Terex AL4000 AU Series Installation and operating instructions

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

TABLE OF CONTENTS
1.0 Safety Precautions Page #
Safety Precautions 4-8
2.0 Operating Instructions
Light Tower Operating Instructions 9-16
General Specifications and Routine Maintenance 17-18
Recommended Engine Oil 19
Fastener Torque Specifications 20
Traceable Numbered Wiring System 21
Criteria for Replacement of Wire Rope 22
Broken Cable Replacement Procedure 23-24
Cable Replacement Diagram 25
Shim Placement Diagram 26
Rear Bearing Inspection Requirements 27
Engine (see manufacturer’s handbook) n/a
Generator (see manufacturer’s handbook) n/a
3.0 Troubleshooting Guide
Light Fixture Troubleshooting Guide 28-30
Light Tower Troubleshooting Guide 31-33
Engine (refer to manufacturer’s handbook) n/a
Generator (refer to manufacturer’s handbook) n/a
4.0 Wiring Diagrams
Fixture with Joy Connector (MH) 36
Metal Halide Ballast / 3-Pin Connector Wiring Diagram 37
AC Wiring 38
Trailer Wiring 39
Coil Cord Wiring 40
DC Wiring 41
Control Box Wiring, Auto Shutdown Timer 42
(continued next page)
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5.0 Parts Manual Page #
Decals 44
Trailer and Related Part 45
Fuel Tank Assembly 46
Axle and Wheels 47
Cabinet Assembly 48-49
Tower Base Assembly – Electric Winch 50
Tower Assembly 51
Tower Section – Six inch diameter base tube 52
Sheave and Shim Assembly - Four inch tower section 53
Tower Section – Four inch square tube 54
Tower Section – Three inch square tube 55
Tower Section - Two inch square tube 56
Crossarm 57
Floodlight Fixtures 58
Radiator Right Side Mounting Bracket 59
Generator Mounting 60
Engine and Generator (Kubota D1105 / Leroy Somer 8 kW) 61-62
RadiatorAssembly and Mounting 63
Ballast Box Assembly – 50 Hz 64
Electrical BoxAssembly 65
Auto Shutdown Timer 66
6.0 Warranty Information
Terex Light Tower Model Coding System 68
Manufacturer’s warranty statement 69
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SECTION 1
S A F E T Y P R E C A U T I O N S
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 injury
including death.
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 recom-
mended below. Also, observe the many additional general safety rules practiced by trained operation and
maintenance personnel in your company and industry.
WARNING:Always wear a hard hat when operating the light tower!
•Guard Against Electric Shock
This light tower also has provisions for producing high voltage electricity 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, pass the
troubleshooting task on to a qualified and trained electrician.
Disconnect electrical power and turn off engine before removing protective covers on high voltage
electrical enclosures.
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.
Earth (ground) wires within the system are also bonded to the equipment frame.
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• 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. It is the responsibility of the person in
charge to comply with the applicable regulations in force in the State in which the
equipment is being operated.
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•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.
Do not allow tools to touch battery terminals and create an arc. Do not test battery voltage by setting
a brief arc at the terminals, use a multimeter instead.
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.
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 ABE by the FPAA 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.
•Protect The Environment And Practice Good Industrial Hygiene
WARNING : DO NOT USE INDOORS UNLESS PROPERLY VENTILATED OR AN EX-
HAUST SCRUBBER IS USED. EXHAUST GASES ARE TOXIC. Provide an adequate exhaust
system to properly expel discharged gases. Check exhaust system regularly for leaks. Periodically
check to ensure that the exhaust manifolds are secure and not warped (see maintenance schedule in
manufacturers handbook). Make sure the unit is well ventilated.
Prevent pollution by catching used oil in a container for proper disposal.
Wash hands to remove oil and fuel. Practice good industrial hygiene.
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•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.
•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 and generator manuals, which are separate booklets that are
provided with this manual.
Do not work on this equipment when mentally or physically fatigued.
Do not work on or operate this equipment when under the influence of performance impairing drugs
or alcohol.
If this manual becomes lost, order a new one from Genie Australia so future operation and
maintenance personnel may read these instructions.
•Beware Of Moving Parts
Avoid being hit or pinched by moving parts of this unit
WARNING: Loose jackets, shirts, sleeves and especially neckties should not be worn while work-
ing on or running the unit. Serious injury or death may result.
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. Take note of WARNING: Entanglement Hazard
decal on kerbside and roadside doors.
•Beware Of Traffic Hazards
Stand clear of traffic when starting or checking the unit along the road. Implement a traffic manage-
ment system before setting up the unit.
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 ensure all are tight and nothing is in danger of
falling off during transit.
•Be Careful When Lifting
Use the lifting eye or forklift pockets on the tower for lifting the trailer and tower assembly only.
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.
WARNING: NEVER suspend any other equipment from the shipping tie-downs. Serious
injury or damage to equipment may result.
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•Use Only Equal Replacement Parts
When a part fails and needs to be replaced only use equivalent parts of equal performance and
strength.
When a bolt is lost or fails, replace only with the 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. 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 GenieAustralia regarding
replacement parts.
•Use Caution Working Near Lamps
WARNING : This unit is equipped with metal halide lamps. Metal halide lamps produce short-wave
ultra-violet radiation and can cause serious skin and eye burns/ inflammation if the outer enve-
lope of the lamp is broken or punctured. Do not operate this unit near people if the outer envelope
of the halide lamp is broken.
•Never Climb On Top Of Unit
WARNING: NEVER climb on top of the cabinet and/ or tower when erected or retracted.
Serious injury or death may result.
•Never Carry Additional Items or Equipment
WARNING: The trailer is not intended to carry any additional items or equipment. The light tower
is not intended to carry any additional equipment such as banners or signs. Risk of overturning or
overload.
•Site Specific Hazards
WARNING: Be mindful of the particular risks that may arise in certain locations. It is the end users
responsibility to identify the hazards associated with setting up the light tower and to control those
risks. Additional precautions may be necessary for example to isolate the public from the tower if it
is left unsupervised in public spaces. In particular the unit should be secured to protect against
vandalism or unauthorised entry into or onto the unit.
•Check Safety Systems Have Not Been Tampered With
WARNING: Be aware of injuries arising from tampering with safety systems. It is the users
responsibility to ensure safety systems are functional before use.
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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 TR U C TI O N S
In addition to the standard model light tower, a mine spec. variation is available which can be
identified by the following additions:
•Drip trays under fuel tank and engine sump
•Louvred vents in engine enclosure doors
•Mast tiedown chains
•Flexible conduit installed on light fixture cables
•Battery isolation switch
•Auxiliary power outlet deleted
•Residual current device (RCD) installed in generator output circuit
Where appropriate, differences in operating instructions and parts information for each model
are highlighted.
I. MOVE LIGHT TOWER TO DESIRED LOCATION KEEPING THE FOLLOWING
IN MIND:
NOTE: Although the light tower is designed to withstand the rigors of the environment it can
only do so if it is properly set up and monitored to ensure that it remains set up according to
the specification.
A. Beware, particularly during inclement weather conditions, of the following:
•Wind conditions, maximum wind speed 100 km/h - risk of overturning
•Subsidence under stabilising pads or the trailer in general - risk of overturning
•Proximity to vehicular traffic - risk of collision
•Proximity to power lines - risk of electrocution
•When left in public places - risk of vandalism or theft
•In winter environments risk of structural or mechanical damage
•It is recommended that a contact phone number is displayed on the unit.
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B. 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).
C. The area where the tower is positioned should be firm and relatively level. The trailer must be set up
within the range indicated on the level gauge provided on the drawbar.
D. The light tower should be located on the same level or on ground higher than the area being lighted
(higher light mounting heights reduce shadow length).
E. Unit should be level to ensure smooth, trouble-free tower telescoping. Tower may not telescope
down properly when unit is not level.
II. UNHITCH FROM THE TOWING VEHICLE AS FOLLOWS:
A. CAUTION: Ensure manual park brake is applied before unhitching from vehicle.
B. Swing the jockey wheel into position and crank jack up to lift tongue off the towing vehicle.
III. LEVEL THE TRAILER, USING THE JACKS AS FOLLOWS:
A. Extend the front and rear outriggers until the lock pins snap into place. Swing the jack on each
outrigger into vertical position and lock into place. Use dunnage under the pad if the ground surface
is soft.
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. Use the level gauge provided on the drawbar to ensure the trailer
is level. Ensure that all jacks are down to prevent the tower from tipping over when raised.
WARNING: NEVER use the jacks to raise tires off ground!
IV. DRIVE GROUNDING ROD INTO EARTH
A. A grounding rod is provided. Please refer to local authorities for use of grounding rods. Drive the rod
a minimum of 1.2 meters into the ground and secure the earth wire to the lug located on the trailer
frame.
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