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.

November 2006
Part No. 833002 Rev A AL4000 LightTower 11
RECEIPT OF DELIVERY CHECKLIST
The tower will be serviced, tested and ready for operation upon delivery. Terex recommends the
following checks:
Insure there is no freight handling damage which should be charged against the carrier.
Make sure the telescoping boom is secure.
Make sure the crosshead assembly is secure.
Check the front and rear jacks for security and proper operation.
Check the outriggers for security and proper operation.
Check that the tires are not damaged, under inflated or that any lugs are loose.
Check the engine/generator for obvious damage, loose connections, or leaks.
Check the control panel for damage or loose connections.
Check the boom wires for obvious damage or loose connections.
Check the light fixtures for damage to the lamps, lenses, reflector or etc.
Check the winches, cables and pulleys for damage and proper operation.
Check the exhaust system for damage.
Check all fluid levels; battery, radiator, and engine oils.
Insure manuals are in the pocket provided inside the unit.

November 2006
12 AL4000 LightTower Part No. 833002 Rev A
TRANSPORT &TOWING
1. Using the front leveling jack, securely attach the light tower to the transporting vehicle.
2. Insure that the coupler is properly secured to the towing vehicle and attach the safety
chains.
ALWAYS USE THE PROPER TRAILER HITCH AND SAFETY
CHAINS. OBEY ALL LOCAL OR STATE D.O.T. LAWS WHEN
TOWINGALIGHT TOWER.
FAILURE TO PROPERLY SECURE THE TRAILER TO THE
TOWING VEHICLE MAY RESULT IN SERIOUS INJURY OR
DEATH.
3. Retract and rotate the front leveling jack into its stowed position.
4. Check the tires for proper inflation (32psi) and verify the lug nuts are tight.
5. Position all outriggers and jacks into the stowed or travel position.
6. Verify that the fixtures are secure and ready for transport.
7. Secure all loose locking pins and retainers.
8. Make sure all doors are closed and tightly locked.
9. Remove tire chocks.
Towing of a Terex light tower is approved with the light fix-
tures in place on the crosshead assembly for all off road
terrain and highway towing as long as the following speed
limits are followed:
Highway towing - 60 MPH max
Off road towing - 10 MPH max
Severe damage may occur from excessive speeds. Damage
created by abuse will void the manufacturer’s warranty.

November 2006
Part No. 833002 Rev A AL4000 LightTower 13
SETUP
A. Move the light tower to desired location keeping the following in mind:
1. The light tower should not be placed where those working under the light are either:
a. Forced to look into the light regularly.
b. Forced to work with their backs to the light (shadows will block the light from the
work area).
2. The area where the tower is positioned should be relatively level for safe and proper
operation of the unit.
3. The light tower should be located on the same level or on ground higher than the work
area.
B. Use tire chocks in front of and behind each tire whenever possible. Always use tire
chocks on an incline.
C. Disconnect the towing chain.
D. Unhitch from the towing vehicle as follows:
1. Rotate the tongue jack into position (90 degrees), release the hitch pin and raise the
tongue off the towing vehicle.
E. Level the trailer, using the jacks as follows:
1. Extend the front outriggers until the outrigger pins lock into place. Rotate
the jack on each outrigger into vertical position and lock into place.
2. Rotate the rear jack and lock into the vertical position.
3. Start at the highest jack position. Rotate the jack handle until the jack foot touches the
ground.
4. Raise the other jacks to level trailer.
OUTRIGGERS ARE NOT DESIGNED TO LIFT THE TIRES OFF
THE GROUND.
Insure that all jacks are down to prevent the tower from
tipping over backwards when raised.
NEVER ATTEMPT TO MOVE THE TOWER WHILE THE LEV-
ELLING JACK ARE DOWN. SERIOUS MACHINE DAMAGE
WILL RESULT.

November 2006
14 AL4000 LightTower Part No. 833002 Rev A
SETUP
F. When applicable, drive grounding rod into earth. (Grounding rod not included)
1. Drive the rod into the ground and secure the grounding wire to the lug located on the
trailer frame.
G. When applicable, install the floodlights on the crossarm.
1. Remove the light fixtures from their packing boxes and install them on the crossarm
with the lens facing the ground.
2. 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
insures the water weep hole in the fixture is down).
3. Set the vertical aim for each light fixture by adjusting the light fixtures and tightening
the lower bolt.
Never adjust fixtures with power on.
4. Set the spread between the fixtures horizontally by adjusting the fixtures and tightening
the mounting nut.
5. The light fixtures may be left on the unit when towed around the job site.
6. Plug each fixture into the receptacles provided. Plug into the numbered receptacles in
a clockwise rotation starting at the upper or 1:00 o’clock position. This makes trouble
shooting easy without lowering the tower.
If Tungsten Halogen lamps are used, the cord must be routed
and secured away from the fixture. Failure to do so may
result in cord burn-through and short circuit due to the high
fixture temperature.

November 2006
Part No. 833002 Rev A AL4000 LightTower 15
SETUP
H. Raising the tower as follows:
1. Remove the tower travel locking pin from the cradle at the rear of the cabinet.
2. Remove the tower locking pin from the tower base. Using the lower pivot winch, raise
the tower to the vertical position. Reinsert the tower locking pin into the tower base.
If there is any difficulty in tilting the boom vertically, check the
tailhook and hook. The tailhook may need to be released.
BEWARE OF PINCH POINTS WHEN ERECTING OR STOW-
ING THE TELESCOPING TOWER.A LOSS OF DIGITS OR
LIMBS MAY RESULT FROM UNSAFE PRACTICES.
Do not attempt to lean the tower down when it is extended.
Serious damage may occur.
WHEN RAISING THE BOOM, MAKE SURE THE BOOM
WIRING DOES NOT BECOME ENTANGLED.

November 2006
16 AL4000 LightTower Part No. 833002 Rev A
SETUP
THE AUTOMATIC BRAKE MUST BE WORKING ON THE
TELESCOPING WINCH. THE WINCH SHOULD NOT ALLOW
THE TOWER TO DROP DOWN WHEN THE HANDLE IS
RELEASED.
UNDER NO CIRCUMSTANCES SHOULD THE LIGHT
TOWER BE MOVED WHEN THE BOOM IS IN A VERTICAL
POSITION.
3. Release the tower rotational lock and adjust the lights to the desired area. Once
positioned correctly, retighten the rotational lock.

November 2006
Part No. 833002 Rev A AL4000 LightTower 17
READ ALL DIRECTIONS IN MANUAL CAREFULLY
BEFORE OPERATING EQUIPMENT
DO NOT RAISE TOWER IN THE VICINITY OF
OVERHEAD POWER LINES!
1. Move Light Tower to desired location keeping the following in mind:
A. 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).
B. The area where the tower is positioned should be relatively level.
C. 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).
D. Unit should be level to insure smooth trouble-free tower telescoping. Tower may not
telescope down properly when unit is not level.
2. Unhitch from the towing vehicle as follows:
A. 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.
B. Swing the tongue jack into position and raise the tongue off the towing vehicle.
3. Level the trailer, using the jacks as follows:
A. Extend the rear outriggers until the springs lock into place. Swing the jack on each
outrigger into vertical position.
B. Start at the highest jack position. Rotate the jack handle until the jack foot touches the
ground.
C. Raise the other jacks to level trailer ensure that the rear jacks are
down to prevent the tower from tipping over backwards when raised.
4. Drive grounding rod into earth.
OPERATING INSTRUCTIONS

November 2006
18 AL4000 LightTower Part No. 833002 Rev A
5. Install the floodlights on the crossarm:
A. Remove the light fixtures from the tower by rotating the wingnuts to free the lights.
Install them on the cross arm studs with the lens facing the ground.
B. 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
insures the water weep hole in the fixture is down).
C. Set the vertical aim for each light fixture by adjusting the light fixtures and tightening the
T-handle located on the fixture.
D. Set the spread between the light fixtures horizontal aiming by adjusting the fixtures and
tightening the wing nut.
E. The unit may be transported with the light fixtures mounted on the crossarm if they
are pointed toward the ground.
6. Raising the tower (refer to drawing above):
A. Remove the tower travel-locking pin from the cradle at the rear of the cabinet.
B. Aim the fixtures, both horizontally and vertically, to the estimated angles that will light
the work area.
C. 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.
D. Release the tension on the cable by backing the winch off slightly and pull the tele-
scoping 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.
DO NOT ATTEMPT TO LEAN THE TOWER DOWN BELOW 45°
WHEN IT IS EXTENDED-SERIOUS DAMAGE MAY OCCUR!
PIVOT PIN
TELESCOPING LOCKING PIN
"T" BOLT FIXTURE TRAVEL STORAGE BRACKETS
VERTICAL LOCKING PIN
TRAVEL LOCKING PIN
KICK-OUT SPRING
OPERATING INSTRUCTIONS

November 2006
Part No. 833002 Rev A AL4000 LightTower 19
7. Start the Engine/Generator Set
A. 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 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).
C. Turn the ignition switch to the “ACC” position (see diagram below). Press the preheat
push-button for a maximum of 20 SECONDS. Do not engage the preheat
button longer than the time specified or damage may occur.
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 manufactur-
ers handbook). Note: If engine will not start, leave switch in run position for additional
10-20 seconds to completely prime the fuel system. Then repeat step “C” and start
engine.
E. Turn on the main circuit breaker.
8. Turn on the floodlights:
A. Turn the circuit breakers “ON” and ensure all lamps come on. Allow a minimum of
two (2) minutes for lamps to reach full luminance.
B. If required, rotate the tower to aim the lights as desired. Tighten the tower rotating
lockingbolt.
C. Adjust the tower vertically and adjust lighting direction of individual fixtures if required.
9. Turn off the floodlights:
OPERATING INSTRUCTIONS

November 2006
20 AL4000 LightTower Part No. 833002 Rev A
10. Lowering the tower to traveling position:
A. Using the winch, telescope the tower down to its fully retracted position until the
telescoping locking pin snaps into place.
B. Ensure that the telescoping locking pin locks before pulling the
vertical lock pin at the bottom of the pivot post. This insures the tower is completely
lowered and cannot be damaged by telescoping out while in the travel position.
C. Loosen rotating lock.
D. Rotate the tower so that the groove in the galvanized ring at the pivot is pointing to the
rear of the trailer to enable the tower to be lowered into the travel position.
E. Tighten rotatinglock.
F. 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. Insert the rear tower horizontal travel-locking pin into the cradle.
OPERATING INSTRUCTIONS
A. Turn light circuit breakers off.
B. Turn engine switch to “OFF” to shut down the engine.
DO NOT SHUT DOWN ENGINE PRIOR TO TURNING LIGHTS OFF.
ALLOW LAMPS TO COOL AT LEAST TEN (10) MINUTES BEFORE
MOVING THE TOWER TO AVOID BREAKING LAMPS.