AL4000 Australia models (PN AL4000AU)
Contents
1. 986 OMG 986cQ0M LHVd L6 0 v 31VG L6 0 v LO ld ANON d31VOS INNO HG 3ovsn N d LYN ga HdQqHOg YOLOANNOO AOF JLYW ILYN ISVTIV8 HINOOO WVWYDVIC SNIHIAA S3904 duVHS 8 p TIM 3AOW3H RE m B o Lr 99109 1011 99 1106 26 08 Ud Soon NOWINOD JONYHO 2 S TIH MOOH A3nH 06S 010 00 XX Sjeuroeq LOH 91 15 Suomnoe14 6 I ul 6 X J 9 L G3I4IO3dS 3SIMH3HLO SSIINN SAONVHSTOL NOWWOD INdNI ALIHM 3ONVHO 003 fazy 29v 18 LINDYID JI10VlddO3H 310 6 A08r ANZ WOO LSVTIVE 3arivH IYLIN M0001 YAWYOSASNVYL AOcL Movid dVO o3us NOLLdlHOS3 s1HVd 4 Wall 9866 986 LUVd 37 4 i S 9 L 8 382. 1001 aos ELES SHL 31995 108 00 y 90 va x 1969 Bora we eek oN ONEENS zs ewsoio wa oosa NOLDndoSESN ANY ONIMIM 2v ONISVHOMhd ONIB33NION3 301 LHOM NYITWALSNV PETE Maesa S NANG sika SEDIVASG SOUNIEINTS NONI 5349 Sig m a NOIVB3N39 Nid 35 2538 ara a 53003 GRVHS ONY suena ADHA 4089 Nid 310d G JLONYLSNOD LHS eF 15 17 8 N3MOd DVAOZZ Z Nid lt xx TMBLO3N Nid as sn Nay NOSE SASS 188 Seva Son NOLLdIOS3O MO 3N01V1ON3AON INAANO NO LANG bus ed 14 1HM ar QNnON2 9 Nid g AOZZ ISVTWG vf 3 Nid agy 1SVTW8 S 3 Nid WaLnaN ISVTYWB r 91 Nid ISING 9 ZH 0 Nid NYO ISVTB Z 8 Nid 18 A0ZZ swe 34 V Nid E o o lt rm A T MOLO3NNOO 30 3015 WOU4 YOLOSNNOOD Nid 4 m LSV IVa 2 31291432384 3104 m 0409 IHM ni v 31891995134 SOLINANOI Z 038 3 3 NYO v v N g 8e 59 85 30 r e NND 3 3 E ok 49 15 TING 30718 p K TS IS HIHN 5 IHM IHM P G E 8 8 935 aay U Y Y NYO NYO V 2 5 5 G ar gt 5 SVITIVH ies E E E E XOH 310193033 a IHM Zot S3HOLI
3. Mode ALAOOO AUS LIGHT TOWER TEREX amida y Tube Tower Section 990650 Cotter Pin 188770 Sheave 794550 Grease Fit 188760 990610 Tee Bolt 2 992765 179850 Clevis Pin Bushing 990620 Look Nut 994920 Cotter Pin 990650 Cotter Pin 124530 6 Round Tube 188760 Sheave 995790 Clevis Pin 52 TEREX W amida Model ALAOOO AUS LIGHT TOWER MA Section Sheave amp shim Assy e d 188760 Sheave 2 990650 Cotter Pin e l4 183286 Shim Ze See Orientation Below ON ra lt gt ps 2 994920 NG 995780 Cotter Pin Mooi Clevis Pin IS SESS ER MAD 992765 Clevis Pin 2 995790 Clevis Pin 183286 5 16 Shim 177830 1 4 Shim 4 183288 3 16 Shim lt gt 177830 1 4 Shim Orientation of Shims Inside Tube 53 F AL4000 AUS LIGHT TOWER TEREX g amida S 4 Tower Section NOTE Telescoping Lock Replacement Kit Order Part 109516 124540 4 Tower Section 990660 Roll Pin 120222 Lock Pin 113362 Assembly 790510 1 16 Cable Wil iis D 790520 Cable Sleeve 4 sa gt gt 980340 120640 Pin Screw p gt 990650 P aN i Cotter Pin AY 3 790710 how pring TR u lt b NG u DN Bc i E 0 Ew P E N 5 NG NS 54 TEREX a
4. Check voltage at ballast input Voltage should be within 10 of nameplate rating Check wiring connec tions for voltage loss Check socket contact point Check ballast nameplate against lamp data Lamp color and brightness decreases and colors change slightly as lamps age Spot replacement with new lamps may cause noticeable differences in lamp colors Group replacement minimizes color differences Dirty fixtures will cause lamps to appear different in color Clean fixture Check data on lamps which appear different in color Replace with correct color lamp Check voltage at ballast Check for current or voltage surges Check for shorted capacitors and replace if defective Lamp operated on ballast designed for higher wattage lamp Check ballast nameplate against lamp data Check for outer bulb cracks If air enters outer bulb arc tube may continue to burn for 100 hours before failure Check for bulb cracks where glass meets the base due to tightening lamp too firmly in socket Look for broken arc tube or loose metal parts Replace lamp 29 LIGHT FIKTURE TROUBLESHOOTING GUIDE CONTINUED SYMPTOM SHORT LAMP LIFE LAMP FLICKERS AND GOES OUT INTERMITTENT OR CYCLING CAUSES Improper ballast Improper ballast New lamp Defective lamp High spike ballast CORRECTIVE ACTION Ballast nameplate data should agree with lamp line voltage and lamp use If improper ballast is used the lamp life will be sh
5. on 742240 1 Tonk Cap amp Gauge 891560 Barb Fitting 1 4M x 1 8H 891590 Barb Fitting 1 4M x 5 16H 792750 5 Hose Clamp 4 990200 Lock Nut L lt 5 Standard 188630 Fuel Mine Spec AUS 1860 Drip Tray Fuel Tank 890875 1 8 ID Fuel Hose 890795 5 16 ID Fuel Hose 742220 Fuel Tank Standard 8 990210 Flat Washer Mine Spec 4 990210 Flat Washer 4 AUS1881 Stat O Seal 4 994650 1 2 13NC x 10 Bolt TEREX tf amida Mods AL4000 AUS LIGHT TOWER Axle Assembly Axle Assy 834340 841051 Axle Front Hanger U Bolt AOE SPS7330 841480 AXLE ACCESSORY COMPLETE HYD BRAKE KIT Grease Seal r Drum Assy Cotter Pin Spindle Nut Grease Cap Inner Bearing Outer Bearing Tire amp Wheel Mounted 841060 Lug nut 840376 3 840395 Axle Spring Nut 840392 Axle Rear Hanger 3 840394 Axle Spring Bolt 841473 Axle Shackle 2 834246 Spring Eye Bushing 834211 Leaf Spring Spring Plate AOE SPS 7610 M12 Spring Nut AOE 4 SPS 7370 47 AL4000 AU LIGHT TOWER TEREX amida Cabinet Assembly 116203 1 Cabinet Assembly 4 796432 Door Shock Bracket 188570 Cabinet Roadside 124420 Ground Rod Storage Tube Mine Spe
6. LIG TOWER Kub D1105 L S 8KW 116398 Genset Complete 116775 Engine Wiring Harness 732200 Engine D 6 866090 Alternator 839190 Low Oil Press Sensor C ala oj 866100 Starter 61 836831 End Kit With Bearing 836832 O Ring 836833 Rear Bearing AL4000 AUS LIGHT TOWER EREX amida Genset Kub 1105 L S 8 kW 866110 Radiator 866120 Radiator Cap 741140 Sender 866125 Cleaner Assembly 866126 Housing 866127 Element 866128 Cop 740455 Pre Cleaner 630412 Generator 836863 Capacitor 866030 Soleniod 866040 Gasket bu 0900900 00000000 856857 Diode 866080 V Belt 866070 Mechanical Fuel Older Models Only 866050 Oil Filter 866020 Gasket 83920
7. cce SM SNDIL23NNDO XIMI0S M Y Nid Ofidd 3D0123NNDO 39nv5 301919409 Y 319 193938 310d WON 40 SS3NDODIHI TIVA YAWOLSV 13 21159 IdOWSSHL 39918 414459 83100 g38802 OILSV IdDONS 3HL NOLLVINSNI S0LINANDI N3339 DT13A SD1vavd3s 09 da NADE HI9N31 3199931393 9 6 H19N31 ONINNOM 0 92 SNOISIA3N L LINER e n 5 G 9 L 40 i 5 9 L ime 335 TWIS 1 31 25 10N 00 wa SI 71568 d Wwe 33NI9N3 ONIH33NION3 NYW3109 nern BS ev HONM 21819313 M N3MOI LHON DNSVHONhd INI NVW3102 5 N04 TONLNOD PECET 30 SI 9NMYHO SIHL Sv 1632 sonaa Tw 53003
8. Change the type of engine oil according to the ambient operating temperature Above 25 C 77 F SAE 30 0 to 25 C 32 F to 77 F SAE 20 Below 0 C 32 F SAE 10W SAE 10W 30 Use 2 diesel fuel NOTES 1 The temperatures in the table are the ambient temperatures at the time when the engine is started If the running ambient temperatures are much higher than the starting temperatures 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 also be used if the sulfur content of the fuel exceeds 0 5 3 Always use a reputable brand of diesel fuel The sulfur content should be below 0 5 higher sulfur content would require more frequent oil changes Observe strict cleanliness when filling the fuel tank 4 Check the engine oil level before starting the engine or more than five minutes after it has been stopped Remove the dipstick wipe clean reinsert it take it out again and check the oil level If the oil level is too low remove the oil filler cap and add new oil until the FULL line on the dipstick is reached I9 FASTENER TORQUE SPECIFICATIONS All fasteners should be torqued to the following specifications in ft lb Nm These are average values and a 5 tolerance is acceptable FASTENER STAINLESS STAINLESS SAE GRADE 5 PLATED amp NUT NYLOC NUT UNC 303 509 134
9. LT7000 LT7 30 Foot Deluxe Hydraulic Tower w optional Acoustic Enclosure and Complete Instrumentation KW Rating 080 is 8 0 kW Diesel D Number of Lights Type of Lights European Version AL4000 Only HPS High Pressure Sodium MH Metal Halide MV Mercury Vapor TH Tungsten Halogen 68 TEREX LIGHT CONSTRUCTION Box 3147 Rock Hill S C 29732 MANUFACTURER S LIMITED WARRANTY TEREX LIGHT CONSTRUCTION TLC warrants to the original purchaser that such equip ment accessories parts and other products manufactured by TLC will be free from defects in work manship and material for a period of one 1 year after the date of first delivery or for one thousand 1 000 hours of use whichever comes first provided that Buyer sends TLC notice of such defect within thirty 30 days of its discovery Should defects be discovered the Buyer must clearly establish that 1 the equipment parts etc have been properly installed and set up maintained and operated within the limits of rated and normal usage and II the defect did not result in any manner from the intentional or negligent action or inaction of Buyer Buyer must also return the defective item or items to TLC Rock Hill SC for inspection at TLC s request If Buyer cannot establish that conditions 1 and II have been met then this warranty shall not cover the alleged defect Failure to give notice of defect within such period shall be a waiver of
10. DO NOT RAISE TOWER IN THE VICINITY OF OVERHEAD POWER LINES ALWAYS WEAR A HARD HAT WHEN OPERATING MACHINERY OPERATING INSTRUCTIONS In addition to the standard model light tower a mine spec variation is available which can be identified by the following additions Drip trays under fuel tank and engine sump Louvred vents in engine enclosure doors Mast tiedown chains Flexible conduit installed on light fixture cables Battery isolation switch Auxiliary power outlet deleted Residual current device RCD installed in generator output circuit Where appropriate differences in operating instructions and parts information for each model are highlighted I MOVE LIGHT TOWER TO DESIRED LOCATION KEEPING THE FOLLOWING IN MIND NOTE Although the light tower is designed to withstand the rigors of the environment it can only do so if it is properly set up and monitored to ensure that it remains set up according to the specification A Beware particularly during inclement weather conditions of the following Wind conditions maximum wind speed 100 km h risk of overturning Subsidence under stabilising pads or the trailer in general risk of overturning Proximity to vehicular traffic risk of collision Proximity to power lines risk of electrocution When left in public places risk of vandalism or theft n winter environments risk of structural or mechanical damage tis recommended that a contact phone numbe
11. dUYHS XN3NB Siung MONIY I NOLLINYISNOI ee xag uM mewa xs Sin isn Slavd IN NOUdIBOS3Q NO ON 9NUJUN3QI 80 1 pi eii T dN N3MO1 QION310S HONIM OL Img O ws Xu Ag 1HM AMBLIVA HONIM OL o ES O 9 NMOG Y3MOL GION310S HONIM OL 18 038 ojojejoj 1025 7303 song ojojejej ov 38nivs3dW3l MO19 1971009 Tanzes a N gt HOIH A 1 majas n AWNINYSL HOLMS T S 3371 0 9 N38 D a 6 6 x 2 15 Q Nu 5 i Nua Nua Nua Kl IHM vg E JE 734 4 L A IHM 29v G 9 ETE gt mg ei mg 033 ES IHM S LHM 038 x v 1595 980 550 950 o OIA g o3su z 2 olje 98 58 1515 iJ 039 Q10H E 5 dT nd 4318915 NUS o or Nua 18 1HM M3lv NYE 9 8 0 3105 T Tans Is 8 IHM 038 vor S 3503 p ThA ojo ym 61 _ E NOLLO8 HSNd Sen v4 1v3H3sd JOIVNH3LIV 038 9 i ava m SNOISIA JY mi 27 y 4 9 L 41 YAWIL NMOGLNHS OLNV TIOH LNOO ZOOL SLEE 2 19 XV4 0991 SZEE Z 19 VITVELSNV 9207 AYVONNOE 165 Q L1 Ald VIIVYLSNV 3IN39 ANVdlAOO V SAHOLIMS ANAL
12. electric winch toggle switch in the up direction to raise the tower After the tower has telescoped slightly the locking pin can be released Raise the tower to the desired height Stop when the red paint is visible on the 75mm 3 inch middle section CAUTION Do not over extend the light tower beyond the lower red mark on the middle mast section WARNING DO NOT ATTEMPT TO LEAN THE TOWER DOWN WHEN EXTENDED DEATH SERIOUS INJURY OR DAMAGE MAY OCCUR STARTING THE ENGINE GENERATOR SET CAUTION Ensure the circuit breakers are turned OFF This prevents the engine from starting under load and prevents electrical equipment from being damaged due to improper voltage and frequency If the engine was previously shutdown by the auto shutdown timer elapsing see Section XV the RESET button must be depressed before the engine can be re started Check the oil fuel and coolant levels If the fuel tank is empty it may be necessary to bleed the fuel line after filling the tank see engine instruction book for procedure Turn the ignition switch to the ACC position see adjacent OFF diagram Press the preheat push button for a maximum of 20 foe PRINS SECONDS Do not engage the preheat button longer than the time specified or damage may occur IGNITION LEGEND 12 VIII Turn the ignition switch to the START position to engage the engine After the engine starts release the switch so that it returns to the R
13. in the State in which the equipment is being operated 6 4 Spotter required zone Variations t i in sag Personal protection barriers NY M MY NY MY FRONT VIEW SIDE VIEW a Distribution lines up to and including 133 kV LEGEND No shading in the front views indicates no proximity requirements Light shading indicated spotter is required Heavy shading indicates the NO GO ZONE Guard Against Battery Hazards WARNING Lead acid batteries can be dangerous The sulfuric acid in the battery can cause severe skin and eye burns The hydrogen gas emitted during charging can explode if an arc or flame is present near the battery Use precautions to prevent acid burns or explosive conditions Do not smoke while servicing batteries Do not allow tools to touch battery terminals and create an arc Do not test battery voltage by setting a brief arc at the terminals use a multimeter instead Disconnect the negative terminal of the battery when working on the engine or other parts to prevent accidental arcing Disconnect the negative cable at the end away from the battery Always wear eye protection when servicing the battery When charging the battery do not remove the vent caps If acid does get on skin or in eyes immediately flush under running water and then obtain medical help as soon as possible Guard Against Fire Hazard Use caution with diesel fuel and motor oil because of fire hazards D
14. this Warranty and any assistance rendered thereafter shall not extend or revive it THIS WARRANTY IS LIMITED TO THE BUYER AND IS NOT ASSIGNABLE OR OTHERWISE TRANSFERABLE TLC MAKES NO WARRANTY WITH RESPECT TO PARTS COMPONENTS EQUIPMENT AND ACCESSORIES NOT MANUFACTURED BY TLC SUCH AS FIXTURES BALLASTS ENGINES HYDRAULIC PUMPS FUEL PUMPS ALTERNATORS GENERATORS WINCHES TIRES AND ELECTRICAL COMPONENTS Accessories assemblies and components included in products of TLC which are not manufactured by TLC are subject 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 warranty shall not cover misuse alteration abuse negligence accident acts of God sabotage or any item in which serial numbers have been altered defaced or removed but shall be limited to repair or replacement of those parts which upon inspection by TLC appear to have been defective in material or workmanship TLC s liability and Buyer s sole and exclusive remedy for a failure of goods to perform as warranted and or for any and all other claims arising out of the purchase and use of the goods including negli gence on the part of TLC shall be limited to the repair or replacement of defective parts returned transportation prepaid to TLC TLC shall in no event be liable for incidental or consequential or other damages or losses resulting fr
15. to thread the new cable through the lower tower and pulleys This can be done by untwisting the cable and inserting the wire or cord into the middle of the cable and thus letting the cable twist back tightly around the fish wire If the old cable is frayed cut off the frayed portion and proceed as above and then remove tower and cable as instructed in section 4 6 Pass the free end of the cable through the sheave slot between the large and middle sections and out of the top of the tower Pull the cable and the middle section completely out of the large section together Be sure to keep the cable tight if slack accumulates it is most difficult to remove If the fish wire doesn t work it is necessary to remove the square mast section from the round mast section Remove the pivot pin from the pivot post and lift the mast from the pivot post and place the mast assembly on a work surface Remove the hex nut from the bottom of the round section remove the bolt at the top of the round section and pull the square mast assembly out of the round section and proceed as instructed in section 4 6 Unfasten the cable by removing the bolt at the base of the middle section REINSTALLING THE LOWER CABLE AND MIDDLE SECTION 5 1 3 2 3 9 5 4 5 5 5 6 If the fish wire worked attach the new cable to the fish wire and pull through the pulleys and the round section If the square tower section was removed from the round section
16. tower section Tower Section Four inch square tube Tower Section Three inch square tube Tower Section Two inch square tube Crossarm Floodlight Fixtures Radiator Right Side Mounting Bracket Generator Mounting Engine and Generator Kubota D1105 Leroy Somer 8 kW Radiator Assembly and Mounting Ballast Box Assembly 50 Hz Electrical Box Assembly Auto Shutdown Timer Warranty Information Terex Light Tower Model Coding System Manufacturer s warranty statement Page 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 68 69 SECTION 1 SAFETY PRECAUTIONS The following symbols in this manual signal potentially dangerous conditions to the operator or equipment Read this manual carefully Know when unsafe conditions can exist Then take necessary steps to protect personnel as well as equipment A WARNING TEREX Amida uses this symbol throughout this manual to warn of possible injury including death CAUTION TEREX Amida uses this symbol to point out potential damage to equipment Lamps fuels electrical equipment batteries exhaust gases loose fasteners and moving parts present potential hazards that could result in serious personal injury Be diligent in following the procedures recom mended below Also observe the many additional general safety rules practiced by trained operation and maintenance personnel in your company and industry A WARNING Always we
17. zz TEREX LIGHT CONSTRUCTION SERIES AL4000 AU LIGHT TOWER OPERATION amp SERVICE MANUAL SERIAL NUMBER FOF 15872 AND LATER P N AL4000 AU REV 19 02 2007 TABLE OF CONTENTS Safety Precautions Safety Precautions Operating Instructions Light Tower Operating Instructions General Specifications and Routine Maintenance Recommended Engine Oil Fastener Torque Specifications Traceable Numbered Wiring System Criteria for Replacement of Wire Rope Broken Cable Replacement Procedure Cable Replacement Diagram Shim Placement Diagram Rear Bearing Inspection Requirements Engine see manufacturer s handbook Generator see manufacturer s handbook Troubleshooting Guide Light Fixture Troubleshooting Guide Light Tower Troubleshooting Guide Engine refer to manufacturer s handbook Generator refer to manufacturer s handbook Wiring Diagrams Fixture with Joy Connector MH Metal Halide Ballast 3 Pin Connector Wiring Diagram AC Wiring Trailer Wiring Coil Cord Wiring DC Wiring Control Box Wiring Auto Shutdown Timer continued next page Page 9 16 17 18 19 20 21 22 23 24 25 26 27 n a n a 28 30 31 33 n a n a 36 37 38 39 40 4 42 Parts Manual Decals Trailer and Related Part Fuel Tank Assembly Axle and Wheels Cabinet Assembly Tower Base Assembly Electric Winch Tower Assembly Tower Section Six inch diameter base tube Sheave and Shim Assembly Four inch
18. 0 of nameplate rating when operating at normal load Increase supply voltage or remove external load Improper ballast Proper HID lamps will perform erratically or fail to start on an improper ballast The ballast name plate data should agree with the line voltage and lamp used Improper ballast will cause lamp to fail LAMP STARTS Lamp has been operating MH lamps require from 4 to 8 minutes cool down SLOWLY ARC time before lamp is cool enough to restrike Switch DOES NOT off breaker and allow lamp to cool STRIKE WHEN SWITCH IS Defective lamp Lamp may glow for extended period of time Replace FIRST TURNED ON after checking voltage and ballast 28 LIGHT FIKTURE TROUBLESHOOTING GUIDE CONTINUED SYMPTOM CIRCUIT BREAKER TRIPS ON LAMP STARTUP LAMP LIGHT OUTPUT LOW LAMP COLORS DIFFERENT ARC TUBE DISCOLORED OR SWOLLEN SHORT LAMP LIFE CAUSES Short circuit or ground Normal lamp depreciation Dirty lamp or fixture Defective ballast Wrong voltage Improper ballast Normal lamp depreciation Dirty fixture Wrong lamp Over voltage from power supply Improper ballast Lamp damaged CORRECTIVE ACTION Check wiring against diagram Check for shorts or ground Replace lamp Clean lamp and fixture Interchange ballast plugs in generator enclosure If lamp returns to normal light output replace ballast Check for swollen capacitors charred wiring core and oil or other signs of excessive heat
19. 0 Fuel Filler 740260 In Line Fuel Filter E 865223 Electric Fuel Pump Frame Mounted 62 x C cc Lu O ES L gt Ilo o o 28 t E 5 3 lt 3 E o 2 5 2 5 5 2 oo c 5 5 5 8l 866120 Radiator 866110 63 Mode AL4000 AUS LIGHT TOWER TEREX amida rem 114359 Ballast Box Metcl Halide Assembly 50HZ 663860 5 Pin Connec tor 160490 Ballast MH ion 50 Hz Operati 160033 Capacitor MH 50 Hz Operation 64 TEREX amida Model 4000 05 LIGHT TOWER Title CNTL BOX LECTRICAL COMP 685155 Breaker Main 30 amp 663780 Toggle Switch 683870 Breaker 15A 1Pole 116807 Control Box Assembly Complete 116785 Wire Harness Engine INTERNAL COMPONENTS NOT SHOWN 116770 Wire Harness R661490 Relay 12 Volt N 682715 Red Indicator 112564 Coil Cord Assembly w Junction Box lt gt 65 685660 7 Pole Plug 660287 Coil Cord Only 260361 Hourmeter 663880 Cap w Chain 852800 Decal 663890 680080 Strain Relief Cordset 5 Pole Ballast L Zu i
20. 1 2 1 3 2 1 2 2 2 3 2 4 2 5 2 6 3 1 3 2 2 2 BROKEN CABLE REPLACEMENT PROCEDURE CAUTION The wire rope must only be replaced with the genuine Terex part This ensures the rope is replaced with the correct grade and rope construction and also a rope of sufficient length PREPARATION refer to fig 1 cable replacement diagram and fig 2 shim placement Collapse tower to where mast is retracted then pivot tower to horizontal position Remove the fixtures and the power cord from the tower Remove the tower from the trailer and place it on a work surface such as two saw horses Lower Cable Sheave Brackets _ z D Telescoping Lock Large Section Middle Section Rivets Small Section REMOVING TOP CABLE AND TOP MAST SECTION Tie middle section and large section together by wrapping band cable chain or rope around the sheave brackets on these two sections This ensures that the middle section stays inside the large section during removal of the small section Remove or lock the telescope lock pin open This is the pin that locks the three sections together during travel Drill out the pop rivets holding the plastic guides at the top of the middle section Using a screwdriver remove these guides Remove the clevis pin anchoring the cable to the top of the middle section and remove the clevis pin a
21. 1 4 NMOGLNHS OLNY 61 1 1 LL6LSNY NMOALNHS OLNV NMOGLNHS OLNV HIMYIHA Tvoad OL6LSNV LL AT8W3SSV TIVH3N39 NMOGLNHS STONLNOO 1v23d 906 snv or 200 9466 19 099 9766 Z 9 4 g ANVdWOO X3a L V V 2 d3 v3id8 LINDUID z 6 ro ii 259 HOLMS 919501 1008 owzuz s QLTALd VITVALSNY v ASVLNFWON 1095 HOLIMS 319901 15081 2 PND AWTS v ece 9 MOWIS YJLNIOd SONM zeeisnv os I OWT GON as LAVHS v LVIQ GAL MOVIE ONA X Oceisnv vs ANON v AVISNNMOGLNHS e ZL AVIAN TOSLNOD ASV3 6 5 z 00968016 3unsoloN3 zieisnv OoNiuva wau OAS NOILISOd LAMIS NI HOLIMS GALYVLS SI YAWIL 340338 ONINNNY 38 LSNW 3NION3 14544 Ache 401 NMOGLNHS O1NY 66 SECTION 6 WARRANTY INFORMATION LIGHT TOWER MODEL CODING SYSTEM IMPORTANT WHEN REQUESTING TECHNICAL HELP AND ORDERING REPLACEMENT PARTS THE MODEL AND SERIAL NUMBER ARE NECESSARY REFER TO THE TEREX SERIAL NUMBER TAG ON THE UNIT FOR CORRECT MODEL NUMBER AND SERIAL NUMBER MODEL NUMBER IDENTIFICATION Sample Light Tower Product Line 080 D 4 MH CE Tower Series AL4000 AL4 30 Foot Basic Tower with winch in cabinet AL5000 ALS 30 Foot Basic Tower with in cabinet light storage and door insulation
22. 5 Tongue weight w lights on 56 7kg 125 Ib 381 mm 15 Tyre pressure a MM DE 220kPa 32 psi Axle 1587 kg 3500 Ib Tot l weicht ee ba agan a gae 1014kg 2235 Ib Puel Capaeify cc 114L 30 gal Unit weicht with full Biel EHE ee 1109kg 2445 Ib Max num ceca ee ceeds ae 100 km h 60 MPH Maximum wind Speed ss asasaran anaa aaa decease shaders an naga a 100 km h 60 MPH Beaufort scale 10 whole gail None Lern P 62 dBA 7 m Electric ee dee vet eve ete eras 12 V 1800 kg 4000 Ib Auxiliary Power Outlet Mine Spec Excluded 10 A 240 V 50 Hz 2500 W 17 BRAKE SYSTEM This light tower is fitted with hydraulic surge brakes and a manual park brake Hydraulic brake system requires DOT3 or higher brake fluid Service interval for brake adjustment every 200 hours ELECTRIC WINCH CAUTION The winch wire rope must be inspected periodically according to the instructions on page 22 The wire rope must only be replaced with the genuine Terex part A A WARNING Never stand under any object lifted by a winch The electric winch is permanently sealed and does not need any periodic lubrication The electric winch must only be replaced with the genuine Terex part AUXILIARY POWER OUTLET MINE SPEC EXCLUDED A competent person must test the RCD according to AS NZS 3760 ev
23. 5 519 arin NOlLdIOS3Q MO IALVTONINON ON YO Lave n iat 015 385337 1424 SNINNNA NOILVINAlAU SOLVOIGNI 1431 LHOIT 325238 14341 LH9I1 DNINNNA THUNSS T A ADT113A LHOIT 3332398 3533217 CJ NADSG NADJA 3017951108 144 T ANNADAS LHOIT SNINNAY JAWAT LIHOIS MOLVOIGNIT LHOTA 555 T ADU 33IA ayo aa x DEI s 22 39 Y 5 9 L I 3 ime 3wos 531 25 SiL 31935 104 00 _ a 50 90 40 wa NM vag SI 95 9 60 90 40 Wa Pete a re xs 30 NOISSINI3d NALIN 0790710 wa O3NONddV Non angola ANY ONIBIM QNOD 109 ONBI33N9N3 9102 M3MOL LHOM Nvrvalsnv 30 SI ONMYAIO SIHL 06162 T 3008 wanti Sy 14303 06 50838 3 NOLLONULSNOS ital Xa N m sow samana xx sawana xe 30 9 Nid NMOYH 4 NOILdINOS30 HO 3MhLYON3ON ON 9NAJUN3O YO Lawa a 3019 3 el LI3NN Ja 1415 MOTI3A Nid AMLN4 JAIA WOdd SLIHM 2 Nid 039 8 Nid OVIB V Nid YOLOANNOO Nid 4 G 9 Sin
24. 5 yd Tea sep 2269 L T m 25365 2169 3589 a T7495 saen Joao nas mare isc so 3 ess sea ne 3 89 33s asa 35619 non T im 2007 1869 om 4064 3406 5385 T sm aa 10036 15003 om 9055 16212 465 so 569 amu 669 37G0 ss san was iom fumo im Com fesses T j An anti seize lubricant MUST be used on all stainless steel hardware 20 TRACEABLE NUMBERED WIRING SYSTEM Using plug in ballasts to troubleshoot When troubleshooting the proceeding problems minimize down time by following the traceable numbered wiring system always follow these steps STEPI Ensure all ballasts 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 appropriately numbered plug at the top of the tower WARNING Ensure that the engine is not running and that the breakers are turned off when connecting and disconnecting the light fixtures and ballast cables By adhering to the traceable numbered wiring system troubleshooting fixture aiming and fixture control will follow a standard predictable pattern 21 CRITERIA FOR REPLACEMENT OF WIRE ROPE TEREX AMIDA LIGHT TOWERS The wire
25. 9 109k OMpSOGke Mine Spec AUS1873 Conduit Fitting AUS1874 Adaptor AUS 1877 Flexible Conduit 833709 Cable Assembly 58 s AL4000 AU LIGHT TOWER TEREX tf amida Radiator Right Side Mtg Brkt C 1000000004 BANA Engine Blook 0 4 2 Bi 4 R980175 Flat Washer ea 4 994830 Lockwasher 4 995110 Screw Radiator Mounting Bracket 2 990190 Screw 2 189290 Engine Mounting Bracket 2 991650 Lock Washer 2 740920 Vibration Mount Assy 2 990410 Fender Washer 59 AL4000 AU LIGHT TOWER TEREX W amida Generator Mounting 00000000 00000000 630412 Generator 4 990200 Lock Nut 2 990190 Screw 2 991650 Lock Washer Pd 17 2 990410 Fender Washer 189555 Generator Mounting Bar 4 990210 Flat Washer 2 990820 Bolt 2 740920 Vibration Mount Assy Trailer Frame Chonnel 60 TEREX amida 42 ode AL4000 AUS
26. ING PIN ah z VERTICAL LOCKING PIN N N AA om N A oma I PIVOT PIN N TELESCOPING LOCKING PIN KICK OUT SPRING 11 VI gt gt VII P RAISING THE TOWER refer to drawing on the previous page MINE SPEC ONLY Disconnect the two 2 mast tiedown chains from the crossarm Remove the tower travel locking pin from the cradle at the rear of the cabinet Failure to remove the tower travel locking pin may cause winch overload Aim the fixture both horizontally and vertically to the estimated angles that will light the Work area CAUTION Ensure that the safety locking pin is removed from the vertical locking pin at the base of the pivot post prior to raising the tower Activate the electric winch by pressing the winch toggle switch in the control box in the up direction this will raise the tower to the vertical position The vertical locking pin at the base of the pivot post will lock automatically and you will hear it snap into place Manually insert the safety locking pin into the locking device and secure with the attached hairpin clip Release the tension on the cable by pressing the winch toggle switch in the control box to the down direction loosen cable approximately Ya 1 2 turn Pull the telescoping locking pin on the galvanized tower section Hold this out while pressing the
27. LNV1000 ANY N NOILINSI X 18 033 S8 42 56344 110 OL al te T 1903 OL eg 0 18 06 18 Av 138 SNILSIX3 LH917 DHO OL 8 0 zu Av 138 M3N SECTION 5 PARTS MANUAL Mees AL4000 AU LIG TEREX i amida T TOWER Decals 850091 BOOM 851640 853296 853296 LH SIDE RH SIDE AUS1845 Terex amida Terex amida AUS1845 AUS1000 850150 853312 853312 853291 REAR 850093 Terex amida 850092 853301 REAR MINE SPEC 853070 853291 MINE SPEC ONLY 850093 851860 850092 853301 44 Mode 4000 LIGHT TOWER TEREX amida Trailer Tongue Outriggers 841430 Swivel Jack 840221 Jack Snap Ring 840221 Swivel Jack Bracket 4 721051 Cap Outrigger Tube 174170 Battery Hold down Bracket 161085 Battery 700CCA T N SS I NI 7 SN E _ NM LN 160270 Battery Cable Set gt 110040 Front Outr 182331 Battery Hold down Rod 171909 Hydraulic Line Bulkhead N 124412 Trailer Frame Weldment 840222 Jack Snap Ring 840221 Swivel Jack Bracket 124474 Tongue Weldment 45 114480 Outrigger Meas ALAOOO AU LIGHT TOWER TEREX 5 amida
28. MS aay 1 ONnON9 2 Nid H3MOd DVAOZT 1 9 Nao eh TONINOO gt SOIIINNOI 751 ext esed c mH 15 MOLVH3N3O 30 3Ql5NI ONnONO OL N3380 MOLVM3N39 40 30ISNI 931 TYMLR3N OL H 3LIHM MOIVH3N39 40 3QISNI 931 OL di vor 3oviH Sod 05 8 01 uayvaue NIVA SON3 03138v1 ONY 2 J OS lt 01 30 N313W ma aa usa 187 SNOISIA 3S L SUN D S 9 L 8 e JHL 804 ONIUM HIYA 3504084 1001 996 08 OLBE DS 30 Alu3dOsd SIHL Kann OMON SY 193943 06 SONIA TN 3 53003 davis ANY Sand JAONIY oF so Snow xxx m3 sawa xx o3 1 ume 3125 11 25 Sri 3195 ION 0 s0 12 10 wa NAYA SI IN 511989 CT eris ums ON NN ONG xs 30 NOISSING3 NALLI 90 18 40 wa 3 ONdHY ANY M3WOL LHOM Nvrivarisny DNSvWONId ONRI3NION3 NVI SOLVIIGNT Nant E 15 41 Asan 1
29. UN position Let the engine come up to speed and stabilize review the engine operating procedures in the manufacturers handbook Note If engine will not start leave switch in run position for additional 15 20 seconds maximum of 45 seconds to completely prime the fuel system Then repeat step D and start engine TURN ON THE FLOODLIGHTS Turn on the main circuit breaker Turn the circuit breakers ON and check to ensure all lamps come on Allow a minimum of two 2 minutes for lamps to reach full luminance If required rotate the tower to aim the lights as desired Tighten the tower rotation T bolt Adjust the tower vertically and adjust lighting direction of individual fixtures if required TURN OFF FLOODLIGHTS Turn light circuit breakers off Turn main breaker off Allow the engine to run approximately 30 seconds after load has been removed prior to turning off the engine Turn engine switch to OFF to shut down the engine CAUTION Do not shut down engine prior to turning lights off CAUTION Allow lamps to cool at least ten to fifteen 10 15 minutes before moving the tower to avoid lens or bulb breakage LOWERING THE TOWER TO TRAVELING POSITION Using the electric winch telescope the tower down to its fully retracted position until the telescoping locking pin snaps into place CAUTION Ensure that the telescoping locking pin locks before pulling the vertical locking pin at the base of the pivot post This e
30. UTION Hot Surface decal adjacent to exhaust tailpipe Be Alert And Attentive To The Task Read the safety instructions and operating procedures before attempting to troubleshoot or work on this unit Also read the engine and generator manuals which are separate booklets that are provided with this manual Do not work on this equipment when mentally or physically fatigued Do not work on or operate this equipment when under the influence of performance impairing drugs or alcohol If this manual becomes lost order a new one from Genie Australia so future operation and maintenance personnel may read these instructions Beware Of Moving Parts Avoid being hit or pinched by moving parts of this unit WARNING Loose jackets shirts sleeves and especially neckties should not be worn while work ing on or running the unit Serious injury or death may result Only remove guards or protective devices from unit temporarily to gain access for maintenance Always replace guards and protective devices promptly Keep your hands away from moving parts Particularly be sure to keep hands clear of the blower and alternator belts when the engine is running Take note of WARNING Entanglement Hazard decal on kerbside and roadside doors Beware Of Traffic Hazards Stand clear of traffic when starting or checking the unit along the road Implement a traffic manage ment system before setting up the unit Check the fuel tank oil pan and fuel and oil
31. anic inspect the valves Have a trained mechanic inspect the governor and injector pumps Drain oil to its proper level Have a trained mechanic inspect for broken or seized rings Also inspect the valve clearance Inspect the front and rear intakes and clean clear as needed Replace the coolant with a 50 water coolant solution Clear the radiator fins Tighten fan belt Have a trained mechanic inspect the alternator LIGHT TOWER TROUBLESHOOTING GUIDE CONTINUED SYMPTOM CAUSES ENGINE RUNS BUT THE Circuit breakers are tripped LIGHTS WILL NOT OPERATE Loose connections in the wiring system BURNED OUT BULB Replace bulbs as needed Defective capacitor Leroy Somer generator Defective AC generator Engine speed is too low UNUSUAL NOISE The generator has a defective bearing COMING FROM THE or has a damaged fan blade GENERATOR CORRECTIVE ACTION Reset the circuit breaker Have a trained electrician inspect the ballast box wiring system Have a trained electrician inspect the capacitor Have a trained electrician inspect the generator Have a trained mechanic inspect the engine speed and reset to 1500 RPM 50 Hz Have a trained electrician inspect the generator WARNING 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 oper
32. ar a hard hat when operating the light tower Guard Against Electric Shock This light tower also has provisions for producing high voltage electricity that can produce a fatal shock to a person who accidentally places their self in the electrical circuit Use every precaution to avoid contact with the high voltage electric circuit Beware of a cut or damaged power cord Replace immediately Take extra precautions when troubleshooting electrical problems When troubleshooting indicates a malfunction in the high voltage AC system pass the troubleshooting task on to a qualified and trained electrician Disconnect electrical power and turn off engine before removing protective covers on high voltage electrical enclosures Understand that the electrical circuits in this light tower complete their paths back to the generator within the equipment The neutral conductor at the generator is bonded to the equipment frame Earth ground wires within the system are also bonded to the equipment frame 6 4 Guard Against Electric Shock Power Lines Ensure protection against overhead high voltage power lines This light tower is not insulated Any contact with high voltage power lines will result in death or serious injury See diagram below for recommended clearances from overhead aerial conductors Note The specified clearances are recommendations It is the responsibility of the person in charge to comply with the applicable regulations in force
33. ation in the field 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 1800 331 660 33 This Page Left Intentionally Blank 34 SECTION 4 WIRING DIAGRAMS vss6z DMa S8620M 1HVd 16 06 ILYA L6 0 F 1014 avos ud LYN HOLO3NNOO AOF M LYN A samben ee HLHV3 GNNOYD MOTI3A M N33H9 N3349 LOLL 99E LLOE FZE 08 NGA 1 5 PH 06S 300 FEXXXX 1SVTIV8 WOH LOH 010 060 SIEWIOSA 15 11 8 WOH NOWINOO 3LIHM eprure xoJoT 91 17 Sun Wily 391412345 ASIMYSHLO SSFINN SS3ONVH3 TOL 300 3SNVHO 093 3lV HO102 HO102 DNIHIM 39 NVadouna aaaav 00 51 V NvadOHn3 OILS3INOG SSYNLXIS N3901VH NSLSONNL HO 3INVS JHL SI NOLLVHNDISNOD Nid LON N yov a l O G3A NHO N3385 tO _ 31IHM v Dadi NOILdIHOS3d LHYd 862 Md G8620M LHVd 36
34. c AUS1031 Battery Isolator Switch AUS1190 Isolator Switch Lockout Kit 188530 2 Cabinet Front 176370 Literature Rack 124430 Cabinet Rear 2 123490 Fender 188580 Cabinet Curbside 4 791840 Rubber B 2 184155 Taillight Bracket HESSE SATUPRE 2 686775 Taillight 2 841350 Reflector Amber 2 841340 Reflector Red 48 TEREX amida AL4000 AU LIGHT Cabinet Assembly 116180 1 Rear Tower Support 4 796436 Gas Shock 4 796432 Door Shock Bracket 2 796610 Hinge 18 990670 Rivet 113399 Ground Rod 720220 Bumper 790540 Pin 124460 Tower Support Crodle 123680 Pin 188550 2 Cabinet Top 794940 Plastic Plug 4 2 790940 Handle Standard 2 188560 Cabinet Door Mine Spec AUS1858 Cabinet Door Assembly 2 189796 Hasp Kit Includes LH and RH Doors 49 od AL4000 AU LIGHT TOWER TEREX W amida Tower Base Assembly 160995 Electrio Winch 124490 Tower Base 195750 Kick Out Spring 186360 Bumper Pad 184510 Spool Sheave 120222 Pin Slide Lock 113362 Pin Slide Lock Assembly 50 Mode ALA000 AUS LIGHT TOWER TEREX le Tower Assembly 113080 Coil Cord Sleeve 51
35. ce in the storage provided inside the trailer Ensure that the tow coupling is properly secured to the towing vehicle and safety chains are attached Raise the jockey wheel and rotate and lock in position Release the manual park brake Do not tow at excessive speeds 100 km h or 60 mph maximum as the weight of the light tower can cause loss of vehicle control especially under emergency conditions AUXILIARY POWER OUTLET MINE SPEC EXCLUDED Total auxiliary power cannot exceed 2500 W A 10 Amp residual current device RCD is installed in the auxiliary power outlet circuit Before plugging in extensions cords feed them up through the trailer frame and connect to the outlet Close the cabinet doors to protect control panel and other components from weather see Miscellaneous Specifications and Routine Maintenance section for power control details Ensure that all extension cords are protected from damage and water The operator must test the RCD using the test button daily or before every use whichever is the longer Ensure that the RCD is on then push the test button and check that it trips 14 XIII XIV XV GENERATOR RESIDUAL CURRENT DEVICE MINE SPEC ONLY A 20 Amp residual current device RCD is installed in the generator output circuit The operator must test the RCD using the test button daily or before every use whichever is the longer Ensure that the RCD is on then push the test button and check that it tri
36. d 26 Rear Bearing Inspection Requirements Leroy Somer 6 amp 8 kW Generators The rear bearing on all 6 amp 8 kW generators should be inspected every two 2 years or 2000 hours whichever occurs first The bearing should be replaced at three 3 years or 3000 hours Careful attention to this inspection procedure will prevent total generator failure resulting from bearing or bearing carrier deterioration There are two areas to examine during the inspection First is the clearance between the bearing outer case and the generator bearing carrier NDE Bracket The bearing should fit snugly into the carrier so that it can be rotated only with some resistance Side to side movement should be less than 010 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 bearing and O Ring The second area of concern is the bearing itself If roughness can be felt when rotating the outer race of the bearing the bearing needs to be replaced 836828 The other area to check is to see if the outer race will rock back and forth along the bearing axis If there is movement in this axis replace the bearing If neither of these conditions exist replace the bearing retaining O Ring 836830 and reassemble Note These bearings are sealed units and cannot be field serviced Follow the same procedure at three 3
37. ery 12 months GENERATOR RESIDUAL CURRENT DEVICE MINE SPEC ONLY A competent person must test the RCD according to AS NZS 3760 every 12 months TRAILER Periodically check the condition of the trailer including the fuel tank lighting and structure NOISE LEVEL Mean SPL sound pressure level hemispherically at 7 meters 62 01 dBA Sound Power level ep M 90 0 LWA re 1 pW WIND SPEED RATING The AL4000 AU light tower has a wind speed rating of 100 km h Beaufort Scale 10 The light tower must be set up as per the operating instructions in this manual to achieve the maximum wind speed rating of 100km h in any direction STATUTORY APPROVALS The Terex AL4000 AU light tower is built to the following standards AS 2790 Electricity generating sets Transportable AS 3010 Electricity installations Generating sets AS 3713 Acoustics Industrial trucks Noise measurement AS 1170 2 Structural design actions Wind actions 18 OIL AIR SERVICE Change the engine oil after the first 50 hours of use and then every 200 hours thereafter Replace the oil filter at 250 hours 2 oil change and after every 400 hours of use thereafter The air filter element should be replaced once every year or after six cleanings see manufacturer s operation manual for details RECOMMENDED ENGINE OIL amp FUEL KUBOTA D1105 DIESEL ENGINE Engine oil should be MIL L 2104C or have properties of API classification of CD grades or higher
38. ight Tower wire rope is due to operator error in using the winch or damage to the cable by tools or other machinery The most common error occurs if the winch is operated when the mast is fully retracted and the telescopic locking pin locked but the vertical locking pin at the base of the pivot post is not pulled out so that the mast can be lowered into the cradle This can result in three problems the loose cable can get trapped underneath itself resulting in a sudden or partial drop of the mast when the loose section releases at a later time thus damaging the cable or the cable can jump off the winch drum and be damaged by the gears of the winch The loose cable can also cause the drum to spin to take up the slack cable Other reasons damage can occur are due to some outside force such as forklift blade nicking or crushing a cable when moving a unit or an accidental blow or damage by a hand tool etc DAMAGE INSPECTION If any nicks partial strand cut through kinks permanent bends or weld spatter on the cable from field service are observed the wire rope should be changed immediately The wire rope must only be replaced with the genuine Terex part If there is a crushed spot somewhere on the wire rope it should be replaced if the width of the crushed spot exceeds 1 1 4 times the nominal diameter of the cable 5 16 on a 1 4 cable and 7 32 on a 3 16 cable or if there are broken wires at the point of damage 22 A 1 1 1
39. lines for leaks that would spill fuel or oil on the road Check fasteners and mounting brackets periodically to ensure all are tight and nothing is in danger of falling off during transit Be Careful When Lifting Use the lifting eye or forklift pockets on the tower for lifting the trailer and tower assembly only Make sure any tie downs at the bottom of the trailer are released and the cradle retaining pin is inserted and secured prior to lifting WARNING NEVER suspend any other equipment from the shipping tie downs Serious injury or damage to equipment may result Use Only Equal Replacement Parts When a part fails and needs to be replaced only use equivalent parts of equal performance and strength When a bolt is lost or fails replace only with the equivalent size length thread grade and material Replace stainless steel fasteners with stainless steel fasteners The engine may use metric or SAE bolts but all other bolts are generally SAE thread Be sure to use Grade 8 bolts and nuts to mount the genset to the trailer If the material grade of a fastener is in question contact Genie Australia for information or part replacement Replace the fuel and oil hoses with items of equal material diameter and length The wire rope must only be replaced with the genuine Terex part Contact Genie Australia regarding replacement parts Use Caution Working Near Lamps WARNING This unit is equipped with metal halide lamps Metal halide lamp
40. mida 3 Tower Section ALA000 AU LIGHT TOWER NOTE Replacement Cable Kit Order Part 109065 990670 Rivet 2 994920 185290 Shim Cotter P LRL See Orientation 990650 Below Cotter Pin 188760 Sheave 992765 Clevis Pin 2 995790 Clevis Pin 124550 3 Tower Section 192904 Orientation of Shims Inside Tube 185290 3 8 Shim 996230 3 8 Screw 990470 Lock Washer S 3 177820 5 16 Shim 55 ALA4000 AU LIGHT TOWER TEREX amida 2 Tower Section NOTE Replacement Cable Kit Order Part 109070 124560 2 Tower Section 190570 Cable 990470 Lock Washer 996230 3 8 Bolt 56 TEREX lt amida Model ALA4000 AU LIGHT TOWER Title CROSSARM e 993180 Nut lock 3 4 990230 Washer Flat 3 4 Cep 720495 Plastic Washer x 981285 ring 790720 spring 69207 59972 Plate lock Clevis pin 57 Mods AL4000 AU LIGHT TOWER Q 7 m OB n TEREX amida TET gt Mine Spec AUS1873 Tie Down Lug 161055 Complete Fixture Assembly MH 124505 Yoke 833708 Lens Gasket 663850 Cordset 3 Pin 5 160077 Lamp 1000MH BH37 833707 Glass Lens 82
41. mine and repair as needed Have a trained mechanic inspect and replace the winch as needed Have a trained mechanic inspect and replace the winch as needed Have a trained mechanic inspect and replace the cable amp pulley as needed Check the battery voltage or for loose cables Have a trained mechanic inspect and repair as needed Fill tank with 2 diesel fuel Press RESET button on auto shutdown timer Check and clean the fuel system as needed Replace any leaking fuel lines amp tighten connections Replace glow plugs Replace fuel line solenoid LIGHT TOWER TROUBLESHOOTING GUIDE CONTINUED SYMPTOM ENGINE RUNS ROUGH ENGINE RUNS BUT PRODUCES A DENSE SMOKE ENGINE OVERHEATS LOW COOLANT LEVEL ENGINE RUNS BUT THE BATTERY VOLTAGE IS LOW CAUSES Clogged or leaking fuel system Clogged exhaust system Clogged air filter Clogged or stuck fuel Valve clearances are out of adjustment or the valve spring s may be damaged Defective governor Crankcases oil level is too high Low compression Blocked radiator air intake Heavy duty use small leak Radiator fins have become clogged Fan belt is loose Alternator has failed 32 CORRECTIVE ACTION Replace fuel lines tighten all connections Inspect the pickup tube and inspect the fuel filter Clear the exhaust system Replace the air filter Have a trained mechanic inspect the injectors Have a trained mech
42. nd the sheave from the middle section Pass the free end of the cable through the sheave slot between the middle and small section and out of the top of the tower Pull the cable and the small section completely out of the middle section together Be sure to keep the cable tight if slack accumulates it is most difficult to remove Unfasten the cable by removing the bolt at the base of the small section REINSTALLING THE SMALL SECTION Fasten new cable to the base of the small section Reversing the procedure described in steps 2 1 through 2 5 reinstall the small section Reinstall the plastic guides with new pop rivets New plastic guides should be used but the old guides can be used if their mounting position is shifted to the point where new holes can be drilled in the tower section to provide a good fit when installing new pop rivets 23 4 4 1 4 2 4 3 4 4 4 5 4 6 4 7 REMOVING THE LOWER CABLE AND MIDDLE TOWER SECTION Remove or lock open the telescope lock pin if not previously done in step 2 2 Drill out the pop rivets holding the plastic guides at the top of the large section Using a screwdriver remove these guides Remove the cable from the winch drum Remove the sheave clevis pin and the sheave from the top of the large section If the old cable is not frayed between the winch and the bottom mast pulley attach a flexible fish wire or snake wire rope cord etc to the end of the cable to be used
43. nsures the tower is completely lowered and cannot be damaged by telescoping out while in the travel position Loosen the tower rotation T bolt Rotate the tower so that the groove in the galvanised ring at the pivot is pointing to the rear of the trailer to enable the tower to be lowered into the travel position Tighten the tower rotation T bolt CAUTION Ensure that personnel are not in close vicinity to the tower particularly behind the trailer when the tower is being lowered 13 XI XII Pull the vertical locking pin at the base of the pivot post the kick out spring should provide sufficient pressure to start the tower pivoting over when the electric winch toggle switch is pressed in the down direction Continue to lower the tower into the cradle using the electric winch Insert the tower travel locking pin into the cradle Secure with hairpin clip RELOCATING LIGHT TOWER TO NEW LOCATION Ensure that tower has been properly lowered see Section X and all locking pins are engaged Ensure all fixtures are rotated down and that adjacent fixtures face each other to minimize possible damage during transportation MINE SPEC ONLY Attach the two 2 mast tiedown chains to the crossarm and tension using the turnbuckle CAUTION Ensure manual park brake is engaged before retracting outriggers All jacks must be raised swivelled up and all outriggers locked into travel position Disconnect the earth rod and lead and pla
44. o not fill fuel tank while engine is running 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 equipment Have a fire extinguisher nearby Be sure the extinguisher is properly maintained and be familiar with its proper use Extinguishers rated ABE by the FPAA are appropriate for all applications Keep this unit clean of excessive build up of spilled oil and fuel Accumulated oil and fuel can cause overheating and subsequent engine damage as well as present a fire hazard Protect The Environment And Practice Good Industrial Hygiene WARNING DO NOT USE INDOORS UNLESS PROPERLY VENTILATED OR AN EX HAUST SCRUBBER IS USED EXHAUST GASES ARE TOXIC Provide an adequate exhaust system to properly expel discharged gases Check exhaust system regularly for leaks Periodically check to ensure that the exhaust manifolds are secure and not warped see maintenance schedule in manufacturers handbook Make sure the unit is well ventilated Prevent pollution by catching used oil in a container for proper disposal Wash hands to remove oil and fuel Practice good industrial hygiene Do Not Touch Hot Parts WARNING The exhaust manifold and tailpipe are very hot Parts of the engine are also hot Avoid touching hot parts of the engine or tailpipe Use protective gloves when handling hot parts Take note of CA
45. om a breach of warranty such as but not by way of limitation labor costs loss of profits loss of use of other than equipment third party repairs personal injury emotional or mental distress improper performance of work penalties of any kind loss of service of personnel or any other damages or losses which may be experienced by the Buyer A product warranty certificate must be filled out in its entirety and returned to TLC in order to process any warranty claims submitted THIS WARRANTY IS EXPRESSLY IN LIEU OF AND EXCLUDES ALL OTHER WARRAN TIES EXPRESSED OR IMPLIED INCLUDING ANY WARRANTY OF MERCHANTABIL ITY AND FITNESS OF ANY PRODUCT OR GOODS FOR A PARTICULAR PURPOSE AND ALL OTHER OBLIGATIONS OR LIABILITIES ON TLC S PART AND TLC NEITHER ASSUMES NOR AUTHORIZES ANY OTHER PERSON TO ASSUME FOR TLC ANY OTHER LIABILITY IN CONNECTION WITH THE SALE OF TLC S PRODUCTS THERE ARE NO WARRANTIES WHICH EXTEND BEYOND THE DESCRIPTION ON THE FACE HEREOF 69
46. ortened A mismatch may also cause the ballast to fail Improper ballasting can cause flickering or erratic operation In the start up period the lamp may ignite start to warm up and then extinguish cycle Under certain conditions new lamps may cycle Usually after three 3 tries to start at 30 to 60 second intervals lamps will stabilize and operate satisfactorily Replace lamp Ballast produces high spike current Measure with oscilloscope Replace ballast as required 30 LIGHT TOWER TROUBLESHOOTING GUIDE The engine and the generator are set at the factory These units are tested and set to 1500 RPM at 50 Hz for proper operation in the field These units should never require additional adjustments in the field Adjustments should only be made by a qualified service technician otherwise the manufacturer s warranty may become void SYMPTOM TOWER WILL NOT RISE TO THE OPERATING POSITION BOOM WILL NOT TELESCOPE ENGINE WILL NOT TURN OVER ENGINE TURNS OVER BUT WLL NOT START CAUSES Cradle pin is in place Defective cable or pulley Defective winch Defective winch Broken cable or pulley Dead battery connection The engine has seized Empty fuel tank Auto shutdown timer not reset Clogged fuel lines or filter Leaking fuel lines or a loss of prime Glow plugs burned out Fuel line solenoid is not open 31 CORRECTIVE ACTION Remove cradle pin Have a trained mechanic exa
47. ps LEAVING THE LIGHT TOWER UNATTENDED Before leaving the light tower unattended secure all items and lock the cabinets to prevent unauthorised use Be mindful that weather conditions may change and ensure that an emergency response procedure is in place Arrange for periodic inspections where necessary Protect the light tower against vandalism and wilful damage by securing the tower and locating it in a secure area AUTO SHUTDOWN TIMER OPTION An auto shutdown timer is available as an option for standard and mine spec light towers The timer will shutdown the engine after a preset run time so that the light tower may be left unattended see Section XIV The engine must first be running before the timer can be started AUTO SHUTDOWN STOP 14 N Q ON START 8 1042 C CIRCUIT BREAKER HOURS 4 RESET ENGINE MUST BE RUNNING BEFORE TIMER IS STARTED HOLD SWITCH IN START POSITION FOR 3 SEC 15 XVI To start timer hold switch in START position until ON lamp illuminates for about 3 sec Select desired run time using rotary switch 6 14 hours The timer can be stopped before the preset run time has elapsed by toggling the switch to the STOP position ON lamp switches off After the preset run time has elapsed the RESET button will trip and the engine will shutdown The RESET button must be depressed before the engine can be re started CAUTION Ensure the circui
48. r is displayed on the unit II The light tower should not be placed where those working under the light are either 1 Forced to look into the light regularly 2 Forced to work with their backs to the light shadows will block the light from the work area The area where the tower is positioned should be firm and relatively level The trailer must be set up within the range indicated on the level gauge provided on the drawbar The light tower should be located on the same level or on ground higher than the area being lighted higher light mounting heights reduce shadow length Unit should be level to ensure smooth trouble free tower telescoping Tower may not telescope down properly when unit is not level UNHITCH FROM THE TOWING VEHICLE AS FOLLOWS CAUTION Ensure manual park brake is applied before unhitching from vehicle Swing the jockey wheel into position and crank jack up to lift tongue off the towing vehicle LEVEL THE TRAILER USING THE JACKS AS FOLLOWS Extend the front and rear outriggers until the lock pins snap into place Swing the jack on each outrigger into vertical position and lock into place Use dunnage under the pad if the ground surface is soft Start at the highest jack position Rotate the jack handle until the jack foot touches the ground Raise the other jacks to level trailer Use the level gauge provided on the drawbar to ensure the trailer is level Ensure that all jacks are down to prevent the to
49. ropes used to raise and lower the masts on a TEREX Amida Light Tower are probably some of the most important mechanical parts used in day to day operation of the machinery It is therefore very important that the cables be inspected on a frequent basis once a month for wear and tear and immediately in the event of possible damage due to operator error in using the winch or possible damage from other equipment NORMAL WEAR AND TEAR When used properly the wire ropes should give years of trouble free service depending on how often the masts are raised and lowered The rule of thumb at TEREX Amida is that if the tower is raised and lowered an average of once per day that the cables should be replaced every two years of service The wire rope must only be replaced with the genuine Terex part NORMAL INSPECTION The wire ropes are constructed of 7 strands of 19 ply steel wires each twisted together and then the assembly is galvanized to resist corrosion Visually inspect the entire length of the cable wear heavy leather gloves to avoid being pricked by a broken wire If any exterior wires are broken they will lift up from main body of the cable and become visible In any 300 mm length of rope if there are 4 or more broken wires in 2 or more strands the rope should be replaced immediately The wire rope must only be replaced with the genuine Terex part OPERATOR ERROR OTHER MACHINERY DAMAGE One of the most common reasons for failure of a L
50. s produce short wave ultra violet radiation and can cause serious skin and eye burns inflammation if the outer enve lope of the lamp is broken or punctured Do not operate this unit near people if the outer envelope of the halide lamp is broken Never Climb On Top Of Unit WARNING NEVER climb on top of the cabinet and or tower when erected or retracted Serious injury or death may result Never Carry Additional Items or Equipment WARNING The trailer is not intended to carry any additional items or equipment The light tower is not intended to carry any additional equipment such as banners or signs Risk of overturning or overload Site Specific Hazards WARNING Be mindful of the particular risks that may arise in certain locations It is the end users responsibility to identify the hazards associated with setting up the light tower and to control those risks Additional precautions may be necessary for example to isolate the public from the tower if it is left unsupervised in public spaces In particular the unit should be secured to protect against vandalism or unauthorised entry into or onto the unit Check Safety Systems Have Not Been Tampered With WARNING Be aware of injuries arising from tampering with safety systems It is the users responsibility to ensure safety systems are functional before use SECTION 2 OPERATING INSTRUCTIONS IMPORTANT READ ALL DIRECTIONS IN MANUAL CAREFULLY BEFORE OPERATING EQUIPMENT WARNING
51. t breakers are turned OFF before re starting the engine This prevents the engine from starting under load and prevents electrical equipment from being damaged due to improper voltage and frequency BATTERY ISOLATOR SWITCH MINE SPEC ONLY A lockable battery isolator switch is provided to prevent unauthorised use of the light tower 16 TEREX AMIDA MODEL AL4000 AU LIGHT TOWER GENERAL SPECIFICATIONS AND ROUTINE MAINTENANCE TEREX Amida Model AL4000 AU Series Light Tower provides mobile trailer mounted floodlighting for night time maintenance construction mining and emergency work It consists of a trailer with diesel powered 8 kW 50 Hz 240 Volt generator and a 30 foot cable actuated tower with four 4 1000 watt flood light fixtures It is ideally suited for heavy duty use and is built to meet the following specifications SPECIFICATIONS Overall length travel position w fixtures amp tongue 4547 mm 179 Overall length tower vertical w tongue 4 jacks 3150 mm 124 Trailer frame length E 1778 mm 70 Overall height floodlighting position 9 14m 3000 Overall height travel position u a 1727 mm 687 Overall width with 1549 mm 61 Overall width with outriggers pulled out 2591 mm 1027 Trailer frame width 1041 mm 41 Tongue length nen 1333 mm 52
52. thread the cable through the pulleys at the bottom of the large section and out of the tubular stud Reinstall the large square section into the round section making sure the white plastic doughnut is placed on the threaded tube on the bottom of the large square section Install the locking bolt and the hex nut on the bottom of the round section The hex locking nut should be tightened and then backed off approximately one half turn or until the tower rotates freely Fasten the new cable to the base of the middle section Reversing the procedures detailed in sections 4 4 through 4 7 reinstall the middle section Fasten the new cable to the winch drum Reinstall the plastic shims as described in section 3 3 24 Cable 2 Point B Hat Section AL4000 LIGHT TOWER Cable Replacement Diagram 2 Section 3 Section 4 Section J 7 Cable 2 Point A Cable 1 Point A Figure 1 6 Round Tube Cable 1 Point B 29 SHIM PLACEMENT Figure 2 183286 5 16 thk 185290 3 8 thk 4 TOWER SECTION 177830 1 4 thk 3 TOWER SECTION 177830 1 4 thk 177820 5 16 thk 177820 5 16 thk 2 TOWER SECTION 177820 5 16 thk 183288 3 16 thk PLACEMENT as viewed from crossarm en
53. wer from tipping over when raised WARNING NEVER use the jacks to raise tires off ground DRIVE GROUNDING ROD INTO EARTH A grounding rod is provided Please refer to local authorities for use of grounding rods Drive the rod a minimum of 1 2 meters into the ground and secure the earth wire to the lug located on the trailer frame 10 INSTALL THE FLOODLIGHTS ON THE CROSSARM MINE SPEC EXCLUDED Remove the light fixtures from their travel position and install them on the crossarm studs Fixtures should be mounted on the crossarm so that the plugs are closest to the mast Ensure all fixtures are rotated down and that adjacent fixtures face each other to minimize possible damage during transportation Route the cords so that they do not interfere with rotating or tilting the light fixtures Set the vertical aim for each light fixture Set the spread between the light fixtures horizontal axis Plug each fixture into the receptacles provided If they are plugged into the numbered receptacles in a clockwise rotation starting at upper or 1 00 position it will be easy to troubleshoot the electrical system without lowering the tower see diagram under Light Fixture Trouble Shooting CAUTION If Tungsten Halogen lamps are used the cord must be routed through the cord support rings Failure to do so may result cord burn through and short circuit due to the high fixture temperature T BOLT FIXTURE STORAGE BRACKETS TRAVEL LOCK
54. years or 3000 hours At this time replace both the bearing and O Ring as well as inspecting the bearing carrier 27 SECTION 3 LIGHT FIKTURE TROUBLESHOOTING GUIDE DANGER Do not open fiktures while light circuit breaker is ON Allow lamp to cool before touching TAKE EXTRA PRECAUTIONS WHEN TROUBLESHOOTING ELECTRICAL PROBLEMS DANGER NO USER SERVICEABLE PARTS INSIDE THIS IS ONLY A GUIDE UNIT TO BE SERVICED BY QUALIFIED ELECTRICIAN ONLY A Only use a voltmeter with two well insulated pin probes rated for 600 V 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 tower power cable SYMPTOM CAUSES CORRECTIVE ACTION LAMP WILL Lamp loose in socket Inspect lamp base to see if there is arcing at center NOT START contact button Tighten lamp snugly Check socket for damage Replace if defective Floodlight plugs not tight Check plug and receptacle Tighten if loose Defective ballast Interchange ballast plugs in generator enclosure If lamp starts replace ballast Check ballast wiring diagram Check for swollen capacitors charred wiring core and coil or other signs of excessive heat Low voltage Check line voltage at ballast input Voltage should be within 1
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