Terex Series AL4000 Operation & Service Manual Download

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OPERATOR’S

MANUAL

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Summary of Contents for Series AL4000

Page 1: ...SERIES AL4000 LIGHT TOWER OPERATION SERVICE MANUAL MAIN MENU D i s c o u n t E q u i p m e n t c o m...

Page 2: ...ie Terex JLG MultiQuip Mayco Toro Stone Diamond Products Magnum Airman Mustang Power Blanket Nifty Lift Atlas Copco Chicago Pneumatic Allmand Brothers Essick Miller Spreader Skyjack Lull Skytrak Tsuru...

Page 3: ...rts 23 31 Engine and Generator Kubota Alpha 32 40 Electrical Box 41 Floodlight Fixtures Ballasts 42 43 Hitches 44 Electric Winch 45 Running Lights 46 Wiring Diagrams Fixture with Joy Connector MH or T...

Page 4: ...OPERATOR S MANUAL D i s c o u n t E q u i p m e n t c o m...

Page 5: ...ving protective covers on high voltage enclo sures Understand that the electrical circuits in this light tower complete their paths back to the generator within the equipment The neutral conductor at...

Page 6: ...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...

Page 7: ...re to keep hands clear of the blower and alternator belts when the engine is running Beware of Traffic Hazards Stand clear of traffic when starting or checking the unit along the road Check the fuel t...

Page 8: ...he following checks A INSURE THERE IS NO FREIGHT HANDLING DAMAGE which should be charged against the carrier B Insure the manuals are in the pocket provided inside the unit C Review the manuals for sa...

Page 9: ...storage and door insulation 5000 5 30 Foot Enhanced Cable Tower 2000 2 Model 5000 with extra corrosion protection LT5000 LT5 30 Foot Deluxe Cable Tower w optional Acoustic Enclosure and Complete Inst...

Page 10: ...n the starting temperatures a com promise must be struck and a higher viscosity oil and fuel used provided they have a suitable specifica tion 2 MIL L 2104B or MIL L 2104C or API CD oils are recommend...

Page 11: ...hadow length D Unit should be level to ensure smooth trouble free tower telescoping Tower may not telescope down properly when unit is not level II UNHITCH FROM THE TOWING VEHICLE AS FOLLOWS A Engage...

Page 12: ...R refer to drawing above A Remove the tower travel locking pin from the cradle at the rear of the cabinet B Aim the fixture both horizontally and vertically to the estimated angles that will light the...

Page 13: ...s handbook E Turn on the main circuit breaker V TURN ON THE FLOODLIGHTS A Turn the circuit breakers ON and check to insure all lamps come on Allow a minimum of two 2 minutes for lamps to reach full lu...

Page 14: ...l jacks must be raised and all outriggers locked into travel position D Insure that the coupler is properly secured to the towing vehicle and attached safety chains if supplied Release any manual brak...

Page 15: ...inch 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...

Page 16: ...A Point A Cable 1 192904 6 Round Tube Point B Cable 1 Tower Base Winch d e f c b a Document Cable Replacement Diagram AL4000 LIGHT TOWER Page Revised By Created 9 5 97 Spectrum c Amida Industries Inc...

Page 17: ...PARTS MANUAL D i s c o u n t E q u i p m e n t c o m...

Page 18: ...IGHT TOWER Trailer Frame Tongue Outriggers Model Page Title 174160 Battery Hold Down 182330 Battery Hold Down Rod 160270 Battery Cable Set 124410 Trailer Frame 124470 Tongue 841430 Jack 840222 Jack Sn...

Page 19: ...4 990200 Lock Nut Model Page Title 188630 Fuel Tank Pan 742220 Fuel Tank 742240 Tank Cap Gauge Spectrum 9 5 97 Document Revised Created c Amida Industries Inc 1997 a b c f e d By AL4000 LIGHT TOWER Fu...

Page 20: ...sy 834225 Grease Seal 834338 Axle 841060 Tire Wheel Mounted 9 5 97 Spectrum By c Amida Industries Inc 1997 Created f c d e b a Revised Document Title Page Model Axle Assy AL4000 LIGHT TOWER 840392 Axl...

Page 21: ...abinet Assy 124420 Ground Rod Storage Tube 188530 Cabinet Front 184150 Winch Handle Bush 188570 Cabinet Roadside Radiator Overflow Bracket 124430 Cabinet Rear 2 189390 Elec Box Mtg Bracket 176370 Lite...

Page 22: ...abinet Assy Model Page Title 2 188560 Cabinet Door Hasp Kit 2 790040 794940 Plastic Plug 188550 Cabinet Top 4 796436 Gas Shock Door Shock 4 796432 Bracket 2 796610 Hinge Ground Rod 111368 720220 Bumpe...

Page 23: ...3301 853301 851640 853296 853312 852410 851860 853730 850090 2 841710 853291 853301 853291 www terex com 850135 Spectrum 9 5 97 Document Revised Created c Amida Industries Inc 1997 a b c f e d By AL40...

Page 24: ...ectrum c Amida Industries Inc 1997 See 2 Section d e f c b a Document Tower Assy AL4000 LIGHT TOWER Page Title Model See 3 Section See 4 Section See 6 Round Tube 113080 Coil Cord Sleeve 23 D i s c o u...

Page 25: ...3 790520 Cable Sleeve 990760 R Pin 120640 Pin 990650 Cotter Pin Spring 790710 980340 Screw Shim 177810 Model Page Title See 6 Round Tube Spectrum 9 5 97 Document Revised Created c Amida Industries Inc...

Page 26: ...n 995780 Clevis Pin 183285 Shim See Orientation Below 2 994920 Cotter Pin Cotter Pin 2 990650 188760 Sheave d e f c b a Document 4 Tower Sec Upr Sheave Shim Assy AL4000 LIGHT TOWER Page Revised By Cre...

Page 27: ...n 2 994920 990650 Cotter Pin Sheave 188760 192904 Cable Orientation of Shims Inside Tube 3 177820 5 16 Shim 185290 3 8 Shim Title Model d e f c b a Document 3 Tower Section AL4000 LIGHT TOWER Page Rev...

Page 28: ...um 9 5 97 Document Revised Created c Amida Industries Inc 1997 a b c f e d By AL4000 LIGHT TOWER 2 Section Model Page Title 990470 Lock Washer 190570 Cable 124560 2 Tower Section 27 D i s c o u n t E...

Page 29: ...rum c Amida Industries Inc 1997 4 See Fixture Assembly d e f c b a Document Tower Crossarm Fixture AL4000 LIGHT TOWER Page 113040 Cross Arm Cross Arm Mounting Plate 4 123080 Fixture Mounting Wing Nut...

Page 30: ...TOWER 6 Round Tube 990610 Tee Bolt 6 Round Tube 124530 Clevis Pin 992765 995790 Clevis Pin Sheave 188760 Cotter Pin 994920 Cotter Pin 990650 Lock Nut 990620 Model Page Title Clevis Pin Bushing 179850...

Page 31: ...L4000 LIGHT TOWER Page Title Model Revised By Created 9 5 97 Spectrum c Amida Industries Inc 1997 113040 Crossarm 116220 Tower Assy w Cables 116170 Tower Base 740050 Winch 1500 124480 Winch Handle 30...

Page 32: ...da Industries Inc 1997 d e f c b a Document Tower Base Assy AL4000 LIGHT TOWER Page 193750 Kick Out Spring 186360 Bumper Pad 184510 Spool Sheave 120220 Pin Slide Lock 124480 Winch Handle 740050 Manual...

Page 33: ...elt 866110 Radiator 741140 Temp Sender 866120 Radiator Cap 865223 Electric Fuel Pump 866040 Gasket Mounted to Trailer Frame Spectrum 9 5 97 Document Revised Created c Amida Industries Inc 1997 a b c f...

Page 34: ...836830 O Ring 836828 Rear Bearing d e f c b a Document Genset Kub D905 L S 6KW AL4000 LIGHT TOWER Page Revised By Created 9 5 97 Spectrum c Amida Industries Inc 1997 866090 Alternator Title Model 866...

Page 35: ...AL4000 LIGHT TOWER Page Title Model Revised By Created 9 5 97 Spectrum c Amida Industries Inc 1997 2 990820 Bolt 4 990210 Flat Washer 189335 Generator Mounting Bar 2 990200 Lock Nut 630910 Generator...

Page 36: ...da Industries Inc 1997 a b c f e d By AL4000 LIGHT TOWER Right Side Radiator Engine Mtg Bracket 4 994830 Lockwasher 4 R980175 Flat Washer Engine Block 189290 Engine Mounting Bracket Radiator Mounting...

Page 37: ...d e f c b a Document Fuel Filter AL4000 LIGHT TOWER Page Title Model Revised By Created 9 5 97 Spectrum c Amida Industries Inc 1997 866080 Kubota Fuel Filter 36 D i s c o u n t E q u i p m e n t c o m...

Page 38: ...10 Radiator Spectrum 9 5 97 Document Revised Created c Amida Industries Inc 1997 a b c f e d By AL4000 LIGHT TOWER Radiator Overflow Tank 975014 Overflow Tank 866120 Radiator Cap 37 D i s c o u n t E...

Page 39: ...4 025 027 026 028 029 030 031 016 035 037 036 034 033 032 GENSET ALPHA LPA3 L S AL4000 WW 2 8 96 9609 003 DWG NO DATE BY DRWN PARTS IDENTIFICATION DRAWING 008 004 005 006 007 009 013 001 GENSET ASSEMB...

Page 40: ...E AIR CLEANER DON HOOD EXT 2X4 5 EA AIR CLEANER HOOD GAX00 2018 PAINT 4628G EA DONALDSON P10 3198 A C VACUATOR VALVE EA AS AIR CLEANER BRACKETALPHA L S 3602 AL4000 EA AIR CLEANER ELBOWS P10 5529 90HL2...

Page 41: ...HF90 EA LISTER 751 40620 GLOW PLUG EA LISTER 750 40310 GLOW PLUG RELAY EA LISTER 570 32390 ALPHA HI TEMP SWITCH EA LISTER 750 13710 STARTER ALPHA LPA3 EA LISTER 750 11740 ALTERNATOR ALPHA LPA3 EA LIST...

Page 42: ...Receptacle 186801 Control Box Top 186730 Control Box Rear 683970 Mini Breaker 684640 Duplex Receptacle W GFI 260360 Hour Meter 684380 Switch R660010 Push Button Switch 682715 Light R661490 Relay 6638...

Page 43: ...BL FIXTURE CSA NRTL C WASHER 1 2 EXTER TOOTH LOCK SS LBL 105C SUPPLY COND 833581 833582 833583 4110953000 690 0121 791 2397 FIBER WASHER FIBERGLASS SLEEVE 2 1 2 LBL WET LOCATION EXTERIOR WASHER 1 4 X...

Page 44: ...1997 114355 Ballast Box MH d e f c b a Document Ballast AL4000 LIGHT TOWER Page Title Model 114895 Ballast Box HPS 160040 Balast HPS 160030 Ballast MH 160042 Capacitor HPS 160032 Capacitor MH 663860 5...

Page 45: ...Document a b c f e d 840120 Coupler 2 213770 Ring Hitch 176335 Plate 176336 Spacer 840470 Ball 2 121572 Combo Hitch Ring 211410 Ring Hitch for Adj Height 841200 Hitch Pintle Ring 3 I D 124450 Hitch 24...

Page 46: ...RT OPTION DWG ITEM 0LTX0690 DESCRIPTION WINCH ELEC 12V DC STD AL4000 LT5000 BLB 2 8 96 001 002 003 004 160992 113583 160993 663780 WINCH 12V WINCH SWITCH W SOLENOID ASS Y WINCH SOLENOID WINCH TOGGLE S...

Page 47: ...ITEM DRAWING NO DATE DRAWN BY OPTION 0LTX0080 STOP TAIL TURN LIGHT AND LICENSE TAG LIGHT 8126 001 8126 002 663510 663520 STOP TAIL TURN LIGHT LICENSE TAG LIGHT W BRACKET CNM 4 4 91 8126 46 D i s c o u...

Page 48: ...S FIXTURE W JOY CONNECTOR 4 30 91 WD2985 2985A REQ DESCRIPTION PART ITEM DWG PART ECO REV DATE CHANGE DR BY SCALE PART DWG MATL MAT P N BORDER B REMOVE ALL BURRS SHARP EDGES XXXX 005 Decimals XX 030 X...

Page 49: ...PART ITEM DWG PART ECO REV DATE CHANGE DR BY CNM SCALE NONE PART DWG MATL MAT P N BORDER B REMOVE ALL BURRS SHARP EDGES XXXX 005 Decimals XX 030 XXX 010 Degrees 1 2 Fractions 1 16 WD2986 2986 MATL WD2...

Page 50: ...30 91 MAT P N MATL PART DR BY CNM ECO DATE 4 30 91 USAGE WD2987 SCALE NONE DWG BORDER 2987 A ITEM PART WD2987 PART DWG 2987 DESCRIPTION REQ 1000W HIGH PRESSURE SODIUM BALLAST IGNITOR 450V 26uF C1 GROU...

Page 51: ...RECEPTACLES 120V 15AMP 10 RED GRN YEL ORN BLUE WHITE RED BLK RECEPTACLE BOX AT TOP OF TOWER 7 CONDUCTOR RETRACTABLE CORD 3 POLE RECEPTACLE TYP 4 BALLAST BALLAST BALLAST BALLAST 1 2 3 4 240V 30 AMP REC...

Page 52: ...D DIODE FOR FUEL PUMP PRIME MAT P N PLOT B 3 23 00 DATE 3 23 00 TOLERANCES UNLESS OTHERWISE SPECIFIED APP BY DR BY JCS FUEL SOLENOID BATTERY 12 VOLT GLOW PLUGS B HOLD PULL COM ACC BAT IGN ST ST STARTE...

Page 53: ...m 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 lb 1588 kg Tongue weight travel position 100 lb 45 4...

Page 54: ...RNING CAUTION 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 There is more current availabl...

Page 55: ...5 28 10 26 32 22 27 40 45 1 4 75 94 64 80 7 9 12 14 5 16 12 Nov 14 Dec 15 17 23 26 3 8 20 22 22 24 28 34 45 50 7 16 31 33 32 35 40 45 70 75 1 2 43 45 45 50 75 85 70 80 100 110 95 105 9 16 57 63 60 65...

Page 56: ...FROM 12 O CLOCK 78 MPH FROM 1 11 O CLOCK 83 8 MPH FROM 2 10 O CLOCK 92 MPH FROM 3 9 O CLOCK 66 MPH FROM 4 8 O CLOCK 62 MPH FROM 5 7 O CLOCK 84 MPH FROM 6 O CLOCK 90 MPH NOTE If optional front outrigge...

Page 57: ...the base of the small section 3 REINSTALLING THE SMALL SECTION 3 1 Fasten new cable to the base of the small section 3 2 Reversing the procedure described in steps 2 1 through 2 5 reinstall the small...

Page 58: ...he cable by removing the bolt at the base of the middle section 5 REINSTALLING THE LOWER CABLE AND MIDDLE SECTION 5 1 If the fish wire worked attach the cable to the fish wire and pull through the pul...

Page 59: ...nspect 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 loo...

Page 60: ...uld be within 10 of nameplate rating Check wiring connections for voltage loss Check socket contact point Improper ballast Check ballast nameplate against lamp data LAMP COLORS Normal lamp depreciatio...

Page 61: ...improper ballast is used the lamp life will be shortened A mismatch may also cause the ballast to fail LAMP Improper ballast Improper ballasting can cause flickering or erratic operation FLICKERS AND...

Page 62: ...allasts 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 appropriat...

Page 63: ...0 If the bearing can be moved easily inside the carrier or if there is visible evidence of bearing carrier wear the housing carrier should be replaced with End Kit 836835 which includes the carrier be...

Page 64: ...LEROY LEROY SOMERS LSA37 SOMERS LSA37 D i s c o u n t E q u i p m e n t c o m...

Page 65: ...PERFORMANCE PERFORMANCE l Brushless l 4 Pole design l Self excited with capacitors l 5 voltage regulation at constant speed l Inherent overvoltage protection D i s c o u n t E q u i p m e n t c o m...

Page 66: ...OF OPERATION l The capacitor s produce the no load excitation for the unit l The rotor magnetic field is produced by the current flowing through the rotating diodes and the main field winding D i s c...

Page 67: ...WIRING WIRING D i s c o u n t E q u i p m e n t c o m...

Page 68: ...TERMINAL BOX LAYOUT TERMINAL BOX LAYOUT Capacitor Terminal Block D i s c o u n t E q u i p m e n t c o m...

Page 69: ...CONSTRUCTION CONSTRUCTION D i s c o u n t E q u i p m e n t c o m...

Page 70: ...REVOLVING FIELD REVOLVING FIELD Rotating Diodes Balancing weights Revolving field D i s c o u n t E q u i p m e n t c o m...

Page 71: ...l Correct voltage at no load but incorrect under load Suspect a rotating diode problem l Wrong voltage Suspect an engine RPM problem l Note As a general rule it is more cost effective to replace the u...

Page 72: ...engine RPM is set properly The output voltage is proportional with the speed and a voltage too high across the capacitor terminals will shorten its life l Make sure the wavy washer is located properl...

Page 73: ...ral Information Parts list Trouble Shooting Assembly Brochures Technical Catalog O M Manuals AutoCAD drawings Data Sheets Outline Drawings Technical Catalog DOCUMENTATION DOCUMENTATION D i s c o u n t...

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Terex Series AL4000, Operation & Service Manual

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