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Terex AL8000HT, Service Manual

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Terex AL8000HT Service Manual Download Page 58

Section 4 • Repair Procedures

REV A

4 - 6

AL8000HT Light Tower

Part No. 116478

September 2008

Tower Components

a

tower extension cylinder

b

light bar

c

light bar cylinder

d

light bar lever

e

light bar link

f

tower tube number 3

g

tower tube number 2

h

tower tube number 1

i

tower lift cylinder

j

tower rotation riser

Summary of Contents for AL8000HT

Page 1: ...Service Manual First Edition Rev A Part No 116478 September 2008 AL8000HT TM...

Page 2: ...ized Terex dealer service center Technical Publications Terex has endeavored to deliver the highest degree of accuracy possible However continuous improvement of our products is a Terex policy Therefo...

Page 3: ...September2008 PartNo 116478 AL8000HTLightTower Serial Number Legend iii How to Read Your Serial Number...

Page 4: ...dentified in the operator s manual are also safety hazards when maintenance andrepairproceduresareperformed Do Not Perform Maintenance Unless You are trained and qualified to perform maintenance on th...

Page 5: ...ear and other protective clothing if the situation warrants it Be aware of potential crushing hazards such as moving parts free swinging or unsecured components when lifting or placing loads Always we...

Page 6: ...ations 2 2 HydraulicComponentSpecifications 2 2 ManifoldComponentSpecifications 2 3 KubotaD1105 EEngine 2 4 Kubota V1505 E Engine 2 5 Isuzu 4LE1 Engine 2 6 GeneratorSpecifications 2 7 Hydraulic Hose a...

Page 7: ...3 14 B 3 Inspect the Tires and Wheels including lug nut torque 3 15 B 4 Perform Hydraulic Oil Analysis 3 15 B 5 Perform Engine Maintenance Isuzu Models 3 16 B 6 PerformGeneratorMaintenance 3 16 B 7 P...

Page 8: ...Models 3 28 E 3 Perform Engine Maintenance Kubota Models 3 29 E 4 PerformGeneratorMaintenance 3 29 E 5 PerformGeneratorMaintenance 3 30 Section 4 Rev RepairProcedures Introduction 4 1 A Lighting 1 1 L...

Page 9: ...end 6 2 A HydraulicSymbolsLegend 6 3 A Electrical Schematic Machine Functions 6 4 A DC Electrical Schematic Control Box and Engine Isuzu Models 6 5 A DC Electrical Schematic Control Box and Engine Kub...

Page 10: ...uzu Models Oil Filter 868075 Air Filter 834460 Fuel Filter 868137 V belt 868067 Parts Stocking List Manuals TEREX Corporation offers the following manuals for these models Title Part No TEREX AL8000HT...

Page 11: ...ordernumber Ship to address Desired method of shipment Name and telephone number of the authorized TEREX Distributor in your area Use the Service Parts Fax Order Form on the next page and fax your ord...

Page 12: ...________________________________ ___________________________________ _________________________________ ___________________________________ _________________________________ ___________________________...

Page 13: ...re maximum cold 75 psi 5 2 bar Specifications Performance Specifications Tongue weight maximum 350 lbs 159 kg Run time full load Kubota D1105 8kW 82 Gallons per hour Single full fuel tank 36 5 hours D...

Page 14: ...Tellus T32 Shell Tellus T46 Chevron Aviation A Continued use of Chevron Aviation A hydraulic fluid when ambient temperatures are consistently above 32 F 0 C may result in componentdamage Note Use Che...

Page 15: ...ur air temperature increases or decreases from 68 F 20 C Valve coil specifications 3 position 4 way solenoid valve 10V DC 6 schematic items B C E and G Machine Torque Specifications Tower rotation ass...

Page 16: ...uding filter 5 1 liters Oil pressure switch 7 psi engine shutoff pressure Oil viscosity requirements Units ship with 10W 30 Extreme operating temperatures may require the use of alternative engine oil...

Page 17: ...28 to 64 psi 1 93 to 4 41 bar Oil capacity 7 08 quarts including filter 6 7 liters Oil pressure switch 7 psi engine shutoff pressure Oil viscosity requirements Units ship with 10W 30 Extreme operating...

Page 18: ...ty requirements Units ship with 10W 30 Extreme operating temperatures may require the use of alternative engine oils For oil requirements refer to the Engine Operating Instructions on your machine Eng...

Page 19: ...SA5412 Generator Generator rpm full load 60 Hz 1800 rpm Temperature ambient maximum 104 F 40 C Power 8 kW Newage BCI164D1J195A Generator Generator rpm full load 60 Hz 1800 rpm Temperature ambient maxi...

Page 20: ...1 Nm Seal Lok Fittings hose end SAE Dash size Torque 4 18 ft lbs 25 Nm 6 30 ft lbs 40 Nm 8 40 ft lbs 55 Nm 10 60 ft lbs 80 Nm 12 85 ft lbs 115 Nm 16 110 ft lbs 150 Nm 20 140 ft lbs 190 Nm 24 180 ft l...

Page 21: ...IZE THREAD in lbs Nm in lbs Nm in lbs Nm in lbs Nm in lbs Nm 20 80 9 100 11 3 110 12 4 140 15 8 130 14 7 28 90 10 1 120 13 5 120 13 5 160 18 140 15 8 ft lbs Nm ft lbs Nm ft lbs Nm ft lbs Nm ft lbs Nm...

Page 22: ...September2008 2 10 AL8000HTLightTower PartNo 116478 Generator FT LB Flex Plate to Flywheel 25 Generator Case to Bellhousing 25 Genset Isolators 75 GENSET TORQUE SPECIFICATIONS...

Page 23: ...parked on a firm level surface Key switch in the off position manual start models Toggle switch in the off position automatic start models Mast in the stowed position Light switches in the off positio...

Page 24: ...tion report to use for each inspection Store completed forms asrequired MaintenanceSchedule There are five types of maintenance inspections that must be performed according to a schedule daily quarter...

Page 25: ...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...

Page 26: ...Section 3 Scheduled Maintenance Procedures 3 4 AL8000HTLightTower PartNo 116478 September2008 This page intentionally left blank...

Page 27: ...ce Perform after 50 miles A 6 Axle maintenance Perform after 40 hours A 7 30 day service Perform every 50 hours A 8 Engine maintenance Perform weekly A 9 Hitch maintenance Perform every 100 hours A 10...

Page 28: ...ace a check in the R box Legend Y yes acceptable N no remove from service R repaired Model Serial number Date Hour meter Machine owner Inspected by print Inspector signature Inspector title Inspector...

Page 29: ...or hazard and could result in unsafe operating conditions 1 Check to make sure that the operator s and safety manuals are present and complete in the storage container inside the cabinet 2 Examine th...

Page 30: ...ction also serves to determine if routine maintenance proceduresarerequired Complete information on how to perform this procedure is available in the appropriate Operator s Manual Refer to the Operato...

Page 31: ...rator Maintenance Note Generator specifications require that this procedure be performed every 8 hours or daily whichever comes first Requiredmaintenanceproceduresandadditional generator information i...

Page 32: ...fe Failure to perform the maintenance procedures can lead to pooraxleperformanceandcomponentdamage Requiredmaintenanceproceduresandadditional axle information is available in the Axis Axle OperatorMai...

Page 33: ...e Instruction Manual Isuzu part number IDE 6033 OR the KubotaD 1105andV 1505Operator sManual Kubotapartnumber16683 89169 Isuzu 4LE1 Diesel Engine Instruction Manual Terex part number 116133 Kubota D 1...

Page 34: ...and level the machine 2 Remove the tower transport lock pin 3 Raise the tower to a vertical position 4 Locate the grease fitting on the inner race of the bearing 5 Pump grease into the tower rotation...

Page 35: ...the KubotaD 1105andV 1505Operator sManual Kubotapartnumber16683 89169 Kubota D 1105 and V 1505 Operator s Manual Terex part number 893020 A 12 Perform Engine Maintenance Kubota Models Note Engine spe...

Page 36: ...generator area for burnt chafed corroded pinched and loose wires and and for a liberal coating of dielectric grease in the harness connections Checklist B Procedures B 1 Inspect the Battery Note Terex...

Page 37: ...usual wear 2 Check each wheel for damage bends and cracked welds 3 Check each lug nut for proper torque Refer to Section 2 Specifications 4 Check the air pressure of each tire Refer to Section 2 Speci...

Page 38: ...Generator specifications require that this procedure be performed every 250 hours or quarterly whichever comes first Requiredmaintenanceproceduresandadditional generator information is available in t...

Page 39: ...eduresandadditional engine information is available in the KubotaD 1105andV 1505Operator sManual Kubotapartnumber16683 89169 Kubota D 1105 and V 1505 Operator s Manual Terex part number 893020 B 9 Per...

Page 40: ...Section 3 Scheduled Maintenance Procedures 3 18 AL8000HTLightTower PartNo 116478 REV A September2008 This page intentionally left blank...

Page 41: ...horizontal direction Tip over hazard The machine will tip over when the tower is extended if the outriggers are not lowered to the ground 4 Visually inspect the cables and components for thefollowing...

Page 42: ...e maintenance procedures can lead to pooraxleperformanceandcomponentdamage Requiredmaintenanceproceduresandadditional axle information is available in the Axis Axle OperatorMaintenanceManual includedw...

Page 43: ...bota Models Note Engine specifications require that this procedure be performed every 800 hours Requiredmaintenanceproceduresandadditional engine information is available in the KubotaD 1105andV 1505O...

Page 44: ...020 D 2 Check the Tower Rotation Bearing Bolts Note Terex requires that this procedure be performed every 1000 hours or annually whichever comes first Maintaining proper torque on the tower rotation b...

Page 45: ...ire that the filter be replaced more often Bodily injury hazard Beware of hot oil Contact with hot oil may cause severeburns 1 Open the road side cabinet cover and locate the hydraulic return filter n...

Page 46: ...s available in the Isuzu 4LE1 Diesel Engine Instruction Manual IsuzupartnumberIDE 6033 Isuzu 4LE1 Diesel Engine Instruction Manual Terex part number 116133 CHECKLIST D PROCEDURES D 5 Perform Engine Ma...

Page 47: ...er 893020 CHECKLIST D PROCEDURES D 7 Perform Generator Maintenance Note Generator specifications require that this procedure be performed every 1500 hours or annually whichever comes first Requiredmai...

Page 48: ...part number 150140 CHECKLIST D PROCEDURES D 9 Perform Axle Maintenance Note Axle specifications require that this procedure be performed annually or every 12 000 miles which ever comes first Proper a...

Page 49: ...pen both cabinet covers 2 Tag and disconnect the battery cables from the battery Electrocution hazard Contact with electrically charged circuits could result in death or serious injury Remove all ring...

Page 50: ...the top with the cylinders collapsed 16 Clean up any oil that may have spilled Properly discard the used oil 17 Operate all machine functions through a full cycle and check for leaks 18 Operate all ma...

Page 51: ...ons require that this procedure be performed every 4500 hours or every 3 years whichever comes first Requiredmaintenanceproceduresandadditional generator information is available in the Leroy Somer LS...

Page 52: ...rator information is available in the Leroy Somer LSA 37 Installation and MaintenanceManual LeroySomerpartnumber 3664EN 09 2005 B ORthe MarathonInstallation OperationandMaintenance Manual Marathon par...

Page 53: ...ls Mast in the stowed position Light switches in the off position Wheelschocked About This Section Most of the procedures in this section should only be performed by a trained service professional in...

Page 54: ...nd a lamp when installing a lamp into a lamp socket How to Check Line Voltage Correct line voltage at the lamp socket is essential for proper operation of the lighting system Electrocution hazard Expo...

Page 55: ...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 e...

Page 56: ...curing each junction box to the light bar 4 Remove the hose and cable clamp retaining fasteners from the light bar and remove the clamp Lay the hydraulic hoses and main power cables with junction boxe...

Page 57: ...tting and or hose end must be replaced and then torqued to specification during installation Refer to Section 2 Hydraulic Hose and Fitting Torque Specifications 1 Tag disconnect and plug the light bar...

Page 58: ...er PartNo 116478 September2008 Tower Components a tower extension cylinder b light bar c light bar cylinder d light bar lever e light bar link f tower tube number 3 g tower tube number 2 h tower tube...

Page 59: ...e 3 2 Tower Assembly How to Remove the Tower Assembly Bodily injury hazard The procedures in this section require specific repair skills lifting equipment and a suitable workshop Attempting this proce...

Page 60: ...y remove the tower assembly from the machine and place it on a structure capable of supporting it Crushinghazard Thetower assembly could become unbalanced and fall when removed from the machine if not...

Page 61: ...a lifting strap from an overhead crane to the number 2 and 3 tower tubes 12 Support and slide the number 2 and 3 tower tubes out of the number 1 tower tube and place them on a structure capable of sup...

Page 62: ...ng 3 3 Tower Lift Cylinder How to Remove the Tower Lift Cylinder The tower lift cylinder raises and lowers the tower assembly The tower lift cylinder is equipped with counterbalance valves to prevent...

Page 63: ...connect and plug the tower extension cylinder hydraulic hoses Cap the fittings on the cylinder Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very...

Page 64: ...cklash TOWERCOMPONENTS How to Adjust the Tower Rotation Gear Backlash The rotation motor mounting fasteners are located in slotted holes to allow the adjustment of gear backlash between the motor pini...

Page 65: ...than 1 The glow plug is faulty 4 3 Coolant Temperature and Oil Pressure Switches The engine coolant temperature switch is a normally open switch The switch contacts close at approximately 225 F 107 C...

Page 66: ...low plug is faulty 5 3 Coolant Temperature and Oil Pressure Switches The engine coolant temperature switch is a normally open switch The switch contacts close at approximately 221 F 105 C If the coola...

Page 67: ...ctrical 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 wi...

Page 68: ...ith the ground 2 Raise the tower to a vertical position Do not extend the tower or raise the light bar Turn the machine off 3 Open each cabinet door Remove the hinge retaining fasteners from the cabin...

Page 69: ...oved from the machine How to Remove the Generator Newage Generator Models Electrocution hazard Exposure to high voltage electrical wires or electrical current will result in death or serious injury Re...

Page 70: ...e a lifting jack or similar device to support the rear of the engine Do not apply any lifting pressure 16 Remove the generator fan screens from both sides of the generator Note The generator fan scree...

Page 71: ...bellhousing 21 Remove the generator from the machine Crushinghazard Thegeneratorwill fall if not properly supported when removed from the machine 3 Using the tip of a pencil or pen press the Reset but...

Page 72: ...located under another ballast box the top ballast box will need to be removed first CHASSISCOMPONENTS 3 Remove the ballast box cover fasteners 4 Using an insulated conductor or a screwdriver with an...

Page 73: ...ith step 2 for the other fuel tank 3 Tag disconnect and plug the fuel hoses from the fuel tank Clean up any fuel that may have spilled CHASSISCOMPONENTS Models without fuel containment option 4 Suppor...

Page 74: ...he fasteners securing the fuel tank containment weldment to the chassis 6 Carefully lower the fuel tank out of the chassis and remove it from the machine Remove the fuel tank from the fuel containment...

Page 75: ...25 ft lbs 34 Nm 2 Solenoid valve 3 position 4 way C Tower extend retract 25 ft lbs 34 Nm 3 Solenoid valve 3 position 4 way B Tower up down 25 ft lbs 34 Nm 4 Relief valve Bi directional 1200 psi 82 7...

Page 76: ...hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 2 Connect a 0 to 5000 psi 0 to 350 bar pressure gauge to the P port of the functi...

Page 77: ...with high voltage electrical components Electrocution hazard Attempting to sevice the machine before the capacitors are fully discharged will result in death or serious injury Electrocution hazard Exp...

Page 78: ...t extend cylinder 3 Engine will not turn over a Dead battery a Check the battery voltage or loose cables b Bad starter b Check voltage at starter and replace as needed 4 Engine turns over but will a E...

Page 79: ...Burned out bulb c Replace the bulbs as needed d Defective generator capacitor d Have a trained electrician inspect Leroy Somers Marathon Generator the capacitor e Defective AC generator e Have a trai...

Page 80: ...xcessive heat d Wrong voltage d Check line voltage at ballast input Voltage should be within 10 of e Improper ballast e Check ballast name plate against lamp data 15 Lamp colors different a Normal lam...

Page 81: ...urned out power cable Light Fixture Troubleshooting IF YOU FEEL AN ELECTRIC SHOCK AT ANY TIME WHILE OPERATING THIS UNIT SHUT IT DOWN IMMEDIATELY HAVETHEUNITINSPECTEDBYATRAINEDELECTRICIAN THISENGINE GE...

Page 82: ...Section 5 Troubleshooting 5 6 AL8000HTLightTower PartNo 116478 REV A September2008 This page intentionally left blank...

Page 83: ...ssary tools and test equipment are available and ready for use About This Section There are two groups of schematics in this section An illustration legend precedes each group of drawings ElectricalSc...

Page 84: ...5A CB1 Coil solenoid or relay Power relay PR1 Toggle switch SPDT TS2 START ENGINE Toggle switch DPDT TS6 UP DOWN PLATFORM LEVEL HM Hour meter N O CTS1 Coolant temperature switch normally open Oil pres...

Page 85: ...cylinder Priority flow regulator valve Filter with bypass valve relief setting 25 psi 1 7 bar E Pump prime mover engine or motor Relief valve with pressure setting 200 psi 13 8 bar Orifice with size...

Page 86: ...H BLK WH GR BLK GR BLK WH BLK RED BLK RED PUMP MOTOR CONTACTOR LIFT PUMP MOTOR STOWED LIMIT SWITCH FUSE 30A UP DOWN TOWER EXTEND RETRACT TOWER UP DOWN LIGHT BAR RIGHT LEFT TOWER ROTATE TOWER ROTATE RI...

Page 87: ...Section 6 Schematics September2008 PartNo 116478 AL8000HTLightTower 6 5 REV A DC Electrical Schematic Control Box and Engine Isuzu Models...

Page 88: ...Section 6 Schematics September2008 6 6 AL8000HTLightTower PartNo 116478 REV A DC Electrical Schematic Control Box and Engine KubotaModels...

Page 89: ...Section 6 Schematics September2008 PartNo 116478 AL8000HTLightTower 6 7 REV A DC Electrical Schematic Control Box and Engine with Autostart Option...

Page 90: ...Section 6 Schematics September2008 6 8 AL8000HTLightTower PartNo 116478 REV A AC Electrical Schematic Standard Models with 4 Lights...

Page 91: ...Section 6 Schematics September2008 PartNo 116478 AL8000HTLightTower 6 9 REV A AC Electrical Schematic Standard Models with 6 Lights...

Page 92: ...Section 6 Schematics September2008 6 10 AL8000HTLightTower PartNo 116478 REV A AC Electrical Schematic Standard Models with 8 Lights...

Page 93: ...Section 6 Schematics September2008 PartNo 116478 AL8000HTLightTower 6 11 REV A AC Electrical Schematic Autostart Models with 4 Lights...

Page 94: ...Section 6 Schematics September2008 6 12 AL8000HTLightTower PartNo 116478 REV A AC Electrical Schematic Autostart Models with 6 Lights...

Page 95: ...Section 6 Schematics September2008 PartNo 116478 AL8000HTLightTower 6 13 REV A AC Electrical Schematic Autostart Models with 8 Lights...

Page 96: ...Section 6 Schematics September2008 6 14 AL8000HTLightTower PartNo 116478 REV A Receptacle Wiring Diagrams Standard Receptacle Package Extra GFCI Receptacle Package Enhanced Receptacle Package...

Page 97: ...Section 6 Schematics September2008 PartNo 116478 AL8000HTLightTower 6 15 REV A Hydraulic Schematic...

Page 98: ...Section 6 Schematics September2008 6 16 AL8000HTLightTower PartNo 116478 REV A This page intentionally left blank...

Page 99: ......

Page 100: ...9 0 4202 8852 20 Genie U K Phone 44 0 1476 584333 Fax 44 0 1476 584334 Genie Mexico City Phone 52 55 5666 5242 Fax 52 55 5666 3241 Before Driving On The Road Before Towing Boom hold down latch is secu...

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