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Terex AL4000 series Operation & Service Manual

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SERIES AL4000
LIGHT TOWER
OPERATION & SERVICE MANUAL

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Summary of Contents for Terex AL4000 series

  • Page 1 MAIN MENU SERIES AL4000 LIGHT TOWER OPERATION & SERVICE MANUAL...
  • Page 2 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,...

  • Page 3: Table Of Contents

    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)
  • Page 4 OPERATOR’S MANUAL...

  • Page 5: Safety Precautions

    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.
  • Page 6 • 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.
  • Page 7 Do not work on 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.

  • Page 8: Check Out On Receipt/Delivery

    CHECK OUT ON RECEIPT OF DELIVERY: The tower will be serviced, tested and ready for operation when received except for export units and skid mount units which are knocked down for shipping (export units are also shipped with dry batteries). Amida recommends the following checks: INSURE THERE IS NO FREIGHT HANDLING DAMAGE which should be charged against the carrier.

  • Page 9: Terex Amida Light Tower Model Coding System

    LIGHT 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 Samp1e: Light Tower Product Line 080 D...

  • Page 10: Recommended Engine Oil

    RECOMMENDED ENGINE OIL & 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...

  • Page 11: Operating Instructions

    MODEL AL4000 OPERATING INSTRUCTIONS I M P O R T A N T: READ ALL DIRECTIONS IN MANUAL CAREFULLY BEFORE OPERATING EQUIPMENT WARNING CAUTION DO NOT RAISE TOWER IN THE VICINITY OF OVERHEAD POWER LINES! O P E R A T I N G I N S T R U C T I O N S 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.
  • Page 12 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).
  • Page 13 START THE ENGINE / GENERATOR SET A. 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. B. 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).
  • Page 14 Operating Procedures (cont’d) 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). G. Let out on the winch cable to lower the tower into the cradle. H.

  • Page 15: Criteria For Replacement Of Wire Rope

    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.
  • Page 16 Model: AL4000 LIGHT TOWER Page: Title: Cable Replacement Diagram 6" Round Tube 2" Section Cable 2 Point B 3" Section 4" Section "Hat" Section Cable 1 Point B Cable 2 (190570) Point A Cable 1 (192904) Point A Winch Tower Base Created: 9-5-97...
  • Page 17 PARTS MANUAL...

  • Page 18: Trailer And Related Parts

    Model: AL4000 LIGHT TOWER Page: Trailer Frame/Tongue/Outriggers Title: 160270, Battery Cable Set 160110, Battery 174160, Battery Hold-Down 182330, Battery Hold-Down Rod 124410, Trailer Frame 124470, Tongue 114480, Outrigger 841430, Jack 840222, Jack Snap Ring 840221, Jack Bracket 110870, Safety Chain Created: Revised: Document:...
  • Page 19 AL4000 LIGHT TOWER Model: Page: Title: Fuel Tank 742240, Tank Cap & Gauge (4) 990200, Lock Nut 742220, Fuel Tank 188630, Fuel Tank Pan (8) 990210, Flat Washer (4) 994650, 1/2"-13NC x 10" Bolt Created: 9-5-97 Revised: Document: Spectrum...

  • Page 20: Axle And Wheels

    Model: AL4000 LIGHT TOWER Page: Title: Axle Assy. (2) 834267, U-Bolt Kit 834225, Grease Seal 834220, Hub Assy. 834255, Cotter Pin 834250, Spindle Nut 834338, Axle 834228, Grease Cap 834226, Inner Bearing 834227, Outer Bearing 841060, Tire & Wheel Mounted 840376, Lug Nut (3) 840395, Axle Spring Nut 840392, Axle Rear Hanger...

  • Page 21: Cabinet And Attachments

    Model: AL4000 LIGHT TOWER Page: Cabinet Assy. Title: (4) 796432, Door Shock Bracket 184150, Winch Handle Bush. 188570, Cabinet, Roadside 124420, Ground Rod Storage Tube 188530, Cabinet, Front Radiator Overflow Bracket (2) 189390 Elec. Box Mtg. Bracket 176370 Literature (2) 930950 Rack Weatherstrip Adhesive...
  • Page 22 Model: AL4000 LIGHT TOWER Page: Title: Cabinet Assy. 720220, Bumper 790540, Pin 116180, Rear 124460, Tower Support Cradle Tower Support 123680, Pin 188550, Cabinet Top (4) 796436, Gas Shock 794940, Plastic Plug (4) 796432 Door Shock Bracket (2) 796610 Hinge (2) 790040 Hasp Kit 111368...
  • Page 23 Model: AL4000 LIGHT TOWER Page: Title: Cab. Decal 851640 853296 853296 Curb Side Road Side 853301 853301 853312 853312 852410 851860 853730 853291 850090 Front Rear (2) 841710 www.terex.com 853291 850135 853301 Created: 9-5-97 Revised: Document: Spectrum...

  • Page 24: Tower And Related Parts

    Model: AL4000 LIGHT TOWER Page: Title: Tower Assy. 113080, Coil Cord Sleeve See 2" Section See 3" Section See 4" Section See 6" Round Tube Created: 9-5-97 Revised: Document: Spectrum...
  • Page 25 Model: AL4000 LIGHT TOWER Page: Title: 4" Tower Section See Sheave & Shim Assembly 124540, 4" Tower Section 990660, Roll Pin 120220, Lock Pin 177810 790510, 1/16" Cable Shim (3) 790520, Cable Sleeve 990760, "R" Pin 120640, Pin 980340 Screw 990650 Cotter Pin 790710...
  • Page 26 Model: AL4000 LIGHT TOWER Page: Title: 4" Tower Sec./Upr. Sheave & Shim Assy. 188760 Sheave (2) 990650 Cotter Pin 183285, Shim See Orientation Below (2) 994920 995780 Cotter Pin Clevis Pin 992765 Clevis Pin (2) 995790 Clevis Pin 183285, 3/8" Shim 183286, 5/16"...
  • Page 27 AL4000 LIGHT TOWER Model: Page: Title: 3" Tower Section 185290, Shim (2) 994920 See Orientation Cotter Pin Below 990650 Cotter Pin 188760 Sheave 992765 Clevis Pin (2) 995790 Clevis Pin 124550 3" Tower Section 192904 Cable Orientation of Shims Inside Tube 185290, 3/8"...
  • Page 28 Model: AL4000 LIGHT TOWER Page: Title: 2" Section 124560, 2" Tower Section 190570, Cable 990470, Lock Washer 996230, 3/8" Bolt Created: 9-5-97 Revised: Document: Spectrum...
  • Page 29 Model: AL4000 LIGHT TOWER Page: Title: Tower Crossarm / Fixture (4) See Fixture Assembly 113040, Cross Arm Cross Arm Mounting Plate (4) 123080, Fixture Mounting Wing Nut Created: 9-5-97 Revised: Document: Spectrum...
  • Page 30 Model: AL4000 LIGHT TOWER Page: Title: 6" Round Tube 990650 Cotter Pin 188770 Sheave 794550 188760 Grease Fit. 990610 Sheave Tee Bolt (2) 992765 179850 Clevis Pin Bushing 994920 990620 Cotter Pin Lock Nut 990650 Cotter Pin 124530 6" Round Tube 992765 Clevis Pin 188760...
  • Page 31 AL4000 LIGHT TOWER Model: Page: Title: Tower w/ Base Assy. 113040, Crossarm 116220, Tower Assy. w/ Cables 116170, Tower Base 740050, Winch 1500# 124480, Winch Handle Created: 9-5-97 Revised: Document: Spectrum...
  • Page 32 Model: AL4000 LIGHT TOWER Page: Tower Base Assy. Title: 124490, Tower Base 193750, Kick-Out Spring 740050, Manual Winch 111680 Winch Socket 124480, Winch Handle 186360, Bumper Pad 184510, Spool Sheave 120220, Pin Slide Lock Created: 9-5-97 Revised: Document: Spectrum...

  • Page 33: Engine And Generator (Kubota / Alpha)

    AL4000 LIGHT TOWER Model: Page: Title: Genset, Kub-D905/L-S 6KW 866120, Radiator Cap 741140, Temp. Sender 866010, Air Cleaner 630041, Generator 109350, Capacitor 866030, Soleniod 866040, Gasket 836857, Diode 866050, Oil Filter 866080, V-Belt 865223, Electric Fuel Pump Mounted to Trailer Frame 866110, Radiator Created: 9-5-97...
  • Page 34 Model: AL4000 LIGHT TOWER Page: Genset, Kub-D905/L-S 6KW Title: 866090, Alternator 839190, Low Oil Press. Sensor 836835, End-Kit With Bearing 836830, O-Ring 866100, Starter 836828, Rear Bearing 9-5-97 Created: Revised: Document: Spectrum...
  • Page 35 AL4000 LIGHT TOWER Model: Page: Title: Generator Mounting Bar 630910, Generator (2) 990200 Lock Nut 189335, Generator Mounting Bar (4) 990210, Flat Washer (2) 990820, Bolt Created: 9-5-97 Revised: Document: Spectrum...
  • Page 36 AL4000 LIGHT TOWER Model: Page: Title: Right Side Radiator/Engine Mtg. Bracket Engine Block (4) R980175, Flat Washer (4) 994830, Lockwasher (4) 995110, Screw Radiator Mounting Bracket 189290, Engine Mounting Bracket 740920, Vibration Mount Assy. Created: 9-5-97 Revised: Document: Spectrum...
  • Page 37 Model: AL4000 LIGHT TOWER Page: Fuel Filter Title: 866080, Kubota Fuel Filter Created: 9-5-97 Revised: Document: Spectrum...
  • Page 38 AL4000 LIGHT TOWER Model: Page: Title: Radiator/Overflow Tank 866120, Radiator Cap 975014, Overflow Tank 866110, Radiator Created: 9-5-97 Revised: Document: Spectrum...

  • Page 39: Parts Identification Drawings

    GENSET ASSEMBLY COMPLETE GENSET, ALPHA LPA3/L-S, AL4000 PARTS IDENTIFICATION DRAWING DRWN DATE DWG NO 2/8/96 9609...
  • Page 40 DRAWING# 9609 - GENSET, ALPHA-LPA3 /L-S 6KW-AL4OOO ITEM * PART # DESCRIPTION -001 116360 MA-GENSET-ALPHA LPA3/ L-S 6KW/7.5KW/AL4OOO -002 732130 ENGINE,LISTER ALPHA LPA3,BUILD 8,12.1HP -003 630950 GENERATOR, L-S,8KW,38M7 N/A:USE PARTI# 630950 -004 740400 AIR CLEANER BODY W/EL FWG05-2512 , PAINT-001BK -005 834450 DONALDSON P18-2050 AIR CLEANER ELEMENT...
  • Page 41 DRAWING# 9609 - GENSET, ALPHA-LPA3 /L-S 6KW-AL4OOO ITEM * PART # DESCRIPTION -024 109350 KIT:CAPACITOR REPLACE FOR 6KW LEROY,70UF -025 836857 DIODE L5A38 MODEL 70HF90 -026 831999 LISTER 751-40620 GLOW PLUG LISTER 750-40310 GLOW PLUG RELAY -027 832000 LISTER 570-32390 (ALPHA)HI-TEMP. SWITCH -028 831996 LISTER 750-13710 STARTER (ALPHA-LPA3)

  • Page 42: Electrical Box

    Model: AL4000 LIGHT TOWER Page: Title: Electrical AC/DC, 4 MH/HPS 186730, Control Box Rear 186801, Control Box Top 185390, Control Box Side 683970, Mini-Breaker 684640, Duplex Receptacle W/ GFI 260360, Hour Meter 683680, Breaker 2P-30A 684380, Switch (4) 683870, Breaker 1P-15A 189170, Control Box Face R660010, Push-Button Switch...

  • Page 43: Floodlight Fixtures / Ballasts

    FIBERGLASS SLEEVE 2-1/2" 833583 791.2397 LBL WET LOCATION/EXTERIOR 833584 LBL 105C SUPPLY COND. 791.2395 833585 791.1137 LBL FIXTURE CSA - NRTL/C 995970 WASHER 1/2 EXTER. TOOTH LOCK SS 4110624000 NOTE: FOR COMPLETE ASSEMBLY ORDER PART# 112605 c TEREX Light Construction, 2000...
  • Page 44 Model: AL4000 LIGHT TOWER Page: Title: Ballast 114355, Ballast Box MH 114895, Ballast Box HPS 663860, 5 Pin Connector 160030, Ballast MH 160040, Balast HPS 160032, Capacitor MH 160042, Capacitor HPS Created: 9-5-97 Revised: Document: Spectrum...

  • Page 45: Hitches

    Model: AL4000 LIGHT TOWER Page: Title: Trailer Hitches 840120, Coupler, 2" 176336, Spacer 176335, Plate 840470, Ball, 2" SAE-2 121572, Combo Hitch Ring 16" Long 940000, Kit, Combo Hitch 213770, Ring Hitch 2-1/2" I.D. 124450, Hitch, 24" Height 221580, Hitch, Adj.

  • Page 46: Electric Winch

    OPTION # 0LTX0690 WINCH, ELEC. 12V DC (STD) AL4000/LT5000 DESCRIPTION DWG/ITEM # PART # 160992 WINCH 12V 113583 WINCH SWITCH W/ SOLENOID ASS'Y 160993 WINCH SOLENOID 663780 WINCH TOGGLE SWITCH 2/8/96 DRAWN BY DATE DRAWING NO. 8149...

  • Page 47: Running Lights

    0LTX0080 STOP TAIL & TURN LIGHT AND LICENSE TAG LIGHT OPTION # DESCRIPTION DWG/ITEM # PART # 8126 - 001 STOP TAIL & TURN LIGHT 663510 8126 - 002 LICENSE TAG LIGHT W/BRACKET 663520 4/4/91 8126 DRAWN BY DATE DRAWING NO.

  • Page 48: Fixture With Joy Connector (Mh Or Th)

    PART# WD2985 DWG.# 2985A PART# DESCRIPTION ITEM# #REQ 14/3 WHITE (BLUE) GREEN (GRN/YEL) BLACK (BROWN) NOTE: PIN CONFIGURATION IS THE SAME FOR TUNGSTEN HALOGEN FIXTURES 3/15/00 ADDED EUROPEAN (CE) WIRING DATA DOMESTIC EUROPEAN COLOR COLOR REV. DATE ECO # CHANGE CODE CODE CIRCUIT...

  • Page 49: Metal Halide Ballast With Joy Connector

    PART# WD2986 DWG.# 2986 ITEM# PART# #REQ DESCRIPTION ORANGE BLACK 120V TRANSFORMER (1000W METAL HALIDE BALLAST) WHITE 24 MF 480V 5-POLE RECEPTACLE COLOR CIRCUIT REV. DATE ECO # CHANGE BLACK INPUT 120V WHITE INPUT COMMON TOLERANCES UNLESS OTHERWISE SPECIFIED: Fractions ±1/16 LAMP HOT Decimals .XX=±.030 .XXX=±.010 ORANGE...

  • Page 50: High Pressure Sodium Ballast With Joy Connector

    PART# WD2987 DWG.# 2987 ITEM# PART# DESCRIPTION #REQ IGNITOR X1 X2 X3 ORANGE BLACK WHITE 26uF 450V GREEN TRANSFORMER (1000W HIGH PRESSURE SODIUM BALLAST) 5-POLE RECEPTACLE REV. DATE ECO # CHANGE COLOR CIRCUIT TOLERANCES UNLESS OTHERWISE SPECIFIED: BLACK INPUT 120V Fractions ±1/16 Decimals .XX=±.030 .XXX=±.010 WHITE...

  • Page 51: Ac Wiring

    PART# WD2763 DWG.# 2763B BATTERY CHARGER (OPTIONAL*) ITEM# PART# DESCRIPTION #REQ * LISTER TR/TS UNITS ONLY FLOODLIGHT CONTROL BOX MAIN BREAKER 30AMP BATTERY CHARGER BLACK BLACK TO "ACC" #14 BLK TERMINAL ON INPUT OUTPUT START SWITCH 120V 120V-15AMP GFI PROTECTED WHITE WHITE RECEPTACLES...

  • Page 52: Dc Wiring

    PART# WD4730 DWG.# 4730E ALTERNATOR FAILURE LIGHT ALTERNATOR GREEN ORANGE PURPLE (NC) LOW OIL PREHEAT PRESSURE PUSH BUTTON (NC) ORANGE BROWN YELLOW YELLOW RELAY 12V SPST HIGH ORANGE COOLANT BROWN TEMPERATURE (NO) GLOW PLUGS HOUR IGN & ACC FUSE METER FUEL START PUMP...

  • Page 53: Specifications, Routine Maintenance, Wind Loading

    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.
  • Page 54 MANUAL WINCH Maintain a light film of automotive-type grease on the pinion, drum gear, and the 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.
  • Page 55 MISCELLANEOUS SPECIFICATIONS The Amida AL4000 light tower is built to NEC standards. FASTENER TORQUE SPECIFICATIONS All fasteners should be torqued to the following specifications in lb-ft (lb-in): FASTENER STAINLESS STAINLESS SAE GRADE SAE GRADE SAE GRADE SAE GRADE SIZE STEEL* STEEL* 5 PLATED 5 PLATED...
  • Page 56 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 FROM 12 O’CLOCK 78 MPH FROM 1 & 11 O’CLOCK 83.8 MPH FROM 2 &...

  • Page 57: Broken Cable Replacement Procedure

    BROKEN CABLE REPLACEMENT PROCEDURE 1. PREPARATION 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. 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.
  • Page 58 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 altogether. Be sure to keep the cable tight, if slack accumulates it is most difficult to remove.

  • Page 59: Light Fixture Troubleshooting

    LIGHT FIXTURE TROUBLESHOOTING DANGER! Do not open fixtures while light circuit breaker is “ON”. Allow lamp to cool before touching. **TAKE EXTRA PRECAUTIONS WHEN TROUBLESHOOTING ELECTRICAL PROBLEMS** A. Only use a voltmeter with two well-insulated pin probes rated for 600 volts. B.
  • Page 60 LIGHT FIXTURE TROUBLESHOOTING (cont’d) SYMPTOM CAUSES CORRECTIVE ACTION LAMP STARTS Defective Lamp Lamp may glow for extended period of time. Replace after SLOWLY (ARC checking voltage and ballast. DOES NOT STRIKE WHEN SWITCH IS FIRST TURNED ON) CIRCUIT Short circuit or ground Checking wiring against diagram.
  • Page 61 LIGHT FIXTURE TROUBLESHOOTING (cont’d) SYMPTOM CAUSES CORRECTIVE ACTIONS SHORT LAMP Lamp damaged Check for outer bulb cracks. If air enters outer bulb, arc tube LIFE 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.

  • Page 62: Terex Amida Numbered Wiring System

    TRACEABLE NUMBERED 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.

  • Page 63: Generator Bearing Inspection

    Rear Bearing Inspection Requirements Leroy-Somer 6 & 8 kw Generators The rear bearing on all 6 & 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 proeedure will prevent total generator failure resulting from bearing or bearing carrier deterioration.

  • Page 64: Engine (Refer To Manufacturer's Handbook) Generator (Refer To Manufacturer's Handbook)

    LEROY SOMERS LSA37 LEROY SOMERS LSA37...
  • Page 65 PERFORMANCE PERFORMANCE Brushless 4 Pole design Self excited with capacitors +/-5% voltage regulation at constant speed Inherent overvoltage protection...
  • Page 66 PRINCIPLE OF OPERATION PRINCIPLE OF OPERATION The capacitor(s) produce the no-load excitation for the unit. The rotor magnetic field is produced by the current flowing through the rotating diodes and the main field winding.
  • Page 67 WIRING WIRING...
  • Page 68 TERMINAL BOX LAYOUT TERMINAL BOX LAYOUT Terminal Block Capacitor...
  • Page 69 CONSTRUCTION CONSTRUCTION...
  • Page 70 REVOLVING FIELD REVOLVING FIELD Rotating Diodes Balancing weights Revolving field...
  • Page 71 TROUBLESHOOTING TIPS TROUBLESHOOTING TIPS No voltage Suspect a capacitor problem (They have a limited life) – Correct voltage at no load but incorrect under load Suspect a 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.
  • Page 72 Do not shut down the units with the lights on. Make sure the engine RPM is set properly. The output voltage is proportional with the speed and a voltage too high across the capacitor terminals will shorten its life. Make sure the wavy washer is located properly if no end play is found on the set.
  • Page 73 DOCUMENTATION DOCUMENTATION Technical Maintenance General Catalog Manuals Information Brochures Data Sheets / Outline Parts list / Trouble Technical Catalog Drawings Shooting / Assembly O&M Manuals AutoCAD drawings...

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