PN SFMAL4D1 - Genie Industries
Contents
1. anwan 0 95 5 E C3AONedV E E DNISYKOMNd NVA3105 v 804 ONIN OY 0 Add 5 NAVE SIL SIVIYA HOLVSINJO NO G GER GION SV 143953 SONJE 23 Sie ONNOHD Nid 372185525 V 3 5 NOILINELSNOD 41121 75 15 77 3 2 17104 6 H 58230 xxx SMN yyJIn3aN Nid X dis NOIO3NNOO 135 0802 9 9 150 5 18 4 EO 3MhLVTONSAON ON 80 Lave 0038 ON 2 022 15 8 if OvAOZZ ISYTIVE Cf H Nid di TVMIO3N ISVTWB 79 9 Nid g our ISYTWB 9 4 2 AS fr 9 2 OVAOZZ ISVIIVE 1 21 OVAOZZ ISVTVE He W 20 2 2973 AldNJ 8 Nid 5 2 3 j 4 ANNOYS Nid 8 0 9 E I MOIO3NNOO 30 JAS 3HIM 80103 03 Nid 8 2 dA 2 g 93199193934 3104 gt 0305 1 31991995139 5 I MO IA 5 P 2 AR ollo V 1 8 8 ojj o 5 2 1 gt RER 91913 0 i 7 j 7 038 SV Ane TM 2 45 1 TO 5 LG d Wee A vu H 038 028 NE MIE2. 34 486c OMG 18620 LHVd 16 0 v 41 0 L6 0 v LO ld ANON 8 INNO A8 aovsn LVN Haquog HOLO3NNOO AOF M TL VIN 5 54 WWHOVIG ONIHIM 3908 Hung TIV NOWNOO 3ONVHO LOL Lage 1 106 508 ud LOH dv O S 069 0107 XXX 080 F XX 591290 NOININOO LNANI 31IHM YT Y 3 TI 91 13 SUONDEI4 lt 3SIMH3HLO SS3 INN S3ONVH3 101 LINDYID 407100 JONVHO 003 310V1d3O3H 31Od S 1SVTIVE WNIGOS 3HnSS3Hd H IH 0001 H3NHOdSNVHI NOS Gay ID a 19 yovga X ZX HOLINDI Oaus NOILLdIHOS3d 1860 486 41 1 2 5 9 es IWS 588690 755 TON 67 0 09 21 HHv1 8 KEN 4 5 S6y9
3. Terex Model Number Serial Number Engine Model Number Serial Number Generator Model Number Serial Number Sold to Ship to Options Production Date Work Order Number Shipping Date In Service Date When this unit left the factory the engine was filled with engine oil grade 12 IMPORTANT WHEN REQUESTING TECHNICAL HELP AND ORDERING REPLACEMENT PARTS THE MODEL AND SERIAL NUMBER ARE NECESSARY REFER TO THE TEREX SERIAL NUMBER TAG ON THE UNIT FOR CORRECT MODEL NUMBER AND SERIAL NUMBER MODEL NUMBER IDENTIFICATION Sample Light Tower Product Line AL4 080 4 MH Tower Series AL4000 ALA 30 Foot Basic Tower with winch in cabinet AL5000 AL5 30 Foot Basic Tower with in cabinet light storage and door insulation LT7000 LT7 30 Foot Deluxe Hydraulic Tower w optional Acoustic Enclosure and Complete Instrumentation kW Rating 080 is 8 0 kW Diesel D Number of Lights Type of Lights High Pressure Sodium MH Metal Halide TH Tungsten Halogen European Version AL4000 Only RECOMMENDED ENGINE OIL amp FUEL KUBOTA D905 DIESEL ENGINE Engine oil should be MIL L 2104C or have properties of API classification of CD grades or higher Change the type of engine oil according to the ambient operating temperature Above 77 F 25 SAE 30 32 F to 77 F 0 to 25 SAE 20 Below 32 F 0 SAE 10W SAE 10W 30 Use 2 diesel fuel NOTES 1
4. 23135 a 50 8 90 Wa WER SI 50 51 90 Me IO An 28 1790 yg 3 8 2 6 18828 01408405 5NSYF5and 105 AMINJ J8IM WO 1880 x YOLOANNOC 0108 5 193052 08 TY 2 o o ge 53003 6065 GN 59808 MONE 901911934 JOVLTON D 9 NOLLOMYLSNOSD nci mor 1 XXX xx NHD avis a Xaaa E N 66 0 1511 4 Loi gt 86 mem 0038 ni z NOILISOd A35 41015 NOUdiM2S30 MO IYNLYTININON ON 9NIAJILN3OI NO gd ALD ma 318 ma z 27 8 821 HILIM 36 A J s n1d AA 1 928 39VI10 2 4 saan 3 9 Z Pa w YNOH 0 T v g la 9 6 T ollo E z c 2 2 Hat 15 6 HA 2 f ON s 8 38 1 824 31 2 E 141005 9 SEN 9 9 ENZ 9 1 S un G NHO 7 Na9 e T o OIA On 980 gay
5. 2 B zb IL Gs 4137 v Zu 77 2 NHO OUT 318 P C t ISVIIVE ES UJ 0 gt P Les E 310 141239 8055 SCH 5 N 313 4 33 z ct 2 T 03M QNnOND 3 OVAOZZ 8 N A Nao Nid XO amp H 1 NO 1 NHO HOIOINNOO 038 E m i 12 63199 93935 N m 89 8 D I yoz T B Ki al ISVTIVE C MOLVNJN3O 40 3qISNI 931 3 RU 888 801 83 9 40 30 5 ANNOND MOIVH3N3O 30 937 0 4 HOLVHINJO 40 JASNI 931 CR BER EI N ac SNOISIA 3H a a 5 8 36 JONVHO dWnd 1304 804 30010 0 WA GIONFTOS vioen MIN 404 540010 10940 daddy 511001 NOILOnOOSd HOIVN OL Q3SIA3H 905 0 vQM 8 00 1140100 62 6 1070 Y N 48 MO 39vsn N d INA 8 0 08 FXL 9060 VLOSNM SNIMIM GM 3203 d it 588 8 35 1011 996 1106 2766 08 Ud 2 25 3008 PH 3 065 0101 X OS0 F XX sjowioag Dr TI p X 91 1 5001201 8 Dt UU 919 13
6. 3 i S 9 8 37 25 11 25 ONMYHO SIHL 37525 LON OG 50 51 90 ova 6 5 9 a 50 61 90 eg NON 2 5 9 WE 0 SNIyaad 5 DNISYHJEN JON NENNE NER 105 AYINI ONIMIM YIMOL 1 5 AVIS ici CLON SV 13953 06 SONJA 8 o o LNVIS 4 sc lia ale ne i 5011934 JOVLIOA in Bo 9 NOLLINELSNOD Lem nagz y 2 stow suerg xxx xx 73 X3us ms EAE E OlOlol o 209 7 50 518 4 5 m aie 0114953 YO ON 9 6 30 Lave bu vu S 818 N lliSUe 218 821 HOLIMS g somd Ane ahs MOTD 2 N MOIV10n93M JOVLIOA 9 GS r E allo z E 2 38 55384 jo x 2 5 ollo x MOT gt EZ LL I ollo g 0L 0 8 e EI 2 K aay 8 a x 120 4 734
7. 990670 Rivet 188760 Sheave 2 990650 Cotter Pin N OY 1 8x 1 NS 183286 Shim ATN Orientation Below 2 994920 Cotter Pin 2 3 32 x 3 4 M 22 T 3 8 x 2 992765 Clevis Pin 1 2x2 2 995790 Clevis Pin 1 4x2 183286 3 8 Shim 177830 1 4 Shim 177830 1 4 Shim 183288 3 16 Shim Orientation of Shims Inside Tube 49 Model 4000 LIGHT TOWER TRU LIGHT CONSTRUCTION Title 3 Tower Section 109065 Cable Kit 996230 3 8 Screw 990470 Lock Washer 2 ro otter Pin 185290 Shim 3 32 x 3 4 Y See Orientation 990650 Below Cotter Pin 1 8 x 1 188760 Sheave 992765 Clevis Pin 1 2x2 2 995790 Clevis Pin 1 4x2 124550 3 Tower Section Orientation of Shims Inside Tube 185290 3 8 Shim 3 177820 5 16 Shim 50 Ne AL4000 LIGHT TOWER pu TEREX Title LIGHT CONSTRUCTION 2 Section 124560 2 Tower Section 109070 Cable Kit 990470 Lock Washer 996230 3 8 Bolt 51 MOE AL4000 LIGHT TOWER in TEREX Title LIGHT CONSTRUCTION Tower Crossarm Fixture 4 See Fixture Assembly 4 990880 Washer Lock Star 113040 Cross Arm 4 191781 Stud Cross Arm Mounting Plate 4 123080 Fixture Mounting Wing Nut 52 AL4000 LIGHT TOWER Model EJ TEREX LIGHT CONSTRUCTION 6 Round Tube 990650 Cotter Pin 794550 990610 Grea
8. NOISE LEVEL Mean SPL sound pressure level hemispherically at 7 meters 62 01dBA Sound Power Level 62 01dBA 20 log d 7 8 90 0 LWA re 1 pW D 7 meters 25 MISCELLANEOUS SPECIFICATIONS The Amida AL4000 light tower is built to NEC standards FASTENER TORQUE SPECIFICATIONS fasteners should be torqued to the following specifications in Ib ft Ib in FASTENER STAINLESS STAINLESS SAE GRADE SAE GRADE SAE GRADE SAE GRADE 546 1012 8510 1419 2022 1719 2528 0 2632 2227 4045 ETE 5 16 12Nov 14Dec 1517 2326 2022 2224 2834 4550 716 31 33 32 35 40 45 J 4mm 2226 1922 2327 6mm 4550 3843 7278 emm NV sio 1416 J 10 1820 1517 4550 4045 7075 12mm 4244 3638 5660 5055 95105 16mm 140148 18 18520 20mm 280290 Ananti seize lubricant MUST be used on all stainless steel hardware 26 WIND LOADING CHARACTERISTICS wind load calculations were performed with the tongue at 12 o clock the wind coming from the direction shown with the lights flat facing into the wind Com 66 i Com um FROM 6 O CLOCK 90 MPH NOTE If optional front outriggers are used the allowable wind loading in th
9. ALONG 3383 SLI 01 DNILOVSIGM HIBN31 ONDISEM WDWIXVN SLT OL ATENISSY DNIGN3LX3 40 51515 2 319429 38 4 1921813313 0 TYDINYHIOIN 1531 372942 000002 V ONIGNVISHLIM 40 3149492 38 Lem 31892 441 1103 8 561 S NZ SSI 1332 3 LON TIWHS 4 87 002 2 JEF 68 19 HLINIT 511 OL ATHA3SSV 31 3 OL 03411038 39804 HL NDISN31X3 33804 1 09 NO 0103 0 dWINI 96 6 910H 38111303 4 3784 IVLSNI 1314 38 15 NV 4818 1 5 ONIA OVISHL 2ILSV 1d g nd 0133 3 3 WW 39099 0 0 6 LANMOOT Z L OG FlddIN 3SVHO Z OG NH Layover 821 30 430 15 5 IlddiN 5 v 9 5238015913 21 5 133997 7 1 WON 620 553 53 052089 9 SEN uy 588 amp ani 0 Ken 31 MOSE COH NY YYYYY Y KRETE M Pred gad Pee ed gp pp B 1 1117 VIG 83 33390 52 5 345 804 SINSNOdAOO ONINnOA 0300Y ilie 83 03 SNOISIA Tia 1910345 9679 gt
10. The temperatures in the table are the ambient temperatures at the time when the engine is started If the running ambient temperatures are much higher than the starting temperatures a compromise must be struck and a higher viscosity oil used Multi grade oils overcome the problem provided they possess a suitable specification MIL L 2104B or MIL L 2104C or API CD must also be used if the sulfur content of the fuel exceeds 0 5 Always use a reputable brand of diesel fuel The sulfur content should be below 0 5 higher sulfur content would require more frequent oil changes Observe strict cleanliness when filling the fuel tank Check the engine oil level before starting the engine or more than five minutes after it has been stopped Remove the dipstick wipe clean reinsert it take it out again and check the oil level If the oil level is too low remove the oil filler cap and add new oil until the FULL line on the dipstick is reached 14 MODEL 4000 OPERATING INSTRUCTIONS AWARNING READALL DIRECTIONS IN MANUAL CAREFULLY BEFORE OPERATING EQUIPMENT DO NOT RAISE TOWER IN THE VICINITY OF overnrsprower nes II III IV OPERATING INSTRUCTIONS MOVE LIGHT TOWER TO DESIRED LOCATION KEEPING THE FOLLOWING IN MIND The light tower should not be placed where those working under the light are either 1 Forced to look into the light regularly 2 Forcedto work with their backs to the light shadows will bloc
11. Ve 6 Wm Z 8 5 IM 8 Az 1 nua v Nd9 1545 4 9 9 ACL on 980 ole 829 038 NS 9 6 0 T aay tJ Q38 ma 9 g 48 0 5 NS 49 5 M3MOd HOLVN id ka NYE 9 8 ow 010 3105 f N 7903 lis 2 5 1HM AIM L TOA i asna 2 d ENZ ALIVE _ NOLIng HSnd HOLVNSILTV 1 S CO 2 SINJNOdAOO 3NION3 X va SNOISIA3Y L L s y 9 8 em 40 TEREX LIGHT CONSTRUCTION Title ne AL4000 LIGHT TOWER SE Trailer Frame Tongue Outriggers 160270 Battery Cable Set 160110 Battery 174170 Battery Hold Down 2 840222 Snap Ring 182330 Battery Hold Down Rod 841430 Jack 114480 Outrigger 124410 Trailer Frame 124470 Tongue 109150 Plinger Pin Kit 721051 Plastic Plug 4 834219 Handle Hammerblow 834204 Handle Fulton 841430 Jack 840222 Jack Snap Ring 840221 Jack Bracket 110870 Safety Chain 41 AL4000 LIGHT TOWER SS E TEREX Title LIGHT CONSTRUCTION Fuel Tank 742240 1 Tank Cap 4 990200 Lock Nut
12. WEAR BUSHING NYLON 61100200 WINCH FULTON 996050 SCREW 1 2 13 BY 7 1 2 LONG NOT INCLUDED WITH 109485 990200 NUT 1 2 13 NYLON LOCK 124857 SPACER 124855 RATCHET ARM 124856 FLANGE BUSHING 990200 NUT 1 2 13 NYLON LOCK 109485 WINCH SAFETY LOC SYSTEM INCLUDES NEW WINCH 109486 WINCH SAFETY LOC SYSTEM DOES NOT INCLUDE NEW WINCH 850107 SAFETY DECAL 56 Model TEREX LIGHT CONSTRUCTION 866125 Air Cleaner Assembly 866126 Air Cleaner Body 866127 Air Cleaner Element 866128 Air Cleaner Cover 866129 Air Cleaner Valve Capacitor 109350 7 6KW 866030 Soleniod 866040 Gasket 836857 Diode 866120 Radiator Cap 741140 Temp Sender Generator AL4000 LIGHT TOWER Genset Kub D905 L S 6KW o 630930 LSA37 6KW 839200 Fuel Filter 866050 Oil Filter 866080 V Belt 866110 Radiator 865223 Electric Fuel Pump Mounted to Trailer Frame 740620 In line Fuel Filter 57 TEREX Medel AL4000 LIGHT TOWER LIGHT CONSTRUCTION Genset Kub D905 L S 6KW 839109 Hose 866090 Alternator 839190 Low Oil Press Sensor 865276 Muffler 832128 Muffler Gaslket 839110 Hose 866394 Hose 865054 Hose 3 836831 Bearing Housing 836832 O Ring 836833 Rear Bearing 866100 Starter 58 14000 LIGHT TOWER Title TEREX LIGHT CONSTRUCTION Radiat
13. the top of the tower Pull the cable and the small section completely out of the middle section together Be sure to keep the cable tight if slack accumulates it is most difficult to remove Unfasten the cable by removing the bolt at the base of the small section 3 REINSTALLING THE SMALL SECTION 3 1 3 2 3 3 Fasten new cable to the base of the small section Reversing the procedure described in steps 2 1 through 2 5 reinstall the small section Reinstall the plastic guides with new pop rivets New plastic guides should be used but the old guides can be used if their mounting position is shifted to the point where new holes can be drilled in the tower section to provide a good fit when installing new pop rivets 4 REMOVING THELOWER CABLE AND MIDDLE TOWER SECTION 4 1 4 2 43 44 4 5 Remove open the telescope lock pin if not previously done step 2 2 Drill outthe aluminum pop rivets holding the plastic guides at the top of the large section Using a screw driver remove these guides Remove the cable from winch drum Remove the sheave clevis pin and the sheave from the top of the large section If the old cable is not frayed between the winch and the bottom mast pulley attach a flexible fish wire or snake wire rope cord etc to the end of the cable to be used to thread the new cable through the lower tower and pulleys This can be done by untwisting the cable and inserting the wire or cord in
14. the heart Always disconnect power from the circuit being measured before connecting test leads to high voltage points Do not try to position both probes at once Instead clamp the common insulated alligator clip to a neutral wire and then probe for voltages with the other probe Never clamp to a hot wire since a severe shock could be received by contact with the other probe Inspect the ground cable between the generator set and the frame If damaged replace immediately Treat all conductors as potentially hot especially when troubleshooting malfunctioning equipment Jewelry should be removed before working around live conductors Proceed through the circuitry systematically operating only one section at a time Use tools with insulated handles when working within the reach of live conductors Maintain a good footing If you slip ora tool drops do not grab for it if live conductors are within reach Concentrate on the task until the danger from high voltage is removed AWARNING Guard Against Battery Hazards Lead acid batteries can be dangerous The sulfuric acid in the battery can cause severe skin and eye burns The hydrogen gas emitted during charging can explode if an arc or flame is present near the battery Use precautions to prevent acid burns or explosive conditions Do not smoke while servicing batteries Do not allow tools to touch battery terminals and create an arc Do not test battery voltage by setting up a brief ar
15. 0 Coupler 2 176336 Spacer 2 gt 176335 Plate 840470 Ball 2 SAE 2 121572 Combo Hitch Ring 16 Long 940000 Kit Combo Hitch 213770 Ring Hitch 2 1 2 124450 Hitch 24 Height 221580 Hitch Adj Height 211410 2 1 2 1 D Ring gt Hitch for Adj Height 841200 Hitch Pintle Ring 3 65 Ej TEREX LIGHT CONSTRUCTION 160992 Electric Winch 12V 663780 Switch 160993 Solenoid 113583 Switch Solenoid Assembly 66 Md TEREX 2 LIGHT CONSTRUCTION STOO 663525 Light Side Marker Amber 663520 License Tag Light w Bracket 663840 Stop Tail amp Turn Light 67 Option LIGHT CONSTRUCTION 68 Model N Option E TEREX LIGHT CONSTRUCTION 69 LIGHT CONSTRUCTION 70 TEREX LIGHT CONSTRUCTION Model 1 AL4000 LIGHT 2 20 Title SPARE AND WHEEL TIRE amp WHEEL 71 LIGHT CONSTRUCTION 72 LIGHT CONSTRUCTION 73 Model TEREX LIGHT CONSTRUCTION Title Option OLTYOS1 AXLE WITH SURGE BRAKES AND FIT TINGS NOT 74 OMMON PARTS GE 3 RING LIGHT CONSTRUCTION 75 Model LAND Option Ej TEREX LIGHT CONSTRUC
16. 1 13 E es 8 077 7744 03 0203 8 3SIMHIHLO 883 S3O9NVH31OL 3ONVHO 093 1 39 Nvadouna aaaav 00 91 8 V NOILdIHOS30 LHVd vS862 S8620M LUVd HLHV3 GNNOYD MOTIT3A M N33H9 LSv TIV8 WOH LOH 148 NOWINOO 31IHM LINOHIO 3009 3009 NVa3douna OILS3NOG N3SO TVH NALSONNL 1 AWVS 3HL SI NOLLVYNDI4NOO Nid ALON NMOUQ IIA NYD N33H5 9079 1 33 9867 98620 EE 16 05 314 16 09 101d ANON 4125 40 JOVSN N d IVN 20408 MOLOINNOO AOP M LYN ISVTIVE HA000 L AVYDVIA ON 53903 5 58808 11 SAOWSY 996 XVI 1106 2926 608 Ud 2 25 MOON PY 065 OLO F XXX OCO T XX E 1 LOH dny ula 0034s 55180 SJONVTTOL NONNOJ 1 ALAM oo IVO FA 1 or 50102 310V1d303M 410d S 087 JN T lo 9 NHO NOD 15 11 84 0001 N30 3SNVHI 2 1 2 0 18 dyo oud 321 9867 OMG 986ZOM
17. 40 Box Body gt 260360 Hour Meter 684380 Switch R660010 Push Button Switch R661490 Relay 663890 Cordset 682715 Light Female Gr d 685671 Connector Male 663870 Connector 3P Female 720440 Weatherstrip Adhesive 680080 Strain Relief 62 TEREX LIGHT CONSTRUCTION Model AL4000 LIGHT TOWER Page Title Electrical AC DC 4 MH HPS DESCRIPTION Qn 1 1 2 HH MS JM PEENED GASKET HIF GASKET SILICQ BINATION CLAMP BAND 19 HANDLE FOR N RELIEF PH MS 2 2 UM 5 16 LENGHT 2 NT METAL HALIDE 1 X 91 4 X 15 32 LENGHT 1 TT HP SODIUM 1 JR TERMINAL STRIP 2 D EPDM SLEEVE 2 1 2 LOCATION EXTERIEUR 63 Model AL4000 LIGHT 095 TEREX Se LIGHT CONSTRUCTION Ballast Page 114355 Ballast Box MH 114895 Ballast Box HPS A 665860 5 Pin Connector I 1 d N G 2 160050 Ballast MH 160040 Ballast HPS 160032 Capacitor MH 160042 Capacitor HPS 64 AL4000 LIGHT TOWER ES LIGHT CONSTRUCTION Trailer Hitches 84012
18. 4345 JSMUIHLO 554 SONO ANS 193H 3Bc O 9 NM 6 av Ad 59014 0100 14 59 om lan NM i 0 OO eje 227 3univuqaNal s 1 9 1 1002 2 9 6 42 94 111504 A3 Y MALIN 9 5 gt 5 lt ollo HE LL H 0 a 2 S Nag N 0 m 7 0 8 8 NYE Nua Ko T 4 L HA 339 34055344 o WO wid Ig s a 22 alle u NYO Y 9 ms i 990 550 9NO 8 038 038 Se 2 T NYS 038 LJ E o a 4318915 NUD YOLVN Id _ o Og NYE a 8 1 821 NYE 2 8 010 3105 ES a d lis B 7 ES 9 i 13 61 3 3 Q38 1HM HON NOLLAG 4 HOLVNHIL IV 38 wg EN a 7 C 2 2 SINJNOdNOO xog IOYLNOO AG OS 40M HVO 37 28 4990 SIAL 3125 LON
19. 6 38 ES d38 NYE 5 8 qus GION310S 7303 a LHM N 038 i 0 3504 BA 5 5 13 LIOA l NOLING HSnd 14 2838 8 Id Y B SLNANOdWNOO xog aal EE SNOISIA3H HH oun 6 S 9 8 L TVIS awas er ue 912145 96y9 833 9 3 08 1 7 8 03 086 81 828 9152 31415 WAY INI 08 4 ONI INISYHIEN d 3 mere 3 5 Ein Q3AUNddv YSI HIDE 38 OL 37692 ul rc uev ING WAIDO3 29 UN 8 0 5 10 1 SV Fe M 1531 5 ZH 09 LIDA 0006 v OL 031937915 38 01 338V2 CAN NOLLOAYLSNOS LHDIT m EM 21 1237310 NV 40549710 Y JG srow Lem 151838 5 8 Bell 395 eov OM 129297 NOLLYTISNI ANIE 504 901 395 119014103 5 31893 NV JAIA 331 80 1507 Slave SINIWIUINOIN ATVI dev OL SWAOSNOY NOTLONSLSNOS 31892 80 WIYILYN
20. 742220 Fuel Tank 109505 Drain Plug Kit 188630 Fuel Tank Pan 8 990210 Flat Washer 4 994650 1 2 13NC x 10 Bolt 42 T E REX Title E Modet AL4000 LIGHT TOWER LIGHT CONSTRUCTION Axle Assy 2 834267 U Bolt Kit 834225 Grease Seal 834220 Hub Assy uA SA 834255 Pin 841050 Complete Axle Assembly gt 834250 Spindle Nut 834228 Grease Cap 834226 Inner Bearing 834227 Outer Bearing 841060 Tire amp Wheel Mounted 8 840395 Axle Spring Nut B2096 840392 Axle Rear Hanger 3 840394 Axle Spring Bolt 841051 Axle Front Hanger 841473 Axle Shackle 2 834246 Spring Eye Bushing 834211 Leaf Spring 43 T E REX Title AL4000 LIGHT TOWER LIGHT CONSTRUCTION Cabinet Assy 116203 1 Cabinet Assembly Complete 4 796432 Door Shock Bracket 184150 Winch Handle Bushing 18859 a 124420 Ground Rod Storage Tube BN d k 188530 Cabinet Front 2 28 por 2 930950 Weatherstrip 124430 Cabinet Rear 2 123490 Fender 188580 Cabinet Curbside 4 791840 Rubber Bumper 44 Model ms LIGHT CONSTRUCTION 116180 1 Rear Tower Support 4 796436 Gas Shock 8 796432 Door Shock Bracket 2 796610 Hinge 113399 Ground Rod 2 176380 Cover Plates AL4000 LIGHT TOWER in Cabinet Assy 720220 Bumper 790540 124460 Tower Support Cra
21. ECTION WITH THE SALE OF TLC S PRODUCTS THERE ARE NO WARRANTIES WHICH EXTEND BEYOND THE DESCRIPTION ON THE FACE HEREOF WARRANTY PROCEDURE The specific language of this warranty will determine TEREX LIGHT 5 5 obligation in connection with its product The information presented below should be used as a general guide for implementation of policy In the event of a component failure during the warranty period it should be repaired as soon as possible preferably at an authorized TEREX LIGHT CONSTRUCTION service center If component is manufactured by a company other than TEREX LIGHT CONSTRUCTION such as Deutz Honda Isuzu Leroy Somer Lister Petter Lombardini Wisconsin etc the applicant should pursue repair and or reimbursement through that manufacturer and its dealer distributor network To file a claim with TEREX LIGHT CONSTRUCTION an APPLICATION FOR WARRANTY ADJUST MENT AWA form must be completed in it s entirety Return the completed form within fourteen days of the repair to ATTENTION WARRANTY TEREX LIGHT CONSTRUCTION 590 Huey Road Rock Hill Industrial Park Rock Hill SC 29730 TEREX LIGHT CONSTRUCTION will review the AWA form Should we desire to inspect the defective parts we will issue you a return authorization for the defective parts After inspecting the defective part s and it is determined that warranty is due we will then at the discretion of TEREX LIGHT CONSTRUCTION credit the applicants
22. N BELOW 45 WHEN IS EXTENDED SERIOUS DAMAGE MAY OCCUR 16 VII VIII A B C START THE ENGINE GENERATOR SET LLYN Ensure the circuit breakers are turned OFF This prevents the engine from starting under load and prevents electrical equipment from being subjected to improper voltage and frequency Check the oil fuel and coolant if liquid cooled levels If the fuel tank is empty it may be necessary to bleed the fuel line after filling the tank see engine instruction book for procedure Turn the ignition switch to the position see diagram below Press the preheat push button for a maximum of 20 SECONDS Do not engage the preheat button longer than the time specified or damage may occur Turn the ignition switch to the START position to engage the engine After the engine starts release the switch so that it returns to the position Let the engine come up to speed and stabilize review the engine operating procedures in the manufacturers handbook Note If engine will not start leave switch in run position for additional 10 20 seconds to completely prime the fuel system Then repeat step and start engine Turn on the main circuit breaker TURN ON THE FLOODLIGHTS Turn the circuit breakers and check to ensure that all lamps come on Allow a minimum of two 2 minutes for lamps to reach full luminance If required rotate the tower to aim the lights as desir
23. TE THE AL4000 LIGHT TOWER WITHOUT READ ING THIS OPERATOR S MANUAL SAFETY ALERT SYMBOL Stop and take time to read ALL Safety alert messages Follow the safety messages to avoid personal injury or property damage ACCIDENT PREVENTION Use protective clothing and safety equipment Always wear approved safety equipment such as gloves safety boots safety hard hat goggles ear protection and dust masks when necessary Wear protective clothing that is snug and belted where required UNAUTHORIZED WELDING UNAUTHORIZED WELDING CAN CAUSE STRUCTURAL FAILURE OR PERSONAL INJURY DO NOT weld on any structural member Any unauthorized welding or repair procedure will void the warranty GENERAL SAFETY LA WARNING Fvetine ALWAYS handle fuel with care It is highly flammable ALWAYS stop engine before refueling Fill fuel tank outdoors Be sure the fuel supply has a positive shut off valve DO NOT replace fuel lines with materials different from those supplied as original equip ment FIRES CAN CAUSE SEVERE PERSONAL INJURY OR MACHINE DAMAGE Prevent fires by keeping the light tower and its surrounding area clean DO NOT refuel while smoking or when near open flame or sparks DO NOT refuel the engine when it is hot Allow to cool for several minutes before refueling DO NOT spill fuel inside the engine compart ment If fuel has leaked wipe it up and have leak repaired before next use Have
24. TION 76 LIGHT CONSTRUCTION 77
25. a fire extinguisher nearby Be sure the extinguisher is properly maintained and be familiar with its use Extinguishers rated ABC by the NFPA are appropriate for all applica tions GENERAL SAFETY AWARNING Guard Against Electrical Shock Equipment produces high voltage electricity up to 480 volts that can produce a fatal shock to a person who accidentally places their self in the electrical circuit Use every precaution to avoid contact with the high voltage electrical circuit Beware of a cut or damaged power cord Have a qualified electrician replace immediately Take extra precautions when troubleshooting electrical problems When troubleshooting indicates a malfunction in the high voltage AC system pass the troubleshooting task on to a qualified and trained electrician Disconnect electrical power and turn off engine before removing protective covers on high voltage enclosures Understand that the electrical circuits in this light tower complete their paths back to the generator within the equip ment The neutral conductor at the generator is bonded to the equipment frame Ground wires within the system are also bonded to the equipment frame Only use a multimeter or voltmeter with two well insulated probes rated for 750 volts each Keep one hand in your pocket when touching the multimeter probe to hot conductors This will prevent electricity from passing into one hand and out the other a path that takes the electricity across
26. account or send replacement parts TEREX LIGHT CONSTRUCTION warranty reimbursements 1 40 00 for each hour s labor we allow toward a repair 2 Distributors cost of parts not more than the price currently available from TEREX LIGHT CONSTRUCTION 3 One way surface freight charges on parts returned to TEREX LIGHT CONSTRUCTION Many repairs are assigned a predetermined labor schedule which is an average time in which a skilled technician should be able to make a repair TEREX LIGHT CONSTRUCTION will reimburse not to exceed the predetermined number of hours for a particular repair TEREX LIGHT CONSTRUCTION does not reimburse for Travel travel time nor travel labor Mileage Excessive diagnostic time Repairs of defects malfunctions or failures resulting from accidents abuse misuse modifica tions alterations improper servicing or lack of performance of required maintenance service 5 Repairs where defective parts were not shipped back when requested by TEREX LIGHT CON STRUCTION Regular maintenance such as parts or labor for oil changes filter changes or filters 7 Repairs where defective parts were not received by TEREX LIGHT CONSTRUCTION after TEREX LIGHT CONSTRUCTION issued a return authorization T D TEREX Light Construction P O Box 3147 Rock Hill S C 29731 USA Phone 803 324 3011 Fax 803 366 1101 10 TEREX AMIDA INC CHECK OUT ON RECEIPT OF DELIVERY The tower will be serviced tested a
27. c atthe terminals Use a multimeter instead Disconnect the negative terminal of the battery when working on the engine or other parts to prevent accidental arcing Disconnect the negative cable at the end away from the battery Always wear eye protection when servicing the battery When charging the battery do not remove the vent caps If acid does get on skin or in eyes immediately flush under running water and then obtain medical help as soon as possible AWARNING Guard Against Fire Hazard Use caution with diesel fuel and motor oil because of fire hazards Do not fill fuel tank while engine is running Do not smoke or use open flame near the unit or the fuel tank Be sure the fuel supply has a positive shut off valve Do not replace fuel lines with materials different from those supplied as original equipment AWARNING Protect The Environment And Practice Good Industrial Hygiene Exhaust Gases Are Toxic Do not use indoors unless properly ventilated Provide an adequate exhaust system to properly expel discharged gases Check exhaust system regularly for leaks Ensure periodically that the exhaust manifolds are secure and not warped Make sure the unit is well ventilated Prevent pollution by catching used oil in a container for proper disposal Wash hands to remove oil and fuel Practice good industrial hygiene ACAUTI ON Do Not Touch Hot Parts The exhaust manifold and tailpipe are very hot Parts of the engine are also
28. dle SH 123680 Pin 188550 2 Cabinet Top 794940 Plastic Plug FV 2 189796 Hasp Kit 124420 Storage tube 2 188560 2 790940 Handle Cabinet Door 45 Model AL4000 LIGHT TOWER Md TEREX LIGHT CONSTRUCTION Cabinet Decals 109471 DECAL KIT COMPLETE Top 850091 851640 853296 853296 Curb Side Road Side 853312 853640 850107 850150 853312 852410 851860 853291 Front Rear 650093 2 841710 0 850092 46 853301 TUM AL4000 LIGHT TOWER dcos TEREX Title LIGHT CONSTRUCTION Tower Assy 113080 Coil Cord Sleeve See 2 Section See 3 Section See 4 Section See 6 Round Tube 47 Mesel AL4000 LIGHT TOWER age TEREX Title LIGHT CONSTRUCTION 4 Tower Section See Sheave amp Shim Assembly 124540 4 Tower Section 4 qu 109516 Lock Pin Kit 990660 Roll Pin 177810 P m 113362 Lock Pin Shim N s 2 790510 1 16 Cable JV 17640 3 790520 Cable Sleeve Shells q 990760 R Pin 980340 120640 Pin Screw 990650 790710 Cotter Pin Spring 9 See 6 Round Tube 48 TEREX AL4000 LIGHT TOWER TS LIGHT CONSTRUCTION 4 Tower Sec Upr Sheave amp Shim Assy
29. e 3 and 9 o clock directions is 79 mph In the 4 and 8 o clock directions the allowable wind velocity would be 94 mph 27 CRITERIA FOR REPLACEMENT OF WIRE ROPE TEREX AMIDA LIGHT TOWERS The wire ropes used to raise and lower the masts on a TEREX Amida Light Tower are probably some of the most important mechanical parts used in day to day operation of the machinery It is therefore very important that the cables be inspected on a frequent basis once a month for wear and tear and immediately in the event of possible damage due to operator error in using the winch or possible damage from other equipment NORMAL WEAR AND TEAR When used properly the wire ropes should give years of trouble free service depending on how often the masts are raised and lowered The rule of thumb at TEREX Amida is that if the tower is raised and lowered an average of once per day that the cables should be replaced every two years of service NORMAL INSPECTION The wire ropes are constructed of 7 strands of 19 plow steel wires each twisted together and then the assembly galva nized to resist corrosion Using a wadded up cloth or heavy leather gloves to avoid being pricked by a broken wire run a hand up and down a length of the cable If any exterior wires are broken they will lift up from main body of the cable and become visible For any given 1 foot of cable length if there are 4 or more wires each on any 2 or more strands broken the suspect rope shou
30. ed Tighten the tower rotating locking bolt Adjust the tower vertically and adjust lighting direction of individual fixtures if required TURN OFF THE FLOODLIGHTS If operating turn light circuit breakers off Turn engine switch to OFF to shut down the engine Do not shut down engine prior to turning lights off Allow lamps to cool at least ten 10 minutes before moving the tower to avoid break ing lamps 17 LOWERING THE TOWER TO TRAVELING POSITION Using the winch telescope the tower down to its fully retracted position until the telescoping locking pin snaps into place LY Ensure that the telescoping locking pin locks before pulling the vertical lock pin at the bottom of the pivot post This ensures the tower is completely lowered and cannot be damaged by telescoping out while in the travel position Loosen rotating lock Rotate the tower so that the groove in the galvanized ring at the pivot is pointing to the rear of the trailer to enable the tower to be lowered into the travel position Tighten rotating 1 ock Pull the vertical locking pin at the base of the pivot post the spring should provide sufficient pressure to start the tower pivoting over Let out on the winch cable to lower the tower into the cradle Insert the rear tower horizontal travel locking pin into the cradle RELOCATING LIGHT TOWER TO NEW LOCATION Insure that tower has been properly lowered see section VII and lockin
31. eter with two well insulated 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 ballasts are receiving power suspect burned out power cable SYMPTOM CAUSES CORRECTIVE ACTION LAMP WILL Check Ballast Status Light a Input lights should be on This confirms power is going NOTSTART to the ballast b Output lights should be on This confirms power is coming from ballasts c Output lights should be normal brightness If one or moreof the output lights stay extra bright then the lamp is notstriking d Use this knowledge to diagnose problem e If ballast status light is out but the floodlight lamp is working suspect burned out ballast status lamp and replace Lamp loose in socket Inspect lamp base to see if there is arcing at center contact button Tighten lamp snugly Check socket for damage Replace if defective Floodlight Plugs not tight Check plug and receptacle Tighten if loose Defective Ballast Interchange ballast plugs in generator enclosure If lamp starts replace ballast Check ballast wiring diagram Check for swollen capacitors charred wiring core and coil or other signs of excessive heat Low Voltage Check line voltage at ballast input Voltage should be within 10 of namepla
32. g pins are engaged Insure all fixtures are pointed toward the ground or mounted on the fixture storage brackets on the lower tower section Alljacks must be raised and all outriggers locked into travel position Insure that the coupler is properly secured to the towing vehicle and safety chains are attached if supplied Release any manual braking mechanism if supplied Do not tow at excessive speeds 60 mph 100 kmh maximum as the weight of the light tower can cause loss of vehicle control especially under emergency stopping conditions The standard trailer has no towing brakes therefore allow extra distance for stopping 18 XII USEOFLIGHT TOWER AUXILIARY POWER A B One 1 30amp 240v Twist Lock and 1 15 amp 120v receptacles are provided for auxiliary power Total auxiliary power cannot exceed main circuit breaker rating Each lamp operating consumes 10 amps of current 120 vac Before plugging in auxiliary power cords feed them up through the trailer frame and attach to receptacles Close the cabinet doors to protect control panel and other components from weather see Miscellaneous Specifications and Routine Maintenance section for power control details 19 LIGHT FIXTURE TROUBLESHOOTING not open fixtures while light circuit breaker is Allow lamp to cool before touching TAKE EXTRA PRECAUTIONS WHEN TROUBLESHOOTING ELECTRICAL PROBLEMS A Only use a voltm
33. he base due to tightening lamp too firmly in socket Look for broken arc tube or loose metal parts Replace lamp Ballast nameplate data should agree with lamp line voltage and lamp use If improper ballast is used the lamp life will be shortened A mismatch may also cause the ballast to fail Improper ballasting can cause flickering or erratic operation In the start up period the lamp may ignite start to warm up and then extinguish cycle Under certain conditions new lamps may cycle Usually after three 3 tries to start at 30 to 60 second intervals lamps will stabilize and operate satisfactorily Replace lamp Ballast produce high spike current Measure with oscillo scope Replace ballast as required 22 TRACEABLE NUMBERED WIRING SYSTEM Using plug in ballasts to troubleshoot When troubleshooting the preceeding problems minimize down time by following the traceable numbered wiring system always follow these steps STEPI Insure all ballasts which are numbered are plugged into lead wires with corresponding numbers STEP 2 Looking at the lights from the glass side and following the diagram below plug each fixture into the appropriately numbered plug at the top of the tower By adhering to the traceable numbered wiring system troubleshooting fixture aiming and fixture control will follow standard predictable pattern 23 TEREX Amida Model AL4000 Light Tower General Specifications And Routine Mainte
34. hooting Guide Specifications Routine Maintenance Wind Loading Torque Specs 24 27 Criteria for Replacement of Wire Rope 28 Broken Cable Replacement Procedure 29 32 Light Fixture Troubleshooting 20 22 TEREX Amida Numbered Wiring System 23 Engine refer to manufacturer s handbook Generator refer to manufacturer s handbook Warranty Information Warranty Procedure e e rrr eR EE 10 Warranty res 9 SAFETY ALERT SYMBOLS MEANS ATTENTION BE ALERT YOUR SAFETY IS INVOLVED THIS SAFETY SYMBOL IS USED FOR IMPORTANT SAFETY MES SAGES WHEN YOU SEE THIS SYMBOL FOLLOW THE SAFETY MES SAGE TO AVOID PERSONAL INJURY OR PROPERTY DAMAGE UNDERSTANDING SIGNAL WORDS Asignal word DANGER WARNING or CAUTION is used with the safety alert symbol DANGER DANGER Identifies the hazard or unsafe practice that will result in severe injury or death WARNING Identifies the hazard or unsafe prac WA H N tice that could result in severe injury or death CAUTION Identifies the hazard or unsafe practice A O N that could result in minor injury or property dam age NOTICE Identifies important installation opera tion or maintenance information NOTICE GENERAL SAFETY DO NOT OPERA
35. hot Avoid touching hot parts of the engine ortailpipe Use protective gloves when handling hot parts AWARNING Be Alert And Attentive To The Task Read the safety instructions and operating procedures before attempting to troubleshoot or work on this unit Also read the engine manual which is a separate booklet that is provided with this manual Do not work on this equipment when mentally or physically fatigued Do not work on this equipment when under the influence of performance impairing drugs or alcohol If this manual becomes lost order new one from TEREX Amida so future operation and maintenance personnel may read these instructions ACAUTION Beware of Moving Parts Avoid being hit or pinched by the moving parts of this unit Loose jackets shirts neckties or sleeves should not be worn while working on or running a unit Only remove guards or protective devices from unit temporarily to gain access for maintenance Always replace guards and protective devices promptly Prior to Operation Keep your hands away from moving parts Particularly be sure to keep hands clear of the blower and alternator belts when the engine is running AWARNING Beware of Traffic Hazards Stand clear of traffic when starting or checking the unit along the road Check the fuel tank oil pan and fuel and oil lines for leaks that would spill fuel or oil on the road Check fasteners and mounting brackets periodically to ensure all are tight and n
36. k the light from the work area The area where the tower is positioned should be relatively level The light tower should be located on the same level or on ground higher than the area being lighted higher light mounting heights reduce the shadow length Unit should be level to ensure smooth trouble free tower telescoping Tower may not telescope down properly when unit is not level UNHITCH FROM THE TOWING VEHICLE AS FOLLOWS Engage the trailer braking system especially if trailer is not on level ground CAUTION If electrical or manual braking system is not supplied chock the wheels instead Swing the tongue jack into position and raise the tongue off the towing vehicle LEVEL THE TRAILER USING THE JACKS AS FOLLOWS Extend the rear outriggers until the springs lock into place Swing the jack on each outrigger into vertical position Start at the highest jack position Rotate the jack handle until the jack foot touches the ground Raise the other jacks to level trailer 6 insure that the rear Jacks are down to prevent the tower from tipping over backwards when raised DRIVE GROUNDING ROD INTO EARTH 15 INSTALL THE FLOODLIGHTS ON THE CROSSBEAM Remove the light fixtures from the tower by removing detent pin and rotating the clamp to free the lights Install them on the cross arm studs with the lens facing the ground on the fixture should be on the side closest to the trailer so
37. kes TEREX LIGHT CONSTRUCTION SERIES AL4000D1 LIGHT TOWER OPERATION SERVICE amp PARTS MANUAL After Serial Number FKF 13923 PART NUMBER SFMALADI SION B SEPTEMBER 2006 TABLE OF CONTENTS Receiving and Set up Safety Alert 15 3 General 4 8 Check Out on 11 serial Number ReBOStet iiie ee e e e 12 TEREX Amida Light Tower Model Coding System 13 Recommended Engine Oil and Fuel 14 Operating Instructions Light Tower Operating Instructions pp 15 19 Engine see manufacturer s handbook Generator see manufacturer s handbook Parts Identification Drawings Trader and Fuel 41 42 Axle and Wheels riri tyr 43 Cabinet and Attachments uqa asada s EEES 44 46 Tower and Related Parts 47 56 Engine and G nerator neci 57 61 Electrical 0 E E EE ANTEE 62 Floodlight Fixtures Ballasts eene 63 64 TECH 65 DUO 66 77 Wiring Diagrams Fixture with Joy Connector MH or TH eene 33 Metal Halide Ballast with Connector 34 High Pressure Sodium Ballast with Connector 35 WIDE UU 36 40 Troubles
38. ld be replaced immediately OPERATOR ERROR OTHER MACHINERY DAMAGE One of the most common reasons for failure of a Light Tower wire rope is due to operator error in using the winch or damage to the cable by tools or other machinery The most common operator error happens when the mast is telescoping down When the upper telescoping lock engages the operator does not pull the lower pivot lock out located on the tower base and keeps on cranking the winch This results in the cable becoming loose around the drum due to the tower not pivoting down This can result in three problems the loose cable can get trapped under neath itself resulting in a sudden or partial drop of the mast when the loose section releases at a later time thus damag ing the cable or the cable can jump off the winch drum and be damaged by the gears of the winch The loose cable can also cause the drum to spin to take up the slack cable If there is enough friction in the threaded parts of the winch the drum can cause the crank handle to start spinning This can cause the tower to freefall and the results can be cata strophic for anyone standing underneath the tower A spinning crank handle can also break bones Other reasons damage can occur are due to some outside force such as forklift blade nicking or crushing a cable when moving a unit or an accidental blow or damage by a hand tool etc DAMAGE INSPECTION If any nicks partial strand cut through kinks perma
39. nance TEREX Amida model AL4000 series light tower provides mobile trailer mounted floodlighting for nighttime maintenance construction mining and emergency work It consists of a trailer with a diesel powered 6 KW 60Hz 50 Hz units available generator and a 30 foot cable actuated tower with four 4 1000 watt floodlight fixtures It is ideally suited for heavy duty use and is built to meet the following specification DIMENSIONS Overall length travel position w fixtures amp tongue 179 4547 mm Overall length tower vertical w tongue amp jacks 124 3150 Trailer frame length 70 1778 mm Overall height floodlighting position 30 9 14 mm Overall height travel position 68 1727 mm Overall width with fenders 61 1549 mm Overall width with outriggers pulled out 102 2591 mm Trailer frame width 41 1041 mm Tongue length 44 1118 mm Wheel size 15 381mm Axle Rating 3500 Ib 1588 kg Tongue weight travel position 100 1 45 4 kg Total weight no fuel 2050 Ib 930 kg Fuel Capacity 30 gal 114 I Unit weight with full fuel tank 2250 Ib 1020 kg This section details specifications and maintenance not covered in the operators and trouble shooting sections of this manual and the 4000 specification sheets OIL AIR SERVICE The engine oil should initially be changed after the first 50 hours of use and then every 200 hours thereafter The oil filter should be replaced after every 400 hours of use The ai
40. nd fixture Let cool sufficiently before cleaning Interchange ballast plugs in generator enclosure Iflamp returns to normal light output replace ballast Check for swollen capacitors charred wiring core and coil or other signs of excessive heat Check voltage at ballast input Voltage should be within 10 of nameplate rating Check wiring connections for voltage loss Check socket contact point Check ballast nameplate against lamp data Lamp color and brightness decreases and colors change slightly as lamps age Spot replacement with new lamps may cause noticeable differences in lamp colors Group replace ment minimizes color differences Dirty fixtures will cause lamps to appear different in color Clean fixture Check data on lamps which appear different in color Replace with correct color lamp Check voltage at ballast Check for current or voltage surges Check for shorted capacitors and replace if defective Lamp operated on ballast designed for higher wattage lamp Check ballast nameplate against lamp data 21 LIGHT FIXTURE TROUBLESHOOTING cont d SYMPTOM SHORTLAMP LIFE LAMP FLICKERS AND GOES OUT INTERMITTET CAUSES Lamp damaged Improper ballast Improper ballast New lamp Defective lamp High spike ballast CORRECTIVE ACTIONS Check for outer bulb cracks If air enters outer bulb arc tube may continue to burn for 100 hours before failure Check for bulb cracks where glass meets t
41. nd ready for operation when received except for export units and skid mount units which are knocked down for shipping export units are sometimes shipped with dry batteries TEREX Amida recommends the following checks INSURE THERE IS NO FREIGHT HANDLING DAMAGE which should be charged against the carrier INSURE THE MANUALS ARE IN THE POCKET PROVIDED INSIDE THE UNIT REVIEW THE MANUALS FOR SAFETY AND OPERATING PROCEDURES CHECK THE ENGINE OIL COOLANT IF LIQUID COOLED AND FUEL LEVELS OPERATE THE TOWER IN ACCORDANCE WITH OPERATING INSTRUCTIONS EXPORT Assemble according to the instructions enclosed 11 TEREX LIGHT CONSTRUCTION PORTABLE LIGHT TOWER OPERATION AND SERVICE MANUAL This Operation and Service Manual contains information pertaining to the operation and maintenance of your Terex Light Tower We suggest that you read this manual carefully prior to operating the tower This manual should be retained and referred to for operation maintenance and ordering parts When ordering parts PLEASE INCLUDE THE MODEL AND SERIAL NUMBER located on th nameplate of the tower For major repair and service or other information contact your local Terex dealer or write to Terex Light Construction P O Box 3147 590 Huey Road Rock Hill SC 29730 Telephone 803 324 3011 FAX 803 366 1101 When returning parts for credit please contact the factory for Return of Goods Authorization
42. nent bends or weld spatter on the cable from field service are observed the suspect wire rope should be changed immediately If there is a crushed spot somewhere on the wire rope it should be replaced only if the width of the crushed spot exceeds 1 1 4 times the nominal diameter of the cable 5 16 on a 1 4 cable and 7 32 on a 3 16 cable or if there are broken wires at the point of damage 28 BROKEN CABLE REPLACEMENT PROCEDURE 1 PREPARATION 1 1 1 2 Collapse tower to where mast is retracted then pivot tower to horizontal position Remove the tower from the trailer and place it on a work surface such as two saw horses 2 REMOVING TOP CABLE AND TOP MAST SECTION 2 1 2 2 2 3 2 4 2 5 2 6 Tie middle section and large section together by wrapping band cable chain or rope around the sheave brackets on these two sections This insures that the middle section stays inside the large section during removal of the small section Remove or lock the telescope lock pin open This is the pin that locks the three sections together during travel Drill out the aluminum pop rivets holding the plastic guides at the top of the middle section Using a screwdriver remove these guides Remove the clevis pin anchoring the cable to the top of the middle section and remove the clevis pin and the sheave from the middle section Pass the free end of the cable through the sheave slot between the middle and small section and out of
43. numbers have been altered defaced or removed but shall be limited to repair or replacement of those parts which upon inspection by TLC appear to have been defective in material or workmanship TLC s liability and Buyer s sole and exclusive remedy for a failure of goods to perform as warranted and or for any and all other claims arising out of the purchase and use of the goods including negligence on the part of TLC shall be limited to the repair or replacement of defective parts returned transportation prepaid to TLC TLC shall in no event be liable for incidental or consequential or other damages or losses resulting from a breach of warranty such as but not by way of limitation labor costs loss of profits loss of use of other than equipment third party repairs personal injury emotional or mental distress improper performance of work penalties of any kind loss of service of personnel or any other damages or losses which may be experienced by the Buyer A product warranty certificate must be filled out in its entirety and returned to TLC in order to process any warranty claims submitted THIS WARRANTY IS EXPRESSLY IN LIEU OF AND EXCLUDES ALL OTHER WARRANTIES EXPRESSED OR IMPLIED INCLUDING ANY WARRANTY OF MERCHANTABILITY AND FITNESS OF ANY PRODUCT OR GOODS FOR A PARTICULAR PURPOSE AND ALL OTHER OBLIGATIONS OR LIABILITIES ON TLC S PART AND TLC NEITHER ASSUMES NOR AUTHORIZES ANY OTHER PERSON TO ASSUME FOR TLC ANY OTHER LIABILITY IN CONN
44. of its discovery Should defects be discovered the Buyer must clearly establish that I the equipment parts etc have been properly installed and set up maintained and operated within the limits of rated and normal usage and II the defect did not result in any manner from the intentional or negligent action or inaction of Buyer Buyer must also return the defective item or items to TLC Rock Hill SC for inspection at TLC s request If Buyer cannot establish that conditions 1 and 11 have been met then this warranty shall not cover the alleged defect Failure to give notice of defect within such period shall be a waiver of this Warranty and any assistance rendered thereafter shall not extend or revive it THIS WARRANTY IS LIMITED TO THE BUYER AND IS NOT ASSIGNABLE OR OTHERWISE TRANSFERABLE TLC MAKES NO WARRANTY WITH RESPECT TO PARTS COMPONENTS EQUIPMENT AND ACCESSORIES NOT MANUFACTURED BY TLC SUCH AS FIXTURES BALLASTS ENGINES HYDRAULIC PUMPS FUEL PUMPS ALTERNATORS GENERATORS WINCHES TIRES AND ELECTRICAL COMPONENTS Accessories assemblies and components included in products of TLC which are not manufactured by TLC are subject only to the warranty of their respective manufacturers TLC makes no other warranty express or implied and makes no warranty of merchantability or fitness for any particular purpose This warranty shall not cover misuse alteration abuse negligence accident acts of God sabotage or any item in which serial
45. or Overflow Tank 866120 Radiator Cap 865307 Overflow Tank Kit 866110 Radiator 59 TEREX Model AL4000 LIGHT TOWER LIGHT CONSTRUCTION Right Side Radiator Engine Bracket 910 Engine Block 4 R980175 Flat Washer 4 994830 Lockwasher 4 995110 Screw Radiator Mounting Bracket 189290 Engine Mounting Bracket 2 184325 Genset Spacer 4 740920 Vibration Mount Assy 60 AL4000 LIGHT TOWER Wie LIGHT CONSTRUCTION Generator Mounting Bar 630930 Generator 6kW Leroy Somer 2 990200 Lock Nut 189335 Generator Mounting Bar 4 990210 Flat Washer 2 990820 Bolt 61 Model TEREX Page AL4000 LIGHT TOWER Title LIGHT CONSTRUCTION Electrical AC DC 4 MH HPS 116805 Complete Assembly 2 186548 Mount Bracket 186543 Top Plate 186546 Front Plate 683680 Breaker 2P 30A 4 683870 Breaker 1P 15A 684640 Duplex Receptacle W GFI 683970 Mini Breaker 684450 T Lock Receptacle 186544 Sub Panel 685672 Connector 0 2 9 660287 Coil Cord Only 663880 Cap For Receptacle 48300108 Nema Junction Box 680190 Cover 852800 Decal NOT SHOWN 116775 Wiring Harness 116765 Wiring Harness Receptacle 186542 Rear Panel 1865
46. othing is in danger of falling off during transit Use Only Equal Replacement Parts When a part fails and needs to be replaced only use equivalent size length thread grade and material Replace stainless steel fasteners with stainless steel fasteners The engine may use metric or SAE bolts but all other bolts are generally SAE thread Be sure to use Grade 8 bolts and nuts to mount the genset to the trailer Replace the fuel and oil hoses with items of equal material diameter and length Contact the manufacturer TEREX Light Construction regarding replacement parts to ensure a correct repair A CAUTION Use Caution Working Near Lamps Metal halide lamps produce short wave ultra violet radiation and can cause serious skin burn or eye inflamma tion if the outer envelope of the lamp is broken or punctured Do not use where people will remain for more than a few minutes unless adequate shielding or other safety precautions are used TEREX LIGHT CONSTRUCTION P O Box 3147 Rock Hill S C 29732 MANUFACTURER S LIMITED WARRANTY TEREX LIGHT CONSTRUCTION TLC warrants to the original purchaser that such equipment accessories parts and other products manufactured by TLC will be free from defects in workmanship and material for a period of one 1 year after the date of first delivery or for one thousand 1 000 hours of use whichever comes first provided that Buyer sends TLC notice of such defect within thirty 30 days
47. r filter element should be replaced once every year or after six cleanings see manufacturer s operation manual for details BRAKE SYSTEM Electrical or mechanical brakes are not standard equipment on AT 4000 Contact your dealer or the factory for option information 24 MANUAL WINCH Maintain a light film of automotive type grease on the pinion drum gear and the O D of the drum bearing at all times Keep the ratchet pawl pivot pinion shaft bushings and pinion threads lubricated with automotive engine oil at all times Before each use check the brake friction discs for wear If less than 1 16 thick cracked or broken replace IMMEDIATELY Ratchet should click when tower is raised and not when itis lowered Always be alert for any fraying of cables and replace any damaged cables IMMEDIATELY Never stand under any object lifted by the winch ELECTRIC WINCH The electric winch is permanently sealed and does not need any periodic lubrication Always be alert for any fraying of cables and replace any damaged cables IMMEDIATELY Never stand under any object lifted by the winch RECETACLE POWER TABLE METAL HALIDE HIGH PRESSURE SODIUM 2 OR4 15 AMPS 16 6 AMPS 1 AND 3 15 AMPS 8 3 AMPS 2 AND 4 8 3 AMPS 8 3 AMPS TUNGSTEN HALOGEN 2OR 4 15 AMPS 17 AMPS 1 AND 3 15 AMPS 10 AMPS 2 AND 4 15 AMPS 10 5 e Thereis more current available than listed The rating of the duplex receptacle is 15 amps
48. se Fit Tee Bolt 994920 Cotter Pin 990620 3 32 x 3 4 Lock Nut 990650 Cotter Pin 1 8x 1 Ny 124530 6 Round Tube pis SS 992765 87 Pin 1 2 2 Sheave Clevis Pin 1 4x2 53 Page 188770 Sheave 2 13 16 x 1 188760 Sheave 3 1 8 x 1 2 992765 179850 Clevis Pin Bushing 14000 LIGHT TOWER Title LIGHT CONSTRUCTION Tower w Base Assy 113040 Crossarm 116220 1 Tower Assy w Cables 116170 1 Tower Base Assembly 61100200 Winch 124480 Winch Handle 54 Model TEREX 8 LIGHT CONSTRUCTION 124490 193750 Kick Out Spring 186360 Bumper Pad 184510 Spool Sheave 171636 Shell 171640 Shell AL4000 LIGHT TOWER Geet Tower Base Assy 184620 Base Winch Mount 61100200 Manual Winch 27 109486 Winch Loc Kit 124480 Winch Handle 8 990660 Roll Pin 990760 980340 Screw 790710 Spring 990650 Pin 113362 Pin Slide Lock 109517 Kit Lock Slide Pin Complete Assembly 120640 Pin 55 LIGHT CONSTRUCTION Model Page AL4000 LIGHT TOWER ne WINCH LOCK ASSEMBLY 990080 WASHER FLAT 3 8 WASHER LOCK 981450 SCREW 3 8 16 1 1 2 LONG 990650 COTTER PIN 1 8 x 1 980480 WASHER FLAT 7 8 OD 124860 HANDLE SOCKET RATCHETING NO PART NUT 1 2 13 NYLON LOCK HALF THK 124858
49. te rating when operating at normal load Increase supply voltage or remove external load Improper ballast Proper HID lamps will perform erratically or fail to start on an improper ballast The ballast nameplate data should agree with the line voltage and lamp used Improper ballast will cause lamp to fail Improper lamp operating Operating position should agree with lamp etch ABUHOR position lamp can be operated base up vertical to and including the horizontal and BD can be operated base down and vertical to approaching but not including the horizontal A lamp operated beyond the specified position may not start Lamp has been operating HID lamps require 4 to 8 minutes cool down time before cool down time insufficient restarting Switch off breaker and allow lamp to cool 20 LIGHT FIXTURE TROUBLESHOOTING cont d SYMPTOM CAUSES LAMPSTARTS Defective Lamp SLOWLY ARC DOES NOT STRIKE WHEN SWITCH IS FIRST TURNED ON CIRCUIT Short circuit BREAKER TRIPS ON LAMP START UP LAMP LIGHT Normal lamp depreciation OUTPUTLOW Dirty lamp or fixture Defective ballast Wrong Voltage Improper ballast LAMP COLORS Normallamp depreciation DIFFERENT Dirty fixture Wrong lamp ARC TUBE Over voltage from DISCOLORED power supply OR SWOLLEN Improper ballast CORRECTIVE ACTION Lamp may glow for extended period of time Replace after checking voltage and ballast Checking wiring against diagram Check for shorts Replace lamp Clean lamp a
50. the cord entry is beneath the fixture when the toweris raised this reduces moisture problems and ensures the water weep hole in the fixture is down Set the vertical aim for each light fixture by adjusting the light fixtures and tightening the lower bolt Set the spread between the light fixtures horizontal aiming by adjusting the fixtures and tightening the wing nut The unit may be transported with the light fixtures mounted on the cross arm if they are pointed toward the ground FIXTURE TRAVEL STORAGE BRACKETS T BOLT y TRAVEL LOCKING PIN SCH PIVOT PIN que TELESCOPING LOCKING PIN KICK OUT SPRING VERTICAL LOCKING PIN 22 RAISING THE TOWER refer to drawing above Remove the tower travel locking pin from the cradle at the rear of the cabinet Aim the fixture both horizontally and vertically to the estimated angles that will light the work area Using the winch raise the tower to the vertical position The tower locking pin at the base of the pivot post will lock automatically and you will hear it snap into place Insert manual pin into locking device Release the tension on the cable by backing the winch off slightly and pull the telescoping locking pin on the galvanized tower section Hold this out while turning the winch to raise the tower After the tower has tele scoped slightly the locking pin can be released Raise the tower to the desired height NOT ATTEMPT TO LEAN THE TOWER DOW
51. tion into the round section Install the T locking bolt and the hex nut on the bottom of the round section The hex locking nut should be tightened and then backed off approximately one half turn or until the tower rotates freely Fasten the new cable to the base of the middle section Reversing the procedures detailed in sections 4 4 through 4 7 reinstall the middle section Fasten the new cable to the winch drum Reinstall the plastic shims as described in section 3 3 30 Model Page AL4000 LIGHT TOWER E TEREX LIGHT CONSTRUCTION Cable Replacement Diagram 2 Section Cable 2 Point B 3 Section 4 Section Hat Section Cable 2 Point A Cable 1 Point A 6 Round Tube Cable 1 Point B Winch Tower Base 31 183286 5 16 thk 185290 3 8 thk 3 TOWER SECTION 4 TOWER SECTION 177830 1 4 thk 177830 1 4 thk 177820 5 16 thk 177820 5 16 thk 2 TOWER SECTION 177820 5 16 thk 183288 3 16 thk PLACEMENT as viewed from crossarm end 32 oaus VS86c DMG G86c0M LHVd 16 06 7 ALVA 46 05 104 ANON 31905 A8 dd N d LYN d YOLOANNOO TLV SdH HO HIN WWHDVIC ONIHIM S390 duvHs TIY 1108 2 608 Ud 011 998 TIH PH 069 0103 00 298 _ Ys Y Y YY YO VID 9
52. to the middle of the cable and thus letting the cable twist back tightly around the fish wire If the old cable is frayed cut off the frayed portion and proceed as above and then remove tower and cable as instructed in section 4 6 29 4 6 4 7 4 8 Pass the free end of the cable through the sheave slot between the large and middle sections and out of the top ofthe tower Pull the cable and the middle section completely out of the large section altogether Be sure to keep the cable tight if slack accumulates it is most difficult to remove Ifthe fish wire doesn t work it is necessary to remove the square mast section from the round mast section Remove the pivot pin from the pivot post and lift the mast from the pivot post and place the assembly on a work surface Remove the hex nut from the bottom of the round section remove the bolt at the top of the round section and pull the square mast assembly out of the round section and proceed as instructed in section 4 6 Unfasten the cable by removing the bolt at the base of the middle section 5 REINSTALLING THELOWER CABLE AND MIDDLE SECTION 5 1 5 2 5 3 5 4 5 5 5 6 If the fish wire worked attach the cable to the fish wire and pull through the pulleys and the round section Ifthe square tower section was removed from the round section thread the cable through the pulleys at the bottom ofthe large section and out of the tubular stud Reinstall the large square sec
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