Terex Series AL4000 Manuals

SERIES AL4000 LIGHT TOWER OPERATION & SERVICE MANUAL MAIN MENU Discount-Equipment.com Discount-Equipment.com is your online resource for commercial and industrial quality parts and equipment sales. Locations: Florida (West Palm Beach): 561-964-4949 Outside Florida TOLL FREE: 877-690-3101 Need parts? Check out our website at www.discount-equipment.com Can’t find what you need? Click on this link: http://www.discount-equipment.com/category/5443-parts/ and fill out the request form. Please have the machine model and serial number available in order to help us get you the correct parts. One of our experienced staff members will get back to you with a quote for the right part that your machine needs. We sell worldwide for the brands: Genie, Terex, JLG, MultiQuip, Mayco, Toro/Stone, Diamond Products, Magnum, Airman, Mustang, Power Blanket, Nifty Lift, Atlas Copco, Chicago Pneumatic, Allmand Brothers, Essick, Miller Spreader, Skyjack, Lull, Skytrak, Tsurumi, Husquvarna/Target, Whiteman-Concrete/Mortar, Stow-Concrete/Mortar, Baldor, Wacker, Sakai, Snorkel, Upright, Mi-T-M, Sullair, Neal, Basic, Dynapac, MBW, Weber, Bartell, Bennar Newman, Haulotte, Ditch Runner, Blaw-Knox, Himoinsa, Best, Buddy, Crown, Edco, Wyco, Bomag, Laymor, Terremite, Barreto, EZ Trench, Takeuchi, Basic, Bil- Jax, Curtis, Gehl, Heli, Honda, ICS/PowerGrit, Puckett, Waldon, ASV, IHI, Partner, Imer, Clipper, MMD, Koshin, Rice, Gorman Rupp, CH&E, Cat Pumps, Comet, General Pump, Giant,AMida, Coleman, NAC, Gradall, Square Shooter, Kent, Stanley, Tamco, Toku, Hatz, Kohler, Robin, Wisconsin, Northrock, Oztec, Toker TK, Rol-Air, Small Line, Wanco, Yanmar Discount-Equipment.com TABLE OF CONTENTS Receiving and Set-up Safety Precautions ................................................................................ 4-6 Check Out on Receipt/Delivery ........................................................... 7 TEREX Amida Light Tower Model Coding System ........................... 8 Recommended Engine Oil ................................................................... 9 Operating Instructions Light Tower Operating Instructions ..................................................... 10-13 Criteria for Replacement of Wire Rope ............................................... 14-15 Engine (see manufacturer’s handbook) Generator (see manufacturer’s handbook) Parts Identification Drawings Trailer and Related Parts ...................................................................... 17-18 Axle and Wheels .................................................................................. 19 Cabinet and Attachments...................................................................... 20-22 Tower and Related Parts ...................................................................... 23-31 Engine and Generator (Kubota / Alpha) .............................................. 32-40 Electrical Box....................................................................................... 41 Floodlight Fixtures / Ballasts ............................................................... 42-43 Hitches.................................................................................................. 44 Electric Winch ...................................................................................... 45 Running Lights ..................................................................................... 46 Wiring Diagrams Fixture with Joy Connector (MH or TH) ............................................. 47 Metal Halide Ballast with Joy Connector ............................................ 48 High Pressure Sodium Ballast with Joy Connector ............................. 49 AC Wiring ............................................................................................ 50 DC Wiring ............................................................................................ 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 handbook)..................................... 63-72 Discount-Equipment.com

Discount-Equipment.com Discount-Equipment.com is your online resource for commercial and industrial quality parts and equipment sales. Locations: Florida (West Palm Beach): 561-964-4949 Outside Florida TOLL FREE: 877-690-3101 Need parts? Check out our website at www.discount-equipment.com Can’t find what you need? Click on this link: http://www.discount-equipment.com/category/5443-parts/ and fill out the request form. Please have the machine model and serial number available in order to help us get you the correct parts. One of our experienced staff members will get back to you with a quote for the right part that your machine needs. We sell worldwide for the brands: Genie, Terex, JLG, MultiQuip, Mayco, Toro/Stone, Diamond Products, Magnum, Airman, Mustang, Power Blanket, Nifty Lift, Atlas Copco, Chicago Pneumatic, Allmand Brothers, Essick, Miller Spreader, Skyjack, Lull, Skytrak, Tsurumi, Husquvarna/Target, Whiteman-Concrete/Mortar, Stow-Concrete/Mortar, Baldor, Wacker, Sakai, Snorkel, Upright, Mi-T-M, Sullair, Neal, Basic, Dynapac, MBW, Weber, Bartell, Bennar Newman, Haulotte, Ditch Runner, Blaw-Knox, Himoinsa, Best, Buddy, Crown, Edco, Wyco, Bomag, Laymor, Terremite, Barreto, EZ Trench, Takeuchi, Basic, Bil- Jax, Curtis, Gehl, Heli, Honda, ICS/PowerGrit, Puckett, Waldon, ASV, IHI, Partner, Imer, Clipper, MMD, Koshin, Rice, Gorman Rupp, CH&E, Cat Pumps, Comet, General Pump, Giant,AMida, Coleman, NAC, Gradall, Square Shooter, Kent, Stanley, Tamco, Toku, Hatz, Kohler, Robin, Wisconsin, Northrock, Oztec, Toker TK, Rol-Air, Small Line, Wanco, Yanmar Discount-Equipment.com August 2016 AL4 • AL4000 Part No. 218567 ii ii Introduction Important Read, understand and obey the safety rules and operating instructions in the appropriate operator's manual on your machine before attempting any maintenance or repair procedure. This manual provides detailed scheduled maintenance information for the machine owner and user. It also provides troubleshooting fault codes and repair procedures for qualifi ed service professionals. Basic mechanical, hydraulic and electrical skills are required to perform most procedures. However, several procedures require specialized skills, tools, lifting equipment and a suitable workshop. In these instances, we strongly recommend that maintenance and repair be performed at an authorized Terex dealer service center. Technical Publications Terex has endeavored to deliver the highest degree of accuracy possible. However, continuous improvement of our products is a Terex policy. Therefore, product specifi cations are subject to change without notice. Readers are encouraged to notify Terex of errors and send in suggestions for improvement. All communications will be carefully considered for future printings of this and all other manuals. Introduction Copyright © 2012 by Terex Corporation 218567 Rev B August 2016 First Edition, Second Printing Terex is a registered trademarks of Terex USA, LLC in the USA and many other countries. Printed on recycled paper Printed in U.S.A. www.discount-equipment.com Discount-Equipment.com

1 SERIES AL4000 LIGHT TOWER OPERATION & SERVICE MANUAL PO Box 3147 • Rock Hill, SC 29732 USA • Phone 803-324-3011 Toll Free 800-433-3026 Parts Department Fax 800-633-5534 After Serial Number: 0302-77560 3 OPERATOR’S MANUAL 4 SAFETY ALERT SYMBOLS MEANS: ATTENTION! BE ALERT! YOUR SAFETY IS INVOLVED THIS SAFETY SYMBOL IS USED FOR IMPORTANT SAFETY MESSAGES. WHEN YOU SEE THIS SYMBOL, FOLLOW THE SAFETY MESSAGE TO AVOID PERSONAL INJURY OR PROPERTY DAMAGE. UNDERSTANDING SIGNAL WORDS A signal word - DANGER, WARNING or CAUTION is used with the safety alert symbol. DANGER Identifies the hazard or unsafe prac- tice that will result in severe injury or death. WARNING Identifies the hazard or unsafe prac- tice that could result in severe injury or death. CAUTION Identifies the hazard or unsafe prac- tice that could result in minor injury or property damage. NOTICE Identifies important installation, opera- tion or maintenance information.