AL4000 Light Tower - Parts Manual - AL4000D2
Contents
1. 4 NN Part 116419 AL4000Light Tower 600 3 Section 600 Mast Components September 2008 TEREX Figure 602 1 Winch Lock Assembly 12 13 16 109485 WINCH SAFETY LOC SYSTEM INCLUDES NEW WINCH 4thru 13 amp 15 17 109486 WINCH SAFETY LOC SYSTEM DOES NOT INCLUDE NEW WINCH 3 thru 6 8 thru 12 amp 15 18 740050 2 KIT CABLE CLAMP FASTENER INCLUDES ATTACHING HARDWARE 600 4 AL4000 Light Tower Part No 116419 September2008 Section 600 Mast Components TEREX REV FIGURE 602 1 DESCRIPTION WASHER FLAT 3 8 WASHER LOCK 3 8 SCREW 3 8 16NC X 1 HHCS GR 5 ZP COTTER PIN 1 8 1 SS WASHER FLAT S S 1 2 F W 7 8 OD ROLLER WEAR BUSHING KIT WINCH amp SOCKET NUT LOCK NYLON INSERT 1 2 13NC GR 2 SCREW 1 2 13NC X 7 1 2 HHC GRADE 5 ZP SPACER 5 ID 1 25 OD RATCHET ARM BUSHING FLANGE 1 25 OD 5 ID NUT LOCK NYLON INSERT 1 2 13NC GR 2 ZPIN NUT 1 2 13 NYLON LOCK HALF THICK PART OF 740050 1 HANDLE SOCKET RATCHETING KIT SAFETY LOC SYSTEM with winch includes items 4 13 15 KIT SAFETY LOC SYSTEM includes items 3 6 8 12 15 KIT CABLE CLAMP FASTENER 00 4 O O1 BR D ND ss N Part 116419 AL4000 Light Tower 600 5 Section 600 Mast Components September 2008 TEREX Figure 603 1 Tower Assembly REVA2. 116419 First Edition TEREX AL4000 Service Manual 116474 First Edition Leroy Somer 116118 Kubota Engine Manual 893020 Axis samaan tto t 116117 Marathon 116188 Copyright O 2008 by TEREX Corporation 116419 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 6 Printed on recycled paper Printed in U S A AL4000 Light Tower Part No 116419 September 2008 How to Read Your Serial Number REV A Serial Number Legend The serial number plate on your AL4000 is located on the cabinet next to the light tower mast 1 MANUFACTURED BY FABRIQUE PAR TEREX ROCK HILL 590 Huey Road Rock Hill SC 29732 TE REX 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 RIMS JANTE 15 0 X 4 5 5H COLD TIRES INFL 35 PSI 250 KPA PRESS DE GONFL AFROID 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 S
3. See 2 Tower Section Assembly See 3 Tower Section Assembly See Figure 606 1 4 Tower Section 3 Shim amp Sheave Assembly See Figure 605 1 6 Round Tube Assembly 113080 COIL CORD SLEEVE 1 851545 DECAL DANGER DO NOT RAISE TOWER IN VICINITY R850475 DECAL WARNING FORKS 851550 DECAL LIFT MACHINE HERE 990160 SCREW 3 8 16NC X 3 3 4 HHC GRADE 2 ZP 990170 NUT LOCK NYLON INSERT 3 8 16NC GR 2 ZPN 990600 SCREW 3 8 16NC X 1 2 HHC GRADE 2 ZP 991690 WASHER LOCK STAR 3 8 EXT TOOTH ZP O 600 6 AL4000Light Tower PartNo 116419 September2008 Section 600 Mast Components TEREX Figure 604 1 Lower Mast Assembly See Figure 606 1 4 Tower Section Sheave amp Shim Assembly pos 7 4 a 2 Kit Lock Slide Pin w Spring amp Shell includes items 3 9 See Figure 605 1 Round Tube 6 7 Assembly 4 SECTION 30 TOWER KIT LOCK SLIDE PIN W SPRING amp SHELL includes 3 9 ROLL PIN 1 4 X 1 5 8 1 2 X 1 1 4 7 1 4 SLIDE LOCK LOCK PIN SHELL LOCK SPRING SHELL SCREW 5 16 18 1 2 HHCS GR 2 ZP SPRING COIL 1 2 2 25 COTTER PIN 1 8 SS SHIM 3 16 X 2 X 19 3 4 2 cla 0 1 0 4 cla cla PartNo 116419 AL4000 Light Tower 600 7 TEREX Section 600 Mast Components Figure 605 1 6 Inch Round Tube Assembly NUT LOCK NYLON INSERT 7 8 14N
4. EE ext EE Renan Service Parts Fax Order Form is xii Section 1 Safety Rules General Safety Rules use V Section 100 Rev Decals A Figure 101 1 Decals AA 100 2 Section 200 Rev Chassis Components A Figure 201 1 Light Tower Chassis 200 2 A Figure 202 1 Axle Assembly 200 4 Figure 203 1 Fuel Tank Assembly Ne 200 6 Section 300 Rev Cabinet Components A Figure 301 1 Cabinet Components 300 2 Section 400 Rev Electrical Components A Figure 401 1 Electrical Control 400 2 Figure 402 1 Ballast Box Assembly 400 4 A Figure 403 1 Light Fixture 400 6 Figure 404 1 Coil Cord amp Junction Box pp 400 8 116419 AL4000 Light Tower September 2008 TEREX TABLE OF CONTENTS REVA Section 500 Rev Engine amp Generator A Figure 501 1 Engine aaa aaa 500 2 Figure 502 1 Marathon Generator 6 500 4 A Figure 503 1 Leroy Somer Generator 6 500 6 A Figure 504 1 Marathon Generator 8 500 8 A Figure 505 1 Leroy Somer Generator 8 KW 500 10 Section 600 Rev Mast Components A Figure 601 1 Tower Base 600 2 A Figure 602 1 Winch Lock
5. 200 8 AL4000 Light Tower PartNo 116419 September2008 Section 300 e Cabinet Components TEREX Section 300 Cabinet Components Part No 116419 AL4000 Light Tower 300 1 Section 300 Cabinet Components September2008 TEREX Figure 301 1 Cabinet Components REVA View A Literature Rack N 1 IN 1 ViewB Battery Tray Mounting Coolant Overflow 300 2 AL4000Light Tower PartNo 116419 September2008 REV A Section 300 e Cabinet Components TEREX FIGURE 301 1 DESCRIPTION REAR TOWER SUPPORT COMPLETE ASSEMBLY 00 4 O O1 BR D PIN QUICK1 4X1 75 ZP BUMPER REAR TOWER SUPPORT PIN W RING 3 4X11 REAR TOWER SUPPORT HINGE PIANO 1 5X51 75 CABINET DOOR PANEL GAS SPRING SHORT BRACKET WITH BALL RIVET POP 3 16X 602 GAS SPRING 16 60 LB CABINET TOP PANEL PLUG PLASTIC HASP CABINET DOOR CABINET DOOR PANEL HANDLE 5 75 CHROME PLATED GROUND ROD STORAGE TUBE COVER PLATE CABINET GROUND ROD LT TWR SCREW 10 32NFX3 4 WASHER FLAT 10 NUT LOCK NYLON INSERT 10 32 HX M S JAM RIVET POP 3 16X1 2 FENDER WITH SKIRT CABINET SIDE PANEL CURBSIDE WINCH HANDLE BUSHING CABINET FRONT PANEL LITERATURE RACK CABINET SIDE PANEL ROADSIDE WEATHERSTRIP ADHESIVE BUMPER RUBBER CABINET REAR PANEL SCREW 1 4 20NCX1 WASHER FLAT 1 4 NUT LOCK NYLON INSERT 1 4 20NC GR 2 ZP SCREW 1 4 20NCX3 4 WASHER FLAT 1 4 SCREW 1 4 20NCX3 4 SCREW 1 4 20NCX5 8 HWH N 3s ox
6. D ng w o Part No 116419 AL4000 Light Tower 300 3 Section 300 Cabinet Components September2008 TEREX Figure 301 1 Cabinet Components REVA View A Literature Rack N 1 IN 1 View Battery Tray Mounting Coolant Overflow 300 4 AL4000LightTower PartNo 116419 September2008 Section 300 Cabinet Components TEREX REVA FIGURE 301 1 BATTERY WET 12V GR24 525 CCA STD DUTY LEAD ACID BATTERY HOLD DOWN ANGLE BATTERY HOLD DOWN ROD BATTERY CABLE SET DECAL WASHER LOCK 1 2 WASHER FLAT 1 2 SCREW 1 2 13 X 1 1 2 COOLANT RECOVERY TANK ASSEMBLY PO Part 116419 AL4000 Light Tower 300 5 Section 300 Cabinet Components September2008 TEREX This page intentionally left blank 300 6 AL4000 Light Tower PartNo 116419 September 2008 Section 400 Electrical Components TEREX Section 400 Electrical Components Part No 116419 4000 Light Tower 400 1 September2008 Section 400 Electrical Components TEREX Figure 401 1 REV A 38 Complete Control Box 37A Kubota Solenoid Pigtail 37 Wiring Harness Electrical Control Box Part 116419 AL4000 Light Tower 400 2 September2008 REV A Section 400 e Electrical Components TEREX FIGURE 401 1 DESCRIPTION 00 4 O O1 5
7. CN 5 p 1 b 2 22 LO N 7 4 7 j N AS 7 Engine Kubota D1105 PartNo 116419 AL4000Light Tower 500 2 September2008 REV A Section 500 Engine amp Generator TEREX FIGURE 501 1 DESCRIPTION 732205PP 995380 991650 990415 740925 184325 990200 124016 124017 124025 990210 839190 741140 866125 866126 866127 866128 866129 866050 740620 839107 839200 660320 866101 866090 O1 5 D KUBOTA D1105 ENGINE POWERPACK BUILD EBG2 SCREW 1 2 13NC X 4HHC GR 2 ZP WASHER LOCK 1 2 WASHER FLAT FENDER 1 2 X 2 ZP VIBRATION MOUNT 390LB GENSET SPACER PLASTIC 2 OD X 9 16 ID X 1 NUT LOCK NYLON INSERT 1 2 13NC GR 2 ZPIN ENGINE MOUNT L BRACKET CURBSIDE ENGINE MOUNT L BRACKET ROADSIDE GENSET RISER 6KW ONLY WASHER FLAT 1 2 LOW OIL PRESSURE SWITCH HIGH TEMPERATURE SWITCH AIR CLEANER VALVE OIL FILTER FUEL FILTER IN LINE 5 16 FUEL FILTER ASSEMBLY FUEL FILTER ELEMENT FUEL PUMP STARTER ALTERNATOR 2 WIRE STOP SOLENOID GASKET SOLENOID MUFFLER D1105 SPACER MUFFLER MUFFLER GASKET MUFFLER TAILPIPE D1105 OIL DRAIN VALVE CLAMP 7 16 TO 25 32 HOSE OIL 3 8 0 250PSI RADIATOR CAP FOR RADIATOR HOSE TOP HOSE BOTTOM COOLANT RECOVERY TANK OPERATION MANUAL D1105 Part No 116419 AL4000 Light Tower 500 3 Section 500 e Engine amp Generator Septe
8. D DECAL AL RL CONTROL BOX AC POWER amp LIGHT BREAKER 2P 30A 240V CONTROL BOX FACE PLATE TERMINAL RING BREAKER 1P 15A 277VAC RECEPTACLE 20A 120V DUPLEX W GFI BREAKER MINI 1P 20 RECEPTACLE 30A 240V NUT NYLOCK 8 32 ZINC SWITCH IGNITION LEVER OPERATED included with item 10 WIRE HARNESS DC ENGINE CONNECTOR 2 SCREW 3 4 CONNECTOR 9P FEMALE SOCKETS FEMALE CONNECTOR WITH WIRES includes 13 and 14 CONNECTOR 2 SCREW 1 25 included with item 16 TERMINAL CLOSED END WRAP CAP CRIMP SLEEVE WIRE HARNESS LOCKNUT CONDUIT 3 4 CORD SET FEMALE 6FT 5P CONTROL BOX REAR PANEL CONTROL BOX BODY HOURMETER DIGITAL DECAL AL RL CONTROL BOX DC ENGINE CONTROLS CONTROL BOX FRONT PANEL SCREW 10 16X3 4 PH ZP SCREW 6 32X1 4 PAN HD WASHER LOCK 6 SWITCH PUSH BUTTON included with item 31 LIGHT INDICATOR 12V RED CONTROL BOX TOP PANEL RELAY 12V DC 30A BRACKET E BOX HANGER NUTSERT 1 4 20UNC WIRING HARNESS FROM ENGINE KUBOTA SOLENOID PIGTAIL COMPLETE ELECTRICAL CONTROL BOX includes 1 36 O1 AP HSH sa 00 ssa PartNo 116419 AL4000 Light Tower 400 3 Section 400 Electrical Components September2008 TEREX Figure 402 1 Ballast Box Assembly REV A ViewA Ballast Connector 400 4 AL4000Light Tower PartNo 116419 September 2008 Section 400 e Electrical Components TEREX REVA FIGURE 402 1 DESCRIPTION BALLAST BOX MH BALLAST
9. Section 700 e Options September2008 TEREX Figure 701 1 Options REV A Engine Coolant Heater Option Combo Hitch Kit Option Hydraulic Surge Brake Option 700 2 AL4000 Light Tower Part No 116419 September2008 REV A Section 700 Options TEREX FIGURE 701 1 DESCRIPTION OLTY0422 741993 OLTX0580 OLTX0481 663515 OLTX0180 663400 663405 OLTX0040 940000 840120 176336 176335 121572 840470 OLTY0316 110870 841220 841480 OPTION LT ENGINE BLOCK HEATER KUBOTA HEATER ENGINE BLOCK 3100003 ZERO START OPTION LT FUEL WATER SEPARATOR RACOR KUBOTA FILTER WATER SEPARATOR DIESEL FUEL STANADYNE ELEMENT 30 MICRON FUEL WATER OPTION LT TAIL LIGHTS RECESSED LIGHT WIRING HARNESS RECESSED LIGHTS LIGHT LICENSE TAG W BRACKET LIGHT SIDE MARKER AMBER 2 5 DIAMETER RECESSED LIGHT SIDE MARKER RED 2 5 DIAMETER RECESSED GROMMET RECESSED LIGHT KIT W PLUG AND WIRES TRAILER HARNESS 4 POLE RUN BRAKE LIGHTS LIGHT TRAILER RECESSED STOP TURN TAIL LIGHTS OPTION LT CONNECTOR 7 POLE RUN LIGHTS ROUND CONNECTOR TAIL LIGHT CONNECTOR TAIL LIGHT 7POLE CABLE GUARD OPTION LT HITCH COMBO BALL amp RING BOLT ON KIT COMBINATION HITCH BALL amp RING COMPLETE COUPLER FOR 2 BALL COMBO HITCH SIDE SPACER BOLT ON COMBO HITCH SIDE PLATE BOLT ON COMBO HITCH RING 16 LONG BOLT ON BALL 2 OPTION LT AXLE
10. o Ship all available parts and contact customer on disposition of backordered parts o Other please specify For TEREX Use Order Number Origin Code Comments Date Scheduled Ship Condition Order Total Terms Code remove this page and make copies remove this page and make copies September2008 Section 100 Decals TEREX Section 100 Decals PartNo 116419 AL4000Light Tower 100 1 Section 100 Decals Spetember2008 TEREX Figure 101 1 Decals Top View 1 Zz Curb Side View old Curb Side View new 3 4 Road Side View new Road Side View old TEREX AMID 4 J Front View Rear View 109471 DECAL KIT COMPLETE 100 2 AL4000 Light Tower Part No 116419 September2008 REV A Section 100 Decals TEREX FIGURE 101 1 DESCRIPTION 4 O O1 R D DANGER CRUSH HAZARD TOWER OPERATING INSTRUCTIONS TEREX AMIDA RED AND BLACK 5X29 5 STRIPING RED BLACK NO 2 DIESEL FUEL ONLY CAUTION WINCHLOCK SYSTEM CAUTION WINCH ROTATION TEREX AMIDA RED AND BLACK 2 75X16 REFLECTORS DO NOT STAND BEHIND TOWER AL4000 BLACK 2 2X9 5 DANGER FALLING BOOM CAUTION READ MANUAL DANGER ELECTRIC SHOCK HAZARD OPERATING INSTRUC
11. product Machine model number Machine serial number Terex part number Part description and quantity Purchase order number Ship to address Desired method of shipment Name and telephone number of the authorized TEREX Distributor in your area 8 8 ERI 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 116419 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
12. 500 12 AL4000 Light Tower PartNo 116419 September 2008 Section 600 Mast Components TEREX Section 600 Mast Components PartNo 116419 AL4000 Light Tower 600 1 Section 600 Mast Components September 2008 TEREX Figure 601 1 Tower Base Assembly REV 600 2 AL4000 Light Tower Part No 116419 September2008 Section 600 Mast Components TEREX REVA FIGURE 601 1 DESCRIPTION TOWER BASE WINCH LOCK ASSEMBLY See Figure 11 B for parts breakdown SCREW 3 8 16NC X 1 1 2 WASHER LOCK 3 8 WASHER FLAT 3 8 SCREW 1 4 20NC X 2 NUT LOCK NYLON INSERT 1 4 20NC GR 2 ZP WINCH HANDLE W TUBE DECAL CRUSH AREA DECAL CAUTION STAND CLEAR OF TOWER DECAL DANGER DO NOT PULL THE VERTICAL KIT LOCK SLIDE PIN includes items 13 21 PIN LOCK SLIDE includes items 14 15 PIN BRIDGE 0915 X 1 7 8 S S PIN W RING 5 16 X 1 5 8 ROLL PIN 1 4 X1 5 8 SCREW 5 16 18NC X 1 2 SPRING COIL 1 2 X 2 25 COTTER 1 8 X 1 SS LOCK PIN SHELL LOCK SPRING SHELL CLEVIS PIN STAINLESS STEEL 1 2 X 3 1 2 SHEAVE SPOOL 3 X 2 1 2 COTTER PIN 1 8 X 1 SS BUMPER PAD NUT LOCK NYLON INSERT 10 32 HX M S JAM WASHER FLAT 10 SCREW 10 32NF X 3 4 LOW HD SHCS ZINC SPRING LEAF CUSTOM KICK OUT NUT LOCK NYLON INSERT 1 2 13NC GR 2 ZPIN SCREW 1 2 13NC X 3 HHC GR 8 Y ZINC COTTER PIN 3 16 X 1 5 SS WASHER FLAT 1 PIN 1X9 1 4 TOWER PIVOT SCREW WASHER NUT NN
13. BOX HPS CONNECTOR 5P MALE MH TRANSFORMER AND CAPACITOR HPS TRANSFORMER AND CAPACITOR CAPACITOR 24uF MH 60Hz CAPACITOR 24uF HPS 60Hz SCREW 1 4 20 5 8 HWH ULTRA DECAL METAL HALIDE BALLAST DECAL DANGER HIGH VOLTAGE DECAL 1 DECAL 2 DECAL 3 DECAL 4 mn 0 2 42 PartNo 116419 AL4000Light Tower 400 5 Section 400 Electrical Components September2008 TEREX Figure 403 1 Light Fixture REV A 24 22 9 S N Z NOTE FOR COMPLETE MH ASSEMBLY ORDER PART C41100720 400 6 AL4000Light Tower PartNo 116419 September2008 REV A Section 400 Electrical Components TEREX FIGURE 403 1 DESCRIPTION 00 4 O O1 BR C41100720 CORD SET MALE 5FT 3P TERMINAL STRIP 2P CASTING FOR NEW FIXTURE WASHER LOCK STAR 1 2 WASHER LOCK 1 2 SCREW 1 2 13 1 1 2 HHC GR 2 ZP TRUNION T HANDLE SCREW 1 2 13 1 1 4 HHC GRADE 5 SOCKET BASE MOGUL GASKET FOR REFLECTOR LABEL FIXTURE CSA APPROVED REFLECTOR RING REINFORCING FOR REFLECTOR RIVET POP 1 8X 390 GR 1 4 5 16 LENS W GASKET CLAMP LENS TO REFLECTOR SCREW 8 32X1 HH SLOT WASHER FIBER FOR BAND NUTSERT FOR BAND 8 32 X 1 4 included with item 17 LAMP MH 1000W SCREW 10 24X5 8 LAMP HPS 1000W SCREW 8 32X3 8 PH SOCKET BRACKET SCREW 8 32X5 8 LABEL 105C CORD RATING LABEL WET LOCATION FIBERGLASS WIRE SLEE
14. AL4000 Light Tower Part No 116419 September2008 REV A Section 200 Chassis Components TEREX FIGURE 202 1 DESCRIPTION AXLE 3500LB 38 5 SPRING CENTER U BOLT KIT 3500 SEAL HYDRAULIC INNER BEARING HUB ASSY HT1000 3500LB OUTER BEARING SPRING FOR AXLE 4 LEAF TIRE amp WHEEL MOUNTED P205 75 15 LOAD C AXLE WHEEL NUT AXLE HUB HYD 8 PARK BRAKE L H AXLE HUB HYD amp PARK AXLE HUB ELECTRIC amp PARK BRAKE LH AXLE HUB ELECTRIC amp PARK BRAKE RH COUPLER SURGE 3 RING COUPLER SURGE 2 BALL NUT SPRING EYE BUSHING N N N N N N N N N N 4 4 4 4 4 4 6 4 4 6 Part No 116419 AL4000 LIght Tower 200 5 Section 200 Chassis Components September2008 TEREX Figure 203 1 Fuel Tank Assembly REV A ing 5 2 Optional 20 Gallon Tank 200 6 AL4000 Light Tower PartNo 116419 September2008 REV A Section 200 Chassis Components TEREX FIGURE 203 1 DESCRIPTION 00 4 O O1 5 D NUT LOCK NYLON INSERT 1 2 13NC GR 2 WASHER FLAT 1 2 TANK CAP NO GAUGE CLAMP 7 16 TO 25 32 HOSE FUEL 5 16 ID HOSE FITTING PIPE BARB HOSE FITTING PIPE BARB HOSE FUEL 1 8 ID TANK FUEL 30GAL KIT FUEL TANK DRAIN PLUG REPLACEMENT FUEL TANK PAN WASHER FLAT 1 2 SCREW 1 2 13NCX10 HHC GRADE2 Part No 116419 AL4000 Light Tower 200 7 Section 200 Chassis Components September2008 TEREX REV This page intentionally left blank
15. Assembly pp 600 4 Figure 603 1 Tower Assembly 600 6 A Figure 604 1 Lower Mast Assembly 600 7 A Figure 605 1 6 Inch Round Tube Assembly 600 8 A Figure 606 1 4 Inch Tower Section Shim amp Sheave Assembly after serial number AL507 00157 600 9 A Figure 607 1 Inch Tower Section 2 600 10 A Figure 608 1 2 Inch Tower Section Assembly 600 11 A Figure 609 1 Tower Cross Arm Assembly 600 12 Section 700 Rev Options A Figure ZONT ns 700 2 Figure 70231 OptiOns 700 4 viii AL4000 Light Tower Part No 116419 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 Qil Filtet a nr ee it 866050 Air FUNG AA AA 866127 Fuel Filter 839200 839209 TEREX Parts Stocking List Part No 116419 AL4000 Light Tower ix September 2008 TEREX REVA This page intentionally left blank x AL4000 Light Tower Part No 116419 September 2008 REV Please be prepared with the following information when ordering replacement parts for your TEREX
16. F HALF JAM COTTER PIN 3 32 4 SS COTTER PIN 1 8 X 1 SS NUT LOCK NYLON INSERT 1 2 20NF HALF NUT BOLT TEE 1 2 20NF 4 1 2 LG SHEAVE 2 13 16 X 11 4 CABLE SHEAVE 3 1 8 X 1 1 4 CABLE CLEVIS PIN STAINLESS STEEL 1 2 X2 BUSHING 2 50D X 13 16 6 ROUND TUBE CLEVIS PIN STAINLESS STEEL 1 4 X2 SHEAVE 3 1 8 X 1 1 4 CABLE September 2008 REVA Sa o 600 8 AL4000Light Tower PartNo 116419 September2008 Section 600 Mast Components TEREX Figure 606 1 4 Inch Tower Section Shim amp Sheave Assembly after serial number AL507 00157 REVA DESCRIPTION COTTER PIN 3 32 X 3 4 SS COTTER PIN 1 8 X1 SS SHEAVE 3 1 8 X 1 1 4 CABLE RIVET POP 3 16 X 1 2 S S BLIND RIVET SHIM 5 16 X 2 X 3 3 16 SHIM 1 4 X 2 X 3 3 16 SHIM 3 16 X 2 X 3 3 16 SCREW 1 2 13 NC X 3 HHC GRADE 2 ZP WASHER FLAT 1 2 LOCK LEVER AL SERIES BUSHING 3 4 OD X 1 2 ID X 285L SAE 841 BRONZE SPACER 11 16 OD X 1 2 ID X 1 1 32 LONG NUT LOCK NYLON INSERT 1 2 13NC GR 2 ZPIN KIT CABLE ASSEMBLY LOWER 1 4 CABLE CLEVIS PIN STAINLESS STEEL 1 4 X 2 CLEVIS PIN STAINLESS STEEL 3 8 X 2 BUSHING 11 16 OD X 1 2 ID X 26L SAE 841 BRONZE Part 116419 AL4000 Light Tower 600 9 TEREX Section 600 Mast Components September 2008 Figure 607 1 3 Inch Tower Section Assembly Orientation of Shims Inside Tu
17. T TERMINAL BATTERY HOLDOWN ANGLE 14 50 BATTERY HOLD DOWN ROD 1 4 X 11 1 4 OPTION LT RECEPTACLE EXTRA GFI DUPLEX RECEPTACLE 20A 120V DUPLEX W GFI BREAKER MINI 1P 20A OPTION LT ELECTRIC WINCH WINCH SWITCH WITH SOLENOID WINCH W O CABLE ELECTRIC WINCH ANGLE BASE MOUNT WINCH SOLENOID PACKAGE SWITCH TOGGLE 1P 2T MOMENTARY 20ADC BREAKER RESETTING 40A SWITCH MOUNT BRACKET LIGHT DOME WITH SWITCH OPTION LT FUEL WATER SEPARATOR WITH HEATER FILTER WATER SEPARATOR ASSEMBLY HEATER TOP LOAD FUEL 100W 12V NOTE OPTION NUMBERS CANNOT BE SOLD AS SPARE PARTS Part No 116419 AL4000 Light Tower 700 5 Section 700 Options September2008 TEREX This page intentionally left blank 700 6 AL4000 Light Tower Part No 116419 Genie North America Phone 425 881 1800 Toll Free USAand 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 Be
18. TANDARDS PRESCRIBED UNDER THE CANADIAN MOTOR VEHICLE SAFETY REGULATIONS IN EFFECT ON THE DATE 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 AL4XXXXX Serial number is stamped into frame Part No 116419 AL4000 Light Tower September 2008 TEREX REVA This page intentionally left blank iv AL4000 Light Tower Part No 116419 September 2008 Section 1 Safety Rules TEREX Safety Rules REVA 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 116419 AL4000 Light Tower V TEREX SAFETY RULES P
19. TEREX 5 AL4000D2 Ny 3 WE gt o 0 Rev Part 116419 September 2008 Introduction September 2008 REV A 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 www TEREX com 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
20. TIONS TEREX COSMETIC ROADSIDE TEREX COSMETIC CURBSIDE AL4000 COSMETIC Part No 116419 AL4000 Light Tower 100 3 Section 100 Decals September2008 TEREX This page intentionally left blank 100 4 AL4000 Light Tower Part 116419 September2008 Section 200 Chassis Components TEREX Section 200 Chassis Components Part No 116419 AL4000 Light Tower 200 1 Section 200 Chassis Components September2008 TEREX Figure 201 1 Light Tower Chassis REV See Figure 402 1 Ballast Box Assembly See Figure 203 1 Fuel Tank Assembly See Figure 202 1 Axle Assembly 200 2 AL4000Light Tower PartNo 116419 September2008 Section 200 Chassis Components TEREX REVA FIGURE 201 1 DESCRIPTION JACK SIDEWIND LONG 3KLB JACK SNAP RING OUTRIGGER 2X2X42 KIT OUTRIGGER PLUNGER PIN KIT CAPLUG TUBE PLUG 2 1 2 HANDLE ARM FOR JACK HAMMERBLOW HANDLE ARM FOR JACK FULTON JACK BRACKET SWIVEL CHAIN SAFETY 3000LB 3 8X30 W S HOOK COUPLER 2 BOLT ON TONGUE WITH JACK BRACKET TRAILER FRAME 41X70 WITHOUT AXLE DECAL SYMBOL FOR GROUND DECAL WARNING ALL JACKS MUST BE SWIVELED NUT 3 3 2 2 4 3 3 1 2 1 1 1 1 1 2 4 1 1 2 1 1 Part No 116419 AL4000 LIght Tower 200 3 Section 200 Chassis Components September2008 TEREX Figure 202 1 Axle Assembly REVA Hydraulic Surge Brake Option Electric Brake Option 200 4
21. VE GASKET 1 2 S R CONN LOCKNUT CONDUIT 1 2 CONNECTOR STRAINRELIEF LAMP SUPPORT COMPLETE FIXTURE ASSEMBLY includes items 1 34 1 2 2 2 1 1 1 1 1 1 1 1 2 1 1 1 1 1 1 1 4 1 2 1 2 1 1 1 1 1 1 1 1 Part No 116419 AL4000 Light Tower 400 7 Section 400 Electrical Components September2008 Figure 404 1 Coil Cord amp Junction Box REVA 13 Junction Box Complete with Coil Cord Includes items 1 12 14 Coil Cord Assembly Includes items 1 2 amp 3 SOCKET CONNECTOR 9P PLUG COIL CORD RETRACT 14 7 CONNECTOR 3P FEMALE DUST CAP W CHAIN JUNCTION BOX BOX COVER 2GANG W GASKET DECAL CAUTION TIGHTEN FIXTURE CONNECTOR GRIP HUBBLE WEATHERSTRIP ADHESIVE PLATE COIL CORD CABINET MOUNT SCREW 6 32 X 5 8 RD HD SLOT S S 22112580 JUNCTION BOX COMPLETE WITH COIL CORD includes 1 12 22112575 COIL CORD ASSEMBLY includes 1 2 and 0 0 D gt 20 A 400 8 AL4000 Light Tower PartNo 116419 September2008 Section 500 Engine amp Generator TEREX Section 500 Engine amp Generator PartNo 116419 AL4000 Light Tower 500 1 September2008 Section 500 Engine amp Generator TEREX REVA Figure 501 1 8kW Mounting Configuration 6kW Mounting Configuration NG o N 155538 ITDA ING d N N N NG lt 40 o
22. W HYD SURGE BRAKES RING HITCH CHAIN SAFETY 1750LB 1 4 X 31 W S HOOK COUPLER SURGE 3 RING 6000LB AXLE ACCESSORY COMPLETE HYD BRAKE KIT AXLE HUB ATTACHING PARTS KIT AXLE HUB HYD amp PARK BRAKE L H AXLE HUB HYD amp PARK BRAKE R H AXLE ASSEMBLY Part No 116419 AL4000 Light Tower 700 3 Section 700 e Options September2008 TEREX Figure 702 1 Options REV A Extra GFI Option Electric Winch 12 V DC Option Dome Light Option Fuel Separator with Heater Option 700 4 AL4000Light Tower PartNo 116419 September2008 REV A Section 700 Options TEREX FIGURE 702 1 DESCRIPTION OLTY0314 110870 841500 841480 841850 841855 841860 OLTY0315 841850 841870 841875 OLTX0222 161085 174170 182331 OLTX0210 684640 683970 OLTX0520 113583 160992 124750 160993 663780 684710 186830 OLTX0270 116218 116154 116144 OPTION LT AXLE W HYD SURGE BRAKES BALL HITCH CHAIN SAFETY 1750LB 1 4 X 31 W S HOOK COUPLER SURGE 2 BALL 6000LB AXLE ACCESSORY COMPLETE HYD BRAKE KIT AXLE HUB ATTACHING PARTS KIT AXLE HUB HYD amp PARK BRAKE L H AXLE HUB HYD amp PARK BRAKE R H OPTION LT AXLE W ELECTRIC BRAKES 3500 AXLE HUB ATTACHING PARTS KIT AXLE HUB ELECTRIC amp PARK BRAKE LH AXLE HUB ELECTRIC amp PARK BRAKE RH OPTION LT BATTERY 700A HEAVY DUTY BATTERY 700 GP24 12V POS
23. X COVER 8LHD354044 CAPACITOR 25MF 8LHD5990012 CLAMP CAPACITOR 8LHD086034 TERMINAL BLOCK TS 6005 DIODE SURGE PROTECTOR SUPPRESSOR VARISITOR MANUAL MARATHON PANCAKE GENERATOR 2 2 2 2 2 4 4 4 4 4 1 1 1 1 1 1 1 1 1 1 1 1 1 1 Part No 116419 AL4000 Light Tower 500 9 Section 500 Engine amp Generator September 2008 TEREX Figure 505 1 Leroy Somer Generator 8 kW LSA 37 M7 REVA Items 2 thru 9 are not shown For detail break down see Leroy Somer Parts amp Service Manual supplied with unit 500 10 AL4000 Light Tower Part No 116419 September2008 Section 500 Engine amp Generator TEREX REVA FIGURE 505 1 GENERATOR L S 8KW 120 240 C106 SAE5 LSA37 M7 NON DRIVE END BEARING HOUSING O RING BEARING BEARING HOUSING 4 O O1 BR D DIODE 70HF90 KIT CAPACITOR REPLACEMENT 8KW 1 5 60HZ 2 50UF NUT LOCK NYLON INSERT 1 2 13 GR 2 WASHER FLAT 1 2 SCREW 1 2 13NCX4HHC GR 2 2 WASHER FLAT FENDER 1 2 X 2 ZP VIBRATION MOUNT 390LB GENERATOR MOUNT BAR L S 1 2 X 3 X 19 LONG SCREW 1 2 13NC X 2 GR 8 Y ZINC GROUND WIRE GENSET TO TRAILER 14 LG WASHER LOCK STAR 1 4 EXT TOOTH S S SCREW 1 4 X 3 4 HH SLOT TYPE B SELF TAPPING MMANMARONMANDANABAAA AA PartNo 116419 AL4000 Light Tower 500 11 Section 500 Engine amp Generator September 2008 TEREX This page intentionally left blank
24. be DECSCRIPTION SCREW 3 8 16 UNC X 1 WASHER LOCK 3 8 KIT CABLE ASSEMBLY LOWER 1 4 CABLE 3 SECTION 30 TOWER SHEAVE 3 1 8 X1 1 4 CABLE COTTER PIN 1 8X1 SS COTTER PIN 3 32X3 4 SS RIVET POP 3 16X1 2 S S BLIND RIVET SHIM 3 8X2X2 1 4 CLEVIS PIN STAINLESS STEEL 1 2 X2 CLEVIS PIN STAINLESS STEEL 1 4 X2 SHIM 5 16 2 2 1 4 SHIM 3 8X2X2 1 4 WASHER FLAT REVA 600 10 AL4000 Light Tower PartNo 116419 September2008 REV A 124560 109070 990470 996230 Section 600 Mast Components Figure 608 1 2 Inch Tower Section Assembly 2 SECTION 30 TOWER KIT CABLE ASSEMBLY UPPER WASHER LOCK 3 8 SCREW 3 8 16NC X 7 8 HHC GR 8 ZP Part No 116419 AL4000 Light Tower 600 11 TEREX Section 600 e Mast Components Figure 609 1 Tower Cross Arm Assembly D See Fixture Assembly 113040 191781 990880 22123080 994460 990080 990170 851760 841890 DESCRIPTION CROSSARM 4 LIGHT STUD 3 4 10NC X 4 3 4 WASHER LOCK STAR 3 4 EXT TOOTH FIXTURE MOUNTING WING NUT SCREW 3 8 16NC X 4 1 2 WASHER FLAT 3 8 NUT LOCK NYLON INSERT 3 8 16NC GR 2 ZPN DECAL DANGER HIGH VOLTAGE REFLECTOR SCOTCHLITE TAPE 2 X18 September 2008 REV 5 600 2 AL4000Light Tower PartNo 116419 September 2008 Section 700 Options TEREX Section 700 Options Part No 116419 AL4000 Light Tower 700 1
25. ersonal Safety Any person working on or around a machine must be aware 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 e Safety Rules September 2008 REV A Be sure to wear protective eye wear and other protective clothing if the situation warrants it Be aware of potential crushing hazards such as moving parts free swinging or unsecured componen
26. fore Driving Fasten safety restraints 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 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. mber 2008 TEREX Figure 502 1 Marathon Generator 6 kW 201CSA5411 REVA 11 25 located in generator 500 4 AL4000 Light Tower Part No 116419 September2008 Section 500 Engine amp Generator REV A TEREX FIGURE 502 1 DESCRIPTION 00 4 O O1 BR D GENERATOR MARATHON PANCAKE 6KW GENERATOR MOUNT BRACKET SCREW 1 2 13NC X 3 1 2 HHC GR 2 ZP WASHER FLAT SNUBBER 1 2 X 2 3 4 X 7GA ZINC ISOLATOR ENGINE MOUNT 40 DURO WASHER FLAT 1 2 NUT LOCK NYLON INSERT 1 2 13NC GR 2 SCREW 3 8 16NC X 1 1 4 HHC GRADE 5 ZP WASHER LOCK 3 8 WASHER FLAT 3 8 FAN 8LHD435044 BEARING ODE A 90006R 30 BEARING BRACKET ODE 5412 8LHD013096 O RING 8LHD766012 POT COVER 8LHD310316 SCREEN ASY W SPGS 8LHD336030 DRIVE DISC C 107 702326 01 HUB SPACER 725334 01 CONN BOX BASE 8LHD354045 CONN BOX COVER 8LHD354044 CAPACITOR 25MF 8LHD5990012 CLAMP CAPACITOR 8LHD086034 TERMINAL BLOCK TS 6005 DIODE SURGE PROTECTOR SUPPRESSOR VARISITOR MANUAL MARATHON PANCAKE GENERATOR 2 2 2 2 2 4 4 4 4 4 1 1 1 1 1 1 1 1 1 1 1 1 1 1 Part No 116419 AL4000 Light Tower 500 5 Section 500 e Engine amp Generator September 2008 TEREX Figure 503 1 Leroy Somer Generator 6 kW LSA 36 M6 Items 1 thru 8 are not shown For detail break down see Leroy Somer Parts amp Service Manual supplied with unit 500 6 AL4000 Light To
28. ts when lifting or placing loads Always wear approved steel toed shoes 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 that your workshop or work area A 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 or Be sure that fasteners intended for one time use i e 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 CA other fluids Use an approved container Please be environmentally safe vi AL4000 Light Tower Part No 116419 September 2008 Table of Contents REV A Introduction Important Information Introduction How to Read Your Serial Number iii Parts Stocking List ii ix Howto Order n creer auta
29. wer Part No 116419 September2008 Section 500 Engine amp Generator TEREX REVA FIGURE 503 1 DESCRIPTION NDE BEARING DIODE KIT includes 2 diodes ROTOR BOLT 8 X 245 TERMINAL BLOCK KIT CAPACITOR 22 5mf Includes two capacitors SCREW M10X1 5X90MM HHC GRADE 8 8 ZP WASHER FLAT SNUBBER VIBRATION MOUNT 30 DUR NUT LOCK NYLON INSERT M10 X 1 5 HEX ZP GENERATOR MOUNT BAR GENERATOR L S 6KW 120 240 C106 SAE5 LSA36 AN PartNo 116419 AL4000Light Tower 500 7 Section 500 e Engine amp Generator September 2008 TEREX Figure 504 1 Marathon Generator 8 kW 201CSA5412 REVA 11 25 located in generator 500 8 AL4000 Light Tower Part No 116419 September2008 Section 500 Engine amp Generator REV A TEREX FIGURE 504 1 DESCRIPTION 4 O O1 BR D GENERATOR MARATHON PANCAKE 8KW GENERATOR MOUNT BRACKET SCREW 1 2 13NC X 3 1 2 GR 2 ZP WASHER FLAT SNUBBER 1 2 X 2 3 4 X 7GA ZINC ISOLATOR ENGINE MOUNT 40 DURO WASHER FLAT 1 2 NUT LOCK NYLON INSERT 1 2 13NC GR 2 SCREW 3 8 16NC X 1 1 4 HHC GRADE 5 ZP WASHER LOCK 3 8 WASHER FLAT 3 8 FAN 8LHD435044 BEARING ODE A 90006R 30 BEARING BRACKET ODE 5412 8LHD013096 O RING 8LHD766012 POT COVER 8LHD310316 SCREEN ASY W SPGS 8LHD336030 DRIVE DISC C 107 702326 01 HUB SPACER 725334 01 CONN BOX BASE 8LHD354045 CONN BO
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