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 specifications are subject to change without notice.
September 2008 How to Read Your Serial Number Serial Number Legend Part No. 116478 AL8000HT Light Tower...
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September 2008 Safety Rules Danger Failure to obey the instructions and safety rules in this manual and the Terex AL8000HT Operator's Manual on your machine will result in death or serious injury. Many of the hazards identified in the operator’s manual are also safety hazards when maintenance and repair procedures are performed.
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Be sure to wear protective eye wear and other protective clothing if the situation warrants it. Be aware of potential crushing hazards such as moving parts, free swinging or unsecured components when lifting or placing loads. Always wear approved steel-toed shoes. Part No. 116478 AL8000HT Light Tower...
September 2008 Parts Stocking List Required Parts The following parts are required to perform maintenance procedures as outlined in the TEREX AL8000HT Parts and Service Manual. Description Part No. Kubota Models Oil Filter .............. 866050 Air Filter .............. 866127 Fuel Filter ............839200 V-belt ..............
September 2008 How To Order Parts Please be prepared with the following information Genie Industries when ordering replacement parts for your TEREX 18340 NE 76th Street product: P.O. Box 97030 Redmond, WA 98073-9730 Machine model number Telephone (877) 367-5606 Machine serial number...
Ship all available parts and contact customer on disposition of backordered parts Other (please specify) TEREX U Order Number ______________ Origin Code ________________ Comments _________________________ AL8000HT Light Tower Part No. 116478 Date Scheduled ____________ Ship Condition _____________ __________________________________ Order Total ________________...
Tire pressure, maximum (cold) 75 psi 5.2 bar Continuous improvement of our products is a For operational specifications, refer to the Terex policy. Product specifications are subject Operator's Manual. to change without notice. Part No. 116478 AL8000HT Light Tower 2 - 1...
205°F / 96°C. Note: Terex specifications require additional equipment and special installation instructions for Continuous improvement of our products is a the approved optional fluids. Consult the Terex Terex policy. Product specifications are subject Service Department before use. to change without notice.
3 position 4 way solenoid valve, 10V DC 6Ω (schematic items B, C, E and G) Continuous improvement of our products is a Terex policy. Product specifications are subject to change without notice. Part No. 116478 AL8000HT Light Tower 2 - 3...
Extreme operating temperatures may require the use of alternative engine oils. For oil requirements, refer to the Engine Operator Handbook on your machine. Continuous improvement of our products is a Terex policy. Product specifications are subject to change without notice. 2 - 4 AL8000HT Light Tower...
(engine shutoff pressure) Oil viscosity requirements Units ship with 10W-30. Extreme operating temperatures may require the use of alternative engine oils. For oil requirements, refer to the Engine Operator Handbook on your machine. Part No. 116478 AL8000HT Light Tower 2 - 5...
Extreme operating temperatures may require the use of alternative engine oils. For oil requirements, refer to the Engine Operating Instructions on your machine. Continuous improvement of our products is a Terex policy. Product specifications are subject to change without notice. 2 - 6 AL8000HT Light Tower...
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Generator rpm @ full load 60 Hz 1800 rpm Temperature, ambient maximum 104°F 40°C Power 20 kW Continuous improvement of our products is a Terex policy. Product specifications are subject to change without notice. Part No. 116478 AL8000HT Light Tower 2 - 7...
Repair any machine damage or malfunction injury. before operating the machine. Indicates a potentially hazardous Use only Terex approved replacement parts. situation which, if not avoided, Machines that have been out of service for a may result in property damage.
Make copies of the Maintenance Inspection Report to use for each inspection. Maintain completed forms for a minimum of 4 years or in compliance with employer, jobsite and governmental regulations and requirements. 3 - 2 AL8000HT Light Tower Part No. 116478...
After repair, place a check in the “R” box. Legend Y = yes, acceptable N = no, remove from service R = repaired Part No. 116478 AL8000HT Light Tower 3 - 5...
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After repair, place a check in the “R” box. Legend Y = yes, acceptable N = no, remove from service R = repaired 3 - 6 AL8000HT Light Tower Part No. 116478...
In addition, maintaining all of the safety and container after use. instructional decals in good condition is mandatory Note: Contact your authorized Terex distributor if for safe machine operation. Decals alert operators replacement manuals or decals are needed. and personnel to the many possible hazards associated with using this machine.
CHECKLIST A PROCEDURES REV A Perform Pre-operation Perform Function Tests Inspection Note: Terex specifications require that this procedure be performed every 8 hours or daily, Note: Terex specifications require that this whichever comes first. procedure be performed every 8 hours or daily, whichever comes first.
Leroy Somer LSA 37 Installation and Maintenance Manual Terex part number 116118 Marathon Installation, Operation and Maintenance Manual Terex part number 116188 Newage Installation, Service and Maintenance Manual Terex part number 830001 Part No. 116478 AL8000HT Light Tower 3 - 9...
Lug Nut Torque Required maintenance procedures and additional axle information is available in the Axis Axle Operator Maintenance Manual included with your machine. Axis Axle Operator Maintenance Manual Terex part number 116117 3 - 10 AL8000HT Light Tower Part No. 116478...
Fulton Coupler User Manual (Kubota part number 16683-89169). Terex part number 150139 Isuzu 4LE1 Diesel Engine Instruction Manual Terex part number 116133 Kubota D-1105 and V-1505 Operator's Manual Terex part number 893020 Part No. 116478 AL8000HT Light Tower 3 - 11...
Bearing and Rotate Gear thoroughly greased. 10 Install the pinion gear guard and securely tighten the retaining fasteners. Do not overtighten. Note: Terex specifications require that this Grease Specification procedure be performed every 100 hours of operation. Perform this procedure more often if Chevron Ultra-duty grease, EP NLGI 2 (lithium based) dusty conditions exist.
Kubota D-1105 and V-1505 Operator's Manual (Kubota part number 16683-89169). (Kubota part number 16683-89169). Kubota D-1105 and V-1505 Operator's Manual Kubota D-1105 and V-1505 Operator's Manual Terex part number 893020 Terex part number 893020 Part No. 116478 AL8000HT Light Tower 3 - 13...
Checklist B Procedures REV A Inspect the Battery Inspect the Electrical Wiring Note: Terex requires that this procedure be Note: Terex requires that this procedure be performed every 250 hours or quarterly, whichever performed every 250 hours or quarterly, whichever comes first.
CHECKLIST B PROCEDURES Inspect the Tires and Wheels Perform Hydraulic Oil Analysis (including lug nut torque) Note: Terex requires that this procedure be performed every 250 hours or quarterly, whichever Note: Terex requires that this procedure be comes first. performed every 250 hours or quarterly, whichever comes first.
Leroy Somer LSA 37 Installation and Maintenance Manual Terex part number 116118 Marathon Installation, Operation and Maintenance Manual Terex part number 116188 Newage Installation, Service and Maintenance Manual Terex part number 830001 3 - 16 AL8000HT Light Tower Part No. 116478...
Required maintenance procedures and additional axle information is available in the Axis Axle Operator Maintenance Manual included with your machine. Axis Axle Operator Maintenance Manual Terex part number 116117 Part No. 116478 AL8000HT Light Tower 3 - 17...
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Section 3 • Scheduled Maintenance Procedures September 2008 REV A This page intentionally left blank. 3 - 18 AL8000HT Light Tower Part No. 116478...
Perform Engine Maintenance Retract Cables and Pulleys Note: Engine specifications require that this procedure be performed every 500 hours or Note: Terex requires that this procedure be semi-annually, whichever comes first. performed every 500 hours or semi-annually, Required maintenance procedures and additional whichever comes first.
Required maintenance procedures and additional Terex part number 116133 axle information is available in the Axis Axle Operator Maintenance Manual included with your machine. Axis Axle Operator Maintenance Manual Terex part number 116117 3 - 20 AL8000HT Light Tower Part No. 116478...
Required maintenance procedures and additional engine information is available in the Kubota D-1105 and V-1505 Operator's Manual (Kubota part number 16683-89169). Kubota D-1105 and V-1505 Operator's Manual Terex part number 893020 Part No. 116478 AL8000HT Light Tower 3 - 21...
Perform Engine Maintenance - Check the Tower Rotation Kubota Models Bearing Bolts Note: Engine specifications require that this Note: Terex requires that this procedure be procedure be performed annually. performed every 1000 hours or annually, whichever comes first. Required maintenance procedures and additional...
Refer to Section 2, Filter Specifications . Tongue Note: Terex requires that this procedure be performed every 1000 hours or annually, whichever comes first. Replacement of the hydraulic return filter is essential for good machine performance and service life.
Isuzu 4LE1 Diesel Engine Instruction Manual (Isuzu part number IDE-6033). (Isuzu part number IDE-6033). Isuzu 4LE1 Diesel Engine Instruction Manual Terex part number 116133 Isuzu 4LE1 Diesel Engine Instruction Manual Terex part number 116133 3 - 24 AL8000HT Light Tower Part No. 116478...
Leroy Somer LSA 37 Installation and Maintenance Manual Terex part number 116118 Marathon Installation, Operation and Maintenance Manual Terex part number 116188 Newage Installation, Service and Maintenance Manual Terex part number 830001 Part No. 116478 AL8000HT Light Tower 3 - 25...
Cequent Tongue Jack Use Manual Terex part number 150140 axle information is available in the Axis Axle Operator Maintenance Manual included with your machine. Axis Axle Operator Maintenance Manual Terex part number 116117 3 - 26 AL8000HT Light Tower Part No. 116478...
Loosen hydraulic connections very slowly to allow Note: Terex requires that this procedure be the oil pressure to dissipate performed every 2000 hours or every two years, gradually. Do not allow oil to squirt whichever comes first.
19 Make sure unit is in a clear area during steps 17 and 18 as air in the cylinders can cause sudden movements of the tower. 3 - 28 AL8000HT Light Tower Part No. 116478...
Leroy Somer LSA 37 Installation and Maintenance Manual Terex part number 116118 Marathon Installation, Operation and Maintenance Manual Terex part number 116188 Newage Installation, Service and Maintenance Manual Terex part number 830001 Part No. 116478 AL8000HT Light Tower 3 - 29...
Leroy Somer LSA 37 Installation and Maintenance Manual Terex part number 116118 Marathon Installation, Operation and Maintenance Manual Terex part number 116188 Newage Installation, Service and Maintenance Manual Terex part number 830001 3 - 30 AL8000HT Light Tower Part No. 116478...
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Be sure that all necessary tools and parts are injury. available and ready for use. Indicates a potentially hazardous Use only Terex approved replacement parts. situation which, if not avoided, may cause minor or moderate Read each procedure completely and adhere to injury.
10 to 20 minutes. Note: Be sure to wrap a clean cloth around a lamp when installing a lamp into a lamp socket. 4 - 2 AL8000HT Light Tower Part No. 116478...
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Refer to the following chart. Open Circuit Voltage 375V AC to 465V AC Specification Note: If there is no reading on the meter. Repair or replace the capacitor, ballast or wiring. Part No. 116478 AL8000HT Light Tower 4 - 3...
3 Remove the pin retaining fasteners from both the rod end and barrel-end pivot pins. 4 Place a rod through the pins and twist to remove. Remove the cylinder from the machine. Part No. 116478 AL8000HT Light Tower 4 - 5...
2 Repeat step 1 for each link. 3 To remove a single link, open the lower clip and then use a screw driver to pry the link to the side. Part No. 116478 AL8000HT Light Tower 4 - 7...
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Crushing hazard. The tower assembly could become unbalanced and fall when removed from the machine if not properly supported and secured to the forklift. 4 - 8 AL8000HT Light Tower Part No. 116478...
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Remove the clevis pins. Do not remove the pulley clevis pin. Note: Always use a new cotter pin when installing a clevis pin. Part No. 116478 AL8000HT Light Tower 4 - 9...
Guide the cylinder out the pivot end of the tower and carefully remove the cylinder from the machine. Component damage hazard. Cables and hoses can be damaged if the cylinder is dragged across them. 4 - 10 AL8000HT Light Tower Part No. 116478...
Do not allow oil to squirt or spray. 2 Attach a lifting strap from an overhead crane to the tower extension cylinder. Part No. 116478 AL8000HT Light Tower 4 - 11...
Note: When installing a rotation motor, the gear Check for tight spots and binding. Readjust if backlash will need to be adjusted. See How to necessary. Adjust the Tower Rotation Gear Backlash. 4 - 12 AL8000HT Light Tower Part No. 116478...
2 Connect the leads from an ohmmeter between each glow plug terminal and ground. Result: The resistance should be approximately 1Ω. Result: The resistance is 0Ω or greater than 1Ω. The glow plug is faulty. Part No. 116478 AL8000HT Light Tower 4 - 13...
2 Connect the leads from an ohmmeter between each glow plug terminal and ground. Result: The resistance should be approximately 1Ω. Result: The resistance is 0Ω or greater than 1Ω. The glow plug is faulty. 4 - 14 AL8000HT Light Tower Part No. 116478...
4 With an ohmmeter set to its highest resistance scale, connect the ohmmeter leads to the capacitor terminals and observe the reading on the meter. Then, reverse the connections and observe the reading on the meter. Part No. 116478 AL8000HT Light Tower 4 - 15...
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2 Raise the tower to a vertical position. Do not engine components may cause extend the tower or raise the light bar. Turn the severe burns. Use caution when machine off. working around a hot engine. 4 - 16 AL8000HT Light Tower Part No. 116478...
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8 Remove the tower rest pad weldment fasteners. Remove the rest pad from the cabinet. 9 Support the cabinet top with a suitable lifting device. Part No. 116478 AL8000HT Light Tower 4 - 17...
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15 Use a lifting jack or similar device to support the high voltage electrical rear of the engine. Do not apply any lifting components. pressure. 13 Tag and disconnect the wires at the top of the generator. Remove the cover. 4 - 18 AL8000HT Light Tower Part No. 116478...
1 Move the engine start switch to timed start. 2 On the timer, move the mode switch (upper left switch) to and the set switch (upper right AUTO switch) to Part No. 116478 AL8000HT Light Tower 4 - 19...
Note: If the ballast capacitor to be tested is located · Incorrect capacitor voltage rating. under another ballast box, the top ballast box will need to be removed first. · Capacitor becomes loose in ballast box. 4 - 20 AL8000HT Light Tower Part No. 116478...
2 for the other fuel tank. 3 Tag, disconnect and plug the fuel hoses from the fuel tank. Clean up any fuel that may have spilled. Part No. 116478 AL8000HT Light Tower 4 - 21...
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Note: Clean the fuel tank and inspect for cracks and other damage before installing it onto the machine. 4 - 22 AL8000HT Light Tower Part No. 116478...
Install the hose to the tee fitting. 3 Activate and hold the tower rotate toggle switch in either direction. 4 Observe the pressure reading on the pressure gauge. Refer to Section 2, Specifications. 4 - 24 AL8000HT Light Tower Part No. 116478...
Remove all rings, watches and other jewelry. Burn hazard. Contact with hot engine components may cause severe burns. Use caution when working around a hot engine. Part No. 116478 AL8000HT Light Tower 5 - 1...
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Voltage should be within 10% of rating when operating at normal load. Increase supply voltage or remove external load. Part No. 116478 AL8000HT Light Tower 5 - 3...
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"cycle". Usually after 3 tries to start at 30 to 60 second intervals, lamp will stabilize and operate normal 5 - 4 AL8000HT Light Tower Part No. 116478...
D. Before disconnecting ballast, turn off circuit breaker and wait 30 seconds for capacitor to discharge. E. If all the lights are out and all the ballasts are receiving power, suspect burned out power cable. Part No. 116478 AL8000HT Light Tower 5 - 5...
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September 2008 Section 5 • Troubleshooting REV A This page intentionally left blank. 5 - 6 AL8000HT Light Tower Part No. 116478...
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Be sure that all necessary tools and test equipment are available and ready for use. Malfunction Identify Troubleshoot symptoms discovered problem still exists Return to Inspect Perform service and test repair problem solved Part No. 116478 AL8000HT Light Tower 6 - 1...
Priority fixed displacement with pressure setting flow regulator valve 3000 psi (206.8 bar) Pump prime mover (engine or motor) Cross-relief valve Counterbalance valve with pressure and pilot ratio Double acting cylinder Part No. 116478 AL8000HT Light Tower 6 - 3...
TOWER RETRACT VALVE COIL BLK/WH RETRACT TOWER EXTEND TOWER EXTEND VALVE COIL TOWER DOWN VALVE COIL RED/BLK DOWN TOWER TOWER UP VALVE COIL STOWED LIMIT SWITCH PUMP MOTOR CONTACTOR LIFT PUMP MOTOR 6 - 4 AL8000HT Light Tower Part No. 116478...
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September 2008 Section 6 • Schematics DC Electrical Schematic - Control Box and Engine REV A Isuzu Models Part No. 116478 AL8000HT Light Tower 6 - 5...
Section 6 • Schematics September 2008 DC Electrical Schematic - Control Box and Engine Kubota Models REV A 6 - 6 AL8000HT Light Tower Part No. 116478...
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September 2008 Section 6 • Schematics DC Electrical Schematic - Control Box and Engine REV A with Autostart Option Part No. 116478 AL8000HT Light Tower 6 - 7...
September 2008 Section 6 • Schematics Hydraulic Schematic REV A Part No. 116478 AL8000HT Light Tower 6 - 15...
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Section 6 • Schematics September 2008 REV A This page intentionally left blank. 6 - 16 AL8000HT Light Tower Part No. 116478...
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California Proposition 65 Warning The exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects or other reproductive harm. Towing Checklist (Use at each stop) · Boom hold-down latch is securely locked in place Before Towing ·...