shall be completed by a person trained and qualified on the repair of this machine Immediately tag and remove from service a damaged or malfunctioning machine Repair any machine damage or malfunction before operating the machine Unless otherwise specified perform each repair procedure with the machine in the following configuration Machine parked on a firm level surface Wheels chocked Toggle switch in OFF position Section 4 Troubleshooting TEREX 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 Be aware of the following hazards and follow generally accepted safe workshop practices ADANGER Electrocution hazard Exposure to electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry ADANGER Electrocution hazard Attempting to sevice the ma
8. 12 530 718 710 962 750 1016 990 T 1342 840 1139 12 870 908 s0 1206 1080 1464 1440 1952 1220 165 12 930 1260 1240 1681 1510 2047 2010 2725 1700 2304 6 1460 1979 1950 2643 2370 3213 3160 4284 2670 3620 12 1640 2223 2190 2969 2670 3620 3560 4826 3000 4087 METRIC FASTENER TORQUE CHART This chart is to be used as a guide only unless noted elsewhere in this manual Class4 6 44 Class 8 8 Class 10 9 Class 12 9 DRY DRY DRY 854 68 775 91 103 R DRY 830 1055 682 925 909 1233 0 1 iz ile 317 ile P Nol D a al oO DA Q NI 1 4 4 0 0 g lt 0 lt 0 i zal as o oo oO oy cof gt IN Oo NI x E eo o ge ojo 21 D Co Co M e N E NINI o OL oy CO o EN rN 2 SC oj
9. THE CANADIAN MOTOR VEHICLE SAFETY REGULATIONS IN EFFECT ON THE DATE MANUFACTURE CE VEHICULE EST CONFORME A TOUTES LES NORMES QUI LUI SONT APPLICABLES EN VERTU DU REGLEMENT SUR LA SECURITE DES VEHICULES AUTOMOBILES DU CANADA EN VIGUEUR A LA DATE DE SA FABRICATION TYPE OF VEHICLE TYPE DE VEHICULE TRAILER REMORQUE MODEL AL5000 SERIAL NUMBER AL508 1003 MODEL YEAR 2008 ALSXXXXX Serial number is stamped into frame Part No 116476 AL5000 Light Tower ili September 2008 TEREX REV This page intentionally left blank iv AL5000 Light Tower Part No 116476 September 2008 Section 1 Safety Rules TEREX Safety Rules REV 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 Part No 116476 AL5000 Light Tower V TEREX SAFETY RULES Personal Safety Any p
10. and contact customer on disposition of backordered parts o Other please specify For TEREX Use Order Number Origin Code Comments Date Scheduled Ship Condition Order Total Terms Code remove this page and make copies remove this page and make copies September 2008 Section 2 Specifications TEREX Specifications REVA MAST ELEVATION 130 9 14M TOWER ROTATION 359 DEGREES TOWER ROTATION MANUAL MAX WIND RATING 62MPH 100KPH SEE CHART ON PAGE 2 3 KUBOTA D1105 DIESEL 13 6 HP ISUZU 4LE1PV02 DIESEL 31 4 HP LEROY SOMER 37M7 8KW 60HZ MARATHON 8KW 201 5 5412 60 2 NEWAGE 20 BCI184E1J203A STANDARD RECEPTACLES QTY 1 120V 20A DUPLEX QTY 1 240V 30A TWISTLOCK QTY 4 1P 15A LAMPS QTY 1 2P 30A MAIN QTY 1 MINI 1P 20A SEPARATELY SWITCHED QTY 4 1000 WATT METAL HALIDE ROUND INTERNAL STORAGE Part No 116476 AL5000 Light Tower 2 1 Section 2 Specifications September 2008 TEREX SPECIFICATIONS REVA TRAILER WHEELS 15 X 4 5 5 HOLE TIRES ST205 75D15 LOAD C COLD PRESSURE 50PSI 350KPA AXLE RATING 3500LBS 2000LBS SPRINGS MAX TOW SPEED 60MPH 96KPH NO BRAKES STANDARD TWO OUTRIGGERS STANDARD FUEL TYPE NO 2 DIESEL ONLY CAPACITY 30 GALLONS 114L MATERIAL POLYETHELENE FUEL CONSUMPTION KUBOTA 787 G HR 2 97L HR KUBOTA RUN TIME 30 GAL 38 3 HRS ISUZU 2 G HR 7 57 L HR ISUZU RUN TIME 3
11. will stabilize and operate normal 4 4 AL5000 Light Tower Part No 116476 September 2008 Section 4 Troubleshooting TEREX REVA TROUBLESHOOTING TROUBLE POSSIBLE CAUSE REMEDY 18 Lamp flickers or goes out c Defective lamp intermittent or cycling d Generator capacitor d Replace as needed IF YOU FEEL AN ELECTRIC SHOCK AT ANY TIME WHILE OPERATING THIS UNIT SHUT IT DOWN IMMEDIATELY HAVE THE UNIT INSPECTED BY A TRAINED ELECTRICIAN THIS ENGINE GENERATOR SET IS FACTORY INSTALLED TESTED AND SET FOR FIELD OPERATION ANY DAMAGE TO THE ENGINE OR GENERATOR UNITS OCCURRING AFTER ADJUSTMENTS ARE MADE IN THE FIELD BY UNAUTHORIZED PERSONNEL WILL NOT BE COVERED BY YOUR MANUFACTURER S WARRANTY AND WILL ALSO VOID THE MANUFACTURER S WARRANTY ON THIS PARTICULAR UNIT IF YOU CAN NOT REACH YOUR LOCAL DEALER CONTACT THE FACTORY SERVICE MANAGER TOLL FREE AT 1 800 433 3026 Light Fixture Troubleshooting DO NOT OPEN FIXTURES WHILE LIGHT CIRCUIT BREAKER IS ON ALLOW LAMP TOCOOL BEFORE TOUCHING TAKE EXTRA PRECAUTIONS WHEN TROUBLESHOOTING ELECTRICAL PROBLEMS A Only use a voltmeter with two well insu lated pin probes rated for 600 volts B Treat all conductors as potentially hot C Proceed through circuits systematically operating only one section at a time D Before disconnecting ballast turn off circuit breaker and wait 30 seconds for capacitor to discharge E If all the lights are out and all the bal
12. 0 GAL 15 HRS 8KW TOTAL WEIGHT NO FUEL 2 239LBS 1 016KG 8KW TOTAL WEIGHT TANK FULL 30 GAL 2449L BS 60 GAL 2659LBS 20KW TOTAL WEIGHT NO FUEL 2340LBS 1062KG 20KW TOTAL WEIGHT TANK FULL 30GAL 2550L BS 60 GAL 2760LBS TONGUE WEIGHT 8KW 30 GALLON 167LBS 76KG 20KW 30 GALLON 130LBS 59KG BATTERY 2 TWET 12V GROUP 24 525 CCA STD DUTY LEAD ACID 2 2 AL5000 Light Tower Part No 116476 September 2008 Section 2 Specifications TEREX REVA SPECIFICATIONS ain 55 s MOcm a 175em 72 ues 5 aL dine u TIN Z ia 30 9 14m EXTENDED HEIGHT lt e 7 1 ca A Er 5 ni 171 60 s 130 188cm 204cm 330cm 117 297cm 313cm Part No 116476 AL5000 Light Tower Section 2 Specifications September 2008 TEREX SPECIFICATIONS REVA SAE FASTENER TORQUE CHART This chart is to be used as a guide only unless noted elsewhere in this manual A574 High Strength THREAD Grade 5 2 Grade 8 CUBED CUBED LUBED 1
13. 05 Nm in lbs Nm in ibs Nm _inibs Nm 1 1 5 Nm 14 20 100 113 80 9 40 158 10 124 10 147 28 90 101 120 135 120 135 160 18 140 158 E LUBED UBED DRY LUBED DRY LUBED Nm bs Nm mis Nm iss Nm mes nm su 38 13 76 17 23 38 24 25 339 21 284 i 1267 2 271 22 356 24 88 38 15 2 312 31 42 38 447 44 596 38 515 24 26 352 35 37 51 49 T 64 48 55 716 4 37 501 40 004 50 678 70 947 61 827 sss 5 1 745 60 813 so T 108 4 Css sr 1 7 75 1016 60 1084 110 03 126 20 867 s 115 90 122 3120 362 rs 142 one 12 80 110 49 120 162 3150 203 130 T 176 i8 s 122 122 16 130 176 170 230 ro T m 58 Lt 110 149 3150 203 160 217 210 284 180 TL 244 i8 130 L 176 oro 230 3180 244 3 5 200 271 sa 10 200 271 270 366 280 379 380 515 320 48 16 220 298 300 306 310 420 420 569 350 474 78 9 320 433 430 583 450 610 610 827 510 en 14 o 474 270 67 500 678 670 908 560 Z s 480 50 640 867 680 922 910 1283 770 1044
14. 1011 5 2 Wire Harness Inside Control Box DC 5 9 A Wiring KubOla 2 5 4 A Wire Harness Control Box European DC 5 5 A DC Wiring European 5 6 A DC Wiring ISUZU 5 7 A or HPS Light Fixture u u u 5 8 1000 nen ate ceed 5 9 1900 HPS Ballast 5 10 viii AL5000 Light Tower Part No 116476 September 2008 REV Required Parts The following parts are required to perform maintenance procedures as outlined in the TEREX AL5000 Parts and Service Manuals Description Part No Kubota Models Filter 4 866050 Ain u 866127 u un u 2 uuu u uu 839200 839209 Isuzu Models 868075 Air Filter 834460 NT 868137 bU 868067 TEREX Parts Stocking List Part No 116476 AL5000 Light Tower September 2008 TEREX REV This page intentionally left blank x AL5000 Light Tower Part No 116476 September 2008 REV Please be prepared with the following information when ordering replacement parts for your TEREX product Ma
15. 1Od S Z YOLINS AL5000 Light Tower Part No 116476 5 10 Genie North America Phone 425 881 1800 Toll Free USA and Canada 800 536 1800 Fax 425 883 3475 Genie Australia Pty Ltd Phone 61 7 3375 1660 Fax 61 7 3375 1002 California Proposition 65 Warning The exhaust from this product contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm Towing Checklist Use at each stop Before Towing Boom hold down latch is securely locked in place Towing hitch is properly secured to tow vehicle Safety chains if required are properly attached and secure chains are crossed below hitch All lights are connected and working Tires are properly inflated Before Driving Fasten safety restraints Properly adjust mirrors On The Road Do not exceed 60 mph 97 km h Obey all local and national towing speed laws Check connections and tire pressure at each stop Slow down for hazardous conditions Allow extra distance for following and passing other vehicles Genie China Phone 86 21 53852570 Fax 86 21 53852569 Genie Scandinavia Phone 46 31 575100 Fax 46 31 579020 Genie Malaysia Phone 65 98 480 775 Fax 65 67 533 544 Genie France Phone 33 0 2 37 26 09 99 Fax 33 0 2 37 26 09 98 Genie Japan Phone 81 3 3453 6082 Fax 81 3 3453 6083
16. 5 1 September 2008 LU Nid TION HOLVH3N39 VdAL Nid u3MOd 31Od S IW31n3N L YOLOANNOD 9 13S 5 91 S96 69 GH LSVTIVE Mi n 1SVTTV8 WHLNAN LSVTIVE 8 WULNAN LSVTIVE 9 L d LSVTIVE 2 LSVT1VE Q ALdW3 8 Nid 9 g i V Nid 2 m YOLOANNOD SHIM HOLO3NNOO 6N 15 119 Y 310d T quoo I 9 9 I 1 lt NYS 0 Nua Gu T p THM 1 1 LO 134 T e aay 5 18 T LT I 4 0 Vio gs 1 3 l 2 m I 144344 i 1111 a I q 08 E 1 AOvZ s
17. Genie Korea Phone 82 25 587 267 Fax 82 25 583 910 Genie Phone 34 93 579 5042 Fax 34 93 579 5059 Genie Germany Phone 49 0 4202 88520 Fax 49 0 4202 8852 20 Genie Brasil Phone 55 11 41 665 755 Fax 55 11 41 665 754 Genie U K Phone 44 0 1476 584333 Fax 44 0 1476 584334 Genie Holland Phone 31 183 581 102 Fax 31 183 581 566 Genie Mexico City Phone 52 55 5666 5242 Fax 52 55 5666 3241
18. TEREX 15000 First Edition First Printing Part No 116476 September 2008 TEREX Introduction September 2008 REV Important Read understand and obey the safety rules and operating instructions in the appropriate Operator s Manual on your machine before attempting any maintenance procedure 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 Corporation 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 www TEREX com Serial Number Information TEREX Corporation offers the following manuals for these models Title Part No TEREX AL4000 5000 Operator s Manual 116416 First Edition TEREX AL5000 Parts Manual 116443 First Edition TEREX AL5000 Service Manual
19. chine before the capacitors are fully discharged will result in death or serious injury 74711711 High voltage Exposure to electrical wires or electrical current will result in death or serious injury Remove all rings watches and other jewelry Turn off all power when not needed for testing Use extreme caution when working with high voltage electrical components ACAUTION Burn hazard Contact with hot engine components may cause severe burns Use caution when working around a hot engine Part No 116476 AL5000 Light Tower 4 1 TEREX Section 4 Troubleshooting September 2008 REVA Troubleshooting Guide The engine generator set is tested and set at the factory for proper operation in the field These units should never require additional adjustments in the field If needed adjustments should only be made by a qualified service technician otherwise the manufacturer s warranty may become void TROUBLE POSSIBLE CAUSE REMEDY 1 Boom will not rise to the operating position 2 Boom will not telescope 3 Engine will not turn over 4 Engine turns over but will not start 5 Engine runs rough a Yoke pin is in place a Remove yoke pin b Defective cable b Have a trained or pulley mechanic examine and repair as needed c Defective winch c Have a trained and replace as needed a Defective winch a Have a trained and replace as needed b Broken cable or pulley b Have a trained mechanic examine and replac
20. chine model number Machine serial number Terex part number Part description and quantity Purchase order number Ship to address Desired method of shipment Name and telephone number of the authorized TEREX Distributor in your area FI FI EI I El ERI Use the Service Parts Fax Order Form on the next page and fax your order to our Parts Department If you don t know the name of your authorized distributor or if your area is not currently serviced by an authorized distributor please call TEREX Corporation Machine Information Model Serial Number Date of Purchase Authorized TEREX Distributor Phone Number TEREX How To Order Parts Genie Industries 18340 NE 76th Street P O Box 97030 Redmond WA 98073 9730 Telephone 877 367 5606 Fax 888 274 6192 genieindustries com Part No 116476 AL5000 Light Tower September 2008 TEREX Service Parts fax Order Form FAX TO 888 274 6192 OR TOLL FREE 877 367 5606 Please fill out completely Date Account Number Your Name Your Fax Number Your Phone Number Bill To Ship To Purchase Order Number Ship Via Model s Serial No s Optional Equipment Part Number Description Quantity Price All backordered parts will be shipped when available via the same ship method as the original order unless noted below Ship complete order only backorders o Ship all available parts
21. e as needed a Dead battery a Check the battery voltage or loose cables b Failed starter b Replace starter c Engine has seized due to loss c Have a trained of fluids mechanic examine and repair as needed system as needed c Leaking fuel lines or a loss of prime and tighten connections f e Fuel line solenoid is not open e Replace fuel line solenoid Electric fuel pump not working f Replace if needed a Clogged or leaking fuel system a Replace fuel lines tighten all connections inspect the pickup tube and inspect the fuel filter b Clogged exhaust system b Clear the exhaust system c Clogged air filter c Clear air filter mechanic examine e Valve clearances are out of e Have a trained adjustment or the valve spring mechanic examine may be damaged f Defective governor or fuel pump f Have a trained AL5000 Light Tower Part No 116476 September 2008 Section 4 Troubleshooting TEREX REVA TROUBLESHOOTING TROUBLE POSSIBLE CAUSE REMEDY 6 Engine runs but produces a dense smoke b Low compression b Have a trained mechanic inspect for broken or seized rings Inspect valve clearances and clear as needed water coolant solution clogged d Fan belt is loose d Tighten fan belt 8 Engine runs but the battery a Alternator has failed a Have a trained mechanic inspect voltage is low the alternator 9 Engine runs but the lights will a Circuit breakers are tripped a Reset the circuit breaker not operate b Loose connections
22. erson 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 77711134 1 Red used to indicate the presence of an imminently hazardous situation which if not avoided will result in death or serious injury AWARNING Orange used to indicate the presence of a potentially hazardous situation which if not avoided could result in death or serious injury Yellow with safety alert symbol ACAUTION used to indicate the presence of a potentially hazardous situation which if not avoided may cause minor or moderate injury Yellow without safety alert symbol used to indicate the presence of a potentially hazardous situation which if not avoided may result in property damage CAUTION Green used to indicate operation or maintenance information Section 1 Safety Rules September 2008 REVA Be sure to wear protective eye wear and other protective clothing if the situation warrants it Be aware of potential crushing hazards Bl such as moving parts free swinging or unsecured components when lifting or
23. hine Keep records on all inspections for three years 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 Toggle switch in the OFF position Wheels chocked 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 Red used to indicate the presence of an imminently hazardous situation which if not avoided will result in death or serious injury ADANGER Orange used to indicate the AWARNING presence of a potentially hazardous situation which if not avoided could result in death or serious injury Yellow with safety alert symbol ACAUTION used to indicate the presence of a potentially hazardous situation which if not avoided may cause minor or moderate injury Yellow without safety alert symbol used to indicate the presence of a potentially hazardous situation which if not avoided may result in property damage CAUTION Green used to indicate ope
24. in the wiring b Have a trained electrician inspect system the ballast box wiring system c Burned out bulb c Replace the bulbs as needed the capacitor the generator f Have a trained mechanic inspect the engine speed and reset to 1800 60hz the ballast and capacitors the generator bearing or damaged fan blade the generator 11 Lamp will not start i a Inspect lamp base to see if there is arcing at center contact button Tighten lamp Check socket for damage Replace if needed if needed Make sure power is off c Defective ballast c Interchange ballast plugs If lamp starts replace ballast Check for swollen capacitors charred wiring core and coil or other signs of excessive heat d Low voltage d Check line voltage at ballast input Voltage should be within 10 of rating when operating at normal load Increase supply voltage or remove external load PartNo 116476 AL5000 Light Tower 4 3 Section 4 Troubleshooting September 2008 TEREX TROUBLESHOOTING REVA POSSIBLE CAUSE 11 Lamp will not start ballast e The ballast name plate data should agree with the line voltage and lamp used If not replace the ballast down time insufficient to cool 12 Lamp starts slowly arc does a Defective lamp a Lamp may glow for an extended not strike when switch is first period of time Replace after turned on checking voltage and ballast 13 Circuit breaker trips on lamp a Short circuit or grou
25. intenance Schedule 8000 Hours 20000 Hours 30000 Hours nspect and verify operator reports Visual inspection of generator housing and air inlet outlets Visually inspect installation for sign of particulate or liquid contaminant instrusion Visually inspect the generator non drive end bearing exterior for dirt and clean if necessary If installed inspect any generator air filters for build up of contaminants and clean or replace as required Visually inspect the stator output leads and insulation for cracking or damage Check all exposed electrical connections for tightness Check transformers fuses capacitors and lightning arrestors for loose or physical damage Check all lead wires and electrical connections for proper clearance and spacing Clean the inside of the outlet box air screens and air baffles with compressed air or electrical 1 solvent if needed Check machine vibrations and bearing condition against those established and recorded during original commissioning period or as defined by OEM Check IR insulation resistance to ground on all generator windings including the main rotating assembly the main stator assembly the exciter field and armature assemblies and any optional PMG assembly record Remove the endbrackets and visually inspect the generator end windings for oil or dirt contamination Excessive contamination may necessitate surface cleaning Diassemble the generator this include
26. ion Tests Use this form to record the results Place a check in the appropriate box after each part is completed Follow the instructions in the operator s manual If any inspection receives an N remove the machine from service repair and re inspect it After repair place a check in the R box Legend Y yes completed N unable to complete R repaired Comments Pre Delivery Preparation Y N R Pre operation inspection completed Maintenance items completed Function tests completed Model Serial number Date Machine owner Inspected by print Inspector signature Inspector title Inspector company September 2008 Section Scheduled Maintenance Procedures TEREX Maintenance Schedules REVA Kubota Lubrication and Maintenance Service Intervals E E E E E E E E ITEM qoo 200 soo FY soo 1500 Two Hours Hours Hours Hours Hours Hours Hours Years Check of fuel pipes and clamp banas e Check engine oil and coolant ievel e Cleaning of aircleanerelement l Check of battery electrolyte level Check offanbelttightness Cleaning of water jacket radiator interior Refer to the manufacturers manuals for detailed maintence intervals and instructions If the information in the manufacturer s manual differs from that in thi
27. lasts are receiving power suspect burned out power cable No 116476 AL5000 Light Tower 4 5 Section 4 Troubleshooting September 2008 TEREX This page intentionally left blank 4 6 AL5000 Light Tower Part No 116476 September 2008 REVA Observe and Obey Troubleshooting and repair procedures shall be completed by a person trained and qualified on the repair of this machine Immediately tag and remove from service a damaged or malfunctioning machine Repair any machine damage or malfunction before operating the machine 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 Section 5 Schematics TEREX Schematics About This Section There are two groups of schematics in this section An illustration legend precedes each group of drawings Electrical Schematics AWARNING Electrocution hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry General Repair Process Malfunction Identify discovered symptoms gt Troubleshoot problem still exists Perform repair Return to service problem solved Part No 116476 AL5000 Light Tower
28. nd a Check wiring against diagram inspect for shorts or ground Fix as needed 14 Lamp light output low a Normal lamp depreciation b Dirty lamp or fixture b Clean lamp and fixture c Defective ballast c Interchange ballast plugs If low light follows change replace ballast Check for swollen capacitors charred wiring core and coil or other signs of excessive heat d Check line voltage at ballast input Voltage should be within 1096 of rating when operating at normal load Check wiring connections for voltage loss Check socket contact point e Improper ballast e Check ballast name plate against lamp data 15 Lamp colors different a Normal lamp depreciation a Replace lamp b Dirty lamp or fixture b Clean lamp and fixture c Check data on lamps and replace as needed 16 Arc tube discolored or swollen a Over voltage from power supply a Check voltage at ballast for current or voltage surges for shorted capacitors and replace as needed b Improper ballast b Check ballast name plate against lamp data 17 Short lamp life a Lamp damaged a Check for outer bulb cracks cracks where lamp meets base and for broken arc tube or loose metal parts Replace as needed b Check ballast name plate against lamp data 18 Lamp flickers or goes out a Check ballast name plate against intermittent or cycling lamp data b New lamp b Under certain conditions new lamps may cycle Usually after 3 tries to start at 30 to 60 second intervals lamp
29. oe 1 OVAOZZ 8 Nid xog JOHINOO gt HO193NNOO I aay 1 9 1 8 149 02 Moz i I ISVTIV8 JO WHLNAN OL OIVH3N3O JO 30ISNI OL 94886 1 1 JO 937 01 85 MOLVH3N3O 40 931 OL l To I NIV I I Ex 1 C NEM s 7 74771 2 CC QE l 5 O 5 lt 2 PartNo 116476 AL5000LIght Tower TEREX Wire Harness Inside Control Box DC Section 5 Schematics September 2008 Drawing 116815 REVA NOILVNIWYSL NI LNO 8 HOLIASA33 88 20 HO LIMSA3 eda 168 NINOLLNSHSNd GL MOTISA vL 3LIHM vL MOTIJA SMV vl 1 1 yN vL MOVIE tL NMOSS SISSVHO SNVrLNSSHS LAS yOOTLSIML YOE ANNOYS owr nn LAS 149 VOZ utu Y3 LINW YNOH woFLYVLS NMOHS HOLIMSAgy F L 319 v OL ALIHM SNOT NI YOLVOICNI SMV NINS HOLIMSA3M swzr
30. pean DC Section 5 Schematics September 2008 Drawing 116810 REVA OdNI NOILVNIAYSL wd LYV LS HOLIMSA3 NI 1 AHOSS39OV T3 ALVIS vL MOTISA NOLLNSHSNd HOllMsA34 T3 vL 3LIHM SMV PL MOTTA vL SMV vl 1 4313 NOH SMV vL MOVIE LIVE LO HILIMSAJA SISSVH2 OLO ANNONS MOVIE AS YOOTLSIML NI SWTTRENUD N33H5 149 YOZ vL 3ONVHO 1 utu YNOH 1 YOLVOINI OMY TT NIH DU HOLIMSAS 85 vL 18 v 0l ALIHM HLIM SNOW CIO WVWYLNAN STVaLNAN QHOO LSVTIVd OL SAIL CXS 1 1 9 voz vL 3LIHM AL5000 Light Tower Part No 116476 REVA September 2008 Section 5 Schematics DC Wiring European Kubota Drawing 116813 TEREX ON ANV1009 d T t zi ana
31. placing loads Always wear approved steel toed shoes Workplace Safety Be sure to keep sparks flames and W 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 am sure that your workshop or work area A is properly ventilated and well lit 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 any forklift overhead crane or 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 properly dispose of old oil or other fluids Use an approved container Please be environmentally safe vi AL5000 Light Tower Part No 116476 September 2008 REVA Introduction Section 1 Section 2 Rev A A A A Section 3 Rev A Section 4 Rev A TEREX Table of Contents Important Information li How to Read Your Serial Number esses iii Parts Stocking Listu
32. ration or maintenance information 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 Part No 116476 AL5000 Light Tower 3 1 Pre Delivery Preparation Fundamentals It is the responsibility of the dealer to perform the Pre delivery Preparation The Pre delivery Preparation is performed prior to each delivery The inspection is designed to discover if anything is apparently wrong with a machine before it is put into service A damaged or modified machine must never be used If damage or any variation from factory delivered condition is discovered the machine must be tagged and removed from service Repairs to the machine may only be made by a qualified service technician according to the manufacturer s specifications Scheduled maintenance inspections shall be performed by qualified service technicians according to the manufacturer s specifications and the requirements listed in the responsibilities manual TEREX TEREX Rock Hill P O BOX 3147 Rock Hill SC 29732 USA Toll Free 800 433 3026 in U S A and Canada Copyright 2006 by TEREX Corporation TEREX is a registered trademark of TEREX Corporation RevB Instructions Use the operator s manual on your machine The Pre delivery Preparation consists of completing the Pre operation Inspection the Maintenance items and the Funct
33. s manual the manufacturer s manual should take precedence No 116476 AL5000 Light Tower 3 3 Section Scheduled Maintenance Procedures September 2008 TEREX MAINTENANCE SCHEDULES CONTINUED REVA Isuzu Lubrication and Maintenance Service Intervals Every Every Every Every Every Every 250 500 750 1000 1250 1500 Hours Hours Hours Hours Hours Ollakagechek P Jj Olpesswewannglam 95 uel leakage check T mio oon lol 2 ele o 2 2153 5 gt 5 e O O lt allo S e 2 Z 2 8 5 Slo 2 519 5 E S 5 2 a 5 x 2 Fan belt tension check Replace if necessary Coolant replacement lectrolyte level check attery cleaning attery charge condition reheating condition check conditions xhaust smoke condition ngine oil replacement uel filter element replacement njection nozzle check cleaning alve clearance check cleaning Coolant replacement Refer to the manufacturers manuals for detailed maintence intervals and instructions If the information in the manufacturer s manual differs from that in this manual the manufacturer s manual should take precedence 3 4 AL5000 Light Tower Part No 116476 September 2008 Section Scheduled Maintenance Procedures TEREX MAINTENANCE SCHEDULES CONTINUED REVA Leroy Somer Generators Ma
34. s rotor removal Clean the generator windings Te Replace the bearings Te Refer to the manufacturers manuals for detailed maintence intervals and instructions If the information in the manufacturer s manual differs from that in this manual the manufacturer s manual should take precedence Part No 116476 AL5000 Light Tower 3 5 Section Scheduled Maintenance Procedures September 2008 TEREX Newage Generators Maintenance Schedule 4500 Hours Months Months Visual inspection Visual inspection plus running audible check Measure stator winding insulation resistance 2 Monitor Monitor bearing s condition condition Remove terminal box lid and check oe Re 18888 Re grease bearings ed Replace bearings Replace NDE oring 100 linspectbearinghousings ST ST Inspect winding conditions J S ST ST S gt e Inspect rotating diode assembly J Refer to the manufacturers manuals for detailed maintence intervals and instructions If the information in the manufacturer s manual differs from that in this manual the manufacturer s manual should take precedence Marathon Generators Maintenance Schedule 10000 Visual inspection Clean and inspect after every 200 hours of normal operating time If generator is housed ina harsh environment it is advisable to clean and inpect the unit more frequently
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