AL4000D2
First Edition
Rev A
Part No. 116419
September 2008
September 2008
Introduction
REV A
Important
Title
Part No.
Technical Publications
Contact Us:
www.TEREX.com
ii
September 2008
REV A
iii
September 2008
REV A
iv
September 2008
Safety Rules
REV A
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
operators manual are also safety hazards
when maintenance and repair procedures
are performed.
SAFETY RULES
September 2008
REV A
Personal Safety
Any person working on or around a machine must
be aware of all known safety hazards. Personal
safety and the continued safe operation of the
machine should be your top priority.
Workplace Safety
Be sure to keep sparks, flames and
lighted tobacco away from flammable and
combustible materials like battery gases
and engine fuels. Always have an approved fire
extinguisher within easy reach.
vi
September 2008
Table of Contents
REV A
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
A
Section 200
Section 300
Rev
Figure 101.1
Chassis Components
Figure 201.1
Figure 202.1
Figure 203.1
Rev
A
Section 400
Decals
Rev
Cabinet Components
Figure 301.1
Electrical Components
Figure 401.1
Figure 402.1
Figure 403.1
Figure 404.1
vii
September 2008
TABLE OF CONTENTS
Section 500
Section 600
Section 700
viii
REV A
Figure 501.1
Figure 502.1
Figure 503.1
Figure 504.1
Figure 505.1
Figure 601.1
Figure 602.1
Figure 603.1
Figure 604.1
Figure 605.1
Figure 606.1
Figure 607.1
Figure 608.1
Figure 609.1
Rev Options
A
Figure 701.1
Figure 702.1
September 2008
REV A
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
ix
September 2008
REV A
September 2008
REV A
Genie Industries
18340 NE 76th Street
P.O. Box 97030
Redmond, WA 98073-9730
Telephone (877) 367-5606
Fax (888) 274-6192
genieindustries.com
Machine Information
Model
Serial Number
Date of Purchase
Authorized TEREX Distributor
Phone Number
xi
September 2008
_________________________________
_________________________________
Ship To
Bill To
___________________________________
_________________________________
___________________________________
_________________________________
___________________________________
_________________________________
Purchase Order Number ____________________
___________________________________
Ship Via
___________________________________
Quantity
Price
Part Number
Date
All backordered parts will be shipped when available via the same ship method as the original order
unless noted below:
o
Ship all available parts and contact customer on disposition of backordered parts
Comments _________________________
__________________________________
__________________________________
September 2008
Section 100
Decals
100 - 1
Figure 101.1
Spetember 2008
REV A
Decals
100 - 2
September 2008
REV A
FIGURE 101.1
ITEM # PART #
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
850091
851640
853296
853312
850155
850107
853640
853291
841710
850093
853301
850092
853070
851860
852410
114448
133225
133000
DESCRIPTION
DECAL: DANGER CRUSH HAZARD
DECAL: TOWER OPERATING INSTRUCTIONS
DECAL: TEREX-AMIDA RED AND BLACK 5X29.5
DECAL: STRIPING RED/BLACK
DECAL: NO.2 DIESEL FUEL ONLY
DECAL: CAUTION,WINCHLOCK SYSTEM
DECAL: "CAUTION",WINCH ROTATION
DECAL: TEREX-AMIDA RED AND BLACK 2.75X16
DECAL: REFLECTORS
DECAL: DO NOT STAND BEHIND TOWER
DECAL: AL4000 BLACK 2.2X9.5
DECAL: DANGER FALLING BOOM
DECAL: CAUTION READ MANUAL
DECAL: DANGER! ELECTRIC SHOCK HAZARD
DECAL: OPERATING INSTRUCTIONS
DECAL: TEREX COSMETIC - ROADSIDE
DECAL: TEREX COSMETIC - CURBSIDE
DECAL: AL4000 COSMETIC
QTY.
1
1
2
2
1
1
1
1
2
1
1
1
1
1
1
1
1
2
100 - 3
September 2008
100 - 4
September 2008
Section 200
Chassis
Components
200 - 1
Figure 201.1
September 2008
REV A
200 - 2
September 2008
REV A
FIGURE 201.1
ITEM #
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
PART #
841430
840222
114480
109150
721051
834219
834204
840221
111936
840120
124470
124410
851820
851310
990200
991650
994200
995310
993860
991690
993240
DESCRIPTION
JACK SIDEWIND LONG 3KLB
JACK SNAP RING
OUTRIGGER 2X2X42
KIT: OUTRIGGER PLUNGER PIN KIT
CAPLUG,TUBE PLUG 2 1/2
HANDLE (ARM)FOR JACK, HAMMERBLOW
HANDLE (ARM)FOR JACK, FULTON
JACK BRACKET SWIVEL
CHAIN SAFETY 3000LB 3/8X30 W/"S"-HOOK
COUPLER 2" BOLT ON
TONGUE WITH JACK BRACKET
TRAILER FRAME 41X70 WITHOUT AXLE
DECAL: SYMBOL FOR GROUND
DECAL: WARNING-ALL JACKS MUST BE SWIVELED
NUT
WASHER, LOCK
SCREW
SCREW
WASHER, FLAT
WASHER
WING NUT
QTY.
3
3
2
2
4
3
3
1
2
1
1
1
1
1
2
4
1
1
2
1
1
200 - 3
Figure 202.1
September 2008
REV A
Axle Assembly
200 - 4
September 2008
REV A
FIGURE 202.1
ITEM #
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
PART #
841050
834267
834225
834226
834220
834227
834255
834250
834228
834211
841061
840376
841855
841860
841870
841875
841220
841500
840395
835246
841473
840394
DESCRIPTION
AXLE 3500LB 38.5 SPRING CENTER
U-BOLT KIT - 3500#
SEAL, HYDRAULIC
INNER BEARING
HUB ASSY HT1000 3500LB
OUTER BEARING
COTTER PIN
SPINDLE NUT
GREASE CAP
SPRING FOR AXLE 4-LEAF
TIRE & WHEEL MOUNTED P205/75-15 LOAD C
AXLE WHEEL NUT
AXLE HUB,HYD. & PARK BRAKE,L/H
AXLE HUB,HYD. & PARK BRAKE,R/H
AXLE HUB,ELECTRIC&PARK BRAKE,LH
AXLE HUB,ELECTRIC&PARK BRAKE,RH
COUPLER,SURGE 3"RING
COUPLER,SURGE,2"BALL
NUT
SPRING EYE BUSHING
SHACKLE
BOLT
QTY.
1
2
2
2
2
2
2
2
2
2
2
10
1
1
1
1
1
1
6
4
4
6
200 - 5
Figure 203.1
September 2008
REV A
200 - 6
September 2008
REV A
FIGURE 203.1
ITEM #
1
2
3
4
5
6
7
8
9
10
11
12
13
PART #
990200
990210
742240-1
792750
890795
898590
891560
890785
742220
22109505
188630
990210
994650
DESCRIPTION
NUT LOCK NYLON INSERT 1/2-13NC GR 2
WASHER FLAT 1/2
TANK CAP NO-GAUGE
CLAMP 7/16 TO 25/32
HOSE,FUEL 5/16 ID
HOSE FITTING,PIPE/BARB
HOSE FITTING,PIPE/BARB
HOSE,FUEL 1/8 ID
TANK FUEL 30GAL
KIT: FUEL TANK DRAIN PLUG REPLACEMENT
FUEL TANK PAN
WASHER FLAT 1/2
SCREW,1/2-13NCX10 HHC GRADE2
QTY.
4
4
1
2
AR
1
1
AR
1
1
1
4
4
200 - 7
September 2008
REV A
200 - 8
September 2008
Section 300
Cabinet
Components
300 - 1
Figure 301.1
September 2008
REV A
Cabinet Components
300 - 2
September 2008
REV A
FIGURE 301.1
ITEM #
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
PART #
116180
790540
720220
123680
124460
796610
188560
796432
992040
796436
188554
794940
189796
188560
790940
124420
176380
113399
995050
R980300
995420
990670
123490
188580
184150
188530-2
176370
188570
930950
791840
124436
994130
993850
990150
993440
990340
993421
995810
DESCRIPTION
REAR TOWER SUPPORT, COMPLETE ASSEMBLY
PIN QUICK1/4X1.75 ZP
BUMPER REAR TOWER SUPPORT
PIN W/RING 3/4X11
REAR TOWER SUPPORT
HINGE PIANO 1.5X51.75
CABINET DOOR PANEL
GAS SPRING SHORT BRACKET WITH BALL
RIVET POP 3/16X.602
GAS SPRING 16", 60 LB.
CABINET TOP PANEL
PLUG PLASTIC
HASP,CABINET DOOR,
CABINET DOOR PANEL
HANDLE 5.75 CHROME PLATED
GROUND ROD STORAGE TUBE
COVER PLATE,CABINET
GROUND ROD LT.TWR.
SCREW,#10-32NFX3/4
WASHER,FLAT,#10
NUT,LOCK NYLON INSERT #10-32 HX M/S JAM
RIVET POP 3/16X1/2
FENDER WITH SKIRT
CABINET SIDE PANEL CURBSIDE
WINCH HANDLE BUSHING
CABINET FRONT PANEL
LITERATURE RACK
CABINET SIDE PANEL ROADSIDE
WEATHERSTRIP ADHESIVE
BUMPER RUBBER
CABINET REAR PANEL
SCREW,1/4-20NCX1
WASHER FLAT 1/4
NUT LOCK NYLON INSERT 1/4-20NC GR 2 ZP
SCREW 1/4-20NCX3/4
WASHER FLAT 1/4
SCREW,1/4-20NCX3/4
SCREW,1/4-20NCX5/8,HWH
QTY.
1
1
1
1
1
2
1
8
16
4
1
1
2
1
2
1
2
1
4
4
4
36
2
1
1
1
1
1
AR
4
1
4
37
18
8
16
2
27
300 - 3
Figure 301.1
September 2008
REV A
Cabinet Components
300 - 4
September 2008
REV A
FIGURE 301.1
ITEM #
39
40
41
42
43
44
45
46
47
PART #
Z112300
174170
182330
160276
851830
991650
993860
994600
865307
DESCRIPTION
BATTERY, WET, 12V/GR24/525 CCA/STD-DUTY LEAD ACID
BATTERY HOLD DOWN ANGLE
BATTERY HOLD DOWN ROD
BATTERY CABLE SET
DECAL
WASHER, LOCK, 1/2"
WASHER, FLAT, 1/2"
SCREW, 1/2-13 X 1-1/2"
COOLANT RECOVERY TANK ASSEMBLY
QTY.
1
1
2
1
1
2
2
2
1
300 - 5
September 2008
300 - 6
September 2008
Section 400
Electrical
Components
400 - 1
Figure 401.1
September 2008
REV A
400 - 2
September 2008
REV A
FIGURE 401.1
ITEM #
1
2
3
4
5
6
7
8
9
10
10A
11
12
13
14
15
16
16A
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
31A
32
33
34
35
36
37
37A
38
PART #
853294
683680
186546
709133
683870
684640
683970
684450
C54100600
684380
116815
680030
685672
685674
800003
686220
709032
680060
680290
116770
680250
663890
186542
186540
260361
853289
186544
996340
995300
994420
R660010
682715
186543
R661490
186554
993310
116820
800004
116808
DESCRIPTION
DECAL: AL/RL CONTROL BOX AC "POWER & LIGHT"
BREAKER 2P 30A 240V
CONTROL BOX,FACE PLATE
TERMINAL,RING
BREAKER 1P 15A 277VAC
RECEPTACLE 20A 120V DUPLEX W/GFI
BREAKER MINI 1P 20A
RECEPTACLE 30A 240V
NUT, NYLOCK, 8-32 ZINC
SWITCH, IGNITION LEVER OPERATED
included with item 10
WIRE HARNESS,DC ENGINE
CONNECTOR,2 SCREW,3/4"
CONNECTOR 9P,FEMALE
SOCKETS, FEMALE
CONNECTOR WITH WIRES (includes 13 and 14)
CONNECTOR,2 SCREW,1.25
included with item 16
TERMINAL,CLOSED END
WRAP CAP
CRIMP SLEEVE
WIRE HARNESS
LOCKNUT, CONDUIT 3/4"
CORD SET FEMALE 6FT 5P
CONTROL BOX,REAR PANEL
CONTROL BOX BODY
HOURMETER, DIGITAL
DECAL: AL/RL CONTROL BOX DC "ENGINE CONTROLS"
CONTROL BOX,FRONT PANEL
SCREW,#10-16X3/4 PH ZP
SCREW,#6-32X1/4 PAN HD
WASHER,LOCK,#6
SWITCH PUSH-BUTTON
included with item 31
LIGHT INDICATOR 12V RED
CONTROL BOX,TOP PANEL
RELAY 12V DC 30A
BRACKET, E-BOX HANGER
NUTSERT,1/4-20UNC
WIRING HARNESS, FROM ENGINE
KUBOTA SOLENOID PIGTAIL
COMPLETE ELECTRICAL CONTROL BOX, includes 1-36
QTY.
1
1
1
2
4
1
1
1
5
1
1
1
1
9
1
1
2
1
1
1
1
4
1
1
1
1
1
12
12
12
1
1
1
1
2
8
1
1
1
400 - 3
Figure 402.1
September 2008
REV A
400 - 4
September 2008
REV A
FIGURE 402.1
ITEM #
1
2
3
4
5
6
7
8
9
10
11
12
13
14
PART #
114355
114895
663860
160030
160040
160032
160042
995810
850120
850130
851691
851692
851693
851694
DESCRIPTION
BALLAST BOX, MH
BALLAST BOX, HPS
CONNECTOR, 5P, MALE
MH TRANSFORMER AND CAPACITOR
HPS TRANSFORMER AND CAPACITOR
CAPACITOR, 24uF, MH, 60Hz
CAPACITOR, 24uF, HPS, 60Hz
SCREW, 1/4-20NCX 5/8,HWH, ROLLOK, ULTRA SEALN
DECAL: "METAL HALIDE BALLAST"
DECAL: DANGER HIGH VOLTAGE
DECAL: 1
DECAL: 2
DECAL: 3
DECAL: 4
QTY.
1
1
1
1
1
1
1
8
1
1
1
1
1
1
400 - 5
Figure 403.1
September 2008
REV A
Light Fixture
400 - 6
September 2008
REV A
FIGURE 403.1
ITEM #
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
PART #
663850
709034
833567
995970
991650
990810
833566
833573
981640
833564
833569
833585
833568
833570
990675
833524
833543
833574
833581
833578
NPN
160071
833571
160140
833565
833563
833577
833584
833583
833582
683950
680020
682470
22120102
C41100720
DESCRIPTION
CORD SET MALE 5FT. 3P
TERMINAL STRIP, 2P
CASTING FOR NEW FIXTURE
WASHER LOCK STAR 1/2
WASHER LOCK 1/2
SCREW 1/2-13NCX1-1/2 HHC GR 2 ZP
TRUNION
T-HANDLE
SCREW 1/2-13NCX1-1/4 HHC GRADE 5
SOCKET BASE-MOGUL
GASKET FOR REFLECTOR
LABEL, FIXTURE CSA APPROVED
REFLECTOR
RING,REINFORCING FOR REFLECTOR
RIVET POP 1/8X.390 GR-1/4-5/16
LENS W/ GASKET
CLAMP;LENS TO REFLECTOR
SCREW,8-32X1" HH SLOT
WASHER, FIBER FOR BAND
NUTSERT FOR BAND,8-32 X 1/4
included with item 17
LAMP MH 1000W
SCREW,10-24X5/8
LAMP HPS 1000W
SCREW 8-32X3/8 PH
SOCKET BRACKET
SCREW,8-32X5/8
LABEL,105C CORD RATING
LABEL,WET LOCATION
FIBERGLASS WIRE SLEEVE
GASKET 1/2 S/R CONN
LOCKNUT CONDUIT 1/2
CONNECTOR STRAINRELIEF
LAMP SUPPORT
COMPLETE FIXTURE ASSEMBLY
(includes items 1-34)
QTY.
1
2
1
2
2
2
1
1
1
1
1
1
1
1
2
1
1
1
1
1
1
1
4
1
2
1
2
1
1
1
1
1
1
1
1
400 - 7
September 2008
Figure 404.1
REV A
ITEM #
1
2
3
4
5
6
7
8
9
10
11
12
13
14
400 - 8
PART #
685674
685671
660287
663870
663880
C48300108
680190
852800
680080
720440
186280
994380
22112580
22112575
DESCRIPTION
QTY.
SOCKET
CONNECTOR 9P, PLUG
COIL CORD, RETRACT, 14/7
CONNECTOR, 3P, FEMALE
DUST CAP W/CHAIN
JUNCTION BOX
BOX COVER, 2GANG W/GASKET
DECAL: CAUTION TIGHTEN FIXTURE CONNECTOR
GRIP, HUBBLE
WEATHERSTRIP ADHESIVE
PLATE, COIL CORD, CABINET MOUNT
SCREW, #6-32 X 5/8", RD HD, SLOT, S/S
JUNCTION BOX, COMPLETE WITH COIL CORD includes 1-12
COIL CORD ASSEMBLY includes 1, 2 and 3
9
1
1
4
4
1
1
1
1
AR
1
4
1
1
September 2008
Section 500
Engine
&
Generator
500 - 1
Figure 501.1
September 2008
REV A
500 - 2
September 2008
REV A
FIGURE 501.1
ITEM #
1
2
3
4
5
6
7
8
9
10
PART #
732205PP
995380
991650
990415
740925
184325
990200
124016
124017
124025
990210
839190
741140
866125
866126
866127
866128
866129
866050
740620
839107
839200
660320
866101
866090
866044
866040
839209
839261
839134
866113
839154
865276
190150
832128
125395
741970
792750
897110
866110
866120
839109
839110
865307
893020
DESCRIPTION
KUBOTA D1105 ENGINE, POWERPACK, BUILD EBG2
SCREW, 1/2-13NC X 4HHC, GR 2, ZP
WASHER, LOCK 1/2"
WASHER, FLAT, FENDER, 1/2 X 2, ZP
VIBRATION MOUNT, 390LB
GENSET SPACER, PLASTIC, 2"OD X 9/16" ID X 1"
NUT, LOCK, NYLON INSERT, 1/2-13NC, GR 2, ZPIN
ENGINE MOUNT, L-BRACKET-CURBSIDE
ENGINE MOUNT, L-BRACKET-ROADSIDE
GENSET RISER, 6KW ONLY
WASHER, FLAT 1/2"
LOW OIL PRESSURE SWITCH
HIGH TEMPERATURE SWITCH
AIR CLEANER ASSEMBLY
AIR CLEANER BODY
AIR CLEANER ELEMENT
AIR CLEANER COVER
AIR CLEANER VALVE
OIL FILTER
FUEL FILTER, IN-LINE, 5/16
FUEL FILTER ASSEMBLY
FUEL FILTER ELEMENT
FUEL PUMP
STARTER
ALTERNATOR
2 WIRE STOP SOLENOID
GASKET, SOLENOID
V-BELT
WATER PUMP
FAN, PUSHER
FAN GUARD
OIL DIPSTICK
MUFFLER, D1105
SPACER, MUFFLER
MUFFLER GASKET
MUFFLER TAILPIPE, D1105
OIL DRAIN VALVE
CLAMP 7/16 TO 25/32
HOSE, OIL, 3/8, 0-250PSI
RADIATOR
CAP FOR RADIATOR
HOSE, TOP
HOSE, BOTTOM
COOLANT RECOVERY TANK
OPERATION MANUAL D1105
QTY.
1
2
4
8
4
6
2
1
1
2
4
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
3
1
1
1
3
1
1
1
1
1
1
500 - 3
Figure 502.1
September 2008
REV A
500 - 4
September 2008
REV A
FIGURE 502.1
ITEM # PART #
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
85206
189347
990220
990415
80379
990210
990200
991761
990470
981120
116167
116168
116169
116172
116174
116176
116177
116178
116179
116182
116183
116184
116187
836853
836856
116188
DESCRIPTION
GENERATOR, MARATHON, PANCAKE, 6KW
GENERATOR MOUNT BRACKET
SCREW, 1/2-13NC X 3-1/2 HHC, GR 2, ZP
WASHER, FLAT SNUBBER, 1/2 X 2-3/4 X 7GA, ZINC
ISOLATOR, ENGINE MOUNT, 40 DURO
WASHER, FLAT, 1/2
NUT, LOCK , NYLON INSERT, 1/2-13NC, GR 2
SCREW, 3/8-16NC X 1-1/4 HHC, GRADE 5, ZP
WASHER, LOCK, 3/8
WASHER, FLAT, 3/8
FAN, 8LHD435044
BEARING, ODE, A-90006R-30
BEARING, BRACKET, ODE(5412), 8LHD013096
O-RING, 8LHD766012
POT COVER, 8LHD310316
SCREEN ASY W/SPGS, 8LHD336030
DRIVE DISC (C-107), 702326-01
HUB SPACER, 725334-01
CONN. BOX BASE, 8LHD354045
CONN. BOX COVER, 8LHD354044
CAPACITOR 25MF, 8LHD5990012
CLAMP, CAPACITOR, 8LHD086034
TERMINAL BLOCK, TS-6005
DIODE
SURGE PROTECTOR, SUPPRESSOR/VARISITOR
MANUAL, MARATHON PANCAKE GENERATOR
QTY.
1
1
2
2
2
2
2
4
4
4
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
500 - 5
Figure 503.1
September 2008
REV A
500 - 6
September 2008
REV A
FIGURE 503.1
ITEM #
1
2
3
4
5
6
7
8
9
10
11
12
13
14
PART #
836704
836705
836706
836707
836708
836709
836710
836711
996290
990415
740925
996496
189344
630905
DESCRIPTION
NDE BEARING
DIODE KIT (includes 2 diodes)
ROTOR BOLT (8 X 245)
TOP COVER
END CAP
FAN
TERMINAL BLOCK
KIT: CAPACITOR, 22.5mf, (Includes two capacitors)
SCREW, M10X1.5X90MM HHC, GRADE 8.8, ZP
WASHER, FLAT SNUBBER
VIBRATION MOUNT, 30 DUR
NUT LOCK NYLON INSERT M10 X 1.5 HEX ZP
GENERATOR MOUNT BAR
GENERATOR L-S 6KW 120/240 C106 SAE5 LSA36
QTY.
1
1
1
1
1
1
1
2
1
2
3
1
1
1
500 - 7
Figure 504.1
September 2008
REV A
500 - 8
September 2008
REV A
FIGURE 504.1
ITEM # PART #
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
116253
189347
990220
990415
80379
990210
990200
991761
990470
981120
116167
116168
116169
116172
116174
116176
116177
116178
116179
116182
116183
116184
116187
836853
836856
116188
DESCRIPTION
GENERATOR, MARATHON, PANCAKE, 8KW
GENERATOR MOUNT BRACKET
SCREW, 1/2-13NC X 3-1/2 HHC, GR 2, ZP
WASHER, FLAT SNUBBER, 1/2 X 2-3/4 X 7GA, ZINC
ISOLATOR, ENGINE MOUNT, 40 DURO
WASHER, FLAT, 1/2
NUT, LOCK , NYLON INSERT, 1/2-13NC, GR 2
SCREW, 3/8-16NC X 1-1/4 HHC, GRADE 5, ZP
WASHER, LOCK, 3/8
WASHER, FLAT, 3/8
FAN, 8LHD435044
BEARING, ODE, A-90006R-30
BEARING, BRACKET, ODE(5412), 8LHD013096
O-RING, 8LHD766012
POT COVER, 8LHD310316
SCREEN ASY W/SPGS, 8LHD336030
DRIVE DISC (C-107), 702326-01
HUB SPACER, 725334-01
CONN. BOX BASE, 8LHD354045
CONN. BOX COVER, 8LHD354044
CAPACITOR 25MF, 8LHD5990012
CLAMP, CAPACITOR, 8LHD086034
TERMINAL BLOCK, TS-6005
DIODE
SURGE PROTECTOR, SUPPRESSOR/VARISITOR
MANUAL, MARATHON PANCAKE GENERATOR
QTY.
1
1
2
2
2
2
2
4
4
4
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
500 - 9
Figure 505.1
September 2008
REV A
500 - 10
September 2008
REV A
FIGURE 505.1
ITEM #
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
PART #
630960
836831
836832
836833
836839
836840
836842
836857
109330
990200
990210
993510
990410
740920
189335
990820
113400
R980000
995490
DESCRIPTION
GENERATOR, L-S, 8KW, 120/240, C106, SAE5, LSA37, M7
NON DRIVE END BEARING HOUSING
O-RING
BEARING
BEARING HOUSING
TERMINAL BOX COVER
WAVY WASHER
DIODE, 70HF90
KIT:CAPACITOR REPLACEMENT, 8KW, L-S, 60HZ, 2-50UF
NUT, LOCK, NYLON INSERT, 1/2-13NC, GR 2
WASHER FLAT 1/2
SCREW,1/2-13NCX4HHC,GR 2,ZP
WASHER, FLAT, FENDER, 1/2 X 2, ZP
VIBRATION MOUNT, 390LB
GENERATOR MOUNT BAR, L-S, 1/2" X 3" X 19" LONG
SCREW, 1/2-13NC, X 2HHC, GR 8, Y-ZINC
GROUND WIRE, GENSET TO TRAILER, 14"LG
WASHER, LOCK, STAR, 1/4 EXT.TOOTH, S/S
SCREW, 1/4 X 3/4, HH SLOT, TYPE B, SELF TAPPING
QTY.
1
1
1
1
1
1
1
2
1
2
4
2
8
4
1
2
1
2
2
500 - 11
September 2008
500 - 12
September 2008
Section 600
Mast
Components
600 - 1
Figure 601.1
September 2008
REV A
600 - 2
September 2008
REV A
FIGURE 601.1
ITEM #
PART #
1
2
124490
740050-1
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
981575
990470
990080
990140
990150
124480
853670
850090
850105
22109517
113362
990760
120640
990660
980340
790710
990650
171636
171640
995760
184510
990650
186360
995420
R980300
995050
193750
990200
981920
990770
994000
173115
994600
993860
990200
DESCRIPTION
TOWER BASE
WINCH LOCK ASSEMBLY (See Figure 11-B for parts
breakdown)
SCREW, 3/8-16NC X 1-1/2
WASHER, LOCK, 3/8
WASHER, FLAT, 3/8
SCREW 1/4-20NC X 2
NUT, LOCK, NYLON INSERT, 1/4-20NC, GR 2, ZP
WINCH HANDLE W/TUBE
DECAL: CRUSH AREA
DECAL: CAUTION STAND CLEAR OF TOWER.
DECAL: DANGER DO NOT PULL THE VERTICAL
KIT: LOCK SLIDE PIN includes items 13-21
PIN, LOCK SLIDE includes items 14-15
PIN, BRIDGE, .0915 X 1-7/8, S/S
PIN, W/RING, 5/16 X 1-5/8
ROLL PIN, 1/4 X1-5/8
SCREW, 5/16-18NC X 1/2
SPRING, COIL, 1/2 X 2.25
COTTER PIN, 1/8 X 1, SS
LOCK PIN SHELL
LOCK SPRING SHELL
CLEVIS PIN, STAINLESS STEEL, 1/2 X 3-1/2
SHEAVE SPOOL, 3 X 2-1/2
COTTER PIN, 1/8 X 1, SS
BUMPER PAD
NUT, LOCK NYLON INSERT, #10-32, HX, M/S, JAM
WASHER, FLAT, #10
SCREW, #10-32NF X 3/4, LOW HD, SHCS, ZINC
SPRING LEAF, CUSTOM, KICK OUT
NUT, LOCK, NYLON INSERT, 1/2-13NC, GR 2, ZPIN
SCREW, 1/2-13NC X 3, HHC, GR 8, Y-ZINC
COTTER PIN, 3/16 X 1.5, SS
WASHER, FLAT, 1"
PIN, 1X9-1/4, TOWER PIVOT
SCREW
WASHER
NUT
QTY.
1
2
2
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
4
2
1
1
1
2
2
1
5
10
5
600 - 3
Figure 602.1
September 2008
REV A
600 - 4
September 2008
REV A
FIGURE 602.1
ITEM #
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
PART #
990080
990470
981575
990650
980480
124858
740050-1
990200
996050
124857
124855
124856
990200
NPN
124860
109485
109486
740050-2
DESCRIPTION
WASHER, FLAT, 3/8"
WASHER, LOCK, 3/8"
SCREW, 3/8-16NC X 1", HHCS, GR 5, ZP
COTTER PIN, 1/8 X 1, SS
WASHER, FLAT, S/S, 1/2 F/W, 7/8 OD
ROLLER WEAR BUSHING
KIT: WINCH & SOCKET
NUT, LOCK, NYLON INSERT, 1/2-13NC, GR 2
SCREW, 1/2-13NC X 7-1/2, HHC ,GRADE 5, ZP
SPACER, .5 ID, 1.25 OD
RATCHET ARM
BUSHING, FLANGE, 1.25 OD, .5 ID
NUT LOCK NYLON INSERT 1/2-13NC GR 2 ZPIN
NUT, 1/2-13, NYLON LOCK, HALF THICK, PART OF 740050-1
HANDLE SOCKET, RATCHETING
KIT:SAFETY-LOC SYSTEM (with winch) includes items 4-13,15
KIT:SAFETY-LOC SYSTEM includes items 3-6, 8-12, 15
KIT: CABLE CLAMP FASTENER
QTY.
2
2
2
1
1
1
1
2
1
1
1
1
1
1
1
1
1
1
600 - 5
Figure 603.1
September 2008
REV A
Tower Assembly
ITEM #
1
2
3
4
5
6
7
8
600 - 6
PART #
113080
851545
R850475
851550
990160
990170
990600
991690
DESCRIPTION
COIL CORD SLEEVE
DECAL: DANGER DO NOT RAISE TOWER IN VICINITY
DECAL: WARNING FORKS
DECAL: LIFT MACHINE HERE
SCREW, 3/8-16NC X 3-3/4, HHC, GRADE 2, ZP
NUT, LOCK, NYLON INSERT, 3/8-16NC, GR 2, ZPN
SCREW, 3/8-16NC X 1/2, HHC, GRADE 2, ZP
WASHER, LOCK STAR, 3/8"EXT.TOOTH, ZP
QTY.
1
1
2
1
1
1
2
2
September 2008
Figure 604.1
REV A
ITEM #
1
2
3
4
5
6
7
8
9
10
PART #
124540
22109516
990660
22120222
171635
171640
980340
790710
990650
177810
DESCRIPTION
4" SECTION, 30' TOWER
KIT: LOCK SLIDE PIN W/ SPRING & SHELL includes 3-9
ROLL PIN, 1/4 X 1-5/8
PIN, 1/2 X 1-1/4 X 7-1/4, SLIDE LOCK
LOCK PIN SHELL
LOCK SPRING SHELL
SCREW, 5/16-18NC X 1/2 HHCS, GR 2, ZP
SPRING, COIL, 1/2 X 2.25
COTTER PIN, 1/8 X 1, SS
SHIM, 3/16 X 2 X 19-3/4
QTY.
1
1
1
1
1
1
1
1
1
1
600 - 7
Figure 605.1
September 2008
REV A
ITEM #
1
2
3
4
5
6
7
8
9
10
11
12
600 - 8
PART#
990620
994920
990650
995190
990610
188770
188760
992765
179850
124530
995790
188760
DESCRIPTION
NUT, LOCK, NYLON INSERT, 7/8-14NF, HALF JAM
COTTER PIN, 3/32 X3 /4, SS
COTTER PIN, 1/8 X 1, SS
NUT, LOCK, NYLON INSERT, 1/2-20NF, HALF NUT
BOLT, TEE, 1/2-20NF, 4-1/2 LG
SHEAVE, 2-13/16 X 11/4 CABLE
SHEAVE, 3-1/8 X 1 1/4 CABLE
CLEVIS PIN, STAINLESS STEEL, 1/2 X 2
BUSHING, 2.5OD X 13/16
6" ROUND TUBE
CLEVIS PIN, STAINLESS STEEL, 1/4 X2
SHEAVE, 3-1/8 X 1 1/4 CABLE
QTY.
1
1
1
1
1
1
1
2
1
1
1
1
September 2008
Figure 606.1
REV A
ITEM #
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
PART #
994920
990650
188760
990670
183286
177830
183288
990190
990210
178335
683460
683450
990200
109065
995790
995780
683455
DESCRIPTION
COTTER PIN, 3/32 X 3/4, SS
COTTER PIN, 1/8 X 1, SS
SHEAVE, 3-1/8 X 1, 1/4 CABLE
RIVET, POP, 3/16 X 1/2, S/S, BLIND RIVET
SHIM, 5/16 X 2 X 3-3/16
SHIM, 1/4 X 2 X 3-3/16
SHIM, 3/16 X 2 X 3-3/16
SCREW, 1/2-13 NC X 3 HHC, GRADE 2, ZP
WASHER, FLAT, 1/2"
LOCK LEVER, AL-SERIES
BUSHING, 3/4 OD X 1/2 ID X .285L, SAE 841, BRONZE
SPACER, 11/16 OD X 1/2 ID X 1-1/32" LONG
NUT, LOCK, NYLON INSERT, 1/2-13NC, GR 2, ZPIN
KIT: CABLE ASSEMBLY, LOWER, 1/4" CABLE
CLEVIS PIN, STAINLESS STEEL, 1/4 X 2
CLEVIS PIN, STAINLESS STEEL, 3/8 X 2
BUSHING, 11/16 OD X 1/2 ID X .26L, SAE 841, BRONZE
QTY.
2
2
2
8
1
2
1
2
3
1
1
1
2
1
2
1
1
600 - 9
Figure 607.1
September 2008
REV A
ITEM #
1
2
3
4
5
6
7
8
9
10
11
12
13
14
600 - 10
PART #
990181
990470
109065
124550
188760
990650
994920
990670
185290
992765
995790
177820
185290
15086
DECSCRIPTION
SCREW, 3/8-16 UNC X 1"
WASHER LOCK 3/8"
KIT: CABLE ASSEMBLY LOWER 1/4 CABLE
3 SECTION 30'TOWER
SHEAVE 3-1/8 X1 1/4 CABLE
COTTER PIN 1/8X1 SS
COTTER PIN 3/32X3/4 SS
RIVET POP 3/16X1/2 S/S BLIND RIVET
SHIM 3/8X2X2-1/4
CLEVIS PIN STAINLESS STEEL 1/2 X2
CLEVIS PIN STAINLESS STEEL 1/4 X2
SHIM 5/16X2X2-1/4
SHIM 3/8X2X2-1/4
WASHER, FLAT
QTY.
1
1
1
1
1
1
2
8
1
1
2
3
1
1
September 2008
Figure 608.1
REV A
ITEM #
PART #
1
2
3
4
124560
109070
990470
996230
DESCRIPTION
2" SECTION, 30' TOWER
KIT: CABLE ASSEMBLY, UPPER
WASHER, LOCK, 3/8
SCREW, 3/8-16NC X 7/8 HHC, GR 8, ZP
QTY.
1
1
1
1
600 - 11
Figure 609.1
September 2008
REV A
ITEM #
1
2
3
4
5
6
7
8
9
600 - 12
PART #
113040
191781
990880
22123080
994460
990080
990170
851760
841890
DESCRIPTION
CROSSARM, 4-LIGHT
STUD, 3/4 X 10NC X 4-3/4
WASHER, LOCK STAR, 3/4 EXT.TOOTH
FIXTURE, MOUNTING WING NUT
SCREW, 3/8-16NC X 4-1/2"
WASHER, FLAT, 3/8
NUT, LOCK, NYLON INSERT, 3/8-16NC, GR 2, ZPN
DECAL: DANGER HIGH VOLTAGE....
REFLECTOR, SCOTCHLITE, TAPE, 2 X18
QTY.
1
4
4
4
2
4
2
1
2
September 2008
Section 700
Options
700 - 1
Figure 701.1
September 2008
REV A
Options
700 - 2
September 2008
REV A
FIGURE 701.1
ITEM #
1
PART #
DESCRIPTION
QTY.
0LTY0422
741993
0LTX0580
116154
116151
1
1
0LTX0481
663515
663520
663527
663528
663529
663843
663840
1
1
2
2
4
1
1
0LTX0180
663400
663405
1
1
0LTX0040
940000
840120
176336
176335
121572
840470
1
1
2
2
1
1
0LTY0316
110870
841220
841480
841850
841855
841860
834340
2
1
1
2
1
1
1
700 - 3
Figure 702.1
September 2008
REV A
Options
700 - 4
September 2008
REV A
FIGURE 702.1
ITEM #
7
PART #
DESCRIPTION
QTY.
0LTY0314
110870
841500
841480
841850
841855
841860
2
1
1
2
1
1
0LTY0315
841850
841870
841875
2
1
1
0LTX0222
161085
174170
182331
1
1
2
0LTX0210
684640
683970
1
1
0LTX0520
113583
160992
124750
160993
663780
684710
186830
1
1
1
1
1
1
1
12
OLTX0270
13
116218
116154
116144
1
1
1
10
11
700 - 5
September 2008
700 - 6
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
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Before Towing
Before Driving
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