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.
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TABLE OF CONTENTS Receiving and Set-up Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Check Out on Receipt/Delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TEREX Amida Light Tower Model Coding System . . . . . . . . . . . . . . Recommended Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7 8 9 10 Operating Instructions Light Tower Operating Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . .
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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.
• 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.
• 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 Task Read the safety instructions and operating procedures before attempting to troubleshoot or work on this unit. Also read the engine manual, which is a separate booklet that is provided with this manual.
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.
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.
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 32°F to 77°F SAE 30 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.
MODEL AL5000 OPERATING INSTRUCTIONS I M P O R T A N T: WARNING CAUTION READ ALL DIRECTIONS IN MANUAL CAREFULLY BEFORE OPERATING EQUIPMENT DO NOT RAISE TOWER IN THE VICINITY OF OVERHEAD POWER LINES! O PE RAT 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.
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.
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).
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.
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.
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Model: Page: AL5000 LIGHT TOWER Title: Cable Replacement Diagram 6" Round Tube 2" Section Cable 2 Point B 3" Section 4" Section "Hat" Section Cable 1 Point B Cable 2 (109070) Point A Cable 1 (109065) Point A Winch c Amida Industries, Inc.
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PARTS MANUAL 19
Model: Title: Page: AL5000 LIGHT TOWER Trailer Frame/Tongue/Outriggers 160110, Battery 174160, Battery Hold-Down 182330, Battery Hold-Down Rod 114612, Outrigger 160273, Battery Cable Set 109150, Plunger Kit 124800, Trailer Frame 124470, Tongue 841430, Jack c Amida Industries, Inc.
Model: Page: AL5000 LIGHT TOWER Title: Fuel Tank 741715, Cap & Gauge Roadside Return & Supply (4) 990170, Lock Nut Curbside Return & Supply 741701, 30 Gal. Fuel Tank 114720, Fuel Mounting Bracket c Amida Industries, Inc.
Model: Page: AL5000 LIGHT TOWER Title: Axle Assy. Note: Axle Ass'y w/o Tires- 840377 (2) 834267, U-Bolt Kit 834225, Grease Seal 834220, Hub Assy. 834255, Cotter Pin 834250, Spindle Nut 834339, Axle 834228, Grease Cap 834226, Inner Bearing 834227, Outer Bearing 841060, Tire & Wheel Mounted (3) 840395, Axle Spring Nut 840376, Lug Nut 840392, Axle Rear Hanger (3) 840394, Axle Spring Bolt 841051, Axle Front Hanger 841473, Axle Shackle (2) 834246, Spring Eye Bushing c Amida Industries, Inc.
Model: Page: AL5000 LIGHT TOWER Title: Cabinet Assy. (4) 796432, Door Shock Bracket 184150, Winch Handle Bush. 189860, Cabinet, Roadside 189820, Cabinet, Front 124420 Ground Rod Storage Tube (2) 189390 Elec. Box Mtg. Bracket Radiator Overflow Bracket 176370 Literature Rack (2) 930950 Weatherstrip Adhesive 124190, Cabinet, Rear (2) 123490 Fender 189870, Cabinet, Curbside c Amida Industries, Inc.
Model: Page: AL5000 LIGHT TOWER Title: Cabinet Assy.-116650 720220, Bumper 790540, Pin 116180, Rear Tower Support 124460, Tower Support Cradle 123680, Pin 189840, Cabinet Top 974680, Plastic Plug (4) 796438, Gas Shock (4) 796432 Door Shock Bracket (2) 796730 Hinge 684030, Dome Light 113390 Ground Rod (2) 189795, Door Hasp c Amida Industries, Inc.
Model: Page: AL5000 LIGHT TOWER Title: Cabinet Decals Top 851640 850091 853296 853296 Curb Side Road Side 853531 853531 853346 851860 853351 852410 851640 853291 Rear Front 850092 850093 c Amida Industries, Inc. 1999 (2) 841710 Created: By: www.terex.
Model: Page: AL5000 LIGHT TOWER Title: Tower Assy. 113080, Coil Cord Sleeve See 2" Section See 3" Section See 4" Section c Amida Industries, Inc.
Model: Page: AL5000 LIGHT TOWER Title: 4" Tower Section See Sheave & Shim Assembly 124540, 4" Tower Section 990660, Roll Pin 120220, Lock Pin 790510, 1/16" Cable 177810 Shim (3) 790520, Cable Sleeve 990760, "R" Pin 980340 Screw 790710 Spring 120640, Pin 990650 Cotter Pin c Amida Industries, Inc.
Model: Title: Page: AL5000 LIGHT TOWER 4" Tower Sec./Upr. Sheave & Shim Assy. 188760 Sheave (2) 990650 Cotter Pin 183285, Shim See Orientation Below (2) 994920 Cotter Pin 995780 Clevis Pin 992765 Clevis Pin (2) 995790 Clevis Pin 183285, 3/8" Shim 183286, 5/16" Shim 177830, 1/4" Shim 183288, 3/16" Shim c Amida Industries, Inc.
Model: Page: AL5000 LIGHT TOWER Title: 3" Tower Section (2) 994920 Cotter Pin 185290, Shim See Orientation Below 990650 Cotter Pin 188760 Sheave 992765 Clevis Pin (2) 995790 Clevis Pin 124550 3" Tower Section 192904 Cable Orientation of Shims Inside Tube 185290, 3/8" Shim 996230 3/8" Screw 990470, Lock Washer c Amida Industries, Inc.
Model: Page: AL5000 LIGHT TOWER Title: 2" Section 124560, 2" Tower Section 190570, Cable 990470, Lock Washer c Amida Industries, Inc.
Model: Page: AL5000 LIGHT TOWER Title: Tower Crossarm / Fixture (4) See Fixture Assembly 113040, Cross Arm c Amida Industries, Inc.
Model: Page: AL5000 LIGHT TOWER Title: 6" Round Tube 990650 Cotter Pin 990610 Tee Bolt 188770 Sheave 794550 Grease Fit. 188760 Sheave 179850 Bushing 990620 Lock Nut 994920 Cotter Pin 990650 Cotter Pin 124530 6" Round Tube 992765 Clevis Pin 995790 Clevis Pin c Amida Industries, Inc.
Model: Page: AL5000 LIGHT TOWER Title: Tower w/ Base Assy. 113040, Crossarm 116220, Tower Assy. w/ Cables 116170, Tower Base 740050, Winch 1500# c Amida Industries, Inc.
Model: Page: AL5000 LIGHT TOWER Title: Tower Base Assy. 124490, Tower Base 193750, Kick-Out Spring 740050, Manual Winch 111680 Winch Socket 124480, Winch Handle 186360, Bumper Pad 184510, Spool Sheave c Amida Industries, Inc.
Model: Page: AL5000 LIGHT TOWER Title: Genset, Kub-D1105/L-S 8KW 866120, Radiator Cap 741140, Temp. Sender 732200, Engine 866010, Air Cleaner 630960, Generator 109350, Capacitor 866030, Soleniod 866040, Gasket 836857, Diode 866050, Oil Filter 866080, V-Belt 865223, Electric Fuel Pump Mounted to Trailer Frame c Amida Industries, Inc.
Model: Page: AL5000 LIGHT TOWER Title: Genset, Kub-D1105/L-S 8KW 732200, Engine 866090, Alternator 839190, Low Oil Press. Sensor 836835, End-Kit With Bearing 836830, O-Ring 866100, Starter c Amida Industries, Inc.
Model: AL5000 LIGHT TOWER Title: Generator Mounting Bar Page: 630960, Generator (2) 990200 Lock Nut 189335, Generator Mounting Bar (4) 990210, Flat Washer c Amida Industries, Inc.
Model: Title: Page: AL5000 LIGHT TOWER Right Side Radiator/Engine Mtg. Bracket Engine Block (4) R980175, Flat Washer (4) 994830, Lockwasher (4) 995110, Screw Radiator Mounting Bracket 189290, Engine Mounting Bracket c Amida Industries, Inc. 1997 740920, Vibration Mount Assy.
Model: Page: AL5000 LIGHT TOWER Title: Fuel Filter c Amida Industries, Inc.
Model: AL5000 LIGHT TOWER Title: Radiator/Overflow Tank Page: 866120, Radiator Cap 865307, Overflow Tank c Amida Industries, Inc.
Model: Page: AL5000 LIGHT TOWER Title: Electrical AC/DC, 4 MH/HPS 186730, Control Box Rear 186801, Control Box Top 185390, Control Box Side 683970, Mini-Breaker 684640, Duplex Receptacle W/ GFI 260360, Hour Meter 683680, Breaker 2P-30A (4) 683870, Breaker 1P-15A 684380, Switch 189170, Control Box Face 851790, Decal R660010, PushButton Switch 853190, Decal 682715, Light R661490, Relay 853280, Decal 186781, Control Box Bottom 684450, T-Lock Receptacle 663880 Cap For Receptacle 663890, Female Cor
MH/ MV/ HPS LIGHT FIXTURE amida TEREX 28 26 30 32 20 31 18 37 21 2 34 1 3 5 12 23 38 40 29 27 16 22 42 41 30 11 25 13 24 4 10 9 15 28 7 8 6 17 36 19 833565 833566 833564 833561 833562 833563 TEREX PART# 8 7 6 4 3 1 # 4103054000 410.5021 310.0056 4605079000 4106781000 410.1021 410.0003 630.1045 410.1023 POWERLITE# BOLT 1/2-13 x 1-1/2" HH MS SS REFLECTOR 18" ALUM. PEENED W / LENS & BAND HOUSING ALUM. CST.
Model: Page: AL5000 LIGHT TOWER Title: Ballast 114355, Ballast Box MH 114895, Ballast Box HPS 663860, 5 Pin Connector 160030, Ballast MH 160040, Balast HPS c Amida Industries, Inc.
Model: Page: AL5000 LIGHT TOWER Title: Trailer Hitches 840120, Coupler, 2" 176336, Spacer 176335, Plate 840470, Ball, 2" SAE-2 121572, Combo Hitch Ring 16" Long 940000, Kit, Combo Hitch 213770, Ring Hitch 2-1/2" I.D. 124450, Hitch, 24" Height 221580, Hitch, Adj. Height c Amida Industries, Inc. 1999 211410, Ring Hitch for Adj Height 841200, Hitch, Pintle Ring, 3" I.D.
001 004 003 002 OPTION # 0LTX0690 DWG/ITEM # WINCH, ELEC. 12V DC (STD) AL4000/AL5000 DESCRIPTION PART # 001 002 003 160992 113583 160993 WINCH 12V WINCH SWITCH W/ SOLENOID ASS'Y WINCH SOLENOID 004 663780 WINCH TOGGLE SWITCH DRAWN BY BLB DATE 2/8/96 DRAWING NO.
002 001 OPTION # 0LTX0080 STOP TAIL & TURN LIGHT AND LICENSE TAG LIGHT DWG/ITEM # 8126 - 001 8126 - 002 DRAWN BY DESCRIPTION PART # 663510 663520 CNM STOP TAIL & TURN LIGHT LICENSE TAG LIGHT W/BRACKET DATE 4/4/91 DRAWING NO.
EUROPEAN COLOR CODE LIGHT BLUE BROWN GREEN W/YELLOW DOMESTIC COLOR CODE WHITE BLACK GREEN COMMON FROM BALLAST HOT FROM BALLAST (LIVE) GROUND (EARTH) CIRCUIT NOTE: PIN CONFIGURATION IS THE SAME FOR TUNGSTEN HALOGEN FIXTURES WHITE (BLUE) GREEN (GRN/YEL) BLACK (BROWN) 14/3 3/15/00 DATE ECO # DWG.# 2985A DESCRIPTION ADDED EUROPEAN (CE) WIRING DATA CHANGE #REQ 590 HUEY Rd, ROCK HILL, S.C. Ph.
GRN CIRCUIT INPUT 120V INPUT COMMON LAMP HOT LAMP COMMON GROUND COLOR BLACK WHITE RED ORANGE GREEN 5-POLE RECEPTACLE RED WHITE BLACK ORANGE C1 24 MF 480V DATE ECO # DWG.# DESCRIPTION 2986 CHANGE TRANSFORMER (1000W METAL HALIDE BALLAST) PART# ITEM# #REQ 590 HUEY Rd, ROCK HILL, S.C. Ph. (803) 324-3011 FAX 366-1101 WIRING DIAGRAM - 1000MH BALLAST REMOVE ALL BURRS & SHARP EDGES BORDER "B" MATL. MATL W / JOY CONNECTOR SCALE: NONE USAGE MAT P/N DR BY: CNM DWG.
CIRCUIT INPUT 120V INPUT COMMON LAMP HOT LAMP COMMON GROUND BLACK WHITE RED ORANGE GREEN 5-POLE RECEPTACLE RED WHITE BLACK COLOR GREEN ORANGE DATE ECO # DESCRIPTION DWG.# 2987 CHANGE #REQ 590 HUEY Rd, ROCK HILL, S.C. Ph. (803) 324-3011 FAX 366-1101 WIRING DIAGRAM - 1000HPS BALLAST REMOVE ALL BURRS & SHARP EDGES BORDER "A" MATL. MATL W / JOY CONNECTOR SCALE: NONE MAT P/N USAGE DR BY:CNM DWG.# 2987 PLOT: 4/30/91 DATE: 4/30/91 PART# WD2987 Fractions ±1/16 Decimals .XX=±.030 .XXX=±.010 .
GREEN RED WHITE 15 AMP (FLOODLIGHT) TYP. 4 RED WHITE #14 ORN POWER CORD FROM GENERATOR #14 BLK #14 ORN #14 BLK #14 ORN #14 BLK #14 ORN 4 #14 GREEN BALLAST BALLAST 3 #14 GREEN BALLAST 2 #14 GREEN #14 BLACK BALLAST 1 #14 GREEN EAB DC EAB DC EAB DC EAB DC #12 RED #14 RED #14 YEL #14 RED #14 YEL #14 RED #14 YEL #14 RED #14 YEL TYP.
BLACK GLOW PLUGS + BATTERY - RED 12 VOLT YELLOW RED RED FUSE 30A RED YELLOW PREHEAT PUSH BUTTON ST STARTER B+ RED BAT RED ACC IGN WHITE ST B IG L RED ALTERNATOR ORANGE BROWN GREEN WHITE HOUR METER ALTERNATOR FAILURE LIGHT E DATE 1/12/01 ECO # ECO # FUEL SOLENOID FUEL PUMP RED IGNITION SWITCH LEGEND BAT OFF START DATE 3/23/00 PART# WD4730 PLOT B 3/23/00 APP BY DWG.# 4730E SCALE D905/D1105, AL4, AL5, TX3 BORDER DR BY JCS USAGE MAT.
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.
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 IMMEDIATELY. Ratchet pawl should “click” when tower is raised, and not when it is lowered.
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.
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.
BROKEN CABLE REPLACEMENT PROCEDURE 1. PREPARATION 1.1 1.2 Collapse tower to where mast is retracted, then pivot tower to horizontal position. Remove the tower from the trailer and place it on a work surface such as two saw horses. 2. REMOVING TOP CABLE AND TOP MAST SECTION 2.1 2.2 2.3 2.4 2.5 2.6 Tie middle section and large section together by wrapping band, cable, chain, or rope around the sheave brackets on these two sections.
4.6 4.7 4.8 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. If the fish wire doesn’t work, it is necessary to remove the square mast section from the round mast section.
LIGHT FIXTURE TROUBLESHOOTING DANGER! 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-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 discharge.
LIGHT FIXTURE TROUBLESHOOTING (cont’d) SYMPTOM CAUSES CORRECTIVE ACTION LAMP STARTS Defective Lamp SLOWLY (ARC DOES NOT STRIKE WHEN SWITCH IS FIRST TURNED ON) Lamp may glow for extended period of time. Replace after checking voltage and ballast. CIRCUIT Short circuit or ground BREAKER TRIPS ON LAMP START-UP Checking wiring against diagram. Check for shorts or ground.
LIGHT FIXTURE TROUBLESHOOTING (cont’d) SYMPTOM CAUSES CORRECTIVE ACTIONS SHORT LAMP LIFE Lamp damaged Check for outer bulb cracks. If air enters outer bulb, arc tube 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.
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.
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.
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.
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.
