Scribd Logo
Upload

Welcome to Scribd!

  • 1K views

    Terex Light Tower Serie AL4000 Operador y Servicios

    Uploaded by

    177393
    SERIES AL4000 LIGHTTOWER OPERATION and SERVICE MANUAL Terex Light Construction Division Toll Free 800-433-3026 Parts Department Fax 800-633-5534 TABLE OF CONTENTS Safety 4-6 Check Out on Receipt / Delivery 7 TEREX Arnida Light Tower Model Coding System 8 Recommended Engine Oil :., 9 operating instructions 1013 Criteria for Replacement of Wire Rope 14-15 Engine (see manufacturer's handbook) Generator (

    Copyright:

    Attribution Non-Commercial (BY-NC)
    Download as PDF, TXT or read online from Scribd

    Terex Light Tower Serie AL4000 Operador y Servicios

    Uploaded by

    177393
    1K views63 pages
    SERIES AL4000 LIGHTTOWER OPERATION and SERVICE MANUAL Terex Light Construction Division Toll Free 800-433-3026 Parts Department Fax 800-633-5534 TABLE OF CONTENTS Safety 4-6 Check Out on Receipt / Delivery 7 TEREX Arnida Light Tower Model Coding System 8 Recommended Engine Oil :., 9 operating instructions 1013 Criteria for Replacement of Wire Rope 14-15 Engine (see manufacturer's handbook) Generator (

    Copyright

    © Attribution Non-Commercial (BY-NC)

    Available Formats

    PDF, TXT or read online from Scribd

    Did you find this document useful?

    Is this content inappropriate?

    SERIES AL4000 LIGHTTOWER OPERATION and SERVICE MANUAL Terex Light Construction Division Toll Free 800-433-3026 Parts Department Fax 800-633-5534 TABLE OF CONTENTS Safety 4-6 Check Out on Receipt / Delivery 7 TEREX Arnida Light Tower Model Coding System 8 Recommended Engine Oil :., 9 operating instructions 1013 Criteria for Replacement of Wire Rope 14-15 Engine (see manufacturer's handbook) Generator (

    Copyright:

    Attribution Non-Commercial (BY-NC)
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    1K views63 pages

    Terex Light Tower Serie AL4000 Operador y Servicios

    Uploaded by

    177393
    SERIES AL4000 LIGHTTOWER OPERATION and SERVICE MANUAL Terex Light Construction Division Toll Free 800-433-3026 Parts Department Fax 800-633-5534 TABLE OF CONTENTS Safety 4-6 Check Out on Receipt / Delivery 7 TEREX Arnida Light Tower Model Coding System 8 Recommended Engine Oil :., 9 operating instructions 1013 Criteria for Replacement of Wire Rope 14-15 Engine (see manufacturer's handbook) Generator (

    Copyright:

    Attribution Non-Commercial (BY-NC)
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    of 63
    lS TEREX SERIES AL4000 LIGHT TOWER OPERATION & SERVICE MANUAL Terex Light Construction Division 590 Huey Road ¢ Rock Hill, SC 29732 USA ¢ Phone 803-324-3011 Toll Free 800-433-3026 Parts Department Fax 800-633-5534 TEREX LIGHT CONSTRUCTION SERIES AL4000 LIGHT TOWER OPERATION & SERVICE MANUAL ee amida = Bartel — Cauleud COLEMAN morrison MULLER Engineering PO Box 3147 + Rock Hill, SC 29732 USA * Phone 803-324-3011 Toll Free 800-433-3026 Parts Department Fax 800-633-5534 7 01-12-2008 TABLE OF CONTEN Receiving and Set-up. Safety Precautions Check Out on Receipt/Delivery TEREX Amida Light Tower Model Coding System. Recommended Engine Oil . aoe Operating Instructions Light Tower Operating Instructions 10-13 Criteria for Replacement of Wire Rope ssnnrrsm 14-15 Engine (see manufacturer's handbook) Generator (see manufacturer's handbook) Parts Identification Drawings Trailer and Related Parts ‘Axle and Wheels Cabinet and Attachments ‘Tower and Related Parts occ. Engine and Generator (Kubota / Alpha). Electrical Box sen Floodlight Fixtures / Ballasts HME rer Flectric Winch Running Lights Wiring Diagrams Fixture with Joy Connector (MH or TH) ... Metal Halide Ballast with Joy Connector. High Pressure Sodium Ballast with Joy Connector AC Wiring .... DC Wiring ..... ‘Troubleshooting Guide Specifications, Routine Maintenance, Wind Loading 52-58 Broken Cable Replacement Procedure 56-57 Light Fixture Troubleshooting .... vmennnnes 58-60 TEREX Amida Numbered Wiring System... 61 Generator Bearing Inspection 2 Engine (refer to manufacturer's handbook) Generator (refer to manuifacturer’s handbOOk)..c.senenrnernnnnen: 68-72 Warranty Information Warranty Procedure... Secs : B Warranty... Perit heitasaeert Tae OPERATOR’S 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 maintenance 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 tur 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 high voltage points. © Do not try to position both probes at once. Instead, clamp the common 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. sulated alligator clip to ¢ neutral Guard Against Battery Hazards Lead acid batteries can be dangerous. The sulfuric acid in the battery can cause severe skin and eye bums. The hydrogen gas emitted during charging can explode if an arc or flame is present near the battery. Use precautions to prevent acid bums 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 are at the terminals. Use a multimeter instead. Disconnect the negative terminal of the battery when working on the engine or other parts to prevent acci- 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 overheating 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 sysiem 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 is 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 on this equipment when mentally or physically fatigued. Do not work on this equipment when under the influence of performance impairing drugs or alcohol. Ifthis 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 parts. 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 bum, 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 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: 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 the manuals for safety and operating procedures. D. Cheek the engine oil, coolant (if liquid cooled) and fuel levels. F. Operate the tower in accordance with operating instructions. EXPORT: Assemble according to the instructions enclosed. 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 Sampte: Light Tower Product Line LTS’ 080D Tower Series Steen AL4000 (AL4) ALS000 (ALS) 0 Foot Basic Tower with winch in cabinet (0 Foot Basic Tower with in-cabinet light storage and door insulation 5000 (5) =30 Foot Enhanced Cable Tower 2000 (2). =Model $000 with extra corrosion protection -15000 (LTS) = 30 Foot Deluxe Cable Tower w/optional Acoustic Enclosure and Complete Instrumentation 172000 (1:72) = Model T5000 with Extra Corrosion Protection, 7000(7) = 30 Foot Enhanced Hydraulic Tower 17000 (LT7) = 30 Foot Deluxe Hydraulic Tower w/optional Acoustic Enclosure and Complete Instrumentation KW Rating (080 is 8.0 kW) Diesel (D) or Gas (G) Number of Lights ‘Type of Lights 4. MH CE European Version (AL4000 Only) HPS = High Pressure Sodium MH= Metal Halide MV= Mereury Vapor ‘TH= Tungsten Halogen 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 SAE10 SAE 10W-30 Use #2 diesel ful 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 CDYSF. 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 & 86°F SAE20/20W-SAE 15/40 Between S°F & 39°F SAE 10W Below 5°F SAE SW Use #2 diesel fuel above S°F, #1 diesel fuel below 5°F. NOTES: 1. The temperatures in the table are the ambient temperature at the time when the engine is started. However, ifthe running ambient temperatures are much higher than the starting temperatures, a com- promise must be struck and a higher viscosity oil and fuel used, provided they have a suitable specitfica- 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 II 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 fil 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 oi changes). At low ambient temperatures (below freezing), use winter rade diesel fuel. At higher temperatures, use sumumer 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. 10 MODEL AL4000 OPERATING INSTRUCTIONS IMPORTANT: READ ALL DIRECTIONS IN MANUAL CAREFULLY BEFORE OPERATING EQUIPMENT WARNING CAUTION DO NOT RAISE TOWER IN THE VICINITY OF i. Ww 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 cither: 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 outrigger 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. insure that the rear jacks are down to prevent the tower from tipping over backwards when raised DRIVE GROUNDING ROD INTO EARTH ul 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. RAISING THE TOWER (refer to drawing above) Remove the tower travel-locking pin from the cradle at the rear of the cabinet. 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! Vv. VL 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 (sce engine instruction book for procedure). ‘Tum 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, ‘Tum 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 (re~ view the engine operating procedures in the manufacturer's handbook). ‘Tum on the main circuit breaker. TURN ON THE FLOODLIGHTS ‘Tum 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 pir 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 the galvanized ring at the pivot is pointing to the rear of the trailer so that the tower can be lowered into the travel position. 3 Operating Procedures (cont'd) BR VuL. Vi 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). 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, tum light circuit breakers off. Tum engine switch to “OFF” to shut down the engine. CAUTION: Do not shut down engine prior to turning lights off, CAUTION: Allow lamps to coo! 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. Before 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). 14 CRITERIA FOR REPLACEMENT OF WIRE ROPE ~ 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-ftee 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 ahend up and down a length of the cable. If any exterior wires are broken, they will lif up from main 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 aperator error in using the winch, or damage to the cable by tools or other machinery. The most common operator extor happens when the mast is telescoping down. When the upper telescoping lock engages, the operator does not pull the lower pivot lock out (ocated on the tower base) and keeps on cranking the winch. This results in the cable becoming loose around the drum duc to the tower not pivoting down, This can result in three problems: the Joose cable can get trapped underneath itself, resulting in a sudden or partial “drop” of the mast when the loose section releases at a Jater 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 dram 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 crushing a cable when moving a unit, or an accidental blow or damage by a hand tool, ete. 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 |-1/4 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 = ae. AL4000 LIGHT TOWER tau amida .. — Cable Replacement Diagram 6" Round Tube 2 Section 23° Section 4” Section : Cable + fee cee / Ponte Gable 2 (190570) Point A i Cable 1 (192904) ! Point A \ (Oise 1 feame 9.597 a * Spectrum ° o PARTS MANUAL Hee AL4000 LIGHT TOWER Ea amida .. pS Trailer Frame/Tongue/Outriggers | 160270, Battery Cable Set 180110, Battery 174160, Battery Hold-Down | 182330, Battery Hold-Down Rod 4124410, Trailer Frame “ 124470, Tongue a 114480, Outrigger! 3 g¢2te, Handle (Hammerbiow) 834204, Handle (Fulton) 3 J 4 Po 841430, Jack J \ \ | 840222, Jack Snap Ring 840221, Jack Bracket 110870, Safety Chain Bisa? [reed 5 6.26.02 3 | i a 4 Spectrum 6 18 4 id a AL4000 LIGHT TOWER Paik amida Fuel Tank 742240-1, Tank Cap (4) 990200, Lock Nut \ 742220, Fuel Tank 188630, Fuel Tank Pan (@) 990210, Flat Washer (4) 994650, 1/2"-13NC x 10” Bolt 96-97 le *) 6-25-02 a Tecan Spectrum | a 19 p 2 = a 9 ; 834338, Axle 841051, Axle Front Hanger : 2 3 AL4000 LIGHT TOWER re Axle Assy. (2) 834267, U-Bolt Kit 834225, Grease Seal 834220, Hub Assy, 834256, Cotter Pin i 824250, Spindle Nut 834228, Grease Cap | 6 ag) £ 834226, Inner Bearing ee 834227, Outer Bearing 841060, Tire & Wheel Mounted (3) 840395, Axle Spring Nut eee ue 840392, Axle Rear Hanger (3) 840394, Axle Spring Bolt 841473, Axle Shackle (2) 834246, Spring Eye Bushing 834211, Leaf Spring AL4000 LIGHT TOWER nae Cabinet Assy. (4) 796432, Door Shock Bracket 184150, Winch Handle Bush. tee tenet 124420, Ground Rod Storage Tube | . eee | sates 7 | i » : my HY [eet esa et | i < - / . | RasiatorQyertow - > | | rake " 5 o ’ \ © (@) 180300 | } \ | Elec. Box. * \\ fila Bracket 7 \\ Gee ‘ pee (2) 930960 , . : Weatherstip 124430, Cabinet, Rear.“ Ve va Adhesive wan J (2125480 ~ Fender 108580, Cabinet, Curbside (10) 791840 Rubber Bumper g i i : ty preset tate woe i Yom = : 4 Spectrum 3 210 He 116180, Rear | Tower Support (4) 786436, Gas Shock (4) 796432 Door Shock Bracket | (2) 796610 | Hinge 9 ( 411368 Ground Rod i z a ‘cess 9.6.97 [= a AL4000 LIGHT TOWER Ea Cabinet Assy. | 720220, Bumper A ? oO 790540, Pin : 124460, Tower Support Cradle eee Bw 123680, Pin 188560, Cabinet Top 794940, Plastic Plug i % | (2) 790040 \ Hosp Kit (2) 188860 (2) 790940, Handle Cabinet Door a ° 22 5 ot AL4000 LIGHT TOWER Lae amida .. — Cab. Decal Top - a5t640 | 653206 ese296 cure side Road Side (amida i| amida | | ; il; al \ ALA900 | | jataooo | | \. 963312 oa) beceiade AW asaa12 852410 851860 i 859730 ot Hee | \ Front Rear | i \ | { \ (2841740 amida mT | i cE \ amida/ ; \ \ / ig \ a i 253201 = rn Se 7 4 “ : Spectrum 3 23.8 id a AL4000 LIGHT TOWER is amida .. Tower Assy. 413080, Coil Cord Sleeve p See 2" Section See 3" Section See 4° Section 2 g fe See 6" Round Tube a 9-5-97 feet fee reece [Oo : 4 “ i Spectrum ° 24 4 | Moos AL4000 LIGHT TOWER amida .. 4" Tower Section See Sheave & Shim Assembly 124540, 4” Tower Section Af 109515, Lock Pin Kit 990660, Roll Pin 477810 Shim 990760, "R" Pin i: 980340 120640, Pin “ Screw (| 990650 x reor10~/ Cotter Pin Spring : 3 é [Revsee: ay 6-25-02 4" » ° Spectrum “ 25 4 113360, Lock Pin 790510, 1/16" Cable (3) 790520, Cable Sleeve — See 6" Round Tube sare | id Mose AL4000 LIGHT TOWER Pe amida .. 4" Tower Sec,/Upr. Sheave & Shim Assy. 4188760 Sheave (2) 990850, 7 eee . 189285, Shim See Orientation Below (2) 994920 “ f * 995780 Cotter Pin Clevis Pin 992765 < Clevis Pin “ (2)995790./ Clevis Pin 183285, 3/8" Shim 183286, 5/16" Shim ¥ f 177830, 1/4" Shim 183828, 3/16" Shim Orientation of Shims inside Tube Trowees @ one — - » * Spectrum | 6 2 5 AL4000 LIGHT TOWER Las QA 185290, 3/8" Shim 996230 3/8" Screw amica mida .. 3" Tower Section 4195290, Shim 2) 994920 tt ‘See Orientation ier Pin pee 990650 Cotter Pin : 4198760 Sheave Le 992765 Clevis Pin (2) 995790 | Clevis Pin 124550, 3" Tower Section | 409005 Cable Kit LE | | U i } ‘i Orientation of Shims Inside Tube | | | “990470, Lock Washer “1. (3) 177820, 5116" Shim iB é é jew 9.5.07 ewses! 5) 6-25-02 ° eames i tes . . Spectrum a 27 4 AL4000 LIGHT TOWER ro 2" Section 124560, 2" Tower Section A 109070, Cable Kit "eso, Lock Washer a 26200, 38" ot a Iockeriasp os gptistce — 1 » ° Spectrum | @ 28 (4) See Fixture Assembly 113040, Cross Arm Cross Arm Mounting Plate (4) 123080, Fixture Mounting Wing Nut 9557 faite Spectrum a 29 - bina AL4000 LIGHT TOWER nia amida .. — Tower Crossarm / Fixture id ae AL4000 LIGHT TOWER amida oe 6" Round Tube 990650 Cotter Pin 794550 g90510... Grease Fit Tee Bolt i | 994920 : 990620 ¥ Peep eee | Cotter Pin | |, ga0es0 | Cotter Pin | 124500 6° Round Tube 992765 levis Pin 995790 Clavis Pin “Chon navies, 1987 | en i rr a gs i 188770 Sheave 188760 Sheave (2) 992765 Cievis Pin 179850 Bushing om AL4000 LIGHT TOWER v amida .. —_ Tower wi Base Assy. 113040, Crossarm 116220, Tower Assy. w! Cables sr : } 116170, Tower Base 740050, Winch 150% 124480, Winch Handle i | E 12 3 — — pm ese ; | fe 31 | | AL4000 LIGHT TOWER Tower Base Assy. 128490, Tower Base 193750, Kick-Out Spring 186960, Bumper Pad 48450, Spool Sheave Beises 5) 6-25-02 6 » ° a 3205 ae 740055, Manual Winch 109486, Winch-Loc Kit 1124480, Winch Handle \ || I Ky 120220, Pin Slide Lock 120859 SPACER, WINCH MNT AL4000 LIGHT TOWER WASHER, FLAT Tower Base Assy. : 90080 990870 318 WASHER LOCK 38 981450 SCREW, 318-16 TSP LONG 990850. COTTERPIN, 980dg0 18 x4 WASHER, ) \ FLAT. 78.00, r24a80 | HANDLE SOCKET i Ratenemne wer, 1t3 Pe NrcoNitoox tease sete | ese eusnn | | stow ‘eooss | Gites uLr0%) iS vans i ost reset : : EE var. mf Ble ex. - BY 7-12" LONG. r. (or BrimctONs, Mwcontocx | 6 | ie aes n oe iueer 1 Se teases ‘ostso reese aw Se “TEE on a Sei TAPING e “USED TO EXTEND KIKOUT ACTION : FaNSeeusnine “use Toe / MOUNT TO TOWER BASE, BEHIND phage KICK-OUT SPRING, JUST BELOW NUT a9 fours Bott g : USE 932 DRILL £09486 vice SAFETY-LOC SYSTEM (INCLUDES NEW WINCH) |{ Tose vnc serervioe SYSTEM Does nor NeLUDE NeW WINCH) i la ‘850107 SAFETY DECAL few Sore [aoe s sasae 7 a r 1 & * | jee i 33 SM id ess ‘AL4000 LIGHT TOWER fe amida Genset, Kub-D905/L-S 6KW 866120, Radiator Cap 741140, Temp. Sender 1866000, Air Cleaner Element Capacitor 109350 (Leroy Somer) 836862 (Marathon) 86030, Soleniod 866040, Gasket Generator | 630185, Marathon Pancake 630930 Leroy Somer (Shown) 866050, Oil Filter | | } 1866080, V-Belt | i i | 866110, Radiator | | | | 865223, Electric Fuel Pump Mounted to Trailer Frame { | 740620, inne | Fue! Fiter | Toons 9.5.97 jf 62502} amet | a ~ - a Spectrum ° . dd Cone AL4000 LIGHT TOWER he /amida .. Genset, Kub-D905/L-S 6KW 866090, Altermator 839190, Low Oil Press. Sensor 836836, End-Kit With Bearing ~ 836830, O-Ring 836828, Rear Bearing / 866100, Starter 9-5-97 ome at HEH Spectrum 8 38g (2) 990200 Cock Nut 4189335, Generator ‘Mounting Bar (4) 990210, Flat Washer (2) 990820, Bolt 9-5-97 Spectrum AL4000 LIGHT TOWER Generator Mounting Bar » 6-25-02 4 » ° ® 36 4 630930, Generator 6KW (Leroy Somer) id AL4000 LIGHT TOWER cams amida -. 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. 9] eimai at 5.6.67 | i “Tones _ » ° Spectrum 8 87 4 7 [? =" 839200, 9-5-97 Spectrum |, Kubota Fuel Filter AL4000 LIGHT TOWER Fuel Filter | Rewind 9) 6-26-02 4 amida .. 9-5-97 Spectrum 866120, Radiator Cap AL4000 LIGHT TOWER Radiator/Overflow Tank 866410, Radiator Revises 4) 6-25-02 o amida a * Electr 4000 LIGHT TOWER res i ical AC/DC, 4 MH/HPS 186730, Control Box Rear 186801 185390, Control Box Side 683680, Breaker 2P-30A (4) 683870, Breaker 1P-15A, 189170, Control Box Face 851790, Decal 853190, Decal | 853280, Decal 684450, T-Lock Receptacle 663880 Cap For Receptacle 1663870, Connector 3P Female, \ 680080, Strain Rell 05.97 Raves Spectrum 4 Control Box Top. 683970, Mini-Breaker > 684640, Duplex Receptacle SWF | . 260360, Hour Meter | | -cecsto,suicn | 660010, Push-Button Switch e276, ight | | | 661490, Relay 486781, Control Box Bottom| 660287, Coil Cord ief , 4 *. 121620, Box W/ Mount Bar 1 852800, Decal 680190, Box Cover Wi Gasket 112555, Junction Box / Coil Cord Kit | 6-25-02 ® | nen ® | 40 ‘or wore WON aL SO9ZLt #LYVd Y3GHO AlBWASSY SIS TAINO HOS 'SLON 112605-STANDARD LIGHT TOWER MH/ MV/ HPS LIGHT FIXTURE AL4000 LIGHT TOWER fur Ballast 114355, Ballast Box MH 114895, Ballast Box HPS 663860, § Pin Connector 160030, Ballast MH 160040, Balast HPS. | fp I 160032, Capacitor MH | 160042, Capacitor HPS | la | 2 i i o4 ja 3 3 = oe AL4000 LIGHT TOWER fe : Trailer Hitches i 840120, Coupler, 2" j 176336, Spacet ' 176335, Piate 840470, Ball, 2" SAE-2 Sar 121672, Combo Hitch Ring 16" Long Ke 940000, Kit, Combo Hite 218770, Ring Hitch j 2472" 1D. f ie 124450, Hitch, 24" Height | Ly | | | f | | ©) 221580, Hitch, | . | / Adj, Height 2 af | F <= 211410, Ring Hitch for Adj Height a 8 | | a | f al i . i ») 8 8 8 |? | | | le Gicenyy | i q ~ 841200, Hitch, Pintle Ring, 3°. i & | j= foieet = Soom | x » 43° | © ° 180992, Electric Winch, 12V 663780, Switch 160993, Solenoid 113583, Switch / Solenoid Assembly toed 3) 6-25.02 3 Beaune ° 4 9 i 663620, License Tag Light wi Bracket | Ns 663510, Stop, Tail & Turn Light ° ene a4 794 fevtes: 9) is | Socumen 5 | 7 45° CNM 2 0 vsBez¥OMG SeeZOM WWE L6I0Ey aLva’ Toe” 1078 ; Ped eceav cerca eeere “BNONa1V05" 9 uO Nidivn _ Haqoa —~-YOLDSNNOD AOFIaA “BUNLXI SdH HO HIN WWeSViIG ONT. aT oe (Hisva) GNNOxO MOTISAIM N3FY9 Na3uO. LOSE OE TIE HZ (08) enna eannass neds HART 5 peed eerie ius eyes eee SOLO, aon atte team: oe : oe wseennenones 1 3805 _ ae toon ae ae ae Re ‘viva ONIMIM (39) NVadOuns G3cdv oosie oy NvadOuna O1LS3WOG ‘SRUNLXIY N3DOTVH NALSONNL HOS BINS SHI SI NOLLY8NDIINOO Nid LON Nou) yOWIa 7 ~CaNINED NSH “Wavsew'omaSaezam wave Pee 46 —__sa62#'9Ma)— SB6Z0M ALN “16/087 Siva 16I0E/F LOTS SNOW avOS WNO Agua Sven” Nid LW “a. Waduoa,—“UYOLSBNNOD AOFM abv uww {ESVTI¥a HAGOD: -vHOVIO ONT S3OGT avis TSR TW rE Leyva Hneodl"Wv¥oviG ONIN "acre annowo ‘Ge XVI HL08-72e (E08) We eon viene 3 sou eee szounso NoWIOD LnaiN 3ONVHO #003 3LvO “ARH aes inoue 0a anv - 10 = we See ‘ALIN | Woo (svTive Sani TW13W M0001) a WANYOSSNVEL nozL r Ht eee Bee Wwe FONG senzain NaRUO soNve0 asa aU, yovie 80705 sTOvLd3034 sss 47 1962# 9M L96Z0M #LUWd 16/0E/r “BVO ——L6/0€/7 “LOTd SNON :3vos —_WNO:AG sovsn Nid Lv uaquog YOLOSNNOO AOFM) TNL ISWTiva SdHOOOL - NWHOVIC ONIMIM 83503

    You might also like