Terex AL5000 User Manual

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Page 1

SERIES AL5000

LIGHT TOWER

OPERATION/SERVICE

& PARTS MANUAL

California Proposition 65

WARNING

The engine exhaust from this product

contains chemicals known to the State of

California to cause cancer, birth defects or

other reproductive harm.

PO Box 3147 • Rock Hill, SC 29732 USA • Phone 803-324-3011

Toll Free 800-433-3026 Parts Department Fax 800-633-5534

Page 2

NOTES

Page 3

TABLE OF CONTENTS

Receiving and Set-up

Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7

Check Out on Receipt/Delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

TEREX Amida Light Tower Model Coding System . . . . . . . . . . . . . . 9

Recommended Engine Oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Operating Instructions

Light Tower Operating Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . 11-14

Criteria for Replacement of Wire Rope . . . . . . . . . . . . . . . . . . . . . . . . 15-17

Engine (see manufacturer’s handbook) Generator (see manufacturer’s handbook)

Parts Identification Drawings

Trailer and Related Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-21

Axle and Wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Cabinet and Attachments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-25

Tower and Related Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26-34

Engine and Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35-40

Electrical Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Floodlight Fixtures / Ballasts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42-43

Hitches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

Electric Winch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

Running Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Wiring Diagrams

Fixture with Joy Connector (MH or TH) . . . . . . . . . . . . . . . . . . . . . . 47

Metal Halide Ballast with Joy Connector . . . . . . . . . . . . . . . . . . . . . . 48

High Pressure Sodium Ballast with Joy Connector . . . . . . . . . . . . . . . 49

AC Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

DC Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

Troubleshooting Guide

Specifications, Routine Maintenance, Wind Loading . . . . . . . . . . . . . 52-55

Broken Cable Replacement Procedure . . . . . . . . . . . . . . . . . . . . . . . . 56-57

Light Fixture Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58-60

TEREX Amida Numbered Wiring System . . . . . . . . . . . . . . . . . . . . . 61

Generator Bearing Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

Engine (refer to manufacturer’s handbook) Generator (refer to manufacturer’s handbook)

Warranty Information

Warranty Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

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NOTES

Page 5

SAFETY PRECAUTIONS

The following symbols in this manual signal potentially dangerous conditions to the operator or equipment. Read this manual carefully. Know when unsafe conditions can exist. Then, take necessary steps to protect personnel, as well as equipment.

WARNING: TEREX Amida uses this symbol throughout this manual to warn of possible fatal injury.

CAUTION: TEREX Amida uses this symbol to point out potential damage to equipment.

Lamps, fuels, electrical equipment, batteries, exhaust gases, loose fasteners, and moving parts present potential hazards that could result in serious personal injury. Be diligent in following the procedures recommended below . Also, observe the many additional general safety rules practiced by trained operation and maintenance

personnel in your company and industry. CAUTION: Always wear a hard hat when operating the light tower!

• Guard Against Electrical Shock

This light tower also has provisions for producing high voltage electricity (up to 480 volts) that can produce a fatal shock to a person who accidentally places their self in the electrical circuit. Use every precaution to avoid contact with the high voltage electric circuit.

Beware of a cut or damaged power cord. Replace immediately.

Take extra precautions when troubleshooting electrical problems:

• When troubleshooting indicates a malfunction in the high voltage AC system, then pass the troubleshooting task on to a qualified and trained electrician.

• Disconnect electrical power and turn off engine before removing protective covers on high voltage enclosures.

• Understand that the electrical circuits in this light tower complete their paths back to the generator within the equipment. The neutral conductor at the generator is bonded to the equipment frame.

• Ground wires within the system are also bonded to the equipment frame.

• Only use a multimeter (or voltmeter) with two well-insulated probes rated for 750 volts.

• Keep one hand in your pocket when touching the multimeter probe to hot conductors. This will prevent

electricity from passing into one hand and out the other, a path that takes the electricity across the heart. Always disconnect power from the circuit being measured before connecting test leads to high voltage points.

• Do not try to position both probes at once. Instead, clamp the common insulated alligator clip to a neutral wire and then probe for voltages with the other probe.

• Never clamp to a hot wire since a severe shock could be received by contact with the other probe.

• Do not use a multimeter with leads or probes that have damaged insulation.

• Inspect the ground cable between the generator set and the frame. If damaged, replace immediately.

• Treat all conductors as potentially hot, especially when troubleshooting malfunctioning equipment. Jewelry

should be removed before working around live conductors.

• Proceed through the circuitry systematically , operating only one section at a time.

• Use tools with insulated handles when working within the reach of live conductors.

• Maintain a good footing. If you slip, or a tool drops, do not grab for it if live conductors are within reach.

• Concentrate on the task until the danger from high voltage is removed.

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• Guard Against Battery Hazards

Lead acid batteries can be dangerous. The sulfuric acid in the battery can cause severe skin and eye burns. The hydrogen gas emitted during charging can explode if an arc or flame is present near the battery. Use precautions to prevent acid burns or explosive conditions.

Do not smoke while servicing batteries. Do not allow tools to touch battery terminals and create an arc. Do not test battery voltage by setting up a

brief arc at the terminals. Use a multimeter instead. Disconnect the negative terminal of the battery when working on the engine or other parts to prevent acci-

dental arcing. Disconnect the negative cable at the end away from the battery. Always wear eye protection when servicing the battery . When charging the battery, do not remove the vent caps. If acid does get on skin or in eyes, immediately flush under running water, and then obtain medical help as

soon as possible.

• Guard Against Fire Hazard

Use caution with diesel fuel and motor oil because of fire hazards. Do not fill fuel tank while engine is running. Do not smoke or use open flame near the unit or the fuel tank. Be sure the fuel supply has a positive shut-off valve. Do not replace fuel lines with materials different from those supplied as original equipment. Have a fire extinguisher nearby. Be sure the extinguisher is properly maintained and be familiar with its

proper use. Extinguishers rated ABC by the NFPA are appropriate for all applications. Keep this unit clean of excessive build-up of spilled oil and fuel. Accumulated oil and fuel can cause over-

heating and subsequent engine damage as well as present a fire hazard. Remember that EXHAUST GASES ARE TOXIC. WARNING: DO NOT USE INDOORS unless

properly ventilated. Provide an adequate exhaust system to properly expel discharged gases. Check exhaust system regularly for leaks. Ensure periodically that the exhaust manifolds are secure and not warped. Make sure the unit is well ventilated.

• Protect The Environment And Practice Good Industrial Hygiene

Prevent pollution by catching used oil in a container for proper disposal. Wash hands to remove oil and fuel. Practice good industrial hygiene. Maintain an adequate exhaust system to properly expel discharged gases. Check the exhaust system regu-

larly for leaks.

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• Do Not Touch Hot Parts

The exhaust manifold and tailpipe are very hot. Parts of the engine are also hot. Avoid touching hot parts of the engine or tailpipe. Use protective gloves when handling hot parts.

• Be Alert And Attentive To The T ask

Read the safety instructions and operating procedures before attempting to troubleshoot or work on this unit. Also read the engine manual, which is a separate booklet that is provided with this manual.

Do not work on this equipment when mentally or physically fatigued. Do not work on this equipment when under the influence of performance impairing drugs or alcohol. If this manual becomes lost, order a new one from TEREX-Amida so future operation and maintenance

personnel may read these instructions.

• Beware of Moving Parts

Avoid being hit or pinched by the moving parts of this unit. Loose jackets, shirts, neckties, or sleeves should not be worn while working or running a unit. Only remove guards or protective devices from unit temporarily to gain access for maintenance. Always

replace guards and protective devices promptly . Keep your hands away from moving parts. Particularly, be sure to keep hands clear of the blower and

alternator belts when the engine is running.

• Beware of Traffic Hazards

Stand clear of traffic when starting or checking the unit along the road. Check the fuel tank, oil pan, and fuel and oil lines for leaks that would spill fuel or oil on the road. Check fasteners and mounting brackets periodically to insure all are tight and nothing is in danger of falling

off during transit.

• Use Only Equal Replacement Parts

When a part fails and needs to be replaced only use equivalent size, length, thread, grade, and material. Replace stainless steel fasteners with stainless steel fasteners. The engine may use metric or SAE bolts, but all other bolts are generally SAE thread. Be sure to use Grade 8 bolts and nuts to mount the genset to the trailer.

Replace the fuel and oil hoses with items of equal material, diameter and length. Contact the manufacturer, TEREX-Amida, regarding replacement parts to ensure a correct repair.

• Use Caution Working Near Lamps

Metal halide lamps produce short wave ultra-violet radiation and can cause serious skin burn, or eye inflammation if the outer envelope of the lamp is broken or punctured. Do not use where people will remain for more than a few minutes unless adequate shielding or other safety precautions are used.

Page 8

CHECK OUT ON RECEIPT OF DELIVERY:

The tower will be serviced, tested and ready for operation when received except for export units and skid mount units which are knocked down for shipping (export units are also shipped with dry batteries). Amida recommends the following checks:

A. INSURE THERE IS NO FREIGHT HANDLING DAMAGE which should be charged against

the carrier.

B. Insure the manuals are in the pocket provided inside the unit.

C. Review the manuals for safety and operating procedures.

D. Check the engine oil, coolant (if liquid cooled) and fuel levels.

E. Operate the tower in accordance with operating instructions.

EXPORT: Assemble according to the instructions enclosed.

Page 9

LIGHT TOWER MODEL CODING SYSTEM

IMPORTANT

WHEN REQUESTING TECHNICAL HELP AND ORDERING REPLACEMENT PARTS THE MODEL AND

SERIAL NUMBER ARE NECESSARY.

REFER TO THE AMIDA SERIAL NUMBER TAG ON THE UNIT FOR CORRECT MODEL NUMBER AND

SERIAL NUMBER.

MODEL NUMBER IDENTIFICATION

Samp1e:

Light Tower Product Line LT5 080 D 4 MH CE

T ower Series

AL4000 (AL4) = 30 Foot Basic Tower with winch in cabinet AL5000 (ALS) = 30 Foot Basic Tower with in-cabinet light

storage and door insulation

5000 (5) =30 Foot Enhanced Cable Tower 2000 (2) =Model 5000 with extra corrosion protection

LT5000 (LT5) = 30 Foot Deluxe Cable Tower w/optional Acoustic

Enclosure and Complete Instrumentation

LT2000 (LT2) = Model LT5000 with Extra Corrosion Protection

7000 (7) = 30 Foot Enhanced Hydraulic Tower LT7000 (LT7) = 30 Foot Deluxe Hydraulic Tower w/optional Acoustic

Enclosure and Complete Instrumentation

KW Rating (080 is 8.0 kW)

Diesel (D) or Gas (G)

Number of Lights

T ype of Lights

European Version (AL4000 Only)

HPS = High Pressure Sodium MH= Metal Halide MV= Mercury Vapor TH= Tungsten Halogen

Page 10

RECOMMENDED ENGINE OIL & FUEL

KUBOTA D905 DIESEL ENGINE

Engine oil should be MIL-L-2104B/MIL-L-2104C or have properties of API designation of CC/SF or CD/SF. Change the type of engine oil according to the ambient operating temperature:

Above 86°F SAE 30 32°F to 77°F SAE20

Below 32°F SAE10

SAE 10W-30

Use #2 diesel fuel.

LISTER-PETTER LPW3/LPA3/LPW4/LPWT4 DIESEL ENGINES

Engine oil should be MIL-L-2104C or have properties of API designation of CC/SF or CD/SF. Use CC grade oil for the initial break-in period. Multi-viscosity oils (such as 10W-40) should not be used at temperatures above 32°F. Be sure to use the correct oil viscosity for the weather you are experiencing. When this engine left the factory, it was filled with engine oil as specified on this page.

Change the type of engine oil according to the ambient operating temperature:

86°F and warmer SAE30 Between 39°F & 86°F SAE20/20W-SAE 15W/40 Between 5°F & 39°F SAE 10W Below 5°F SAE 5W

Use #2 diesel fuel above 5°F, #1 diesel fuel below 5°F.

NOTES:

1. The temperatures in the table are the ambient temperature at the time when the engine is started. However, if the running ambient temperatures are much higher than the starting temperatures, a compromise must be struck and a higher viscosity oil and fuel used, provided they have a suitable specification.

2. MIL-L-2104B or MIL-L-2104C or API CD oils are recommended, particularly in high temperature applications. They must also be used if the sulfur content of the fuel exceeds 0.5%.

3. CAUTION: The use of Series III oils in new , or overhauled naturally aspirated engines can inhibit breakin and give rise to cylinder bore glazing in engines on low duty cycles. Therefore, they should not be used for the first fill in new or newly overhauled naturally aspirated engines, but may be used advantageously after the first 250 hours, when the engine is operating in hot ambient temperatures and high load factor.

4. Always use a reputable brand of diesel fuel. The sulfur content should be below 0.5% (higher sulfur content would require more frequent oil changes). At low ambient temperatures (below freezing), use winter grade diesel fuel. At higher temperatures, use summer grade diesel fuel. Observe strict cleanliness when filling the fuel tank.

5. Check the engine oil level before starting the engine or more than five minutes after it has been stopped. Remove the dipstick, wipe clean, reinsert it, take it out again, and check the oil level. If the oil level is too low, remove the oil plug and add new oil to the FULL line on the dipstick.

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MODEL AL5000

OPERATING INSTRUCTIONS

I M P O R T A N T: READ ALL DIRECTIONS IN MANUAL CAREFULLY

BEFORE OPERATING EQUIPMENT

WARNING CAUTION DO NOT RAISE TOWER IN THE VICINITY OF

OVERHEAD POWER LINES!

O P E R A T I N G I N S T R U C T I O N S

I. MOVE LIGHT TOWER TO DESIRED LOCATION KEEPING THE FOLLOWING IN MIND:

A. The light tower should not be placed where those working under the light are either:

1) Forced to look into the light regularly .

2) Forced to work with their backs to the light (shadows will block the light from the work area).

B. The area where the tower is positioned should be relatively level.

C. The light tower should be located on the same level or on ground higher than the area being lighted

(higher light mounting heights reduce the shadow length).

D. Unit should be level to ensure smooth trouble-free tower telescoping. Tower may not telescope down

properly when unit is not level.

II. UNHITCH FROM THE TOWING VEHICLE AS FOLLOWS:

A. Engage the trailer braking system, especially if trailer is not on level ground. CAUTION: If electrical

or manual braking system is not supplied, chock the wheels instead.

B. Swing the tongue jack into position and raise the tongue off the towing vehicle.

III. LEVEL THE TRAILER, USING THE JACKS AS FOLLOWS:

A. Extend the rear outriggers until the springs lock into place. Swing the jack on each outrigger into verti-

cal position.

B. Start at the highest jack position. Rotate the jack handle until the jack foot touches the ground.

C. Raise the other jacks to level trailer…WARNING…CAUTION…insure that the rear jacks are down to

prevent the tower from tipping over backwards when raised.

IV. DRIVE GROUNDING ROD INTO EARTH

Page 12

IV. INSTALL THE FLOODLIGHTS ON THE CROSSBEAM

A. Remove the light fixtures from the tower by removing detent pin and rotating the clamp to free the

lights. Install them on the cross arm studs with the lens facing the ground.

B. The cord on the fixture should be on the side closest to the trailer so the cord entry is beneath the fixture when

the tower is raised ( this reduces moisture problems and ensures the water weep hole in the fixture is down).

C. Set the vertical aim for each light fixture by adjusting the light fixtures and tightening the lower bolt.

D. Set the spread between the light fixtures horizontal aiming by adjusting the fixtures and tightening the

wing nut.

E. The unit may be transported with the light fixtures mounted on the cross-arm if they are pointed toward

the ground.

"T" BOLT

TRAVEL LOCKING PIN

HORIZONTAL LOCKING PIN

KICK-OUT SPRING

VERTICAL LOCKING PIN

HORIZONTAL LOCKING PIN

TELESCOPING LOCKING PIN

V. RAISING THE TOWER (refer to drawing above)

A. Remove the tower travel-locking pin from the cradle at the rear of the cabinet.

B. Aim the fixture, both horizontally and vertically, to the estimated angles that will light the work area.

C. Using the winch, raise the tower to the vertical position. The tower-locking pin at the base of the pivot

post will lock automatically and you will hear it “snap” into place. Insert manual pin into locking device.

D. Release the tension on the cable by backing the winch off slightly and pull the telescoping locking pin on

the galvanized tower section. Hold this out while turning the winch to raise the tower. After the tower has telescoped slightly, the locking pin can be released. Raise the tower to the desired height.

CAUTION: DO NOT A TTEMPT TO LEAN THE TOWER DOWN WHEN IT IS EXTENDEDSERIOUS DAMAGE MA Y OCCUR!

Page 13

IV. START THE ENGINE / GENERATOR SET

A. CAUTION: Ensure the circuit breakers are turned “OFF”. This prevents the engine from starting under

load and prevents electrical equipment from being subjected to improper voltage and frequency .

B. Check the oil, fuel, and coolant (if liquid cooled) levels. If the fuel tank is empty, it may be necessary to

bleed the fuel line after filling the tank (see engine instruction book for procedure).

C. Turn the ignition switch to the “RUN” position (see diagram below). Press the preheat push button for a

maximum of 7 seconds. Do not engage the preheat button longer than the time specified or damage may occur.

D. Turn the ignition switch to the “START” position to engage the engine. After the engine starts, release

the switch so that it returns to the “RUN” position. Let the engine come up to speed and stabilize (review the engine operating procedures in the manufacturer’s handbook).

E. T urn on the main circuit breaker.

V. TURN ON THE FLOODLIGHTS

A. Turn the circuit breakers “ON” and check to insure all lamps come on. Allow a minimum of two (2)

minutes for lamps to reach full luminance.

B. If required, rotate the tower to aim the lights as desired. Tighten the tower rotating locking bolt.

C. Adjust the tower vertically and adjust lighting direction of individual fixtures if required.

VI. LOWERING THE TOWER TO TRAVELING POSITION

A. Loosen rotating lock.

B. Using the winch, telescope the tower down to its fully retracted position until the telescoping locking pin

snaps into place.

D. CAUTION: Ensure that the telescoping locking pin locks before pulling the tower locking pin at the

bottom of the pivot post. This ensures the tower is completely lowered and cannot be damaged by telescoping out while in the travel position.

E. Rotate the tower so that the groove in the galvanized ring at the pivot is pointing to the rear of the trailer

so that the tower can be lowered into the travel position.

Page 14

Operating Procedures (cont’d)

F. Pull the vertical locking-pin at the base of the pivot post (the kick-out spring should provide sufficient

pressure to start the tower pivoting over).

G. Let out on the winch cable to lower the tower into the cradle.

H. Insert the rear tower horizontal travel-locking pin into the cradle.

VII. TURN OFF FLOODLIGHTS

A. If operating, turn light circuit breakers off.

B. Turn engine switch to “OFF” to shut down the engine. CAUTION: Do not shut down engine prior to turning lights off.

C. CAUTION: Allow lamps to cool at least ten (10) minutes before moving the tower to avoid breaking

lamps.

VIII. RELOCATING LIGHT TOWER TO NEW LOCATION

A. Insure that tower has been properly lowered (see section VI) and locking pins are engaged.

B. Insure all fixtures are pointed toward the ground, or mounted on the fixture storage brackets on the lower

tower section.

C. CAUTION: All jacks must be raised and all outriggers locked into travel position.

D. Insure that the coupler is properly secured to the towing vehicle and attached safety chains (if supplied).

Release any manual braking mechanism (if supplied).

E. Do not tow at excessive speeds (60 mph – 100-kmh maximum) as the weight of the light tower can

cause loss of vehicle control, especially under emergency stopping conditions. The standard trailer has no towing brakes; therefore allow extra distance for stopping.

VI. USE OF LIGHT TOWER AUXILIARY POWER

A. One (1) 30amp/240v Twist-Lock and (1) 20 amp/120v receptacles are provided for auxiliary power.

B. Total auxiliary power cannot exceed main circuit breaker rating. Each lamp operating consumes 10

amps of current @ 120 volts ac.

C. Before plugging in auxiliary power cords, feed them up through the trailer frame and attach to recep-

tacles. Close the cabinet doors to protect control panel and other components from weather (see Miscellaneous Specifications and Routine Maintenance section for power control details).

Page 15

CRITERIA FOR REPLACEMENT OF WIRE ROPE – TEREX-AMIDA LIGHT TOWERS

The wire ropes used to raise and lower the masts on a TEREX-Amida Light Tower are probably some of the most important mechanical parts used in day-to-day operation of the machinery. It is therefore very important that the cables be inspected on a frequent basis (once a month) for wear and tear, and immediately in the event of possible damage due to operator error in using the winch, or possible damage from other equipment.

NORMAL WEAR AND TEAR

When used properly, the wire ropes should give years of trouble-free service, depending on how often the masts are raised and lowered. The rule of thumb at TEREX-Amida is that if the tower is raised and lowered an average of once per day, that the cables should be replaced every two years of service.

NORMAL INSPECTION

The wire ropes are constructed of 7 strands of 19 plow steel wires each twisted together, and then the assembly galvanized to resist corrosion. Using a wadded-up cloth or heavy leather gloves (to avoid being pricked by a broken wire), run a hand up and down a length of the cable. If any exterior wires are broken, they will lift up from main body of the cable and become visible. For any given 1 foot of cable length; if there are 4 or more wires each, on any 2 or more strands broken, the suspect rope should be replaced immediately.

OPERA TOR ERROR – OTHER MACHINERY DAMAGE

One of the most common reasons for failure of a Light Tower wire rope is due to operator error in using the winch, or damage to the cable by tools or other machinery. The most common operator error happens when the mast is telescoping down. When the upper telescoping lock engages, the operator does not pull the lower pivot lock out (located on the

tower base) and keeps on cranking the winch. This results in the cable becoming loose around the drum due to the tower not pivoting down. This can result in three problems: the loose cable can get trapped underneath itself, resulting

in a sudden or partial “drop” of the mast when the loose section releases at a later time, thus damaging the cable; or the cable can jump off the winch drum and be damaged by the gears of the winch. The loose cable can also cause the drum to spin to take up the slack cable. If there is enough friction in the threaded parts of the winch, the drum can cause the crank handle to start spinning. This can cause the tower to “freefall” and the results can be catastrophic for anyone standing underneath the tower. A spinning crank handle can also break bones.Other reasons damage can occur are due to some outside force such as forklift blade nicking or crushing a cable when moving a unit, or an accidental blow or damage by a hand tool, etc.

DAMAGE INSPECTION

If any nicks (partial strand cut through), kinks (permanent bends), or weld spatter on the cable (from field service) are observed, the suspect wire rope should be changed immediately. If there is a crushed spot somewhere on the wire rope, it should be replaced only if the width of the crushed spot exceeds 1-1/4 times the nominal diameter of the cable (5/16” on a 1/4” cable, and 7/32” on a 3/16” cable), or if there are broken wires at the point of damage.

Page 16

NOTES

Page 17

Cable 2 Point B

Model:

Title:

AL5000 LIGHT TOWER

Cable Replacement Diagram

2" Section

3" Section

4" Section

Page:

6" Round Tube

"Hat" Section

c Amida Industries, Inc. 1999

Created:

By:

2-2-99 Spectrum

Cable 2 (109070) Point A

Cable 1 (109065) Point A

Revised:

a) b)

Cable 1 Point B

Winch

Tower Base

d) e) f)c)

Document:

Page 18

NOTES

Page 19

PARTS MANUAL

Page 20

Model: Page:

Title:

174160, Battery Hold-Down

182330, Battery Hold-Dow n R od

160273, Battery Cable Set

124800, Trailer Frame

AL5000 LIGHT TOWER

Trailer Frame/Tongue/Outriggers

160110, Battery

114612, Outrigger

109150, Plunger Kit

124470, Tongue

840222, Jack Snap Ring

840221, Jack Bracket

110870, Safety Chain

841430, Jack

By:

c Amida Industries, Inc. 1999

2-2-99 Spectrum

a) b) c) f)

d) e)

Document:Revised:Created:

Page 21

Model: Page:

Title:

AL5000 LIGHT TOWER

Fuel Tank

741715, Cap & Gauge

Roadside Return & Supply

(4) 990170, Lock Nut

Curbside Return & Supply

741701, 30 Gal. Fuel Tank

c Amida Industries, Inc. 1999

By:

114720, Fuel Mounting

Bracket

2-2-99 Spectrum

a) b) c) f)

(8) 990080, Flat Washer

(4) 992310, 3/16"-16x6" Bolt

d) e)

Document:Revised:Created:

Page 22

Title:

Note: Axle Ass'y w/o Tires- 840377

834339, Axle

AL5000 LIGHT TOWER

Axle Assy.

(2) 834267, U-Bolt Kit

834225, Grease Seal

834226, Inner Bearing

Page:Model:

834220, Hub Assy.

834255, Cott e r Pin

834250, Spindle Nut

834228, Grease Cap

841051, Axle Front Hanger

834227, Outer Bearing

841060, Tire & Wheel Mounted

(3) 840395, Axle Spring Nut

840392, Axle Rear Hanger

841473, Axle Shackle

(2) 834246, Spring Eye Bushing

834211, Leaf Spring

840376, Lug Nut

(3) 840394, Axle Spring Bolt

c Amida Industries, Inc. 1999

Created:

By:

2-2-99 Spectrum

Revised: Document:

d) e)b) f)c)

Page 23

Model: Page:

Title:

184150, Winch Handle Bush.

189860, Cabinet, Roadside

AL5000 LIGHT TOWER

Cabinet Assy.

(4) 796432, Door Shock Bracket

124420 Ground Rod Storage Tube

189820, Cabinet, Front

Radiator Overflow Bracket

124190, Cabinet, Rear

(2) 189390 Elec. Box Mtg. Bracket

176370 Literature Rack

(2) 930950 Weatherstrip Adhesive

(2) 123490 Fender

189870, Cabinet, Curbside

(10) 791840 Rubber Bumper

By:

c Amida Industries, Inc. 1999

2-2-99 Spectrum

a) b) c) f)

d) e)

Document:Revised:Created:

Page 24

Model: Page:

Title:

AL5000 LIGHT TOWER

Cabinet Assy.-116650

720220, Bumper

116180, Rear Tower Support

(4) 796438, Gas Shock

(4) 796432 Door Shock

Bracket

(2) 796730 Hinge

790540, Pin

124460, Tower Support Cradle

123680, Pin

189840, Cabinet Top

974680, Plastic Plug

By:

113390

684030, Dome Light

Ground Rod

(2) 189795,

(2) 189920,

Door Hasp

Door Foam Insulation

(2) 189851

(2) 790940, Handle

c Amida Industries, Inc. 1999

2-2-99 Spectrum

a) b) c) f)

d) e)

Document:Revised:Created:

Cabinet Door

Page 25

Model:

Title:

853296

AL5000 LIGHT TOWER

Cabinet Dec a ls

Top

850091

Page:

851640

853296

Curb Side

851860

851640

Front

853346

852410

853531

(2) 841710

850092

Road Side

853531

853351

853291

Rear

850093

c Amida Industries, Inc. 1999

Created:

By:

853291

1-26-99 Spectrum

Revised:

www.terex.com

853531

a) b)

d) e) f)c)

Document:

850135

Page 26

Model:

Title:

AL5000 LIGHT TOWER

Tower Assy.

113080, Coil Cord Sleeve

Page:

See 2" Section

See 3" Section

See 6" Round Tube

See 4" Section

c Amida Industries, Inc. 1999

Created:

By:

2-2-99 Spectrum

Revised:

a) b)

d) e) f)c)

Document:

Page 27

Model: Page:

Title:

AL5000 LIGHT TOWER

4" Tower Section

See Sheave & Shim Assembly

124540, 4" Tower Section

990660, Roll Pin

177810 Shim

120220, Lock Pin

790510, 1/16" Cable

(3) 790520, Cable Sleeve

990760, "R" Pin

980340 Screw

790710 Spring

120640, Pin

990650 Cotter Pin

See 6" Round Tube

By:

c Amida Industries, Inc. 1999

2-2-99 Spectrum

a) b) c) f)

d) e)

Document:Revised:Created:

Page 28

Model:

Title:

AL5000 LIGHT TOWER

4" Tower Sec./Upr. Sheave & Shim Assy.

188760 Sheave

(2) 990650 Cotter Pin

Page:

183285, Shim See Orientation Below

(2) 994920 Cotter Pin

183286, 5/16" Shim

183288, 3/16" Shim

995780 Clevis Pin

992765 Clevis Pin

(2) 995790 Clevis Pin

183285, 3/8" Shim

177830, 1/4" Shim

c Amida Industries, Inc. 1999

Created:

By:

2-2-99 Spectrum

Revised:

Orientation of Shims Inside Tube

a) b)

d) e) f)c)

Document:

Page 29

Model:

Title:

AL5000 LIGHT TOWER

3" Tower Section

Page:

192904 Cable

(2) 994920 Cotter Pin

990650 Cotter Pin

188760 Sheave

124550 3" Tower Section

185290, Shim See Orientation Below

992765 Clevis Pin

(2) 995790 Clevis Pin

c Amida Industries, Inc. 1999

Created:

By:

996230 3/8" Screw 990470, Lock Washer

2-2-99 Spectrum

Revised:

Orientation of Shims Inside Tube

185290, 3/8" Shim

(3) 177820, 5/16" Shim

a) b)

d) e) f)c)

Document:

Page 30

Model: Page:

Title:

AL5000 LIGHT TOWER

2" Section

124560, 2" Tower Section

By:

190570, Cable

990470, Lock Washer

996230, 3/8" Bolt

c Amida Industries, Inc. 1999

2-2-99 Spectrum

a) b) c) f)

d) e)

Document:Revised:Created:

Page 31

Model:

Title:

(4) See Fixture Assembly

113040, Cross Arm

AL5000 LIGHT TOWER

Tower Crossarm / Fixture

Page:

c Amida Industries, Inc. 1999

Created:

By:

Cross Arm Mounting Plate

(4) 123080, Fixture Mounting Wing Nut

2-2-99

Revised:

Spectrum

a) b)

d) e) f)c)

Document:

Page 32

Model: Page:

Title:

AL5000 LIGHT TOWER

6" Round Tube

990620 Lock Nut

994920 Cotter Pin

990650 Cotter Pin

990610 Tee Bolt

990650 Cotter Pin

794550 Grease Fit.

188770 Sheave

179850 Bushing

188760 Sheave

(2) 992765 Clevis Pin

By:

124530 6" Round Tube

992765 Clevis Pin

188760 Sheave

c Amida Industries, Inc. 1999

2-2-99 Spectrum

995790 Clevis Pin

a) b) c) f)

d) e)

Document:Revised:Created:

Page 33

Model:

Title:

AL5000 LIGHT TOWER

Tower w/ Base Assy.

116220, Tower Assy. w/ Cables

Page:

113040, Crossarm

116170, Tower Base

740050, Winch 1500#

124480, Winch Handle

c Amida Industries, Inc. 1999

Created:

By:

2-2-99 Spectrum

Revised:

a) b)

d) e) f)c)

Document:

Page 34

Model:

Title:

124490, Tower Base

193750, Kick-Out Spring

AL5000 LIGHT TOWER

Tower Base Assy.

Page:

740050, Manual Winch 111680 Winch Socket

186360, Bumper Pad

184510, Spool Sheave

124480, Winch Handle

120220, Pin Slide Lock

c Amida Industries, Inc. 1999

Created:

By:

2-2-99 Spectrum

Revised:

a) b)

d) e) f)c)

Document:

Page 35

Model: Page:

Title:

866010, Air Cleaner

630960, Generator

AL5000 LIGHT TOWER

Genset, Kub-D1105/L-S 8KW

866120, Radiator Cap

741140, Temp. Sender 732200, Engine

109350, Capacitor

866030, Soleniod 866040, Gasket

836857, Diode

865223, Electric Fuel Pump

Mounted to Trailer Frame

866050, Oil Filter

866080, V-Belt

866110, Radiator

By:

c Amida Industries, Inc. 1997

9-5-97 Spectrum

a) b) c) f)

d) e)

Document:Revised:Created:

Page 36

Model:

Title:

AL5000 LIGHT TOWER

Genset, Kub-D1105/L-S 8KW

732200, Engine

866090, Alternator

839190, Low Oil Press. Sensor

Page:

c Amida Industries, Inc. 1997

Created:

By:

9-5-97 Spectrum

866100, Starter

Revised:

836835, End-Kit With Bearing

836830, O-Ring

836828, Rear Bearing

a) b)

d) e) f)c)

Document:

Page 37

Model:

Title:

AL5000 LIGHT TOWER Generator Mounting Bar

Page:

630960, Generator

(2) 990200 Lock Nut

189335, Generator Mounting Bar

(4) 990210, Flat Washer

(2) 990820, Bolt

c Amida Industries, Inc. 1997

Created:

By:

9-5-97 Spectrum

Revised:

a) b)

d) e) f)c)

Document:

Page 38

Model: Page:

Title:

Right Side Radiator/Engine Mtg. Bracket

AL5000 LIGHT TOWER

Engine Block

Radiator Mounting Bracket

189290, Engine Mounting Bracket

740920, Vibration Mount Assy.

(4) R980175, Flat Washer

(4) 994830, Lockwasher

(4) 995110, Screw

By:

c Amida Industries, Inc. 1997

9-5-97 Spectrum

a) b) c) f)

d) e)

Document:Revised:Created:

Page 39

Model:

Title:

AL5000 LIGHT TOWER

Fuel Filter

Page:

839200, Kubota Fuel Filter

c Amida Industries, Inc. 1997

Created:

By:

9-5-97 Spectrum

Revised:

a) b)

d) e) f)c)

Document:

Page 40

Model: Page:

Title:

866120, Radiator Cap

AL5000 LIGHT TOWER

Radiator/Overflow Tank

866110, Radiator

865307, Overflow Tank

By:

c Amida Industries, Inc. 1997

9-5-97 Spectrum

a) b) c) f)

d) e)

Document:Revised:Created:

Page 41

Model:

Title:

185390, Control Box Side

683680, Breaker 2P-30A

(4) 683870, Breaker 1P-15A

189170, Control Box Face

851790, Decal

853190, Decal 853280, Decal

AL5000 LIGHT TOWER

Electrical AC/DC, 4 MH/HPS

186730, Control Box Rear

186801, Control Box Top

683970, Mini-Breaker

684640, Duplex Receptacle W/ GFI

260360, Hour Meter

Page:

684380, Switch

R660010, Push-

Button Switch

682715, Light

R661490, Relay

c Amida Industries, Inc. 1999

Created:

By:

663880 Cap For Receptacle

680190, Box Cover W/ Gasket

1-26-99 Spectrum

684450, T-Lock Receptacle

663870, Connector 3P Female

680080, Strain Relief

121620, Box W/ Mount Bar

852800, Decal

Revised:

a) b)

660287, Coil Cord

d) e) f)c)

186781, Control

Box Bottom

663890, Female

Cord Set

Document:

Page 42

TEREX

amida

112605-STANDARD LIGHT TOWER

MH/ MV/ HPS LIGHT FIXTURE

Page:

3132 18

1936

NOTE:

FOR COMPLETE ASSEMBLY

ORDER PART# 112605

833585

995970

791.1137

4110624000

LBL FIXTURE CSA - NRTL/C

WASHER 1/2 EXTER. TOOTH LOCK SS

833584

404142

791.2395

LBL 105C SUPPLY COND.

833583

791.2397

LBL WET LOCATION/EXTERIOR

833582

690.0121

FIBERGLASS SLEEVE 2-1/2"

833581

4110953000

FIBER WASHER

833580

635.1110

WASHER 1/4 X 1-1/4" OD

680020

634.0042

LOCKNUT 1/2

683950

690.0446

SEAL RING .755" ID - EPDM

160130

LAMP, 1000 WATT MERCURY VAPOR (OPT.)

160140

833579

282930

4100109000

MARRETS 150°C 2 WIRE NUT #16

LAMP, 1000 WATT HIGH PRESSURE SODIUM (OPT.)

NUTSERT 8-32 X Ø1/4" X 13/32 " LENGHT

833578

634.8005

160071

LAMP, 1000 WATT METAL HALIDE

990675

991650

242526

4104021000

4110310000

SPLIT WASHER 1/2 SS

RIVETS Ø1/8" ALUM. 3/16" LENGHT

833577

833576

4107742000

4106784000

SCRW 6-32"TT" X 3/8 PH PH ZN

SCREW 8-32 x 5/8" FH PH MS ZC

833575

245.0121

O-RING 0.206" ID x Ø0.103 SILICON

202122

84287

CORD #16-3 SIOW 105°C + 2 TERM. RING

663850

833574

630.8928

SCREW 8-32 X 1 HH SL MS SS

682470

690.0447

STRAIN RELIEF #2521 T&B

410.1032

HANDLE FOR 1/2-13 BOLT (DWG) (OPTIONAL)

833573

833572

161718

245.0119

O-RING 1.925" ID x Ø0.103" SILICON

833543

410.2027

CLAMP BAND Ø19.5" ALUMINUM

833524

555.0079

COMBINATION

245.0124

VULCANIZED GASKET SILICONE - 1/8" LENS

833571

70463

SCREW 10-24 x 5/8 HW SL TT

833570

410.1024

REINFORCING RING (T&B - B60198)

833564

833565

4605079000

4106781000

SOCKET MOGUL BASE W/ WIRES

SCREW 8-32 x 3/8" PH PH TT ZC

833563

410.1023

SOCKET BRACKET (T&B 057-05-80643)

833562

630.1045

SCREW 1/4-20 x 2" PH SS

833561

1234567891011

410.0003

ALUM. CONNECTION BOX

TEREX PART#

POWERLITE#

DESCRIPTION

833567

990810

833547

833569

833566

310.0056

4103054000

410.5021

245.0120

GASKET HIF (T&B - B61178)

410.1021

HOUSING ALUM. CST. FOR GENERATOR

BOLT 1/2-13 x 1-1/2" HH MS SS

REFLECTOR 18" ALUM. PEENED W / LENS & BAND

TRUNNION FOR GENERATOR

c TEREX Light Construction, 2000

211

111.52

222

11111

111

QTY.

111

Page 43

Model:

Title:

AL5000 LIGHT TOWER

Ballast

114355, Ballast Box MH 114895, Ballast Box HPS

663860, 5 Pin Connector

Page:

c Amida Industries, Inc. 1999

Created:

By:

160030, Ballast MH 160040, Balast HPS

2-2-99 Spectrum

Revised:

160032, Capacitor MH 160042, Capacitor HPS

a) b)

d) e) f)c)

Document:

Page 44

Model:

Title:

840470, Ball, 2"

SAE-2

AL5000 LIGHT TOWER

Trailer Hitches

840120, Coupler, 2"

176336, Spacer

121572, Combo Hitch Ring

16" Long

Page:

176335, Plate

940000, Kit, Combo

Hitch

213770, Ring Hitch

124450, Hitch, 24" Height

211410, Ring Hitch for Adj Height

2-1/2" I.D.

221580, Hitch,

Adj. Height

By:

841200, Hitch, Pintle Ring, 3" I.D.

c Amida Industries, Inc. 1999

2-2-99 Spectrum

Revised:Created:

a) b) c) f)

d) e)

Document:

Page 45

001

004

003

OPTION #

DWG/ITEM #

001 002 003 004

DRAWN BY DATE

0LTX0690

160992 113583 160993 663780

BLB

WINCH, ELEC. 12V DC (STD) AL4000/AL5000

PART #

002

DESCRIPTION

WINCH 12V WINCH SWITCH W/ SOLE NO ID ASS'Y WINCH SOLENOID WINCH TOGGLE SWITCH

2/8/96

DRAWING NO.

8149

Page 46

002

001

OPTION #

8126 - 001 8126 - 002

0LTX0080 STOP TAIL & TURN LIGHT AND LICENSE TAG LIGHT

DESCRIPTION

DRAWING NO.

8126

CNM

PART #DWG/ITEM #

663510 663520

STOP TAIL & TURN LIGHT LICENSE TAG LIGHT W/BRACKET

DATEDRAWN BY

4/4/91

Page 47

#REQ

"B"

NONE

2985A

DWG.#

2985A

BORDER

SCALE

DWG.#

DESCRIPTION

CHANGE

WD2985

PART#

ITEM#

590 HUEY Rd, ROCK HILL, S.C.

Ph. (803) 324-3011 FAX 366-1101

WIRING DIAGRAM, MH OR HPS FIXTURE

WD2985

DR BY

W/JOY CONNECTOR

PART#

ADDED EUROPEAN (CE) WIRING DATA

ECO #

.XXXX=±.005

Degrees ±1/2°

Fractions ±1/16

DATE

3/15/00

REV.

TOLERANCES UNLESS OTHERWISE SPECIFIED:

REMOVE ALL BURRS & SHARP EDGES

Decimals .XX=±.030 .XXX=±.010

MATL.

4/30/91

MAT P/N

PLOT 4/30/91DATE

COMMON FROM BALLAST

HOT FROM BALLAST (LIVE)

CIRCUIT

GROUND (EARTH)

14/3

LIGHT BLUE

GREEN W/YELLOW

BROWN

CODE

EUROPEAN

DOMESTIC

COLOR

CODE

GREEN

BLACK

WHITE

WHITE (BLUE)

GREEN (GRN/YEL)

NOTE:

PIN CONFIGURATION IS THE SAME

FOR TUNGSTEN HALOG E N FIXTURES

BLACK (BROWN)

Page 48

#REQ

"B"

2986

DWG.#

DESCRIPTION

2986

BORDER

SCALE: NONE

DWG.#

CHANGE

PART#

WD2986

TRANSFORMER

(1000W METAL HALIDE BALLAST)

ITEM#

PART#

590 HUEY Rd, ROCK HILL, S.C.

Ph. (803) 324-3011 FAX 366-1101

WIRING DIAGRAM - 1000MH BALLAST

W / JOY CONNECTOR

WD2986

DR BY: CNM

PART#

CAP

USAGE

COM

ECO #

.XXXX=±.005

Degrees ±1/2°

Fractions ±1/16

DATE

MATL

Decimals .XX=±.030 .XXX=±.010

REV.

TOLERANCES UNLESS OTHERWISE SPECIFIED:

REMOVE ALL BURRS & SHARP EDGES

PLOT: 4/30/91 DATE: 4/30/91

MAT P/N

MATL.

24 MF

480V

LAMP COMMON

INPUT COMMON

BLACK 120V

WHITE

INPUT 120V

RED

ORANGE

COLOR CIRCUIT

RED LAMP HOT

ORANGE

WHITE

BLACK

GREEN GROUND

5-POLE

RECEPTACLE

GRN

Page 49

#REQ

"A"

WD2987

2987

DWG.#

PART#

2987

BORDER

SCALE: NONE

DWG.#

DESCRIPTION

TRANSFORMER

CHANGE

PART#

WD2987

590 HUEY Rd, ROCK HILL, S.C.

ITEM#

Ph. (803) 324-3011 FAX 366-1101

WIRING DIAGRAM - 1000HPS BALLAST

W / JOY CONNECTOR

DR BY:CNM

PART#

(1000W HIGH PRESSURE SODIUM BALLAST)

26uF

450V

ECO #

DATE: 4/30/91

USAGE

IGNITOR

X2 X3 X1

BLACK

.XXXX=±.005

Fractions ±1/ 16

Degrees ±1/2°

DATE

MATL

Decimals .XX=±.030 .XXX=±.010

INPUT COMMON

REMOVE ALL BURRS & SHARP EDGES

LAMP COMMON

LAMP HOT

PLOT: 4/30/91

MAT P/N

MATL.

GROUND

TOLERANCES UNLESS OTHERWISE SPECIFIED:

REV.

WHITE

RED

INPUT 120V

5-POLE

RECEPTACLE

GREEN

COLOR CIRCUIT

GREEN

ORANGE

RED

WHITE

BLACK

ORANGE

Page 50

#REQ

"B"

NONE

2763B

DWG.#

DESCRIPTION

2763B

BORDER

SCALE

DWG.#

CHANGE

PART#

WD2763

ITEM#

PART#

TO "ACC"

TERMINAL ON

START SWITCH

RED

12V

OUTPUT

BATTERY

BATTERY CHARGER (OPTIONAL*)

CHARGER

* LISTER TR/TS UNITS ONLY

INPUT

120V

#10 BLK

120V-15AMP

GFI PROTECTED

RECEPTACLE BOX AT TOP OF TOWER

RECEPTACLES

TYP. 4

240V

30 AMP

RECEPTACLE

#10 RED

#14 BLK

3 POLE RECEPTACLE

#14 YEL

#14 GREEN

CORD

RETRACTABLE

7-CONDUCTOR

ORN BLUE

YEL

GRN

RED

WHITE

ECO #

DATE

REV.

#14 YEL

#14 GREEN

#14 RED

#14 YEL

#14 BLACK

BALLAST

#14 GREEN

BALLAST

#14 YEL

#14 GREEN

#14 RED

BALLAST

BLK

TYP.4

5-POLE

RECEPTACLE

20 AMP

#12 RED

BALLAST

590 HUEY Rd, ROCK HILL, S.C.

Ph. (803) 324-3011 FAX 366-1101

.XXXX=±.005

Degrees ±1/2°

Fractions ±1/16

Decimals .XX=±.030 .XXX=±.010

TOLERANCES UNLESS OTHERWISE SPECIFIED:

GMB

DR BY

WD-AC CONTROL BOX, 4MH/HPS

AL4/AL5/LT5/SL4

USAGE

REMOVE ALL BURRS & SHARP EDGES

MAT P/N

MATL.

WD2763

PART#

DATE 7/9/93

7/9/93

PLOT

#14 BLK

FLOODLIGHT CONTROL BOX

#14 BLK

BLACK

MAIN BREAKER 30AMP

BLACK

#14 ORN

WHITE

RED

GREEN

POWER CORD FROM GENERATOR

#14 ORN

15 AMP

TYP. 4

(FLOODLIGHT)

#14 BLK

#14 ORN

Page 51

4730E

"B"

N/A

4730E

START

DWG.#

ORANGE

(NC)

LOW OIL

PRESSURE

(NO)

HIGH

COOLANT

TEMPERATURE

IGN & ACC

OFF

BAT

ACC

SWITCH

LEGEND

IGNITION

CHANGE

WD4730

ORANGE

PART#

590 HUEY Rd, ROCK HI L L, S.C.

Ph. (803) 324-3011 FAX 366-1101

ADDED DIODE FOR FUEL PUMP/ PRIME

ECO #

PUMP

RED

(NC)

PURPLE

BROWN

SPST

RELAY 12V

FUEL

BROWN

HOLD

PULL

COM

ECO #

SOLENOID

DATE

1/12/01

REV.

.XXXX=±.005

Degrees ±1/2°

Fractions ±1/16

Decimals .XX=±.030 .XXX=±.010

TOLERANCES UNLESS OTHERWISE SPECIFI ED:

SCALE

DWG.#

APP BYDR BY JCS

WD4730

WD - DC ENGINE WIRING, KUBOTA

PART#

D905/D1105, AL 4, AL5, TX3

USAGE

REMOVE ALL BURRS & SH AR P E D GES

MATL. BORDER

MAT. P/N

PLOT B 3/23/00 DATE 3/23/00

HOUR

METER

LIGHT

BROWN

GREEN

ALTERNATOR FAILURE

IGBL

RED

ALTERNATOR

PREHEAT

PUSH BUTTON

ORANGE

IGN

BAT

WHITE

RED

ACC

RED

YELLOW

RED

30A

FUSE

RED

GLOW

PLUGS

YELLOW

WHITE

B+

RED

BLACK

STARTER

BATTERY

12 VOLT

Page 52

TEREX Amida Model AL5000

Light Tower – General Specifications

And Routine Maintenance

TEREX Amida model AL5000 series light tower provides mobile; trailer mounted floodlighting for nighttime maintenance, construction, mining, and emergency work. It consists of a trailer with a diesel powered 8 kW 60Hz (STD.) generator , and a 30 foot cable actuated tower with four (4) 1000 watt floodlight fixtures. It is ideally suited for heavy-duty use and is built to meet the following specification:

DIMENSIONS

Overall length, travel position w/fixtures & tongue 183” (4648 mm) Overall length, tower vertical w/tongue & jacks 128” (3251 mm) Trailer frame length 74” (1879 mm) Overall height, floodlighting position 30’ (9.14 m) Overall height, travel position 69” (1752 mm) Overall width with fenders 80” (2032 mm) Overall width with outriggers pulled out 108” (2743 mm) Trailer frame width 60” (1524 mm) T ongue length 47” (1193 mm) Wheel size 15” (381mm) Axle Rating 3500 lb. (1588 kg) Tongue weight travel position 220 lb. (99.79 kg) Total weight no fuel 2425 lb. (1100 kg) Fuel Capacity 30 gal. (1141)

This section details specifications and maintenance not covered in the operators and trouble-shooting sections of this manual and the AL5000 specification sheets.

OIL / AIR SERVICE

The engine oil should initially be changed after the first 50 hours of use and then every 200 hours thereafter. The oil filter should be replaced after every 400 hours of use. The air filter element should be replaced once every year, or after six cleanings (see manufacturer’ s operation manual for details).

BRAKE SYSTEM

Electrical or mechanical brakes are not standard equipment on the AL5000. Contact your dealer or the factory for option information.

Page 53

MANUAL WINCH

Maintain a light film of automotive-type grease on the pinion, drum gear, and the O.D. of the drum bearing at all times. Keep the ratchet pawl pivot, pinion shaft bushings, and pinion threads lubricated with automotive engine oil at all times. WARNING: Before each use, check the brake friction discs for wear . If less than 1/16” thick, cracked, or broken, replace IMMEDI-

ATELY. Ratchet pawl should “click” when tower is raised, and not when it is lowered. WARNING…CAUTION: Always be alert for any fraying of cables, and replace any damaged cables IMMEDIATELY. Never stand under any object lifted by the winch.

ELECTRIC WINCH

The electric winch is permanently sealed and does not need any periodic lubrication. WARNING…CAUTION: Always be alert for any fraying of cables, and replace any damaged cables IMMEDIATELY. Never stand under any object lifted by the winch.

RECETACLE POWER TABLE

METAL HALIDE/ HIGH PRESSURE SODIUM

STATUS RECEPTACLE POWER AVAILABLE 120/240 VAC

LIGHTS ON DUPLEX W/FI 240V- 30A REC.

ALL OFF 15 AMPS* 30 AMPS*

1 OR 3 15 AMPS* 16.6 AMPS

2 OR 4 15 AMPS* 16.6 AMPS 1 AND 3 15 AMPS* 8.3 AMPS 2 AND 4 8.3 AMPS 8.3 AMPS

TUNGSTEN HALOGEN

STATUS RECEPTACLE POWER AVAILABLE 120/240 VAC

LIGHTS ON DUPLEX W/FGI 240V- 30A REC.

ALL OFF 15 AMPS* 30 AMPS*

1 OR 3 15 AMPS* 17 AMPS

2 OR 4 15 AMPS* 17 AMPS 1 AND 3 15 AMPS* 10 AMPS 2 AND 4 15 AMPS* 10 AMPS

• There is more current available than listed. The rating of the duplex receptacle is 15 amps.

NOISE LEVEL

Mean SPL (sound pressure level) hemispherically at 7 meters: 70.80 dBA Sound Power Level (62.01dBA + 20 log d + 7.8): 95.5 LWA re 1 pW D = 7 meters using Alpha LPW3 engine and insulated doors.

Page 54

MISCELLANEOUS SPECIFICATIONS

The Amida AL5000 light tower is built to NEC standards.

FASTENER TORQUE SPECIFICATIONS

All fasteners should be torqued to the following specifications in lb-ft (lb-in):

FASTENER STAINLESS STAINLESS SAE GRADE SAE GRADE SAE GRADE SAE GRADE

SIZE STEEL* STEEL* 5 PLATED 5 PLATED 8 PLATED 8 PLATED

UNF NYLOK (METRIC NYLOK (METRIC NYLOK

& NUT 8.8) NUT 10.9) NUT

UNC

#6 (10-12) (8.5-10) (14-16)

#8 (20-22) (17-19) (25-28) #10 (26-32) (22-27) (40-45) 1/4" (75-94) (64-80) 7-9 12-14

5/16" 12-Nov 14-Dec 15-17 23-26

3/8" 20-22 22-24 28-34 45-50

7/16" 31-33 32-35 40-45 70-75

1/2" 43-45 45-50 75-85 70-80 100-110 95-105

9/16" 57-63 60-65 80-100 75-95 145-160 135-150

5/8" 92-104 100-105 130-170 125-165 175-205 165-195 3/4" 128-135 140-150 220-240 205-225 380-420 365-405

4mm (22-26) (19-22) (23-27) 6mm (45-50) (38-43) (72-78)

8mm 12-Nov 9-10 14-16 10mm 18-20 15-17 45-50 40-45 70-75 12mm 42-44 36-38 56-60 50-55 95-105 16mm 140-148 18mm 185-200 20mm 280-290

* An anti-seize lubricant MUST be used on all stainless steel hardware.

Page 55

WIND LOADING CHARACTERISTICS

All wind load calculations were performed with the winch at 12 o’clock, the wind coming from the

direction shown with the lights flat-facing into the wind.

WIND DIRECTION SPEED FROM 12 O’CLOCK 83 MPH FROM 1 & 11 O’CLOCK 99 MPH FROM 2 & 10 O’CLOCK 109 MPH FROM 3 & 9 O’CLOCK 72 MPH FROM 4 & 8 O’CLOCK 73 MPH FROM 5 & 7 O’CLOCK 101 MPH FROM 6 O’CLOCK 108 MPH

Page 56

BROKEN CABLE REPLACEMENT PROCEDURE

1. PREPARATION

1.1 Collapse tower to where mast is retracted, then pivot tower to horizontal position.

1.2 Remove the tower from the trailer and place it on a work surface such as two saw horses.

2. REMOVING TOP CABLE AND T OP MAST SECTION

2.1 T ie middle section and large section together by wrapping band, cable, chain, or rope around the sheave brackets on these two sections. This insures that the middle section stays inside the large section during removal of the small section.

2.2 Remove or lock the telescope lock pin open. This is the pin that locks the three sections together during travel.

2.3 Drill out the aluminum pop rivets holding the plastic guides at the top of the middle section. Using a screwdriver, remove these guides.

2.4 Remove the clevis pin anchoring the cable to the top of the middle section and remove the clevis pin and the sheave from the middle section.

2.5 Pass the free end of the cable through the sheave slot between the middle and small section, and out of the top of the tower. Pull the cable and the small section completely out of the middle section together. Be sure to keep the cable tight; if slack accumulates it is most difficult to remove.

2.6 Unfasten the cable by removing the bolt at the base of the small section.

3. REINST ALLING THE SMALL SECTION

3.1 Fasten new cable to the base of the small section.

3.2 Reversing the procedure described in steps 2.1 through 2.5, reinstall the small section.

3.3 Reinstall the plastic guides with new pop rivets. New plastic guides should be used, but the old guides can be used if their mounting position is shifted to the point where new holes can be drilled in the tower section to provide a good fit when installing new pop rivets.

4. REMOVING THE LOWER CABLE AND MIDDLE T OWER SECTION

4.1 Remove or lock open the telescope lock pin if not previously done in step 2.2.

4.2 Drill out the aluminum pop rivets holding the plastic guides at the top of the large section. Using a screwdriver, remove these guides.

4.3 Remove the cable from winch drum.

4.4 Remove the sheave clevis pin and the sheave from the top of the large section.

4.5 If the old cable is not frayed between the winch and the bottom mast pulley, attach a flexible “fish wire” or “snake” (wire, rope cord, etc.) to the end of the cable to be used to thread the new cable through the lower tower and pulleys. This can be done by “untwisting” the cable and inserting the wire or cord into the middle of the cable and thus letting the cable twist back tightly around the fish wire. If the old cable is frayed, cut off the frayed portion and proceed as above and then remove tower and cable as instructed in section 4.6.

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4.6 Pass the free end of the cable through the sheave slot between the large and middle sections and out of the top of the tower. Pull the cable and the middle section completely out of the large section altogether. Be sure to keep the cable tight, if slack accumulates it is most difficult to remove.

4.7 If the fish wire doesn’t work, it is necessary to remove the square mast section from the round mast section. Remove the pivot pin from the pivot post and lift the mast from the pivot post and place the assembly on a work surface. Remove the hex nut from the bottom of the round section, remove the “T” bolt at the top of the round section, and pull the square mast assembly out of the round section, and proceed as instructed in section 4.6.

4.8 Unfasten the cable by removing the bolt at the base of the middle section.

5. REINST ALLING THE LOWER CABLE AND MIDDLE SECTION

5.1 If the “fish wire” worked, attach the cable to the fish wire and pull through the pulleys and the round section.

5.2 If the square tower section was removed from the round section, thread the cable through the pulleys at the bottom of the large section and out of the tubular stud. Reinstall the large square section into the round section. Install the “T” locking bolt, and the hex nut on the bottom of the round section. The hex-locking nut should be tightened and then backed off approximately onehalf turn or until the tower rotates freely .

5.3 Fasten the new cable to the base of the middle section.

5.4 Reversing the procedures detailed in sections 4.4 through 4.7, reinstall the middle section.

5.5 Fasten the new cable to the winch drum.

5.6 Reinstall the plastic shims as described in section 3.3.

Page 58

LIGHT FIXTURE TROUBLESHOOTING

DANGER! Do not open fixtures while light circuit breaker is “ON”. Allow lamp to cool before touching.

**T AKE EXTRA PRECAUTIONS WHEN TROUBLESHOOTING ELECTRICAL PROBLEMS** A.Only use a voltmeter with two well-insulated 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 dischar ge. E. If all the lights are out and all the ballasts are receiving power, suspect burned out power cable.

SYMPTOM CAUSES CORRECTIVE ACTION LAMP WILL Check Ballast Status Light a.Input lights should be on. This confirms power is going

NOT START to the ballast.

b.Output lights should be on. This confirms power is coming from ballasts. c.Output lights should be normal brightness. If one or more of the output lights stay extra-bright, then the lamp is not striking.

d.Use this knowledge to diagnose problem. e.If ballast status light is out, but the floodlight lamp is working, suspect burned out ballast status lamp and replace

Lamp loose in socket Inspect lamp base to see if there is arcing at center contact

button. Tighten lamp snugly. Check socket for damage. Replace if defective.

Floodlight Plugs not tight Check plug and receptacle. Tighten if loose. Defective Ballast Interchange ballast plugs in generator enclosure. If lamp

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

Low Voltage Check line voltage at ballast input. Voltage should be

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

Improper ballast Proper HID lamps will perform erratically or fail to start on

an improper ballast. The ballast nameplate data should agree with the line voltage and lamp used. Improper ballast will cause lamp to fail.

Improper lamp operating Operating position should agree with lamp etch. A BUHOR position lamp can be operated base up vertical to and including the

horizontal and BD can be operated base down and vertical to, approaching, but not including the horizontal. A lamp operated beyond the specified position may not start.

Lamp has been operating; HID lamps require 4 to 8 minutes cool-down time before

cool down time insufficient restarting. Switch off breaker and allow lamp to cool.

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LIGHT FIXTURE TROUBLESHOOTING (cont’d)

SYMPTOM CAUSES CORRECTIVE ACTION

LAMP STARTS Defective Lamp Lamp may glow for extended period of time. Replace after SLOWLY (ARC checking voltage and ballast. DOES NOT STRIKE WHEN SWITCH IS FIRST TURNED ON)

CIRCUIT Short circuit or ground Checking wiring against diagram. Check for shorts or ground. BREAKER TRIPS ON LAMP START-UP

LAMP LIGHT Normal lamp depreciation Replace lamp OUTPUT LOW

Dirty lamp or fixture Clean lamp and fixture

Defective ballast Interchange ballast plugs in generator enclosure. If lamp

returns to normal light output, replace ballast. Check for swollen capacitors, charred wiring, core and coil, or other signs of excessive heat.

Wrong Voltage Check voltage at ballast input. Voltage should be within 10%

of nameplate rating. Check wiring connections for voltage loss. Check socket contact point.

Improper ballast Check ballast nameplate against lamp data.

LAMP COLORS Normal lamp depreciation Lamp color and brightness decreases and colors change DIFFERENT slightly as lamps age. Spot replacement with new lamps may

cause noticeable differences in lamp colors. Group replacement minimizes color differences.

Dirty fixture Dirty fixtures will cause lamps to appear different in color.

Clean fixture.

Wrong lamp Check data on lamps, which appear different in color .

Replace with correct color lamp.

ARC TUBE Over voltage from Check voltage at ballast. Check for current or voltage surges. DISCOLORED power supply Check for shorted capacitors and replace if defective. OR SWOLLEN

Improper ballast Lamp operated on ballast designed for higher wattage lamp.

Check ballast nameplate against lamp data.

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LIGHT FIXTURE TROUBLESHOOTING (cont’d)

SYMPTOM CAUSES CORRECTIVE ACTIONS

SHORT LAMP Lamp damaged Check for outer bulb cracks. If air enters outer bulb, arc tube LIFE may continue to burn for 100 hours before failure. Check for

bulb cracks where glass meets the base due to tightening lamp too firmly in socket. Look for broken arc tube or loose metal parts. Replace lamp.

Improper ballast Ballast nameplate data should agree with lamp line voltage

and lamp use. If improper ballast is used, the lamp life will be shortened. A mismatch may also cause the ballast to fail.

LAMP Improper ballast Improper ballasting can cause flickering or erratic operation. FLICKERS AND In the start-up period the lamp may ignite, start to warm-up GOES OUT and then extinguish (cycle). INTERMITTET

New lamp Under certain conditions new lamps may “cycle”. Usually

after three (3) tries to start at 30 to 60 second intervals, lamps will stabilize and operate satisfactorily.

Defective lamp Replace lamp.

Page 61

TRACEABLE NUMBERED WIRING SYSTEM

(Using plug in ballasts to troubleshoot)

When troubleshooting the preceeding problems, minimize down time by following the traceable numbered wiring system, always follow these steps:

STEP1: Insure all ballasts, which are numbered, are plugged into lead wires with corresponding

numbers.

STEP 2: Looking at the lights from the glass side and following the diagram below, plug each

fixture into the appropriately numbered plug at the top of the tower.

By adhering to the traceable numbered wiring system, troubleshooting, fixture aiming, and fixture control will follow a standard predictable pattern.

Page 62

Rear Bearing Inspection Requirements

Leroy-Somer 6 & 8 kw Generators

The rear bearing on all 6 & 8 kw generators should be inspected every two (2) years or 2000 hours, whichever occurs first. The bearing should be replaced at three (3) years or 3000 hours. Careful attention to this inspection proeedure will prevent total generator failure resulting from bearing or bearing carrier deterioration.

There are two areas to examine during the inspection. First is the clearance between the bearing outer case and thegenerator bearing carrier (NDE Bracket). The bearing should fit snugly into the carrier so that it can be rotated only with some resistance. Side to side movement should be less than .010". If the bearing can be moved easily inside the carrier or if there is visible evidence of bearing carrier wear, the housing carrier should be replaced with End Kit #836835 (which includes the carrier, bearing and 0-Ring). The second area of concern is the bearing itself. If roughness can be felt when rotating the outer race of the bearing, the bearing needs to be replaced (#836828). The other area to check is to see if the outer race will rock back and forth along the bearing axis. If there is movement in this axis, replace the bearing. If neither of these conditions exist, replace the bearing retaining 0-Ring (#836830) and reassemble. Note: These bearings are sealed units and cannot be field serviced.

Follow the same procedure at three (3) years or 3000 hours. At this time replace both the bearing and O-Ring as well as inspecting the bearing carrier.

Page 63

WARRANTY PROCEDURE

The specific language of this warranty will determine TEREX LIGHT CONSTRUCTION's obligation in connection with its product. The information presented below should be used as a general guide for implementation of policy. In the event of a component failure during the warranty period it should be repaired as soon as possible, preferably at an authorized TEREX LIGHT CONSTRUCTION service center. If component is manufactured by a company other than TEREX LIGHT CONSTRUCTION, such as Deutz, Honda, Isuzu, Leroy Somer, Lister Petter, Lombardini, Wisconsin, etc., the applicant should pursue repair and/or reimbursement through that manufacturer, and its dealer/distributor network

To file a claim with TEREX LIGHT CONSTRUCTION, an WARRANTY APPLICATION (WA) form must be completed in it’s entirety. Return the completed form within fourteen days of the repair to:

ATTENTION: WARRANTY TEREX LIGHT CONSTRUCTION 590 Huey Road Rock Hill Industrial Park Rock Hill, SC 29730

TEREX LIGHT CONSTRUCTION will review the AWA form. Should we desire to inspect the defective parts, we will issue you a return authorization for the defective parts. After inspecting the defective part(s), and it is determined that warranty is due, we will then, at the discretion of TEREX LIGHT CONSTRUCTION , credit the applicants account or send replacement parts.

TEREX LIGHT CONSTRUCTION warranty reimbursements:

1. $40.00 for each hour’s labor we allow toward a repair.

2. Distributors cost of parts not more than the price currently available from TEREX LIGHT CONSTRUCTION.

3. One way surface freight charges on parts returned to TEREX LIGHT CONSTRUCTION.

Many repairs are assigned a predetermined labor schedule which is an average time in which a skilled technician should be able to make a repair. TEREX LIGHT CONSTRUCTION will reimburse not to exceed the predetermined number of hours for a particular repair.

TEREX LIGHT CONSTRUCTION does not reimburse for:

1. Travel, travel time, nor travel labor.

2. Mileage.

3. Excessive diagnostic time.

4. Repairs of defects, malfunctions, or failures resulting from accidents, abuse, misuse, modifications, alterations, improper servicing or lack of performance of required maintenance service.

5. Repairs where defective parts were not shipped back when requested by TEREX LIGHT CONSTRUCTION.

6. Regular maintenance such as parts or labor for oil changes, filter changes or filters.

7. Repairs where defective parts were not received by TEREX LIGHT CONSTRUCTION after TEREX LIGHT CONSTRUCTION issued a return authorization.

Page 64

TEREX Amida

P.O. Box 3147

Rock Hill, SC 29730

MANUFACTURER’S LIMITED WARRANTY

TEREX Amida warrants to the original purchaser that goods manufactured by it will be free from defects in workmanship and material for a period of one year after invoice from TEREX Amida, provided such goods are installed, operated and maintained in accordance with TEREX Amida’s written instructions.

TEREX Amida makes warranty with respect to components and accessories furnished to TEREX Amida, by third parties only to the extent of the original manufacturer’s warranty to TEREX Amida. Third party components and accessories are parts such as fixtures, ballasts, engines, hydraulic pumps, fuel pumps, alternators, generators, winches, tires and electrical components. TEREX Amida makes no other warranty , express or implied, and makes no warranty of merchantability or fitness for any particular purpose.

Warranty for repair or replacement parts after warranty period shall extend for 90 days after invoice date. Manufacturer’s liability and purchaser’s sole and exclusive remedy for a failure of goods to perform as warranted for any and all other claims arising out of the purchase and use of the goods, including negligence on the part of TEREX Amida, shall be limited to the repair of replacement of goods returned, transportation prepaid to TEREX Amida. TEREX Amida shall in no event be liable for incidental or consequential damages.

No employee or representative is authorized to change this warranty in any way or grant any other warranty unless such change is made in writing and signed by an officer of TEREX Amida, at it’s home office.