Service Manual

AL8000HT
TM

First Edition
Rev A
Part No. 116478
September 2008
 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.

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: Copyright © 2008 by Terex

Internet: www.genielift.com Terex Rock Hill

590 Huey Road
e-mail: techpub@genieind.com
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 Terex AL8000HT Operator's
Manual on your machine will result in death or
serious injury.

Many of the hazards identified in the operator’s

manual are also safety hazards when maintenance
and repair procedures are performed.

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

September 2008 Section 1 • Safety Rules

SAFETY RULES

Personal Safety Workplace Safety

Any person working on or around a machine must Be sure to keep sparks, flames and
be aware of all known safety hazards. Personal lighted tobacco away from flammable and
safety and the continued safe operation of the combustible materials like battery gases
machine should be your top priority. and engine fuels. Always have an approved fire
extinguisher within easy reach.
Be sure that all tools and working areas
Read each procedure thoroughly. This
are properly maintained and ready for use.
manual and the decals on the machine,
Keep work surfaces clean and free of
use signal words to identify the following:
debris that could get into machine components and
Safety alert symbol—used to alert cause damage.
personnel to potential personal
Be sure any forklift, overhead crane or
injury hazards. Obey all safety
other lifting or supporting device is fully
messages that follow this symbol
capable of supporting and stabilizing the
to avoid possible injury or death.
weight to be lifted. Use only chains or straps that
Indicates an imminently hazardous are in good condition and of ample capacity.
situation which, if not avoided, will
result in death or serious injury. Be sure that fasteners intended for one
time use (i.e., cotter pins and self-locking
Indicates a potentially hazardous nuts) are not reused. These components
situation which, if not avoided, may fail if they are used a second time.
could result in death or serious
injury. Be sure to properly dispose of old oil or
other fluids. Use an approved container.
Indicates a potentially hazardous Please be environmentally safe .
situation which, if not avoided,
may cause minor or moderate Be sure that your workshop or work area is
injury. 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

 September 2008

Table of Contents

Introduction
Important Information ........................................................................................................... ii
How to Read Your Serial Number ........................................................................................ iii
Parts Stocking List ............................................................................................................. x
How to Order Parts ............................................................................................................. xi
Service Parts Fax Order Form ........................................................................................... xii

Section 1 Safety Rules

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

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
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

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September 2008

TABLE OF CONTENTS

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
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

 September 2008

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

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
A Isuzu 4LE1 Engine
5-1 Timing Adjustment ..................................................................................... 4 - 14

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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
 September 2008

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

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

x AL8000HT Light Tower Part No. 116478

September 2008

How To Order Parts

Please be prepared with the following information Genie Industries
when ordering replacement parts for your TEREX 18340 NE 76th Street
product:
P.O. Box 97030
Machine model number Redmond, WA 98073-9730
Machine serial number Telephone (877) 367-5606
Terex part number Fax (888) 274-6192
Part description and quantity genieindustries.com
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

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

FAX TO: (888) 274-6192 OR TOLL FREE: 877-367-5606
Please fill out completely
Date _________________________________ Account Number _______________________________
Your Name ______________________________ Your Fax Number _____________________________
_________________________________ Your Phone Number ___________________________
Bill To _________________________________ Ship To ___________________________________

remove this page and make copies

_________________________________ ___________________________________
_________________________________ ___________________________________
_________________________________ ___________________________________
Purchase Order Number ____________________ Ship Via ___________________________________

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

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 ONLY

Order Number ______________ Origin Code ________________ Comments _________________________
Date Scheduled ____________ AL8000HT
Ship Condition Light Tower __________________________________
_____________ Part No. 116478
Order Total ________________ Terms Code _______________ __________________________________
September 2008 Section 2 • Specifications

REV A
Specifications
Machine Specifications Performance Specifications
Lights Tongue weight, maximum 350 lbs
159 kg
Type: BT-37 Metal Halide, 1000 watt
Run time, full load
Total lighting wattage Kubota D1105 (8kW) @ .82 Gallons per hour
4 lights 4000 watts
8 lights 8000 watts Single full fuel tank 36.5 hours

Axle Dual full fuel tanks 73 hours

Axle load capacity, maximum 4200 lbs Run time, full load
1905 kg Kubota V1505 (12kW) @ 1.1 Gallons per hour

Fluid capacities Single full fuel tank 27.25 hours

Hydraulic tank capacity 1.4 gallons Dual full fuel tanks 54.5 hours
5.3 liters
Run time, full load
Hydraulic system capacity 2 gallons Isuzu 4LE1 (20kW) @ 1.8 Gallons per hour
(including tank) 7.6 liters
Single full fuel tank 16.5 hours
Single fuel tank 30 gallons
114 liters Dual full fuel tanks 33 hours

Dual fuel tanks 60 gallons Towing speed, maximum 62 mph

227 liters 100 km/h

Tires and wheels (U.S. models) Function speeds

Tire size ST205/75R15 Boom up 12 to 24 seconds

Load range C
Boom down 12 to 21 seconds
Lug nut torque, dry 80 ft-lbs
Boom extend 17 to 37 seconds
108 Nm
Boom retract 13 to 27 seconds
Tire pressure, maximum (cold) 50 psi
3.4 bar Light bar up 18 to 30 seconds
Tires and wheels (Australia models) Light bar down 14 to 24 seconds
Tire size 7.5R16 C 112/110L Tower rotate, 359° 31 to 68 seconds
Lug nut torque, dry 80 ft-lbs
108 Nm

Tire pressure, maximum (cold) 75 psi

5.2 bar

Continuous improvement of our products is a

For operational specifications, refer to the Terex policy. Product specifications are subject
Operator's Manual. to change without notice.

Part No. 116478 AL8000HT Light Tower 2-1

 Section 2 • Specifications September 2008

SPECIFICATIONS REV A

Hydraulic Oil Specifications Hydraulic Component

Specifications
Hydraulic Oil Specifications

Hydraulic oil type Chevron Rando HD Premium MV Function pump

Viscosity grade Multi-viscosity
Type: Fixed displacement gear pump
Viscosity index 200
Displacement 0.056 cu in
Cleanliness level, minimum 15/13
per revolution 0.92 cc
Water content, maximum 200 ppm
Flow rate @ 3200 psi 0.6 gpm
Chevron Rykon MV oil is fully compatible and 2.27 L/min
mixable with Shell Donax TG (Dexron III) oils.
System relief pressure 3200 psi
Genie specifications require hydraulic oils which are
220.6 bar
designed to give maximum protection to hydraulic
systems, have the ability to perform over a wide Function manifold
temperature range, and the viscosity index should
exceed 140. They should provide excellent antiwear, Light bar up/down 0.2 gpm
oxidation, corrosion inhibition, seal conditioning, and flow regulator 0.76 L/min
foam and aeration suppression properties.
Tower rotate relief 1200 psi
Optional fluids valve pressure 82.7 bar

Biodegradable Petro Canada Environ MV46 Hydraulic filter

Statoil Hydra Way Bio Pa 32
BP Biohyd SE-S Hydraulic tank Beta 10 ≥ 200
return filter with 25 psi / 1.7 bar bypass
Fire resistant UCON Hydrolube HP-5046
Quintolubric 822

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 Continuous improvement of our products is a
the approved optional fluids. Consult the Terex Terex policy. Product specifications are subject
Service Department before use. to change without notice.

2-2 AL8000HT Light Tower Part No. 116478

September 2008 Section 2 • Specifications

REV A SPECIFICATIONS

Manifold Component Machine Torque Specifications

Specifications
Tower rotation assembly
Plug torque Rotate bearing mounting bolts, lubricated
1/2 -13 SHC bolts 95 ft-lbs
SAE No. 2 36 in-lbs / 4 Nm
129 Nm
5/8 -11 SHC bolts 195 ft-lbs
SAE No. 4 10 ft-lbs / 13 Nm
264 Nm
SAE No. 6 14 ft-lbs / 19 Nm
Rotation motor mounting bolts, dry 75 ft-lbs
SAE No. 8 38 ft-lbs / 51 Nm 1/2 -13, GR 5 102 Nm

SAE No. 10 41 ft-lbs / 55 Nm Rotation motor mounting bolts, lubricated 57 ft-lbs

1/2 -13, GR 5 77 Nm
SAE No. 12 56 ft-lbs / 76 Nm
Generator
Valve Coil Resistance
Generator case to engine 25 ft-lbs
Note: The following coil resistance specifications are at bell housing fasteners 34 Nm
an ambient temperature of 68°F / 20°C. As valve coil
resistance is sensitive to changes in air temperature, Generator vibration 75 ft-lbs
the coil resistance will typically increase or decrease by isolator fasteners 102 Nm
4% for each 18°F / 20°C that your air temperature
increases or decreases from 68°F / 20°C. Flex plate to flywheel 25 ft-lbs
34 Nm
Valve coil specifications

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 REV A

Kubota D1105-E Engine Injection system

Displacement 68.53 cu in Injection pump make Bocsh MD mini

1.12 liters Injection timing 19° BTDC
Number of cylinders 3 Injection pump pressure 1991 psi
Bore and stroke 3.07 x 3.09 inches 137 bar
78 x 78.4 mm Fuel requirement
Horsepower, continuous 13.6 @ 1800 rpm For fuel requirements, refer to the engine Operator's
10.1 kW Manual on your machine.
Firing order 1-2-3 Battery
Compression ratio 23:1 Type 12V DC
Compression pressure 412 to 469 psi Group 27TM
28.4 to 32.3 bar
Quantity 1
Engine speed 1800 rpm
Cold cranking ampere 500
Governor centrifugal mechanical
Reserve capacity @ 25A rate 105 minutes
Valve clearance, cold 0.0057 to 0.0072 in
0.145 to 0.185 mm Alternator
Engine coolant Output 40A, 12V DC
Capacity 3.27 quarts Fan belt deflection 1/4 to 3/8 inch
3.1 liters 7 to 9 mm
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.

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 SPECIFICATIONS

Kubota V1505-E Engine Injection system

Displacement 91.41 cu in Injection pump make Bocsh MD mini

1.5 liters Injection timing 19° BTDC
Number of cylinders 4 Injection pump pressure 1991 psi
Bore and stroke 3.07 x 3.09 inches 137 bar
78 x 78.4 mm Fuel requirement
Horsepower, continuous 17.9 @ 1800 rpm For fuel requirements, refer to the engine Operator's
13.4 kW Manual on your machine.
Firing order 1-3-4-2 Battery
Compression ratio 22:1 Type 12V DC
Compression pressure 412 to 469 psi Group 27TM
28.4 to 32.3 bar
Quantity 1
Engine speed 1800 rpm
Cold cranking ampere 630
Governor centrifugal mechanical
Reserve capacity @ 25A rate 105 minutes
Valve clearance, cold 0.0057 to 0.0072 in
0.145 to 0.185 mm Alternator
Engine coolant Output 30A, 12V DC
Capacity 4.23 quarts Fan belt deflection 1/4 to 3/8 inch
4 liters 7 to 9 mm
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.

Part No. 116478 AL8000HT Light Tower 2-5

 Section 2 • Specifications September 2008

SPECIFICATIONS REV A

Isuzu 4LE1 Engine Engine coolant

Displacement 133 cu in Capacity 4 quarts

2.179 liters 3.8 liters

Number of cylinders 4 Coolant temperature switch 221° ±7°F

(engine shut-off temperature) 105° ±4°C
Bore and stroke 3.35 x 3.78 inches
85 x 96 mm Injection system

Horsepower, continuous 31.4 @ 1800 rpm Injection pump make Bosch, PFR ype
23.4kW Injection timing 16° BTDC
Firing order 1-3-4-2 Injection pump pressure 1920 psi
Compression ratio 21.5:1 132.8 bar

Engine speed 1800 rpm Fuel requirement

Governor variable speed, mechanical For fuel requirements, refer to the engine Operator's
Manual on your machine.
Valve clearance, cold
Battery
Intake 0.0157 in
0.4 mm Type 12V DC

Exhaust 0.0157 in Group 27TM

0.4 mm Quantity 1
Lubrication system Cold cranking ampere 630
Oil pressure (hot @ 1800 rpm) 64 psi Reserve capacity @ 25A rate 105 minutes
4.4 bar
Alternator
Oil capacity 7.08 quarts
(including filter) 6.7 liters Output 35A, 12V DC
Oil pressure switch 14 psi Fan belt deflection 1/4 to 3/8 inch
(engine shut-off pressure) 0.96 bar 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 SPECIFICATIONS

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

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 REV A

Hydraulic Hose and Fitting Seal-Lok® fittings

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

anytime the seal has been broken. The O-ring
Your machine is equipped with Parker Seal-Lok® cannot be re-used if the fitting or hose end has
fittings and hose ends. Genie specifications require been tightened beyond finger tight.
that fittings and hose ends be torqued to
specification when they are removed and installed Note: The O-rings used in the Parker Seal Lok®
or when new hoses or fittings are installed. 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).
SAE O-ring Boss Port
(tube fitting - installed into Aluminum) 2 Lubricate the O-ring before installation.
SAE Dash size Torque 3 Be sure that the face seal O-ring is seated and
retained properly.
-4 11 ft-lbs / 14.9 Nm
4 Position the tube and nut squarely on the face
-6 23 ft-lbs / 31.2 Nm
seal end of the fitting and tighten the nut finger
-8 40 ft-lbs / 54.2 Nm tight.

-10 69 ft-lbs / 93.6 Nm 5 Tighten the nut or fitting to the appropriate

torque per given size as shown in the table.
-12 93 ft-lbs / 126.1 Nm
6 Operate all machine functions and inspect the
-16 139 ft-lbs / 188.5 Nm hoses and fittings and related components to
confirm that there are no leaks.
-20 172 ft-lbs / 233.2 Nm

-24 208 ft-lbs / 282 Nm

SAE O-ring Boss Port Seal-Lok Fittings

®

(tube fitting - installed into Steel) (hose end)

SAE Dash size Torque SAE Dash size Torque

-4 16 ft-lbs / 21.7 Nm -4 18 ft-lbs / 25 Nm

-6 35 ft-lbs / 47.5 Nm -6 30 ft-lbs / 40 Nm

-8 60 ft-lbs / 81.3 Nm -8 40 ft-lbs / 55 Nm

-10 105 ft-lbs / 142.4 Nm -10 60 ft-lbs / 80 Nm

-12 140 ft-lbs / 190 Nm -12 85 ft-lbs / 115 Nm

-16 210 ft-lbs / 284.7 Nm -16 110 ft-lbs / 150 Nm

-20 260 ft-lbs / 352.5 Nm -20 140 ft-lbs / 190 Nm

-24 315 ft-lbs / 427.1 Nm -24 180 ft-lbs / 245 Nm

2-8 AL8000HT Light Tower Part No. 116478

September 2008 Section 2 • Specifications

REV A SPECIFICATIONS

SAE FASTENER TORQUE CHART

• This chart is to be used as a guide only unless noted elsewhere in this manual •
A574 High Strength
SIZE THREAD Grade 5 Grade 8 Black Oxide Bolts
LUBED DRY LUBED DRY LUBED
in-lbs Nm in-lbs Nm in-lbs Nm in-lbs Nm in-lbs Nm
1/4 20 80 9 100 11.3 110 12.4 140 15.8 130 14.7
28 90 10.1 120 13.5 120 13.5 160 18 140 15.8
LUBED DRY LUBED DRY LUBED
ft-lbs Nm ft-lbs Nm ft-lbs Nm ft-lbs Nm ft-lbs Nm
5/16 18 13 17.6 17 23 18 24 25 33.9 21 28.4
24 14 19 19 25.7 20 27.1 27 36.6 24 32.5
3/8 16 23 31.2 31 42 33 44.7 44 59.6 38 51.5
24 26 35.2 35 47.4 37 50.1 49 66.4 43 58.3
7/16 14 37 50.1 49 66.4 50 67.8 70 94.7 61 82.7
20 41 55.5 55 74.5 60 81.3 80 108.4 68 92.1
1/2 13 57 77.3 75 101.6 80 108.4 110 149 93 126
20 64 86.7 85 115 90 122 120 162 105 142
9/16 12 80 108.4 110 149 120 162 150 203 130 176
18 90 122 120 162 130 176 170 230 140 189
5/8 11 110 149 150 203 160 217 210 284 180 244
18 130 176 170 230 180 244 240 325 200 271
3/4 10 200 271 270 366 280 379 380 515 320 433
16 220 298 300 406 310 420 420 569 350 474
7/8 9 320 433 430 583 450 610 610 827 510 691
14 350 474 470 637 500 678 670 908 560 759
8 480 650 640 867 680 922 910 1233 770 1044
1
12 530 718 710 962 750 1016 990 1342 840 1139
7 590 800 790 1071 970 1315 1290 1749 1090 1477
1 1/8
12 670 908 890 1206 1080 1464 1440 1952 1220 1654
7 840 1138 1120 1518 1360 1844 1820 2467 1530 2074
1 1/4
12 930 1260 1240 1681 1510 2047 2010 2725 1700 2304
1 6 1460 1979 1950 2643 2370 3213 3160 4284 2670 3620
1 /2
12 1640 2223 2190 2969 2670 3620 3560 4826 3000 4067

METRIC FASTENER TORQUE CHART

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

Size Class 4.6 4.6 Class 8.8 8.8 Class 10.9 10.9 Class 12.9 12.9

(m m ) LUBED DRY LUBED DRY LUBED DRY LUBED DRY

in- lbs Nm in- lbs Nm in- lbs Nm in- lbs Nm in- lbs Nm in- lbs Nm in- lbs Nm in- lbs Nm
5 16 1.8 21 2.4 41 4.63 54 6.18 58 6.63 78 8.84 68 7.75 91 10.3
6 19 3.05 36 4.07 69 7.87 93 10.5 100 11.3 132 15 116 13.2 155 17.6
7 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
LUBED DRY LUBED DRY LUBED DRY LUBED DRY
f t - lbs Nm f t - lbs Nm f t - lbs Nm f t - lbs Nm f t - lbs Nm f t - lbs Nm f t - lbs Nm f t - lbs Nm
8 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
10 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
12 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
14 30.1 40.8 40 54.3 77.4 105 103 140 110 150 147 200 129 175 172 234
16 46.9 63.6 62.5 84.8 125 170 166 226 173 235 230 313 202 274 269 365
18 64.5 87.5 86.2 117 171 233 229 311 238 323 317 430 278 377 371 503
20 91 124 121 165 243 330 325 441 337 458 450 610 394 535 525 713
22 124 169 166 225 331 450 442 600 458 622 612 830 536 727 715 970
24 157 214 210 285 420 570 562 762 583 791 778 1055 682 925 909 1233

Part No. 116478 AL8000HT Light Tower 2-9

 September 2008

GENSET TORQUE SPECIFICATIONS

Generator FT*LB

Flex Plate to Flywheel 25

Generator Case to Bellhousing 25

Genset Isolators 75

2 - 10 AL8000HT Light Tower Part No. 116478

September 2008 Section 3 • Scheduled Maintenance Procedures

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: Symbols Legend

Maintenance inspections shall be completed by Safety alert symbol—used to alert

a person trained and qualified on the personnel to potential personal
maintenance of this machine. injury hazards. Obey all safety
messages that follow this symbol
Scheduled maintenance inspections shall be to avoid possible injury or death.
completed daily, quarterly, semi-annually,
Indicates an imminently hazardous
annually and every 2 years as specified on the
situation which, if not avoided, will
Maintenance Inspection Report.
result in death or serious injury.
Failure to perform each procedure
Indicates a potentially hazardous
as presented and scheduled could
situation which, if not avoided,
result in death, serious injury or
could result in death or serious
substantial damage.
injury.
Immediately tag and remove from service a
Indicates a potentially hazardous
damaged or malfunctioning machine.
situation which, if not avoided,
Repair any machine damage or malfunction may cause minor or moderate
before operating the machine. injury.

Use only Terex approved replacement parts. Indicates a potentially hazardous

situation which, if not avoided,
Machines that have been out of service for a may result in property damage.
period longer than 3 months must complete the
quarterly inspection. Indicates that a specific result is expected after
performing a series of steps.
Unless otherwise specified, perform each
maintenance procedure with the machine in the Indicates that an incorrect result has occurred
following configuration: after performing a series of steps.

· 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

Part No. 116478 AL8000HT Light Tower 3-1

 Section 3 • Scheduled Maintenance Procedures September 2008

SCHEDULED MAINTENANCE PROCEDURES

Maintenance Symbols Legend Pre-delivery Preparation Report

The following symbols have been used in this The pre-delivery preparation report contains
manual to help communicate the intent of the checklists for each type of scheduled inspection.
instructions. When one or more of the symbols
appear at the beginning of a maintenance Make copies of the Pre-delivery Preparation report
procedure, it conveys the meaning below. to use for each inspection. Store completed forms
as required.
Maintenance Schedule
Indicates that tools will be required to
perform this procedure. There are five types of maintenance inspections
that must be performed according to a schedule—
daily, quarterly, semi-annually, annual and
two year. The Scheduled Maintenance Procedures
Indicates that new parts will be required
Section and the Maintenance Inspection Report
to perform this procedure.
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
Indicates that a cold engine will be scheduled inspection.
required to perform this procedure.
Inspection Checklist

Indicates that a warm engine will be Daily or every 8 hours A

required to perform this procedure.
Quarterly or every 250 hours A+B

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

Indicates that dealer service will be
required to perform this procedure. 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-Deliver
Pre-Deliveryy Preparation

Fundamentals Instructions
It is the responsibility of the dealer to perform the Use the operator’s manual on your machine.
Pre-delivery Preparation.
The Pre-delivery Preparation consists of completing the
The Pre-delivery Preparation is performed prior to each Pre-operation Inspection, the Maintenance items and the
delivery. The inspection is designed to discover if anything Function Tests.
is apparently wrong with a machine before it is put into
service. Use this form to record the results. Place a check in the
appropriate box after each part is completed. Follow the
A damaged or modified machine must never be used. If instructions in the operator’s manual.
damage or any variation from factory delivered condition is
discovered, the machine must be tagged and removed from If any inspection receives an N, remove the machine from
service. service, repair and re-inspect it. After repair, place a check
in the R box.
Repairs to the machine may only be made by a qualified
service technician, according to the manufacturer's Legend
specifications. Y = yes, completed
Scheduled maintenance inspections shall be performed by N = no, unable to complete
qualified service technicians, according to the R = repaired
manufacturer's specifications and the requirements listed in Comments
the responsibilities manual.

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

TEREX Rock Hill

P.O. BOX 3147
Rock Hill, SC 29732 USA
Toll Free (800) 433-3026 in U.S.A. and Canada
Copyright © 2006 by TEREX Corporation. TEREX® is a registered trademark of TEREX
Corporation.
Rev B
 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 Checklist A - Rev A Y N R Checklist B - Rev A Y N R
A-1 Manuals and decals B-1 Battery
Serial number
A-2 Pre-operation inspect B-2 Electrical wiring
Date A-3 Function tests B-3 Tires and wheels
Perform every 8 hours: B-4 Hydraulic oil analysis
Hour meter
A-4 Engine maintenance - B-5 Engine maintenance -
Isuzu models Isuzu models
Machine owner
A-5 Generator B-6 Generator
Inspected by (print) maintenance maintenance
Perform after 10 miles: Perform quarterly:
Inspector signature A-6 Axle maintenance B-7 Hitch coupler
Perform after 25 miles: maintenance
Inspector title
A-6 Axle maintenance Perform every 400 hours:

Inspector company Perform after 50 miles: B-8 Engine maintenance -

Kubota models
A-6 Axle maintenance
Instructions Perform every 3000 miles:
Perform after 40 hours:
· Make copies of this report to use for B-9 Axle maintenance
A-7 30 day service
each inspection.
Perform every 50 hours:
· Select the appropriate checklist(s) Checklist C - Rev A Y N R
for the type of inspection to be A-8 Engine maintenance
C-1 Extend/retract cables
performed. Perform weekly:
and pulleys
A-9 Hitch maintenance
Daily or 8 hours C-2 Engine maintenance
Inspection: A Perform every 100 hours:
Perform every 6000 miles:
Quarterly or 250 hours A-10 Grease rotation
C-3 Axle maintenance
Inspection: A+B bearing
Perform every 750 hours:
A-11 Engine maintenance -
Semi-annually or C-5 Engine maintenance -
Kubota models
500 hours Isuzu models
Inspection: A+B+C Perform every 200 hours:
Perform every 800 hours:
Annually or A-12 Engine maintenance -
Kubota models C-6 Engine maintenance -
1000 hours
Kubota models
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

Part No. 116478 AL8000HT Light Tower 3-5

 Section 3 • Scheduled Maintenance Procedures September 2008

MAINTENANCE INSPECTION REPORT

Model Checklist D - Rev A Y N R

D-1 Engine maintenance -
Serial number Kubota models

Date D-2 Tower rotation bearing

bolts
Hour meter D-3 Hydraulic filter
D-4 Engine maintenance -
Machine owner Isuzu models
Perform every 1250 hours:
Inspected by (print)
D-5 Engine maintenance -
Inspector signature Isuzu models
Perform every 1500 hours:
Inspector title D-6 Engine maintenance
D-7 Generator
Inspector company maintenance
Perform annually:
Instructions
· Make copies of this report to use for D-8 Tongue and outrigger
each inspection. jack maintenance

· Select the appropriate checklist(s) Perform every 12,000 miles:

for the type of inspection to be D-9 Axle maintenance
performed.

Daily or 8 hours Checklist E - Rev A Y N R

Inspection: A E-1 Test or replace
hydraulic oil
Quarterly or 250 hours
Inspection: A+B Perform every 3000 hours:
Semi-annually or E-2 Engine maintenance -
500 hours Kubota models
Inspection: A+B+C Perform every 2 years:
Annually or E-3 Engine maintenance -
1000 hours Kubota models
Inspection: A+B+C+D Perform every 4500 hours:
Two year or E-4 Generator
2000 hours maintenance
Inspection: A+B+C+D+E Perform every 15,000 hours:
· Place a check in the appropriate box E-5 Generator
after each inspection procedure is maintenance
completed.
· Use the step-by-step procedures in
this section to learn how to perform Comments
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

3-6 AL8000HT Light Tower Part No. 116478

September 2008 Section 3 • Scheduled Maintenance Procedures

REV A
Checklist A Procedures
A-1 3 Open the operator's manual to the decals
inspection section. Carefully and thoroughly
Inspect the Manuals and Decals inspect all decals on the machine for legibility
Note: Terex specifications require that this and damage.
procedure be performed daily or every 8 hours, Result: The machine is equipped with all
whichever comes first. required decals, and all decals are legible and in
Maintaining the operator’s and safety manuals in good condition.
good condition is essential to safe machine Result: The machine is not equipped with all
operation. Manuals are included with each machine required decals, or one or more decals are
and should be stored in the container provided in illegible or in poor condition. Remove the
the cabinet. An illegible or missing manual will not machine from service until the decals are
provide safety and operational information replaced.
necessary for a safe operating condition.
4 Always return the manuals to the storage
In addition, maintaining all of the safety and container after use.
instructional decals in good condition is mandatory
for safe machine operation. Decals alert operators Note: Contact your authorized Terex distributor if
and personnel to the many possible hazards replacement manuals or decals are needed.
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.

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 REV A

A-2 A-3
Perform Pre-operation Perform Function Tests
Inspection Note: Terex specifications require that this
Note: Terex specifications require that this procedure be performed every 8 hours or daily,
procedure be performed every 8 hours or daily, whichever comes first.
whichever comes first. Completing the function tests is essential to safe
Completing a pre-operation inspection is essential machine operation. Function tests are designed to
to safe machine operation. The pre-operation discover any malfunctions before the machine is
inspection is a visual inspection performed by the put into service. A malfunctioning machine must
operator prior to each work shift. The inspection is never be used. If malfunctions are discovered, the
designed to discover if anything is apparently wrong machine must be tagged and removed from
with a machine before the operator performs the service.
function tests. The pre-operation inspection also Complete information on how to perform this
serves to determine if routine maintenance procedure is available in the appropriate Operator's
procedures are required. Manual. Refer to the Operator's Manual on your
Complete information on how to perform this machine.
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 CHECKLIST A PROCEDURES

A-4 A-5
Perform Engine Maintenance - Perform Generator Maintenance
Isuzu Models

Note: Generator specifications require that this

Note: Engine specifications require that this procedure be performed every 8 hours or daily,
procedure be performed every 8 hours or daily, whichever comes first.
whichever comes first. Required maintenance procedures and additional
Required maintenance procedures and additional generator information is available in the
engine information is available in the Leroy Somer LSA 37 Installation and
Isuzu 4LE1 Diesel Engine Instruction Manual Maintenance Manual (Leroy Somer part number
(Isuzu part number IDE-6033). 3664EN-09.2005/B) OR the
Marathon Installation, Operation and Maintenance
Manual (Marathon part number GPN012) OR the
Isuzu 4LE1 Diesel Engine Instruction Manual Newage Installation, Service and Maintenance
Terex part number 116133
Manual (Newage part number BCH-018).

Leroy Somer LSA 37 Installation and

Maintenance Manual
Terex part number 116118

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 REV A

A-6 A-7
Perform Axle Maintenance Perform 30 Day Service

Note: Axle specifications require that this procedure The 30 day maintenance procedure is a one time
be performed initially and following a wheel change procedure to be performed after the first 30 days or
after the first 10, 25 and 50 miles. 40 hours of usage. After this interval, refer to the
maintenance tables for continued scheduled
Proper axle maintenance, following the axle maintenance.
manufacturer's maintenance schedule, is essential
to good axle performance and service life. Failure 1 Perform the following maintenance procedures:
to perform the maintenance procedures can lead to
· B-3 Inspect the Tires, Wheels and
poor axle performance and component damage.
Lug Nut Torque
Required maintenance procedures and additional
axle information is available in the Axis Axle
Operator Maintenance Manual included with your
machine.

Axis Axle Operator Maintenance Manual

Terex part number 116117

3 - 10 AL8000HT Light Tower Part No. 116478

September 2008 Section 3 • Scheduled Maintenance Procedures

REV A CHECKLIST A PROCEDURES

A-8 A-9
Perform Engine Maintenance Perform Hitch Maintenance

Note: Engine specifications require that this Note: Hitch specifications require that this
procedure be performed every 50 hours. procedure be performed weekly.
Required maintenance procedures and additional Required maintenance procedures and additional
engine information is available in the hitch information is available in the Fulton Coupler
Isuzu 4LE1 Diesel Engine Instruction Manual User Manual (Fulton part number F1937).
(Isuzu part number IDE-6033) OR the
Kubota D-1105 and V-1505 Operator's Manual Fulton Coupler User Manual
(Kubota part number 16683-89169). Terex part number 150139

Isuzu 4LE1 Diesel Engine Instruction Manual

Terex part number 116133

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

Terex part number 893020

Part No. 116478 AL8000HT Light Tower 3 - 11

 Section 3 • Scheduled Maintenance Procedures September 2008

CHECKLIST A PROCEDURES REV A

A-10 8 Rotate the tower to transfer the grease from the

pinion gear to the teeth of the rotation bearing.
Grease the Turntable Rotation
9 Repeat steps 5 and 6 until all gear teeth are
Bearing and Rotate Gear thoroughly greased.
10 Install the pinion gear guard and securely tighten
the retaining fasteners. Do not overtighten.
Note: Terex specifications require that this
procedure be performed every 100 hours of Grease Specification
operation. Perform this procedure more often if
dusty conditions exist. Chevron Ultra-duty grease, EP NLGI 2 (lithium based)
or equivalent
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.
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 CHECKLIST A PROCEDURES

A-11 A-12
Perform Engine Maintenance - Perform Engine Maintenance -
Kubota Models Kubota Models

Note: Engine specifications require that this Note: Engine specifications require that this
procedure be performed every 100 hours. procedure be performed every 200 hours.
Required maintenance procedures and additional Required maintenance procedures and additional
engine information is available in the engine information is available in the
Kubota D-1105 and V-1505 Operator's Manual Kubota D-1105 and V-1505 Operator's Manual
(Kubota part number 16683-89169). (Kubota part number 16683-89169).

Kubota D-1105 and V-1505 Operator's Manual Kubota D-1105 and V-1505 Operator's Manual
Terex part number 893020 Terex part number 893020

Part No. 116478 AL8000HT Light Tower 3 - 13

 Section 3 • Scheduled Maintenance Procedures September 2008

Checklist B Procedures REV A

B-1 B-2
Inspect the Battery Inspect the Electrical Wiring

Note: Terex requires that this procedure be Note: Terex requires that this procedure be
performed every 250 hours or quarterly, whichever performed every 250 hours or quarterly, whichever
comes first. comes first.
Proper battery condition is essential to good Maintaining electrical wiring in good condition is
machine performance and operational safety. essential to safe operation and good machine
Improper fluid levels or damaged cables and performance. Failure to find and replace burnt,
connections can result in component damage and chafed, corroded or pinched wires could result in
hazardous conditions. unsafe operating conditions and may cause
component damage.
Electrocution hazard. Contact with
hot or live circuits could result in Electrocution hazard. Contact with
death or serious injury. Remove all hot or live circuits could result in
rings, watches and other jewelry. death or serious injury. Remove all
Bodily injury hazard. Batteries rings, watches and other jewelry.
contain acid. Avoid spilling or 1 Inspect the following areas for burnt, chafed,
contacting battery acid. Neutralize corroded and loose wires, and for a liberal
battery acid spills with baking soda coating of dielectric grease in the harness
and water. connections:
1 Put on protective clothing and eye wear. · Mast
2 Open the cabinet cover at the curb side of the · Chassis
machine and locate the battery. · Trailer lighting
3 Be sure that the battery cable connections are 2 Inspect for a liberal coating of dielectric grease
free of corrosion. in the harness connections between the
generator, ballasts and the mast light
Note: Adding terminal protectors and a corrosion
assemblies.
preventative sealant will help eliminate corrosion on
the battery terminals and cables. 3 Inspect the engine and generator area for burnt,
chafed, corroded, pinched and loose wires, and
4 Be sure that the battery retainers and cable
and for a liberal coating of dielectric grease in
connections are tight.
the harness connections.

3 - 14 AL8000HT Light Tower Part No. 116478

September 2008 Section 3 • Scheduled Maintenance Procedures

REV A CHECKLIST B PROCEDURES

B-3 B-4
Inspect the Tires and Wheels Perform Hydraulic Oil Analysis
(including lug nut torque)

Note: Terex requires that this procedure be

performed every 250 hours or quarterly, whichever
Note: Terex requires that this procedure be
comes first.
performed every 250 hours or quarterly, whichever
comes first. Replacement or testing of the hydraulic oil is
essential for good machine performance and
Maintaining the tires and wheels in good
service life. Dirty oil and suction strainers may
condition is essential to safe operation and good
cause the machine to perform poorly and continued
performance. Tire and/or wheel failure could result
use may cause component damage. Extremely
in a machine tip-over. Component damage may
dirty conditions may require oil changes to be
also result if problems are not discovered and
performed more often.
repaired in a timely fashion.
Note: Before replacing the hydraulic oil, the oil may
Bodily injury hazard. An over-
be tested by an oil distributor for specific levels of
inflated tire can explode and could
contamination to verify that changing the oil is
result in death or serious injury.
necessary. If the hydraulic oil is not replaced at
Tip-over hazard. Do not use the two year inspection, test the oil quarterly.
temporary flat tire repair products. Replace the oil when it fails the test. See E-1,
Test or Replace the Hydraulic Oil.
1 Check the tire tread and sidewalls for cuts,
cracks, punctures and unusual wear.
2 Check each wheel for damage, bends and
cracked welds.
3 Check each lug nut for proper torque. Refer to
Section 2, Specifications.
4 Check the air pressure of each tire. Refer to
Section 2, Specifications.

Part No. 116478 AL8000HT Light Tower 3 - 15

 Section 3 • Scheduled Maintenance Procedures September 2008

CHECKLIST B PROCEDURES REV A

B-5 B-6
Perform Engine Maintenance - Perform Generator Maintenance
Isuzu Models

Note: Generator specifications require that this

Note: Engine specifications require that this procedure be performed every 250 hours or
procedure be performed every 250 hours or quarterly, whichever comes first.
quarterly, whichever comes first. Required maintenance procedures and additional
Required maintenance procedures and additional generator information is available in the
engine information is available in the Leroy Somer LSA 37 Installation and
Isuzu 4LE1 Diesel Engine Instruction Manual Maintenance Manual (Leroy Somer part number
(Isuzu part number IDE-6033). 3664EN-09.2005/B) OR the
Marathon Installation, Operation and Maintenance
Manual (Marathon part number GPN012) OR the
Isuzu 4LE1 Diesel Engine Instruction Manual Newage Installation, Service and Maintenance
Terex part number 116133
Manual (Newage part number BCH-018).

Leroy Somer LSA 37 Installation and

Maintenance Manual
Terex part number 116118

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 CHECKLIST B PROCEDURES

B-7 B-8
Perform Hitch Coupler Perform Engine Maintenance -
Maintenance Kubota Models

Note: Hitch specifications require that this Note: Engine specifications require that this
procedure be performed quarterly. procedure be performed every 400 hours.
Required maintenance procedures and additional Required maintenance procedures and additional
hitch information is available in the Fulton Coupler engine information is available in the
User Manual (Fulton part number F1937). Kubota D-1105 and V-1505 Operator's Manual
(Kubota part number 16683-89169).
Fulton Coupler User Manual
Terex part number 150139 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 Axis Axle
Operator Maintenance Manual included with your
machine.

Axis Axle Operator Maintenance Manual

Terex part number 116117

Part No. 116478 AL8000HT Light Tower 3 - 17

 Section 3 • Scheduled Maintenance Procedures September 2008

REV A

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3 - 18 AL8000HT Light Tower Part No. 116478

September 2008 Section 3 • Scheduled Maintenance Procedures

REV A
Checklist C Procedures
C-1 C-2
Inspect the Tower Extend/ Perform Engine Maintenance
Retract Cables and Pulleys

Note: Engine specifications require that this

procedure be performed every 500 hours or
Note: Terex requires that this procedure be semi-annually, whichever comes first.
performed every 500 hours or semi-annually,
whichever comes first. Required maintenance procedures and additional
engine information is available in the
Detection of damage to the cables or pulleys is Isuzu 4LE1 Diesel Engine Instruction Manual
essential for safe machine operation. An unsafe (Isuzu part number IDE-6033) OR the
working condition exists if these components are Kubota D-1105 and V-1505 Operator's Manual
damaged and do not operate smoothly. Regular (Kubota part number 16683-89169).
inspection of this system allows the inspector to
identify changes in the operating condition that may Isuzu 4LE1 Diesel Engine Instruction Manual
indicate damage. Terex part number 116133
Note: Perform this procedure with the tower in the
Kubota D-1105 and V-1505 Operator's Manual
stowed position.
Terex part number 893020
1 Lower all four outriggers to the ground and level
the machine.
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 REV A

C-3 C-4
Perform Axle Maintenance Perform Engine Maintenance -
Isuzu Models

Note: Axle specifications require that this procedure

be performed every 6 months or 6000 miles, Note: Engine specifications require that this
whichever comes first. procedure be performed every 750 hours.

Proper axle maintenance, following the axle Required maintenance procedures and additional
manufacturer's maintenance schedule, is essential engine information is available in the
to good axle performance and service life. Failure Isuzu 4LE1 Diesel Engine Instruction Manual
to perform the maintenance procedures can lead to (Isuzu part number IDE-6033).
poor axle performance and component damage.
Isuzu 4LE1 Diesel Engine Instruction Manual
Required maintenance procedures and additional Terex part number 116133
axle information is available in the Axis Axle
Operator Maintenance Manual included with your
machine.

Axis Axle Operator Maintenance Manual

Terex part number 116117

3 - 20 AL8000HT Light Tower Part No. 116478

September 2008 Section 3 • Scheduled Maintenance Procedures

REV A CHECKLIST C PROCEDURES

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

Part No. 116478 AL8000HT Light Tower 3 - 21

 Section 3 • Scheduled Maintenance Procedures September 2008

Checklist D Procedures REV A

D-1 D-2
Perform Engine Maintenance - Check the Tower Rotation
Kubota Models Bearing Bolts

Note: Engine specifications require that this

Note: Terex requires that this procedure be
procedure be performed annually.
performed every 1000 hours or annually, whichever
Required maintenance procedures and additional comes first.
engine information is available in the
Maintaining proper torque on the tower rotation
Kubota D-1105 and V-1505 Operator's Manual
bearing bolts is essential to safe machine
(Kubota part number 16683-89169).
operation. Improper bolt torque could result in an
unsafe operating condition and component damage.
Kubota D-1105 and V-1505 Operator's Manual
Terex part number 893020 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.
4 Check to be sure that each tower mounting bolt
is torqued in sequence to specification. Refer to
Section 2, Specifications.

Tongue

1
9 5

4 3

10
6 7
2
Bolt torque sequence

3 - 22 AL8000HT Light Tower Part No. 116478

September 2008 Section 3 • Scheduled Maintenance Procedures

REV A CHECKLIST D PROCEDURES

5 Check to be sure that each bearing mounting D-3

bolt under the tower support is torqued in
sequence to specification. Refer to Section 2, Replace the Hydraulic Return
Specifications. Filter
Tongue

Note: Terex requires that this procedure be

1 performed every 1000 hours or annually, whichever
4 7 comes first.
Replacement of the hydraulic return filter is
6 3 essential for good machine performance and
service life. A dirty or clogged filter may cause the
machine to perform poorly and continued use may
2 5 cause component damage. Extremely dirty
8
conditions may require that the filter be replaced
more often.
Bolt torque sequence
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 REV A

D-4 D-5
Perform Engine Maintenance - Perform Engine Maintenance -
Isuzu Models Isuzu Models

Note: Engine specifications require that this Note: Engine specifications require that this
procedure be performed every 1000 hours or procedure be performed every 1250 hours.
annually, whichever comes first.
Required maintenance procedures and additional
Required maintenance procedures and additional engine information is available in the
engine information is available in the Isuzu 4LE1 Diesel Engine Instruction Manual
Isuzu 4LE1 Diesel Engine Instruction Manual (Isuzu part number IDE-6033).
(Isuzu part number IDE-6033).
Isuzu 4LE1 Diesel Engine Instruction Manual
Isuzu 4LE1 Diesel Engine Instruction Manual Terex part number 116133
Terex part number 116133

3 - 24 AL8000HT Light Tower Part No. 116478

September 2008 Section 3 • Scheduled Maintenance Procedures

REV A CHECKLIST D PROCEDURES

D-6 D-7
Perform Engine Maintenance Perform Generator Maintenance

Note: Engine specifications require that this Note: Generator specifications require that this
procedure be performed every 1500 hours. procedure be performed every 1500 hours or
annually, whichever comes first.
Required maintenance procedures and additional
engine information is available in the Required maintenance procedures and additional
Isuzu 4LE1 Diesel Engine Instruction Manual generator information is available in the
(Isuzu part number IDE-6033) OR the Leroy Somer LSA 37 Installation and
Kubota D-1105 and V-1505 Operator's Manual Maintenance Manual (Leroy Somer part number
(Kubota part number 16683-89169). 3664EN-09.2005/B) OR the
Marathon Installation, Operation and Maintenance
Isuzu 4LE1 Diesel Engine Instruction Manual Manual (Marathon part number GPN012) OR the
Terex part number 116133 Newage Installation, Service and Maintenance
Manual (Newage part number BCH-018).
Kubota D-1105 and V-1505 Operator's Manual
Terex part number 893020 Leroy Somer LSA 37 Installation and
Maintenance Manual
Terex part number 116118

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 REV A

D-8 D-9
Perform Tongue Jack and Perform Axle Maintenance
Outrigger Jack Maintenance

Note: Axle specifications require that this procedure

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

Required maintenance procedures and additional Proper axle maintenance, following the axle
hitch information is available in the manufacturer's maintenance schedule, is essential
Cequent Tongue Jack Use Manual to good axle performance and service life. Failure
(Cequent part number F3282ML). to perform the maintenance procedures can lead to
poor axle performance and component damage.

Cequent Tongue Jack Use Manual Required maintenance procedures and additional
Terex part number 150140 axle information is available in the Axis Axle
Operator Maintenance Manual included with your
machine.

Axis Axle Operator Maintenance Manual

Terex part number 116117

3 - 26 AL8000HT Light Tower Part No. 116478

September 2008 Section 3 • Scheduled Maintenance Procedures

REV A
Checklist E Procedures
E-1 3 Tag, disconnect and plug the hydraulic hoses
from the power unit. Cap the fittings.
Test or Replace the Hydraulic Oil
Bodily injury hazard. Spraying
hydraulic oil can penetrate and
burn skin. Loosen hydraulic
connections very slowly to allow
Note: Terex requires that this procedure be
the oil pressure to dissipate
performed every 2000 hours or every two years,
gradually. Do not allow oil to squirt
whichever comes first.
or spray.
Replacement or testing of the hydraulic oil is 4 Tag and disconnect the electrical wiring and
essential for good machine performance and cables from the power unit.
service life. Dirty oil and suction strainers may
cause the machine to perform poorly and continued 5 Support and secure the power unit to a suitable
use may cause component damage. Extremely lifting device.
dirty conditions may require oil changes to be
6 Remove the fasteners securing the power unit to
performed more often.
the cabinet. Carefully remove the power unit
Note: Before replacing the hydraulic oil, the oil may from the curb side of the machine.
be tested by an oil distributor for specific levels of Component damage hazard. The
contamination to verify that changing the oil is hydraulic reservoir is plastic and
necessary. If the hydraulic oil is not replaced at may become damaged if allowed
the two year inspection, test the oil quarterly. to fall when removed from the
Replace the oil when it fails the test. machine.
Note: When removing a hose assembly or fitting, 7 Place a suitable container under the hydraulic
the O-ring on the fitting and/or hose end must be reservoir. Refer to Section 2, Specifications for
replaced and then torqued to specification during capacity specifications.
installation. Refer to Section 2, Hydraulic Hose and
Fitting Torque Specifications. 8 Remove the hydraulic reservoir retaining
fasteners from the power unit. Carefully remove
1 Open both cabinet covers. the hydraulic reservoir from the power unit and
completely drain it into a suitable container.
2 Tag and disconnect the battery cables from the
battery. Bodily injury hazard. Beware of hot
oil. Contact with hot oil may cause
Electrocution hazard. Contact with
severe burns.
electrically charged circuits could
result in death or serious injury.
Remove all rings, watches and
other jewelry.

Part No. 116478 AL8000HT Light Tower 3 - 27

 Section 3 • Scheduled Maintenance Procedures September 2008

CHECKLIST E PROCEDURES REV A

9 Remove the suction strainer and clean it using a E-2

mild solvent.
Perform Engine Maintenance -
10 Rinse out the inside of the reservoir using a mild
solvent.
Kubota Models
11 Install the suction strainer.
12 Install the hydraulic reservoir onto the power Note: Engine specifications require that this
unit. procedure be performed every 3000 hours.
13 Install the hydraulic reservoir retaining fasteners
Required maintenance procedures and additional
and securely tighten. Do not overtighten.
engine information is available in the
14 Install the hydraulic power unit onto the Kubota D-1105 and V-1505 Operator's Manual
machine. (Kubota part number 16683-89169).
15 Fill the reservoir with hydraulic oil to within a
1/2" from the top with the cylinders collapsed. Kubota D-1105 and V-1505 Operator's Manual
Terex part number 893020
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.
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 CHECKLIST E PROCEDURES

E-3 E-4
Perform Engine Maintenance - Perform Generator Maintenance
Kubota Models

Note: Generator specifications require that this

Note: Engine specifications require that this procedure be performed every 4500 hours or every
procedure be performed every 2 years. 3 years, whichever comes first.

Required maintenance procedures and additional Required maintenance procedures and additional
engine information is available in the generator information is available in the
Kubota D-1105 and V-1505 Operator's Manual Leroy Somer LSA 37 Installation and
(Kubota part number 16683-89169). Maintenance Manual (Leroy Somer part number
3664EN-09.2005/B) OR the
Marathon Installation, Operation and Maintenance
Kubota D-1105 and V-1505 Operator's Manual Manual (Marathon part number GPN012) OR the
Terex part number 893020
Newage Installation, Service and Maintenance
Manual (Newage part number BCH-018).

Leroy Somer LSA 37 Installation and

Maintenance Manual
Terex part number 116118

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 REV A

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 (Leroy Somer part number
3664EN-09.2005/B) OR the
Marathon Installation, Operation and Maintenance
Manual (Marathon part number GPN012) OR the
Newage Installation, Service and Maintenance
Manual (Newage part number BCH-018).

Leroy Somer LSA 37 Installation and

Maintenance Manual
Terex part number 116118

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

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
Observe and Obey: the point where repairs can be completed. To
re-assemble, perform the disassembly steps in
Repair procedures shall be completed by a reverse order.
person trained and qualified on the repair of this
Symbols Legend
machine.
Immediately tag and remove from service a Safety alert symbol—used to alert
personnel to potential personal
damaged or malfunctioning machine.
injury hazards. Obey all safety
Repair any machine damage or malfunction messages that follow this symbol
before operating the machine. to avoid possible injury or death.
Indicates an imminently hazardous
Before Repairs Start: situation which, if not avoided, will
Read, understand and obey the safety rules result in death or serious injury.
and operating instructions in the appropriate Indicates a potentially hazardous
operator's manual on your machine. situation which, if not avoided,
could result in death or serious
Be sure that all necessary tools and parts are
injury.
available and ready for use.
Indicates a potentially hazardous
Use only Terex approved replacement parts.
situation which, if not avoided,
Read each procedure completely and adhere to may cause minor or moderate
the instructions. Attempting shortcuts may injury.
produce hazardous conditions. Indicates a potentially hazardous
Unless otherwise specified, perform each repair situation which, if not avoided,
procedure with the machine in the following may result in property damage.
configuration: Indicates that a specific result is expected after
· Machine parked on a firm, level surface performing a series of steps.
· Key switch in the off position Indicates that an incorrect result has occurred
(manual start models) after performing a series of steps.
· Toggle switch in the off position
(automatic start models)
· Mast in the stowed position
· Light switches in the off position
· Wheels chocked

Part No. 116478 AL8000HT Light Tower 4-1

 Section 4 • Repair Procedures September 2008

Lighting REV A

1-1 How to Check Line Voltage

Lighting Correct line voltage at the lamp socket is essential
for proper operation of the lighting system.
How to Remove a Lamp Electrocution hazard. Exposure to
High voltage. Exposure to high voltage electrical wires or
electrical wires or electrical current electrical current will result in death
will result in death or serious or serious injury. Remove all rings,
injury. Remove all rings, watches watches and other jewelry. Turn off
and other jewelry. Turn off all all power when not needed for
power when not needed for testing. Use extreme caution when
testing. Use extreme caution when working with high voltage electrical
working with high voltage electrical components.
components.
1 Turn off all machine power.
Burn hazard. Contact with hot lamp
2 Remove the cover from the lamp junction box.
components may cause severe
burns. Use caution when working Note: The junction box is located between the light
around lamps. housings at the top of the mast.
1 Turn off all machine power. 3 Locate the correct wiring for the lamp to be
tested.
2 Remove the light lens mounting fasteners and
remove the lens. 4 Connect a voltmeter to the lamp wires.
3 Remove the spring securing the lamp to the 5 Start the engine.
lamp retainer.
6 Turn the appropriate circuit breaker light switch
Component damage hazard. to the "ON" position.
Contacting the lamp with bare skin
can cause damage to the lamp. 7 Observe the voltage as the lamps warm up.
Do not allow bare-skin contact Refer to the following chart.
with the lamps. Note: It can take up to 5 minutes for the lights to
4 Wrap a clean cloth around the lamp and reach full intensity. If the lights are turned off and
remove the lamp from the socket. then turned back on while they are still warm, they
may not light up again for 10 to 20 minutes.
Note: Be sure to wrap a clean cloth around a lamp
when installing a lamp into a lamp socket.

4-2 AL8000HT Light Tower Part No. 116478

September 2008 Section 4 • Repair Procedures

REV A LIGHTING

Time Line Voltage How to Check the Open Circuit

Initial ignition 415V AC
Voltage
Correct line voltage at the lamp socket is essential
30 seconds 412V AC for proper operation of the lighting system.

1 minute 413V AC Electrocution hazard. Exposure to

high voltage electrical wires or
2 minutes 416V AC electrical current will result in death
or serious injury. Remove all rings,
5 minutes 246V AC watches and other jewelry. Turn off
all power when not needed for
10 minutes 251V AC testing. Use extreme caution when
working with high voltage electrical
components.
Note: If the voltage reading remains high during
warm up, check for loose or broken wire 1 Turn off all machine power.
connections OR the lamp may be faulty. 2 Locate the electrical cable of the lamp to be
tested. Disconnect the cable from the junction
Note: The voltage readings provided in the chart are
box attached to the light bar.
averages; voltage on your machine may vary.
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.

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 REV A

2-1 6 Remove the pin retaining fasteners from light bar

lift cylinder barrel-end pivot pin "D". Place a rod
Light Bar through the pin and twist to remove the pin.
7 Remove the pin retaining fasteners from the light
How to Remove the Light Bar bar pivot pin "B" and the light bar lever pivot
Assembly pin"A". Place a rod through the pins and twist to
remove the pins.
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, Hydraulic Hose and
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.
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.
a light bar lever pivot pin
4 Remove the hose and cable clamp retaining b light bar pivot pin
fasteners from the light bar and remove the c light bar connecting link pivot pin
clamp. Lay the hydraulic hoses and main power d cylinder barrel-end pivot pin
cables, with junction boxes attached, over the
8 Carefully remove the light bar assembly from the
back of the cabinet.
machine.
5 Attach a lifting strap from an overhead crane to
Crushing hazard. The light bar
the light bar assembly. Support the light bar. Do
assembly could become
not apply any lifting pressure.
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 LIGHT BAR COMPONENTS

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, Hydraulic Hose and
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.
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 TOWER COMPONENTS

3-1 3-2
Plastic Cable Track Tower Assembly

How to Remove the Cable Track How to Remove the Tower

The tower cable track guides the cables and hoses Assembly
running up the tower. It can be repaired link by link Bodily injury hazard. The
without removing the cables and hoses that run procedures in this section require
through it. Removing the entire tower cable track is specific repair skills, lifting
only necessary when performing major repairs that equipment and a suitable
involve removing the tower. workshop. Attempting this
procedure without these skills and
How to Repair the Plastic Cable tools could result in death or
Track serious injury and significant
component damage. Dealer
Component damage hazard. The service is required.
tower cable track can be damaged
if it is twisted. 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, Hydraulic Hose and
Fitting Torque Specifications.
1 Remove the light bar. See 2-1, How to Remove
a the Light Bar Assembly.
2 Remove the cable track tube retaining fasteners
b at the number 3 tower tube.
3 Remove the hose and cable clamp fasteners
a link separation point and clamps from the underside of the cable
b lower clip track on the side of tower tube number 1.

1 Use a slotted screwdriver to pry down on the 4 Place blocks between the cable track tube and
lower clip. the lower cable track. Secure the cable track
together.
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.

Part No. 116478 AL8000HT Light Tower 4-7

 Section 4 • Repair Procedures September 2008

TOWER COMPONENTS REV A

5 Attach a suitable lifting device to the cable How to Disassemble the Tower
track. Carefully remove the cable track from the
tower and rest it on top of the cabinet. Note: When removing a hose assembly or fitting,
the O-ring on the fitting and/or hose end must be
Component damage hazard. replaced and then torqued to specification during
Cables and hoses can become installation. Refer to Section 2, Hydraulic Hose and
damaged if they are kinked or Fitting Torque Specifications.
pinched.
1 Remove the tower assembly. See 3-2, How to
6 Place a block under the tower lift cylinder for
Remove the Tower Assembly.
support.
2 Tag, disconnect and plug the light bar lift
7 Remove the pin retaining fasteners from the
cylinder hydraulic hoses. Cap the fittings on the
tower lift cylinder rod-end pivot pin.
cylinder.
8 Use a soft metal drift to remove the pin. Rest
Bodily injury hazard. Spraying
the tower lift cylinder on the block.
hydraulic oil can penetrate and
9 Tag, disconnect and plug the tower extension burn skin. Loosen hydraulic
cylinder hydraulic hoses. Cap the fittings on the connections very slowly to allow
cylinder. the oil pressure to dissipate
gradually. Do not allow oil to squirt
Bodily injury hazard. Spraying
or spray.
hydraulic oil can penetrate and
burn skin. Loosen hydraulic 3 Attach a suitable lifting device to the light bar
connections very slowly to allow cylinder.
the oil pressure to dissipate
4 Remove the pin retaining fasteners from the light
gradually. Do not allow oil to squirt
bar link pivot pin. Use a soft metal drift to
or spray.
remove the pin. Remove the cylinder from the
10 Position the forks from a forklift into the forklift tower assembly with links and levers attached.
pockets located under the tower. Secure the
Note: There is a spacer tube between the two links
tower to the forks.
that may fall out when the pivot pin is removed.
11 Remove the transport lock pin from the tower
near the tower rest pad. 5 Remove the cable retaining nut from the extend
cable at the extension end of the tower, located
12 Remove the pin retaining fasteners from the near the extend cylinder rod-end pivot pin. Pull
tower pivot pin at the tower rotation riser. the cable end out of the pivot pin.
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 TOWER COMPONENTS

6 Remove the external snap rings from both the 12 Support and slide the number 2 and 3 tower
tower extension cylinder rod-end pivot pin and tubes out of the number 1 tower tube and place
the extend cable pivot pin. Use a soft metal drift them on a structure capable of supporting them.
to remove the pins.
Crushing hazard. The number 2
7 Attach a lifting strap from an overhead crane to and 3 tower tubes could become
the tower extension cylinder. unbalanced and fall when removed
from the number 1 tube if not
8 Remove the external snap rings from the tower
properly supported by the overhead
extension cylinder barrel-end pivot pin. Use a
crane.
soft metal drift to remove the pin. Carefully
remove the cylinder from the machine. Bodily injury hazard. Cables can
fray. Always wear adequate hand
Crushing hazard. The tower
protection when handling the cable.
extension cylinder could become
unbalanced and fall when removed Component damage hazard.
from the machine if not properly Cables can be damaged if they are
supported by the overhead crane. kinked or pinched.
9 Remove the cable retaining nut from the retract Note: During removal, the overhead crane strap will
cable, located on the bottom of tower tube need to be carefully adjusted for proper balancing.
number 1, at the extension end of the tower.
Note: As the number 2 and 3 tower tubes are
10 Label and remove the wear pads from the removed from the number 1 tower tube, guide the
extension end of the number 1 tower tube. retract cable out from the slot in the bottom of the
11 Attach a lifting strap from an overhead crane to number 1 tower tube.
the number 2 and 3 tower tubes. 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 REV A

14 Pull the extend cable free of the pulley mount 3-3

and lay it flat on top of the number 3 tower tube.
Tower Lift Cylinder
Bodily injury hazard. Cables can
fray. Always wear adequate hand
protection when handling the cable.
How to Remove the Tower Lift
Cylinder
15 Label and remove the wear pads from the
extension end of the number 2 tower tube. The tower lift cylinder raises and lowers the tower
assembly. The tower lift cylinder is equipped with
16 Attach a lifting strap from an overhead crane to
counterbalance valves to prevent movement in the
the number 3 tower tube.
event of a hydraulic line failure.
17 Support and slide the number 3 tower tube from
the number 2 tower tube and place it on a Note: When removing a hose assembly or fitting,
structure capable of supporting it. the O-ring on the fitting and/or hose end must be
replaced and then torqued to specification during
Crushing hazard. The number 2 installation. Refer to Section 2, Hydraulic Hose and
and 3 tower tubes could become Fitting Torque Specifications.
unbalanced and fall when removed
from the number 1 tube if not 1 Tag, disconnect and plug the tower lift cylinder
properly supported by the overhead hydraulic hoses. Cap the fittings on the cylinder.
crane. Bodily injury hazard. Spraying
Bodily injury hazard. Cables can hydraulic oil can penetrate and
fray. Always wear adequate hand burn skin. Loosen hydraulic
protection when handling the cable. connections very slowly to allow
the oil pressure to dissipate
Component damage hazard. gradually. Do not allow oil to squirt
Cables can be damaged if they are or spray.
kinked or pinched.
2 Support both ends of the cylinder with a suitable
Note: During removal, the overhead crane strap will device to prevent it from falling.
need to be carefully adjusted for proper balancing.
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. 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 TOWER COMPONENTS

3-4 3 Remove the external snap rings from the tower

extension cylinder rod-end pivot pin. Use a soft
Tower Extension Cylinder metal drift to remove the pin.
4 Remove the external snap rings from the tower
How to Remove the Tower extension cylinder barrel-end pivot pin. Use a
Extension Cylinder soft metal drift to remove the pin.
The tower extension cylinder extends and retracts 5 Slide the extension cylinder towards the tongue
the tower assembly. The cylinder is used to extend end of the machine slightly and carefully
and retract the number 2 tower tube while cables remove the cylinder from the machine.
are used to extend and retract the number 3 tower
Crushing hazard. The tower
tube. The tower extension cylinder is equipped with
extension cylinder could become
counterbalance valves to prevent movement in the
unbalanced and fall when removed
event of a hydraulic line failure.
from the machine if not properly
Note: When removing a hose assembly or fitting, supported by the overhead crane.
the O-ring on the fitting and/or hose end must be
replaced and then torqued to specification during
installation. Refer to Section 2, Hydraulic Hose and
Fitting Torque Specifications.
1 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.
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 REV A

3-5 How to Adjust the Tower

Tower Rotation Motor Rotation Gear Backlash
The rotation motor mounting fasteners are located
How to Remove the Tower in slotted holes to allow the adjustment of gear
Rotation Motor backlash between the motor pinion gear and the
rotation bearing ring gear. Proper backlash
Note: When removing a hose assembly or fitting, adjustment is critical to safe machine operation and
the O-ring on the fitting and/or hose end must be component service life. An improper backlash
replaced and then torqued to specification during adjustment could decrease component service life
installation. Refer to Section 2, Hydraulic Hose and and may result in component damage.
Fitting Torque Specifications.
Note: Perform this procedure with the tower in the
Note: Perform this procedure with the tower in the stowed position and the transport lock pin installed.
stowed position and the transport lock pin installed.
1 Loosen the tower rotation motor mounting
1 Tag, disconnect and plug the tower rotation fasteners. Do not remove them.
motor hydraulic hoses. Cap the fittings on the
motor. 2 Push the rotation motor towards the rotation
bearing as far as possible (this will push the
Bodily injury hazard. Spraying pinion gear into the rotation bearing ring gear).
hydraulic oil can penetrate and
burn skin. Loosen hydraulic 3 Loosen the lock nut on the adjustment bolt.
connections very slowly to allow 4 Adjust the lock nuts until there is approximately
the oil pressure to dissipate 1/16 inch / 1.5 mm gap between the end of the
gradually. Do not allow oil to squirt bolt and the rotation motor case. Tighten the
or spray. lock nuts of the adjustment bolt.
2 Remove the rotation motor pinion gear guard 5 Rotate the rotation motor away from the bearing
fasteners. Remove the guard. until it contacts the adjustment bolt. Torque the
3 Remove the rotation motor mounting fasteners. rotation motor fasteners to specification. Refer
Remove the motor from the machine. to Section 2, Specifications.

Note: When installing a rotation motor, the gear 6 Rotate the tower through full range of motion.
backlash will need to be adjusted. See How to Check for tight spots and binding. Readjust if
Adjust the Tower Rotation Gear Backlash. necessary.

4 - 12 AL8000HT Light Tower Part No. 116478

September 2008 Section 4 • Repair Procedures

REV A
Kubota D1105-E / V1505-E Engine
4-1 4-3
Timing Adjustment Coolant Temperature and
Oil Pressure Switches
Complete information to perform this procedure is
available in the Kubota 05 Series Workshop Manual The engine coolant temperature switch is a
(Kubota part number: 97897-02432). normally open switch. The switch contacts close at
approximately 225°F / 107°C. If the coolant
Kubota 05 Series Workshop Manual temperature rises above the switch point, the
Terex part number 31742 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.
4-2 Make sure that the coolant system is at the proper
level.
Glow Plugs
The engine oil pressure switch is a normally closed
switch. The switch contacts open at approximately
How to Check the Glow Plugs 7 psi / 0.48 bar. If the oil pressure drops below the
1 Disconnect the wiring and buss bar from the switch point, the contacts open and the engine will
glow plugs. 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 REV A

5-1 5-3
Timing Adjustment Coolant Temperature and
Oil Pressure Switches
Complete information to perform this procedure is
available in the Isuzu 4LE1 Workshop Manual The engine coolant temperature switch is a
(Isuzu part number: IDE-2270). normally open switch. The switch contacts close at
approximately 221°F / 105°C. If the coolant
Isuzu 4LE1 Workshop Manual temperature rises above the switch point, the
Terex part number 116166 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.
5-2 Make sure that the coolant system is at the proper
level.
Glow Plugs
The engine oil pressure switch is a normally closed
switch. The switch contacts open at approximately
How to Check the Glow Plugs 14 psi / 0.96 bar. If the oil pressure drops below the
1 Disconnect the wiring and buss bar from the switch point, the contacts open and the engine will
glow plugs. 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
Generator
6-1 How to Check a Generator
Generator Capacitor - Leroy Somer Models
Electrocution hazard. Exposure to
How to Remove the Generator high voltage electrical wires or
Capacitor Cover - Leroy Somer electrical current will result in death
or serious injury. Remove all rings,
Models watches and other jewelry. Turn off
Electrocution hazard. Exposure to all power when not needed for
high voltage electrical wires or testing. Use extreme caution when
electrical current will result in death working with high voltage electrical
or serious injury. Remove all rings, components.
watches and other jewelry. Turn off Electrocution hazard. Attempting
all power when not needed for to service the machine before the
testing. Use extreme caution when capacitors are fully discharged will
working with high voltage electrical result in death or serious injury.
components.
Note: Be sure the engine has been turned off for at
Note: Be sure the engine has been turned off for at least 15 minutes before servicing the machine. Use
least 15 minutes before servicing the machine. Use a voltmeter to confirm there is no residual voltage
a voltmeter to confirm there is no residual voltage in the capacitors.
in the capacitors.
1 Remove the generator capacitor cover.
1 Loosen but do not remove the fasteners See 6-1, How to Remove the Generator
securing the capacitor cover to the top of the Capacitor Cover.
generator.
2 Tag and disconnect the wires attached to the
Burn hazard. Contact with hot capacitor(s).
engine components may cause
severe burns. Use caution when 3 Using an insulated conductor or a screwdriver
working around a hot engine. with an insulated handle, discharge the
capacitor by shorting across the capacitor
2 Pull the cover off the top of the generator to terminals. Repeat for the second capacitor, if
access the wire harness where it connects to equipped.
the generator.
Electrocution hazard. Exposure to
3 Tag and disconnect the wires at the top of the high voltage electrical wires or
generator. Remove the cover. 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 REV A

Result: The meter indicates a very low 3 Open each cabinet door. Remove the hinge
resistance which then gradually increases AND retaining fasteners from the cabinet top for each
a very high resistance which then gradually cabinet door.
decreases. The capacitor is working. 4 Disconnect the gas struts from each cabinet
Result: The meter indicates a very high door. Remove each door from the machine.
resistance which does not decrease. The 5 Locate the domelight mounted to the cabinet top
capacitor is faulty and should be replaced. above the engine. Remove the lens from the
Result: The meter indicates a very low domelight. Remove the domelight mounting
resistance which does not increase. The fasteners and set the domelight aside.
capacitor is faulty and should be replaced. 6 Locate the wiring for the limit switch located at
Probable causes of capacitor failure: the transport lock pin. Tag and disconnect the
limit switch wiring from inside the engine
· Starting engine with circuit breakers on. compartment.
· Shutting off engine with circuit breakers on. 7 Remove the limit switch mounting fasteners and
· Normal end-of-life failure. set the switch aside.
· Overheated due to light fixture heat or high 8 Remove the tower rest pad weldment fasteners.
ambient temperature. Remove the rest pad from the cabinet.
· Incorrect capacitor voltage rating. 9 Support the cabinet top with a suitable lifting
device.

How to Remove the Generator - 10 Remove all fasteners securing the cabinet top to
the cabinet end panels. Carefully remove the
Marathon Generator Models cabinet top from the machine.
Electrocution hazard. Exposure to Crushing hazard. The cabinet top
high voltage electrical wires or may become unbalanced and fall if
electrical current will result in death not properly supported when
or serious injury. Remove all rings, removed from the machine.
watches and other jewelry. Turn off
all power when not needed for Models with Marathon generators:
testing. Use extreme caution when
11 Disconnect the battery from the machine.
working with high voltage electrical
components. Electrocution hazard. Contact with
hot or live circuits could result in
Note: Be sure the engine has been turned off for at
death or serious injury. Remove all
least 15 minutes before servicing the machine. Use
rings, watches and other jewelry.
a voltmeter to confirm there is no residual voltage
in the capacitors. 12 Remove the fasteners securing the terminal box
cover to the top of the generator. Remove the
1 Extend all four outriggers. Lower each outrigger
cover.
until they make contact with the ground.
Burn hazard. Contact with hot
2 Raise the tower to a vertical position. Do not
engine components may cause
extend the tower or raise the light bar. Turn the
severe burns. Use caution when
machine off.
working around a hot engine.

4 - 16 AL8000HT Light Tower Part No. 116478

September 2008 Section 4 • Repair Procedures

REV A GENERATOR

13 Tag and disconnect the black, white, and green How to Remove the Generator -
wires, that enter the terminal box, from the
generator. Newage Generator Models
Electrocution hazard. Exposure to Electrocution hazard. Exposure to
high voltage electrical wires or high voltage electrical wires or
electrical current will result in death electrical current will result in death
or serious injury. Remove all rings, or serious injury. Remove all rings,
watches and other jewelry. Use watches and other jewelry. Turn off
extreme caution when working with all power when not needed for
high voltage electrical testing. Use extreme caution when
components. working with high voltage electrical
components.
14 Loosen the wiring clamp located on the back of
the capacitor compartment of the generator. Pull Note: Be sure the engine has been turned off for at
the wiring out of the terminal box through the least 15 minutes before servicing the machine. Use
wiring clamp. a voltmeter to confirm there is no residual voltage
in the capacitors.
15 Use a lifting jack or similar device to support the
rear of the engine. Do not apply any lifting 1 Extend all four outriggers. Lower each outrigger
pressure. until they make contact with the ground.
16 Remove the generator fan screens from both 2 Raise the tower to a vertical position. Do not
sides of the generator. extend the tower or raise the light bar. Turn the
machine off.
17 Remove the fasteners securing the generator to
the engine flywheel. 3 Open each cabinet door. Remove the hinge
retaining fasteners from the cabinet top for each
18 Remove the fasteners securing the generator to cabinet door.
the chassis.
4 Disconnect the gas struts from each cabinet
19 Attach a lifting strap from an overhead crane or door. Remove each door from the machine.
other suitable device to both lifting eyes on the
generator. Support the generator. Do not apply 5 Locate the domelight mounted to the cabinet top
any lifting pressure. above the engine. Remove the lens from the
domelight. Remove the domelight mounting
20 Remove the fasteners securing the generator to fasteners and set the domelight aside.
the engine bellhousing.
6 Locate the wiring for the limit switch located at
21 Remove the generator from the machine. the transport lock pin. Tag and disconnect the
Crushing hazard. The generator limit switch wiring from inside the engine
may become unbalanced and fall if compartment.
not properly supported when 7 Remove the limit switch mounting fasteners and
removed from the machine. 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 REV A

10 Remove all fasteners securing the cabinet top to 16 Remove the generator fan screens from both
the cabinet end panels. Carefully remove the sides of the generator.
cabinet top from the machine.
Note: The generator fan screens cover the
Crushing hazard. The cabinet top generator fan blades and are located between the
may become unbalanced and fall if generator and the engine bellhousing.
not properly supported when
removed from the machine. 17 Remove the fasteners securing the generator to
the engine flywheel.
Models with Newage generators:
18 Remove the fasteners securing the generator to
11 Disconnect the battery from the machine. the chassis.
Electrocution hazard. Contact with 19 Attach a lifting strap from an overhead crane or
hot or live circuits could result in other suitable device to both lifting eyes on the
death or serious injury. Remove all generator. Support the generator. Do not apply
rings, watches and other jewelry. any lifting pressure.
12 Remove the fasteners securing the terminal box 20 Remove the fasteners securing the generator to
cover to the top of the generator. Remove the the engine bellhousing.
cover.
21 Remove the generator from the machine.
Burn hazard. Contact with hot
Crushing hazard. The generator
engine components may cause
may become unbalanced and fall if
severe burns. Use caution when
not properly supported when
working around a hot engine.
removed from the machine.
13 Tag and disconnect the black, white, and green
Models with Leroy Somer generators:
wires, that enter the terminal box, from the
generator. 11 Pull the cover off the top of the generator to
Electrocution hazard. Exposure to access the wire harness where it connects to
high voltage electrical wires or the generator.
electrical current will result in death 12 Using an insulated conductor or a screwdriver
or serious injury. Remove all rings, with an insulated handle, discharge the
watches and other jewelry. Use capacitor by shorting across the capacitor
extreme caution when working with terminals. Repeat for the second capacitor, if
high voltage electrical equipped.
components.
Electrocution hazard. Exposure to
14 Loosen the wiring clamp located on the back of high voltage electrical wires or
the capacitor compartment of the generator. Pull electrical current will result in death
the wiring out of the terminal box through the or serious injury. Remove all rings,
wiring clamp. watches and other jewelry. Use
15 Use a lifting jack or similar device to support the extreme caution when working with
rear of the engine. Do not apply any lifting high voltage electrical
pressure. 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
Chassis Components
14 Tag and disconnect the ground wire from the 3 Using the tip of a pencil or pen, press the Reset
generator mount. button (R). A blinking display will show 0:00 for
the time and an arrow under the day 7 (for
15 Use a lifting jack or similar device to support the
Sunday).
rear of the engine. Do not apply any lifting
pressure. 4 Move the set switch to the left (clock icon) to
set the present day and time.
16 Remove the generator fan screen from the
generator. 5 A default time of AM 12:00 will appear on the
display screen.
Note: The generator fan screen covers the
generator fan blades and is located between the 6 Press the day button (1..7) repeatedly until the
generator and the engine bellhousing. arrow points to the actual day of the week.

17 Remove the fasteners securing the generator to 7 Press the hour button (h) repeatedly until the
the engine flywheel. actual hour of the day is displayed.
18 Remove the fasteners securing the generator to 8 Press the minute button (m) repeatedly until the
the chassis. minute of the present hour is displayed.
19 Attach a lifting strap from an overhead crane to 9 Move the Set switch to the program position (P)
the generator. Support the generator. Do not to set the desired stop and start time. A default
apply any lifting pressure. time of AM 12:00 will appear. A small 1 will
appear to the right of the time with a lamp
20 Remove the fasteners securing the generator to symbol above it.
the engine bellhousing.
10 Use the day, hour and minute buttons to set the
21 Remove the generator from the machine. timer to the desired start day and time.
Crushing hazard. The generator will 11 Press the program button (P) to set the timer for
fall if not properly supported when the desired shut-off time. AM 12:00 will appear
removed from the machine. in the display with a small 2 to the right.
Note: The lamp symbol will not appear above the 2.
7-1
12 Use the day, hour and minute buttons to set the
Ground Controls timer to the desired shut-off day and time.

How to Program the Engine 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 REV A

7-2 3 Remove the ballast box cover fasteners.

Light Ballast 4 Using an insulated conductor or a screwdriver

with an insulated handle, discharge the
capacitor by shorting across the capacitor
How to Check a terminals.
Ballast Capacitor
Electrocution hazard. Exposure to
Electrocution hazard. Exposure to high voltage electrical wires or
high voltage electrical wires or electrical current will result in death
electrical current will result in death or serious injury. Remove all rings,
or serious injury. Remove all rings, watches and other jewelry. Use
watches and other jewelry. Use extreme caution when working with
extreme caution when working with high voltage electrical
high voltage electrical components.
components.
5 With an ohmmeter set to its highest resistance
Electrocution hazard. Attempting scale, connect the ohmmeter leads to the
to service the machine before the capacitor terminals and observe the reading on
capacitors are fully discharged the meter. Then, reverse the connections and
could result in death or serious observe the reading on the meter.
injury.
Result: The meter indicates a resistance which
Note: Be sure the engine has been turned off for at then gradually decreases. The capacitor is
least 15 minutes before servicing the machine. Use working.
a voltmeter to confirm there is no residual voltage
in the capacitors. Result: The meter indicates a very high
resistance which does not decrease. The
Note: This procedure is only for the capacitors capacitor is faulty and should be replaced.
which are attached to the lighting ballasts. To test a
Result: The meter indicates a very low
generator capacitor, see 6-1, How to Check a
resistance which does not increase. The
Generator Capacitor.
capacitor is faulty and should be replaced.
1 Open both cabinet doors and locate the light
Probable causes of capacitor failure:
ballast boxes on each side of the machine.
· Normal end-of-life failure.
2 Choose a ballast box. Tag and disconnect the
wire harness connector from the ballast box. · Overheated due to light fixture heat or high
ambient temperature.
Note: If the ballast capacitor to be tested is located
under another ballast box, the top ballast box will · Incorrect capacitor voltage rating.
need to be removed first. · Capacitor becomes loose in ballast box.

4 - 20 AL8000HT Light Tower Part No. 116478

September 2008 Section 4 • Repair Procedures

REV A CHASSIS COMPONENTS

7-3 Models without fuel containment option:

Fuel Tank 4 Support the fuel tank support weldment at each

end using lifting jacks and blocks. Do not apply
How to Remove a Fuel Tank any lifting pressure. Do not directly support the
fuel tank.
1 Open both cabinet doors.
Component damage hazard. The
2 Remove the fuel filler cap from the tank. Using fuel tank is plastic and may
an approved hand-operated pump, drain the fuel become damaged if the lifting
tank into a container of suitable capacity. Refer jacks are in direct contact with the
to Section 2, Specifications. plastic tank.
Explosion and fire hazard. Engine 5 Remove the fasteners securing the fuel tank
fuels are combustible. Perform this support weldment to the chassis.
procedure in an open, well-
6 Carefully lower the fuel tank out of the chassis
ventilated area away from heaters,
and remove it from the machine.
sparks, flames and lighted
tobacco. Always have an approved Component damage hazard. The
fire extinguisher within easy reach. fuel tank is plastic and may
become damaged if allowed to fall.
Explosion and fire hazard. When
transferring fuel, connect a Note: It may be necessary to lower the outriggers
grounding wire between the to the ground and raise the machine using the
machine and pump or container. outriggers to obtain adequate clearance to
completely remove the fuel tank from the machine.
Be sure to only use a hand-
operated pump suitable for use Note: Clean the fuel tank and inspect for cracks
with diesel fuel. and other damage before installing it onto the
Note: If your machine is equipped with dual fuel machine.
tanks, repeat this procedure beginning with step 2
for the other fuel tank.

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 REV A

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.

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 6
1

C
2

B
3

H
4

G F
5 7

Part No. 116478 AL8000HT Light Tower 4 - 23

 Section 4 • Repair Procedures September 2008

CHASSIS COMPONENTS REV A

8-2 5 Use a wrench to hold the relief valve and

remove the cap (item H).
Valve Adjustments -
6 Adjust the internal hex socket. Turn it clockwise
Function Manifold to increase the pressure or counterclockwise to
decrease the pressure. Install the relief valve
How to Adjust the Tower Rotate cap.
Relief Valve Component damage hazard. Do
not adjust the relief valve higher
Note: When removing a hose assembly or fitting,
than specified.
the O-ring on the fitting and/or hose end must be
replaced and then torqued to specification during 7 Repeat steps 3 through 6 and recheck relief
installation. Refer to Section 2, Hydraulic Hose and valve pressure.
Fitting Torque Specifications.
8 Remove the pressure gauge.
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.
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, Specifications.

4 - 24 AL8000HT Light Tower Part No. 116478

September 2008 Section 5 • Troubleshooting

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.
Observe and Obey:
Be aware of the following hazards and follow
Troubleshooting and repair procedures shall be generally accepted safe workshop practices.
completed by a person trained and qualified on
Use only a voltmeter with insulated probes rated
the repair of this machine.
at a minimum of 600V AC.
Immediately tag and remove from service a
Allow lamps to cool before opening the fixtures.
damaged or malfunctioning machine.
Electrocution hazard. Exposure to
Repair any machine damage or malfunction
high voltage electrical wires or
before operating the machine.
electrical current will result in death
Unless otherwise specified, perform each or serious injury. Remove all rings,
repair procedure with the machine in the watches and other jewelry. Turn off
following configuration: all power when not needed for
· Machine parked on a firm, level surface. testing. Use extreme caution when
working with high voltage electrical
· Wheels chocked. components.
· Toggle switch in off position.
Electrocution hazard. Attempting
· All circuit breakers are in the off position. 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 injectors 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 b.Check plug and receptacle. Tighten
if needed. Make sure power is off.
c.Defective ballast c.Interchange ballast plugs. If lamp
starts, replace ballast. Check for
swollen capacitors, charred wiring,
core and coil, or other signs of
excessive heat.
d.Low voltage d.Check line voltage at ballast input.
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 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. Check 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 a.Check voltage at ballast, for current
or voltage surges, for shorted
capacitors and replace as needed
b.Improper ballast b.Check ballast name plate against
lamp data
17.Short lamp life a.Lamp damaged a.Check for outer bulb cracks,
cracks where lamp meets base, and
for broken arc tube or loose metal
parts. Replace as needed.
b.Improper ballast b.Check ballast name plate against
lamp data
18.Lamp flickers or goes out- a.Improper Ballast a.Check ballast name plate against
intermittent or cycling lamp data
b.New lamp b.Under certain conditions new lamps
may "cycle". Usually after 3 tries to
start at 30 to 60 second intervals,
lamp will stabilize and operate normal

5-4 AL8000HT Light Tower Part No. 116478

September 2008 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 e.Ballast produces high spike current.
Measure with oscilloscope. Replace
ballast as required.

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 LO-
CAL DEALER, CONTACT THE FACTORY SERVICE MANAGER TOLL FREE AT 1-800-433-3026.

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

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5-6 AL8000HT Light Tower Part No. 116478

September 2008 Section 6 • Schematics

REV A
Schematics
About This Section
There are two groups of schematics in this section.
An illustration legend precedes each group of
drawings.
Electrical Schematics

Observe and Obey: Electrocution hazard. Contact with

electrically charged circuits could
Troubleshooting and repair procedures shall be result in death or serious injury.
completed by a person trained and qualified on Remove all rings, watches and
the repair of this machine. other jewelry.
Immediately tag and remove from service a Hydraulic Schematics
damaged or malfunctioning machine.
Bodily injury hazard. Spraying
Repair any machine damage or malfunction hydraulic oil can penetrate and
before operating the machine. burn skin. Loosen hydraulic
connections very slowly to allow
Before Troubleshooting: the oil pressure to dissipate
Read, understand and obey the safety rules and gradually. Do not allow oil to squirt
operating instructions in the appropriate or spray.
Operator's Manual on your machine. General Repair Process
Be sure that all necessary tools and test
equipment are available and ready for use.
Malfunction Identify Troubleshoot
discovered symptoms

problem
still exists

Return to Inspect Perform

service problem and test repair
solved

Part No. 116478 AL8000HT Light Tower 6-1

 Section 6 • Schematics September 2008

Electrical Symbols Legend

REV A

BLK

Pump
WHT

Quick disconnect Starting aid:

terminal Power unit glow plug or
Coil flame ignitor
solenoid or relay
TS2

ENGINE
START
T-circuits connect
FB

Flashing beacon
Connection Toggle switch SPDT
no terminal

HM TS6
DOWN
UP

Circuits crossing Hour meter

no connection
PLATFORM LEVEL

L3
Toggle switch DPDT
Diode
LED
CTS1
+
F1 N.O.

25A
- Coolant temperature
Fuse switch
with amperage normally open
Battery

OPS1
N.C.
LS3
CB1 N.O.H.C N.C.H.O

15A Limit switch Oil pressure switch

normally closed
Circuit breaker
with amperage
A B C
PR1
PULL IN
HOLD

Power relay
Main circuit
breaker Fuel or RPM
solenoid
CR4
N.O.

Control relay contact

Light switch normally open Coil

6-2 AL8000HT Light Tower Part No. 116478

September 2008 Section 6 • Schematics

Hydraulic Symbols Legend

REV A

25 psi
(1.7 bar) .035"
(0.89 mm)
Orifice with size

Solenoid operated 3 position,

Filter with 4 way, directional valve
bypass valve
relief setting
Check valve

200 psi
(13.8 bar)

Pump
fixed displacement Relief valve Priority
with pressure setting flow regulator valve

E
3000 psi
(206.8 bar)
Pump prime mover 3:1
(engine or motor)

Cross-relief valve

Counterbalance valve
with pressure and pilot ratio
Double acting
cylinder

Part No. 116478 AL8000HT Light Tower 6-3

 Section 6 • Schematics September 2008

Electrical Schematic - Machine Functions

REV A

TOWER ROTATE LEFT

LEFT WH
TOWER VALVE COIL
ROTATE
RIGHT TOWER ROTATE RIGHT
WH/BLK VALVE COIL

LIGHT BAR DOWN

DOWN GR/BLK VALVE COIL
LIGHT
UP BAR
LIGHT BAR UP
GR VALVE COIL

TOWER RETRACT
RETRACT BLK/WH VALVE COIL
TOWER
EXTEND TOWER EXTEND
BLK VALVE COIL

TOWER DOWN
DOWN RED/BLK VALVE COIL
TOWER
UP TOWER UP
VALVE COIL
RED
N.C./H.O.

STOWED
LIMIT SWITCH

PUMP MOTOR
CONTACTOR

LIFT PUMP
MOTOR
FUSE
30A

6-4 AL8000HT Light Tower Part No. 116478

September 2008 Section 6 • Schematics

DC Electrical Schematic - Control Box and Engine

REV A Isuzu Models

Part No. 116478 AL8000HT Light Tower 6-5

 Section 6 • Schematics September 2008

DC Electrical Schematic - Control Box and Engine

Kubota Models REV A

6-6 AL8000HT Light Tower Part No. 116478

September 2008 Section 6 • Schematics

DC Electrical Schematic - Control Box and Engine

REV A with Autostart Option

Part No. 116478 AL8000HT Light Tower 6-7

 Section 6 • Schematics September 2008

AC Electrical Schematic -
Standard Models with 4 Lights REV A

6-8 AL8000HT Light Tower Part No. 116478

September 2008 Section 6 • Schematics

AC Electrical Schematic -
REV A Standard Models with 6 Lights

Part No. 116478 AL8000HT Light Tower 6-9

 Section 6 • Schematics September 2008

AC Electrical Schematic -
Standard Models with 8 Lights REV A

6 - 10 AL8000HT Light Tower Part No. 116478

September 2008 Section 6 • Schematics

AC Electrical Schematic -
REV A Autostart Models with 4 Lights

Part No. 116478 AL8000HT Light Tower 6 - 11

 Section 6 • Schematics September 2008

AC Electrical Schematic -
Autostart Models with 6 Lights REV A

6 - 12 AL8000HT Light Tower Part No. 116478

September 2008 Section 6 • Schematics

AC Electrical Schematic -
REV A Autostart Models with 8 Lights

Part No. 116478 AL8000HT Light Tower 6 - 13

 Section 6 • Schematics September 2008

Receptacle Wiring Diagrams

REV A

Standard Receptacle Package

Extra GFCI Receptacle Package

Enhanced Receptacle Package

6 - 14 AL8000HT Light Tower Part No. 116478

September 2008 Section 6 • Schematics

Hydraulic Schematic
REV A

Part No. 116478 AL8000HT Light Tower 6 - 15

 Section 6 • Schematics September 2008

REV A

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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 Checklist
(Use at each stop)
Before Towing · 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

Before Driving · Fasten safety restraints

· Properly adjust mirrors

On The Road · 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 North America
Phone 425.881.1800
Toll Free USA and Canada
800.536.1800
Fax 425.883.3475

Genie Australia Pty Ltd.

Phone +61 7 3375 1660
Fax +61 7 3375 1002

Genie China Genie Scandinavia

Phone +86 21 53852570 Phone +46 31 575100
Fax +86 21 53852569 Fax +46 31 579020
Distributed By:

Genie Malaysia Genie France

Phone +65 98 480 775 Phone +33 (0)2 37 26 09 99
Fax +65 67 533 544 Fax +33 (0)2 37 26 09 98

Genie Japan Genie Iberica

Phone +81 3 3453 6082 Phone +34 93 579 5042
Fax +81 3 3453 6083 Fax +34 93 579 5059

Genie Korea Genie Germany

Phone +82 25 587 267 Phone +49 (0)4202 88520
Fax +82 25 583 910 Fax +49 (0)4202 8852-20

Genie Brasil Genie U.K.

Phone +55 11 41 665 755 Phone +44 (0)1476 584333
Fax +55 11 41 665 754 Fax +44 (0)1476 584334

Genie Holland Genie Mexico City

Phone +31 183 581 102 Phone +52 55 5666 5242
Fax +31 183 581 566 Fax +52 55 5666 3241