Terex Series AL4000 Installation and operating instructions

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SERIES AL4000
LIGHT TOWER
OPERATION & SERVICE MANUAL
PO Box 3147 • Rock Hill, SC 29732 USA • Phone [phone]
Toll Free 800-433-3026 Parts Department Fax [phone]
After Serial Number:
0302-77560

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OPERATOR’S
MANUAL

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SAFETY ALERT SYMBOLS
MEANS:
ATTENTION! BE ALERT!
YOUR SAFETY IS INVOLVED
THIS SAFETY SYMBOL IS USED FOR IMPORTANT SAFETY MESSAGES.
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 prac-
tice that will result in severe injury or death.
WARNING Identifies the hazard or unsafe prac-
tice that could result in severe injury or death.
CAUTION Identifies the hazard or unsafe prac-
tice that could result in minor injury or property
damage.
NOTICE Identifies important installation, opera-
tion or maintenance information.

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GENERAL SAFETY
DO NOT OPERATE THE AL4000 LIGHT TOWER WITHOUT READ-
ING THIS OPERATOR’S MANUAL.
SAFETY ALERT SYMBOL
Stop and take time to read ALL Safety alert
messages. Follow the safety messages to
avoid personal injury or property damage.
ACCIDENT PREVENTION
Use protective clothing and safety equip-
ment. Always wear approved safety equip-
ment 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.

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GENERAL SAFETY
FUELING
ALWAYS handle fuel with care. It is highly
flammable.
ALWAYS stop engine before refueling. Fill
fuel 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 compart-
ment.
If fuel has leaked, wipe it up and have leak
repaired before next use.
Have a fire extinguisher nearby. Be sure the
extinguisher is properly maintained and be
familiar with its use. Extinguishers rated ABC
by the NFPA are appropriate for all applica-
tions.

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Guard Against Electrical Shock
Equipment produces 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 electrical circuit.
Beware of a cut or damaged power cord. Have a qualified electrician replace immediately.
Take extra precautions when troubleshooting electrical problems. When troubleshooting indicates a mal-
function in the high voltage AC system, pass the troubleshooting task on to a qualified and trained electri-
cian.
Disconnect electrical power and turn 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 each.
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 insulated alligator clip to a neutral
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.
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.
GENERAL SAFETY

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Guard Against 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 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 up 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 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.
Protect The Environment And Practice Good Industrial Hygiene
Exhaust Gases Are Toxic. Do not use indoors unless properly ventilated. Provide an adequate exhaust
system 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.
Prevent pollution by catching used oil in a container for proper disposal.
Wash hands to remove oil and fuel. Practice good industrial hygiene.
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.

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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.
If this 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 on 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 (Prior to Operation).
Keep your hands away from moving parts. Particularly, be sure to keep hands clear of the blower and alter-
nator 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 ensure 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 Light Construction, 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 burn, or eye
inflammation 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.

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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.
C. Review the manuals for safety and operating procedures.
D. Check the engine oil, coolant (if liquid cooled) and fuel levels.
E. Operate the tower in accordance with operating instructions.
EXPORT: Assemble according to the instructions enclosed.

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LIGHT TOWER MODEL CODING SYSTEM
IMPORTANT
WHEN REQUESTING TECHNICAL HELPAND 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
Samp1e:
Light Tower Product Line AL4 080 D 4 MH CE
Tower Series
AL4000 (AL4) = 30 Foot Basic Tower with winch in cabinet
AL5000 (ALS) = 30 Foot Basic Tower with in-cabinet light
storage and door insulation
5000 (5) =30 Foot Enhanced Cable Tower
2000 (2) =Model 5000 with extra corrosion protection
LT5000 (LT5) = 30 Foot Deluxe Cable Tower w/optional Acoustic
Enclosure and Complete Instrumentation
LT2000 (LT2) = Model LT5000 with Extra Corrosion Protection
7000 (7) = 30 Foot Enhanced Hydraulic Tower
LT7000 (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
HPS = High Pressure Sodium
MH= Metal Halide
MV= Mercury Vapor
TH= Tungsten Halogen
European Version (AL4000 Only)