Terex AL4000D2 Series Guide

November 2006
Part No. 833002 Rev A AL4000 LightTower 1
OPERATOR/SERVICE
& PARTS MANUAL
SeriesAL4000D2
Light Tower
P.O.BOX3147
ROCKHILL, S.C. 29732 USA
PART NUMBER 833002
REVISION A
November 2006
TOLLFREE 800-433-3026
FAX (PartsDept) 800-633-5534

November 2006
2 AL4000 LightTower Part No. 833002 Rev A
OPERATOR’S MANUAL
TotheOperator ................................................................................................................4
SafetyAlert Symbols ........................................................................................................5
GeneralSafety ............................................................................................................6-10
Receiptof Delivery Checklist.......................................................................................... 11
Transport &Towing.........................................................................................................12
Setup ........................................................................................................................13-16
OperatingInstructions................................................................................................17-21
Maintenance .............................................................................................................22-24
Specifications and Dimensions .................................................................................25-26
TorqueSpecifications.....................................................................................................27
Troubleshooting.........................................................................................................28-32
Warrranty ..................................................................................................................33-34
SerialNumber Record ...................................................................................................35
ModelNumberIdentification ...........................................................................................36
RecomendedOil ............................................................................................................37
WireRope Replacement ...........................................................................................38-42
PARTS MANUAL
Wiring Diagrams.......................................................................................................44-50
GeneralInformationPartsManual...................................................................................52
PartsOrderingInformation .............................................................................................53
Trailer Frame/Tongue/Outriggers ....................................................................................54
FuelTank .......................................................................................................................55
AxleAssembly................................................................................................................56
CabinetAssembly ..........................................................................................................58
CabinetAssembly (Top & Doors) ...................................................................................60
Cabinet Decals ..............................................................................................................62
TowerAssembly .............................................................................................................63
4”TowerSection ............................................................................................................64
4”TowerSection (Sheave & Shim).................................................................................65
3”TowerSection ............................................................................................................66
2”TowerSection ............................................................................................................67
TowerCrossarmFixture .................................................................................................68
6”RoundTube................................................................................................................69
TABLE OF CONTENTS

November 2006
Part No. 833002 Rev A AL4000 LightTower 3
TABLE OF CONTENTS
PARTS MANUAL (Continued)
Tower BaseAssembly ....................................................................................................70
WinchAssembly.............................................................................................................72
Engine/GensetAssembly ...............................................................................................74
RadiatorAssembly.........................................................................................................75
RadiatorMounting Bracket.............................................................................................76
GeneratorMountingBar .................................................................................................77
ElectricalControl BoxAssembly .....................................................................................78
MH/HPSLight FixtureAssembly.....................................................................................80
BallastAssembly............................................................................................................82
Coil Cord & Junction Box ...............................................................................................83
Trailer Hitches ................................................................................................................84
AL4000 Options........................................................................................................85-86

November 2006
4 AL4000 LightTower Part No. 833002 Rev A
DO NOT ATTEMPT TO SETUP, OPERATE, OR WORK ON THE LIGHT TOWER
UNLESS YOU HAVE READ AND STUDIED THIS MANUAL AND THE ENGINE AND
GENERATOR MANUALS CAREFULLY. READING THESE MANUALS WILL TEACH
YOU HOW TO SAFELY SETUP, OPERATE, AND PROPERLY MAINTAIN THE
TOWER AND ITS COMPONENTS.
REMEMBER THAT YOU ARE THE KEY TO SAFETY. GOOD SAFETY PRACTICES
NOT ONLY PROTECT YOU, BUT ALSO THOSE WORKING AROUND YOU. MAKE
THIS MANUALAWORKING PART OF YOUR SAFETY PROGRAM.
An operator should never use drugs, alcohol or any other substance which can change his
alertness or coordination.
Do not work on this equipment when mentally or physically fatigued.
This manual is compiled from information available and current at time of approval for printing.
Terex reserves the right to improve its products without giving prior notice or incurring any obliga-
tion.
If this manual becomes lost, order a new one from Terex so future operation and maintenance
personnel may read these instructions.
TO THE OPERATOR

November 2006
Part No. 833002 Rev A AL4000 LightTower 5
SAFETY ALERT SYMBOLS
MEANS:
ATTENTION! BE ALERT!
YOUR SAFETY IS INVOLVED
THIS SAFETY SYMBOL IS USED FOR IMPORTANT SAFETY MES-
SAGES. WHEN YOU SEE THIS SYMBOL, FOLLOW THE SAFETY
MESSAGE TO AVOID PERSONAL INJURY OR PROPERTY DAMAGE.
UNDERSTANDING SIGNAL WORDS
A signal word - DANGER, WARNING or CAUTION is used with the safety alert symbol.
DANGER Identifies the hazard or unsafe practice
that will result in severe injury or death.
WARNING Identifies the hazard or unsafe practice
that could result in severe injury or death.
CAUTION Identifies the hazard or unsafe practice
that could result in minor injury or property damage.
NOTICE Identifies important installation, operation
or maintenance information.

November 2006
6 AL4000 LightTower Part No. 833002 Rev A
GENERAL SAFETY
DO NOT OPERATE THE AL4000 LIGHT TOWER WITHOUT
READING THIS OPERATOR’S MANUAL.
SAFETYALERT SYMBOL
Stop and take time to readALL Safety alert mes-
sages. Follow the safety messages to avoid
personal injury or property damage.
ACCIDENT PREVENTION
Use protective clothing and safety equipment.
Always wear approved safety equipment such as
gloves, safety boots, safety hard hat, goggles, ear
protection, and dust masks when necessary.
Wear protective clothing that is snug and belted
where required.
UNAUTHORIZED WELDING
UNAUTHORIZED
WELDING CAN CAUSE
STRUCTURAL FAILURE OR PERSONAL
INJURY.
DO NOT weld on any structural member.
Any unauthorized welding or repair procedure will
void the warranty.
DO NOT WORK ON OR OPERATE THE LIGHT TOWER WHILE UNDER THE INFLU-
ENCE OF PERFORMANCE IMPAIRING DRUGS OR ALCOHOL.

November 2006
Part No. 833002 Rev A AL4000 LightTower 7
GENERAL SAFETY
FUELING
ALWAYS handle fuel with care. It is highly flam-
mable.
ALWAYS stopenginebeforerefueling. Fillfuel
tank outdoors.
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.
FIRES CAN CAUSE
SEVERE PERSONAL
INJURY OR MACHINE
DAMAGE.
Prevent fires by keeping the light tower and its
surrounding area clean.
DO NOT refuel while smoking or when near open
flame or sparks.
DO NOT refuel the engine when it is hot. Allow to
cool for several minutes before refueling.
DO NOT spill fuel inside the engine compartment.
If fuel has leaked, wipe it up and have leak re-
paired before next use.
Have a fire extinguisher nearby. Be sure the
extinguisher is properly maintained and be familiar
with its use. Extinguishers ratedABC by the NFPA
are appropriate for all applications.

November 2006
8 AL4000 LightTower Part No. 833002 Rev A
GENERAL SAFETY
EXHAUST GASES ARE TOXIC. DO NOT USE INDOORS
UNLESS PROPERLY VENTILATED OR AN EXHAUST
SCRUBBER IS USED.
Check exhaust system regularly for leaks and ensure that the exhaust manifolds are secure and
not warped.
Make sure the unit is well ventilated.
ELECTRICAL SAFETY
This equipment utilizes high voltage circuits. Always exercise extreme caution when trouble
shooting or repairing any electrical circuit.
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.
Always ground the unit when possible. Consult local electrical codes for grounding
instructions.
A grounding lug has been added to the trailer frame for your convenience.
Disconnect electrical power and turn off engine before removing protective covers on high
voltage electrical enclosures.
Beware of a cut or damaged power cord. Have a qualified electrician replace immediately.
When troubleshooting indicates a malfunction in the high voltageAC system, pass the task to a
qualifiedand trained electrician.
DO NOT TOUCH HOT PARTS
The exhaust manifold and tail pipe are very hot. Parts of the engine are also hot. Use protective
gloves when handling hot parts.
The light fixtures become very hot during operations. To avoid burns, always allow any fixture to
cool before handling.

November 2006
Part No. 833002 Rev A AL4000 LightTower 9
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.
DO NOT smoke while servicing the battery.
DO NOT allow tools to touch battery terminals and create an arc.
Disconnect the negative terminal of the battery when working on the engine or other parts to
prevent accidental arcing. Disconnect the negative cable at the end away from the battery.
DO NOT remove the vent caps when charging the battery.
Always wear eye protection when servicing the battery.
If acid gets on skin or eyes, immediately flush under running water and obtain medical attention.
METAL HALIDE LAMPS PRODUCE SHORTWAVE ULTRAVIO-
LET RADIATION AND CAN CAUSE SERIOUS SKIN AND EYE
BURNS OR INFLAMMATION IF THE OUTER ENVELOPE OF
THE LAMP IS BROKEN OR PUNCTURED.
DO NOT use where people will remain close to the lamps for more than a few minutes unless
adequate shielding or other safety precautions are used.
KEEP ALL BODY PARTS AND CLOTHING AWAY FROM
MOVING PARTS
Loose jackets, shirts, sleeves, and especially neckties should not be worn while working on or
runningthe unit.
Only remove guards or protective devices from unit temporarily to gain access for maintenance.
Always replace guards immediately after servicing. Never remove guards while unit is operating.
Keep your hands away from moving parts, particularly clear of the radiator fan and alternator
belts when the engine is running.
GENERAL SAFETY

November 2006
10 AL4000 LightTower Part No. 833002 Rev A
GENERAL SAFETY
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.
Be careful when lifting. Never suspend any other equipment
from the shipping tie downs.
BEWARE OF TRAFFIC HAZARDS
Use the lifting eye or forklift pockets on the tower for lifting the trailer and tower assembly only
(with tower and cabinet).
Make sure any tie-downs at the bottom of the trailer are released, and the cradle retaining pin is
inserted and secured, prior to lifting.
NEVER CLIMB ON TOP OF THE CABINET AND/OR TOWER
WHEN ERECTED OR RETRACTED.