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)
2

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
3

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.
4

• 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.
5

•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.
6

•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.
7

•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.
8

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.
9

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.
10

V. INSTALLTHE FLOODLIGHTS ON THE CROSSARM (MINE SPEC. EXCLUDED)
A. 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.
B. Route the cords so that they do not interfere with rotating or tilting the light fixtures.
C. Set the vertical aim for each light fixture.
D. Set the spread between the light fixtures horizontal axis.
E. Plug each fixture into the receptacles provided. If they are plugged into the numbered receptacles in a
clockwise rotation, starting at upper or 1:00 position, it will be easy to troubleshoot the electrical
system without lowering the tower (see diagram under Light Fixture Trouble-Shooting).
CAUTION: If Tungsten Halogen lamps are used, the cord must be routed through the cord
support rings. Failure to do so may result cord burn-through and short circuit due to the high
fixture temperature.
11
"T" BOLT
KICK-OUT SPRING
TELESCOPING LOCKING PIN
TRAVEL LOCKING PIN
VERTICAL LOCKING PIN
PIVOT PIN
FIXTURE STORAGE BRACKETS

VI. RAISING THE TOWER (refer to drawing on the previous page)
A. MINE SPEC. ONLY: Disconnect the two (2) mast tiedown chains from the crossarm.
B. 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.
C. Aim the fixture, both horizontally and vertically, to the estimated angles that will light the
work area.
CAUTION: Ensure that the safety locking pin is removed from the vertical locking pin at
the base of the pivot post prior to raising the tower.
D. Activate the electric winch by pressing the winch toggle switch in the control box in the up
direction this will raise the tower to the vertical position. The vertical locking pin at the base
of the pivot post will lock automatically and you will hear it “snap” into place. Manually
insert the safety locking pin into the locking device and secure with the attached hairpin clip.
E. Release the tension on the cable by pressing the winch toggle switch in the control box to the
down direction (loosen cable approximately ¼ - ½ turn). Pull the telescoping locking pin on
the galvanized tower section. Hold this out while pressing the electric winch toggle switch in
the up direction to raise the tower. After the tower has telescoped slightly, the locking pin can
be released. Raise the tower to the desired height. Stop when the red paint is visible on the
75mm (3 inch) middle section.
CAUTION: Do not over extend the light tower beyond the lower red mark on the middle
mast section.
WARNING: DO NOTATTEMPT TO LEAN THE TOWER DOWN WHEN
EXTENDED - DEATH, SERIOUS INJURY OR DAMAGE MAY OCCUR.
VII. STARTINGTHE 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 damaged due to improper
voltage and frequency.
A. If the engine was previously shutdown by the auto shutdown timer elapsing (see Section XV),
the RESET button must be depressed before the engine can be re-started.
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 adjacent
diagram). 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.
12

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. Then repeat step “D” and
start engine.
VIII. TURN ON THE FLOODLIGHTS
A. Turn on the main circuit breaker. Turn the circuit breakers “ON” and check to 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 rotation T-bolt.
C. Adjust the tower vertically and adjust lighting direction of individual fixtures if required.
IX. TURN OFF FLOODLIGHTS
A. Turn light circuit breakers off. Turn main breaker off.
B. Allow the engine to run approximately 30 seconds after load has been removed prior to
turning off the engine.
C. Turn engine switch to “OFF” to shut down the engine.
CAUTION: Do not shut down engine prior to turning lights off.
CAUTION: Allow lamps to cool at least ten to fifteen (10-15) minutes before moving the
tower to avoid lens or bulb breakage.
X. LOWERING THE TOWER TO TRAVELING POSITION
A. Using the electric winch, telescope the tower down to its fully retracted position until the
telescoping locking pin snaps into place.
CAUTION: Ensure that the telescoping locking pin locks before pulling the vertical locking
pin at the base of the pivot post. This ensures the tower is completely lowered and cannot be
damaged by telescoping out while in the travel position.
B. Loosen the tower rotation T-bolt.
C. Rotate the tower so that the groove in the galvanised ring at the pivot is pointing to the rear of
the trailer to enable the tower to be lowered into the travel position.
D. Tighten the tower rotation T-bolt.
CAUTION: Ensure that personnel are not in close vicinity to the tower, particularly behind
the trailer when the tower is being lowered.
13

E. 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).
F. Continue to lower the tower into the cradle using the electric winch.
G. Insert the tower travel locking pin into the cradle. Secure with hairpin clip.
XI. RELOCATING LIGHT TOWER TO NEW LOCATION
A. Ensure that tower has been properly lowered (see Section X) and all locking pins are
engaged.
B. Ensure all fixtures are rotated down, and that adjacent fixtures face each other to minimize
possible damage during transportation.
C. MINE SPEC. ONLY: Attach the two (2) mast tiedown chains to the crossarm and tension
using the turnbuckle.
CAUTION: Ensure manual park brake is engaged before retracting outriggers.
D. All jacks must be raised, swivelled up and all outriggers locked into travel position.
Disconnect the earth rod and lead and place in the storage provided inside the trailer.
E. Ensure that the tow coupling is properly secured to the towing vehicle and safety chains are
attached. Raise the jockey wheel and rotate and lock in position. Release the manual park
brake.
F. Do not tow at excessive speeds (100 km/h or 60 mph maximum) as the weight of the light
tower can cause loss of vehicle control, especially under emergency conditions.
XII. AUXILIARY POWER OUTLET (MINE SPEC. EXCLUDED)
A. Total auxiliary power cannot exceed 2500 W. A 10 Amp residual current device (RCD) is
installed in the auxiliary power outlet circuit.
B. Before plugging in extensions cords, feed them up through the trailer frame and connect to
the outlet. Close the cabinet doors to protect control panel and other components from
weather (see Miscellaneous Specifications and Routine Maintenance section for power
control details).
C. Ensure that all extension cords are protected from damage and water.
D. The operator must test the RCD using the test button daily, or before every use, whichever is
the longer. Ensure that the RCD is on, then push the test button and check that it trips.
14

XIII. GENERATOR RESIDUAL CURRENT DEVICE (MINE SPEC. ONLY)
A. A 20 Amp residual current device (RCD) is installed in the generator output circuit.
B. The operator must test the RCD using the test button daily, or before every use, whichever is
the longer. Ensure that the RCD is on, then push the test button and check that it trips.
XIV. LEAVING THE LIGHT TOWER UNATTENDED
A. Before leaving the light tower unattended, secure all items and lock the cabinets to prevent
unauthorised use.
B. Be mindful that weather conditions may change and ensure that an emergency response
procedure is in place.
C. Arrange for periodic inspections where necessary.
D. Protect the light tower against vandalism and wilful damage by securing the tower and
locating it in a secure area.
XV. AUTO SHUTDOWN TIMER (OPTION)
An auto shutdown timer is available as an option for standard and mine spec. light towers.
The timer will shutdown the engine after a preset run time so that the light tower may be left
unattended (see Section XIV).
A. The engine must first be running before the timer can be started.
15

B. To start timer, hold switch in START position until ON lamp illuminates (for about 3 sec.)
C. 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).
E. After the preset run time has elapsed, the RESET button will trip and the engine will
shutdown.
F. The RESET button must be depressed before the engine can be re-started.
CAUTION: Ensure the circuit breakers are turned “OFF” before re-starting the engine. This
prevents the engine from starting under load and prevents electrical equipment from being
damaged due to improper voltage and frequency.
XVI. BATTERY ISOLATOR SWITCH (MINE SPEC. ONLY)
Alockable battery isolator switch is provided to prevent unauthorised use of the light tower.
16

TEREX-AMIDAMODELAL4000AU
LIGHT TOWER GENERALSPECIFICATIONS
AND ROUTINE MAINTENANCE
TEREX-Amida ModelAL4000 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. It is ideally suited for heavy-duty use and is built to meet the following specifications:
SPECIFICATIONS
Overall length, travel position w/fixtures & tongue ................... 4547 mm (179”)
Overall length, tower vertical w/tongue & jacks ........................ 3150 mm (124”)
Trailer frame length .................................................................... 1778 mm (70”)
Overall height, floodlighting position ........................................ 9.14 m (30ft)
Overall height, travel position .................................................... 1727 mm (68”)
Overall width with fenders ......................................................... 1549 mm (61”)
Overall width with outriggers pulled out.................................... 2591 mm (102”)
Trailer frame width ..................................................................... 1041 mm (41”)
Tongue length ............................................................................. 1333 mm (52.5”)
Tongue weight w/lights on crossarm .......................................... 56.7 kg (125 lb)
Wheel size .................................................................................. 381 mm (15”)
Tyre pressure................................................................................ 220 kPa (32 psi)
Axle Rating................................................................................. 1587 kg (3500 lb)
Total weight no fuel .................................................................... 1014 kg (2235 lb)
Fuel Capacity .............................................................................. 114 L (30 gal)
Unit weight with full fuel tank ................................................... 1109 kg (2445 lb)
Maximum towing speed...............................................................100 km/h (60 MPH)
Maximum wind speed..................................................................100 km/h (60 MPH)
Beaufort scale - 10 (whole gail)
Noise Level................................................................................. 62 dBA @ 7 m
Electric Winch ............................................................................ 12 V 1800 kg (4000 lb)
Auxiliary Power Outlet (Mine Spec. Excluded)......................... 10 A, 240 V 50 Hz, 2500 W
17

BRAKE SYSTEM
This light tower is fitted with hydraulic surge brakes and a manual park brake.
- Hydraulic brake system requires DOT3 or higher brake fluid
- Service interval for brake adjustment every 200 hours.
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.
The electric winch is permanently sealed and does not need any periodic lubrication.
The electric winch must only be replaced with the genuine Terex part.
AUXILIARYPOWER OUTLET (MINE SPEC. EXCLUDED)
A competent person must test the RCD according to AS/NZS 3760 every 12 months.
GENERATOR RESIDUAL CURRENT DEVICE (MINE SPEC. ONLY)
A competent person must test the RCD according to AS/NZS 3760 every 12 months.
TRAILER
Periodically check the condition of the trailer including the fuel tank, lighting and structure.
NOISE LEVEL
Mean SPL (sound pressure level) hemispherically at 7 meters:..................62.01 dBA
Sound Power Level:.....................................................................................90.0 LWA re 1 pW
WIND SPEED RATING
The AL4000 AU light tower has a wind speed rating of 100 km/h (Beaufort Scale 10).
The light tower must be set up as per the operating instructions in this manual to achieve the
maximum wind speed rating of 100km/h in any direction.
STATUTORYAPPROVALS
The TerexAL4000AU light tower is built to the following standards:
- AS 2790 Electricity generating sets - Transportable
- AS 3010 Electricity installations - Generating sets
- AS 3713 Acoustics - Industrial trucks - Noise measurement
- AS 1170.2 Structural design actions - Wind actions
18

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 (2nd 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).
RECOMMENDED ENGINE OIL & FUEL
KUBOTA D1105 DIESEL ENGINE
Engine oil should be MIL-L-2104C or have properties ofAPI classification of CD grades or higher.
Change the type of engine oil according to the ambient operating temperature:
Above 25°C (77°F) SAE 30
0 to 25°C (32°F to 77°F) SAE 20
Below 0°C (32°F) SAE 10W
SAE 10W-30
Use #2 diesel fuel.
NOTES:
1. The temperatures in the table are the ambient temperatures at the time when the engine is
started. If the running ambient temperatures are much higher than the starting temperatures, a
compromise must be struck and a higher viscosity oil used. Multi-grade oils overcome the
problem, provided they possess a suitable specification.
2. MIL-L-2104B or MIL-L-2104C orAPI CD must also be used if the sulfur content of the fuel
exceeds 0.5%.
3. Always use a reputable brand of diesel fuel. The sulfur content should be below 0.5%
(higher sulfur content would require more frequent oil changes). Observe strict cleanliness
when filling the fuel tank.
4. 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 filler cap and add new oil until the FULL
line on the dipstick is reached.
19

FASTENER
SIZE
UNF
&
UNC
STAINLESS
STEEL* STAINLESS STEEL*
NYLOC
NUT
SAE
GRADE 5
PLATED
(METRIC
8.8)
SAE
GRADE 5
PLATED
NYLOC
NUT
SAE
GRADE 8
PLATED
(METRIC
10.9)
SAE
GRADE 8
PLATED
NYLOC
NUT
#6 .92 (1.24) .75 (1.0) 1.3 (1.7)
#8 1.8 (2.4) 1.5 (2.1) 2.2 (3.0)
#10 2.43 (3.3) 2.1 (2.8) 3.5 (4.8)
1/4" 7.1 (9.5) 6.0 (8.1) 8.0 (11.0) 13 (17.6)
5/16" 11 (15) 13 (17.6) 16 (21.6) 25 (34)
3/8" 21 (28.5) 23 (31.2) 31 (42) 47.5 (64.4)
7/16" 32 (43.4) 33.5 (45.4) 42.5 (57.6) 72 (97)
1/2" 44 (60) 47 (64) 80 (108) 75 (102) 105 (142) 100 (135)
9/16" 60 (81) 63 (85) 90 (122) 85 (115) 153 (207) 142 (193)
5/8" 99 (133) 102 (138) 150 (203) 145 (197) 190 (258) 180 (244)
3/4" 132 (179) 145 (197) 230 (312) 215 (292) 400 (542) 385 (522)
4 mm 2.0 (2.7) 1.8 (2.4) 2.1 (2.8)
6 mm 4.0 (5.4) 3.4 (4.6) 6.3 (8.5)
8 mm 1.0 (1.4) 10 (13.6) 15 (20.3)
10 mm 19 (25.7) 16 (21.7) 48 (65) 43 (58) 73 (99)
12 mm 43 (58) 37 (50) 58 (79) 53 (72) 100 (135)
16 mm 144 (195)
18 mm 193 (262)
20 mm 285 (386)
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.
* An anti-seize lubricant MUST be used on all stainless steel hardware.
20