Parts Manual: First Edition Rev A Part No. 116419 September 2008

Parts Manual
AL4000D2
First Edition
Rev A
Part No. 116419
September 2008
September 2008
Introduction REV A
Important Serial Number Information

Read, understand and obey the safety rules and TEREX Corporation offers the following manuals
operating instructions in the appropriate Operator's for these models:
Manual on your machine before attempting any
maintenance procedure. Title Part No.
Basic mechanical, hydraulic and electrical TEREX AL4000/5000 Operator's Manual ........... 116416
skills are required to perform most procedures. First Edition
However, several procedures require specialized TEREX AL4000 Parts Manual ............................ 116419
skills, tools, lifting equipment and a suitable First Edition
workshop. In these instances, we strongly
recommend that maintenance and repair be TEREX AL4000 Service Manual ......................... 116474
performed at an authorized TEREX dealer First Edition
service center. Leroy Somer Manual ........................................... 116118
Kubota Engine Manual ....................................... 893020
Technical Publications Axis Manual ........................................................ 116117
Marathon Manual ................................................ 116188

TEREX Corporation 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 Corporation
www.TEREX.com 116419 Rev A September 2008

First Edition, First Printing
"TEREX" is a registered trademark of TEREX

Corporation in the USA and many other countries.
"Super Quiet" is a trademark of TEREX
Corporation.
Printed on recycled paper
Printed in U.S.A.
ii AL4000 Light Tower Part No. 116419

September 2008
REV A
How to Read Your Serial Number
Serial Number Legend

The serial number plate on your AL4000 is located
on the cabinet next to the light tower mast.
Part No. 116419 AL4000 Light Tower iii

September 2008
REV A
This page intentionally left blank.
iv AL4000 Light Tower Part No. 116419

September 2008 Section 1 • Safety Rules
REV A
Safety Rules
Danger
Failure to obey the instructions and safety rules
in this manual and the appropriate 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.
Part No. 116419 AL4000 Light Tower v

Section 1 • Safety Rules September 2008
SAFETY RULES REV A
Personal Safety Be sure to wear protective eye wear and

other protective clothing if the situation
Any person working on or around a machine must warrants it.
be aware of all known safety hazards. Personal
safety and the continued safe operation of the Be aware of potential crushing hazards
machine should be your top priority. such as moving parts, free swinging or
unsecured components when lifting or
placing loads. Always wear approved steel-toed
shoes.
Read each procedure thoroughly. This
manual and the decals on the machine,
use signal words to identify the following:
Safety alert symbol—used to alert Workplace Safety

personnel to potential personal Be sure to keep sparks, flames and
injury hazards. Obey all safety lighted tobacco away from flammable and
messages that follow this symbol combustible materials like battery gases
to avoid possible injury or death. and engine fuels. Always have an approved fire
Red—used to indicate the extinguisher within easy reach.
presence of an imminently
hazardous situation which, if not
avoided, will result in death or Be sure that all tools and working areas
serious injury. are properly maintained and ready for
Orange—used to indicate the use. Keep work surfaces clean and free of
presence of a potentially debris that could get into machine components and
hazardous situation which, if not cause damage.
avoided, could result in death or
serious injury.
Be sure that your workshop or work area
Yellow with safety alert symbol— is properly ventilated and well lit.
used to indicate the presence of a
potentially hazardous situation
which, if not avoided, may cause
Be sure any forklift, overhead crane or
minor or moderate injury.
other lifting or supporting device is fully
Yellow without safety alert capable of supporting and stabilizing the
symbol—used to indicate the weight to be lifted. Use only chains or straps that
presence of a potentially are in good condition and of ample capacity.
hazardous situation which, if not
avoided, may result in property
damage. Be sure that fasteners intended for one
Green—used to indicate operation time use (i.e., cotter pins and self-locking
or maintenance information. nuts) are not reused. These components
may fail if they are used a second time.
Be sure to properly dispose of old oil or

other fluids. Use an approved container.
Please be environmentally safe .
vi AL4000 Light Tower Part No. 116419

September 2008
REV A
Table of Contents
Introduction
Important Information - Introduction ................................................................... ii
How to Read Your Serial Number ..................................................................... iii
Parts Stocking List ............................................................................................ ix
How to Order Parts ........................................................................................... xi
Service Parts Fax Order Form ......................................................................... xii
Section 1 Safety Rules

General Safety Rules ........................................................................................ v
Section 100 Rev Decals

A Figure 101.1 Decals ............................................................................. 100 - 2
Section 200 Rev Chassis Components

A Figure 201.1 Light Tower Chassis ........................................................ 200 - 2
A Figure 202.1 Axle Assembly ................................................................. 200 - 4
A Figure 203.1 Fuel Tank Assembly ........................................................ 200 - 6
Section 300 Rev Cabinet Components

A Figure 301.1 Cabinet Components ....................................................... 300 - 2
Section 400 Rev Electrical Components

A Figure 401.1 Electrical Control Box ...................................................... 400 - 2
A Figure 402.1 Ballast Box Assembly ...................................................... 400 - 4
A Figure 403.1 Light Fixture ..................................................................... 400 - 6
A Figure 404.1 Coil Cord & Junction Box ................................................. 400 - 8
Part No. 116419 AL4000 Light Tower vii

September 2008
TABLE OF CONTENTS REV A
Section 500 Rev Engine & Generator

A Figure 501.1 Engine - Kubota ............................................................... 500 - 2
A Figure 502.1 Marathon Generator - 6 kW ............................................. 500 - 4
A Figure 503.1 Leroy Somer Generator - 6 kW ........................................ 500 - 6
A Figure 504.1 Marathon Generator - 8 kW ............................................. 500 - 8
A Figure 505.1 Leroy Somer Generator - 8 kW ...................................... 500 - 10
Section 600 Rev Mast Components

A Figure 601.1 Tower Base Assembly ..................................................... 600 - 2
A Figure 602.1 Winch Lock Assembly ..................................................... 600 - 4
A Figure 603.1 Tower Assembly .............................................................. 600 - 6
A Figure 604.1 Lower Mast Assembly ..................................................... 600 - 7
A Figure 605.1 6" Inch Round Tube Assembly ........................................ 600 - 8
A Figure 606.1 4" Inch Tower Section Shim & Sheave Assembly
(after serial number AL507-00157) .................................. 600 - 9
A Figure 607.1 3" Inch Tower Section ................................................... 600 - 10
A Figure 608.1 2" Inch Tower Section Assembly ................................... 600 - 11
A Figure 609.1 Tower Cross Arm Assembly .......................................... 600 - 12
Section 700 Rev Options

A Figure 701.1 Options ............................................................................ 700 - 2
A Figure 702.1 Options ............................................................................ 700 - 4
viii AL4000 Light Tower Part No. 116419

September 2008
REV A
Parts Stocking List
Required Parts
The following parts are required to perform
maintenance procedures as outlined in the
TEREX AL4000Parts and Service Manual.
Description Part No.
Kubota Models
Oil Filter .............................................................. 866050

Air Filter .............................................................. 866127
Fuel Filter ........................................................... 839200
V-belt .................................................................. 839209
Part No. 116419 AL4000 Light Tower ix

September 2008
REV A
x AL4000 Light Tower Part No. 116419

September 2008
REV A
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. 116419 AL4000 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 _________________________
AL4000 Light Tower Part No. 116419
Date Scheduled ____________ Ship Condition ______________ __________________________________
Order Total ________________ Terms Code ________________ __________________________________
September 2008 Section 100 • Decals
Section 100
Decals
Part No. 116419 AL4000 Light Tower 100 - 1

Section 100 • Decals Spetember 2008
Figure 101.1 REV A

Decals
100 - 2 AL4000 Light Tower Part No. 116419

September 2008 Section 100 • Decals
REV A FIGURE 101.1
ITEM # PART # DESCRIPTION QTY.

1 850091 DECAL: DANGER CRUSH HAZARD 1
2 851640 DECAL: TOWER OPERATING INSTRUCTIONS 1
3 853296 DECAL: TEREX-AMIDA RED AND BLACK 5X29.5 2
4 853312 DECAL: STRIPING RED/BLACK 2
5 850155 DECAL: NO.2 DIESEL FUEL ONLY 1
6 850107 DECAL: CAUTION,WINCHLOCK SYSTEM 1
7 853640 DECAL: "CAUTION",WINCH ROTATION 1
8 853291 DECAL: TEREX-AMIDA RED AND BLACK 2.75X16 1
9 841710 DECAL: REFLECTORS 2
10 850093 DECAL: DO NOT STAND BEHIND TOWER 1
11 853301 DECAL: AL4000 BLACK 2.2X9.5 1
12 850092 DECAL: DANGER FALLING BOOM 1
13 853070 DECAL: CAUTION READ MANUAL 1
14 851860 DECAL: DANGER! ELECTRIC SHOCK HAZARD 1
15 852410 DECAL: OPERATING INSTRUCTIONS 1
16 114448 DECAL: TEREX COSMETIC - ROADSIDE 1
17 133225 DECAL: TEREX COSMETIC - CURBSIDE 1
18 133000 DECAL: AL4000 COSMETIC 2

Section 100 • Decals September 2008

September 2008 Section 200 • Chassis Components
Section 200
Chassis
Components

Section 200 • Chassis Components September 2008
Figure 201.1 REV A

LIght Tower Chassis

REV A FIGURE 201.1

1 841430 JACK SIDEWIND LONG 3KLB 3
2 840222 JACK SNAP RING 3
3 114480 OUTRIGGER 2X2X42 2
4 109150 KIT: OUTRIGGER PLUNGER PIN KIT 2
5 721051 CAPLUG,TUBE PLUG 2 1/2 4
6 834219 HANDLE (ARM)FOR JACK, HAMMERBLOW 3
7 834204 HANDLE (ARM)FOR JACK, FULTON 3
8 840221 JACK BRACKET SWIVEL 1
9 111936 CHAIN SAFETY 3000LB 3/8X30 W/"S"-HOOK 2
10 840120 COUPLER 2" BOLT ON 1
11 124470 TONGUE WITH JACK BRACKET 1
12 124410 TRAILER FRAME 41X70 WITHOUT AXLE 1
13 851820 DECAL: SYMBOL FOR GROUND 1
14 851310 DECAL: WARNING-ALL JACKS MUST BE SWIVELED 1
15 990200 NUT 2
16 991650 WASHER, LOCK 4
17 994200 SCREW 1
18 995310 SCREW 1
19 993860 WASHER, FLAT 2
20 991690 WASHER 1
21 993240 WING NUT 1
Part No. 116419 AL4000 LIght Tower 200 - 3

Figure 202.1 REV A

Axle Assembly

REV A FIGURE 202.1

1 841050 AXLE 3500LB 38.5 SPRING CENTER 1
2 834267 U-BOLT KIT - 3500# 2
3 834225 SEAL, HYDRAULIC 2
4 834226 INNER BEARING 2
5 834220 HUB ASSY HT1000 3500LB 2
6 834227 OUTER BEARING 2
7 834255 COTTER PIN 2
8 834250 SPINDLE NUT 2
9 834228 GREASE CAP 2
10 834211 SPRING FOR AXLE 4-LEAF 2
11 841061 TIRE & WHEEL MOUNTED P205/75-15 LOAD C 2
12 840376 AXLE WHEEL NUT 10
13 841855 AXLE HUB,HYD. & PARK BRAKE,L/H 1
14 841860 AXLE HUB,HYD. & PARK BRAKE,R/H 1
15 841870 AXLE HUB,ELECTRIC&PARK BRAKE,LH 1
16 841875 AXLE HUB,ELECTRIC&PARK BRAKE,RH 1
17 841220 COUPLER,SURGE 3"RING 1
18 841500 COUPLER,SURGE,2"BALL 1
19 840395 NUT 6
20 835246 SPRING EYE BUSHING 4
21 841473 SHACKLE 4
22 840394 BOLT 6

Figure 203.1 REV A

Fuel Tank Assembly

REV A FIGURE 203.1

1 990200 NUT LOCK NYLON INSERT 1/2-13NC GR 2 4
2 990210 WASHER FLAT 1/2 4
3 742240-1 TANK CAP NO-GAUGE 1
4 792750 CLAMP 7/16 TO 25/32 2
5 890795 HOSE,FUEL 5/16 ID AR
6 898590 HOSE FITTING,PIPE/BARB 1
7 891560 HOSE FITTING,PIPE/BARB 1
8 890785 HOSE,FUEL 1/8 ID AR
9 742220 TANK FUEL 30GAL 1
10 22109505 KIT: FUEL TANK DRAIN PLUG REPLACEMENT 1
11 188630 FUEL TANK PAN 1
12 990210 WASHER FLAT 1/2 4
13 994650 SCREW,1/2-13NCX10 HHC GRADE2 4

REV A

September 2008 Section 300 • Cabinet Components
Section 300
Cabinet
Components

Section 300 • Cabinet Components September 2008
Figure 301.1 REV A

Cabinet Components

REV A FIGURE 301.1

1 116180 REAR TOWER SUPPORT, COMPLETE ASSEMBLY 1
2 790540 PIN QUICK1/4X1.75 ZP 1
3 720220 BUMPER REAR TOWER SUPPORT 1
4 123680 PIN W/RING 3/4X11 1
5 124460 REAR TOWER SUPPORT 1
6 796610 HINGE PIANO 1.5X51.75 2
7 188560 CABINET DOOR PANEL 1
8 796432 GAS SPRING SHORT BRACKET WITH BALL 8
9 992040 RIVET POP 3/16X.602 16
10 796436 GAS SPRING 16", 60 LB. 4
11 188554 CABINET TOP PANEL 1
12 794940 PLUG PLASTIC 1
13 189796 HASP,CABINET DOOR, 2
14 188560 CABINET DOOR PANEL 1
15 790940 HANDLE 5.75 CHROME PLATED 2
16 124420 GROUND ROD STORAGE TUBE 1
17 176380 COVER PLATE,CABINET 2
18 113399 GROUND ROD LT.TWR. 1
19 995050 SCREW,#10-32NFX3/4 4
20 R980300 WASHER,FLAT,#10 4
21 995420 NUT,LOCK NYLON INSERT #10-32 HX M/S JAM 4
22 990670 RIVET POP 3/16X1/2 36
23 123490 FENDER WITH SKIRT 2
24 188580 CABINET SIDE PANEL CURBSIDE 1
25 184150 WINCH HANDLE BUSHING 1
26 188530-2 CABINET FRONT PANEL 1
27 176370 LITERATURE RACK 1
28 188570 CABINET SIDE PANEL ROADSIDE 1
29 930950 WEATHERSTRIP ADHESIVE AR
30 791840 BUMPER RUBBER 4
31 124436 CABINET REAR PANEL 1
32 994130 SCREW,1/4-20NCX1 4
33 993850 WASHER FLAT 1/4 37
34 990150 NUT LOCK NYLON INSERT 1/4-20NC GR 2 ZP 18
35 993440 SCREW 1/4-20NCX3/4 8
36 990340 WASHER FLAT 1/4 16
37 993421 SCREW,1/4-20NCX3/4 2
38 995810 SCREW,1/4-20NCX5/8,HWH 27

Figure 301.1 REV A

Cabinet Components

REV A FIGURE 301.1

39 Z112300 BATTERY, WET, 12V/GR24/525 CCA/STD-DUTY LEAD ACID 1
40 174170 BATTERY HOLD DOWN ANGLE 1
41 182330 BATTERY HOLD DOWN ROD 2
42 160276 BATTERY CABLE SET 1
43 851830 DECAL 1
44 991650 WASHER, LOCK, 1/2" 2
45 993860 WASHER, FLAT, 1/2" 2
46 994600 SCREW, 1/2-13 X 1-1/2" 2
47 865307 COOLANT RECOVERY TANK ASSEMBLY 1


September 2008 Section 400 • Electrical Components
Section 400
Electrical
Components

Section 400 • Electrical Components September 2008
Figure 401.1 REV A

Electrical Control Box

REV A FIGURE 401.1

1 853294 DECAL: AL/RL CONTROL BOX AC "POWER & LIGHT" 1
2 683680 BREAKER 2P 30A 240V 1
3 186546 CONTROL BOX,FACE PLATE 1
4 709133 TERMINAL,RING 2
5 683870 BREAKER 1P 15A 277VAC 4
6 684640 RECEPTACLE 20A 120V DUPLEX W/GFI 1
7 683970 BREAKER MINI 1P 20A 1
8 684450 RECEPTACLE 30A 240V 1
9 C54100600 NUT, NYLOCK, 8-32 ZINC 5
10 684380 SWITCH, IGNITION LEVER OPERATED 1
10A included with item 10
11 116815 WIRE HARNESS,DC ENGINE 1
12 680030 CONNECTOR,2 SCREW,3/4" 1
13 685672 CONNECTOR 9P,FEMALE 1
14 685674 SOCKETS, FEMALE 9
15 800003 CONNECTOR WITH WIRES (includes 13 and 14) 1
16 686220 CONNECTOR,2 SCREW,1.25 1
17 709032 TERMINAL,CLOSED END 2
18 680060 WRAP CAP 1
19 680290 CRIMP SLEEVE 1
20 116770 WIRE HARNESS 1
21 680250 LOCKNUT, CONDUIT 3/4" 1
22 663890 CORD SET FEMALE 6FT 5P 4
23 186542 CONTROL BOX,REAR PANEL 1
24 186540 CONTROL BOX BODY 1
25 260361 HOURMETER, DIGITAL 1
26 853289 DECAL: AL/RL CONTROL BOX DC "ENGINE CONTROLS" 1
27 186544 CONTROL BOX,FRONT PANEL 1
28 996340 SCREW,#10-16X3/4 PH ZP 12
29 995300 SCREW,#6-32X1/4 PAN HD 12
30 994420 WASHER,LOCK,#6 12
31 R660010 SWITCH PUSH-BUTTON 1
32 682715 LIGHT INDICATOR 12V RED 1
33 186543 CONTROL BOX,TOP PANEL 1
34 R661490 RELAY 12V DC 30A 1
35 186554 BRACKET, E-BOX HANGER 2
36 993310 NUTSERT,1/4-20UNC 8
37 116820 WIRING HARNESS, FROM ENGINE 1
37A 800004 KUBOTA SOLENOID PIGTAIL 1
38 116808 COMPLETE ELECTRICAL CONTROL BOX, includes 1-36 1

Figure 402.1 REV A

Ballast Box Assembly

REV A FIGURE 402.1

1 114355 BALLAST BOX, MH 1
2 114895 BALLAST BOX, HPS 1
3 663860 CONNECTOR, 5P, MALE 1
4 160030 MH TRANSFORMER AND CAPACITOR 1
5 160040 HPS TRANSFORMER AND CAPACITOR 1
6 160032 CAPACITOR, 24uF, MH, 60Hz 1
7 160042 CAPACITOR, 24uF, HPS, 60Hz 1
8 995810 SCREW, 1/4-20NCX 5/8,HWH, ROLLOK, ULTRA SEALN 8
9 850120 DECAL: "METAL HALIDE BALLAST" 1
10 850130 DECAL: DANGER HIGH VOLTAGE 1
11 851691 DECAL: 1 1
12 851692 DECAL: 2 1
13 851693 DECAL: 3 1
14 851694 DECAL: 4 1

Figure 403.1 REV A

Light Fixture

REV A FIGURE 403.1

1 663850 CORD SET MALE 5FT. 3P 1
2 709034 TERMINAL STRIP, 2P 2
3 833567 CASTING FOR NEW FIXTURE 1
4 995970 WASHER LOCK STAR 1/2 2
5 991650 WASHER LOCK 1/2 2
6 990810 SCREW 1/2-13NCX1-1/2 HHC GR 2 ZP 2
7 833566 TRUNION 1
8 833573 T-HANDLE 1
9 981640 SCREW 1/2-13NCX1-1/4 HHC GRADE 5 1
10 833564 SOCKET BASE-MOGUL 1
11 833569 GASKET FOR REFLECTOR 1
12 833585 LABEL, FIXTURE CSA APPROVED 1
13 833568 REFLECTOR 1
14 833570 RING,REINFORCING FOR REFLECTOR 1
15 990675 RIVET POP 1/8X.390 GR-1/4-5/16 2
16 833524 LENS W/ GASKET 1
17 833543 CLAMP;LENS TO REFLECTOR 1
18 833574 SCREW,8-32X1" HH SLOT 1
19 833581 WASHER, FIBER FOR BAND 1
20 833578 NUTSERT FOR BAND,8-32 X 1/4 1
21 NPN included with item 17 1
22 160071 LAMP MH 1000W 1
23 833571 SCREW,10-24X5/8 4
24 160140 LAMP HPS 1000W 1
25 833565 SCREW 8-32X3/8 PH 2
26 833563 SOCKET BRACKET 1
27 833577 SCREW,8-32X5/8 2
28 833584 LABEL,105C CORD RATING 1
29 833583 LABEL,WET LOCATION 1
30 833582 FIBERGLASS WIRE SLEEVE 1
31 683950 GASKET 1/2 S/R CONN 1
32 680020 LOCKNUT CONDUIT 1/2 1
33 682470 CONNECTOR STRAINRELIEF 1
34 22120102 LAMP SUPPORT 1
35 C41100720 COMPLETE FIXTURE ASSEMBLY 1
(includes items 1-34)

Figure 404.1 REV A

Coil Cord & Junction Box

1 685674 SOCKET 9
2 685671 CONNECTOR 9P, PLUG 1
3 660287 COIL CORD, RETRACT, 14/7 1
4 663870 CONNECTOR, 3P, FEMALE 4
5 663880 DUST CAP W/CHAIN 4
6 C48300108 JUNCTION BOX 1
7 680190 BOX COVER, 2GANG W/GASKET 1
8 852800 DECAL: CAUTION TIGHTEN FIXTURE CONNECTOR 1
9 680080 GRIP, HUBBLE 1
10 720440 WEATHERSTRIP ADHESIVE AR
11 186280 PLATE, COIL CORD, CABINET MOUNT 1
12 994380 SCREW, #6-32 X 5/8", RD HD, SLOT, S/S 4
13 22112580 JUNCTION BOX, COMPLETE WITH COIL CORD includes 1-12 1
14 22112575 COIL CORD ASSEMBLY includes 1, 2 and 3 1

September 2008 Section 500 • Engine & Generator
Section 500
Engine
&
Generator

Section 500 • Engine & Generator September 2008
Figure 501.1 REV A

Engine- Kubota D1105

REV A FIGURE 501.1

1 732205PP KUBOTA D1105 ENGINE, POWERPACK, BUILD EBG2 1
2 995380 SCREW, 1/2-13NC X 4HHC, GR 2, ZP 2
3 991650 WASHER, LOCK 1/2" 4
4 990415 WASHER, FLAT, FENDER, 1/2 X 2, ZP 8
5 740925 VIBRATION MOUNT, 390LB 4
6 184325 GENSET SPACER, PLASTIC, 2"OD X 9/16" ID X 1" 6
7 990200 NUT, LOCK, NYLON INSERT, 1/2-13NC, GR 2, ZPIN 2
8 124016 ENGINE MOUNT, L-BRACKET-CURBSIDE 1
124017 ENGINE MOUNT, L-BRACKET-ROADSIDE 1
9 124025 GENSET RISER, 6KW ONLY 2
10 990210 WASHER, FLAT 1/2" 4
839190 LOW OIL PRESSURE SWITCH 1
741140 HIGH TEMPERATURE SWITCH 1
866125 AIR CLEANER ASSEMBLY 1
866126 AIR CLEANER BODY 1
866127 AIR CLEANER ELEMENT 1
866128 AIR CLEANER COVER 1
866129 AIR CLEANER VALVE 1
866050 OIL FILTER 1
740620 FUEL FILTER, IN-LINE, 5/16 1
839107 FUEL FILTER ASSEMBLY 1
839200 FUEL FILTER ELEMENT 1
660320 FUEL PUMP 1
866101 STARTER 1
866090 ALTERNATOR 1
866044 2 WIRE STOP SOLENOID 1
866040 GASKET, SOLENOID 1
839209 V-BELT 1
839261 WATER PUMP 1
839134 FAN, PUSHER 1
866113 FAN GUARD 1
839154 OIL DIPSTICK 1
865276 MUFFLER, D1105 1
190150 SPACER, MUFFLER 2
832128 MUFFLER GASKET 3
125395 MUFFLER TAILPIPE, D1105 1
741970 OIL DRAIN VALVE 1
792750 CLAMP 7/16 TO 25/32 1
897110 HOSE, OIL, 3/8, 0-250PSI 3
866110 RADIATOR 1
866120 CAP FOR RADIATOR 1
839109 HOSE, TOP 1
839110 HOSE, BOTTOM 1
865307 COOLANT RECOVERY TANK 1
893020 OPERATION MANUAL D1105 1

Figure 502.1 REV A

Marathon Generator - 6 kW - 201CSA5411

REV A FIGURE 502.1

1 85206 GENERATOR, MARATHON, PANCAKE, 6KW 1
2 189347 GENERATOR MOUNT BRACKET 1
3 990220 SCREW, 1/2-13NC X 3-1/2 HHC, GR 2, ZP 2
4 990415 WASHER, FLAT SNUBBER, 1/2 X 2-3/4 X 7GA, ZINC 2
5 80379 ISOLATOR, ENGINE MOUNT, 40 DURO 2
6 990210 WASHER, FLAT, 1/2 2
7 990200 NUT, LOCK , NYLON INSERT, 1/2-13NC, GR 2 2
8 991761 SCREW, 3/8-16NC X 1-1/4 HHC, GRADE 5, ZP 4
9 990470 WASHER, LOCK, 3/8 4
10 981120 WASHER, FLAT, 3/8 4
11 116167 FAN, 8LHD435044 1
12 116168 BEARING, ODE, A-90006R-30 1
13 116169 BEARING, BRACKET, ODE(5412), 8LHD013096 1
14 116172 O-RING, 8LHD766012 1
15 116174 POT COVER, 8LHD310316 1
16 116176 SCREEN ASY W/SPGS, 8LHD336030 1
17 116177 DRIVE DISC (C-107), 702326-01 1
18 116178 HUB SPACER, 725334-01 1
19 116179 CONN. BOX BASE, 8LHD354045 1
20 116182 CONN. BOX COVER, 8LHD354044 1
21 116183 CAPACITOR 25MF, 8LHD5990012 1
22 116184 CLAMP, CAPACITOR, 8LHD086034 1
23 116187 TERMINAL BLOCK, TS-6005 1
24 836853 DIODE 1
25 836856 SURGE PROTECTOR, SUPPRESSOR/VARISITOR 1
26 116188 MANUAL, MARATHON PANCAKE GENERATOR 1

Figure 503.1 REV A

Leroy Somer Generator - 6 kW - LSA 36, M6

REV A FIGURE 503.1

1 836704 NDE BEARING 1
2 836705 DIODE KIT (includes 2 diodes) 1
3 836706 ROTOR BOLT (8 X 245) 1
4 836707 TOP COVER 1
5 836708 END CAP 1
6 836709 FAN 1
7 836710 TERMINAL BLOCK 1
8 836711 KIT: CAPACITOR, 22.5mf, (Includes two capacitors) 2
9 996290 SCREW, M10X1.5X90MM HHC, GRADE 8.8, ZP 1
10 990415 WASHER, FLAT SNUBBER 2
11 740925 VIBRATION MOUNT, 30 DUR 3
12 996496 NUT LOCK NYLON INSERT M10 X 1.5 HEX ZP 1
13 189344 GENERATOR MOUNT BAR 1
14 630905 GENERATOR L-S 6KW 120/240 C106 SAE5 LSA36 1

Figure 504.1 REV A

Marathon Generator - 8 kW - 201CSA5412

REV A FIGURE 504.1

1 116253 GENERATOR, MARATHON, PANCAKE, 8KW 1
2 189347 GENERATOR MOUNT BRACKET 1
3 990220 SCREW, 1/2-13NC X 3-1/2 HHC, GR 2, ZP 2
4 990415 WASHER, FLAT SNUBBER, 1/2 X 2-3/4 X 7GA, ZINC 2
5 80379 ISOLATOR, ENGINE MOUNT, 40 DURO 2
6 990210 WASHER, FLAT, 1/2 2
7 990200 NUT, LOCK , NYLON INSERT, 1/2-13NC, GR 2 2
8 991761 SCREW, 3/8-16NC X 1-1/4 HHC, GRADE 5, ZP 4
9 990470 WASHER, LOCK, 3/8 4
10 981120 WASHER, FLAT, 3/8 4
11 116167 FAN, 8LHD435044 1
12 116168 BEARING, ODE, A-90006R-30 1
13 116169 BEARING, BRACKET, ODE(5412), 8LHD013096 1
14 116172 O-RING, 8LHD766012 1
15 116174 POT COVER, 8LHD310316 1
16 116176 SCREEN ASY W/SPGS, 8LHD336030 1
17 116177 DRIVE DISC (C-107), 702326-01 1
18 116178 HUB SPACER, 725334-01 1
19 116179 CONN. BOX BASE, 8LHD354045 1
20 116182 CONN. BOX COVER, 8LHD354044 1
21 116183 CAPACITOR 25MF, 8LHD5990012 1
22 116184 CLAMP, CAPACITOR, 8LHD086034 1
23 116187 TERMINAL BLOCK, TS-6005 1
24 836853 DIODE 1
25 836856 SURGE PROTECTOR, SUPPRESSOR/VARISITOR 1
26 116188 MANUAL, MARATHON PANCAKE GENERATOR 1

Figure 505.1 REV A

Leroy Somer Generator - 8 kW - LSA 37, M7

REV A FIGURE 505.1

1 630960 GENERATOR, L-S, 8KW, 120/240, C106, SAE5, LSA37, M7 1
2 836831 NON DRIVE END BEARING HOUSING 1
3 836832 O-RING 1
4 836833 BEARING 1
5 836839 BEARING HOUSING 1
6 836840 TERMINAL BOX COVER 1
7 836842 WAVY WASHER 1
8 836857 DIODE, 70HF90 2
9 109330 KIT:CAPACITOR REPLACEMENT, 8KW, L-S, 60HZ, 2-50UF 1
10 990200 NUT, LOCK, NYLON INSERT, 1/2-13NC, GR 2 2
11 990210 WASHER FLAT 1/2 4
12 993510 SCREW,1/2-13NCX4HHC,GR 2,ZP 2
13 990410 WASHER, FLAT, FENDER, 1/2 X 2, ZP 8
14 740920 VIBRATION MOUNT, 390LB 4
15 189335 GENERATOR MOUNT BAR, L-S, 1/2" X 3" X 19" LONG 1
16 990820 SCREW, 1/2-13NC, X 2HHC, GR 8, Y-ZINC 2
17 113400 GROUND WIRE, GENSET TO TRAILER, 14"LG 1
18 R980000 WASHER, LOCK, STAR, 1/4 EXT.TOOTH, S/S 2
19 995490 SCREW, 1/4 X 3/4, HH SLOT, TYPE B, SELF TAPPING 2


September 2008 Section 600 • Mast Components
Section 600
Mast
Components

Section 600 • Mast Components September 2008
Figure 601.1 REV A

Tower Base Assembly

REV A FIGURE 601.1

1 124490 TOWER BASE 1
2 740050-1 WINCH LOCK ASSEMBLY (See Figure 11-B for parts
breakdown)
3 981575 SCREW, 3/8-16NC X 1-1/2 2
4 990470 WASHER, LOCK, 3/8 2
5 990080 WASHER, FLAT, 3/8 2
6 990140 SCREW 1/4-20NC X 2 1
7 990150 NUT, LOCK, NYLON INSERT, 1/4-20NC, GR 2, ZP 1
8 124480 WINCH HANDLE W/TUBE 1
9 853670 DECAL: CRUSH AREA 1
10 850090 DECAL: CAUTION STAND CLEAR OF TOWER. 1
11 850105 DECAL: DANGER DO NOT PULL THE VERTICAL 1
12 22109517 KIT: LOCK SLIDE PIN includes items 13-21 1
13 113362 PIN, LOCK SLIDE includes items 14-15 1
14 990760 PIN, BRIDGE, .0915 X 1-7/8, S/S 1
15 120640 PIN, W/RING, 5/16 X 1-5/8 1
16 990660 ROLL PIN, 1/4 X1-5/8 1
17 980340 SCREW, 5/16-18NC X 1/2 1
18 790710 SPRING, COIL, 1/2 X 2.25 1
19 990650 COTTER PIN, 1/8 X 1, SS 1
20 171636 LOCK PIN SHELL 1
21 171640 LOCK SPRING SHELL 1
22 995760 CLEVIS PIN, STAINLESS STEEL, 1/2 X 3-1/2 1
23 184510 SHEAVE SPOOL, 3 X 2-1/2 1
24 990650 COTTER PIN, 1/8 X 1, SS 1
25 186360 BUMPER PAD 1
26 995420 NUT, LOCK NYLON INSERT, #10-32, HX, M/S, JAM 2
27 R980300 WASHER, FLAT, #10 4
28 995050 SCREW, #10-32NF X 3/4, LOW HD, SHCS, ZINC 2
29 193750 SPRING LEAF, CUSTOM, KICK OUT 1
31 981920 SCREW, 1/2-13NC X 3, HHC, GR 8, Y-ZINC 1
32 990770 COTTER PIN, 3/16 X 1.5, SS 2
33 994000 WASHER, FLAT, 1" 2
34 173115 PIN, 1X9-1/4, TOWER PIVOT 1
35 994600 SCREW 5
36 993860 WASHER 10
37 990200 NUT 5

Figure 602.1 REV A

Winch Lock Assembly

REV A FIGURE 602.1

1 990080 WASHER, FLAT, 3/8" 2
2 990470 WASHER, LOCK, 3/8" 2
3 981575 SCREW, 3/8-16NC X 1", HHCS, GR 5, ZP 2
4 990650 COTTER PIN, 1/8 X 1, SS 1
5 980480 WASHER, FLAT, S/S, 1/2 F/W, 7/8 OD 1
6 124858 ROLLER WEAR BUSHING 1
7 740050-1 KIT: WINCH & SOCKET 1
8 990200 NUT, LOCK, NYLON INSERT, 1/2-13NC, GR 2 2
9 996050 SCREW, 1/2-13NC X 7-1/2, HHC ,GRADE 5, ZP 1
10 124857 SPACER, .5 ID, 1.25 OD 1
11 124855 RATCHET ARM 1
12 124856 BUSHING, FLANGE, 1.25 OD, .5 ID 1
13 990200 NUT LOCK NYLON INSERT 1/2-13NC GR 2 ZPIN 1
14 NPN NUT, 1/2-13, NYLON LOCK, HALF THICK, PART OF 740050-1 1
15 124860 HANDLE SOCKET, RATCHETING 1
16 109485 KIT:SAFETY-LOC SYSTEM (with winch) includes items 4-13,15 1
17 109486 KIT:SAFETY-LOC SYSTEM includes items 3-6, 8-12, 15 1
18 740050-2 KIT: CABLE CLAMP FASTENER 1

Figure 603.1 REV A

Tower Assembly

1 113080 COIL CORD SLEEVE 1
2 851545 DECAL: DANGER DO NOT RAISE TOWER IN VICINITY 1
3 R850475 DECAL: WARNING FORKS 2
4 851550 DECAL: LIFT MACHINE HERE 1
5 990160 SCREW, 3/8-16NC X 3-3/4, HHC, GRADE 2, ZP 1
6 990170 NUT, LOCK, NYLON INSERT, 3/8-16NC, GR 2, ZPN 1
7 990600 SCREW, 3/8-16NC X 1/2, HHC, GRADE 2, ZP 2
8 991690 WASHER, LOCK STAR, 3/8"EXT.TOOTH, ZP 2

REV A
Figure 604.1
Lower Mast Assembly

1 124540 4" SECTION, 30' TOWER 1
2 22109516 KIT: LOCK SLIDE PIN W/ SPRING & SHELL includes 3-9 1
3 990660 ROLL PIN, 1/4 X 1-5/8 1
4 22120222 PIN, 1/2 X 1-1/4 X 7-1/4, SLIDE LOCK 1
5 171635 LOCK PIN SHELL 1
6 171640 LOCK SPRING SHELL 1
7 980340 SCREW, 5/16-18NC X 1/2 HHCS, GR 2, ZP 1
8 790710 SPRING, COIL, 1/2 X 2.25 1
9 990650 COTTER PIN, 1/8 X 1, SS 1
10 177810 SHIM, 3/16 X 2 X 19-3/4 1

Figure 605.1 REV A

6" Inch Round Tube Assembly
ITEM # PART# DESCRIPTION QTY.

1 990620 NUT, LOCK, NYLON INSERT, 7/8-14NF, HALF JAM 1
2 994920 COTTER PIN, 3/32 X3 /4, SS 1
3 990650 COTTER PIN, 1/8 X 1, SS 1
4 995190 NUT, LOCK, NYLON INSERT, 1/2-20NF, HALF NUT 1
5 990610 BOLT, TEE, 1/2-20NF, 4-1/2 LG 1
6 188770 SHEAVE, 2-13/16 X 11/4 CABLE 1
7 188760 SHEAVE, 3-1/8 X 1 1/4 CABLE 1
8 992765 CLEVIS PIN, STAINLESS STEEL, 1/2 X 2 2
9 179850 BUSHING, 2.5OD X 13/16 1
10 124530 6" ROUND TUBE 1
11 995790 CLEVIS PIN, STAINLESS STEEL, 1/4 X2 1
12 188760 SHEAVE, 3-1/8 X 1 1/4 CABLE 1

REV A
Figure 606.1
4" Inch Tower Section
Shim & Sheave Assembly
(after serial number AL507-00157)

1 994920 COTTER PIN, 3/32 X 3/4, SS 2
2 990650 COTTER PIN, 1/8 X 1, SS 2
3 188760 SHEAVE, 3-1/8 X 1, 1/4 CABLE 2
4 990670 RIVET, POP, 3/16 X 1/2, S/S, BLIND RIVET 8
5 183286 SHIM, 5/16 X 2 X 3-3/16 1
6 177830 SHIM, 1/4 X 2 X 3-3/16 2
7 183288 SHIM, 3/16 X 2 X 3-3/16 1
8 990190 SCREW, 1/2-13 NC X 3 HHC, GRADE 2, ZP 2
9 990210 WASHER, FLAT, 1/2" 3
10 178335 LOCK LEVER, AL-SERIES 1
11 683460 BUSHING, 3/4 OD X 1/2 ID X .285L, SAE 841, BRONZE 1
12 683450 SPACER, 11/16 OD X 1/2 ID X 1-1/32" LONG 1
14 109065 KIT: CABLE ASSEMBLY, LOWER, 1/4" CABLE 1
17 683455 BUSHING, 11/16 OD X 1/2 ID X .26L, SAE 841, BRONZE 1

Figure 607.1 REV A

3" Inch Tower Section Assembly
ITEM # PART # DECSCRIPTION QTY.

1 990181 SCREW, 3/8-16 UNC X 1" 1
2 990470 WASHER LOCK 3/8" 1
3 109065 KIT: CABLE ASSEMBLY LOWER 1/4 CABLE 1
4 124550 3 SECTION 30'TOWER 1
5 188760 SHEAVE 3-1/8 X1 1/4 CABLE 1
6 990650 COTTER PIN 1/8X1 SS 1
7 994920 COTTER PIN 3/32X3/4 SS 2
8 990670 RIVET POP 3/16X1/2 S/S BLIND RIVET 8
9 185290 SHIM 3/8X2X2-1/4 1
10 992765 CLEVIS PIN STAINLESS STEEL 1/2 X2 1
11 995790 CLEVIS PIN STAINLESS STEEL 1/4 X2 2
12 177820 SHIM 5/16X2X2-1/4 3
13 185290 SHIM 3/8X2X2-1/4 1
14 15086 WASHER, FLAT 1

REV A
Figure 608.1
2" Inch Tower Section Assembly

1 124560 2" SECTION, 30' TOWER 1
2 109070 KIT: CABLE ASSEMBLY, UPPER 1
3 990470 WASHER, LOCK, 3/8 1
4 996230 SCREW, 3/8-16NC X 7/8 HHC, GR 8, ZP 1

Figure 609.1 REV A

Tower Cross Arm Assembly

1 113040 CROSSARM, 4-LIGHT 1
2 191781 STUD, 3/4 X 10NC X 4-3/4 4
3 990880 WASHER, LOCK STAR, 3/4 EXT.TOOTH 4
4 22123080 FIXTURE, MOUNTING WING NUT 4
5 994460 SCREW, 3/8-16NC X 4-1/2" 2
6 990080 WASHER, FLAT, 3/8 4
7 990170 NUT, LOCK, NYLON INSERT, 3/8-16NC, GR 2, ZPN 2
8 851760 DECAL: DANGER HIGH VOLTAGE.... 1
9 841890 REFLECTOR, SCOTCHLITE, TAPE, 2 X18 2

September 2008 Section 700 • Options
Section 700
Options

Section 700 • Options September 2008
Figure 701.1 REV A

Options

REV A FIGURE 701.1
1 0LTY0422 OPTION LT: ENGINE BLOCK HEATER, KUBOTA

741993 HEATER, ENGINE BLOCK, 3100003, ZERO START 1
2 0LTX0580 OPTION LT: FUEL/WATER SEPARATOR, RACOR, KUBOTA

116154 FILTER, WATER SEPARATOR, DIESEL FUEL, STANADYNE 1
116151 ELEMENT, 30 MICRON, FUEL WATER 1
3 0LTX0481 OPTION LT: TAIL LIGHTS, RECESSED

663515 LIGHT WIRING HARNESS, RECESSED LIGHTS 1
663520 LIGHT, LICENSE TAG W/BRACKET 1
663527 LIGHT, SIDE MARKER, AMBER, 2.5" DIAMETER, RECESSED 2
663528 LIGHT, SIDE MARKER, RED, 2.5" DIAMETER, RECESSED 2
663529 GROMMET, RECESSED LIGHT KIT, W/PLUG AND WIRES 4
663843 TRAILER HARNESS, 4 POLE, RUN/BRAKE LIGHTS 1
663840 LIGHT, TRAILER, RECESSED, STOP, TURN, TAIL LIGHTS 1
4 0LTX0180 OPTION LT: CONNECTOR 7-POLE, RUN LIGHTS, ROUND

663400 CONNECTOR, TAIL LIGHT 1
663405 CONNECTOR, TAIL LIGHT, 7POLE CABLE GUARD 1
5 0LTX0040 OPTION LT: HITCH, COMBO, BALL & RING, BOLT-ON

940000 KIT: COMBINATION HITCH, BALL & RING, COMPLETE 1
840120 COUPLER FOR 2" BALL 1
176336 COMBO HITCH SIDE SPACER, BOLT-ON 2
176335 COMBO HITCH SIDE PLATE, BOLT-ON 2
121572 COMBO HITCH RING, 16" LONG, BOLT-ON 1
840470 BALL, 2" 1
6 0LTY0316 OPTION LT: AXLE W/HYD SURGE BRAKES, RING HITCH

110870 CHAIN, SAFETY, 1750LB, 1/4 X 31, W/ S HOOK 2
841220 COUPLER, SURGE, 3"RING, 6000LB 1
841480 AXLE ACCESSORY, COMPLETE HYD BRAKE KIT 1
841850 AXLE HUB, ATTACHING PARTS KIT 2
841855 AXLE HUB, HYD. & PARK BRAKE, L/H 1
841860 AXLE HUB, HYD. & PARK BRAKE, R/H 1
834340 AXLE ASSEMBLY 1

Figure 702.1 REV A

Options

REV A FIGURE 702.1
7 0LTY0314 OPTION LT: AXLE W/HYD.SURGE BRAKES, BALL HITCH

110870 CHAIN, SAFETY, 1750LB, 1/4 X 31, W/ S HOOK 2
841500 COUPLER, SURGE, 2"BALL, 6000LB 1
841480 AXLE ACCESSORY, COMPLETE, HYD BRAKE KIT 1
841855 AXLE HUB, HYD. & PARK BRAKE, L/H 1
841860 AXLE HUB, HYD. & PARK BRAKE, R/H 1
8 0LTY0315 OPTION LT: AXLE, W/ELECTRIC BRAKES, 3500#

841870 AXLE HUB, ELECTRIC & PARK BRAKE, LH 1
841875 AXLE HUB, ELECTRIC & PARK BRAKE, RH 1
9 0LTX0222 OPTION LT: BATTERY, 700A, HEAVY DUTY

161085 BATTERY, 700AMP, GP24, 12V, POST/TERMINAL 1
174170 BATTERY, HOLDOWN ANGLE, 14.50 1
182331 BATTERY, HOLD-DOWN ROD, 1/4 X 11-1/4 2
10 0LTX0210 OPTION LT: RECEPTACLE, EXTRA GFI, DUPLEX

684640 RECEPTACLE, 20A, 120V, DUPLEX W/GFI 1
683970 BREAKER, MINI, 1P, 20A 1
11 0LTX0520 OPTION LT: ELECTRIC WINCH

113583 WINCH SWITCH WITH SOLENOID 1
160992 WINCH W/O CABLE 1
124750 ELECTRIC WINCH, ANGLE, BASE MOUNT 1
160993 WINCH SOLENOID PACKAGE 1
663780 SWITCH, TOGGLE, 1P, 2T, MOMENTARY, 20ADC 1
684710 BREAKER, RESETTING, 40A 1
186830 SWITCH MOUNT BRACKET 1
12 OLTX0270 LIGHT DOME WITH SWITCH 1
13 116218 OPTION LT: FUEL WATER SEPARATOR WITH HEATER 1

116154 FILTER, WATER SEPARATOR, ASSEMBLY 1
116144 HEATER, TOP LOAD, FUEL, 100W, 12V 1
NOTE: OPTION NUMBERS CANNOT BE SOLD
AS SPARE PARTS.


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

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Parts Manual

Important Serial Number Information

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

Technical Publications Axis Manual ........................................................ 116117

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

Contact Us: Copyright © 2008 by TEREX Corporation

www.TEREX.com 116419 Rev A September 2008

"TEREX" is a registered trademark of TEREX

Printed on recycled paper

ii AL4000 Light Tower Part No. 116419

Serial Number Legend

Part No. 116419 AL4000 Light Tower iii

This page intentionally left blank.

iv AL4000 Light Tower Part No. 116419

Many of the hazards identified in the

Do Not Perform Maintenance

Part No. 116419 AL4000 Light Tower v

SAFETY RULES REV A

Personal Safety Be sure to wear protective eye wear and

Safety alert symbol—used to alert Workplace Safety

Be sure to properly dispose of old oil or

vi AL4000 Light Tower Part No. 116419

Section 1 Safety Rules

Section 100 Rev Decals

Section 200 Rev Chassis Components

Section 300 Rev Cabinet Components

Section 400 Rev Electrical Components

Part No. 116419 AL4000 Light Tower vii

TABLE OF CONTENTS REV A

Section 500 Rev Engine & Generator

Section 600 Rev Mast Components

Section 700 Rev Options

viii AL4000 Light Tower Part No. 116419

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

Part No. 116419 AL4000 Light Tower ix

This page intentionally left blank.

x AL4000 Light Tower Part No. 116419

Use the Service Parts Fax Order Form on the

Authorized TEREX Distributor

Part No. 116419 AL4000 Light Tower xi

Service Parts fax Order Form

remove this page and make copies

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

Part Number Description Quantity Price

remove this page and make copies

FOR TEREX USE ONLY

Part No. 116419 AL4000 Light Tower 100 - 1

Figure 101.1 REV A

100 - 2 AL4000 Light Tower Part No. 116419

REV A FIGURE 101.1

ITEM # PART # DESCRIPTION QTY.

Part No. 116419 AL4000 Light Tower 100 - 3

This page intentionally left blank.

100 - 4 AL4000 Light Tower Part No. 116419

Part No. 116419 AL4000 Light Tower 200 - 1

Figure 201.1 REV A

200 - 2 AL4000 Light Tower Part No. 116419

REV A FIGURE 201.1

ITEM # PART # DESCRIPTION QTY.

Model(s) ______________________________________ Serial No.(s) _