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Terex AL4000D2 Series - User Manual

Terex AL4000D2 Series
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November 2006
Part No. 833002 Rev A AL4000 Light Tower 1
OPERATOR/SERVICE
& PARTS MANUAL
Series AL4000D2
Light Tower
P.O. BOX 3147
ROCK HILL, S.C. 29732 USA
PART NUMBER 833002
REVISION A
November 2006
TOLL FREE 800-433-3026
FAX (Parts Dept) 800-633-5534

Questions and Answers

  • J
    John WallsSep 12, 2025
    Why Terex Flood Light arc tube is discolored or swollen?
    • S
      Sheila NelsonSep 12, 2025
      If the Terex Flood Light arc tube is discolored or swollen, it may be due to over voltage from the power supply. Check the voltage at the ballast for current or voltage surges, and inspect for shorted capacitors, replacing as needed. Another potential cause is an improper ballast, so check the ballast name plate against the lamp data.
  • C
    Catherine CarlsonAug 23, 2025
    Why is Terex Flood Light engine overheating?
    • P
      patty17Aug 23, 2025
      If the Terex Flood Light engine is overheating, several factors could be responsible. Start by inspecting the front and rear cooling air intakes for any blockages and clear them as needed. Check the coolant levels and replenish with a 50% water/coolant solution if low. Also, inspect the radiator fins for clogs and clear them. Finally, ensure the fan belt is properly tightened.
  • P
    Pamela HarmonAug 25, 2025
    Why does Terex Flood Light engine run rough?
    • N
      Nichole SalazarAug 26, 2025
      If the Terex Flood Light engine runs rough, there are several potential causes. Begin by inspecting the fuel system for clogs or leaks; replace fuel lines, tighten connections, and inspect both the pickup tube and fuel filter. A clogged exhaust system can also cause rough running, so clear any obstructions. Similarly, check and clear the air filter. For issues such as clogged or stuck fuel injectors, incorrect valve clearances, damaged valve springs, or a defective governor or fuel pump, it's best to have a trained mechanic examine the engine.
  • T
    Travis HernandezAug 27, 2025
    Why Terex Flood Light engine runs but the lights will not operate?
    • A
      Andrew MendozaAug 27, 2025
      If the Terex Flood Light engine runs but the lights won't operate, there are several potential reasons. First, check if the circuit breakers have tripped and reset them if necessary. Loose connections in the wiring system could also be the cause, so have a trained electrician inspect the ballast box wiring. Additionally, inspect the bulbs and replace them if they are burned out. For issues related to a defective capacitor (in Leroy Somers Generators), a defective AC generator, engine speed being too low, or defective ballast and capacitors, it's recommended to have a trained electrician or mechanic perform an inspection.
  • D
    Daniel FreemanAug 27, 2025
    How to troubleshoot Terex Flood Light engine that will not turn over?
    • J
      Jennifer RichardAug 28, 2025
      If the Terex Flood Light engine will not turn over, the possible cause is a dead battery. Check the battery voltage or look for loose cables. If the engine has seized due to loss of fluids, have a trained mechanic examine and repair it as needed.
  • R
    robertsondawnAug 29, 2025
    What to do if Terex Flood Light boom will not rise?
    • F
      frederickrobertAug 29, 2025
      If your Terex Flood Light boom will not rise to the operating position, it could be due to a few reasons. Check if the yoke pin is in place and remove it if it is. If the problem persists, a defective cable or pulley, or a defective winch might be the issue, and it's best to have a trained mechanic examine and repair or replace them as needed.
  • P
    Patrick McdanielSep 22, 2025
    Why Terex Flood Light engine runs but the battery voltage is low?
    • C
      Christopher PageSep 22, 2025
      If the Terex Flood Light engine runs but the battery voltage is low, it is possible that the alternator has failed. Have a trained mechanic inspect the alternator.
  • E
    Emily WoodSep 12, 2025
    Why Terex Flood Light lamp has short lamp life?
    • M
      michaelrubioSep 12, 2025
      If the Terex Flood Light lamp has a short life, it could be due to lamp damage. Check for outer bulb cracks, cracks where the lamp meets the base, and for a broken arc tube or loose metal parts, replacing as needed. Another possible cause is an improper ballast, so check the ballast name plate against the lamp data.
  • D
    Dylan MccoySep 9, 2025
    Why Terex Flood Light lamp colors different?
    • C
      Cassie TurnerSep 9, 2025
      If the Terex Flood Light lamp colors are different, it could be due to normal lamp depreciation, requiring a lamp replacement. Another possibility is a dirty lamp or fixture, so clean them. Also, ensure the correct lamp is being used by checking the data on the lamps and replacing as needed.
  • L
    Lisa KirbySep 6, 2025
    Why does Terex Flood Light circuit breaker trips on lamp startup?
    • L
      Lauren JonesSep 6, 2025
      If the Terex Flood Light circuit breaker trips on lamp startup, it indicates a short circuit or ground. Check the wiring against the diagram and inspect for shorts or grounds, fixing as needed.

Summary

TO THE OPERATOR

SAFETY ALERT SYMBOLS

GENERAL SAFETY

ACCIDENT PREVENTION

Covers personal safety, protective gear, and general accident prevention measures.

FUELING SAFETY PRECAUTIONS

Safety guidelines for handling fuel, preventing fires, and refueling procedures.

EXHAUST GASES AND ELECTRICAL SAFETY

Warnings about toxic exhaust gases and precautions for high voltage electrical systems.

BATTERY HAZARDS AND LAMP RADIATION SAFETY

Safety information for batteries and ultraviolet radiation from lamps.

TRANSPORT & TOWING

SETUP

POSITIONING AND LEVELING THE TOWER

Steps for moving, leveling, and securing the light tower using jacks and outriggers.

RAISING AND SECURING THE TOWER

Steps and warnings related to raising the telescoping tower and securing it in place.

OPERATING INSTRUCTIONS

PRE-OPERATION SETUP AND CHECKS

Instructions for moving, unhitching, leveling the trailer, and driving ground rods.

FLOODLIGHT INSTALLATION AND TOWER RAISING

Procedures for installing floodlights and raising the tower to the operational position.

STARTING AND OPERATING THE ENGINE;GENERATOR

Steps for starting the engine, turning on floodlights, and adjusting them for the work area.

MAINTENANCE

SPECIFICATIONS & DIMENSIONS

TORQUE SPECIFICATIONS

TROUBLESHOOTING

ENGINE AND BOOM RELATED ISSUES

Troubleshooting guide for problems like boom not rising, telescoping, or engine not starting.

ENGINE AND LIGHTING SYSTEM ISSUES

Troubleshooting for engine smoke, overheating, low voltage, and lights not operating.

LAMP PERFORMANCE AND LIFE ISSUES

Troubleshooting guide for low light output, color differences, short lamp life, and flickering.

WARRANTY

RECOMMENDED ENGINE OIL & FUEL

WIRE ROPE REPLACEMENT

WIRING DIAGRAMS SECTION

WINCH LOCK ASSEMBLY PARTS

ENGINE;GENSET ASSEMBLY PARTS

ELECTRICAL CONTROL BOX ASSEMBLY PARTS

LIGHT FIXTURE ASSEMBLY PARTS

BALLAST ASSEMBLY PARTS

Terex AL4000D2 Series Specifications

General IconGeneral
Rated Output Power6 kW
Voltage120/240 V
Frequency60 Hz
Fuel TypeDiesel
Number of Lamps4
Lamp Wattage1000 W
Lamp TypeMetal Halide
Light Output440, 000 lumens
Fuel Tank Capacity30 gallons
Lumens per Lamp110, 000 lumens
Mast Height30 ft
Mounting Height30 ft