Terex AL4000 AU Series Operation & Service Manual
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Terex AL4000 AU Series Operation & Service Manual

Terex AL4000 AU Series Operation & Service Manual

Light tower operation & service manual
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SERIES AL4000 AU
LIGHT TOWER
OPERATION & SERVICE MANUAL
SERIAL NUMBER FOF-15872 AND LATER
P/N - AL4000 AU REV. 19-02-2007

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Summary of Contents for Terex AL4000 AU Series

  • Page 1 SERIES AL4000 AU LIGHT TOWER OPERATION & SERVICE MANUAL SERIAL NUMBER FOF-15872 AND LATER P/N - AL4000 AU REV. 19-02-2007...

  • Page 2: Table Of Contents

    TABLE OF CONTENTS Safety Precautions Page # Safety Precautions Operating Instructions Light Tower Operating Instructions 9-16 General Specifications and Routine Maintenance 17-18 Recommended Engine Oil Fastener Torque Specifications Traceable Numbered Wiring System Criteria for Replacement of Wire Rope Broken Cable Replacement Procedure 23-24 Cable Replacement Diagram Shim Placement Diagram...
  • Page 3 Generator Mounting Engine and Generator (Kubota D1105 / Leroy Somer 8 kW) 61-62 Radiator Assembly and Mounting Ballast Box Assembly – 50 Hz Electrical Box Assembly Auto Shutdown Timer Warranty Information Terex Light Tower Model Coding System Manufacturer’s warranty statement...

  • Page 4: 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 injury including death. CAUTION: TEREX-Amida uses this symbol to point out potential damage to equipment.
  • Page 5 • Guard Against Electric Shock (Power Lines) Ensure protection against overhead high voltage power lines. This light tower is not insulated. Any contact with high voltage power lines will result in death or serious injury. See diagram below for recommended clearances from overhead aerial conductors. Note: The specified clearances are recommendations.
  • Page 6 • Guard Against Battery Hazards WARNING: Lead acid batteries can be dangerous. The sulfuric acid in the battery can cause severe skin and eye burns. The hydrogen gas emitted during charging can explode if an arc or flame is present near the battery. Use precautions to prevent acid burns or explosive conditions. Do not smoke while servicing batteries.
  • Page 7 • Do Not Touch Hot Parts WARNING : The exhaust manifold and tailpipe are very hot. Parts of the engine are also hot. Avoid touching hot parts of the engine or tailpipe. Use protective gloves when handling hot parts Take note of CAUTION: Hot Surface decal adjacent to exhaust tailpipe. •...
  • Page 8 If the material/ grade of a fastener is in question, contact Genie Australia for information or part replacement. Replace the fuel and oil hoses with items of equal material, diameter and length. The wire rope must only be replaced with the genuine Terex part. Contact Genie Australia regarding replacement parts. •...

  • Page 9: Operating Instructions

    SECTION 2 OPERATING INSTRUCTIONS I M P O R T A N T : READ ALL DIRECTIONS IN MANUAL CAREFULLY BEFORE OPERATING EQUIPMENT WARNING: DO NOT RAISE TOWER IN THE VICINITY OF OVERHEAD POWER LINES! ALWAYS WEAR A HARD HAT WHEN OPERATING MACHINERY! O P E R A T I N G I N S T R U C T I O N S In addition to the standard model light tower, a mine spec.
  • Page 10 The light tower should not be placed where those working under the light are either: 1) Forced to look into the light regularly. 2) Forced to work with their backs to the light (shadows will block the light from the work area). The area where the tower is positioned should be firm and relatively level.
  • Page 11 INSTALL THE FLOODLIGHTS ON THE CROSSARM (MINE SPEC. EXCLUDED) Remove the light fixtures from their travel position and install them on the crossarm studs. Fixtures should be mounted on the crossarm so that the plugs are closest to the mast. Ensure all fixtures are rotated down, and that adjacent fixtures face each other to minimize possible damage during transportation.
  • Page 12 RAISING THE TOWER (refer to drawing on the previous page) A. MINE SPEC. ONLY: Disconnect the two (2) mast tiedown chains from the crossarm. Remove the tower travel locking pin from the cradle at the rear of the cabinet. Failure to remove the tower travel locking pin may cause winch overload.
  • Page 13 D. Turn the ignition switch to the “START” position to engage the engine. After the engine starts, release the switch so that it returns to the “RUN” position. Let the engine come up to speed and stabilize (review the engine operating procedures in the manufacturers handbook). Note: If engine will not start, leave switch in run position for additional 15-20 seconds (maximum of 45 seconds) to completely prime the fuel system.
  • Page 14 Pull the vertical locking pin at the base of the pivot post (the kick-out spring should provide sufficient pressure to start the tower pivoting over when the electric winch toggle switch is pressed in the down direction). Continue to lower the tower into the cradle using the electric winch. Insert the tower travel locking pin into the cradle.
  • Page 15 XIII. GENERATOR RESIDUAL CURRENT DEVICE (MINE SPEC. ONLY) A. A 20 Amp residual current device (RCD) is installed in the generator output circuit. The operator must test the RCD using the test button daily, or before every use, whichever is the longer.
  • Page 16 To start timer, hold switch in START position until ON lamp illuminates (for about 3 sec.) Select desired run time using rotary switch (6-14 hours). D. The timer can be stopped before the preset run time has elapsed by toggling the switch to the STOP position (ON lamp switches off).

  • Page 17: General Specifications And Routine Maintenance

    LIGHT TOWER GENERAL SPECIFICATIONS AND ROUTINE MAINTENANCE TEREX- Amida Model AL4000 AU Series Light Tower provides mobile, trailer mounted floodlighting for night time maintenance, construction, mining, and emergency work. It consists of a trailer with diesel powered 8 kW 50 Hz 240 Volt generator, and a 30 foot cable actuated tower with four (4) 1000 watt flood- light fixtures.
  • Page 18 ELECTRIC WINCH CAUTION: The winch wire rope must be inspected periodically according to the instructions on page 22. The wire rope must only be replaced with the genuine Terex part. WARNING: Never stand under any object lifted by a winch.

  • Page 19: Recommended Engine Oil

    OIL/AIR SERVICE Change the engine oil after the first 50 hours of use, and then every 200 hours thereafter. Replace the oil filter at 250 hours (2 oil change) and after every 400 hours of use thereafter. The air filter element should be replaced once every year, or after six cleanings (see manufacturer’s operation manual for details).

  • Page 20: Fastener Torque Specifications

    FASTENER TORQUE SPECIFICATIONS All fasteners should be torqued to the following specifications in ft-lb (Nm). These are average values and a +/- 5% tolerance is acceptable. FASTENER STAINLESS STAINLESS SIZE STEEL* STEEL* GRADE 5 GRADE 5 GRADE 8 GRADE 8 NYLOC PLATED PLATED...

  • Page 21: Traceable Numbered Wiring System

    TRACEABLE NUMBERED WIRING SYSTEM (Using plug in ballasts to troubleshoot) When troubleshooting the proceeding problems, minimize down time by following the traceable numbered wiring system, always follow these steps: STEP1: Ensure all ballasts, which are numbered, are plugged into lead wires with corresponding numbers.

  • Page 22: Criteria For Replacement Of Wire Rope

    The wire rope must only be replaced with the genuine Terex part. If there is a crushed spot somewhere on the wire rope, it should be replaced if the width of the crushed spot exceeds 1-1/4 times the nominal diameter of the cable (5/16” on a 1/4” cable, and...

  • Page 23: Broken Cable Replacement Procedure

    BROKEN CABLE REPLACEMENT PROCEDURE CAUTION: The wire rope must only be replaced with the genuine Terex part. This ensures the rope is replaced with the correct grade and rope construction and also a rope of sufficient length. PREPARATION (refer to fig. 1 cable replacement diagram and fig.2 shim placement) 1.1 Collapse tower to where mast is retracted, then pivot tower to horizontal position.
  • Page 24 REMOVING THE LOWER CABLE AND MIDDLE TOWER SECTION 4.1 Remove or lock open the telescope lock pin if not previously done in step 2.2. 4.2 Drill out the pop rivets holding the plastic guides at the top of the large section. Using a screwdriver, remove these guides.

  • Page 25: Cable Replacement Diagram

    AL4000 LIGHT TOWER Cable Replacement Diagram Figure 1 6" Round Tube 2" Section Cable 2 Point B 3" Section 4" Section "Hat" Section Cable 1 Point B Cable 2 Point A Cable 1 Point A Winch Tower Base...

  • Page 26: Shim Placement Diagram

    SHIM PLACEMENT Figure 2 183286 (5/16" thk) 185290 (3/8" thk) 3" TOWER SECTION 4" TOWER SECTION 177830 (1/4" thk) 177830 (1/4" thk) 177820 (5/16" thk) 177820 (5/16" thk) 2" TOWER SECTION 177820 (5/16" thk) 183288 (3/16" thk) SHIM PLACEMENT( as viewed from crossarm end)

  • Page 27: Rear Bearing Inspection Requirements

    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 procedure will prevent total generator failure resulting from bearing or bearing carrier deterioration.

  • Page 28: Light Fixture Troubleshooting Guide

    SECTION 3 LIGHT FIXTURE TROUBLESHOOTING GUIDE DANGER! Do not open fixtures while light circuit breaker is “ON”. Allow lamp to cool before touching. **TAKE EXTRA PRECAUTIONS WHEN TROUBLESHOOTING ELECTRICAL PROBLEMS** DANGER! NO USER SERVICEABLE PARTS INSIDE! THIS IS ONLY A GUIDE.
  • Page 29 LIGHT FIXTURE TROUBLESHOOTING GUIDE (CONTINUED) SYMPTOM CAUSES CORRECTIVE ACTION CIRCUIT Short circuit or ground Check wiring against diagram. Check for shorts or BREAKER ground. TRIPS ON LAMP STARTUP LAMP LIGHT Normal lamp depreciation Replace lamp OUTPUT LOW Dirty lamp or fixture Clean lamp and fixture Defective ballast Interchange ballast plugs in generator enclosure.
  • Page 30 LIGHT FIXTURE TROUBLESHOOTING GUIDE (CONTINUED) SYMPTOM CAUSES CORRECTIVE ACTION SHORT LAMP Improper ballast Ballast nameplate data should agree with lamp line LIFE voltage and lamp use. If improper ballast is used, the lamp life will be shortened. A mismatch may also cause the ballast to fail.

  • Page 31: Light Tower Troubleshooting Guide

    LIGHT TOWER TROUBLESHOOTING GUIDE The engine and the generator are set at the factory. These units are tested and set to 1500 RPM at 50 Hz for proper operation in the field. These units should never require additional adjustments in the field. Adjustments should only be made by a qualified service technician, otherwise the manufacturer’s warranty may become void.
  • Page 32 LIGHT TOWER TROUBLESHOOTING GUIDE (CONTINUED) SYMPTOM CAUSES CORRECTIVE ACTION ENGINE RUNS ROUGH Clogged or leaking fuel system. Replace fuel lines, tighten all connections. Inspect the pickup tube, and inspect the fuel filter. Clogged exhaust system. Clear the exhaust system. Clogged air filter. Replace the air filter.
  • Page 33 LIGHT TOWER TROUBLESHOOTING GUIDE (CONTINUED) SYMPTOM CAUSES CORRECTIVE ACTION ENGINE RUNS, BUT THE Circuit breakers are tripped. Reset the circuit breaker. LIGHTS WILL NOT OPERATE Loose connections in the wiring system. Have a trained electrician inspect the ballast box wiring system.
  • Page 34 This Page Left Intentionally Blank...

  • Page 35: Wiring Diagrams

    SECTION 4 WIRING DIAGRAMS...
  • Page 43 SECTION 5 PARTS MANUAL...
  • Page 44 TEREX amida Decals...
  • Page 45 TEREX amida (4) 721051, Cap Outrigger Tube 6714, Bubble Level...
  • Page 46 TEREX amida Standard: 188630, Fuel Tank Pan Mine Spec: AUS1860 Drip Tray Fuel Tank Standard: (8) 990210, Flat Washer Mine Spec: (4) 990210, Flat Washer (4) AUS1881, Stat-O-Seal...
  • Page 47 TEREX amida...
  • Page 48 TEREX amida Mine Spec: AUS1031, Battery Isolator Switch AUS1190, Isolator Switch Lockout Kit...
  • Page 49 TEREX amida Standard: (2) 188560, Cabinet Door Mine Spec: AUS1858, Cabinet Door Assembly (Includes LH and RH Doors)
  • Page 50 TEREX amida...
  • Page 51 TEREX amida...
  • Page 52 TEREX amida...
  • Page 53 TEREX amida...
  • Page 54 TEREX amida...
  • Page 55 TEREX amida...
  • Page 56 TEREX amida...
  • Page 57 TEREX amida 993180, Nut, lock, 3/4 990230, Washer, Flat 3/4 720495, Plastic Washer 981285 Rue ring 790720 Spring 69207 Plate, lock 59972 Clevis pin...
  • Page 58 TEREX amida Mine Spec: AUS1873, Tie Down Lug 663850 Cordset, 3 Pin, 5’ Mine Spec: AUS1873, Conduit Fitting AUS1874, Adaptor AUS1877, Flexible Conduit...
  • Page 59 TEREX amida...
  • Page 60 TEREX amida...
  • Page 61 TEREX amida 116398, Genset Complete 116775, Engine Wiring Harness 732200, Engine 866090, Alternator 839190, Low Oil Press. Sensor 836831, End-Kit With Bearing 836832, O-Ring 866100, Starter 836833, Rear Bearing...
  • Page 62 TEREX amida...
  • Page 63 TEREX amida...
  • Page 64 TEREX amida...
  • Page 65 TEREX amida...
  • Page 67 SECTION 6 WARRANTY INFORMATION...
  • Page 68 LIGHT TOWER MODEL CODING SYSTEM IMPORTANT WHEN REQUESTING TECHNICAL HELP AND ORDERING REPLACEMENT PARTS THE MODEL AND SERIAL NUMBER ARE NECESSARY. REFER TO THE TEREX SERIAL NUMBER TAG ON THE UNIT FOR CORRECT MODEL NUMBER AND SERIAL NUMBER. MODEL NUMBER IDENTIFICATION Samp1e:...
  • Page 69 Rock Hill, S.C. 29732 MANUFACTURER’S LIMITED WARRANTY TEREX LIGHT CONSTRUCTION (“TLC”) warrants to the original purchaser that such equip- ment, accessories, parts and other products manufactured by TLC will be free from defects in work- manship and material for a period of one (1) year after the date of first delivery or for one thousand (1,000) hours of use, whichever comes first;...

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