Terex 833002 Operator, Service & Parts Manual Download

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November 2006

Part No. 833002 Rev A

AL4000 Light Tower

OPERATOR/SERVICE

& PARTS MANUAL

Series AL4000D2

Light Tower

P.O. BOX 3147

ROCK HILL, S.C. 29732 USA

PART NUMBER 833002

REVISION A

November 2006

TOLL FREE

800-433-3026

FAX (Parts Dept)

800-633-5534

Summary of Contents for 833002

Page 1: ...833002 Rev A AL4000LightTower 1 OPERATOR SERVICE PARTS MANUAL Series AL4000D2 Light Tower P O BOX 3147 ROCK HILL S C 29732 USA PART NUMBER 833002 REVISION A November 2006 TOLL FREE 800 433 3026 FAX Pa...

Page 2: ...28 32 Warrranty 33 34 Serial Number Record 35 Model Number Identification 36 Recomended Oil 37 Wire Rope Replacement 38 42 PARTS MANUAL Wiring Diagrams 44 50 General Information Parts Manual 52 Parts...

Page 3: ...d Tower BaseAssembly 70 WinchAssembly 72 Engine GensetAssembly 74 RadiatorAssembly 75 Radiator Mounting Bracket 76 Generator Mounting Bar 77 Electrical Control BoxAssembly 78 MH HPS Light FixtureAssem...

Page 4: ...SO THOSE WORKING AROUND YOU MAKE THIS MANUAL A WORKING PART OF YOUR SAFETY PROGRAM An operator should never use drugs alcohol or any other substance which can change his alertness or coordination Do n...

Page 5: ...AGE UNDERSTANDING SIGNAL WORDS A signal word DANGER WARNING or CAUTION is used with the safety alert symbol DANGER Identifies the hazard or unsafe practice that will result in severe injury or death W...

Page 6: ...ing 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 an...

Page 7: ...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...

Page 8: ...me Ground wires within the system are also bonded to the equipment frame Always ground the unit when possible Consult local electrical codes for grounding instructions A grounding lug has been added t...

Page 9: ...immediately flush under running water and obtain medical attention METAL HALIDE LAMPS PRODUCE SHORTWAVE ULTRAVIO LET RADIATION AND CAN CAUSE SERIOUS SKIN AND EYE BURNS OR INFLAMMATION IF THE OUTER EN...

Page 10: ...are tight and nothing is in danger of falling off during transit Be careful when lifting Never suspend any other equipment from the shipping tie downs BEWARE OF TRAFFIC HAZARDS Use the lifting eye or...

Page 11: ...ration Check the outriggers for security and proper operation Check that the tires are not damaged under inflated or that any lugs are loose Check the engine generator for obvious damage loose connect...

Page 12: ...ck into its stowed position 4 Check the tires for proper inflation 32psi and verify the lug nuts are tight 5 Position all outriggers and jacks into the stowed or travel position 6 Verify that the fixt...

Page 13: ...n an incline C Disconnect the towing chain D Unhitch from the towing vehicle as follows 1 Rotate the tongue jack into position 90 degrees release the hitch pin and raise the tongue off the towing vehi...

Page 14: ...ures the water weep hole in the fixture is down 3 Set the vertical aim for each light fixture by adjusting the light fixtures and tightening the lower bolt Never adjust fixtures with power on 4 Set th...

Page 15: ...rtical position Reinsert the tower locking pin into the tower base If there is any difficulty in tilting the boom vertically check the tailhook and hook The tailhook may need to be released BEWARE OF...

Page 16: ...WINCH THE WINCH SHOULD NOT ALLOW THE TOWER TO DROP DOWN WHEN THE HANDLE IS RELEASED UNDER NO CIRCUMSTANCES SHOULD THE LIGHT TOWER BE MOVED WHEN THE BOOM IS IN A VERTICAL POSITION 3 Release the tower...

Page 17: ...ngth D Unit should be level to insure smooth trouble free tower telescoping Tower may not telescope down properly when unit is not level 2 Unhitch from the towing vehicle as follows A Engage the trail...

Page 18: ...nted toward the ground 6 Raising the tower refer to drawing above A Remove the tower travel locking pin from the cradle at the rear of the cabinet B Aim the fixtures both horizontally and vertically t...

Page 19: ...rn the ignition switch to the START position to engage the engine After the engine starts release the switch so that it returns to the RUN position Let the engine come up to speed and stabilize review...

Page 20: ...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 E Tighten rotating lock F Pull the vertical locking pin...

Page 21: ...h 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 dist...

Page 22: ...t levels and fill as required Note Use a 50 solution of water and antifreeze for the engine coolant Weekly Check the air cleaner and clean as required Inspect the radiator fins for damage or clogging...

Page 23: ...RY OR DEATH BY ELECTRIC SHOCK Exterior Cleaning 1 The exterior housing may be washed by most conventional cleaners and methods 2 The exterior housing may be waxed using any conventional automotive wax...

Page 24: ...roken replace IMMEDIATELY Ratchet pawl should click when tower is raised and not when it is lowered Always be alert for any fraying of ca bles and replace any damaged cables IMMEDIATELY Never stand un...

Page 25: ...November2006 Part No 833002 Rev A AL4000LightTower 25 SPECIFICATIONS DIMENSIONS...

Page 26: ...mm Overall width with fenders 62 1575 mm Overall width with outriggers pulled out 105 2667 mm Trailer frame width 41 1041 mm Tongue length 49 1245 mm Wheel size 15 381mm Axle Rating 3500 lb 1588 kg T...

Page 27: ...40 2223 2190 2969 2670 3620 3560 4826 3000 4067 5 16 3 8 7 16 1 2 1 5 9 16 5 8 3 4 7 8 1 1 125 1 25 LUBED 1 4 LUBED DRY LUBED DRY LUBED DRY LUBED SAE FASTENER TORQUE CHART Grade 5 DRY LUBED This chart...

Page 28: ...c Open telescope lock pin 3 Engine will not turn over a Dead battery a Check the battery voltage or loose cables b Engine has seized due to loss b Have a trained of fluids mechanic examine and repair...

Page 29: ...e bulbs as needed d Defective capacitor d Have a trained electrician inspect Leroy Somers Generator the capacitor e Defective AC generator e Have a trained electrician inspect the generator f Engine s...

Page 30: ...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 lamp depreciation...

Page 31: ...re 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 TRO...

Page 32: ...ow these steps STEP1 Ensure all ballasts which are numbered are plugged into lead wires with corre sponding numbers STEP 2 Looking at the lights from the glass side and following the diagram below plu...

Page 33: ...and it is determined that warranty is due we will then at the discretion of TEREX LIGHT CONSTRUCTION credit the applicants account or send replacement parts TEREX LIGHT CONSTRUCTION warranty reimburse...

Page 34: ...ubject 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 warrant...

Page 35: ...803 366 1101 When returning parts for credit please contact the factory for Return of Goods Authorization Terex Model Number _______________________ Serial Number ____________________ Engine Model Num...

Page 36: ...November2006 36 AL4000LightTower Part No 833002 Rev A MODEL NUMBER IDENTIFICATION...

Page 37: ...ratures a compromise must be struck and a higher viscosity oil used Multi grade oils overcome the problem provided they possess a suitable specification 2 MIL L 2104B or MIL L 2104C or API CD must als...

Page 38: ...ced 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 galvanized to resist corrosion Using a w...

Page 39: ...lt to remove 2 6 Unfasten the cable by removing the bolt at the base of the small section 3 REINSTALLINGTHE SMALL SECTION 3 1 Fasten new cable to the base of the small section 3 2 Reversing the proced...

Page 40: ...ion and proceed as instructed in section 4 6 4 8 Unfasten the cable by removing the bolt at the base of the middle section 5 REINSTALLINGTHE LOWER CABLE AND MIDDLE SECTION 5 1 If the fish wire worked...

Page 41: ...November2006 Part No 833002 Rev A AL4000LightTower 41 WIRE ROPE REPLACEMENT Cable Replacement Diagram...

Page 42: ...November2006 42 AL4000LightTower Part No 833002 Rev A WIRE ROPE REPLACEMENT Tower Shim Placement...

Page 43: ...November2006 Part No 833002 Rev A AL4000LightTower 43 Wiring Diagrams Section...

Page 44: ...November2006 44 AL4000LightTower Part No 833002 Rev A FixtureWiring Diagram...

Page 45: ...November2006 Part No 833002 Rev A AL4000LightTower 45 1000MH Ballast Diagram...

Page 46: ...November2006 46 AL4000LightTower Part No 833002 Rev A 1000HPS Ballast Diagram...

Page 47: ...November2006 Part No 833002 Rev A AL4000LightTower 47 AC Wiring For A Light Tower Diagram...

Page 48: ...November2006 48 AL4000LightTower Part No 833002 Rev A DC Engine Wiring Diagram...

Page 49: ...November2006 Part No 833002 Rev A AL4000LightTower 49 AC Light Tower Wiring Diagram Perkins...

Page 50: ...November2006 50 AL4000LightTower Part No 833002 Rev A Consolidated Coil Cord With Plug End...

Page 51: ...November2006 Part No 833002 Rev A AL4000LightTower 51 Parts Catalog Section...

Page 52: ...red NOTES and DESIGNATIONS This manual is compiled from information available and current at time of approval for printing Terex reserves the right to improve its product without notice to follow its...

Page 53: ...Send your order to the nearest Terex distributor in your area 2 Give the light tower model and serial number 3 Write the quantity required part number and description of the parts wanted 4 Give the s...

Page 54: ...PLUG TUBE PLUG 2 1 2 4 6 834219 HANDLE ARM FOR JACK HAMMERBLOW 3 7 834204 HANDLE ARM FOR JACK FULTON 3 8 840221 JACK BRACKET SWIVEL 1 9 111936 CHAIN SAFETY 3000LB 3 8X30 W S HOOK 2 10 840120 COUPLER 2...

Page 55: ...8 3 742240 1 TANK CAP NO GAUGE 1 4 792750 CLAMP 7 16 TO 25 32 2 5 890795 HOSE FUEL 5 16 ID AR 6 898590 HOSE FITTING PIPE BARB 1 7 891560 HOSE FITTING PIPE BARB 1 8 890785 HOSE FUEL 1 8 ID AR 9 742220...

Page 56: ...November2006 56 AL4000LightTower Part No 833002 Rev A AXLE ASSEMBLY...

Page 57: ...TIRE WHEEL MOUNTED P205 75 15 LOAD B2 2 11 840376 AXLE WHEEL NUT 10 12 840395 AXLE SPRING NUT 6 13 840392 AXLE REAR HANGER 2 14 840394 AXLE SPRING BOLT 6 15 841473 AXLE SHACKLE 2 16 834246 SPRING EYE...

Page 58: ...November2006 58 AL4000LightTower Part No 833002 Rev A CABINET ASSEMBLY...

Page 59: ...6 188530 2 CABINET FRONT PANEL 1 7 176370 LITERATURE RACK 1 8 188580 CABINET SIDE PANEL CURBSIDE 1 9 930950 WEATHERSTRIP ADHESIVE AR 10 791840 BUMPER RUBBER 4 11 124430 CABINET REAR PANEL 1 12 994130...

Page 60: ...November2006 60 AL4000LightTower Part No 833002 Rev A CABINET ASSEMBLY TOP DOORS...

Page 61: ...ANEL 1 8 796432 GAS SPRING SHORT BRACKET WITH BALL 8 9 992040 RIVET POP 3 16X 602 16 10 796436 GAS SPRING 16 60 LB 4 11 188550 2 CABINET TOP PANEL 1 12 794940 PLUG PLASTIC 1 13 189796 HASP CABINET DOO...

Page 62: ...EL FUEL ONLY 1 6 850107 DECAL CAUTION WINCHLOCK SYSTEM 1 7 853640 DECAL CAUTION WINCH ROTATION 1 8 853291 DECAL TEREX AMIDA RED AND BLACK 2 75X16 1 9 CU51A112 DECAL DANGER HOT EXHAUST 1 10 850093 DECA...

Page 63: ...33002 Rev A AL4000LightTower 63 ITEM PART DESCRIPTION QTY 1 113080 COIL CORD SLEEVE 1 2 851545 DECAL DANGER DO NOT RAISE TOWER IN VICINITY 1 3 R850475 DECAL WARNING FORKS 2 4 851550 DECAL LIFT MACHINE...

Page 64: ...109516 KIT LOCK SLIDE PIN W SPRING SHELL includes 3 9 1 3 990660 ROLL PIN 1 4 X1 5 8 1 4 113362 PIN LOCK SLIDE WITH RING includes 10 13 1 5 171635 LOCK PIN SHELL 1 6 171640 LOCK SPRING SHELL 1 7 9803...

Page 65: ...E 3 1 8 X1 1 4 CABLE 2 4 990670 RIVET POP 3 16X1 2 S S BLIND RIVET 8 5 183286 SHIM 5 16X2X3 3 16 1 6 995780 CLEVIS PIN STAINLESS STEEL 3 8 X2 1 7 992765 CLEVIS PIN STAINLESS STEEL 1 2 X2 1 8 995790 CL...

Page 66: ...1 4 124550 3 SECTION 30 TOWER 1 5 188760 SHEAVE 3 1 8 X1 1 4 CABLE 1 6 990650 COTTER PIN 1 8X1 SS 1 7 994920 COTTER PIN 3 32X3 4 SS 2 8 990670 RIVET POP 3 16X1 2 S S BLIND RIVET 8 9 185290 SHIM 3 8X2...

Page 67: ...No 833002 Rev A AL4000LightTower 67 ITEM PART DESCRIPTION QTY 1 124560 2 SECTION 30 TOWER 1 2 109070 KIT CABLE ASSEMBLY UPPER 1 3 990470 WASHER LOCK 3 8 1 4 996230 SCREW 3 8 16NCX7 8 HHC GR 8 ZP 1 2 I...

Page 68: ...ARM 4 LIGHT 1 2 191781 STUD 3 4X10NCX4 3 4 4 3 990880 WASHER LOCK STAR 3 4 EXT TOOTH 4 4 123080 FIXTURE MOUNTING WING NUT 4 5 994460 SCREW 3 8 16NCX4 1 2 2 6 990080 WASHER FLAT 3 8 4 7 990170 NUT LOCK...

Page 69: ...990650 COTTER PIN 1 8 X 1 SS 1 4 995190 NUT LOCK NYLON INSERT 1 2 20NF HALF NUT 1 5 990610 BOLT TEE 1 2 20NF 4 1 2 LG 1 6 188770 SHEAVE 2 13 16 X 1 1 4 CABLE 1 7 188760 SHEAVE 3 1 8 X 1 1 4 CABLE 1 8...

Page 70: ...November2006 70 AL4000LightTower Part No 833002 Rev A TOWER BASE ASSEMBLY...

Page 71: ...3 113362 PIN LOCK SLIDE includes items 14 15 1 14 990760 PIN BRIDGE 0915 X 1 7 8 S S 1 15 120640 PIN W RING 5 16 X 1 5 8 1 16 990660 ROLL PIN 1 4 X1 5 8 1 17 980340 SCREW 5 16 18NCX1 2 1 18 790710 SPR...

Page 72: ...November2006 72 AL4000LightTower Part No 833002 Rev A WINCH LOCK ASSEMBLY...

Page 73: ...0 1 KIT WINCH SOCKET 1 8 990200 NUT LOCK NYLON INSERT 1 2 13NC GR 2 ZPIN 1 9 996050 BOLT 1 2 13NC X 7 1 2 HHC GRADE 5 ZP 1 10 124857 SPACER 5 ID 1 25 OD 1 11 124855 RATCHET ARM 1 12 124856 BUSHING FLA...

Page 74: ...SEMBLY 1 866126 AIR CLEANER BODY 1 866127 AIR CLEANER ELEMENT 1 866128 AIR CLEANER COVER 1 866129 AIR CLEANER VALVE 1 866050 OIL FILTER 1 740620 FUEL FILTER IN LINE 5 16 1 839107 FUEL FILTER ASSEMBLY...

Page 75: ...0LightTower 75 ITEM PARTS DESCRIPTION QTY 1 866114 RADIATOR 1 2 866120 CAP FOR RADIATOR 1 3 839109 HOSE TOP 1 4 839110 HOSE BOTTOM 1 5 866113 FAN GUARD 1 6 865307 COOLANT RECOVERY TANK 1 7 890790 HOSE...

Page 76: ...5 ZP 2 2 990210 WASHER FLAT 1 2 4 3 990415 WASHER FLAT SNUBBER 2 4 740925 VIBRATION MOUNT 30 DUR 2 5 740770 VIBRATION MOUNT 35 LB 2 6 124015 ENG FT RAD SUPPORT ROADSIDE D1105 LSA36 shown 1 7 124016 EN...

Page 77: ...245 1 4 836707 TOP COVER 1 5 836708 END CAP 1 6 836709 FAN 1 7 836710 TERMINAL BLOCK 1 8 836711 CAPACITOR 22 5mf two per unit required 2 9 996290 SCREW M10X1 5X90MM HHC GRADE 8 8 ZP 1 10 990415 WASHE...

Page 78: ...November2006 78 AL4000LightTower Part No 833002 Rev A ELECTRICAL CONTROL BOX ASSEMBLY...

Page 79: ...NNECTOR 2 SCREW 1 25 1 16A included with item 16 17 709032 TERMINAL CLOSED END 2 18 680060 WRAP CAP 1 19 680290 CRIMP SLEEVE 1 20 116770 WIRE HARNESS 1 21 680250 LOCKNUT CONDUIT 3 4 1 22 663890 CORD S...

Page 80: ...November2006 80 AL4000LightTower Part No 833002 Rev A MH HPS LIGHT FIXTURE ASSEMBLY...

Page 81: ...G FOR REFLECTOR 1 15 990675 RIVET POP 1 8X 390 GR 1 4 5 16 2 16 833524 LENS W GASKET 1 17 833543 CLAMP LENS TO REFLECTOR 1 18 833574 SCREW 8 32X1 HH SLOT 1 19 833581 WASHER FIBER FOR BAND 1 20 833578...

Page 82: ...Y ITEM PART DESCRIPTION QTY 1 114355 BALLAST BOX MH 1 2 114895 BALLAST BOX HPS 1 3 663860 CONNECTOR 5P MALE 1 4 160030 MH TRANSFORMER AND CAPACITOR 1 5 160040 HPS TRANSFORMER AND CAPACITOR 1 6 160032...

Page 83: ...663870 CONNECTOR 3P FEMALE 4 5 663880 DUST CAP W CHAIN 4 6 C48300108 JUNCTION BOX 1 7 680190 BOX COVER 2GANG W GASKET 1 8 852800 DECAL CAUTION TIGHTEN FIXTURE CONNECTOR 1 9 680080 GRIP HUBBLE 1 10 72...

Page 84: ...76336 COMBO HITCH SIDE SPACER 2 4 176335 COMBO HITCH SIDE PLATE 2 5 840470 BALL 2 1 6 121572 COMBO HITCH RING 16 LONG 1 7 213770 RING HITCH BOLT ON 2 1 2 ID 1 8 124450 ADJUSTABLE HEIGHT HITCH 24 1 9 2...

Page 85: ...E BRKT TONGUE MNT 2 3 841060 TIRE WHEEL MOUNTED P205 75 15 LOAD B 1 4 160530 BATTERY BLANKET THERMO 284 4001 36 LG 1 5 684030 LIGHT DOME WITH SWITCH 1 6 741690 FUEL LINE HEATER DIESEL 12V 150W 1 7 684...

Page 86: ...X2X30 2 15 124412 TRAILER FRAME 41X70 FOR EXTRA OUTRIGGERS 1 16 109150 KIT OUTRIGGER PLUNGER PIN ASSY 2 17 840222 JACK SNAP RING 2 18 841430 JACK SIDEWIND LONG 3000 LB 2 19 663525 LIGHT SIDE MARKER AM...

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