Genie AL4000 / AL5000 / AL8000HT Service Manual

Service Manual

TM

AL8000HT

First Edition

Rev A

Part No. 116478

September 2008

Introduction

Important

Read, understand and obey the safety rules and
operating instructions in the appropriate Operator's
Manual on your machine before attempting any
maintenance procedure.

Basic mechanical, hydraulic and electrical
skills are required to perform most procedures.
However, several procedures require specialized
skills, tools, lifting equipment and a suitable
workshop. In these instances, we strongly
recommend that maintenance and repair be
performed at an authorized Terex dealer
service center.

September 2008

Technical Publications

Terex has endeavored to deliver the highest degree
of accuracy possible. However, continuous
improvement of our products is a Terex policy.
Therefore, product specifications are subject to
change without notice.

Readers are encouraged to notify Terex of errors
and send in suggestions for improvement. All
communications will be carefully considered for
future printings of this and all other manuals.

Contact Us:

Internet: www.genielift.com
e-mail: [e-mail]

Copyright © 2008 by Terex

Terex Rock Hill
590 Huey Road
Rock Hill, SC. 29730

116478 Rev A September 2008
First Edition, First Printing

" Printed on recycled paper

Printed in U.S.A.

ii

AL8000HT Light Tower Part No. 116478

September 2008

How to Read Your Serial Number

Serial Number Legend

Part No. 116478 AL8000HT Light Tower

iii

Section 1 • Safety Rules September 2008

Safety Rules

Danger

Failure to obey the instructions and safety rules
in this manual and the

Manual

serious injury.

Many of the hazards identified in the operator’s
manual are also safety hazards when maintenance
and repair procedures are performed.

on your machine will result in death or

Terex AL8000HT Operator's

Do Not Perform Maintenance
Unless:

You are trained and qualified to perform

maintenance on this machine.

You read, understand and obey:

- manufacturer’s instructions and safety rules

- employer’s safety rules and worksite
regulations

- applicable governmental regulations

You have the appropriate tools, lifting

equipment and a suitable workshop.

iv

AL8000HT Light Tower Part No. 116478

Section 1 • Safety RulesSeptember 2008

SAFETY RULES

Personal Safety

Any person working on or around a machine must
be aware of all known safety hazards. Personal
safety and the continued safe operation of the
machine should be your top priority.

Read each procedure thoroughly. This
manual and the decals on the machine,
use signal words to identify the following:

Safety alert symbol—used to alert
personnel to potential personal
injury hazards. Obey all safety
messages that follow this symbol
to avoid possible injury or death.

Indicates an imminently hazardous
situation which, if not avoided, will
result in death or serious injury.

Indicates a potentially hazardous
situation which, if not avoided,
could result in death or serious
injury.

Indicates a potentially hazardous
situation which, if not avoided,
may cause minor or moderate
injury.

Workplace Safety

Be sure to keep sparks, flames and
lighted tobacco away from flammable and

combustible materials like battery gases
and engine fuels. Always have an approved fire
extinguisher within easy reach.

Be sure that all tools and working areas

are properly maintained and ready for use.

Keep work surfaces clean and free of
debris that could get into machine components and
cause damage.

Be sure any forklift, overhead crane or

other lifting or supporting device is fully

capable of supporting and stabilizing the
weight to be lifted. Use only chains or straps that
are in good condition and of ample capacity.

Be sure that fasteners intended for one
time use (i.e., cotter pins and self-locking
nuts) are not reused. These components

may fail if they are used a second time.

Be sure to properly dispose of old oil or
other fluids. Use an approved container.
Please be environmentally safe .

Be sure that your workshop or work area is

properly ventilated and well lit.

Indicates a potentially hazardous
situation which, if not avoided,
may result in property damage.

Be sure to wear protective eye wear and
other protective clothing if the situation
warrants it.

Be aware of potential crushing hazards
such as moving parts, free swinging or

unsecured components when lifting or
placing loads. Always wear approved steel-toed
shoes.

Part No. 116478 AL8000HT Light Tower

v

Table of Contents

Introduction

September 2008

Important Information ...........................................................................................................

How to Read Your Serial Number ........................................................................................

Parts Stocking List .............................................................................................................

How to Order Parts .............................................................................................................

Service Parts Fax Order Form ...........................................................................................

Section 1 Safety Rules

General Safety Rules ..................................................................................................

Section 2 Rev Specifications

A Machine Specifications .......................................................................................... 2 - 1

Performance Specifications ................................................................................... 2 - 1

Hydraulic Oil Specifications ................................................................................... 2 - 2

Hydraulic Component Specifications ...................................................................... 2 - 2

Manifold Component Specifications ....................................................................... 2 - 3

Kubota D1105-E Engine ......................................................................................... 2 - 4

Kubota V1505-E Engine ........................................................................................ 2 - 5

ii

iii

x

xi

xii

iv

Isuzu 4LE1 Engine................................................................................................. 2 - 6

Generator Specifications ........................................................................................ 2 - 7

Hydraulic Hose and Fitting Torque Specifications .................................................. 2 - 8

SAE and Metric Fasteners Torque Charts .............................................................. 2 - 9

Genset Torque Specifications .............................................................................. 2 - 10

Section 3 Rev Scheduled Maintenance Procedures

Introduction ............................................................................................................ 3 - 1

Pre-delivery Preparation Report .............................................................................. 3 - 3

Maintenance Inspection Report .............................................................................. 3 - 5

A Checklist A Procedures

A-1 Inspect the Manuals and Decals .................................................................. 3 - 7

A-2 Perform Pre-operation Inspection ................................................................. 3 - 8

A-3 Perform Function Tests ................................................................................ 3 - 8

vi

AL8000HT Light Tower Part No. 116478

September 2008

A-4 Perform Engine Maintenance - Isuzu Models ............................................... 3 - 9

Section 3 Rev Scheduled Maintenance Procedures, continued

A-5 Perform Generator Maintenance ................................................................... 3 - 9

A-6 Perform Axle Maintenance ......................................................................... 3 - 10

A-7 Perform 30 Day Service ............................................................................. 3 - 10

A-8 Perform Engine Maintenance ..................................................................... 3 - 11

A-9 Perform Hitch Maintenance ........................................................................ 3 - 11

A-10 Grease the Turntable RotationBearing and Rotate Gear ............................. 3 - 12

A-11 Perform Engine Maintenance - Kubota Models ........................................... 3 - 13

A-12 Perform Engine Maintenance - Kubota Models ........................................... 3 - 13

A Checklist B Procedures

TABLE OF CONTENTS

B-1 Inspect the Battery ..................................................................................... 3 - 14

B-2 Inspect the Electrical Wiring ....................................................................... 3 - 14

B-3 Inspect the Tires and Wheels (including lug nut torque) .............................. 3 - 15

B-4 Perform Hydraulic Oil Analysis ................................................................... 3 - 15

B-5 Perform Engine Maintenance - Isuzu Models ............................................. 3 - 16

B-6 Perform Generator Maintenance ................................................................. 3 - 16

B-7 Perform Hitch Maintenance ........................................................................ 3 - 17

B-8 Perform Engine Maintenance - Kubota Models ........................................... 3 - 17

B-9 Perform Axle Maintenance ......................................................................... 3 - 17

A Checklist C Procedures

C-1 Inspect the Tower Extend/Retract Cables and Pulleys ............................... 3 - 19

C-2 Perform Engine Maintenance ..................................................................... 3 - 19

C-3 Perform Axle Maintenance ......................................................................... 3 - 20

C-4 Perform Engine Maintenance - Isuzu Models ............................................. 3 - 20

C-5 Perform Engine Maintenance - Kubota Models ........................................... 3 - 21

A Checklist D Procedures

D-1 Perform Engine Maintenance - Kubota Models ........................................... 3 - 22

D-2 Check the Tower Rotation Bearing Bolts .................................................... 3 - 22

D-3 Replace the Hydraulic Return Filter ............................................................ 3 - 23

D-4 Perform Engine Maintenance - Isuzu Models ............................................. 3 - 24

Part No. 116478 AL8000HT Light Tower

vii

TABLE OF CONTENTS

D-5 Perform Engine Maintenance - Isuzu Models ............................................. 3 - 24

D-6 Perform Engine Maintenance ..................................................................... 3 - 25

Section 3 Rev Scheduled Maintenance Procedures, continued

D-7 Perform Generator Maintenance ................................................................. 3 - 25

D-8 Perform Tongue Jack and Outrigger Jack Maintenance ............................. 3 - 26

D-9 Perform Axle Maintenance ......................................................................... 3 - 26

E-1 Test or Replace the Hydraulic Oil ............................................................... 3 - 27

E-2 Perform Engine Maintenance - Kubota Models ........................................... 3 - 28

E-3 Perform Engine Maintenance - Kubota Models ........................................... 3 - 29

E-4 Perform Generator Maintenance ................................................................. 3 - 29

E-5 Perform Generator Maintenance ................................................................. 3 - 30

September 2008

Section 4 Rev Repair Procedures

Introduction ............................................................................................................ 4 - 1

A Lighting

1-1 Lighting ........................................................................................................ 4 - 2

A Light Bar Components

2-1 Light Bar ...................................................................................................... 4 - 4

2-2 Light Bar Lift Cylinder ................................................................................... 4 - 5

A Tower Components

3-1 Plastic Cable Track ...................................................................................... 4 - 7

3-2 Tower Assembly .......................................................................................... 4 - 7

3-3 Tower Lift Cylinder ..................................................................................... 4 - 10

3-4 Tower Extension Cylinder ........................................................................... 4 - 11

3-5 Tower Rotation Motor ................................................................................. 4 - 12

A Kubota D1105-E/V1505-E Engine

4-1 Timing Adjustment ..................................................................................... 4 - 13

4-2 Glow Plugs ................................................................................................. 4 - 13

4-3 Coolant Temperature and Oil Pressure Switches ........................................ 4 - 13

viii

A Isuzu 4LE1 Engine

5-1 Timing Adjustment ..................................................................................... 4 - 14

AL8000HT Light Tower Part No. 116478

September 2008

TABLE OF CONTENTS

5-2 Glow Plugs ................................................................................................. 4 - 14

5-3 Coolant Temperature and Oil Pressure Switches ........................................ 4 - 14

Section 4 Rev Repair Procedures, continued

A Generator

6-1 Generator ................................................................................................... 4 - 15

A Chassis Components

7-1 Ground Controls ......................................................................................... 4 - 19

7-2 Light Ballast ............................................................................................... 4 - 20

7-3 Fuel Tank ................................................................................................... 4 - 21

8-1 Function Manifold Components .................................................................. 4 - 23

8-2 Valve Adjustments - Function Manifold ...................................................... 4 - 24

Section 5 Rev Troubleshooting

Introduction ............................................................................................................ 5 - 1

A Troubleshooting Guide ........................................................................................... 5 - 2

A Light Fixture Troubleshooting ................................................................................. 5 - 5

Section 6 Rev Schematics

A Introduction ............................................................................................................ 6 - 1

A Electrical Symbols Legend .................................................................................... 6 - 2

A Hydraulic Symbols Legend .................................................................................... 6 - 3

A Electrical Schematic - Machine Functions ............................................................. 6 - 4

A DC Electrical Schematic - Control Box and Engine - Isuzu Models ....................... 6 - 5

A DC Electrical Schematic - Control Box and Engine - Kubota Models .................... 6 - 6

A DC Electrical Schematic - Control Box and Engine - with Autostart Option ........... 6 - 7

A AC Electrical Schematic - Standard Models with 4 Lights ...................................... 6 - 8

A AC Electrical Schematic - Standard Models with 6 Lights ...................................... 6 - 9

A AC Electrical Schematic - Standard Models with 8 Lights .................................... 6 - 10

A AC Electrical Schematic - Autostart Models with 4 Lights .................................... 6 - 11

A AC Electrical Schematic - Autostart Models with 6 Lights .................................... 6 - 12

A AC Electrical Schematic - Autostart Models with 8 Lights .................................... 6 - 13

A Receptacle Wiring Diagrams ................................................................................ 6 - 14

A Hydraulic Schematic ............................................................................................ 6 - 15

Part No. 116478 AL8000HT Light Tower

ix

Parts Stocking List

Required Parts

The following parts are required to perform
maintenance procedures as outlined in the

TEREX AL8000HT Parts and Service Manual.

Description Part No.

Kubota Models

Oil Filter .............................................................. 866050

Air Filter .............................................................. 866127

Fuel Filter ........................................................... 839200

V-belt ................................................................. 839209

Isuzu Models

Oil Filter .............................................................. 868075

Air Filter .............................................................. 834460

Fuel Filter ........................................................... 868137

V-belt ................................................................. 868067

September 2008

Manuals

TEREX Corporation offers the following manuals for
these models:

Title Part No.

TEREX AL8000HT Operator's Manual, .............. 114426

First Edition

TEREX AL8000HT Part's Manual, ..................... 116447

First Edition

TEREX AL8000HT Service Manual, ..................116478

First Edition

Newage Generator Manual ................................ 830001

Leroy Somer Manual .......................................... 116118

Isuzu Engine Manual ......................................... 116133

Kubota Engine Manual ....................................... 893020

Axis Manual ........................................................ 116117

Marathon Manual ............................................... 116188

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AL8000HT Light Tower Part No. 116478

September 2008

How To Order Parts

Please be prepared with the following information
when ordering replacement parts for your TEREX
product:

Machine model number
Machine serial number
Terex part number
Part description and quantity
Purchase order number
"Ship to" address
Desired method of shipment
Name and telephone number of the
authorized TEREX Distributor in your area

Use the Service Parts Fax Order Form on the
next page and fax your order to our Parts
Department.

If you don't know the name of your authorized
distributor, or if your area is not currently serviced
by an authorized distributor, please call TEREX
Corporation.

Machine Information

Genie Industries

18340 NE 76th Street
P.O. Box 97030
Redmond, WA 98073-9730
Telephone [phone]
Fax [phone]

genieindustries.com

Model

Serial Number

Date of Purchase

Authorized TEREX Distributor

Phone Number

Part No. 116478 AL8000HT Light Tower

xi

September 2008

Service Parts fax Order Form

Please fill out completely

Date _________________________________ Account Number _______________________________

Your Name ______________________________ Your Fax Number _____________________________

_________________________________ Your Phone Number ___________________________

Bill To _________________________________ Ship To ___________________________________

_________________________________ ___________________________________

_________________________________ ___________________________________

_________________________________ ___________________________________

Purchase Order Number ____________________ Ship Via ___________________________________

Model(s) ______________________________________________________ Serial No.(s) _________________

FAX TO: [phone] OR TOLL FREE: 877-367-5606

Optional Equipment ___________________________________________________________________________

Part Number Description Quantity Price

remove this page and make copies

All backordered parts will be shipped when available via the same ship method as the original order unless
noted below:

o Ship complete order only - no backorders

o Ship all available parts and contact customer on disposition of backordered parts

o Other (please specify)

FOR TEREX USE O NLY

Order Number ______________ Origin Code ________________ Comments _________________________

Date Scheduled ____________ Ship Condition _____________ __________________________________

Order Total ________________ Terms Code _______________ __________________________________

AL8000HT Light Tower Part No. 116478

remove this page and make copies

September 2008

Section 2 • Specifications

REV A

Machine Specifications

Lights

Type: BT-37 Metal Halide, 1000 watt

Total lighting wattage

4 lights 4000 watts
8 lights 8000 watts

Axle

Axle load capacity, maximum 4200 lbs

1905 kg

Fluid capacities

Hydraulic tank capacity 1.4 gallons

5.3 liters

Hydraulic system capacity 2 gallons
(including tank) 7.6 liters

Single fuel tank 30 gallons

114 liters

Dual fuel tanks 60 gallons

227 liters

Tires and wheels (U.S. models)

Tire size ST205/75R15

Load range C

Lug nut torque, dry 80 ft-lbs

108 Nm

Tire pressure, maximum (cold) 50 psi

3.4 bar

Tires and wheels (Australia models)

Tire size 7.5R16 C 112/110L

Lug nut torque, dry 80 ft-lbs

108 Nm

Specifications

Performance Specifications

Tongue weight, maximum 350 lbs

159 kg

Run time, full load
Kubota D1105 (8kW) @ .82 Gallons per hour

Single full fuel tank 36.5 hours

Dual full fuel tanks 73 hours

Run time, full load
Kubota V1505 (12kW) @ 1.1 Gallons per hour

Single full fuel tank 27.25 hours

Dual full fuel tanks 54.5 hours

Run time, full load
Isuzu 4LE1 (20kW) @ 1.8 Gallons per hour

Single full fuel tank 16.5 hours

Dual full fuel tanks 33 hours

Towing speed, maximum 62 mph

100 km/h

Function speeds

Boom up 12 to 24 seconds

Boom down 12 to 21 seconds

Boom extend 17 to 37 seconds

Boom retract 13 to 27 seconds

Light bar up 18 to 30 seconds

Light bar down 14 to 24 seconds

Tower rotate, 359° 31 to 68 seconds

Tire pressure, maximum (cold) 75 psi

5.2 bar

Continuous improvement of our products is a
For operational specifications, refer to the
Operator's Manual.

Terex policy. Product specifications are subject

to change without notice.

Part No. 116478 AL8000HT Light Tower 2 - 1

Section 2 • Specifications

September 2008

SPECIFICATIONS

Hydraulic Oil Specifications

Hydraulic Oil Specifications

Hydraulic oil type Chevron Rando HD Premium MV
Viscosity grade Multi-viscosity
Viscosity index 200

Cleanliness level, minimum 15/13

Water content, maximum 200 ppm

Chevron Rykon MV oil is fully compatible and
mixable with Shell Donax TG (Dexron III) oils.

Genie specifications require hydraulic oils which are
designed to give maximum protection to hydraulic
systems, have the ability to perform over a wide
temperature range, and the viscosity index should
exceed 140. They should provide excellent antiwear,
oxidation, corrosion inhibition, seal conditioning, and
foam and aeration suppression properties.

Optional fluids

Biodegradable Petro Canada Environ MV46

Statoil Hydra Way Bio Pa 32

BP Biohyd SE-S

Fire resistant UCON Hydrolube HP-5046

Quintolubric 822

REV A

Hydraulic Component

Specifications

Function pump

Type: Fixed displacement gear pump

Displacement 0.056 cu in

per revolution 0.92 cc

Flow rate @ 3200 psi 0.6 gpm

2.27 L/min

System relief pressure 3200 psi

220.6 bar

Function manifold

Light bar up/down 0.2 gpm

flow regulator 0.76 L/min

Tower rotate relief 1200 psi

valve pressure 82.7 bar

Hydraulic filter

Hydraulic tank Beta 10 ≥ 200

return filter with 25 psi / 1.7 bar bypass

Mineral based Shell Tellus T32

Shell Tellus T46

Chevron Aviation A

Continued use of Chevron Aviation
A hydraulic fluid when ambient
temperatures are consistently
above 32°F / 0°C may result in
component damage.

Note: Use Chevron Aviation A hydraulic fluid when
ambient temperatures are consistently below
0°F / -18°C.

Note: Use Shell Tellus T46 hydraulic oil when oil
temperatures consistently exceed 205°F / 96°C.

Note: Terex specifications require additional
equipment and special installation instructions for
the approved optional fluids. Consult the Terex
Service Department before use.

Continuous improvement of our products is a

Terex policy. Product specifications are subject

to change without notice.

2 - 2 AL8000HT Light Tower Part No. 116478

September 2008

Section 2 • Specifications

REV A

Manifold Component
Specifications

Plug torque

SAE No. 2 36 in-lbs / 4 Nm

SAE No. 4 10 ft-lbs / 13 Nm

SAE No. 6 14 ft-lbs / 19 Nm

SAE No. 8 38 ft-lbs / 51 Nm

SAE No. 10 41 ft-lbs / 55 Nm

SAE No. 12 56 ft-lbs / 76 Nm

Valve Coil Resistance

Note: The following coil resistance specifications are at
an ambient temperature of 68°F / 20°C. As valve coil
resistance is sensitive to changes in air temperature,
the coil resistance will typically increase or decrease by
4% for each 18°F / 20°C that your air temperature
increases or decreases from 68°F / 20°C.

Valve coil specifications

SPECIFICATIONS

Machine Torque Specifications

Tower rotation assembly

Rotate bearing mounting bolts, lubricated

1

/2 -13 SHC bolts 95 ft-lbs

5

/8 -11 SHC bolts 195 ft-lbs

Rotation motor mounting bolts, dry 75 ft-lbs

1

/2 -13, GR 5 102 Nm

Rotation motor mounting bolts, lubricated 57 ft-lbs

1

/2 -13, GR 5 77 Nm

Generator

Generator case to engine 25 ft-lbs

bell housing fasteners 34 Nm

Generator vibration 75 ft-lbs

isolator fasteners 102 Nm

Flex plate to flywheel 25 ft-lbs

129 Nm

264 Nm

34 Nm

3 position 4 way solenoid valve, 10V DC 6Ω
(schematic items B, C, E and G)

Continuous improvement of our products is a

Terex policy. Product specifications are subject

to change without notice.

Part No. 116478 AL8000HT Light Tower 2 - 3

Section 2 • Specifications

September 2008

SPECIFICATIONS

Kubota D1105-E Engine

Displacement 68.53 cu in

1.12 liters

Number of cylinders 3

Bore and stroke 3.07 x 3.09 inches

78 x 78.4 mm

Horsepower, continuous 13.6 @ 1800 rpm

10.1 kW

Firing order 1 - 2 - 3

Compression ratio 23:1

Compression pressure 412 to 469 psi

28.4 to 32.3 bar

Engine speed 1800 rpm

Governor centrifugal mechanical

Valve clearance, cold 0.0057 to 0.0072 in

0.145 to 0.185 mm

REV A

Injection system

Injection pump make Bocsh MD mini

Injection timing 19° BTDC

Injection pump pressure 1991 psi

137 bar

Fuel requirement

For fuel requirements, refer to the engine Operator's

Manual on your machine.

Battery

Type 12V DC

Group 27TM

Quantity 1

Cold cranking ampere 500

Reserve capacity @ 25A rate 105 minutes

Alternator

Engine coolant

Capacity 3.27 quarts

3.1 liters

Lubrication system

Oil pressure 28 to 64 psi

1.93 to 4.41 bar

Oil capacity 5.4 quarts
(including filter) 5.1 liters

Oil pressure switch 7 psi
(engine shutoff pressure)

Oil viscosity requirements

Units ship with 10W-30.
Extreme operating temperatures may require the use of
alternative engine oils. For oil requirements, refer to the
Engine Operator Handbook on your machine.

Output 40A, 12V DC

Fan belt deflection

1

/4 to 3/8 inch

7 to 9 mm

Continuous improvement of our products is a

Terex policy. Product specifications are subject

to change without notice.

2 - 4 AL8000HT Light Tower Part No. 116478

September 2008

Section 2 • Specifications

REV A

Kubota V1505-E Engine

Displacement 91.41 cu in

1.5 liters

Number of cylinders 4

Bore and stroke 3.07 x 3.09 inches

78 x 78.4 mm

Horsepower, continuous 17.9 @ 1800 rpm

13.4 kW

Firing order 1 - 3 - 4 - 2

Compression ratio 22:1

Compression pressure 412 to 469 psi

28.4 to 32.3 bar

Engine speed 1800 rpm

Governor centrifugal mechanical

Valve clearance, cold 0.0057 to 0.0072 in

0.145 to 0.185 mm

SPECIFICATIONS

Injection system

Injection pump make Bocsh MD mini

Injection timing 19° BTDC

Injection pump pressure 1991 psi

137 bar

Fuel requirement

For fuel requirements, refer to the engine Operator's

Manual on your machine.

Battery

Type 12V DC

Group 27TM

Quantity 1

Cold cranking ampere 630

Reserve capacity @ 25A rate 105 minutes

Alternator

Engine coolant

Capacity 4.23 quarts

4 liters

Lubrication system

Oil pressure 28 to 64 psi

1.93 to 4.41 bar

Oil capacity 7.08 quarts
(including filter) 6.7 liters

Oil pressure switch 7 psi
(engine shutoff pressure)

Oil viscosity requirements

Units ship with 10W-30.
Extreme operating temperatures may require the use of
alternative engine oils. For oil requirements, refer to the
Engine Operator Handbook on your machine.

Output 30A, 12V DC

Fan belt deflection

1

/4 to 3/8 inch

7 to 9 mm

Part No. 116478 AL8000HT Light Tower 2 - 5

Section 2 • Specifications

September 2008

SPECIFICATIONS

Isuzu 4LE1 Engine

Displacement 133 cu in

2.179 liters

Number of cylinders 4

Bore and stroke 3.35 x 3.78 inches

85 x 96 mm

Horsepower, continuous 31.4 @ 1800 rpm

23.4kW

Firing order 1 - 3 - 4 - 2

Compression ratio 21.5:1

Engine speed 1800 rpm

Governor variable speed, mechanical

Valve clearance, cold

Intake 0.0157 in

0.4 mm

Exhaust 0.0157 in

0.4 mm

Lubrication system

Oil pressure (hot @ 1800 rpm) 64 psi

4.4 bar

Oil capacity 7.08 quarts
(including filter) 6.7 liters

Oil pressure switch 14 psi
(engine shut-off pressure) 0.96 bar

REV A

Engine coolant

Capacity 4 quarts

3.8 liters

Coolant temperature switch 221° ±7°F

(engine shut-off temperature) 105° ±4°C

Injection system

Injection pump make Bosch, PFR ype

Injection timing 16° BTDC

Injection pump pressure 1920 psi

132.8 bar

Fuel requirement

For fuel requirements, refer to the engine Operator's

Manual on your machine.

Battery

Type 12V DC

Group 27TM

Quantity 1

Cold cranking ampere 630

Reserve capacity @ 25A rate 105 minutes

Alternator

Output 35A, 12V DC

Fan belt deflection

1

/4 to 3/8 inch

7 to 9 mm

Oil viscosity requirements

Units ship with 10W-30.
Extreme operating temperatures may require the use of
alternative engine oils. For oil requirements, refer to the
Engine Operating Instructions on your machine.

Continuous improvement of our products is a

Terex policy. Product specifications are subject

to change without notice.

2 - 6 AL8000HT Light Tower Part No. 116478

September 2008

Section 2 • Specifications

REV A

Leroy Somer LSA37M7
Generator

Generator speed @ full load 60 Hz 1800 rpm

Temperature, ambient maximum 104°F

40°C

Power 8 kW

Capacitor (disconnected) 100 µF @ 240V

Marathon 201CSA5412
Generator

Generator rpm @ full load 60 Hz 1800 rpm

Temperature, ambient maximum 104°F

40°C

Power 8 kW

SPECIFICATIONS

Newage BCI164D1J195A
Generator

Generator rpm @ full load 60 Hz 1800 rpm

Temperature, ambient maximum 104°F

40°C

Power 12 kW

Newage BCI184E1J203A
Generator

Generator rpm @ full load 60 Hz 1800 rpm

Temperature, ambient maximum 104°F

40°C

Power 20 kW

Continuous improvement of our products is a

Terex policy. Product specifications are subject

to change without notice.

Part No. 116478 AL8000HT Light Tower 2 - 7

Section 2 • Specifications

September 2008

SPECIFICATIONS

Hydraulic Hose and Fitting
Torque Specifications

Your machine is equipped with Parker Seal-Lok®
fittings and hose ends. Genie specifications require
that fittings and hose ends be torqued to
specification when they are removed and installed
or when new hoses or fittings are installed.

SAE O-ring Boss Port

(tube fitting - installed into Aluminum)

SAE Dash size Torque

-4 11 ft-lbs / 14.9 Nm

-6 23 ft-lbs / 31.2 Nm

-8 40 ft-lbs / 54.2 Nm

-10 69 ft-lbs / 93.6 Nm

-12 93 ft-lbs / 126.1 Nm

-16 139 ft-lbs / 188.5 Nm

-20 172 ft-lbs / 233.2 Nm

REV A

Seal-Lok® fittings

1 Replace the O-ring. The O-ring must be replaced

anytime the seal has been broken. The O-ring
cannot be re-used if the fitting or hose end has
been tightened beyond finger tight.

Note: The O-rings used in the Parker Seal Lok®

fittings and hose ends are custom-size O-rings.

They are not standard SAE size O-rings. They are

available in the O-ring field service kit (Genie part

number 49612).

2 Lubricate the O-ring before installation.

3 Be sure that the face seal O-ring is seated and

retained properly.

4 Position the tube and nut squarely on the face

seal end of the fitting and tighten the nut finger
tight.

5 Tighten the nut or fitting to the appropriate

torque per given size as shown in the table.

6 Operate all machine functions and inspect the

hoses and fittings and related components to
confirm that there are no leaks.

-24 208 ft-lbs / 282 Nm

SAE O-ring Boss Port

(tube fitting - installed into Steel)

SAE Dash size Torque

-4 16 ft-lbs / 21.7 Nm

-6 35 ft-lbs / 47.5 Nm

-8 60 ft-lbs / 81.3 Nm

-10 105 ft-lbs / 142.4 Nm

-12 140 ft-lbs / 190 Nm

-16 210 ft-lbs / 284.7 Nm

-20 260 ft-lbs / 352.5 Nm

-24 315 ft-lbs / 427.1 Nm

SAE Dash size Torque

Seal-Lok® Fittings

(hose end)

-4 18 ft-lbs / 25 Nm

-6 30 ft-lbs / 40 Nm

-8 40 ft-lbs / 55 Nm

-10 60 ft-lbs / 80 Nm

-12 85 ft-lbs / 115 Nm

-16 110 ft-lbs / 150 Nm

-20 140 ft-lbs / 190 Nm

-24 180 ft-lbs / 245 Nm

2 - 8 AL8000HT Light Tower Part No. 116478

September 2008

Section 2 • Specifications

REV A

SIZE THREAD

1/4

5/16

3/8

7/16

1/2

9/16

5/8

3/4

7/8

1
1 1/
1 1/

1

1

/

8

4

2

20
28 90 10.1 120 13.5

18
24 14 19 19 25.7
16
24
14 37 50.1 49 66.4
20
13
20 64 86.7 85 115
12
18
11
18
10 200 271 270 366
16

14 350 474 470 637

12

12

12

12

SAE FASTENER TORQUE CHART

• This chart is to be used as a guide only unless noted elsewhere in this manual •

Grade 5

DRYLUBED

in-lbs Nm in-lbs Nm in-lbs Nm in-lbs Nm in-lbs Nm

80 9 100 11.3

LUBED DRY LUBED DRY

ft-lbs Nm ft-lbs Nm ft-lbs Nm ft-lbs Nm ft-lbs Nm

13 17.6 17 23 18 24 25 33.9 21 28.4
23 31.2 31 42

26 35.2 35 47.4
41 55.5 55 74.5

57 77.3 75 101.6
80 108.4 110 149

90 122 120 162
110 149 150 203
130 176 170 230

9

8
7 590 800 790 1071

7

6

220 298 300 406
320 433 430 583

480 650 640 867
530 718 710 962

670 908 890 1206 1080 1464 1440 1952 1220 1654
840 1138 1120 1518 1360 1844 1820 2467 1530 2074
930 1260 1240 1681

1460 1979 1950 2643
1640 2223 2190 2969 2670 3620 3560 4826 3000 4067

110 12.4 140 15.8
120

20 27.1 27 36.6
33 44.7 44 59.6
37 50.1 49 66.4
50 67.8 70 94.7
60 81.3 80 108.4
80 108.4 110 149

90 122 120 162
120 162 150 203
130 176 170 230
160 217 210 284
180 244 240 325
280 379 380 515
310 420 420 569
450 610 610 827
500 678 670 908
680 922 910 1233
750 1016 990 1342
970 1315 1290 1749

1510 2047 2010 2725
2370 3213 3160 4284

Grade 8

13.5

160 18

SPECIFICATIONS

A574 High Strength

Black Oxide Bolts

LUBEDDRYLUBED

130 14.7
140 15.8

LUBED

24 32.5
38 51.5
43 58.3
61 82.7
68 92.1

93 126
105 142
130 176
140 189
180 244
200 271
320 433
350 474
510 691
560 759
770 1044
840 1139

1090 1477

1700 2304
2670 3620

METRIC FASTENER TORQUE CHART

• T his chart i s t o be used as a gu i de onl y unless noted elsewhere in this manual •

Size

(mm)

in-lbs Nm in-lbs N m in-lbs Nm in-lbs N m in-lbs N m in-lbs Nm in-lbs N m in-lbs N m

16 1.8 21 2.4 41 4.63 54 6.18 58 6.63 78 8.84 68 7.75 91 10.3

5

19 3.05 36 4.07 69 7.87 93 10.5 100 11.3 132 15 116 13.2 155 17.6

6

45 5.12 60 6.83 116 13.2 155 17.6 167 18.9 223 25.2 1.95 22.1 260 29.4

7

DRYLUBED

Class 10.9Class 8.8

LUBEDDRYLUBED

10.9 12.98.84.6

DRY

LUBED DRY LUBED DRYLUBED DRY LUBED DRY

ft-lbs Nm ft-lbs Nm ft-lbs N m ft-lbs Nm ft-lbs Nm ft-lbs Nm ft-lbs Nm ft-lbs N m

5.4 7.41 7.2 9.88 14 19.1 18.8 25.5 20.1 27.3 26.9 36.5 23.6 32 31.4 42.6

8

10.8 14.7 14.4 19.6 27.9 37.8 37.2 50.5 39.9 54.1 53.2 72.2 46.7 63.3 62.3 84.4

10

18.9 25.6 25.1 34.1 48.6 66 64.9 88 69.7 94.5 92.2 125 81 110 108 147

12

30.1 40.8 40 54.3 77.4 105 103 140 110 150 147 200 129 175 172 234

14

46.9 63.6 62.5 84.8 125 170 166 226 173 235 230 313 202 274 269 365

16

64.5 87.5 86.2 117 171 233 229 311 238 323 317 430 278 377 371 503

18

91 124 121 165 243 330 325 441 337 458 450 610 394 535 525 713

20

124 169 166 225 331 450 442 600 458 622 612 830 536 727 715 970

22

157 214 210 285 420 570 562 762 583 791 778 1055 682 925 909 1233

24

Part No. 116478 AL8000HT Light Tower 2 - 9

Class 12.9Class 4.6

LUBED DRY

GENSET TORQUE SPECIFICATIONS

Generator FT*LB

Flex Plate to Flywheel 25
Generator Case to Bellhousing 25
Genset Isolators 75

September 2008

2 - 10 AL8000HT Light Tower Part No. 116478

September 2008

Scheduled Maintenance Procedures

Section 3 • Scheduled Maintenance Procedures

About This Section

This section contains detailed procedures for each
scheduled maintenance inspection.

Each procedure includes a description, safety
warnings and step-by-step instructions.

Observe and Obey:

Maintenance inspections shall be completed by

a person trained and qualified on the
maintenance of this machine.

Scheduled maintenance inspections shall be

completed daily, quarterly, semi-annually,
annually and every 2 years as specified on the

Maintenance Inspection Report.

Failure to perform each procedure
as presented and scheduled could
result in death, serious injury or
substantial damage.

Immediately tag and remove from service a

damaged or malfunctioning machine.

Repair any machine damage or malfunction

before operating the machine.

Use only Terex approved replacement parts.

Machines that have been out of service for a

period longer than 3 months must complete the
quarterly inspection.

Unless otherwise specified, perform each

maintenance procedure with the machine in the
following configuration:

· Machine parked on a firm, level surface

· Key switch in the off position
(manual start models)

· Toggle switch in the off position
(automatic start models)

· Mast in the stowed position

· Light switches in the off position

· Wheels chocked

Symbols Legend

Safety alert symbol—used to alert
personnel to potential personal
injury hazards. Obey all safety
messages that follow this symbol
to avoid possible injury or death.

Indicates an imminently hazardous
situation which, if not avoided, will
result in death or serious injury.

Indicates a potentially hazardous
situation which, if not avoided,
could result in death or serious
injury.

Indicates a potentially hazardous
situation which, if not avoided,
may cause minor or moderate
injury.

Indicates a potentially hazardous
situation which, if not avoided,
may result in property damage.

Indicates that a specific result is expected after

performing a series of steps.

Indicates that an incorrect result has occurred

after performing a series of steps.

Part No. 116478 AL8000HT Light Tower 3 - 1

Section 3 • Scheduled Maintenance Procedures

SCHEDULED MAINTENANCE PROCEDURES

September 2008

Maintenance Symbols Legend

The following symbols have been used in this
manual to help communicate the intent of the
instructions. When one or more of the symbols
appear at the beginning of a maintenance
procedure, it conveys the meaning below.

Indicates that tools will be required to
perform this procedure.

Indicates that new parts will be required
to perform this procedure.

Indicates that a cold engine will be
required to perform this procedure.

Indicates that a warm engine will be
required to perform this procedure.

Pre-delivery Preparation Report

The pre-delivery preparation report contains
checklists for each type of scheduled inspection.

Make copies of the Pre-delivery Preparation report

to use for each inspection. Store completed forms
as required.

Maintenance Schedule

There are five types of maintenance inspections
that must be performed according to a schedule—
daily, quarterly, semi-annually, annual and
two year. The

Section

Scheduled Maintenance Procedures

and the

Maintenance Inspection Report

have been divided into five subsections—A, B, C,
D and E. Use the following chart to determine which
group(s) of procedures are required to perform a
scheduled inspection.

Inspection Checklist

Daily or every 8 hours A

Quarterly or every 250 hours A + B

Indicates that dealer service will be
required to perform this procedure.

Semi-annually or every 500 hours A + B + C

Annually or every 1000 hours A + B + C + D

Two years or every 2000 hours A + B + C + D + E

Maintenance Inspection Report

The maintenance inspection report contains
checklists for each type of scheduled inspection.

Make copies of the

Maintenance Inspection Report

to use for each inspection. Maintain completed

forms for a minimum of 4 years or in compliance
with employer, jobsite and governmental
regulations and requirements.

3 - 2 AL8000HT Light Tower Part No. 116478

Pre-DeliverPre-Deliver

Pre-Deliver

Pre-DeliverPre-Deliver

y Preparationy Preparation

y Preparation

y Preparationy Preparation

Fundamentals

It is the responsibility of the dealer to perform the
Pre-delivery Preparation.

The Pre-delivery Preparation is performed prior to each
delivery. The inspection is designed to discover if anything
is apparently wrong with a machine before it is put into
service.

A damaged or modified machine must never be used. If
damage or any variation from factory delivered condition is
discovered, the machine must be tagged and removed from
service.

Repairs to the machine may only be made by a qualified
service technician, according to the manufacturer's
specifications.

Scheduled maintenance inspections shall be performed by
qualified service technicians, according to the
manufacturer's specifications and the requirements listed in
the responsibilities manual.

Instructions

Use the operator’s manual on your machine.

The Pre-delivery Preparation consists of completing the
Pre-operation Inspection, the Maintenance items and the
Function Tests.

Use this form to record the results. Place a check in the
appropriate box after each part is completed. Follow the
instructions in the operator’s manual.

If any inspection receives an N, remove the machine from
service, repair and re-inspect it. After repair, place a check
in the R box.

Legend

Y = yes, completed
N = no, unable to complete
R = repaired

Comments

TEREX Rock Hill

P.O. BOX 3147
Rock Hill, SC 29732 USA

Toll Free [phone] in U.S.A. and Canada

Copyright © 2006 by TEREX Corporation. TEREX® is a registered trademark of TEREX
Corporation.
Rev B

Pre-Delivery Preparation Y N R

Pre-operation inspection completed

Maintenance items completed

Function tests completed

Model

Serial number

Date

Machine owner

Inspected by (print)

Inspector signature

Inspector title

Inspector company

Section 3 • Scheduled Maintenance Procedures

September 2008

This page intentionally left blank.

3 - 4 AL8000HT Light Tower Part No. 116478

September 2008

Section 3 • Scheduled Maintenance Procedures

Maintenance Inspection Report

Model

Serial number

Date

Hour meter

Machine owner

Inspected by (print)

Inspector signature

Inspector title

Inspector company

Instructions

· Make copies of this report to use for
each inspection.

· Select the appropriate checklist(s)
for the type of inspection to be
performed.

Daily or 8 hours
Inspection: A

Quarterly or 250 hours
Inspection: A+B

Semi-annually or
500 hours
Inspection: A+B+C

Annually or
1000 hours
Inspection: A+B+C+D

Two year or
2000 hours
Inspection: A+B+C+D+E

· Place a check in the appropriate box
after each inspection procedure is
completed.

· Use the step-by-step procedures in
this section to learn how to perform
these inspections.

· If any inspection receives an “N”, tag
and remove the machine from
service, repair and re-inspect it. After
repair, place a check in the “R” box.

Legend

Y = yes, acceptable
N = no, remove from service

R = repaired

Checklist A - Rev A YNR

A-1 Manuals and decals

A-2 Pre-operation inspect

A-3 Function tests

Perform every 8 hours:

A-4 Engine maintenance -

Isuzu models

A-5 Generator

maintenance

Perform after 10 miles:

A-6 Axle maintenance

Perform after 25 miles:

A-6 Axle maintenance

Perform after 50 miles:

A-6 Axle maintenance

Perform after 40 hours:

A-7 30 day service

Perform every 50 hours:

A-8 Engine maintenance

Perform weekly:

A-9 Hitch maintenance

Perform every 100 hours:

A-10 Grease rotation

bearing

A-11 Engine maintenance -

Kubota models

Perform every 200 hours:

A-12 Engine maintenance -

Kubota models

Checklist B - Rev A YNR

B-1 Battery

B-2 Electrical wiring

B-3 Tires and wheels

B-4 Hydraulic oil analysis

B-5 Engine maintenance -

Isuzu models

B-6 Generator

maintenance

Perform quarterly:

B-7 Hitch coupler

maintenance

Perform every 400 hours:

B-8 Engine maintenance -

Kubota models

Perform every 3000 miles:

B-9 Axle maintenance

Checklist C - Rev A YNR

C-1 Extend/retract cables

and pulleys

C-2 Engine maintenance

Perform every 6000 miles:

C-3 Axle maintenance

Perform every 750 hours:

C-5 Engine maintenance -

Isuzu models

Perform every 800 hours:

C-6 Engine maintenance -

Kubota models

Part No. 116478 AL8000HT Light Tower 3 - 5

Section 3 • Scheduled Maintenance Procedures

MAINTENANCE INSPECTION REPORT

September 2008

Model

Serial number

Date

Hour meter

Machine owner

Inspected by (print)

Inspector signature

Inspector title

Inspector company

Instructions

· Make copies of this report to use for
each inspection.

· Select the appropriate checklist(s)
for the type of inspection to be
performed.

Daily or 8 hours
Inspection: A

Quarterly or 250 hours
Inspection: A+B

Semi-annually or
500 hours
Inspection: A+B+C

Annually or
1000 hours
Inspection: A+B+C+D

Two year or
2000 hours
Inspection: A+B+C+D+E

· Place a check in the appropriate box
after each inspection procedure is
completed.

· Use the step-by-step procedures in
this section to learn how to perform
these inspections.

· If any inspection receives an “N”, tag
and remove the machine from
service, repair and re-inspect it. After
repair, place a check in the “R” box.

Legend

Y = yes, acceptable
N = no, remove from service

R = repaired

Checklist D - Rev A YNR

D-1 Engine maintenance -

Kubota models

D-2 Tower rotation bearing

bolts

D-3 Hydraulic filter

D-4 Engine maintenance -

Isuzu models

Perform every 1250 hours:

D-5 Engine maintenance -

Isuzu models

Perform every 1500 hours:

D-6 Engine maintenance

D-7 Generator

maintenance

Perform annually:

D-8 Tongue and outrigger

jack maintenance

Perform every 12,000 miles:

D-9 Axle maintenance

Checklist E - Rev A YNR

E-1 Test or replace

hydraulic oil

Perform every 3000 hours:

E-2 Engine maintenance -

Kubota models

Perform every 2 years:

E-3 Engine maintenance -

Kubota models

Perform every 4500 hours:

E-4 Generator

maintenance

Perform every 15,000 hours:

E-5 Generator

maintenance

Comments

3 - 6 AL8000HT Light Tower Part No. 116478

September 2008

Section 3 • Scheduled Maintenance Procedures

REV A

Checklist A Procedures

A-1
Inspect the Manuals and Decals

Note: Terex specifications require that this
procedure be performed daily or every 8 hours,
whichever comes first.

Maintaining the operator’s and safety manuals in
good condition is essential to safe machine
operation. Manuals are included with each machine
and should be stored in the container provided in
the cabinet. An illegible or missing manual will not
provide safety and operational information
necessary for a safe operating condition.

In addition, maintaining all of the safety and
instructional decals in good condition is mandatory
for safe machine operation. Decals alert operators
and personnel to the many possible hazards
associated with using this machine. They also
provide users with operation and maintenance
information. An illegible decal will fail to alert
personnel of a procedure or hazard and could result
in unsafe operating conditions.

3 Open the operator's manual to the decals

inspection section. Carefully and thoroughly
inspect all decals on the machine for legibility
and damage.

Result: The machine is equipped with all

required decals, and all decals are legible and in
good condition.

Result: The machine is not equipped with all

required decals, or one or more decals are
illegible or in poor condition. Remove the
machine from service until the decals are
replaced.

4 Always return the manuals to the storage

container after use.

Note: Contact your authorized Terex distributor if
replacement manuals or decals are needed.

1 Check to make sure that the operator's and

safety manuals are present and complete in the
storage container inside the cabinet.

2 Examine the pages of each manual to be sure

that they are legible and in good condition.

Result: The operator's manual is appropriate for

the machine and all manuals are legible and in
good condition.

Result: The operator's manual is not appropriate

for the machine or all manuals are not in good
condition or are illegible. Remove the machine
from service until the manual is replaced.

Part No. 116478 AL8000HT Light Tower 3 - 7

Section 3 • Scheduled Maintenance Procedures

September 2008

CHECKLIST A PROCEDURES

A-2
Perform Pre-operation
Inspection

Note: Terex specifications require that this
procedure be performed every 8 hours or daily,
whichever comes first.

Completing a pre-operation inspection is essential
to safe machine operation. The pre-operation
inspection is a visual inspection performed by the
operator prior to each work shift. The inspection is
designed to discover if anything is apparently wrong
with a machine before the operator performs the
function tests. The pre-operation inspection also
serves to determine if routine maintenance
procedures are required.

Complete information on how to perform this
procedure is available in the appropriate Operator's
Manual. Refer to the Operator's Manual on your
machine.

REV A

A-3
Perform Function Tests

Note: Terex specifications require that this
procedure be performed every 8 hours or daily,
whichever comes first.

Completing the function tests is essential to safe
machine operation. Function tests are designed to
discover any malfunctions before the machine is
put into service. A malfunctioning machine must
never be used. If malfunctions are discovered, the
machine must be tagged and removed from
service.

Complete information on how to perform this
procedure is available in the appropriate Operator's
Manual. Refer to the Operator's Manual on your
machine.

3 - 8 AL8000HT Light Tower Part No. 116478

September 2008

Section 3 • Scheduled Maintenance Procedures

REV A

A-4
Perform Engine Maintenance ­Isuzu Models

Note: Engine specifications require that this
procedure be performed every 8 hours or daily,
whichever comes first.

Required maintenance procedures and additional
engine information is available in the

Isuzu 4LE1 Diesel Engine Instruction Manual

(Isuzu part number IDE-6033).

Isuzu 4LE1 Diesel Engine Instruction Manual

Terex part number 116133

CHECKLIST A PROCEDURES

A-5
Perform Generator Maintenance

Note: Generator specifications require that this
procedure be performed every 8 hours or daily,
whichever comes first.

Required maintenance procedures and additional
generator information is available in the

Leroy Somer LSA 37 Installation and
Maintenance Manual

3664EN-09.2005/B) OR the

Marathon Installation, Operation and Maintenance
Manual
Newage Installation, Service and Maintenance
Manual

Leroy Somer LSA 37 Installation and
Maintenance Manual

Terex part number 116118

(Marathon part number GPN012) OR the

(Newage part number BCH-018).

(Leroy Somer part number

Marathon Installation, Operation
and Maintenance Manual

Terex part number 116188

Newage Installation, Service and
Maintenance Manual

Terex part number 830001

Part No. 116478 AL8000HT Light Tower 3 - 9

Section 3 • Scheduled Maintenance Procedures

September 2008

CHECKLIST A PROCEDURES

A-6
Perform Axle Maintenance

Note: Axle specifications require that this procedure
be performed initially and following a wheel change
after the first 10, 25 and 50 miles.

Proper axle maintenance, following the axle
manufacturer's maintenance schedule, is essential
to good axle performance and service life. Failure
to perform the maintenance procedures can lead to
poor axle performance and component damage.

Required maintenance procedures and additional
axle information is available in the

Operator Maintenance Manual

machine.

Axis Axle Operator Maintenance Manual

Terex part number 116117

Axis Axle

included with your

REV A

A-7
Perform 30 Day Service

The 30 day maintenance procedure is a one time
procedure to be performed after the first 30 days or
40 hours of usage. After this interval, refer to the
maintenance tables for continued scheduled
maintenance.

1 Perform the following maintenance procedures:

· B-3 Inspect the Tires, Wheels and
Lug Nut Torque

3 - 10 AL8000HT Light Tower Part No. 116478

September 2008

Section 3 • Scheduled Maintenance Procedures

REV A

A-8
Perform Engine Maintenance

Note: Engine specifications require that this
procedure be performed every 50 hours.

Required maintenance procedures and additional
engine information is available in the

Isuzu 4LE1 Diesel Engine Instruction Manual

(Isuzu part number IDE-6033) OR the

Kubota D-1105 and V-1505 Operator's Manual

(Kubota part number 16683-89169).

Isuzu 4LE1 Diesel Engine Instruction Manual

Terex part number 116133

Kubota D-1105 and V-1505 Operator's Manual

Terex part number 893020

CHECKLIST A PROCEDURES

A-9
Perform Hitch Maintenance

Note: Hitch specifications require that this
procedure be performed weekly.

Required maintenance procedures and additional
hitch information is available in the

User Manual

Fulton Coupler User Manual

Terex part number 150139

(Fulton part number F1937).

Fulton Coupler

Part No. 116478 AL8000HT Light Tower 3 - 11

Section 3 • Scheduled Maintenance Procedures

September 2008

CHECKLIST A PROCEDURES

A-10
Grease the Turntable Rotation
Bearing and Rotate Gear

Note: Terex specifications require that this
procedure be performed every 100 hours of
operation. Perform this procedure more often if
dusty conditions exist.

Frequent application of lubrication to the turntable
rotation bearing and rotate gear is essential to good
machine performance and service life. Continued
use of an improperly greased bearing and gear will
result in component damage.

1 Lower all four outriggers to the ground and level

the machine.

2 Remove the tower transport lock pin.

REV A

8 Rotate the tower to transfer the grease from the

pinion gear to the teeth of the rotation bearing.

9 Repeat steps 5 and 6 until all gear teeth are

thoroughly greased.

10 Install the pinion gear guard and securely tighten

the retaining fasteners. Do not overtighten.

Grease Specification

Chevron Ultra-duty grease, EP NLGI 2 (lithium based)
or equivalent

3 Raise the tower to a vertical position.

4 Locate the grease fitting on the inner race of the

bearing.

5 Pump grease into the tower rotation bearing.

Rotate the tower in increments of
4 to 5 inches / 10 to 13 cm at a time and repeat
this step until the entire bearing has been
greased.

6 Remove retaining fasteners from the the pinion

gear guard. Remove the guard.

7 Apply grease to each tooth of the pinion gear.

3 - 12 AL8000HT Light Tower Part No. 116478

September 2008

Section 3 • Scheduled Maintenance Procedures

REV A

A-11
Perform Engine Maintenance ­Kubota Models

Note: Engine specifications require that this
procedure be performed every 100 hours.

Required maintenance procedures and additional
engine information is available in the

Kubota D-1105 and V-1505 Operator's Manual

(Kubota part number 16683-89169).

Kubota D-1105 and V-1505 Operator's Manual

Terex part number 893020

CHECKLIST A PROCEDURES

A-12
Perform Engine Maintenance ­Kubota Models

Note: Engine specifications require that this
procedure be performed every 200 hours.

Required maintenance procedures and additional
engine information is available in the

Kubota D-1105 and V-1505 Operator's Manual

(Kubota part number 16683-89169).

Kubota D-1105 and V-1505 Operator's Manual

Terex part number 893020

Part No. 116478 AL8000HT Light Tower 3 - 13

Section 3 • Scheduled Maintenance Procedures

September 2008

Checklist B Procedures

B-1
Inspect the Battery

Note: Terex requires that this procedure be
performed every 250 hours or quarterly, whichever
comes first.

Proper battery condition is essential to good
machine performance and operational safety.
Improper fluid levels or damaged cables and
connections can result in component damage and
hazardous conditions.

Electrocution hazard. Contact with
hot or live circuits could result in
death or serious injury. Remove all
rings, watches and other jewelry.

Bodily injury hazard. Batteries
contain acid. Avoid spilling or
contacting battery acid. Neutralize
battery acid spills with baking soda
and water.

1 Put on protective clothing and eye wear.

2 Open the cabinet cover at the curb side of the

machine and locate the battery.

3 Be sure that the battery cable connections are

free of corrosion.

Note: Adding terminal protectors and a corrosion
preventative sealant will help eliminate corrosion on
the battery terminals and cables.

4 Be sure that the battery retainers and cable

connections are tight.

B-2
Inspect the Electrical Wiring

Note: Terex requires that this procedure be
performed every 250 hours or quarterly, whichever
comes first.

Maintaining electrical wiring in good condition is
essential to safe operation and good machine
performance. Failure to find and replace burnt,
chafed, corroded or pinched wires could result in
unsafe operating conditions and may cause
component damage.

1 Inspect the following areas for burnt, chafed,

corroded and loose wires, and for a liberal
coating of dielectric grease in the harness
connections:

2 Inspect for a liberal coating of dielectric grease

in the harness connections between the
generator, ballasts and the mast light
assemblies.

3 Inspect the engine and generator area for burnt,

chafed, corroded, pinched and loose wires, and
and for a liberal coating of dielectric grease in
the harness connections.

REV A

Electrocution hazard. Contact with
hot or live circuits could result in
death or serious injury. Remove all
rings, watches and other jewelry.

· Mast

· Chassis

· Trailer lighting

3 - 14 AL8000HT Light Tower Part No. 116478

September 2008

Section 3 • Scheduled Maintenance Procedures

REV A

B-3
Inspect the Tires and Wheels
(including lug nut torque)

Note: Terex requires that this procedure be
performed every 250 hours or quarterly, whichever
comes first.

Maintaining the tires and wheels in good
condition is essential to safe operation and good
performance. Tire and/or wheel failure could result
in a machine tip-over. Component damage may
also result if problems are not discovered and
repaired in a timely fashion.

Bodily injury hazard. An over­inflated tire can explode and could
result in death or serious injury.

Tip-over hazard. Do not use
temporary flat tire repair products.

1 Check the tire tread and sidewalls for cuts,

cracks, punctures and unusual wear.

CHECKLIST B PROCEDURES

B-4
Perform Hydraulic Oil Analysis

Note: Terex requires that this procedure be
performed every 250 hours or quarterly, whichever
comes first.

Replacement or testing of the hydraulic oil is
essential for good machine performance and
service life. Dirty oil and suction strainers may
cause the machine to perform poorly and continued
use may cause component damage. Extremely
dirty conditions may require oil changes to be
performed more often.

Note: Before replacing the hydraulic oil, the oil may
be tested by an oil distributor for specific levels of
contamination to verify that changing the oil is
necessary. If the hydraulic oil is not replaced at

the two year inspection, test the oil quarterly.
Replace the oil when it fails the test. See E-1,

Test or Replace the Hydraulic Oil.

2 Check each wheel for damage, bends and

cracked welds.

3 Check each lug nut for proper torque. Refer to

Section 2,

4 Check the air pressure of each tire. Refer to

Section 2,

Part No. 116478 AL8000HT Light Tower 3 - 15

Specifications

Specifications

.

.

Section 3 • Scheduled Maintenance Procedures

September 2008

CHECKLIST B PROCEDURES

B-5
Perform Engine Maintenance ­Isuzu Models

Note: Engine specifications require that this
procedure be performed every 250 hours or
quarterly, whichever comes first.

Required maintenance procedures and additional
engine information is available in the

Isuzu 4LE1 Diesel Engine Instruction Manual

(Isuzu part number IDE-6033).

Isuzu 4LE1 Diesel Engine Instruction Manual

Terex part number 116133

REV A

B-6
Perform Generator Maintenance

Note: Generator specifications require that this
procedure be performed every 250 hours or
quarterly, whichever comes first.

Required maintenance procedures and additional
generator information is available in the

Leroy Somer LSA 37 Installation and
Maintenance Manual

3664EN-09.2005/B) OR the

Marathon Installation, Operation and Maintenance
Manual
Newage Installation, Service and Maintenance
Manual

Leroy Somer LSA 37 Installation and
Maintenance Manual

Terex part number 116118

(Marathon part number GPN012) OR the

(Newage part number BCH-018).

(Leroy Somer part number

Marathon Installation, Operation
and Maintenance Manual

Terex part number 116188

Newage Installation, Service and
Maintenance Manual

Terex part number 830001

3 - 16 AL8000HT Light Tower Part No. 116478

September 2008

Section 3 • Scheduled Maintenance Procedures

REV A

B-7
Perform Hitch Coupler
Maintenance

Note: Hitch specifications require that this
procedure be performed quarterly.

Required maintenance procedures and additional
hitch information is available in the

User Manual

Fulton Coupler User Manual

Terex part number 150139

(Fulton part number F1937).

Fulton Coupler

CHECKLIST B PROCEDURES

B-8
Perform Engine Maintenance ­Kubota Models

Note: Engine specifications require that this
procedure be performed every 400 hours.

Required maintenance procedures and additional
engine information is available in the

Kubota D-1105 and V-1505 Operator's Manual

(Kubota part number 16683-89169).

Kubota D-1105 and V-1505 Operator's Manual

Terex part number 893020

B-9
Perform Axle Maintenance

Note: Axle specifications require that this procedure
be performed quarterly or every 3000 miles,
whichever comes first.

Proper axle maintenance, following the axle
manufacturer's maintenance schedule, is essential
to good axle performance and service life. Failure
to perform the maintenance procedures can lead to
poor axle performance and component damage.

Required maintenance procedures and additional
axle information is available in the

Operator Maintenance Manual

machine.

Axis Axle Operator Maintenance Manual

Terex part number 116117

Axis Axle

included with your

Part No. 116478 AL8000HT Light Tower 3 - 17

Section 3 • Scheduled Maintenance Procedures

September 2008

REV A

This page intentionally left blank.

3 - 18 AL8000HT Light Tower Part No. 116478

September 2008

Section 3 • Scheduled Maintenance Procedures

REV A

Checklist C Procedures

C-1
Inspect the Tower Extend/
Retract Cables and Pulleys

Note: Terex requires that this procedure be
performed every 500 hours or semi-annually,
whichever comes first.

Detection of damage to the cables or pulleys is
essential for safe machine operation. An unsafe
working condition exists if these components are
damaged and do not operate smoothly. Regular
inspection of this system allows the inspector to
identify changes in the operating condition that may
indicate damage.

Note: Perform this procedure with the tower in the
stowed position.

1 Lower all four outriggers to the ground and level

the machine.

C-2
Perform Engine Maintenance

Note: Engine specifications require that this
procedure be performed every 500 hours or
semi-annually, whichever comes first.

Required maintenance procedures and additional
engine information is available in the

Isuzu 4LE1 Diesel Engine Instruction Manual

(Isuzu part number IDE-6033) OR the

Kubota D-1105 and V-1505 Operator's Manual

(Kubota part number 16683-89169).

Isuzu 4LE1 Diesel Engine Instruction Manual

Terex part number 116133

Kubota D-1105 and V-1505 Operator's Manual

Terex part number 893020

2 Remove the tower transport lock pin.

3 Fully extend the tower in a horizontal direction.

Tip-over hazard. The machine will
tip over when the tower is
extended if the outriggers are not
lowered to the ground.

4 Visually inspect the cables and components for

the following:

· frayed or broken wire strands

· kinks in the cable

· corrosion

· paint or foreign materials

· split or cracked cable ends

· cables are on all pulleys

· cables at end of adjustment range

· no broken or damaged pulleys

· no unusual or excessive pulley wear

· all fasteners in place and secure

Part No. 116478 AL8000HT Light Tower 3 - 19

Section 3 • Scheduled Maintenance Procedures

September 2008

CHECKLIST C PROCEDURES

C-3
Perform Axle Maintenance

Note: Axle specifications require that this procedure
be performed every 6 months or 6000 miles,
whichever comes first.

Proper axle maintenance, following the axle
manufacturer's maintenance schedule, is essential
to good axle performance and service life. Failure
to perform the maintenance procedures can lead to
poor axle performance and component damage.

Required maintenance procedures and additional
axle information is available in the

Operator Maintenance Manual

machine.

Axis Axle Operator Maintenance Manual

Terex part number 116117

Axis Axle

included with your

REV A

C-4
Perform Engine Maintenance ­Isuzu Models

Note: Engine specifications require that this
procedure be performed every 750 hours.

Required maintenance procedures and additional
engine information is available in the

Isuzu 4LE1 Diesel Engine Instruction Manual

(Isuzu part number IDE-6033).

Isuzu 4LE1 Diesel Engine Instruction Manual

Terex part number 116133

3 - 20 AL8000HT Light Tower Part No. 116478

September 2008

Section 3 • Scheduled Maintenance Procedures

REV A

C-5
Perform Engine Maintenance ­Kubota Models

Note: Engine specifications require that this
procedure be performed every 800 hours.

Required maintenance procedures and additional
engine information is available in the

Kubota D-1105 and V-1505 Operator's Manual

(Kubota part number 16683-89169).

Kubota D-1105 and V-1505 Operator's Manual

Terex part number 893020

CHECKLIST C PROCEDURES

Part No. 116478 AL8000HT Light Tower 3 - 21

Section 3 • Scheduled Maintenance Procedures

1

5

8

3

10

7

2

6

4

9

Tongue

September 2008

Checklist D Procedures

D-1
Perform Engine Maintenance ­Kubota Models

Note: Engine specifications require that this
procedure be performed annually.

Required maintenance procedures and additional
engine information is available in the

Kubota D-1105 and V-1505 Operator's Manual

(Kubota part number 16683-89169).

Kubota D-1105 and V-1505 Operator's Manual

Terex part number 893020

D-2
Check the Tower Rotation
Bearing Bolts

Note: Terex requires that this procedure be
performed every 1000 hours or annually, whichever
comes first.

Maintaining proper torque on the tower rotation
bearing bolts is essential to safe machine
operation. Improper bolt torque could result in an
unsafe operating condition and component damage.

1 Lower all four outriggers to the ground and level

the machine.

2 Remove the tower transport lock pin.

3 Raise the tower to a vertical position.

REV A

4 Check to be sure that each tower mounting bolt

is torqued in sequence to specification. Refer to
Section 2,

Specifications

Bolt torque sequence

.

3 - 22 AL8000HT Light Tower Part No. 116478

September 2008

Section 3 • Scheduled Maintenance Procedures

REV A

5 Check to be sure that each bearing mounting

bolt under the tower support is torqued in
sequence to specification. Refer to Section 2,

Specifications

.

Tongue

1

4

6

2

8

Bolt torque sequence

7

3

5

CHECKLIST D PROCEDURES

D-3
Replace the Hydraulic Return
Filter

Note: Terex requires that this procedure be
performed every 1000 hours or annually, whichever
comes first.

Replacement of the hydraulic return filter is
essential for good machine performance and
service life. A dirty or clogged filter may cause the
machine to perform poorly and continued use may
cause component damage. Extremely dirty
conditions may require that the filter be replaced
more often.

Bodily injury hazard. Beware of hot
oil. Contact with hot oil may cause
severe burns.

1 Open the road side cabinet cover and locate the

hydraulic return filter next to the power unit.

2 Place a suitable container under the hydraulic

filter.

3 Clean the area around the filter. Remove the

filter with an oil filter wrench.

4 Apply a thin layer of fresh oil to the gasket of

the new oil filter.

5 Install the new filter and tighten it securely by

hand. Clean up any oil that may have spilled.

6 Pull out the red Emergency Stop button (if

equipped) to the on position located on the back
panel of the light tower cabinet.

7 Activate any tower function and inspect the filter

and related components to be sure that there
are no leaks.

8 Use a permanent ink marker to write the date

and number of hours from the hour meter on the
oil filter.

Part No. 116478 AL8000HT Light Tower 3 - 23

Section 3 • Scheduled Maintenance Procedures

September 2008

CHECKLIST D PROCEDURES

D-4
Perform Engine Maintenance ­Isuzu Models

Note: Engine specifications require that this
procedure be performed every 1000 hours or
annually, whichever comes first.

Required maintenance procedures and additional
engine information is available in the

Isuzu 4LE1 Diesel Engine Instruction Manual

(Isuzu part number IDE-6033).

Isuzu 4LE1 Diesel Engine Instruction Manual

Terex part number 116133

REV A

D-5
Perform Engine Maintenance ­Isuzu Models

Note: Engine specifications require that this
procedure be performed every 1250 hours.

Required maintenance procedures and additional
engine information is available in the

Isuzu 4LE1 Diesel Engine Instruction Manual

(Isuzu part number IDE-6033).

Isuzu 4LE1 Diesel Engine Instruction Manual

Terex part number 116133

3 - 24 AL8000HT Light Tower Part No. 116478

September 2008

Section 3 • Scheduled Maintenance Procedures

REV A

D-6
Perform Engine Maintenance

Note: Engine specifications require that this
procedure be performed every 1500 hours.

Required maintenance procedures and additional
engine information is available in the

Isuzu 4LE1 Diesel Engine Instruction Manual

(Isuzu part number IDE-6033) OR the

Kubota D-1105 and V-1505 Operator's Manual

(Kubota part number 16683-89169).

Isuzu 4LE1 Diesel Engine Instruction Manual

Terex part number 116133

Kubota D-1105 and V-1505 Operator's Manual

Terex part number 893020

CHECKLIST D PROCEDURES

D-7
Perform Generator Maintenance

Note: Generator specifications require that this
procedure be performed every 1500 hours or
annually, whichever comes first.

Required maintenance procedures and additional
generator information is available in the

Leroy Somer LSA 37 Installation and
Maintenance Manual

3664EN-09.2005/B) OR the

Marathon Installation, Operation and Maintenance
Manual
Newage Installation, Service and Maintenance
Manual

Leroy Somer LSA 37 Installation and
Maintenance Manual

Terex part number 116118

(Marathon part number GPN012) OR the

(Newage part number BCH-018).

(Leroy Somer part number

Marathon Installation, Operation
and Maintenance Manual

Terex part number 116188

Newage Installation, Service and
Maintenance Manual

Terex part number 830001

Part No. 116478 AL8000HT Light Tower 3 - 25

Section 3 • Scheduled Maintenance Procedures

September 2008

CHECKLIST D PROCEDURES

D-8
Perform Tongue Jack and
Outrigger Jack Maintenance

Note: Tongue and outrigger jack specifications
require that this procedure be performed annually.

Required maintenance procedures and additional
hitch information is available in the

Cequent Tongue Jack Use Manual

(Cequent part number F3282ML).

Cequent Tongue Jack Use Manual

Terex part number 150140

REV A

D-9
Perform Axle Maintenance

Note: Axle specifications require that this procedure
be performed annually or every 12,000 miles, which
ever comes first.

Proper axle maintenance, following the axle
manufacturer's maintenance schedule, is essential
to good axle performance and service life. Failure
to perform the maintenance procedures can lead to
poor axle performance and component damage.

Required maintenance procedures and additional
axle information is available in the

Operator Maintenance Manual

machine.

Axis Axle Operator Maintenance Manual

Terex part number 116117

Axis Axle

included with your

3 - 26 AL8000HT Light Tower Part No. 116478

September 2008

Section 3 • Scheduled Maintenance Procedures

REV A

Checklist E Procedures

E-1
Test or Replace the Hydraulic Oil

Note: Terex requires that this procedure be
performed every 2000 hours or every two years,
whichever comes first.

Replacement or testing of the hydraulic oil is
essential for good machine performance and
service life. Dirty oil and suction strainers may
cause the machine to perform poorly and continued
use may cause component damage. Extremely
dirty conditions may require oil changes to be
performed more often.

Note: Before replacing the hydraulic oil, the oil may
be tested by an oil distributor for specific levels of
contamination to verify that changing the oil is
necessary. If the hydraulic oil is not replaced at

the two year inspection, test the oil quarterly.
Replace the oil when it fails the test.

Note: When removing a hose assembly or fitting,
the O-ring on the fitting and/or hose end must be
replaced and then torqued to specification during
installation. Refer to Section 2,

Fitting Torque Specifications.

1 Open both cabinet covers.

2 Tag and disconnect the battery cables from the

battery.

Electrocution hazard. Contact with
electrically charged circuits could
result in death or serious injury.
Remove all rings, watches and
other jewelry.

Hydraulic Hose and

3 Tag, disconnect and plug the hydraulic hoses

from the power unit. Cap the fittings.

Bodily injury hazard. Spraying
hydraulic oil can penetrate and
burn skin. Loosen hydraulic
connections very slowly to allow
the oil pressure to dissipate
gradually. Do not allow oil to squirt
or spray.

4 Tag and disconnect the electrical wiring and

cables from the power unit.

5 Support and secure the power unit to a suitable

lifting device.

6 Remove the fasteners securing the power unit to

the cabinet. Carefully remove the power unit
from the curb side of the machine.

Component damage hazard. The
hydraulic reservoir is plastic and
may become damaged if allowed
to fall when removed from the
machine.

7 Place a suitable container under the hydraulic

reservoir. Refer to Section 2,
capacity specifications.

8 Remove the hydraulic reservoir retaining

fasteners from the power unit. Carefully remove
the hydraulic reservoir from the power unit and
completely drain it into a suitable container.

Bodily injury hazard. Beware of hot
oil. Contact with hot oil may cause
severe burns.

Specifications

for

Part No. 116478 AL8000HT Light Tower 3 - 27

Section 3 • Scheduled Maintenance Procedures

September 2008

CHECKLIST E PROCEDURES

9 Remove the suction strainer and clean it using a

mild solvent.

10 Rinse out the inside of the reservoir using a mild

solvent.

11 Install the suction strainer.

12 Install the hydraulic reservoir onto the power

unit.

13 Install the hydraulic reservoir retaining fasteners

and securely tighten. Do not overtighten.

14 Install the hydraulic power unit onto the

machine.

15 Fill the reservoir with hydraulic oil to within a

1/2" from the top with the cylinders collapsed.

16 Clean up any oil that may have spilled. Properly

discard the used oil.

17 Operate all machine functions through a full

cycle and check for leaks.

REV A

E-2
Perform Engine Maintenance ­Kubota Models

Note: Engine specifications require that this
procedure be performed every 3000 hours.

Required maintenance procedures and additional
engine information is available in the

Kubota D-1105 and V-1505 Operator's Manual

(Kubota part number 16683-89169).

Kubota D-1105 and V-1505 Operator's Manual

Terex part number 893020

18 Operate all machine functions through 5-10 full

cycles to fully remove air from the system.

19 Make sure unit is in a clear area during steps 17

and 18 as air in the cylinders can cause sudden
movements of the tower.

3 - 28 AL8000HT Light Tower Part No. 116478

September 2008

Section 3 • Scheduled Maintenance Procedures

REV A

E-3
Perform Engine Maintenance ­Kubota Models

Note: Engine specifications require that this
procedure be performed every 2 years.

Required maintenance procedures and additional
engine information is available in the

Kubota D-1105 and V-1505 Operator's Manual

(Kubota part number 16683-89169).

Kubota D-1105 and V-1505 Operator's Manual

Terex part number 893020

CHECKLIST E PROCEDURES

E-4
Perform Generator Maintenance

Note: Generator specifications require that this
procedure be performed every 4500 hours or every
3 years, whichever comes first.

Required maintenance procedures and additional
generator information is available in the

Leroy Somer LSA 37 Installation and
Maintenance Manual

3664EN-09.2005/B) OR the

Marathon Installation, Operation and Maintenance
Manual
Newage Installation, Service and Maintenance
Manual

Leroy Somer LSA 37 Installation and
Maintenance Manual

Terex part number 116118

(Marathon part number GPN012) OR the

(Newage part number BCH-018).

(Leroy Somer part number

Marathon Installation, Operation
and Maintenance Manual

Terex part number 116188

Newage Installation, Service and
Maintenance Manual

Terex part number 830001

Part No. 116478 AL8000HT Light Tower 3 - 29

Section 3 • Scheduled Maintenance Procedures

September 2008

CHECKLIST E PROCEDURES

E-5
Perform Generator Maintenance

Note: Generator specifications require that this
procedure be performed every 15000 hours or every
19 years, whichever comes first.

Required maintenance procedures and additional
generator information is available in the

Leroy Somer LSA 37 Installation and
Maintenance Manual

3664EN-09.2005/B) OR the

Marathon Installation, Operation and Maintenance
Manual

(Marathon part number GPN012) OR the

Newage Installation, Service and Maintenance
Manual

Leroy Somer LSA 37 Installation and
Maintenance Manual

Terex part number 116118

(Newage part number BCH-018).

(Leroy Somer part number

REV A

Marathon Installation, Operation
and Maintenance Manual

Terex part number 116188

Newage Installation, Service and
Maintenance Manual

Terex part number 830001

3 - 30 AL8000HT Light Tower Part No. 116478

September 2008

Section 4 • Repair Procedures

Observe and Obey:

Repair procedures shall be completed by a

person trained and qualified on the repair of this
machine.

Immediately tag and remove from service a

damaged or malfunctioning machine.

Repair any machine damage or malfunction

before operating the machine.

Repair Procedures

About This Section

Most of the procedures in this section should only
be performed by a trained service professional
in a suitably equipped workshop. Select the
appropriate repair procedure after troubleshooting
the problem. Perform disassembly procedures to
the point where repairs can be completed. To
re-assemble, perform the disassembly steps in
reverse order.

Symbols Legend

Safety alert symbol—used to alert
personnel to potential personal
injury hazards. Obey all safety
messages that follow this symbol
to avoid possible injury or death.

Before Repairs Start:

Read, understand and obey the safety rules

and operating instructions in the appropriate
operator's manual on your machine.

Be sure that all necessary tools and parts are

available and ready for use.

Use only Terex approved replacement parts.

Read each procedure completely and adhere to

the instructions. Attempting shortcuts may
produce hazardous conditions.

Unless otherwise specified, perform each repair

procedure with the machine in the following
configuration:

· Machine parked on a firm, level surface

· Key switch in the off position
(manual start models)

· Toggle switch in the off position
(automatic start models)

· Mast in the stowed position

· Light switches in the off position

· Wheels chocked

Indicates an imminently hazardous
situation which, if not avoided, will
result in death or serious injury.

Indicates a potentially hazardous
situation which, if not avoided,
could result in death or serious
injury.

Indicates a potentially hazardous
situation which, if not avoided,
may cause minor or moderate
injury.

Indicates a potentially hazardous
situation which, if not avoided,
may result in property damage.

Indicates that a specific result is expected after

performing a series of steps.

Indicates that an incorrect result has occurred

after performing a series of steps.

Part No. 116478 AL8000HT Light Tower 4 - 1

Section 4 • Repair Procedures

September 2008

Lighting

1-1
Lighting

How to Remove a Lamp

High voltage. Exposure to
electrical wires or electrical current
will result in death or serious
injury. Remove all rings, watches
and other jewelry. Turn off all
power when not needed for
testing. Use extreme caution when
working with high voltage electrical
components.

Burn hazard. Contact with hot lamp
components may cause severe
burns. Use caution when working
around lamps.

1 Turn off all machine power.

2 Remove the light lens mounting fasteners and

remove the lens.

REV A

How to Check Line Voltage

Correct line voltage at the lamp socket is essential
for proper operation of the lighting system.

Electrocution hazard. Exposure to
high voltage electrical wires or
electrical current will result in death
or serious injury. Remove all rings,
watches and other jewelry. Turn off
all power when not needed for
testing. Use extreme caution when
working with high voltage electrical
components.

1 Turn off all machine power.

2 Remove the cover from the lamp junction box.

Note: The junction box is located between the light
housings at the top of the mast.

3 Locate the correct wiring for the lamp to be

tested.

4 Connect a voltmeter to the lamp wires.

3 Remove the spring securing the lamp to the

lamp retainer.

Component damage hazard.
Contacting the lamp with bare skin
can cause damage to the lamp.
Do not allow bare-skin contact
with the lamps.

4 Wrap a clean cloth around the lamp and

remove the lamp from the socket.

Note: Be sure to wrap a clean cloth around a lamp
when installing a lamp into a lamp socket.

5 Start the engine.

6 Turn the appropriate circuit breaker light switch

to the "ON" position.

7 Observe the voltage as the lamps warm up.

Refer to the following chart.

Note: It can take up to 5 minutes for the lights to
reach full intensity. If the lights are turned off and
then turned back on while they are still warm, they
may not light up again for 10 to 20 minutes.

4 - 2 AL8000HT Light Tower Part No. 116478

September 2008

Section 4 • Repair Procedures

REV A

Time Line Voltage

Initial ignition 415V AC

30 seconds 412V AC

1 minute 413V AC

2 minutes 416V AC

5 minutes 246V AC

10 minutes 251V AC

Note: If the voltage reading remains high during
warm up, check for loose or broken wire
connections OR the lamp may be faulty.

Note: The voltage readings provided in the chart are
averages; voltage on your machine may vary.

LIGHTING

How to Check the Open Circuit
Voltage

Correct line voltage at the lamp socket is essential
for proper operation of the lighting system.

Electrocution hazard. Exposure to
high voltage electrical wires or
electrical current will result in death
or serious injury. Remove all rings,
watches and other jewelry. Turn off
all power when not needed for
testing. Use extreme caution when
working with high voltage electrical
components.

1 Turn off all machine power.

2 Locate the electrical cable of the lamp to be

tested. Disconnect the cable from the junction
box attached to the light bar.

3 Set a voltmeter to read 0 to 750V AC. Insert the

leads of the voltmeter into pins A and B of the
electrical connector socket at the junction box.

c

b

a

4 Start the engine.

5 Turn the appropriate circuit breaker light switch

to the "ON" position and observe the reading on
the voltmeter. Refer to the following chart.

Open Circuit Voltage 375V AC to 465V AC
Specification

Note: If there is no reading on the meter. Repair or
replace the capacitor, ballast or wiring.

Part No. 116478 AL8000HT Light Tower 4 - 3

Section 4 • Repair Procedures

September 2008

Light Bar Components

2-1
Light Bar

How to Remove the Light Bar
Assembly

Note: Perform this procedure with the tower in the
stowed position.

Note: When removing a hose assembly or fitting,
the O-ring on the fitting and/or hose end must be
replaced and then torqued to specification during
installation. Refer to Section 2,

Fitting Torque Specifications.

1 Tag, disconnect and plug the light bar cylinder

hydraulic hoses. Cap the fittings on the cylinder.

Bodily injury hazard. Spraying
hydraulic oil can penetrate and
burn skin. Loosen hydraulic
connections very slowly to allow
the oil pressure to dissipate
gradually. Do not allow oil to squirt
or spray.

Hydraulic Hose and

6 Remove the pin retaining fasteners from light bar

7 Remove the pin retaining fasteners from the light

REV A

lift cylinder barrel-end pivot pin "D". Place a rod
through the pin and twist to remove the pin.

bar pivot pin "B" and the light bar lever pivot
pin"A". Place a rod through the pins and twist to
remove the pins.

2 Tag and disconnect the lamp electrical cables

from each junction box. Do not disconnect the
main power cables from the junction boxes

3 Remove the fasteners securing each junction

box to the light bar.

4 Remove the hose and cable clamp retaining

fasteners from the light bar and remove the
clamp. Lay the hydraulic hoses and main power
cables, with junction boxes attached, over the
back of the cabinet.

5 Attach a lifting strap from an overhead crane to

the light bar assembly. Support the light bar. Do
not apply any lifting pressure.

a light bar lever pivot pin
b light bar pivot pin
c light bar connecting link pivot pin
d cylinder barrel-end pivot pin

8 Carefully remove the light bar assembly from the

machine.

Crushing hazard. The light bar
assembly could become
unbalanced and fall when removed
from the machine if not properly
supported by the overhead crane.

Note: During removal, the overhead crane strap will
need to be carefully adjusted for proper balancing.

4 - 4 AL8000HT Light Tower Part No. 116478

September 2008

Section 4 • Repair Procedures

REV A

2-2
Light Bar Lift Cylinder

How to Remove the Light Bar
Lift Cylinder

The light bar lift cylinder raises and lowers the light
bar assembly. The light bar lift cylinder is equipped
with counterbalance valves to prevent movement in
the event of a hydraulic line failure.

Note: Perform this procedure with the tower in the
stowed position.

Note: When removing a hose assembly or fitting,
the O-ring on the fitting and/or hose end must be
replaced and then torqued to specification during
installation. Refer to Section 2,

Fitting Torque Specifications.

1 Tag, disconnect and plug the light bar cylinder

hydraulic hoses. Cap the fittings on the cylinder.

Hydraulic Hose and

LIGHT BAR COMPONENTS

Bodily injury hazard. Spraying
hydraulic oil can penetrate and
burn skin. Loosen hydraulic
connections very slowly to allow
the oil pressure to dissipate
gradually. Do not allow oil to squirt
or spray.

2 Support the cylinder with a suitable device to

prevent it from falling.

3 Remove the pin retaining fasteners from both

the rod end and barrel-end pivot pins.

4 Place a rod through the pins and twist to

remove. Remove the cylinder from the machine.

Part No. 116478 AL8000HT Light Tower 4 - 5

Section 4 • Repair Procedures

September 2008

Tower Components

REV A

a tower extension cylinder
b light bar
c light bar cylinder
d light bar lever
e light bar link
f tower tube number 3
g tower tube number 2
h tower tube number 1
i tower lift cylinder
j tower rotation riser

4 - 6 AL8000HT Light Tower Part No. 116478

September 2008

Section 4 • Repair Procedures

REV A

3-1
Plastic Cable Track

How to Remove the Cable Track

The tower cable track guides the cables and hoses
running up the tower. It can be repaired link by link
without removing the cables and hoses that run
through it. Removing the entire tower cable track is
only necessary when performing major repairs that
involve removing the tower.

How to Repair the Plastic Cable
Track

Component damage hazard. The
tower cable track can be damaged
if it is twisted.

TOWER COMPONENTS

3-2
Tower Assembly

How to Remove the Tower
Assembly

Bodily injury hazard. The
procedures in this section require
specific repair skills, lifting
equipment and a suitable
workshop. Attempting this
procedure without these skills and
tools could result in death or
serious injury and significant
component damage. Dealer
service is required.

Note: When removing a hose assembly or fitting,
the O-ring on the fitting and/or hose end must be
replaced and then torqued to specification during
installation. Refer to Section 2,

Fitting Torque Specifications.

Hydraulic Hose and

a link separation point
b lower clip

1 Use a slotted screwdriver to pry down on the

lower clip.

2 Repeat step 1 for each link.

3 To remove a single link, open the lower clip

and then use a screw driver to pry the link to the
side.

1 Remove the light bar. See 2-1,

a

b

the Light Bar Assembly.

2 Remove the cable track tube retaining fasteners

at the number 3 tower tube.

3 Remove the hose and cable clamp fasteners

and clamps from the underside of the cable
track on the side of tower tube number 1.

4 Place blocks between the cable track tube and

the lower cable track. Secure the cable track
together.

How to Remove

Part No. 116478 AL8000HT Light Tower 4 - 7

Section 4 • Repair Procedures

September 2008

TOWER COMPONENTS

5 Attach a suitable lifting device to the cable

track. Carefully remove the cable track from the
tower and rest it on top of the cabinet.

Component damage hazard.
Cables and hoses can become
damaged if they are kinked or
pinched.

6 Place a block under the tower lift cylinder for

support.

7 Remove the pin retaining fasteners from the

tower lift cylinder rod-end pivot pin.

8 Use a soft metal drift to remove the pin. Rest

the tower lift cylinder on the block.

9 Tag, disconnect and plug the tower extension

cylinder hydraulic hoses. Cap the fittings on the
cylinder.

Bodily injury hazard. Spraying
hydraulic oil can penetrate and
burn skin. Loosen hydraulic
connections very slowly to allow
the oil pressure to dissipate
gradually. Do not allow oil to squirt
or spray.

10 Position the forks from a forklift into the forklift

pockets located under the tower. Secure the
tower to the forks.

11 Remove the transport lock pin from the tower

near the tower rest pad.

12 Remove the pin retaining fasteners from the

tower pivot pin at the tower rotation riser.

REV A

How to Disassemble the Tower

Note: When removing a hose assembly or fitting,
the O-ring on the fitting and/or hose end must be
replaced and then torqued to specification during
installation. Refer to Section 2,

Fitting Torque Specifications.

1 Remove the tower assembly. See 3-2,

Remove the Tower Assembly

2 Tag, disconnect and plug the light bar lift

cylinder hydraulic hoses. Cap the fittings on the
cylinder.

Bodily injury hazard. Spraying
hydraulic oil can penetrate and
burn skin. Loosen hydraulic
connections very slowly to allow
the oil pressure to dissipate
gradually. Do not allow oil to squirt
or spray.

3 Attach a suitable lifting device to the light bar

cylinder.

4 Remove the pin retaining fasteners from the light

bar link pivot pin. Use a soft metal drift to
remove the pin. Remove the cylinder from the
tower assembly with links and levers attached.

Note: There is a spacer tube between the two links
that may fall out when the pivot pin is removed.

5 Remove the cable retaining nut from the extend

cable at the extension end of the tower, located
near the extend cylinder rod-end pivot pin. Pull
the cable end out of the pivot pin.

Hydraulic Hose and

How to

.

13 Use a soft metal drift to remove the tower pivot

pin. Carefully remove the tower assembly from
the machine and place it on a structure capable
of supporting it.

Crushing hazard. The tower
assembly could become
unbalanced and fall when removed
from the machine if not properly
supported and secured to the
forklift.

4 - 8 AL8000HT Light Tower Part No. 116478

September 2008

Section 4 • Repair Procedures

REV A

6 Remove the external snap rings from both the

tower extension cylinder rod-end pivot pin and
the extend cable pivot pin. Use a soft metal drift
to remove the pins.

7 Attach a lifting strap from an overhead crane to

the tower extension cylinder.

8 Remove the external snap rings from the tower

extension cylinder barrel-end pivot pin. Use a
soft metal drift to remove the pin. Carefully
remove the cylinder from the machine.

Crushing hazard. The tower
extension cylinder could become
unbalanced and fall when removed
from the machine if not properly
supported by the overhead crane.

9 Remove the cable retaining nut from the retract

cable, located on the bottom of tower tube
number 1, at the extension end of the tower.

10 Label and remove the wear pads from the

extension end of the number 1 tower tube.

11 Attach a lifting strap from an overhead crane to

the number 2 and 3 tower tubes.

TOWER COMPONENTS

12 Support and slide the number 2 and 3 tower

tubes out of the number 1 tower tube and place
them on a structure capable of supporting them.

Crushing hazard. The number 2
and 3 tower tubes could become
unbalanced and fall when removed
from the number 1 tube if not
properly supported by the overhead
crane.

Bodily injury hazard. Cables can
fray. Always wear adequate hand
protection when handling the cable.

Component damage hazard.
Cables can be damaged if they are
kinked or pinched.

Note: During removal, the overhead crane strap will
need to be carefully adjusted for proper balancing.

Note: As the number 2 and 3 tower tubes are
removed from the number 1 tower tube, guide the
retract cable out from the slot in the bottom of the
number 1 tower tube.

13 Working at the extension end of the number 2

tower tube, remove the cotter pins from the two
clevis pins that surround the cable pulley.
Remove the clevis pins. Do not remove the
pulley clevis pin.

Note: Always use a new cotter pin when installing a
clevis pin.

Part No. 116478 AL8000HT Light Tower 4 - 9

Section 4 • Repair Procedures

September 2008

TOWER COMPONENTS

14 Pull the extend cable free of the pulley mount

and lay it flat on top of the number 3 tower tube.

Bodily injury hazard. Cables can
fray. Always wear adequate hand
protection when handling the cable.

15 Label and remove the wear pads from the

extension end of the number 2 tower tube.

16 Attach a lifting strap from an overhead crane to

the number 3 tower tube.

17 Support and slide the number 3 tower tube from

the number 2 tower tube and place it on a
structure capable of supporting it.

Crushing hazard. The number 2
and 3 tower tubes could become
unbalanced and fall when removed
from the number 1 tube if not
properly supported by the overhead
crane.

Bodily injury hazard. Cables can
fray. Always wear adequate hand
protection when handling the cable.

Component damage hazard.
Cables can be damaged if they are
kinked or pinched.

Note: During removal, the overhead crane strap will
need to be carefully adjusted for proper balancing.

REV A

3-3
Tower Lift Cylinder

How to Remove the Tower Lift
Cylinder

The tower lift cylinder raises and lowers the tower
assembly. The tower lift cylinder is equipped with
counterbalance valves to prevent movement in the
event of a hydraulic line failure.

Note: When removing a hose assembly or fitting,
the O-ring on the fitting and/or hose end must be
replaced and then torqued to specification during
installation. Refer to Section 2,

Fitting Torque Specifications.

1 Tag, disconnect and plug the tower lift cylinder

hydraulic hoses. Cap the fittings on the cylinder.

Bodily injury hazard. Spraying
hydraulic oil can penetrate and
burn skin. Loosen hydraulic
connections very slowly to allow
the oil pressure to dissipate
gradually. Do not allow oil to squirt
or spray.

2 Support both ends of the cylinder with a suitable

device to prevent it from falling.

3 Remove the pin retaining fasteners from both

the rod end and barrel-end pivot pins.

Hydraulic Hose and

4 Place a rod through the pins and twist to

remove. Guide the cylinder out the pivot end of
the tower and carefully remove the cylinder from
the machine.

Component damage hazard.
Cables and hoses can be damaged
if the cylinder is dragged across
them.

4 - 10 AL8000HT Light Tower Part No. 116478

September 2008

Section 4 • Repair Procedures

REV A

3-4
Tower Extension Cylinder

How to Remove the Tower
Extension Cylinder

The tower extension cylinder extends and retracts
the tower assembly. The cylinder is used to extend
and retract the number 2 tower tube while cables
are used to extend and retract the number 3 tower
tube. The tower extension cylinder is equipped with
counterbalance valves to prevent movement in the
event of a hydraulic line failure.

Note: When removing a hose assembly or fitting,
the O-ring on the fitting and/or hose end must be
replaced and then torqued to specification during
installation. Refer to Section 2,

Fitting Torque Specifications.

1 Tag, disconnect and plug the tower extension

cylinder hydraulic hoses. Cap the fittings on the
cylinder.

Hydraulic Hose and

TOWER COMPONENTS

3 Remove the external snap rings from the tower

extension cylinder rod-end pivot pin. Use a soft
metal drift to remove the pin.

4 Remove the external snap rings from the tower

extension cylinder barrel-end pivot pin. Use a
soft metal drift to remove the pin.

5 Slide the extension cylinder towards the tongue

end of the machine slightly and carefully
remove the cylinder from the machine.

Crushing hazard. The tower
extension cylinder could become
unbalanced and fall when removed
from the machine if not properly
supported by the overhead crane.

Bodily injury hazard. Spraying
hydraulic oil can penetrate and
burn skin. Loosen hydraulic
connections very slowly to allow
the oil pressure to dissipate
gradually. Do not allow oil to squirt
or spray.

2 Attach a lifting strap from an overhead crane to

the tower extension cylinder.

Part No. 116478 AL8000HT Light Tower 4 - 11

Section 4 • Repair Procedures

September 2008

TOWER COMPONENTS

3-5
Tower Rotation Motor

How to Remove the Tower
Rotation Motor

Note: When removing a hose assembly or fitting,
the O-ring on the fitting and/or hose end must be
replaced and then torqued to specification during
installation. Refer to Section 2,

Fitting Torque Specifications.

Note: Perform this procedure with the tower in the
stowed position and the transport lock pin installed.

1 Tag, disconnect and plug the tower rotation

motor hydraulic hoses. Cap the fittings on the
motor.

Bodily injury hazard. Spraying
hydraulic oil can penetrate and
burn skin. Loosen hydraulic
connections very slowly to allow
the oil pressure to dissipate
gradually. Do not allow oil to squirt
or spray.

2 Remove the rotation motor pinion gear guard

fasteners. Remove the guard.

3 Remove the rotation motor mounting fasteners.

Remove the motor from the machine.

Note: When installing a rotation motor, the gear
backlash will need to be adjusted. See

Adjust the Tower Rotation Gear Backlash.

Hydraulic Hose and

How to

REV A

How to Adjust the Tower
Rotation Gear Backlash

The rotation motor mounting fasteners are located
in slotted holes to allow the adjustment of gear
backlash between the motor pinion gear and the
rotation bearing ring gear. Proper backlash
adjustment is critical to safe machine operation and
component service life. An improper backlash
adjustment could decrease component service life
and may result in component damage.

Note: Perform this procedure with the tower in the
stowed position and the transport lock pin installed.

1 Loosen the tower rotation motor mounting

fasteners. Do not remove them.

2 Push the rotation motor towards the rotation

bearing as far as possible (this will push the
pinion gear into the rotation bearing ring gear).

3 Loosen the lock nut on the adjustment bolt.

4 Adjust the lock nuts until there is approximately

1

/16 inch / 1.5 mm gap between the end of the
bolt and the rotation motor case. Tighten the
lock nuts of the adjustment bolt.

5 Rotate the rotation motor away from the bearing

until it contacts the adjustment bolt. Torque the
rotation motor fasteners to specification. Refer
to Section 2,

6 Rotate the tower through full range of motion.

Check for tight spots and binding. Readjust if
necessary.

Specifications.

4 - 12 AL8000HT Light Tower Part No. 116478

September 2008

Section 4 • Repair Procedures

REV A

Kubota D1105-E / V1505-E Engine

4-1
Timing Adjustment

Complete information to perform this procedure is
available in the
(Kubota part number: 97897-02432).

Kubota 05 Series Workshop Manual

Terex part number 31742

Kubota 05 Series Workshop Manual

4-2
Glow Plugs

How to Check the Glow Plugs

1 Disconnect the wiring and buss bar from the

glow plugs.

4-3
Coolant Temperature and
Oil Pressure Switches

The engine coolant temperature switch is a
normally open switch. The switch contacts close at
approximately 225°F / 107°C. If the coolant
temperature rises above the switch point, the
switch contacts close and the engine will shut off
to prevent damage. The engine will not start until
the temperature drops below the switch point.
Additionally a low collant level can cause the
coolant temperature switch to not work properly.
Make sure that the coolant system is at the proper
level.

The engine oil pressure switch is a normally closed
switch. The switch contacts open at approximately
7 psi / 0.48 bar. If the oil pressure drops below the
switch point, the contacts open and the engine will
shut off to prevent damage.

2 Connect the leads from an ohmmeter between

each glow plug terminal and ground.

Result: The resistance should be approximately

1Ω.

Result: The resistance is 0Ω or greater than

1Ω. The glow plug is faulty.

Part No. 116478 AL8000HT Light Tower 4 - 13

Section 4 • Repair Procedures

September 2008

Isuzu 4LE1 Engine

5-1
Timing Adjustment

Complete information to perform this procedure is
available in the
(Isuzu part number: IDE-2270).

Isuzu 4LE1 Workshop Manual

Terex part number 116166

5-2
Glow Plugs

How to Check the Glow Plugs

1 Disconnect the wiring and buss bar from the

glow plugs.

Isuzu 4LE1 Workshop Manual

REV A

5-3
Coolant Temperature and
Oil Pressure Switches

The engine coolant temperature switch is a
normally open switch. The switch contacts close at
approximately 221°F / 105°C. If the coolant
temperature rises above the switch point, the
switch contacts close and the engine will shut off
to prevent damage. The engine will not start until
the temperature drops below the switch point.
Additionally a low collant level can cause the
coolant temperature switch to not work properly.
Make sure that the coolant system is at the proper
level.

The engine oil pressure switch is a normally closed
switch. The switch contacts open at approximately
14 psi / 0.96 bar. If the oil pressure drops below the
switch point, the contacts open and the engine will
shut off to prevent damage.

2 Connect the leads from an ohmmeter between

each glow plug terminal and ground.

Result: The resistance should be approximately

1Ω.

Result: The resistance is 0Ω or greater than

1Ω. The glow plug is faulty.

4 - 14 AL8000HT Light Tower Part No. 116478

September 2008

Section 4 • Repair Procedures

REV A

6-1
Generator

How to Remove the Generator
Capacitor Cover - Leroy Somer
Models

Electrocution hazard. Exposure to
high voltage electrical wires or
electrical current will result in death
or serious injury. Remove all rings,
watches and other jewelry. Turn off
all power when not needed for
testing. Use extreme caution when
working with high voltage electrical
components.

Note: Be sure the engine has been turned off for at
least 15 minutes before servicing the machine. Use
a voltmeter to confirm there is no residual voltage
in the capacitors.

1 Loosen but do not remove the fasteners

securing the capacitor cover to the top of the
generator.

Burn hazard. Contact with hot
engine components may cause
severe burns. Use caution when
working around a hot engine.

2 Pull the cover off the top of the generator to

access the wire harness where it connects to
the generator.

3 Tag and disconnect the wires at the top of the

generator. Remove the cover.

Generator

How to Check a Generator
Capacitor - Leroy Somer Models

Electrocution hazard. Exposure to
high voltage electrical wires or
electrical current will result in death
or serious injury. Remove all rings,
watches and other jewelry. Turn off
all power when not needed for
testing. Use extreme caution when
working with high voltage electrical
components.

Electrocution hazard. Attempting
to service the machine before the
capacitors are fully discharged will
result in death or serious injury.

Note: Be sure the engine has been turned off for at
least 15 minutes before servicing the machine. Use
a voltmeter to confirm there is no residual voltage
in the capacitors.

1 Remove the generator capacitor cover.

See 6-1,

Capacitor Cover

2 Tag and disconnect the wires attached to the

capacitor(s).

3 Using an insulated conductor or a screwdriver

with an insulated handle, discharge the
capacitor by shorting across the capacitor
terminals. Repeat for the second capacitor, if
equipped.

How to Remove the Generator

.

Electrocution hazard. Exposure to
high voltage electrical wires or
electrical current will result in death
or serious injury. Remove all rings,
watches and other jewelry. Use
extreme caution when working with
high voltage electrical
components.

4 With an ohmmeter set to its highest resistance

scale, connect the ohmmeter leads to the
capacitor terminals and observe the reading on
the meter. Then, reverse the connections and
observe the reading on the meter.

Part No. 116478 AL8000HT Light Tower 4 - 15

Section 4 • Repair Procedures

September 2008

GENERATOR

Result: The meter indicates a very low

resistance which then gradually increases AND
a very high resistance which then gradually
decreases. The capacitor is working.

Result: The meter indicates a very high

resistance which does not decrease. The
capacitor is faulty and should be replaced.

Result: The meter indicates a very low

resistance which does not increase. The
capacitor is faulty and should be replaced.

Probable causes of capacitor failure:

· Starting engine with circuit breakers on.

· Shutting off engine with circuit breakers on.

· Normal end-of-life failure.

· Overheated due to light fixture heat or high
ambient temperature.

· Incorrect capacitor voltage rating.

REV A

3 Open each cabinet door. Remove the hinge

retaining fasteners from the cabinet top for each
cabinet door.

4 Disconnect the gas struts from each cabinet

door. Remove each door from the machine.

5 Locate the domelight mounted to the cabinet top

above the engine. Remove the lens from the
domelight. Remove the domelight mounting
fasteners and set the domelight aside.

6 Locate the wiring for the limit switch located at

the transport lock pin. Tag and disconnect the
limit switch wiring from inside the engine
compartment.

7 Remove the limit switch mounting fasteners and

set the switch aside.

8 Remove the tower rest pad weldment fasteners.

Remove the rest pad from the cabinet.

9 Support the cabinet top with a suitable lifting

device.

How to Remove the Generator ­Marathon Generator Models

Electrocution hazard. Exposure to
high voltage electrical wires or
electrical current will result in death
or serious injury. Remove all rings,
watches and other jewelry. Turn off
all power when not needed for
testing. Use extreme caution when
working with high voltage electrical
components.

Note: Be sure the engine has been turned off for at
least 15 minutes before servicing the machine. Use
a voltmeter to confirm there is no residual voltage
in the capacitors.

1 Extend all four outriggers. Lower each outrigger

until they make contact with the ground.

2 Raise the tower to a vertical position. Do not

extend the tower or raise the light bar. Turn the
machine off.

10 Remove all fasteners securing the cabinet top to

the cabinet end panels. Carefully remove the
cabinet top from the machine.

Crushing hazard. The cabinet top
may become unbalanced and fall if
not properly supported when
removed from the machine.

Models with Marathon generators:

11 Disconnect the battery from the machine.

Electrocution hazard. Contact with
hot or live circuits could result in
death or serious injury. Remove all
rings, watches and other jewelry.

12 Remove the fasteners securing the terminal box

cover to the top of the generator. Remove the
cover.

Burn hazard. Contact with hot
engine components may cause
severe burns. Use caution when
working around a hot engine.

4 - 16 AL8000HT Light Tower Part No. 116478

September 2008

Section 4 • Repair Procedures

REV A

13 Tag and disconnect the black, white, and green

wires, that enter the terminal box, from the
generator.

Electrocution hazard. Exposure to
high voltage electrical wires or
electrical current will result in death
or serious injury. Remove all rings,
watches and other jewelry. Use
extreme caution when working with
high voltage electrical
components.

14 Loosen the wiring clamp located on the back of

the capacitor compartment of the generator. Pull
the wiring out of the terminal box through the
wiring clamp.

15 Use a lifting jack or similar device to support the

rear of the engine. Do not apply any lifting
pressure.

16 Remove the generator fan screens from both

sides of the generator.

17 Remove the fasteners securing the generator to

the engine flywheel.

18 Remove the fasteners securing the generator to

the chassis.

19 Attach a lifting strap from an overhead crane or

other suitable device to both lifting eyes on the
generator. Support the generator. Do not apply
any lifting pressure.

20 Remove the fasteners securing the generator to

the engine bellhousing.

21 Remove the generator from the machine.

Crushing hazard. The generator
may become unbalanced and fall if
not properly supported when
removed from the machine.

GENERATOR

How to Remove the Generator ­Newage Generator Models

Electrocution hazard. Exposure to
high voltage electrical wires or
electrical current will result in death
or serious injury. Remove all rings,
watches and other jewelry. Turn off
all power when not needed for
testing. Use extreme caution when
working with high voltage electrical
components.

Note: Be sure the engine has been turned off for at
least 15 minutes before servicing the machine. Use
a voltmeter to confirm there is no residual voltage
in the capacitors.

1 Extend all four outriggers. Lower each outrigger

until they make contact with the ground.

2 Raise the tower to a vertical position. Do not

extend the tower or raise the light bar. Turn the
machine off.

3 Open each cabinet door. Remove the hinge

retaining fasteners from the cabinet top for each
cabinet door.

4 Disconnect the gas struts from each cabinet

door. Remove each door from the machine.

5 Locate the domelight mounted to the cabinet top

above the engine. Remove the lens from the
domelight. Remove the domelight mounting
fasteners and set the domelight aside.

6 Locate the wiring for the limit switch located at

the transport lock pin. Tag and disconnect the
limit switch wiring from inside the engine
compartment.

7 Remove the limit switch mounting fasteners and

set the switch aside.

8 Remove the tower rest pad weldment fasteners.

Remove the rest pad from the cabinet.

9 Support the cabinet top with a suitable lifting

device.

Part No. 116478 AL8000HT Light Tower 4 - 17

Section 4 • Repair Procedures

September 2008

GENERATOR

10 Remove all fasteners securing the cabinet top to

the cabinet end panels. Carefully remove the
cabinet top from the machine.

Crushing hazard. The cabinet top
may become unbalanced and fall if
not properly supported when
removed from the machine.

Models with Newage generators:

11 Disconnect the battery from the machine.

Electrocution hazard. Contact with
hot or live circuits could result in
death or serious injury. Remove all
rings, watches and other jewelry.

12 Remove the fasteners securing the terminal box

cover to the top of the generator. Remove the
cover.

Burn hazard. Contact with hot
engine components may cause
severe burns. Use caution when
working around a hot engine.

13 Tag and disconnect the black, white, and green

wires, that enter the terminal box, from the
generator.

Electrocution hazard. Exposure to
high voltage electrical wires or
electrical current will result in death
or serious injury. Remove all rings,
watches and other jewelry. Use
extreme caution when working with
high voltage electrical
components.

14 Loosen the wiring clamp located on the back of

the capacitor compartment of the generator. Pull
the wiring out of the terminal box through the
wiring clamp.

15 Use a lifting jack or similar device to support the

rear of the engine. Do not apply any lifting
pressure.

REV A

16 Remove the generator fan screens from both

sides of the generator.

Note: The generator fan screens cover the
generator fan blades and are located between the
generator and the engine bellhousing.

17 Remove the fasteners securing the generator to

the engine flywheel.

18 Remove the fasteners securing the generator to

the chassis.

19 Attach a lifting strap from an overhead crane or

other suitable device to both lifting eyes on the
generator. Support the generator. Do not apply
any lifting pressure.

20 Remove the fasteners securing the generator to

the engine bellhousing.

21 Remove the generator from the machine.

Crushing hazard. The generator
may become unbalanced and fall if
not properly supported when
removed from the machine.

Models with Leroy Somer generators:

11 Pull the cover off the top of the generator to

access the wire harness where it connects to
the generator.

12 Using an insulated conductor or a screwdriver

with an insulated handle, discharge the
capacitor by shorting across the capacitor
terminals. Repeat for the second capacitor, if
equipped.

Electrocution hazard. Exposure to
high voltage electrical wires or
electrical current will result in death
or serious injury. Remove all rings,
watches and other jewelry. Use
extreme caution when working with
high voltage electrical
components.

13 Tag and disconnect the wires at the top of the

generator. Remove the cover.

4 - 18 AL8000HT Light Tower Part No. 116478

September 2008

Section 4 • Repair Procedures

REV A

14 Tag and disconnect the ground wire from the

generator mount.

15 Use a lifting jack or similar device to support the

rear of the engine. Do not apply any lifting
pressure.

16 Remove the generator fan screen from the

generator.

Note: The generator fan screen covers the
generator fan blades and is located between the
generator and the engine bellhousing.

17 Remove the fasteners securing the generator to

the engine flywheel.

18 Remove the fasteners securing the generator to

the chassis.

19 Attach a lifting strap from an overhead crane to

the generator. Support the generator. Do not
apply any lifting pressure.

20 Remove the fasteners securing the generator to

the engine bellhousing.

21 Remove the generator from the machine.

Crushing hazard. The generator will
fall if not properly supported when
removed from the machine.

Chassis Components

3 Using the tip of a pencil or pen, press the Reset

button (R). A blinking display will show 0:00 for
the time and an arrow under the day 7 (for
Sunday).

4 Move the set switch to the left (clock icon) to

set the present day and time.

5 A default time of AM 12:00 will appear on the

display screen.

6 Press the day button (1..7) repeatedly until the

arrow points to the actual day of the week.

7 Press the hour button (h) repeatedly until the

actual hour of the day is displayed.

8 Press the minute button (m) repeatedly until the

minute of the present hour is displayed.

9 Move the Set switch to the program position (P)

to set the desired stop and start time. A default
time of AM 12:00 will appear. A small 1 will
appear to the right of the time with a lamp
symbol above it.

10 Use the day, hour and minute buttons to set the

timer to the desired start day and time.

11 Press the program button (P) to set the timer for

the desired shut-off time. AM 12:00 will appear
in the display with a small 2 to the right.

7-1

Note: The lamp symbol will not appear above the 2.

Ground Controls

How to Program the Engine

12 Use the day, hour and minute buttons to set the

timer to the desired shut-off day and time.

13 Move the set switch to RUN.

Start Timer (machines with
auto start option)

The timer is used to automatically start the engine
and turn on the lights at a preset time.

1 Move the engine start switch to timed start.

2 On the timer, move the mode switch (upper left

switch) to AUTO and the set switch (upper right
switch) to RUN.

Part No. 116478 AL8000HT Light Tower 4 - 19

Section 4 • Repair Procedures

September 2008

CHASSIS COMPONENTS

7-2
Light Ballast

How to Check a
Ballast Capacitor

Electrocution hazard. Exposure to
high voltage electrical wires or
electrical current will result in death
or serious injury. Remove all rings,
watches and other jewelry. Use
extreme caution when working with
high voltage electrical
components.

Electrocution hazard. Attempting
to service the machine before the
capacitors are fully discharged
could result in death or serious
injury.

Note: Be sure the engine has been turned off for at
least 15 minutes before servicing the machine. Use
a voltmeter to confirm there is no residual voltage
in the capacitors.

Note: This procedure is only for the capacitors
which are attached to the lighting ballasts. To test a
generator capacitor, see 6-1,

Generator Capacitor

1 Open both cabinet doors and locate the light

ballast boxes on each side of the machine.

2 Choose a ballast box. Tag and disconnect the

wire harness connector from the ballast box.

Note: If the ballast capacitor to be tested is located
under another ballast box, the top ballast box will
need to be removed first.

.

How to Check a

REV A

3 Remove the ballast box cover fasteners.

4 Using an insulated conductor or a screwdriver

with an insulated handle, discharge the
capacitor by shorting across the capacitor
terminals.

Electrocution hazard. Exposure to
high voltage electrical wires or
electrical current will result in death
or serious injury. Remove all rings,
watches and other jewelry. Use
extreme caution when working with
high voltage electrical
components.

5 With an ohmmeter set to its highest resistance

scale, connect the ohmmeter leads to the
capacitor terminals and observe the reading on
the meter. Then, reverse the connections and
observe the reading on the meter.

Result: The meter indicates a resistance which

then gradually decreases. The capacitor is
working.

Result: The meter indicates a very high

resistance which does not decrease. The
capacitor is faulty and should be replaced.

Result: The meter indicates a very low

resistance which does not increase. The
capacitor is faulty and should be replaced.

Probable causes of capacitor failure:

· Normal end-of-life failure.

· Overheated due to light fixture heat or high
ambient temperature.

· Incorrect capacitor voltage rating.

· Capacitor becomes loose in ballast box.

4 - 20 AL8000HT Light Tower Part No. 116478

September 2008

Section 4 • Repair Procedures

REV A

7-3
Fuel Tank

How to Remove a Fuel Tank

1 Open both cabinet doors.

2 Remove the fuel filler cap from the tank. Using

an approved hand-operated pump, drain the fuel
tank into a container of suitable capacity. Refer
to Section 2,

Note: If your machine is equipped with dual fuel
tanks, repeat this procedure beginning with step 2
for the other fuel tank.

Specifications

Explosion and fire hazard. Engine
fuels are combustible. Perform this
procedure in an open, well­ventilated area away from heaters,
sparks, flames and lighted
tobacco. Always have an approved
fire extinguisher within easy reach.

Explosion and fire hazard. When
transferring fuel, connect a
grounding wire between the
machine and pump or container.

Be sure to only use a hand­operated pump suitable for use
with diesel fuel.

.

CHASSIS COMPONENTS

Models without fuel containment option:

4 Support the fuel tank support weldment at each

end using lifting jacks and blocks. Do not apply
any lifting pressure. Do not directly support the
fuel tank.

Component damage hazard. The
fuel tank is plastic and may
become damaged if the lifting
jacks are in direct contact with the
plastic tank.

5 Remove the fasteners securing the fuel tank

support weldment to the chassis.

6 Carefully lower the fuel tank out of the chassis

and remove it from the machine.

Component damage hazard. The
fuel tank is plastic and may
become damaged if allowed to fall.

Note: It may be necessary to lower the outriggers
to the ground and raise the machine using the
outriggers to obtain adequate clearance to
completely remove the fuel tank from the machine.

Note: Clean the fuel tank and inspect for cracks
and other damage before installing it onto the
machine.

3 Tag, disconnect and plug the fuel hoses from

the fuel tank. Clean up any fuel that may have
spilled.

Part No. 116478 AL8000HT Light Tower 4 - 21

Section 4 • Repair Procedures

September 2008

CHASSIS COMPONENTS

Models with fuel containment option:

4 Support the fuel tank containment weldment at

each end using lifting jacks and blocks. Do not
apply any lifting pressure.

Component damage hazard. The
fuel tank is plastic and may
become damaged if the lifting
jacks are in direct contact with the
plastic tank.

5 Remove the fasteners securing the fuel tank

containment weldment to the chassis.

6 Carefully lower the fuel tank out of the chassis

and remove it from the machine. Remove the
fuel tank from the fuel containment weldment.

Component damage hazard. The
fuel tank is plastic and may
become damaged if allowed to fall.

Note: It may be necessary to lower the outriggers
to the ground and raise the machine using the
outriggers to obtain adequate clearance to
completely remove the fuel tank.

REV A

Note: Clean the fuel tank and inspect for cracks
and other damage before installing it onto the
machine.

4 - 22 AL8000HT Light Tower Part No. 116478

September 2008

Section 4 • Repair Procedures

REV A

CHASSIS COMPONENTS

8-1
Function Manifold Components

The function manifold is located next to the hydraulic power unit inside the engine compartment.

Index Schematic

No. Description Item Function Torque

1 Solenoid valve, 3 position 4 way ...... E ........... Light bar up/down ........................................ 25 ft-lbs / 34 Nm

2 Solenoid valve, 3 position 4 way ...... C ........... Tower extend/retract .................................... 25 ft-lbs / 34 Nm

3 Solenoid valve, 3 position 4 way ...... B ........... Tower up/down ............................................ 25 ft-lbs / 34 Nm

4 Relief valve - Bi-directional,

1200 psi / 82.7 bar ............................ H ........... Tower rotate left/right ................................... 20 ft-lbs / 27 Nm

5 Solenoid valve, 3 position 4 way ...... G ........... Tower rotate left/right ................................... 25 ft-lbs / 34 Nm

6 Priority flow regulator valve,

0.2 gpm / 0.76 L/min .......................... D ........... Light bar up/down circuit ............................. 20 ft-lbs / 27 Nm

7 Orifice plug,

0.025 inch / 0.64 mm ......................... F ........... Tower rotate circuit

D

E

1

C

2

B

3

H

4

G

5

6

F

7

Part No. 116478 AL8000HT Light Tower 4 - 23

Section 4 • Repair Procedures

September 2008

CHASSIS COMPONENTS

8-2
Valve Adjustments ­Function Manifold

How to Adjust the Tower Rotate
Relief Valve

Note: When removing a hose assembly or fitting,
the O-ring on the fitting and/or hose end must be
replaced and then torqued to specification during
installation. Refer to Section 2,

Fitting Torque Specifications.

Note: Perform this procedure with the tower in the
stowed position.

1 Disconnect and plug the hydraulic hose from the

"P" port at the function manifold.

Bodily injury hazard. Spraying
hydraulic oil can penetrate and
burn skin. Loosen hydraulic
connections very slowly to allow
the oil pressure to dissipate
gradually. Do not allow oil to squirt
or spray.

Hydraulic Hose and

REV A

5 Use a wrench to hold the relief valve and

remove the cap (item H).

6 Adjust the internal hex socket. Turn it clockwise

to increase the pressure or counterclockwise to
decrease the pressure. Install the relief valve
cap.

Component damage hazard. Do
not adjust the relief valve higher
than specified.

7 Repeat steps 3 through 6 and recheck relief

valve pressure.

8 Remove the pressure gauge.

2 Connect a 0 to 5000 psi / 0 to 350 bar pressure

gauge to the "P" port of the function manifold
using a tee fitting. Install the hose to the tee
fitting.

3 Activate and hold the tower rotate toggle switch

in either direction.

4 Observe the pressure reading on the pressure

gauge. Refer to Section 2,

4 - 24 AL8000HT Light Tower Part No. 116478

Specifications.

September 2008

Section 5 • Troubleshooting

Observe and Obey:

Troubleshooting and repair procedures shall be

completed by a person trained and qualified on
the repair of this machine.

Immediately tag and remove from service a

damaged or malfunctioning machine.

Repair any machine damage or malfunction

before operating the machine.

Unless otherwise specified, perform each

repair procedure with the machine in the
following configuration:

· Machine parked on a firm, level surface.

· Wheels chocked.

· Toggle switch in off position.

· All circuit breakers are in the off position.

Troubleshooting

Before Troubleshooting:

Read, understand and obey the safety rules and

operating instructions in the appropriate
operator's manual on your machine.

Be sure that all necessary tools and test

equipment are available and ready for use.

Be aware of the following hazards and follow

generally accepted safe workshop practices.

Use only a voltmeter with insulated probes rated

at a minimum of 600V AC.

Allow lamps to cool before opening the fixtures.

Electrocution hazard. Exposure to
high voltage electrical wires or
electrical current will result in death
or serious injury. Remove all rings,
watches and other jewelry. Turn off
all power when not needed for
testing. Use extreme caution when
working with high voltage electrical
components.

Electrocution hazard. Attempting
to sevice the machine before the
capacitors are fully discharged will
result in death or serious injury.

Electrocution hazard. Exposure to
electrically charged circuits could
result in death or serious injury.
Remove all rings, watches and
other jewelry.

Burn hazard. Contact with hot
engine components may cause
severe burns. Use caution when
working around a hot engine.

Part No. 116478 AL8000HT Light Tower 5 - 1

Section 5 • Troubleshooting

September 2008

REV A

Troubleshooting Guide

The engine/generator set is tested and set at the factory for proper operation in the field. These units
should never require additional adjustments in the field. If needed, adjustments should only be made by a
qualified service technician, otherwise the manufacturer’s warranty may become void.

TROUBLE POSSIBLE CAUSE REMEDY

1.Boom will not rise to a.Travel lock pin is in place a.Remove travel lock pin
the operating position. b.Defective cable b.Have a trained

or pulley mechanic examine and

repair as needed

2.Boom will not telescope. a.Problem with hydraulics a.Trouble shoot
hydraulic system
and service as needed

b.Broken cable or pulley b.Have a trained

mechanic examine
and replace as needed

c.Extend cylinder damaged c.Inspect extend cylinder

3.Engine will not turn over a.Dead battery a.Check the battery voltage or
loose cables

b.Bad starter b.Check voltage at

starter and replace
as needed

4.Engine turns over but will a.Empty fuel tank a.Fill tank with #2 diesel fuel

not start b.Clogged fuel lines or filter b.Check and clean the fuel

system as needed

c.Leaking fuel lines or a loss c.Replace any leaking fuel lines
of prime and tighten connections
d.Heater elements burned out d.Replace heater elements
e.Fuel line solenoid is not open e.Replace fuel line solenoid

5.Engine runs rough a.Clogged or leaking fuel system a.Replace fuel lines, tighten all
connections, inspect the pickup
tube and inspect the fuel filter

b.Clogged exhaust system b.Clear the exhaust system
c.Clogged air filter c.Clear air filter
d.Clogged or stuck fuel injec t o r s d.Have a trained

mechanic examine

e.Valve clearances are out of e.Have a trained
adjustment or the valve spring mechanic examine
may be damaged
f.Defective governor or fuel pump f.Have a trained

mechanic examine

5 - 2 AL8000HT Light Tower Part No. 116478

September 2008

Section 5 • Troubleshooting

REV A

TROUBLESHOOTING

TROUBLE POSSIBLE CAUSE REMEDY

6.Engine runs but produces a a.Crankcase oil level is too high a.Drain oil to its proper level

dense smoke b.Low compression b.Have a trained mechanic

inspect for broken or seized
rings. Inspect valve clearances

7.Engine overheats a.Blocked cooling air intakes a.Inspect the front and rear intakes
and clear as needed

b.Low coolant levels b.Replace the coolant with a 50%

water/coolant solution

c.Radiator fins have become c.Clear the radiator fins
clogged
d.Fan belt is loose d.Tighten fan belt
e.Thermostat is bad e.Check/Replace thermostat

8.Engine runs but the battery a.Alternator has failed a.Have a trained mechanic inspect

voltage is low the alternator

9.Engine runs but the lights will a.Circuit breakers are tripped a.Reset the circuit breaker

not operate b.Loose connections in the wiring b.Have a trained electrician inspect

system the ballast box wiring system
c.Burned out bulb c.Replace the bulbs as needed
d.Defective generator capacitor d.Have a trained electrician inspect
(Leroy Somers/Marathon Generator) the capacitor
e.Defective AC generator e.Have a trained electrician inspect

the generator

f.Engine speed is too low f.Have a trained mechanic inspect

the engine speed and reset to
1800rpm @ 60hz

g.Defective ballast and capacitors g.Have a trained electrician inspect

the ballast and capacitors

10.Unusual noise coming from a.The generator has a defective a.Have a trained electrician inspect

the generator bearing or damaged fan blade the generator

11.Lamp will not start a.Lamp loose in socket a.Inspect lamp base to see if there
is arcing at center contact button.
Tighten lamp. Check socket for
damage. Replace if needed.

b.Floodlight plugs not tight

c.Defective ballast c.Interchange ballast plugs. If lamp

d.Low voltage d.Check line voltage at ballast input.

b.Check plug and receptacle. Tighten
if needed. Make sure power is off.

starts, replace ballast. Chec k for
swollen capacitors, charred wiring,
core and coil, or other signs of
excessive heat.

Voltage should be within 10% of
rating when operating at normal load.
Increase supply voltage or remove
external load.

Part No. 116478 AL8000HT Light Tower 5 - 3

Section 5 • Troubleshooting

p

September 2008

TROUBLESHOOTING

REV A

TROUBLE POSSIBLE CAUSE REMEDY

11.Lamp will not start e.Improper ballast e.The ballast name plate data should
agree with the line voltage and lamp
used. If not, replace the ballast.

f.Lamp has been operating; cool f.Switch off breaker and allow lamp
down time insufficient to cool.

12.Lamp starts slowly (arc does a.Defective lamp a.Lamp may glow for an extended

not strike when switch is first period of time. Replace after
turned on checking voltage and ballast

13.Circuit breaker trips on lamp a.Short circuit or ground a.Check wiring against diagram.

startup inspect for shorts or ground. Fix as

needed.

14.Lamp light output low a.Normal lamp depreciation a.Replace lamp

b.Dirty lamp or fixture b.Clean lamp and fixture
c.Defective ballast c.Interchange ballast plugs. If lamp

starts, replace ballast. Chec k for
swollen capacitors, charred wiring,
core and coil, or other signs of
excessive heat.

d.Wrong voltage d.Check line voltage at ballast input.

Voltage should be within 10% of
rating when operating at normal load.
Check wiring connections for voltage
loss. Check socket contact point.

e.Improper ballast e.Check ballast name plate against

lamp data

15.Lamp colors different a.Normal lamp depreciation a.Replace lamp

b.Dirty lamp or fixture b.Clean lamp and fixture
c.Wrong lamp c.Check data on lamps and replace

as needed.

16.Arc tube discolored or swollen a.Over voltage from power supply

b.Improper ballast b.Check ballast name plate against

17.Short lamp life a.Lamp damaged a.Check for outer bulb cracks,

b.Improper ballast b.Check ballast name plate against

18.Lamp flickers or goes out- a.Improper Ballast a.Check ballast name plate against

intermittent or cycling lamp data

b.New lamp

a.Check voltage at ballast, for current
or voltage surges, for shorted
capacitors and replace as needed

lamp data

cracks where lamp meets base, and
for broken arc tube or loos e metal
parts. Replace as needed.

lamp data

b.Under certain conditions new lamps
may "cycle". Usually after 3 tries to
start at 30 to 60 second intervals,
lam

will stabilize and operate normal

5 - 4 AL8000HT Light Tower Part No. 116478

September 2008

q

Section 5 • Troubleshooting

REV A

TROUBLESHOOTING

TROUBLE POSSIBLE CAUSE REMEDY

18.Lamp flickers or goes out- c.Defective capacitor c.Replace capacitor

intermittent or cycling d.Defective lamp d.Replace lamp

e.High spike ballast

IF YOU FEEL AN ELECTRIC SHOCK AT ANY TIME WHILE OPERATING THIS UNIT, SHUT IT DOWN
IMMEDIATELY! HAVE THE UNIT INSPECTED BY A TRAINED ELECTRICIAN.

THIS ENGINE/GENERATOR SET IS FACTORY INSTALLED, TESTED, AND SET FOR FIELD
OPERATION. ANY DAMAGE TO THE ENGINE OR GENERATOR UNITS OCCURRING AFTER
ADJUSTMENTS ARE MADE IN THE FIELD BY UNAUTHORIZED PERSONNEL WILL NOT BE
COVERED BY YOUR MANUFACTURER’S WARRANTY AND WILL ALSO VOID THE
MANUFACTURER’S WARRANTY ON THIS PARTICULAR UNIT. IF YOU CAN NOT REACH YOUR LO­CAL DEALER, CONTACT THE FACTORY SERVICE MANAGER TOLL FREE AT 1-800-433-3026.

e.Ballast produces high spike current.
Measure with oscilloscope. Replace
ballast as re

uired.

Light Fixture Troubleshooting

DO NOT OPEN FIXTURES WHILE LIGHT
CIRCUIT BREAKER IS “ON”. ALLOW
LAMP TO COOL BEFORE TOUCHING.

**TAKE EXTRA PRECAUTIONS WHEN

TROUBLESHOOTING ELECTRICAL PROBLEMS**

A. Only use a voltmeter with two well-insu-

lated pin probes rated for 600 volts.
B. Treat all conductors as potentially hot.
C. Proceed through circuits systematically,

operating only one section at a time.
D. Before disconnecting ballast, turn off circuit

breaker and wait 30 seconds for capacitor

to discharge.
E. If all the lights are out and all the ballasts

are receiving power, suspect burned out

power cable.

Part No. 116478 AL8000HT Light Tower 5 - 5

Section 5 • Troubleshooting

September 2008

REV A

This page intentionally left blank.

5 - 6 AL8000HT Light Tower Part No. 116478

September 2008

Section 6 • Schematics

REV A

Observe and Obey:

Troubleshooting and repair procedures shall be

completed by a person trained and qualified on
the repair of this machine.

Immediately tag and remove from service a

damaged or malfunctioning machine.

Repair any machine damage or malfunction

before operating the machine.

Before Troubleshooting:

Read, understand and obey the safety rules and

operating instructions in the appropriate
Operator's Manual on your machine.

Be sure that all necessary tools and test

equipment are available and ready for use.

Schematics

About This Section

There are two groups of schematics in this section.
An illustration legend precedes each group of
drawings.

Electrical Schematics

Electrocution hazard. Contact with
electrically charged circuits could
result in death or serious injury.
Remove all rings, watches and
other jewelry.

Hydraulic Schematics

Bodily injury hazard. Spraying
hydraulic oil can penetrate and
burn skin. Loosen hydraulic
connections very slowly to allow
the oil pressure to dissipate
gradually. Do not allow oil to squirt
or spray.

General Repair Process

Malfunction
discovered

Identify

symptoms

Troubleshoot

problem

still exists

Return to

service

Part No. 116478 AL8000HT Light Tower 6 - 1

problem

solved

Inspect

and test

Perform

repair

Electrical Symbols Legend

+

-

BLK

WHT

Quick disconnect

terminal

T-circuits connect

Connection
no terminal

Coil

solenoid or relay

FB

Flashing beacon

Section 6 • Schematics

Pump

Power unit

TS2

ENGINE

START

Toggle switch SPDT

Starting aid:
glow plug or
flame ignitor

September 2008

REV A

REV A

Circuits crossing

no connection

Circuit breaker
with amperage

Diode

Battery

CB1

15A

Main circuit

breaker

HM

Hour meter

L3

LED

F1

25A

Fuse

with amperage

LS3

N.O.H.C

N.C.H.O

Limit switch

PR1

Power relay

CR4
N.O.

TS6

DOWN

UP

PLATFORM LEVEL

Toggle switch DPDT

CTS1

N.O.

Coolant temperature

switch

normally open

OPS1

N.C.

Oil pressure switch

normally closed

CAB

HOLD

PULL IN

Fuel or RPM

solenoid

Control relay contact

Light switch

normally open

Coil

6 - 2 AL8000HT Light Tower Part No. 116478

September 2008

E

REV A

REV A

25 psi
(1.7 bar)

Filter with
bypass valve
relief setting

.035"

(0.89 mm)

Orifice with size

Check valve

200 psi
(13.8 bar)

Section 6 • Schematics

Hydraulic Symbols Legend

Solenoid operated 3 position,

4 way, directional valve

Pump

fixed displacement

Pump prime mover

Relief valve

with pressure setting

Priority

flow regulator valve

3000 psi

(206.8 bar)

3:1

(engine or motor)

Cross-relief valve

Double acting

cylinder

Counterbalance valve

with pressure and pilot ratio

Part No. 116478 AL8000HT Light Tower 6 - 3

Section 6 • Schematics

Electrical Schematic - Machine Functions

September 2008

REV A

LEFT

RIGHT

DOWN

UP

RETRACT

TOWER

EXTEND

DOWN

TOWER

UP

TOWER
ROTATE

LIGHT
BAR

WH

WH/BLK

GR/BLK

GR

BLK/WH

BLK

RED/BLK

RED

N.C./H.O.

TOWER ROTATE LEFT
VALVE COIL

TOWER ROTATE RIGHT
VALVE COIL

LIGHT BAR DOWN
VALVE COIL

LIGHT BAR UP
VALVE COIL

TOWER RETRACT
VALVE COIL

TOWER EXTEND
VALVE COIL

TOWER DOWN
VALVE COIL

TOWER UP
VALVE COIL

STOWED
LIMIT SWITCH

PUMP MOTOR
CONTACTOR

LIFT PUMP
MOTOR

FUSE

30A

6 - 4 AL8000HT Light Tower Part No. 116478

September 2008

REV A

Section 6 • Schematics

DC Electrical Schematic - Control Box and Engine

Isuzu Models

Part No. 116478 AL8000HT Light Tower 6 - 5

Section 6 • Schematics

DC Electrical Schematic - Control Box and Engine

Kubota Models

September 2008

REV A

6 - 6 AL8000HT Light Tower Part No. 116478

September 2008

REV A

Section 6 • Schematics

DC Electrical Schematic - Control Box and Engine

with Autostart Option

Part No. 116478 AL8000HT Light Tower 6 - 7

Section 6 • Schematics

AC Electrical Schematic ­Standard Models with 4 Lights

September 2008

REV A

6 - 8 AL8000HT Light Tower Part No. 116478

September 2008

REV A

Section 6 • Schematics

AC Electrical Schematic -

Standard Models with 6 Lights

Part No. 116478 AL8000HT Light Tower 6 - 9

Section 6 • Schematics

AC Electrical Schematic ­Standard Models with 8 Lights

September 2008

REV A

6 - 10 AL8000HT Light Tower Part No. 116478

September 2008

REV A

Section 6 • Schematics

AC Electrical Schematic -

Autostart Models with 4 Lights

Part No. 116478 AL8000HT Light Tower 6 - 11

Section 6 • Schematics

AC Electrical Schematic ­Autostart Models with 6 Lights

September 2008

REV A

6 - 12 AL8000HT Light Tower Part No. 116478

September 2008

REV A

Section 6 • Schematics

AC Electrical Schematic -

Autostart Models with 8 Lights

Part No. 116478 AL8000HT Light Tower 6 - 13

Section 6 • Schematics

Receptacle Wiring Diagrams

Standard Receptacle Package

Extra GFCI Receptacle Package

September 2008

REV A

Enhanced Receptacle Package

6 - 14 AL8000HT Light Tower Part No. 116478

September 2008

REV A

Section 6 • Schematics

Hydraulic Schematic

Part No. 116478 AL8000HT Light Tower 6 - 15

Section 6 • Schematics

September 2008

REV A

This page intentionally left blank.

6 - 16 AL8000HT Light Tower Part No. 116478

California Proposition 65

Warning

The exhaust from this product

contains chemicals known to

the State of California to

cause cancer, birth defects

or other reproductive harm.

Towing Checklis t

(Use at each stop)

Genie North America

Phone [phone]

Toll Free USA and Canada

800.536.1800

Fax [phone]

Genie Australia Pty Ltd.

Phone [phone]

Fax [phone]

Before Towing

Before Driving

On The Road

· Boom hold-down latch is securely locked in place

· Towing hitch is properly secured to tow vehicle

· Safety chains (if required) are properly attached
and secure (chains are crossed below hitch)

· All lights are connected and working

· Tires are properly inflated

· Fasten safety restraints

· Properly adjust mirrors

· Do not exceed 60 mph / 97 km/h. Obey all local
and national towing speed laws

· Check connections and tire pressure at each stop

· Slow down for hazardous conditions

· Allow extra distance for following and passing other
vehicles

Genie China

Phone [phone]

Fax [phone]

Genie Malaysia

Phone [phone]

Fax [phone]

Genie Japan

Phone [phone]

Fax [phone]

Genie Korea

Phone [phone]

Fax [phone]

Genie Brasil

Phone [phone]

Fax [phone]

Genie Holland

Phone [phone]

Fax [phone]

Genie Scandinavia

Phone [phone]

Fax [phone]

Genie France

Phone [phone]

Fax [phone]

Genie Iberica

Phone [phone]

Fax [phone]

Genie Germany

Phone [phone]

Fax [phone]

Genie U.K.

Phone [phone]

Fax [phone]

Genie Mexico City

Phone [phone]

Fax [phone]

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