SERIES AL4000 LIGHT TOWER - Manuals
Contents
1. V M gt Ji p 28 836857 Diode 1111 866050 Oil Filter 866080 V Belt 865223 Electric Fuel Pump Mounted to Trailer Frame 866110 Radiator E Created 9 97 Revised a d Document m b e Spectrum 32 Model id amida LE AL4000 LIGHT TOWER Genset Kub D905 L S 6KW 866090 Alternator 839190 Low Oil Press Sensor 836835 End Kit With Bearing 866100 Starter pce qubd MN 836828 Rear Bearing _ 9 9 5 8 Created 9 5 97 Revised a d Document b e By i Spectrum 9 33 Mo Amida Industries Inc 1997 2 990200 Lock Nut i gt 189335 Generator Mounting Bar del Title 1 T 14000 LIGHT TOWER dud Generator Mounting Bar2. o MH i T 1 m 10001101 a EE le a dH a 2 990820 Bolt Created 9 5 97 Revised By Spectrum a b 9 Document 34 4 Model amida AAA AL4000 LIGHT TOWER cd Right Side Radiator Engine Mtg Bracket 4 R980175 Flat Washer 4 994830 Lockwasher 4 995110 Screw Radiator Mounting Bracket 4 189290 Engine Mounting Bracket 0 40 x Z J 740920 Vibration Mount Assy 5 2 Created 9 5 97 Revised 9 Document b e By Spectrum 35 9 Model AL4000 LIGHT TOWER Fuel Filter Title E gt o 5 Created 9 5 97 Revised a d Document b e By Spectrum 36 9 5 5 9 2 2 tv J m 975014 Overflow Tank 866120 Radiator Cap 866110 Radiator 2661 Ul seujsnpu 9 Document
3. Document Spectrum 44 OPTION OLTX0690 WINCH ELEC 12V DC STD AL4000 LT5000 DWG ITEM PART DESCRIPTION 001 160992 WINCH 12V 002 113583 WINCH SWITCH W SOLENOID ASS Y 003 160993 WINCH SOLENOID 004 663780 WINCH TOGGLE SWITCH DRAWN BY BLB DATE 2 8 96 DRAWING NO 8149 45 002 OPTION 4 OLTX0080 STOP TAIL 8 TURN LIGHT AND LICENSE TAG LIGHT DWG ITEM PART DESCRIPTION 8126 001 663510 STOP TAIL amp TURN LIGHT 8126 002 663520 LICENSE TAG LIGHT W BRACKET DRAWN DATE 4 4 91 DRAWINGNO 8126 46 47 PART WD2985 ITEM DWG 2985A DESCRIPTION 25 14 3 ED WHITE BLUE EE j Iu c GREEN GRN YEL BLACK BROWN Na i NOTE PIN CONFIGURATION IS THE SAME FOR TUNGSTEN HALOGEN FIXTURES DOMESTIC EUROPEAN A 3 15 00 ADDED EUROPEAN CE WIRING DATA COLOR COLOR REV DATE ECO CHANGE CODE CODE CIRCUIT TOLERANCES UNLESS OTHERWISE SPECIFIED arn Ja C X WHITE LIGHT BLUE COMMON FROM BALLAST Decimals 3 030 010 cmd HOA BLACK BROWN HOT FROM BALLAST LIVE XXXX 005 590 HUEY Rd ROCK HILL S C GREEN GREEN W YELLOW GROUND EARTH Degrees 1 2 Ph 803 324 3011 FAX 366 1101 REMOVE ALL BURRS amp SHARP EDGES WIRING DIAGRA
4. m 2 BLACK INPUT 120V Fractions 1 16 le QT C X 1111 1 oh WHITE INPUT COMMON Decimals 2 590 HUEY Rd ROCK HILL S C RED LAMP HOT o ds Ph 803 324 3011 FAX 366 1101 ORANGE LAMP COMMON REMOVE ALL BURRS amp SHARP EDGES WIRING DIAGRAM 1000HPS BALLAST MATL MATL W JOY CONNECTOR USAGE DRBY CNM SCALE NONE PLOT 4 30 91 DATE 4 30 91 PART WD2987 DWG 2987 06 CORD FROM GENERATOR PART WD2763 DWG 2763 BATTERY CHARGER OPTIONAL ITEM PART DESCRIPTION REQ FLOODLIGHT CONTROL BOX LISTER TR TS UNITS ONLY MAIN BREAKER 30AMP BATTERY p BLACK 4 y BLACK um m Z N RED _ 7 2 DC gt TERMINAL ON INPUT OUTPUT START SWITCH x 120V 12V 2 120V 15AMP 7 GFI PROTECTED WHITE WHITE z 4 RECEPTACLES lt 5 RECEPTACLE BOX AT TOP OF TOWER 29 rs amp amp ua UR 5 30 AMP 1 3 7 RED 4 o C 0 RECEPTACLE Ke PSH SS h 2RED 5 E 5 gt 20 AMP 2 4 N 2 1 14 a GREEN 97 ww 2 v e 4 5 POLE V RECEPTACLE BALLAST 1 YP 4 14 GREEN 14YEL 2 es
5. 185290 Shim 2 994920 d See Orientation otter Pin 19 Below 990650 Cotter Pin 188760 Sheave Clevis Pin 2 995790 Clevis Pin 124550 3 Tower Section me able Orientation of Shims Inside Tube amp 185290 3 8 Shim 996230 3 8 Screw M 990470 Lock Washer N 3 177820 5 16 Shim 9 Created 9 5 97 Revised a d Document b e Spectrum 26 MOOR AL4000 LIGHT TOWER NE amida VALS 2 Section 124560 2 Section 190570 Cable 7 990470 Lock Washer 996230 3 8 Bolt 9 8 5 s Created 9 5 97 Revised a d Document b e By Spectrum 27 4 xa AL4000 LIGHT TOWER Title Tower Crossarm Fixture Page 4 See Fixture Assembly NN ues N 113040 Cross Arm Cross Arm Mounting Plate 4 123080 Fixture Mounting Wing Nut 8 2 2 s Created 9 97 Revised 9 Document b e By 4 Spectrum 28 id Model AL4000 LIGHT TOWER Title 6 Round Tube 990650 Cotter Pin 188770 Sheave 794550 990610 Grease Fit Tee N Fd 5 2 992765 Bashing Pin pi 994920 990620 Lo
6. before touching EXTRA PRECAUTIONS WHEN TROUBLESHOOTING ELECTRICAL PROBLEMS A Only use a voltmeter with two well insulated pin probes rated for 600 volts B Treat all conductors as potentially hot C Proceed through circuits systematically operating only one section at a time D Before disconnecting ballast turn off circuit breaker and wait 30 seconds for capacitor to discharge E If all the lights are out and all the ballasts are receiving power suspect burned out power cable SYMPTOM CAUSES LAMP WILL Check Ballast Status Light NOT START Lamp loose in socket Floodlight Plugs not tight Defective Ballast Low Voltage Improper ballast Improper lamp operating position Lamp has been operating cool down time insufficient CORRECTIVE ACTION a Input lights should be on This confirms power is going to the ballast b Output lights should be on This confirms power is coming from ballasts c Output lights should be normal brightness If one or moreof the output lights stay extra bright then the lamp is notstriking d Use this knowledge to diagnose problem e If ballast status light is out but the floodlight lamp is working suspect burned out ballast status lamp and replace Inspect lamp base to see if there is arcing at center contact button Tighten lamp snugly Check socket for damage Replace if defective Check plug and receptacle Tighten if loose Interchange ballast plugs in gen
7. Revised 9 5 97 Created Spectrum By 028 003 022 GENSET ALPHA LPA3 L S AL4000 PARTS IDENTIFICATION DRAWING DRWN BY Www DATE 2 8 96 DWGNO 9609 001 GENSET ASSEMBLY COMPLETE 035 036 037 023 021 38 DRAWING 9609 GENSET ALPHA LPA3 L S ITEM PART DESCRIPTION U M 001 116360 MA GENSET ALPHA LPA3 L S 6KW 7 5KW ALAOOO EA 002 732130 ENGINE LISTER ALPHA LPA3 BUILD 8 12 1 HP EA 003 630950 GENERATOR L S 8KW 38M7 N A USE PARTI 630950 EA 004 740400 AIR CLEANER BODY W EL FWG05 2512 PAINT 001BK EA 005 834450 DONALDSON P18 2050 AIR CLEANER ELEMENT EA 006 740443 TUBE AIR CLEANER DON EXT 2 4 5 007 740430 AIR CLEANER HOOD 0 2018 PAINT 4628G EA 008 834465 DONALDSON P10 3198 A C VACUATOR VALVE EA 009 124220 AS AIR CLEANER BRACKET ALPHA L S 3602 AL4000 EA 010 740420 AIR CLEANER ELBOWS P10 5529 amp 90HL2 EA 011 740410 AIR CLEANER BANDS 2348 PAINT 0018K EA 012 791380 CLAMP HOSE 32 1 9 16 TO 2 1 2 S S EA 013 742200 MUFFLER LISTER ALPHA LPA3 EA 014 795050 CLAMP MUFFLER 1 3 4 ZP EA 015 18
8. Aim the fixture both horizontally and vertically to the estimated angles that will light the work area Using the winch raise the tower to the vertical position The tower locking pin at the base of the pivot post will lock automatically and you will hear it snap into place Insert manual pin into locking device Release the tension on the cable by backing the winch off slightly and pull the telescoping locking pin on the galvanized tower section Hold this out while turning the winch to raise the tower After the tower has telescoped slightly the locking pin can be released Raise the tower to the desired height CAUTION DO NOT ATTEMPT TO LEAN THE TOWER DOWN BELOW 45 WHEN IT IS EXTENDED SERIOUS DAMAGE MAY OCCUR 11 IV VI START 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 subjected to improper voltage and frequency Check the oil fuel and coolant if liquid cooled 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 RUN position see diagram below Press the preheat push button for a maximum of 7 seconds Do not engage the preheat button longer than the time specified or damage may occur Turn the ignition switch to the START position to engage t
9. Mtg Bracket 76370 2 2 Rack ee _ 2 930950 Weatherstrip 124430 Cabinet _ 2 E Adhesive C JN 2 123490 bo Fender 188580 Cabinet Curbside N 10 791840 Rubber Bumper 3 Created 9 5 97 Revised d Document b Spectrum 20 Model um amida AL4000 LIGHT TOWER ica Cabinet Assy 720220 Bumper 790540 Pin 116180 Rear Support 124460 Tower Support Cradle 123680 Pin 4 796436 Gas Shock 188550 Cabinet 794940 Plastic Plug 4 796432 Door Shock Bracket 2 796610 Hinge _ 2 790040 Hasp Kit 111368 Ground Rod 2 188560 2 790940 Handle Cabinet Door 3 Created 9 97 Revised 9 Document b e Spectrum 210 id AL4000 LIGHT TOWER emi ea Title Cab Decal Top 851640 853296 853296 Curb Side Road Side 14000 14000 853312 E d d 853312 852410 _ 851860 853730 853291 850090 Front 1 mE 2 841710 amida AL4000 www terex com 853291 850135 853301 i Created 9 97 Revised 9 Document Spectrum 22 b AL4000 LIGHT TOWER DER Title
10. Repairs where defective parts were not received by TEREX LIGHT CONSTRUCTION after TEREX LIGHT CONSTRUCTION issued a return authorization Tom TEREX Light Construction P 0 Box 3147 Rock Hill S C 29731 USA Phone 803 324 3011 Fax 803 366 1101 63 Amida PO Box 3147 Rock 29730 MANUFACTURER S LIMITED WARRANTY TEREX Amida warrants to the original purchaser that goods manufactured by it will be free from defects in workmanship and material for a period of one year after invoice from TEREX Amida provided such goods are installed operated and maintained in accordance with TEREX Amida s written instructions TEREX Amida makes warranty with respect to components and accessories furnished to TEREX Amida by third parties only to the extent of the original manufacturer s warranty to TEREX Amida Third party components and accessories are parts such as fixtures ballasts engines hydraulic pumps fuel pumps alternators generators winches tires and electrical components TEREX Amida makes no other warranty express or implied and makes no warranty of merchantability or fitness for any particu lar purpose Warranty for repair or replacement parts after warranty period shall extend for 90 days after invoice date Manufacturer s liability and purchaser s sole and exclusive remedy for a failure of goods to perform as warranted for any and all other claims arising out of the purchase and use of the goods includi
11. Tower Assy 113080 Coil Cord Sleeve See 2 Section _ See 3 Section See 4 Section See 6 Round Tube 8 5 Created 9 97 Revised d Document b Spectrum c 23 id amida AL4000 LIGHT TOWER 4 Tower Section Sheave amp Shim Assembly gt 124540 4 Tower Section 990660 Roll Pin 120220 Lock 790510 1 16 Cable sp 3 790520 Cable Sleeve 4 990760 Pin _Shim ers 2 980340 120640 Pin gt Screw 990650 2 s _ 790710 Cotter Pin Spring 2 See 6 Round Tube N 2 2 E 8 5 Created 9 5 97 Revised 9 Document Spectrum 24 4 Model id amida AL4000 LIGHT TOWER 4 Sec Upr Sheave 8 Shim Assy Amida Industries Inc 1997 188760 Sheave k 2 990650 Cotter Pin 183285 Shim See Orientation Below 22 2225 995780 Pin 2 994920 Cotter Pin 2 992765 d Clevis Pin 2 995790 Clevis Pin 183285 3 8 Shim 183286 5 16 Shim 177830 1 4 Shim 183828 3 16 Shim Orientation of Shims Inside Tube By Created Revised Document 9 5 97 a 9 b e Spectrum 25 id AL4000 LIGHT TOWER amida 3 Section
12. 2 2 14 7 CONDUCTOR RETRACTABLE 15 AMP E 14 BLACK gt 2 CORD FLOODLIGHT BALLAST og 4 14 GREEN Ai 14 YEL 7 EAB 14 RED 3 14 GREEN 14 YEL 14 ORN 14 RED E 2 BALLAST 4 14 14 GREEN 13 14 YEL 14 ORN E B sa RED REV DATE Decimals 030 010 XXXX 005 Degrees 1 2 REMOVE ALL BURRS amp SHARP EDGES TOLERANCES UNLESS OTHERWISE SPECIFIED Fractions 1 16 r 1 Ps 6 wW S hh s ff 6 Ww lerex amaida 590 HUEY Rd ROCK HILL S C Ph 803 324 3011 FAX 366 1101 WD AC CONTROL BOX 4MH HPS MATL AL4 AL5 LT5 SL4 BORDER MAT P N USAGE DR BY GMB SCALE NONE PLOT 7 9 93 DATE 7 9 98 WD2763 DWG 2763B PART WD4730 DWG 4730E ALTERNATOR FAILURE IG ALTERNATOR H HIGHT GREEN PURPLE ORANGE E b LOW OIL I PREHEAT m PRESSURE PUSH BUTTON RED NC ORANGE BROWN YELLO YELLOW pom RELAY 12V Pal ORANGE SPST COOLANT BROWN TEMPERATURE 1 BAT RED N RED ST RED 22289 ak OFF e HOUR N FUSE METER IGN amp ACC 30A FUEL 1 BAT RED j RED NT 1 s IGNITION SWIT
13. Lamp may glow for extended period of time Replace after checking voltage and ballast Checking 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 coil or other signs of excessive heat Check voltage at ballast input Voltage should be within 10 of nameplate rating Check wiring connections 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 replace ment 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 59 LIGHT FIXTURE TROUBLESHOOTING cont d SYMPTOM SHORT LAMP LIFE LAMP FLICKERS AND GOES OUT INTERMITTET CAUSES Lamp damaged Improper ballast Improper ballast New lamp Defective lamp High spike ballast CORRECTIVE ACTIONS Check for
14. Park Rock Hill SC 29730 TEREX LIGHT CONSTRUCTION will review the AWA form Should we desire to inspect the defective parts we will issue you areturn authorization for the defective parts After inspecting the defective part s and itis determined that warranty is due we will then at the discretion of TEREX LIGHT CONSTRUCTION credit the applicants account or send replacement parts TEREX LIGHT CONSTRUCTION warranty reimbursements 1 30 00 for each labor we allow toward repair Distributors cost of parts not more than the price currently available from TEREX LIGHT CONSTRUCTION 3 One way surface freight charges on parts returned to TEREX LIGHT CONSTRUCTION Many repairs are assigned a predetermined labor schedule which is an average time in which a skilled technician should be able to make a repair TEREX LIGHT CONSTRUCTION will reimburse not to exceed the predetermined number of hours for a particular repair TEREX LIGHT CONSTRUCTION does not reimburse for Travel travel time nor travel labor Mileage Excessive diagnostic time Repairs of defects malfunctions or failures resulting from accidents abuse misuse modifica tions alterations improper servicing or lack of performance of required maintenance service 5 Repairs where defective parts were not shipped back when requested by TEREX LIGHT CON STRUCTION 6 Regular maintenance such as parts or labor for oil changes filter changes or filters 7
15. REMOVING TOP CABLEAND TOP MAST SECTION 2 1 2 2 2 3 2 4 2 9 2 6 Tie middle section and large section together by wrapping band cable chain or rope around the sheave brackets on these two sections This insures 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 aluminum pop rivets holding the plastic guides at the top of the middle section Using screwdriver remove these guides Remove the clevis pin anchoring the cable to the top of the middle section and remove the clevis pin and 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 3 REINSTALLING THE SMALL SECTION 3 1 3 2 3 3 Fasten new cable to of small section Reversing procedure described in steps 2 1 through 2 5 reinstall small section Reinstall plastic guides with new rivets New plastic guides should be used but old guides can be used if their mounting position 1 shifted to the point where new hol
16. Ratchet pawl should click when tower is raised and not when it is lowered WARNING CAUTION Always be alert for any fraying of cables and replace any damaged cables IMMEDIATELY Never stand under any object lifted by the winch ELECTRIC WINCH The electric winch is permanently sealed and does not need any periodic lubrication WARNING CAUTION Always be alert for any fraying of cables and replace any damaged cables IMMEDIATELY Never stand under any object lifted by the winch RECETACLE POWER TABLE METAL HALIDE HIGH PRESSURE SODIUM STATUS RECEPTACLE POWER AVAILABLE 120 240 VAC IGHTS ON 240 30 REC ALL OFF 30 AMPS 1 3 16 6 5 2084 16 6 AMPS 1AND 3 8 3 AMPS 2 AND 4 8 3 AMPS TUNGSTEN HALOGEN STATUS ALLOFF 1oR3 2084 1AND3 2 04 STATUS RECEPTACLE POWER AVAILABLE 120 240 VAC IGHTS ON 240V 30A ALL OFF 30 AMPS 3 17 AMPS 20R4 15 AMPS 17 AMPS 1 AND 3 15 AMPS 10 AMPS 2 AND 4 15 AMPS 10 AMPS There is more current available than listed The rating of the duplex receptacle is 15 amps NOISE LEVEL Mean SPL sound pressure level hemispherically at 7 meters 62 01dBA Sound Power Level 62 01dBA 20 log d 4 7 8 90 0 LWA re 1 pW D 7 meters 53 MISCELLANEOUS 5 5 Amida AL4000 light tower is built to standards FASTENER TORQUE SPECIFICATIONS fasteners should be torqued to the following specification
17. body of the cable and become visible For any given 1 foot of cable length if there are 4 or more wires each on any 2 or more strands broken the suspect rope should be replaced immediately OPERATOR ERROR OTHER MACHINERY DAMAGE One of the most common reasons for failure of a Light 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 operator error happens when the mast is telescoping down When the upper telescoping lock engages the operator does not pull the lower pivot lock out located on the tower base and keeps on cranking the winch This results in the cable becoming loose around the drum due to the tower not pivoting down 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 If there is enough friction in the threaded parts of the winch the drum can cause the crank handle to start spinning This can cause the tower to freefall and the results can be catastrophic for anyone standing underneath the tower A spinning crank handle can also break bones Other reasons damage can occur are due to some outside force such as forklift blade nicking or crush
18. over Let out on the winch cable to lower the tower into the cradle Insert the rear tower horizontal travel locking pin into the cradle TURN OFF FLOODLIGHTS If operating turn light circuit breakers off 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 10 minutes before moving the tower to avoid breaking lamps RELOCATING LIGHT TOWER TO NEW LOCATION Insure that tower has been properly lowered see section VI and locking pins are engaged Insure all fixtures are pointed toward the ground or mounted on the fixture storage brackets on the lower tower section CAUTION All jacks must be raised and all outriggers locked into travel position Insure that the coupler is properly secured to the towing vehicle and attached safety chains if supplied Release any manual braking mechanism if supplied Do not tow at excessive speeds 60 mph 100 kmh maximum as the weight of the light tower can cause loss of vehicle control especially under emergency stopping conditions The standard trailer has no towing brakes therefore allow extra distance for stopping USE OF LIGHT TOWER AUXILIARY POWER One 1 30amp 240v Twist Lock and 1 15 amp 120v receptacles are provided for auxiliary power Total auxiliary power cannot exceed main circuit breaker rating Each lamp operating consumes 10 amps of current 120 volts ac Befor
19. rotating diode problem Wrong voltage Suspect an engine RPM problem Note As a general rule it is more cost effective to replace the unit under warranty if the rotating diodes and the capacitor are good with the lights on M is set properly The 17 ALTERMATEURS ALTERNATORS LEA 37 2 4 P tie dcs Top ER LF ue acm Brochures Technical Catalog O amp M Manuals AutoCAD drawings WARRANTY PROCEDURE The specific language of this warranty will determine TEREX LIGHT CONSTRUCTION s obligation in connection with its product The information presented below should be used as a general guide for implementation of policy In the event of a component failure during the warranty period it should be repaired as soon as possible preferably at an authorized TEREX LIGHT CONSTRUCTION service center If component is manufactured by a company other than TEREX LIGHT CONSTRUCTION such as Deutz Honda Isuzu Leroy Somer Lister Petter Lombardini Wisconsin etc the applicant should pursue repair and or reimbursement through that manufacturer and its dealer distributor network To file a claim with TEREX LIGHT CONSTRUCTION an APPLICATION FOR WARRANTY ADJUST MENT AWA form must be completed in it s entirety Return the completed form within fourteen days of the repair to ATTENTION WARRANTY TEREX LIGHT CONSTRUCTION 590 Huey Road Rock Hill Industrial
20. travel position 68 1727 mm Overall width with fenders 61 1549 mm Overall width with outriggers pulled out 102 2591 mm Trailer frame width 41 1041 mm Tongue length 44 1118 mm Wheel size 15 381mm Axle Rating 3500 Ib 1588 kg Tongue weight travel position 100 Ib 45 4 kg Total weight no fuel 2050 Ib 930 kg Fuel Capacity 30 gal 1141 Unit weight with full fuel tank 2250 Ib 1020 kg This section details specifications and maintenance not covered in the operators and trouble shooting sections of this manual and the AL4000 specification sheets OIL AIR SERVICE The engine oil should initially be changed after the first 50 hours of use and then every 200 hours thereafter The oil filter should be replaced after every 400 hours of use The air filter element should be replaced once every year or after six cleanings see manufacturer s operation manual for details BRAKE SYSTEM Electrical or mechanical brakes are not standard equipment on the AL4000 Contact your dealer or the factory for option information 52 MANUAL WINCH Maintain light film of automotive type grease on pinion drum gear and O D of the drum bearing at all times Keep the ratchet pawl pivot pinion shaft bushings and pinion threads lubricated with automotive engine oil at all times WARNING Before each use check the brake friction discs for wear If less than 1 16 thick cracked or broken replace IMMEDI ATELY
21. 7 Revised a d Document b e By 2 Spectrum 17 9 Model m amida VALS ie Lid AL 4 990200 Lock Nut 2 AL4000 LIGHT Page Fuel Tank b Spectrum N 1 N 742220 Fuel Tank Z ME 2 188630 Fuel Tank Pan e 8 990210 Flat Washer 8 4 994650 1 2 13NC 10 Bolt Created 9 5 97 Revised 9 Document Model id amida LEYLA AL4000 LIGHT TOWER Fage Axle Assy 2 834267 U Bolt Kit 834225 Grease Seal 834220 Hub Assy 834255 Cotter Pin 834338 Axle 834250 Spindle Nut 834228 Grease Cap 834226 Inner Bearing 2 834227 Outer Bearing 841060 Tire amp Wheel Mounted gt 8 840395 Axle Spring Nut eere ng Nu pe 840392 Axle Rear Hanger 2 3 840394 Axle Spring Bolt 841473 Axle Shackle 2 834246 Spring Eye Bushing 834211 Leaf Spring 8 8 to a 2 Created 9 5 97 Revised d Document b Spectrum 19 4 Model id amida Page AL4000 LIGHT TOWER Cabinet Assy 4 796432 Door Shock Bracket 184150 Winch Handle Bush pO sides 124420 Ground Rod Storage Tube 188530 Cabinet Front 192 Radiator Overflow Bracket 2 189390 Elec Box
22. 8450 FP MUFFLER TAILPIPE ALPHA LPA3 4357 EA 016 831998 LISTER 750 10190 AIR INLET DUCT ADAPTOR EA 017 187500 FP AIR TUBE 8 25ID X6L SPONGE EA 018 831993 LISTER 751 10620 OIL FILTER EA 019 631995 LISTER 750 10231 LOP SWITCH KIT EA 020 832750 SOLENOID LISTER 3 WIRE SYNCHRO START 1502 5 EA 021 740920 VIBRATION MOUNT 300LB C8A20 300 11 EA 022 185100 FP GENERATOR MOUNT BAR L S LIMA 2466 4C AL4 EA 023 990410 WASHER FLAT FENDER 2 ODX1 7 32 IDX16GA ZP EA 39 DRAWING 9609 GENSET ALPHA LPA3 L S PART DESCRIPTION U M 024 109350 FOR 6KW LEROY 70UF EA 025 836857 DIODE L5A38 MODEL 70HF90 EA 026 831999 LISTER 751 40620 GLOW PLUG EA 027 832000 LISTER 750 40310 GLOW PLUG RELAY EA 028 831996 LISTER 570 32390 ALPHA HI TEMP SWITCH EA 029 831997 LISTER 750 13710 STARTER ALPHA LPA3 EA 030 831991 LISTER 750 11740 ALTERNATOR ALPHA LPA3 EA 031 831992 LISTER 751 17820 FAN BELT ALPHA LPA3 EA 032 896340 PIPE NIPPLE 3 8X2 GALV EA 033 891600 PIPE ELBOW 90 DEG 3 8 GALV EA 034 894340 PIPE PLUG 3 S GALV EA 035 836835 LEROY SOMER 9AMBHLSA3S NDE END KIT W O BRGING EA 036 836830 LEROY SOMER 0 RING ZL LSA3S 257 RUBBER EA 037 836828 LEROY SOMER 9ASR6306ZZ REAR BRG LSA 38 EA 40 Model id amida AL4000 LIGHT TOWER TRE Electrical AC DC 4 MH HPS 186730 Control Box Rear 1 186801 Control Top 185390 Control B
23. CH RED WHITE BROWN LEGEND BLACK RED WHITE BUT 1 5 P ST 2 FUEL BATTE RY DN 220 SO L E N Ol D 12 VOLT STARTER 1 12 01 ADDED DIODE FOR FUEL PUMP PRIME REV DATE TOLERANCES UNLESS OTHERWISE SPECIFIED Fractions 1 16 Decimals XX 030 XXX 010 XXXX 005 Degrees 1 2 REMOVE ALL BURRS amp SHARP EDGES CHANGE lerex amuida 590 HUEY Rd ROCK HILL S C Ph 803 324 3011 FAX 366 1101 WD DC ENGINE WIRING KUBOTA MATL MAT P N USAGE PLOT B 3 23 00 3 23 00 PART WD4730 5905 AL4 TX3 BORDER DR BY JCS APP BY SCALE DWG 4730E Amida AL4000 Light Tower General Specifications And Routine Maintenance TEREX Amida model AL4000 series light tower provides mobile trailer mounted floodlighting for nighttime maintenance construction mining and emergency work It consists of a trailer with a diesel powered 6 kW 60Hz 50 Hz units available generator and a 30 foot cable actuated tower with four 4 1000 watt floodlight fixtures It is ideally suited for heavy duty use and is built to meet the following specification DIMENSIONS Overall length travel position w fixtures amp tongue 179 4547 mm Overall length tower vertical w tongue amp jacks 124 3150 mm Trailer frame length 70 1778 mm Overall height floodlighting position 30 9 14 mm Overall height
24. EXTERIOR 1 833584 40 791 2395 LBL 105 SUPPLY 1 833585 41 791 1137 LBL FIXTURE CSA 995970 42 4110624000 WASHER 1 2 EXTER TOOTH LOCK SS 2 NOTE FOR COMPLETE ASSEMBLY ORDER PART 112605 6 TEREX Light Construction 2000 amida AL4000 TOWER iu Ballast 2 114355 Ballast 114895 Ballast Box HPS 663860 5 Pin Connector _ 160030 Ballast 160040 Balast HPS 160032 Capacitor 160042 Capacitor HPS 8 E E s Created 9 5 97 Revised d Document b Spectrum AL4000 LIGHT TOWER Page Trailer Hitches 840120 Coupler 2 0 de 176336 Spacer 220 2 176335 Plate p lt lt 840470 Ball 2 2 121572 Combo Hitch Ring 16 Long 213770 Ring Hitch 2 1 2 1 0 N N S O N QN N NJ N N 211410 Ring Hitch for Adj Height O 9 SU aa O cs S lt 1 sZ Amida Industries Inc 1999 p y 124450 Hitch 24 Height b 841200 Hitch Pintle Ring 3 1 0 E 940000 Kit Combo Hitch 221580 Hitch Adj Height Created 2 2 9 9 Revised
25. Joy Connector 49 P NGA ATIVE 50 iere rere 51 Troubleshooting Guide Specifications Routine Maintenance Wind Loading 52 55 Broken Cable Replacement Procedure 56 57 Light Fixture Troubleshooting 58 60 TEREX Amida Numbered Wiring System 61 Generator Bearing Inspection 62 Engine refer to manufacturer s handbook Generator refer to manufacturer s 63 72 Warranty Information Warranty Procedure pp 73 Wattanty 74 5 MANUAL 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 WARNING TEREX Amida uses this symbol throughout this manual to warn of possible fatal injury 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 recommended below Also observe the many additional general safety rules practiced by trained operation and maint
26. M MH OR HPS FIXTURE MATL W JOY CONNECTOR BORDER MAT P N DR BY SCALE NONE PLOT 4 30 91 DATE 4 30 91 PART WD2985 DWG 2985A 8v PART WD2986 ITEM DWG 2986 DESCRIPTION REQ CAP ORANGE BLACK 120V 2 TRANSFORMER 1000W HALIDE BALLAST GRN WHITE 27 24 RED 480V 5 POLE RECEPTACLE COLOR CIRCUIT BLACK INPUT 120V REV DATE CHANGE m TOLERANCES UNLESS OTHERWISE SPECIFIED NE LE v RED POLT Fractions lerex amuida Decimals XX 030 010 590 HUEY HILL S C ORANGE LAMP COMMON XXXX 005 Pa GREEN GROUND Degrees 1 2 Ph 803 324 3011 FAX 366 1101 REMOVE ALL BURRS amp SHARP EDGES MATL MATL WIRING DIAGRAM 1000MH BALLAST W JOY CONNECTOR BORDER SCALE PLOT 4 30 91 4 30 91 PART WD2986 DWG 2986 6 PART WD2987 DWG 2987 ITEM PART DESCRIPTION IGNITOR X1 2 ORANGE gt BLACK WHITE 448 05 26uF GREEN o 450W P das TRANSFORMER 1000W HIGH PRESSURE SODIUM BALLAST 5 POLE RECEPTACLE REV DATE TOLERANCES UNLESS OTHERWISE SPECIFIED
27. MAIN MENU TEREX LIGHT CONSTRUCTION SERIES AL4000 LIGHT TOWER OPERATION amp SERVICE MANUAL amida artel sentore morrison MULLER 3147 Rock Hill SC 29732 USA Phone 803 324 3011 Toll Free 800 433 3026 Parts Department Fax 800 633 5534 TABLE OF CONTENTS Receiving and Set up Safety i oe ette eo tiet e eei ie c ia Heide 4 6 Check Out on Receipt Delivery 7 TEREX Amida Light Tower Model Coding System 8 Recommended Engine 9 Operating Instructions Light Tower Operating Instructions 10 13 Criteria for Replacement of Wire 14 15 Engine see manufacturer s handbook Generator see manufacturer s handbook Parts Identification Drawings Trailer and Related Parts pt 17 18 Axle and Wheels a 2 ette rr 19 Cabinet and Attachments pp 20 22 Tower and Related Parts 23 31 Engine and Generator Kubota Alpha RN 32 40 Blectrical BOx 3 erri ttc rr LE ERR RN 41 Floodlight Fixtures Ballasts 42 43 eed 44 codon do 45 Runnin Et StS sasa n mua aa teas 46 Wiring Diagrams Fixture with Joy Connector MH or 47 Metal Halide Ballast with Joy Connector 48 High Pressure Sodium Ballast with
28. NS IN MANUAL CAREFULLY BEFORE OPERATING EQUIPMENT WARNING CAUTION DO NOT RAISE TOWER IN THE VICINITY OF II III IV OVERHEAD POWER LINES OPERATING INSTRUCTIONS MOVE LIGHT TOWER TO DESIRED LOCATION KEEPING THE FOLLOWING IN MIND 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 relatively level The light tower should be located on the same level or on ground higher than the area being lighted higher light mounting heights reduce the 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 Engage the trailer braking system especially if trailer is not on level ground CAUTION If electrical or manual braking system is not supplied chock the wheels instead Swing the tongue jack into position and raise the tongue off the towing vehicle LEVEL THE TRAILER USING THE JACKS AS FOLLOWS Extend the rear outriggers until the springs lock into place Swing the jack on each outrigger into verti cal position Start at the highest jack position Rotate the jack handle until the jack foot touches the ground Raise the other jacks to level trailer WARNING CAUTION
29. ck Nut Cotter Pin 990650 P Cotter Pin 124530 6 Round Tube _ 992765 a Clevis Pin 188760 Sheave Clevis Pin Created 9 97 Revised al 4 b Spectrum 200 5 AL4000 LIGHT TOWER amida Tower w Base 113040 Crossarm 116220 Tower Assy w Cables 116170 Tower Base 740050 Winch 1500 124480 Winch Handle 2 8 E o s S Created 9 5 97 Revised a d Document b e By Spectrum o 30 Model AL4000 LIGHT TOWER Page amida ELE I L a Tower Base Assy 193750 Kick Out Spring EN 186360 Bumper Pad Amida Industries Inc 1997 124490 Tower Base 2 184510 Spool Sheave 740050 Manual Winch 111680 Winch Socket 124480 Winch Handle ON gt 120220 Pin Slide Lock Created 9 5 97 By Spectrum a d b e 3 1 f Document Model id amida AL4000 LIGHT TOWER Genset Kub D905 L S 6KW 866120 Radiator Cap 866010 Air Cleaner On 630041 Generator 2 109350 Capacitor 866030 Soleniod _ 866040 Gasket cae 7 7 1 22
30. e bearing If neither of these conditions exist replace the bearing retaining 0 836830 and reassemble Note These bearings are sealed units and cannot be field serviced Follow the same procedure at three 3 years or 3000 hours At this time replace both the bearing and O Ring as well as inspecting the bearing carrier 62 r lt o 2 O d LEROY PERFORMANCE Brushless 4 Pole design Self excited with capacitors 5 voltage regulation at constant speed Inherent overvoltage protection PRINCIPLE ROTOR STATOR U6 T4 21 5 Jaune Yellow Wh te Jeu de Condensateur s Set of Capacitor s U5 T3 No r Blacx VeruGreen Brun Brown Phase principale Main winding Phase auxiliaire Auxiliary winding BRANCHEMENT CONNECTION DIAGRAM COUPLAGE PAR ALLELE PARALLEL CONNECTION COUPLAGE SERIE SERIES CONNECTION u2 11 r 12 TENSION HAUTE HIGHERVOLTAGE TENSION BASSE LOWER VOLTAGE SORTIE OUTPUT RELIER CONNECT SORTIE OUTPUT RELIER CONNECT Ui T US T3 2 2 06 74 U2 T2 5 73 AV TENSION BASSE LOWER VOLTAGE ARIMDE1 TENSION HAUTE HIGHER VOLTAGE Rotating Diodes TROUBLESHOOTING TIPS No voltage Suspect a capacitor problem They have a limited life Correct voltage at no load but incorrect under load Suspect a
31. e plugging in auxiliary power cords feed them up through the trailer frame and attach to recep tacles Close the cabinet doors to protect control panel and other components from weather see Miscel laneous Specifications and Routine Maintenance section for power control details 13 CRITERIA FOR REPLACEMENT OF WIRE TEREX AMIDA LIGHT TOWERS The wire 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 NORMAL INSPECTION The wire ropes are constructed of 7 strands of 19 plow steel wires each twisted together and then the assembly galva nized to resist corrosion Using a wadded up cloth or heavy leather gloves to avoid being pricked by a broken wire run a hand up and down a length of the cable If any exterior wires are broken they will lift up from main
32. enance personnel in your company and industry CAUTION Always wear a hard hat when operating the light tower Guard Against Electrical Shock This light tower also has provisions for producing high voltage electricity up to 480 volts 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 then 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 enclo sures Understand that the electrical circuits in this light tower complete their paths back to the generator within the equipment The neutral conductor at the generator is bonded to the equipment frame Ground wires within the system are also bonded to the equipment frame Only use a multimeter or voltmeter with two well insulated probes rated for 750 volts Keep one hand in your pocket when touching the multimeter probe to hot conductors This will prevent electricity from passing into one hand and out the other a path that takes the electricity across the heart Always disconnect power from the circuit being measured before connecting test leads to
33. entation KW Rating 080 is 8 0 kW Diesel D or Gas G Number of Lights Type of Lights European Version AL4000 Only HPS High Pressure Sodium Metal Halide Mercury Vapor TH Tungsten Halogen RECOMMENDED ENGINE OIL amp FUEL KUBOTA D905 DIESEL ENGINE Engine oil should be MIL L 2104B MIL L 2104C or have properties of API designation of CC SF or CD SF Change the type of engine oil according to the ambient operating temperature Above 86 F SAE 30 32 F to 77 F SAE20 Below 32 F SAE10 SAE 10W 30 Use 2 diesel fuel LISTER PETTER LPW3 LPA3 LPW4 LPWT4 DIESEL ENGINES Engine oil should be MIL L 2104C or have properties of API designation of CC SF or CD SE Use CC grade oil for the initial break in period Multi viscosity oils such as 10W 40 should not be used at temperatures above 32 F Be sure to use the correct oil viscosity for the weather you are experiencing When this engine left the factory it was filled with engine oil as specified on this page Change the type of engine oil according to the ambient operating temperature 86 F and warmer SAE30 Between 39 F amp 86 SAE20 20W SAE 15W 40 Between 5 F amp 39 F SAE 10W Below 5 F SAE 5W Use 2 diesel fuel above 5 F 1 diesel fuel below 5 F NOTES 1 temperatures in table ambient temperature at time when engine 15 started However if running ambient temperatures are much higher t
34. erator 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 Check line voltage at ballast input Voltage should be within 10 of nameplate rating when operating at normal load Increase supply voltage or remove external load Proper HID lamps will perform erratically or fail to start on an improper ballast The ballast nameplate data should agree with the line voltage and lamp used Improper ballast will cause lamp to fail Operating position should agree with lamp etch ABUHOR lamp can be operated base up vertical to and including the horizontal and BD can be operated base down and vertical to approaching but not including the horizontal A lamp operated beyond the specified position may not start HID lamps require 4 to 8 minutes cool down time before restarting Switch off breaker and allow lamp to cool 58 LIGHT FIXTURE TROUBLESHOOTING cont d SYMPTOM CAUSES LAMP STARTS Defective Lamp SLOWLY ARC DOES NOT STRIKE WHEN SWITCH IS FIRST TURNED ON CIRCUIT Short circuit or ground BREAKER TRIPS ON LAMP START UP LAMP LIGHT Normal lamp depreciation OUTPUT LOW Dirty lamp or fixture Defective ballast Wrong Voltage Improper ballast LAMP COLORS Normal lamp depreciation DIFFERENT Dirty fixture Wrong lamp ARC TUBE Over voltage from DISCOLORED power supply OR SWOLLEN Improper ballast CORRECTIVE ACTION
35. es can be drilled in the tower section to provide a good fit when installing new pop rivets 4 REMOVING THELOWER CABLE AND MIDDLE TOWER SECTION 4 1 4 2 4 3 4 4 4 5 Remove or lock open the telescope lock pin if not previously done in step 2 2 Drill out the aluminum pop rivets holding the plastic guides at the top of the large section Using a screwdriver remove these guides Remove the cable from winch drum Remove the sheave clevis pin and the sheave from the top of the large section If the old cable 1 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 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 56 4 0 4 7 4 8 Pass free end of cable through sheave slot between 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 altogether 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 sectio
36. han starting temperatures promise must be struck and a higher viscosity oil and fuel used provided they have a suitable specifica tion 2 MIL L 2104B or MIL L 2104C or API CD oils are recommended particularly in high temperature applications They must also be used if the sulfur content of the fuel exceeds 0 5 3 CAUTION The use of Series III oils in new or overhauled naturally aspirated engines can inhibit break in and give rise to cylinder bore glazing in engines on low duty cycles Therefore they should not be used for the first fill in new or newly overhauled naturally aspirated engines but may be used advantageously after the first 250 hours when the engine is operating in hot ambient temperatures and high load factor 4 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 At low ambient temperatures below freezing use winter grade diesel fuel At higher temperatures use summer grade diesel fuel Observe strict cleanliness when filling the fuel tank 5 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 plug and add new oil to the FULL line on the dipstick 9 MODEL AL4000 OPERATING INSTRUCTIONS IMPORTANT READ ALL DIRECTIO
37. he engine After the engine starts release the switch so that it returns to the RUN position Let the engine come up to speed and stabilize re view the engine operating procedures in the manufacturer s handbook Turn on the main circuit breaker TURN ON THE FLOODLIGHTS Turn the circuit breakers ON and check to insure all lamps come on Allow a minimum of two 2 minutes for lamps to reach full luminance If required rotate the tower to aim the lights as desired Tighten the tower rotating locking bolt Adjust the tower vertically and adjust lighting direction of individual fixtures if required LOWERING THE TOWER TO TRAVELING POSITION Loosen rotating lock Using the winch telescope the tower down to its fully retracted position until the telescoping locking pin snaps into place Insert manual locking device CAUTION Ensure that the telescoping locking pin locks before pulling the tower locking pin at the bottom of the pivot post This ensures the tower is completely lowered and cannot be damaged by telescoping out while in the travel position Rotate the tower so that the groove in galvanized ring at the pivot is pointing to the rear of the trailer so that the tower can be lowered into the travel position 12 Operating Procedures cont d F VIII Pull the vertical locking pin at base of the pivot post kick out spring should provide sufficient pressure to start the tower pivoting
38. high voltage points Do not try to position both probes at once Instead clamp the common insulated alligator clip to a neutral wire and then probe for voltages with the other probe Never clamp to a hot wire since a severe shock could be received by contact with the other probe Do not use a multimeter with leads or probes that have damaged insulation Inspect the ground cable between the generator set and the frame If damaged replace immediately Treat all conductors as potentially hot especially when troubleshooting malfunctioning equipment Jewelry should be removed before working around live conductors Proceed through the circuitry systematically operating only one section at a time Use tools with insulated handles when working within the reach of live conductors Maintain a good footing If you slip or a tool drops do not grab for it if live conductors are within reach Concentrate on the task until the danger from high voltage is removed Guard Against Battery Hazards 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 up a brief arc at the terminals Use a multimeter i
39. id mount units which are knocked down for shipping export units are also shipped with dry batteries Amida recommends the following checks A INSURE THERE IS NO FREIGHT HANDLING DAMAGE which should be charged against the carrier B Insure the manuals are in the pocket provided inside the unit Review manuals safety and operating Check engine oil coolant if cooled and fuel levels E Operate the tower in accordance with operating instructions EXPORT Assemble according to the instructions enclosed 11 TOWER MODEL CODING SYSTEM IMPORTANT WHEN REQUESTING TECHNICAL HELP AND ORDERING REPLACEMENT PARTS THE MODEL AND SERIAL NUMBER ARE NECESSARY REFER TO THE AMIDA SERIAL NUMBER TAG ON THE UNIT FOR CORRECT MODEL NUMBER AND SERIAL NUMBER MODEL NUMBER IDENTIFICATION Sample Light Tower Product Line LI3 080D 4 CE Tower Series 2 AL4000 AL4 30 Foot Basic Tower with winch in cabinet AL5000 ALS 30 Foot Basic Tower with in cabinet light storage and door insulation 5000 5 30 Foot Enhanced Cable Tower 2000 2 Model 5000 with extra corrosion protection LT5000 LT5 30 Foot Deluxe Cable Tower w optional Acoustic Enclosure and Complete Instrumentation LT2000 LT2 2 Model LT5000 with Extra Corrosion Protection 7000 7 30 Foot Enhanced Hydraulic Tower LT7000 LT7 30 Foot Deluxe Hydraulic Tower w optional Acoustic Enclosure and Complete Instrum
40. ing 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 suspect wire rope should be changed immediately If there is a crushed spot somewhere on the wire rope it should be replaced only 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 14 Model AL4000 LIGHT TOWER amida Cable Diagram gt 2 Section BIN A 3 Section Cable 2 Point B 4 Section Hat Section 6 Round Tube r Cable 1 N Point B Cable 2 190570 Point A Cable 192904 Point Winch Tower 5 Base 5 lt Created 9 5 97 Revised 9 Document b e zi Spectrum TE PARTS MANUAL Z Tun AL4000 LIGHT TOWER FRE amida Trailer Frame Tongue Outriggers 160270 Battery Cable Set 160110 Battery 174160 Battery Hold Down 182330 Battery Hold Down Rod 124410 Trailer Frame 124470 Tongue 841430 Jack 840222 Jack Snap Ring L 840221 Jack Bracket L 110870 Safety Chain 9 8 5 Created 9 5 9
41. insure that the rear jacks are down to prevent the tower from tipping over backwards when raised DRIVE GROUNDING ROD INTO EARTH 10 IV INSTALL THE FLOODLIGHTS ON THE CROSSBEAM Remove the light fixtures from the tower by removing detent pin and rotating the clamp to free the lights Install them on the cross arm studs with the lens facing the ground The cord on the fixture should be on the side closest to the trailer so the cord entry is beneath the fixture when the tower is raised this reduces moisture problems and ensures the water weep hole in the fixture is down Set the vertical aim for each light fixture by adjusting the light fixtures and tightening the lower bolt Set the spread between the light fixtures horizontal aiming by adjusting the fixtures and tightening the wing nut The unit may be transported with the light fixtures mounted on the cross arm if they are pointed toward the ground TRAVEL LOCKING PIN Gp p Fl A 4 A x 9 I HAc L J lu 19 N N 7 2 N X 1 N N HORIZONTAL LOCKING PIN HORIZONTAL LOCKING PIN N 4 72 TELESCOPING LOCKING PIN KICK OUT SPRING 28 9 K 31 VERTICAL LOCKING PIN ee RAISING THE TOWER refer to drawing above Remove the tower travel locking pin from the cradle at the rear of the cabinet
42. n from the round mast section Remove the pivot pin from the pivot post and lift the mast from the pivot post and place the assembly on a work surface Remove the hex nut from the bottom of the round section re move the T 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 5 REINSTALLING THE LOWER CABLE AND MIDDLE SECTION 5 1 5 2 5 3 5 4 5 5 5 6 If the fish wire worked attach the cable to fish wire and pull through the pulleys and the round section If the square tower section was removed from the round section 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 Install the locking bolt and the hex nut 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 57 LIGHT TROUBLESHOOTING Do not open fixtures while light circuit breaker is Allow lamp to
43. ng negli gence on the part of TEREX Amida shall be limited to the repair of replacement of goods returned transportation prepaid to TEREX Amida TEREX Amida shall in no event be liable for incidental or consequential damages No employee or representative is authorized to change this warranty in any way or grant any other warranty unless such change is made in writing and signed by an officer of TEREX Amida at it s home office 64
44. nstead Disconnect the negative terminal of the battery when working on the engine or other parts to prevent 1 dental 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 Do 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 ABC by the NFPA are appropriate for all applications Keep this unit clean of excessive build up of spilled oil and fuel Accumulated oil and fuel can cause over heating and subsequent engine damage as well as present a fire hazard Remember that EXHAUST GASES ARE TOXIC WARNING DO NOT USE INDOORS unless properly ventilated Provide an adequate exhaust system to properly expel discharged gases Check exhaust system regularly for leaks Ensure periodically that the exhaust manifolds are secure and not warped Make sure the unit i
45. 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 Ballast nameplate data should agree with lamp line voltage and lamp use If improper ballast is used the lamp life will be shortened 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 produce high spike current Measure with oscillo scope Replace ballast as required 60 WIRING SYSTEM Using plug in ballasts to troubleshoot When troubleshooting the preceeding problems minimize down time by following the traceable numbered wiring system always follow these steps STEP1 Insure 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 By adhering to the traceable numbered wiring system troubleshooting fixt
46. ox Side 683970 Mini Breaker 684640 Duplex Receptacle W GFI 683680 Breaker 2P 30A 4 683870 Breaker 1 15 189170 Control Box Face 851790 Decal _ 853190 Decal 684380 Switch 9660010 Push Button Switch 682715 Light 8661490 Relay 853280 Decal T 186781 Control Bottom 663890 Female Cord Set 684450 T Lock Receptacle 663880 For Receptacle 663870 Connector Female 660287 Coil Cord 680080 Strain Relief 121620 Box W Mount Bar 852800 Decal Q o g 680190 Box Cover W Gasket 8 lt Created 9 5 97 Revised 9 Document b Spectrum 41 b Page 112605 STANDARD LIGHT TOWER MV HPS LIGHT FIXTURE TEREX 42 PART POWERLITE DESCRIPTION 833561 1 410 0003 ALUM CONNECTION 1 833562 2 630 1045 SCREW 1 4 20 2 PH 1 833563 3 410 1023 SOCKET BRACKET T amp B 057 05 80643 1 833564 4 4605079000 SOCKET MOGUL BASE W WIRES 1 833565 5 4106781000 SCREW 8 32 x 3 8 PH PH TT ZC 2 833566 6 410 1021 TRUNNION FOR GENERATOR 1 833567 7 310 0056 HOUSING ALUM CST FOR GENERATOR 1 990810 8 4103054000 BOLT 1 2 13
47. rts Particularly be sure to keep hands clear of the blower and alternator belts when the engine is running Beware of Traffic Hazards Stand clear of traffic when starting or checking the unit along the road Check the fuel tank oil pan and fuel and oil lines for leaks that would spill fuel or oil on the road Check fasteners and mounting brackets periodically to insure all are tight and nothing is in danger of falling off during transit Use Only Equal Replacement Parts When a part fails and needs to be replaced only use 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 Replace the fuel and oil hoses with items of equal material diameter and length Contact the manufacturer TEREX Amida regarding replacement parts to ensure a correct repair Use Caution Working Near Lamps Metal halide lamps produce short wave ultra violet radiation and can cause serious skin burn or eye inflam mation if the outer envelope of the lamp is broken or punctured Do not use where people will remain for more than a few minutes unless adequate shielding or other safety precautions are used CHECK OUT ON OF DELIVERY The tower will be serviced tested and ready for operation when received except for export units and sk
48. s in lb ft Ib in FASTENER STAINLESS STAINLESS SAE GRADE SAE GRADE SAE GRADE SAE GRADE 5 PLATED 5PLATED 8PLATED 8 PLATED METRIC NYLOK METRIC 5 16 15 17 20 22 22 24 2834 4550 7 16 31 33 32 35 40 45 70 75 92 104 4mm 2226 19 22 2327 6mm 4550 38 43 72 78 10 180 1517 4550 4045 7075 12mm 4244 3638 5660 5055 95105 16 4 8 lamm 11520 20mm 280 290 An anti seize lubricant MUST be used on all stainless steel hardware 54 WIND LOADING CHARACTERISTICS All wind load calculations were performed with the winch at 12 o clock the wind coming from the direction shown with the lights flat facing into the wind WIND DIRECTION SPEED 10 2 FROM 12 O CLOCK 78 MPH FROM 1 amp 11 O CLOCK 83 8 MPH 9 3 FROM 2 amp 10 O CLOCK 2 amp 10 O CLOCK 92 MPH 66 MPH If optional front outriggers are used the allowable wind loading in 3 9 o clock directions is 79 mph In the 4 and 8 o clock directions the allowable wind velocity would be 94 mph 55 CABLE PROCEDURE 1 1 1 1 2 Collapse tower to where mast is retracted then pivot tower to horizontal position Remove the tower from the trailer and place it on a work surface such as two saw horses 2
49. s well ventilated Protect The Environment And Practice Good Industrial Hygiene Prevent pollution by catching used oil in a container for proper disposal Wash hands to remove oil and fuel Practice good industrial hygiene Maintain an adequate exhaust system to properly expel discharged gases Check the exhaust system regu larly for leaks Do Not Touch Hot Parts 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 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 manual which is a separate booklet that is provided with this manual Do not work this equipment when mentally or physically fatigued Do not work on this equipment when under the influence of performance impairing drugs or alcohol If this manual becomes lost order a new one from TEREX Amida so future operation and maintenance personnel may read these instructions Beware of Moving Parts Avoid being hit or pinched by the moving parts of this unit Loose jackets shirts neckties or sleeves should not be worn while working or running a unit 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 pa
50. ure aiming and fixture control will follow a standard predictable pattern 2 N ES 1 1 N N 4 ae KCN 4 p P4 2 Xe u gt 61 Bearing Inspection Requirements Leroy Somer 6 amp 8 kw Generators rear bearing on all 6 amp 8 kw generators should be inspected every two 2 years 2000 hours whichever occurs first bearing should be replaced at three 3 years 3000 hours Careful attention to this Inspection proeedure will prevent total generator failure resulting from bearing or bearing deterioration There are two areas to examine during the inspection First is the clearance between the bearing outer case and thegenerator 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 th
51. x 1 1 2 MS SS 2 833547 9 410 5021 REFLECTOR 18 ALUM W LENS 8 BAND 1 833569 10 245 0120 GASKET HIF T amp B 61178 1 833570 11 410 1024 REINFORCING RING T amp B B60198 1 833571 12 70463 SCREW 10 24 5 8 HW SL TT 4 553524 13 245 0124 VULCANIZED GASKET SILICONE 1 8 LENS 1 555 0079 COMBINATION 833543 15 410 2027 CLAMP BAND 19 5 ALUMINUM 1 833572 16 245 0119 O RING 1 925 ID x 20 103 SILICON 1 833573 17 410 1032 HANDLE FOR 1 2 13 BOLT DWG OPTIONAL 1 682470 18 690 0447 STRAIN RELIEF 2521T amp B 1 833574 19 630 8928 SCREW 8 32X 1 SL MS SS 1 663850 20 84287 CORD 16 3 SIOW 105 2 RING 1 833575 21 245 0121 O RING 0 206 ID 20 103 SILICON 2 833576 22 4107742000 SCRW 6 32 X 3 8 PH PH ZN 1 833577 23 4106784000 SCREW 8 32 x 5 8 FH PH MS ZC 2 991650 24 4110310000 SPLIT WASHER 1 2 SS 2 990675 25 4104021000 RIVETS 01 8 ALUM 3 16 LENGHT 2 160071 26 LAMP 1000 WATT METAL HALIDE 1 833578 27 634 8005 NUTSERT 8 32 X 01 4 X 13 32 LENGHT 1 160140 28 LAMP 1000 WATT HIGH PRESSURE SODIUM OPT 1 833579 29 4100109000 MARRETS 150 2 WIRE NUT 16 2 160130 30 LAMP 1000 WATT MERCURY VAPOR OPT 1 683950 31 690 0446 SEAL RING 755 ID EPDM 1 680020 32 634 0042 LOCKNUT 1 2 1 833580 34 635 1110 WASHER 1 4 X 1 1 4 OD 1 833581 36 4110953000 FIBER WASHER 1 833582 37 690 0121 FIBERGLASS SLEEVE 2 1 2 5 833583 38 791 2397 LBL LOCATION
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