AL4000 Service Manual
Contents
1. 116474 First Edition Leroy Somer 116118 Kubota Engine Manual 893020 116117 Marathon Manual 116188 Copyright 2008 by TEREX Corporation 116474 Rev A September 2008 First Edition First Printing TEREX is a registered trademark of TEREX Corporation in the USA and many other countries Super Quiet is a trademark of TEREX Corporation Ze Printed on recycled paper Printed in U S A 4000 Light Tower Part No 116474 September 2008 How to Read Your Serial Number REVA Serial Number Legend The serial number plate on your AL4000 is located on the cabinet next to the light tower mast a N MANUFACTURED BY FABRIQUE PAR TEREX ROCK HILL 590 Huey Road Rock Hill SC 29732 DATE FEBRUARY 2008 GVWR PNBV 1 244 KG 2 743 LBS GAWR PNBE 1 244 KG 2 743 LBS TIRES PNEU ST205 75D15 LOAD RANGE C RIMS JANTE 15 0 X 4 5 5H COLD TIRES INFL 35 PSI 250 KPA PRESS DE GONFL A FROID SINGLE THIS VEHICLE CONFORMS TO ALL APPLICABLE U S FEDERAL MOTOR VEHICLE SAFETY STANDARDS IN EFFECT ON THE DATE OF MANUFACTURE SHOWN ABOVE THIS VEHICLE CONFORMS TO ALL APPLICABLE STANDARDS PRESCRIBED UNDER THE CANADIAN MOTOR VEHICLE SAFETY REGULATIONS IN EFFECT ON THE D2. SISSVHD OL MOVIE EAS YOOTLSIML YOE NI YOLYOIANI 9 149 YOZ SONVEO utu Co YNOH YOLVOINI OMY TT NIH uNOILIND la gt p HOLIMSAS 15 vl vl 918 7 01 SNOW OO 5 WVWYLNAN STVaLNAN 9 LSVTIVd OL SAIL CXS 1 149 VOZ 4000 Light Tower Part No 116474 September 2008 Section 5 Schematics DC Wiring European Kubota Drawing 116813 TEREX ON ANV1009 sa soll MOT 850 gay NYS TBA GION310S ali Jans x T Nua 2 1545 NOLLN AWAY 5 AYALIVE 134 syn v4 YOLVNYALIV SLNANOdWODS ANISNA Part No 116474 AL4000 Light Tower TEREX Section 5 Schem
3. ix Howto Order e a E xi Service Parts Fax Order 1 xii Safety Rules General Safety RUES Specifications sds 2 1 Specifications Continued 2 2 Specifications sssini aen anaa a Ea 2 3 Specitications 2 4 Genset Torque Specifications 2 5 Scheduled Maintenance Procedures INTODUCTION 3 1 Pre delivery Preparation 3 2 Maintenance Schedules Kubota Lubrication and Maintenance Service Intervals 3 3 Leroy Somer Generators Maintenance Schedule 3 4 Marathon Generators Maintenance Schedule 3 5 Troubleshooting INTRODUCTION 4 1 Troubleshooting Gude 4 2 Part No 116474 AL4000 Light Tower vil September 2008 TEREX TABLE OF CONTENTS REVA Section 5 Rev Schematics A INMTOGUCTION T Geen ater ane 5 1 AC
4. AL4000D2 First Edition First Printing Part No 116474 September 2008 Introduction September 2008 REV Important Read understand and obey the safety rules and operating instructions in the appropriate Operator s Manual on your machine before attempting any maintenance procedure Basic mechanical hydraulic and electrical skills are required to perform most procedures However several procedures require specialized skills tools lifting equipment and a suitable workshop In these instances we strongly recommend that maintenance and repair be performed at an authorized TEREX dealer service center Technical Publications TEREX Corporation has endeavored to deliver the highest degree of accuracy possible However continuous improvement of our products is a TEREX policy Therefore product specifications are subject to change without notice Readers are encouraged to notify TEREX of errors and send in suggestions for improvement All communications will be carefully considered for future printings of this and all other manuals Contact Us Serial Number Information TEREX Corporation offers the following manuals for these models Title Part No TEREX AL4000 5000 Operator s Manual 116416 First Edition TEREX AL4000 Parts Manual 116419 First Edition TEREX AL4000 Service
5. J Cleaning of aircleanerelement f Joe J Check of radiator hoses and clamp bands Cleaning of water jacket radiator interior pressure heck of turbo charger heck of injection pump heck of injection timer hange of radiator coolant L L C Replacement of battery Replacement of radiator hoses and clamp bands Replacement of fuel pipes and clamp bands Replacement of intake air line Refer to the manufacturers manuals for detailed maintence intervals and instructions If the information in the manufacturer s manual differs from that in this manual the manufacturer s manual should take precedence Part No 116474 AL4000 Light Tower 3 3 Section Scheduled Maintenance Procedures September 2008 TEREX MAINTENANCE SCHEDULES CONTINUED REVA Leroy Somer Generators Maintenance Schedule 2000 Hours 8000 Hours 20000 Hours 30000 Hours Inspect and verify operator reports inlet outlets or liquid contaminant instrusion Check control panel voltmeter for proper stability and voltage output Monitor the power factor and generator loading during operation Visually inspect the generator non drive end Pf we ff If installed inspect any generator air filters for build up of contaminants and clean or replace as required Visually inspect the stator output leads and tightness Check transforme
6. cof Oo NI F aS o D O 2 M N o O NINI OL 2 OFS o CO EN oee EN rN ny AY NIS EN a o N gt 15 ao ojo RIN ofj 4 roy Kes lt gt A 9 2 4 AL4000 Light Tower Part No 116474 September 2008 Section 2 Specifications TEREX REVA GENSET TORQUE SPECIFICATIONS Generator Flex Plate to Flywheel Generator Case to Bellhousing Genset Isolators Part No 116474 AL4000 Light Tower 2 5 Section 2 Specifications September 2008 TEREX REVA This page intentionally left blank 2 6 AL4000 Light Tower Part No 116474 September 2008 Section Scheduled Maintenance Procedures TEREX Scheduled Maintenance Procedures REVA Observe and Obey Maintenance inspections shall be completed by a person trained and qualified on the maintenance of this machine Scheduled maintenance inspections shall be completed as sp
7. REVA AL4000 Light Tower Part No 116474 September 2008 Section 2 Specifications TEREX REVA SPECIFICATIONS 132cm 30 9 14m EXTENDED HEIGHT of 0 1 77 41 104 177cm 62 124 156cm 315cm 99 252cm 105 267cm Part No 116474 AL4000 Light Tower Section 2 Specifications September 2008 TEREX SPECIFICATIONS REVA SAE FASTENER TORQUE CHART This chart is to be used as a guide only unless noted elsewhere in this manual A574 High Strength THREAD Grade 5 Grade 8 CUBED CUBED LUBED _in Ibs_ in lbs in Ilbs Nm 5 17 16 Nm 14 2 100 113 f 80 9 140 158 10 124 130 147 28 90 101 120 135 120 135 169 18 140 158 LUBED UBED DRY LUBED DRY LUBED Nm Nm mis Nm Nm nm sie 8 3 76 17 2 39 284 9 257 20 art 27 366 325 6 2 31 33 447 44 596 515 a 52 5 64 3 588 mel 4 501 40 654 50 078 70 827 55 5 95 6 108 4 68 9 7 16 60 1084 110 149 126 20 04 5 9 12 10 16 1 18 one 12 80 108 4 10 149 120 162 150 23 30 16 5 122 162 186 1 110 19 150 203 16 217 2
8. 5 2 Wire Harness Control Box European DC 5 3 A DC Wiring European Kubota 5 4 A DG Wiring RUB Ota 5 5 Wire Harness Inside Control DC 5 6 A MH or HPS Light Fixture 5 7 A MA 5 8 1000 APS 5 9 viii AL4000 Light Tower Part No 116474 September 2008 REV Required Parts The following parts are required to perform maintenance procedures as outlined in the TEREX AL4000Parts and Service Manual Description Part No Kubota Models 866050 Ain FANG 866127 Fuel 839200 WeD 839209 Parts Stocking List Part No 116474 AL4000 Light Tower Ix September 2008 This page intentionally left blank x AL4000 Light Tower Part No 116474 September 2008 REV Please be prepared with the following information when ordering replacement parts for your TEREX product Machine model number Machine serial number Terex part number Part description and quantity Purchase order numbe
9. ALIHM LINDUID 1 310 amp 15 M0001 1 y9v14 Part No 116474 AL4000 Light Tower TEREX 1000 HPS Ballast Section 5 Schematics September 2008 Drawing 2987 REVA 1svTiva WNIGOS 934 M000 5 339 dAV1 J NVYO LOH day LAdNI A LIHM 0 LNNI Mov 1d 14 410d S Z EXI CX LX YOLINS AL4000 Light Tower Part No 116474 Genie North America Phone 425 881 1800 Toll Free USA and Canada 800 536 1800 Fax 425 883 3475 Genie Australia Pty Ltd Phone 61 7 3375 1660 Fax 61 7 3375 1002 California Proposition 65 Warning The exhaust from this product contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm Towing Checklist Use at each stop Before Towing Boom hold down latch is securely locked in place Towing hitch is properly secured to tow vehicle Safety chains if required are properly attached and secure chains are crossed below hitch All lights are connected and working Tires are properly inflated Before Driving Fasten safety restra
10. serious injury Yellow with safety alert symbol ACAUTION used to indicate the presence of a potentially hazardous situation which if not avoided may cause minor or moderate injury Yellow without safety alert symbol used to indicate the presence of a potentially hazardous situation which if not avoided may result in property damage CAUTION Green used to indicate operation or maintenance information Indicates that a specific result is expected after performing a series of steps W Indicates that an incorrect result has occurred after performing a series of steps Part No 116474 AL4000 Light Tower 3 1 Pre Delivery Preparation Fundamentals It is the responsibility of the dealer to perform the Pre delivery Preparation The Pre delivery Preparation is performed prior to each delivery The inspection is designed to discover if anything is apparently wrong with a machine before it is put into service A damaged or modified machine must never be used If damage or any variation from factory delivered condition is discovered the machine must be tagged and removed from service Repairs to the machine may only be made by a qualified service technician according to the manufacturer s specifications Scheduled maintenance inspections shall be performed by qualified service technicians according to the manufacturer s specifications and the requirements listed in the responsibilities manual T
11. Origin Code Comments Date Scheduled Ship Condition Order Total Terms Code remove this page and make copies remove this page and make copies September 2008 Section 2 Specifications MAST ELEVATION 30 9 14 TOWER ROTATION 359 DEGREES TOWER ROTATION MANUAL MAX WIND RATING 62 100KPH SEE CHART ON PAGE 2 3 STANDARD KUBOTA D1105 DIESEL 13 6 HP LEROY SOMER 36M6 6KW 60HZ MARATHON 6 KW 201CSA5411 60HZ LEROY SOMER 37M7 8KW 60HZ MARATHON 8KW 201CSA5412 60HZ QTY 1 120V 20 GFI DUPLEX QTY 1 240V 30A TWISTLOCK STANDARD RECEPTACLES STANDARD BREAKERS QTY 4 1P 15A LAMPS QTY 1 2P 30A MAIN QTY 1 MINI 1P 20A SEPARATELY SWITCHED QTY 4 1000 WATT METAL HALIDE ROUND TEREX Specifications Part No 116474 AL4000 Light Tower TEREX SPECIFICATIONS Section 2 Specifications September 2008 TRAILER WHEELS 15 X 4 5 5 HOLE TIRES ST205 75D15 LOAD C COLD PRESSURE 50PSI 350KPA AXLE RATING 3500LBS 2000LBS SPRINGS MAX TOW SPEED 60MPH 96KPH NO BRAKES STANDARD TWO OUTRIGGERS STANDARD UEL TANK FUEL TYPE NO 2 DIESEL ONLY CAPACITY 30 GALLONS 1141 MATERIAL POLYETHELENE 6KW TOTAL WEIGHT NO FUEL 1 950LBS 885KG 8KW TOTAL WEIGHT NO FUEL 2 074LBS 941KG ONGUE WEIGHT 6KW 30 GALLON 147LBS 67KG 8KW 30 GALLON 147LBS 67KG BATTERY 12V GROUP 24 525 CCA STD DUTY LEAD ACID
12. lamp a Lamp may glow for an extended not strike when switch is first period of time Replace after turned on checking voltage and ballast 13 Circuit breaker trips on lamp a Short circuit or ground a Check wiring against diagram inspect for shorts or ground Fix as needed 14 Lamp light output low a Normal lamp depreciation b Dirty lamp or fixture b Clean lamp and fixture c Defective ballast c Interchange ballast plugs If lamp starts replace capacitor Check for swollen capacitors charred wiring core and coil or other signs of excessive heat d Check line voltage at ballast input Voltage should be within 10 of rating when operating at normal load Check wiring connections for voltage loss Check socket contact point ballast e Check ballast name plate against lamp data 15 Lamp colors different a Normal lamp depreciation b Dirty lamp or fixture b Clean lamp and fixture c Check data on lamps and replace as needed 16 Arc tube discolored or swollen a Over voltage from power supply a Check voltage at ballast for current oe or voltage surges for shorted capacitors and replace as needed b Improper ballast b Check ballast name plate against lamp data 17 Short lamp life a Lamp damaged a Check for outer bulb cracks cracks where lamp meets base and for broken arc tube or loose metal parts Replace as needed lamp data c Always use lamp support when towing 18 Lamp flickers or goes out a Check ballast
13. name plate against intermittent or cycling lamp data b New lamp b Under certain conditions new lamps may cycle Usually after 3 tries to start at 30 to 60 second intervals lamp will stabilize and operate normal 4 4 AL4000 Light Tower Part No 116474 September 2008 Section 4 Troubleshooting TEREX REVA TROUBLESHOOTING TROUBLE POSSIBLE CAUSE REMEDY 18 Lamp flickers or goes out intermittent or cycling d High spike ballast d Ballast produces high spike current Measure with oscilloscope Replace ballast as required 19 One or more lamps go out a Generator capacitor a Have a trained mechanic examine IF YOU FEEL AN ELECTRIC SHOCK AT ANY TIME WHILE OPERATING THIS UNIT SHUT IT DOWN IMMEDIATELY HAVE THE UNIT INSPECTED BY A TRAINED ELECTRICIAN THIS ENGINE GENERATOR SET IS FACTORY INSTALLED TESTED AND SET FOR FIELD OPERATION ANY DAMAGE TO THE ENGINE OR GENERATOR UNITS OCCURRING AFTER ADJUSTMENTS ARE MADE IN THE FIELD BY UNAUTHORIZED PERSONNEL WILL NOT BE COVERED BY YOUR MANUFACTURER S WARRANTY AND WILL ALSO VOID THE MANUFACTURER S WARRANTY ON THIS PARTICULAR UNIT IF YOU CAN NOT REACH YOUR LOCAL DEALER CONTACT THE FACTORY SERVICE MANAGER TOLL FREE AT 1 800 433 3026 Light Fixture Troubleshooting DO NOT OPEN FIXTURES WHILE LIGHT CIRCUIT BREAKER IS ALLOW LAMP TOCOOL BEFORE TOUCHING EXTRA PRECAUTIONS WHEN TROUBLESHOOTING ELECTRICAL 5 A Only use a voltmeter wi
14. 0 24 244 176 170 236 24 26 325 200 377 za 10 20 27 270 366 280 379 380 55 30 433 16 20 208 300 406 310 40 40 56 35 44 9 350 433 490 583 o 610 60 87 50 en a o 44 40 637 50 68 60 908 50 79 e 480 eo 60 857 680 922 90 1233 70 104 72 5 78 70 962 750 6 90 132 80 1130 eo 908 850 1205 1080 1440 1952 10 16 50 1260 1240 1681 1510 2047 2010 275 0 2304 6 1460 1979 1950 2643 2370 3213 3160 4284 2670 3620 12 1640 2223 2190 2969 2670 3620 3560 4825 300 4057 METRIC FASTENER TORQUE CHART This chart is to be used as a guide only unless noted elsewhere in this manual Class 4 6 4 5 Class 8 8 Class 10 9 Class 12 9 DRY DRY DRY 854 68 775 9 03 R DRY 830 1055 682 925 909 1233 0 iz ile 559 iz gk D P a Nol ah ai a al o w Ny oO DA x D e NI 00 0 iw lt 0 i lt 00 i 24 o tof 2 lt NI BLA
15. 01 ALIHM SNOT STVeLNAN LSVTIVd OL SAIL NI YOLVOICNI vl MOVIE 1 9 19 3339 OL GAHOVLLV Le tl SMV vl GNV HOLIMS SHL gt LSNW HOLIMSASY JHL p 8 NZNSI LNO o0 HOLIMSAAM 1 149 YOZ SMV pL SLIHM Part No 116474 AL4000 Light Tower TEREX MH or HPS Light Fixture Section 5 Schematics September 2008 Drawing 2985A REVA 1 ANNOYS LSV11Vd WON LOH 15 LINDYION MOTISA M 3339 9539 Movi 1 lt ALIHM Nvadouna SILSAWOG NSDOTWH NSLSONNL 303 AWVS AHL SI NOILVEYNDIANOO Nid LON MOVIE SLIHM 4000 Light Tower Part No 116474 September 2008 Section 5 Schematics TEREX 1000 MH Ballast Drawing 2986 REVA GQNNOYS 339 AONVYO LOH
16. ATE MANUFACTURE CE VEHICULE EST CONFORME A TOUTES LES NORMES QUI LUI SONT APPLICABLES EN VERTU DU REGLEMENT SUR LA SECURITE DES VEHICULES AUTOMOBILES DU CANADA EN VIGUEUR A LA DATE DE SA FABRICATION TYPE OF VEHICLE TYPE DE VEHICULE TRAILER REMORQUE MODEL AL4000 SERIAL NUMBER AL408 1003 MODEL YEAR 2008 AL4AXXXXX Serial number is stamped into frame Part No 116474 AL4000 Light Tower iii September 2008 This page intentionally blank iv AL4000 Light Tower Part No 116474 September 2008 Section 1 Safety Rules TEREX Safety Rules REV Danger Failure to obey the instructions and safety rules in this manual and the appropriate Operator s Manual on your machine will result in death or serious injury Many of the hazards identified in the operator s manual are also safety hazards when maintenance and repair procedures are performed Do Not Perform Maintenance Unless You are trained and qualified to perform maintenance on this machine You read understand and obey manufacturer s instructions and safety rules employer s safety rules and worksite regulations applicable governmental regulations You have the appropriate tools lifting equipment and a suitable workshop Part No 116474 AL4000 Light Tower TEREX SAFETY RULES Personal Safety Any person working on or around a machine must be a
17. EREX TEREX Rock Hill P O BOX 3147 Rock Hill SC 29732 USA Toll Free 800 433 3026 in U S A and Canada Copyright 2006 by TEREX Corporation is a registered trademark of TEREX Corporation RevB Instructions Use the operator s manual on your machine The Pre delivery Preparation consists of completing the Pre operation Inspection the Maintenance items and the Function Tests Use this form to record the results Place a check in the appropriate box after each part is completed Follow the instructions in the operator s manual If any inspection receives an N remove the machine from service repair and re inspect it After repair place a check in the R box Legend Y yes completed unable to complete R repaired Comments Pre Delivery Preparation Y N R Pre operation inspection completed Maintenance items completed Function tests completed Model Serial number Date Machine owner Inspected by print Inspector signature Inspector title Inspector company September 2008 Section Scheduled Maintenance Procedures TEREX Maintenance Schedules REVA Kubota Lubrication and Maintenance Service Intervals ITEM Every tog soo EY 1500 Two Hours Year Hours Hours Hours Hours Hours Hours Hours Years Check of fuel pipes and camp banas P T Check engine and coolant ievel
18. R Electrocution hazard Exposure to electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry ADANGER Electrocution hazard Attempting to sevice the machine before the capacitors are fully discharged will result in death or serious injury High voltage Exposure to electrical wires or electrical current will result in death or serious injury Remove all rings watches and other jewelry Turn off all power when not needed for testing Use extreme caution when working with high voltage electrical components ACAUTION Burn hazard Contact with hot engine components may cause severe burns Use caution when working around a hot engine Part No 116474 AL4000 Light Tower 4 1 Section 4 Troubleshooting September 2008 TEREX REVA Troubleshooting Guide The engine generator set is tested and set at the factory for proper operation in the field These units should never require additional adjustments in the field If needed adjustments should only be made by a qualified service technician otherwise the manufacturer s warranty may become void TROUBLE POSSIBLE CAUSE REMEDY 1 Boom will not rise to the operating position b Defective cable b Have a trained or pulley mechanic examine and repair as needed c Defective winch c Have a trained mechanic examine and replace as needed 2 Boom will not telescope a Open telescope lock pin b Broken cabl
19. WOU MIIA YOLOANNOD Nid 6N 1511 371019399 310d 1 1 YOLONAGNOOD L de 1 Nu 1 6 Las L39 ae 1 1571159 213 9 SHA 1 1 aay agy I wa 5 5 as 8 29 Jaag 15 xog A1IOVLds03y J19YLd303Y 1 __ 05 ANNOYS 9 Adve INN TOYNLNOD 1 27 TE m e L LSVTIVd 2077 JO JAISNI 931 OL 3015 951 OL 7 yanvays l Part No 116474 AL4000 Light Tower TEREX Wire Harness Control Box European DC Section 5 Schematics September 2008 Drawing 116810 REVA OANI NOILVNIAYSL wd LYV LS HOLIMSAAM wAYOSSAOOWn Co NI OO HOLIMSAA wd LYVLS FL MOTTA lt NOLLNSHSNd HOLIMSASY 1071 tL 3LIHM NI SMV FI MOTIKA NI SMV vl 1 4313 NOH SMV vl MOVIE LIVE 5
20. advisable to clean and inpect the unit more frequently Replace the bearing Refer to the manufacturers manuals for detailed maintence intervals and instructions If the information in the manufacturer s manual differs from that in this manual the manufacturer s manual should take precedence Part No 116474 AL4000 Light Tower 3 5 Section Scheduled Maintenance Procedures September 2008 TEREX This page intentionally left blank 3 6 AL4000 Light Tower Part No 116474 September 2008 Observe and Obey Troubleshooting and repair procedures shall be completed by a person trained and qualified on the repair of this machine Immediately tag and remove from service a damaged or malfunctioning machine Repair any machine damage or malfunction before operating the machine Unless otherwise specified perform each repair procedure with the machine in the following configuration Machine parked on a firm level surface Wheels chocked Toggle switch in OFF position Section 4 Troubleshooting TEREX Troubleshooting Before Troubleshooting Read understand and obey the safety rules and operating instructions in the appropriate operator s manual on your machine sure that all necessary tools and test equipment are available and ready for use Be aware of the following hazards and follow generally accepted safe workshop practices ADANGE
21. atics September 2008 ov 922 5r os O lt gt 05891 LYYd SSANYVH 1NY1009 HOIH ON ayunssaud 189 YASWNN LYVd SSANYVH 18 990 ejaj ofj 9 9 faf o ef of ofn e GION310S WHT BLK voe 3503 LION 51 4 ANISNA 7 NOLLN AZL AVIS 13A NYS YOLVNYALIV eee 4 4000 Light Tower Part No 116474 September 2008 Section 5 Schematics Wire Harness Inside Control Box DC Drawing 116815 TEREX NOILWNIAYSL 16 HOLIMSAS CTO NoLinaHsnd 9 5 eu lL MOTISA NOLLNGHSNd J LHVLS HOLIMSASM Co SMV PL NINOLLASHSNd 1 1 MOTISA SMV tL WAAULWOANs YLIN NOH vl MOVIE SISSVHO ANNOYS awrina AAS yOOTLSIML YOE ANNOYS awrina LAS 149 VO utu YNOH 14 15 HOLIMSAgy
22. e or pulley b Have a trained and replace as needed 3 Engine will not turn over 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 Empty fuel tank a Fill tank with 2 diesel fuel not start b Check and clean the fuel system as needed f prime and tighten connections d Heater elements burned out d Replace heater elements e Fuel line solenoid is not open e Replace fuel line solenoid 5 Engine runs rough a Clogged or leaking fuel system a Replace fuel lines tighten all connections inspect the pickup tube and inspect the fuel filter b Clogged exhaust system b Clear the exhaust system c Clogged air filter c Clear air filter d Clogged or stuck fuel injectors e Valve clearances are out of e Have a trained adjustment or the valve spring mechanic examine may be damaged f Defective governor or fuel pump mechanic examine g Contaminated fuel g Have a trained or air in fuel system mechanic examine 4 2 AL4000 Light Tower Part No 116474 September 2008 Section 4 Troubleshooting TEREX REVA TROUBLESHOOTING TROUBLE POSSIBLE CAUSE REMEDY 6 Engine runs but produces a dense smoke b Low compression b Have a trained mechanic inspect for broken or seized rings Inspect valve clearances and clear as needed water coolant solution clogged d Fan belt is loose d Tighten fan belt 8 Engine runs but the battery a Alternator has fai
23. ecified using the supplied Lubrication and Maintenance Service Interval Charts provided in this section AWARNING Failure to perform each procedure as presented and scheduled could result in death serious injury or substantial damage Immediately tag and remove from service a damaged or malfunctioning machine Repair any machine damage or malfunction before operating the machine Keep records all inspections for three years Machines that have been out of service for period longer than 3 months must complete the quarterly inspection Unless otherwise specified perform each maintenance procedure with the machine in the following configuration Machine parked on a firm level surface Toggle switch in the OFF position Wheels chocked About This Section This section contains detailed procedures for each scheduled maintenance inspection Each procedure includes a description safety warnings and step by step instructions Symbols Legend Safety alert symbol used to alert personnel to potential personal injury hazards Obey all safety messages that follow this symbol to avoid possible injury or death Red used to indicate the presence of an imminently hazardous situation which if not avoided will result in death or serious injury ADANGER Orange used to indicate the AWARNING presence of a potentially hazardous situation which if not avoided could result in death or
24. es Workplace Safety Be sure to keep sparks flames and W lighted tobacco away from flammable and combustible materials like battery gases and engine fuels Always have an approved fire extinguisher within easy reach Be sure that all tools and working areas are properly maintained and ready for use Keep work surfaces clean and free of debris that could get into machine components and cause damage ama sure that your workshop or work area W is properly ventilated and well lit other lifting or supporting device is fully capable of supporting and stabilizing the weight to be lifted Use only chains or straps that are in good condition and of ample capacity Be sure any forklift overhead crane Be sure that fasteners intended for one time use cotter pins and self locking nuts are not reused These components may fail if they are used a second time Be sure properly dispose of old oil or LA other fluids Use an approved container Please be environmentally safe vi AL4000 Light Tower Part No 116474 September 2008 Introduction Section 1 Section 2 Rev A A A A A Section 3 Rev A Section 4 Rev A TEREX Table of Contents Important Information INtrOGUCTION How to Read Your Serial NUMDEL iii Parts Stocking List srianan esseede eena raa ea
25. in death or serious injury Remove all rings watches and other jewelry General Repair Process Malfunction Identify discovered symptoms gt Troubleshoot problem still exists Perform repair Return to service problem solved Part No 116474 AL4000 Light Tower 5 1 Section 5 Schematics September 2008 x 14 Light Tower Wiring REVA Drawing 6495 596 6 9 d96 6 0L0H LO LSVTTVE L Nid LSVTIVE Nid TWULNAN LSVTIVE 8 2 WHLNAN LSVTIVE L Nid LSVTIVE 2 Nid OWA0ZZ LSVTIVE YOLYYINI 5 Nid Nid Nid 18 YIMOd 2 Nid Nid YOLIINNOI 13S GYOO vdAL 5 O 9 Nid 9 A 2 a YOLOANNOO 2015 SHIM
26. ints Properly adjust mirrors On The Road Do not exceed 60 mph 97 km h Obey all local and national towing speed laws Check connections and tire pressure at each stop Slow down for hazardous conditions Allow extra distance for following and passing other vehicles Genie China Phone 86 21 53852570 Fax 86 21 53852569 Genie Scandinavia Phone 46 31 575100 Fax 46 31 579020 Genie Malaysia Phone 65 98 480 775 Fax 65 67 533 544 Genie France Phone 33 0 2 37 26 09 99 Fax 33 0 2 37 26 09 98 Genie Japan Phone 81 3 3453 6082 Fax 81 3 3453 6083 Genie Korea Phone 82 25 587 267 Fax 82 25 583 910 Genie Iberica Phone 34 93 579 5042 Fax 34 93 579 5059 Genie Germany Phone 49 0 4202 88520 Fax 49 0 4202 8852 20 Genie Brasil Phone 55 11 41 665 755 Fax 55 11 41 665 754 Genie U K Phone 44 0 1476 584333 Fax 44 0 1476 584334 Genie Holland Phone 31 183 581 102 Fax 31 183 581 566 Genie Mexico City Phone 52 55 5666 5242 Fax 52 55 5666 3241
27. led a Have a trained mechanic inspect voltage is low the alternator 9 Engine runs but the lights will a Circuit breakers are tripped a Reset the circuit breaker not operate b Loose connections in the wiring b Have a trained electrician inspect system the ballast box wiring system c Burned out bulb c Replace the bulbs as needed the capacitor the generator f Have a trained mechanic inspect the engine speed and reset to 1800rpm 60hz the ballast and capacitors the generator bearing or damaged fan blade the generator 11 Lamp will not start a Inspect lamp base to see if there is arcing at center contact button Tighten lamp Check socket for damage Replace if needed if needed Make sure power is off c Defective ballast c Interchange ballast plugs If lamp starts replace ballast Check for swollen capacitors charred wiring core and coil or other signs of excessive heat d Low voltage d Check line voltage at ballast input Voltage should be within 10 of rating when operating at normal load Increase supply voltage or remove external load Part No 116474 AL4000 Light Tower 4 3 Section 4 Troubleshooting September 2008 TEREX TROUBLESHOOTING REVA POSSIBLE CAUSE 11 Lamp will not start ballast e The ballast name plate data should agree with the line voltage and lamp used If not replace the ballast down time insufficient to cool 12 Lamp starts slowly arc does a Defective
28. r 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 the next page and fax your order to our Parts Department If you don t know the name of your authorized distributor or if your area is not currently serviced by an authorized distributor please call TEREX Corporation Machine Information Model Serial Number Date of Purchase Authorized TEREX Distributor Phone Number TEREX How To Order Parts Genie Industries 18340 NE 76th Street P O Box 97030 Redmond WA 98073 9730 Telephone 877 367 5606 Fax 888 274 6192 genieindustries com Part No 116474 AL4000 Light Tower September 2008 TEREX Service Parts fax Order Form FAX TO 888 274 6192 OR TOLL FREE 877 367 5606 Please fill out completely Date Account Number Your Name Your Fax Number Your Phone Number Bill To Ship To Purchase Order Number Ship Via Model s Serial No s Optional Equipment Part Number Description Quantity Price All backordered parts will be shipped when available via the same ship method as the original order unless noted below Ship complete order only backorders Ship all available parts and contact customer on disposition of backordered parts Other please specify For TEREX Use Order Number
29. rs fuses capacitors and lightning arrestors for loose or physical damage proper clearance and spacing Clean the inside of the outlet box air screens and air baffles with compressed air or electrical solvent if needed Check machine vibrations and bearing condition against those established and recorded during original commissioning period or as defined by OEM Check IR insulation resistance to ground on all generator windings including the main rotating assembly the main stator assembly the exciter field and armature assemblies and any optional PMG assembly record Remove the endbrackets and visually inspect the generator end windings for oil or dirt contamination Excessive contamination may necessitate surface cleaning Diassemble the generator this includes rotor removal Clean the generatorwindings TT Te Replace the bearings Refer to the manufacturers manuals for detailed maintence intervals and instructions If the information in the manufacturer s manual differs from that in this manual the manufacturer s manual should take precedence 3 4 AL4000 Light Tower Part No 116474 September 2008 Section Scheduled Maintenance Procedures TEREX MAINTENANCE SCHEDULES CONTINUED REVA Marathon Generators Maintenance Schedule 10000 Visual inspection Clean and inspect after every 200 hours of normal operating time If generator is housed ina harsh environment it is
30. th two well insu lated pin probes rated for 600 volts B Treat all conductors as potentially hot C Proceed through circuits systematically operating only one section at a time D Before disconnecting ballast turn off circuit breaker and wait 30 seconds for capacitor to discharge E If all the lights are out and all the ballasts are receiving power suspect burned out power cable Part No 116474 AL4000 Light Tower 4 5 Section 4 Troubleshooting September 2008 TEREX This page intentionally left blank 4 6 AL4000 Light Tower Part No 116474 September 2008 Observe and Obey Troubleshooting and repair procedures shall be completed by a person trained and qualified on the repair of this machine Immediately tag and remove from service a damaged or malfunctioning machine Repair any machine damage or malfunction before operating the machine Before Troubleshooting Read understand and obey the safety rules and operating instructions in the appropriate operator s manual on your machine Be sure that all necessary tools and test equipment are available and ready for use Section 5 Schematics TEREX Schematics About This Section There are two groups of schematics in this section An illustration legend precedes each group of drawings Electrical Schematics AWARNING Electrocution hazard Contact with electrically charged circuits could result
31. ware of all known safety hazards Personal safety and the continued safe operation of the machine should be your top priority Read each procedure thoroughly This manual and the decals on the machine use signal words to identify the following Safety alert symbol used to alert personnel to potential personal injury hazards Obey all safety messages that follow this symbol to avoid possible injury or death 777 1 Red used to indicate the presence of an imminently hazardous situation which if not avoided will result in death or serious injury AWARNING Orange used to indicate the presence of a potentially hazardous situation which if not avoided could result in death or serious injury Yellow with safety alert symbol ACAUTION used to indicate the presence of a potentially hazardous situation which if not avoided may cause minor or moderate injury Yellow without safety alert symbol used to indicate the presence of a potentially hazardous situation which if not avoided may result in property damage CAUTION Green used to indicate operation or maintenance information Section 1 Safety Rules September 2008 REVA Be sure to wear protective eye wear and other protective clothing if the situation warrants it Be aware of potential crushing hazards Bl such as moving parts free swinging or unsecured components when lifting or placing loads Always wear approved steel toed sho
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