Terex RL4000 Service Manual
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Terex RL4000 Service Manual

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Summary of Contents for Terex RL4000

  • Page 2 One of our experienced staff members will get back to you with a quote for the right part that your machine needs. We sell worldwide for the brands: Genie, Terex, JLG, MultiQuip, Mayco, Toro/Stone, Diamond Products, Magnum, Airman, Mustang, Power Blanket, Nifty Lift, Atlas Copco,...

  • Page 3: Introduction

    Copyright © 2009 by TEREX Corporation 116694 June 2013 First Edition, Second Printing TEREX and "Super Quiet" are registered trademarks of TEREX USA LLC in the USA and many other countries. Printed on recycled paper Printed in U.S.A. RL4000 • TML-4000...

  • Page 4: Revision History

    Kubota Engine_Section 2_Specifications. Electronic Version A-6,B-3,C-7_Section 3_Maintenance Procedure. Click on any procedure or page number 3-2, 6-4, 9-1_Section 4_Repair Procedure. highlighted in blue to view the update. Fault Codes_Section 5. 6-35, 6-56, 6-104_Section 6_Schematic Page #. Part No. 116694 RL4000 • TML-4000...
  • Page 5 Kubota Engine_Section 2_Specifications. Electronic Version A-6,B-3,C-7_Section 3_Maintenance Procedure. Click on any procedure or page number 3-2, 6-4, 9-1_Section 4_Repair Procedure. highlighted in blue to view the update. Fault Codes_Section 5. 6-35, 6-56, 6-104_Section 6_Schematic Page #. RL4000 • TML-4000 Part No. 116694...

  • Page 6: How To Read Your Serial Number

    June 2013 How to Read Your Serial Number Serial Number Legend The serial number plate on your RL4000/TML-4000 is located on the cabinet next to the light tower mast. RL4 08 - 1003 Sequence Model number Model year Part No. 116694...

  • Page 7: Safety Rules

    Yellow without safety alert symbol—used to indicate the presence of a potentially hazardous situation which, if not avoided, may result in property damage. RL4000 • TML-4000 Part No. 116694...
  • Page 8 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 . Part No. 116694 RL4000 • TML-4000...

  • Page 9: Table Of Contents

    Safety Rules General Safety Rules ..................vi Section 2 Specifications Model - RL4000 and TML-4000 ..............2 - 1 RL4000 ......................2 - 2 TML-4000 ....................2 - 3 SAE and Metric Fastener Torque Charts ............. 2 - 4 Section 3 Scheduled Maintenance Procedures Introduction ....................
  • Page 10 DC Wiring, Perkins ..................5 - 4 Engine Harness, Perkins ................5 - 5 Wire Harness, Inside Control Box, DC ............5 - 6 MH Light Fixture ..................5 - 7 1000 MH Ballast ..................5 - 8 Part No. 116694 RL4000 • TML-4000...

  • Page 11: Specifications

    June 2013 Section 2 • Specifications Specifications Model - RL4000 & TML-4000 Height, stowed 5 ft 9.5 in 1.765 m Length, stowed 14 ft 2 in 4.331 m Width, stowed 4 ft 6 in 1.372 m Extended tower height 30 ft 9.114 m...

  • Page 12: Rl4000

    Section 2 • Specifications June 2013 SPECIFICATIONS RL4000 69 1/2" (1765mm) 170 1/2" (4331mm) TRAVEL POSITION 360" (9144mm) 38" (965mm) 61 1/2" 54" (1562mm) (1372mm) 124" 126" (3150mm) (3200mm) OPERATING POSITION 2 - 2 RL4000 • TML-4000 Part No. 116694...
  • Page 13 June 2013 Section 2 • Specifications SPECIFICATIONS TML-4000 69 1/2" (1765mm) 170 1/2" (4331mm) TRAVEL POSITION 360" (9144mm) 38" (965mm) 61 1/2" 54" (1562mm) (1372mm) 124" 126" (3150mm) (3200mm) OPERATING POSITION Part No. 116694 RL4000 • TML-4000 2 - 3...
  • Page 14 Section 2 • Specifications June 2013 SPECIFICATIONS 10.9 12.9 2 - 4 RL4000 • TML-4000 Part No. 116694...

  • Page 15: Scheduled Maintenance Procedures

    • Toggle switch in the off position Indicates that a specific result is expected after • Wheels chocked performing a series of steps. Indicates that an incorrect result has occurred after performing a series of steps. Part No. 116694 RL4000 • TML-4000 3 - 1...
  • Page 16 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 Copyright © 2006 by TEREX Corporation. TEREX® is a registered trademark of TEREX USA, LLC. Rev C...

  • Page 17: Maintenance Schedules

    *Refer to the manufacturer's manuals for detailed maintence intervals and instructions. If the information in the manufacturer's manual differs from that in this manual the manufacturer's manual should take precedence. Kubota Engine Manual Genie part number 893020 Part No. 116694 RL4000 • TML-4000 3 - 5...

  • Page 18: Perkins Lubrication And Maintenance Service Intervals

    • Water pump - inspect Cooling system coolant (commercial • heavy-duty) - change Cooling system coolant extender • (ELC) - add Cooling system coolant (ELC) - • change Perkins Operations Manual 3 - 6 RL4000 • TML-4000 Part No. 116694...

  • Page 19: Marathon Generators Maintenance Schedule

    *Refer to the manufacturer's manuals for detailed maintence intervals and instructions. If the information in the manufacturer's manual differs from that in this manual the manufacturer's manual should take precedence. Marathon Manual Genie part number 116188 Part No. 116694 RL4000 • TML-4000 3 - 7...

  • Page 20: Troubleshooting

    Use extreme caution when working with high voltage electrical components. Burn hazard. Contact with hot engine components may cause severe burns. Use caution when working around a hot engine. Part No. 116694 RL4000 • TML-4000 4 - 1...

  • Page 21: Troubleshooting Guide

    4 - 2 RL4000 • TML-4000 Part No. 116694...
  • Page 22 Voltage should be within 10% of rating when operating at normal load. Increase supply voltage or remove external load. Part No. 116694 RL4000 • TML-4000 4 - 3...
  • Page 23 "cycle". Usually after 3 tries to start at 30 to 60 second intervals, lamp will stabilize and operate normal 4 - 4 RL4000 • TML-4000 Part No. 116694...
  • Page 24 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. 116694 RL4000 • TML-4000 4 - 5...
  • Page 25 Return to Inspect Perform Be sure that all necessary tools and test service and test repair equipment are available and ready for use. problem solved Part No. 116694 RL4000 • TML-4000 5 - 1...

  • Page 26: Dc Wiring, Kubota

    Section 5 • Schematics June 2013 DC Wiring, Kubota Drawing #116814C OR/BK WH/BK 5 - 2 RL4000 • TML-4000 Part No. 116694...

  • Page 27: Engine Harness, Kubota

    Engine Harness, Kubota Drawing #116820B ALTERNATOR STARTER (IG) BATT + ALTERNATOR (B+) STARTER OIL PRESSURE SOLENOID SWITCH STARTER SOLENOID FUEL SOLENOID TEMPERATURE SWITCH GLOW PLUGS GROUND FUEL PUMP FUSE E-STOP (OPTION) Part No. 116694 RL4000 • TML-4000 5 - 3...

  • Page 28: Dc Wiring, Perkins

    Section 5 • Schematics June 2013 DC Wiring, Perkins Drawing #116819B 5 - 4 RL4000 • TML-4000 Part No. 116694...

  • Page 29: Engine Harness, Perkins

    SWITCH STARTER SOLENOID GLOW PLUGS GROUND OIL PRESSURE SWITCH FUEL SOLENOID FUSE PERKINS ENGINE CONNECTOR REFERENCE E-STOP (OPTION) (WIRE ENTRY VIEW) FUEL SOLENOID BLK RED OIL PRESS SWITCH WATER TEMP SWITCH Part No. 116694 RL4000 • TML-4000 5 - 5...

  • Page 30: Wire Harness, Inside Control Box, Dc

    Section 5 • Schematics June 2013 Wire Harness, Inside Control Box, DC Drawing #116815F 5 - 6 RL4000 • TML-4000 Part No. 116694...

  • Page 31: Mh Light Fixture

    June 2013 Section 5 • Schematics MH Light Fixture Drawing #2985A Part No. 116694 RL4000 • TML-4000 5 - 7...

  • Page 32: 1000 Mh Ballast

    Section 5 • Schematics June 2013 1000 MH Ballast Drawing #2986 5 - 8 RL4000 • TML-4000 Part No. 116694...
  • Page 33 California Proposition 65 California Proposition 65 Warning Warning Battery post terminals and related The exhaust from this product accessories contain lead compounds, contains chemicals known to chemicals known to the State of the State of California to California to cause cancer cause cancer, birth defects and other reproductive harm.

This manual is also suitable for:

Tml-4000

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