Related Manuals for Terex RL4000D2
Summary of Contents for Terex RL4000D2
- Page 1 Service Manual RL4000D2 First Edition First Printing Part No. 116473 September 2008 Courtesy of Machine.Market...
- Page 2 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.
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Page 3: How To Read Your Serial Number
September 2008 How to Read Your Serial Number Serial Number Legend The serial number plate on your RL4000 is located on the cabinet next to the light tower mast. Part No. 116473 RL4000 Light Tower Courtesy of Machine.Market... -
Page 4: Rl4000 Light Tower
September 2008 This page intentionally left blank. RL4000 Light Tower Part No. 116473 Courtesy of Machine.Market... -
Page 5: Rl4000 Light Tower
Section 1 • Safety Rules September 2008 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. -
Page 6: Rl4000 Light Tower
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 Be aware of potential crushing hazards safety and the continued safe operation of the such as moving parts, free swinging or... -
Page 7: Table Of Contents
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 .................. - Page 8 September 2008 TABLE OF CONTENTS REV A Section 5 Schematics Introduction ....................5 - 1 AC Light Tower Wiring ................. 5 - 2 Wire Harness, Control Box, European, DC ..........5 - 3 DC Wiring, European, Kubota ..............5 - 4 DC Wiring, Kubota ..................
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Page 9: Parts Stocking List
September 2008 Parts Stocking List REV A Required Parts The following parts are required to perform maintenance procedures as outlined in the TEREX RL4000 Parts and Service Manuals. Description Part No. Kubota Models Oil Filter .............. 866050 Air Filter .............. 866127 Fuel Filter ............ - Page 10 September 2008 REV A This page intentionally left blank. RL4000 Light Tower Part No. 116473 Courtesy of Machine.Market...
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Page 11: How To Order Parts
September 2008 How To Order Parts REV A 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 Redmond, WA 98073-9730 Machine model number Telephone (877) 367-5606... -
Page 12: Service Parts Fax Order Form
All backordered parts will be shipped when available via the same ship method as the original order unless noted below: Ship complete order only - no backorders Ship all available parts and contact customer on disposition of backordered parts Other (please specify) TEREX U Order Number ______________ Origin Code ________________ Comments _________________________ RL4000 Light Tower Part No. -
Page 13: Specifications
September 2008 Section 2 • Specifications Specifications REV A MAST MAST ELEVATION 30' / 9.14M TOWER ROTATION 359 DEGREES TOWER ROTATION MANUAL MAX WIND RATING 62MPH / 100KPH DIMENSIONS SEE CHART ON PAGE 2-3 ENGINES STANDARD KUBOTA, D1105 DIESEL, 13.6 HP GENERATORS STANDARD MARATHON, 6 KW... -
Page 14: Specifications (Continued)
Section 2 • Specifications September 2008 SPECIFICATIONS REV A TRAILER WHEELS 13 X 4.5, 5 HOLE TIRES, ST175/80D13, LOAD B COLD PRESSURE, 35PSI / 250KPA AXLE RATING 2000LBS MAX TOW SPEED, 60MPH / 96KPH NO BRAKES, STANDARD TWO OUTRIGGERS, STANDARD FUEL TANK FUEL TYPE, NO.2 DIESEL ONLY CAPACITY, 30 GALLONS / 114L... - Page 15 September 2008 Section 2 • Specifications REV A SPECIFICATIONS Part No. 116473 RL4000 Light Tower 2 - 3 Courtesy of Machine.Market...
- Page 16 Section 2 • Specifications September 2008 SPECIFICATIONS REV A SAE FASTENER TORQUE CHART • This chart is to be used as a guide only unless noted elsewhere in thi s manual • A574 High Strength Grade 5 Grade 8 SIZE THREAD Black Oxide Bolts LUBED LUBED...
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Page 17: Observe And Obey
September 2008 Section 3 • Scheduled Maintenance Procedures Scheduled Maintenance Procedures REV A 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 Safety alert symbol—used to alert Maintenance inspections shall be completed by personnel to potential personal... - Page 18 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 Courtesy of Machine.Market...
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Page 19: Maintenance Schedules
September 2008 Section 3 • Scheduled Maintenance Procedures Maintenance Schedules REV A Kubota Lubrication and Maintenance Service Intervals Every Every Every Every Every Every Every Every Every 50 Every ITEM 1500 3000 Hours Year Hours Hours Hours Hours Hours Hours Hours Years •... -
Page 20: Leroy Somer Generators Maintenance Schedule
Section 3 • Scheduled Maintenance Procedures September 2008 MAINTENANCE SCHEDULES CONTINUED REV A Leroy Somer Generators Maintenance Schedule 2000 Hours 8000 Hours 20000 Hours 30000 Hours ITEM DAILY Weekly or 6 Months or 1 Year or 3 Years or 5 Years •... -
Page 21: Marathon Generators Maintenance Schedule
September 2008 Section 3 • Scheduled Maintenance Procedures MAINTENANCE SCHEDULES CONTINUED REV A Marathon Generators Maintenance Schedule 10000 ITEM DAILY 200 Hours Hours • Visual inspection Clean and inspect after every 200 hours of normal operating time. If generator is housed in a harsh environment, it is advisable to clean and inpect the unit more frequently. - Page 22 Section 3 • Scheduled Maintenance Procedures September 2008 This page intentionally left blank. 3 - 6 RL4000 Light Tower Part No. 116473 Courtesy of Machine.Market...
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Page 23: Troubleshooting And Repair Procedures Shall Be Completed By A Person Trained And Qualified On The Repair Of This Machine
September 2008 Section 4 • Troubleshooting Troubleshooting REV A 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 generally accepted safe workshop practices. -
Page 24: Troubleshooting Guide
Section 4 • 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. - Page 25 September 2008 Section 4 • Troubleshooting TROUBLESHOOTING REV A 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.
- Page 26 Section 4 • 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.
- Page 27 September 2008 Section 4 • Troubleshooting TROUBLESHOOTING REV A TROUBLE POSSIBLE CAUSE REMEDY 18.Lamp flickers or goes out- c.Defective lamp c.Replace lamp intermittent or cycling d.High spike ballast d.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.
- Page 28 Section 4 • Troubleshooting September 2008 This page intentionally left blank. 4 - 6 RL4000 Light Tower Part No. 116473 Courtesy of Machine.Market...
- Page 29 September 2008 Section 5 • Schematics Schematics REV A 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.
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Page 30: Ac Light Tower Wiring
Section 5 • Schematics September 2008 AC Light Tower Wiring Drawing #6495 REV A 5 - 2 RL4000 Light Tower Part No. 116473 Courtesy of Machine.Market... -
Page 31: Wire Harness, Control Box, European, Dc
September 2008 Section 5 • Schematics Wire Harness, Control Box, European, DC Drawing #116810 REV A Part No. 116473 RL4000 Light Tower 5 - 3 Courtesy of Machine.Market... -
Page 32: Dc Wiring, European, Kubota
Section 5 • Schematics September 2008 DC Wiring, European, Kubota Drawing #116813 REV A 5 - 4 RL4000 Light Tower Part No. 116473 Courtesy of Machine.Market... -
Page 33: Dc Wiring, Kubota
September 2008 Section 5 • Schematics DC Wiring, Kubota Drawing #116814 REV A Part No. 116473 RL4000 Light Tower 5 - 5 Courtesy of Machine.Market... -
Page 34: Wire Harness, Inside Control Box, Dc
Section 5 • Schematics September 2008 Wire Harness, Inside Control Box, DC Drawing #116815 REV A 5 - 6 RL4000 Light Tower Part No. 116473 Courtesy of Machine.Market... -
Page 35: Mh Or Hps Light Fixture
September 2008 Section 5 • Schematics MH or HPS Light Fixture Drawing #2985A REV A Part No. 116473 RL4000 Light Tower 5 - 7 Courtesy of Machine.Market... -
Page 36: 1000 Mh Ballast
Section 5 • Schematics September 2008 1000 MH Ballast Drawing #2986 REV A 5 - 8 RL4000 Light Tower Part No. 116473 Courtesy of Machine.Market... -
Page 37: 1000 Hps Ballast
September 2008 Section 5 • Schematics 1000 HPS Ballast Drawing #2987 REV A Part No. 116473 RL4000 Light Tower 5 - 9 Courtesy of Machine.Market... - Page 38 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) · Boom hold-down latch is securely locked in place Before Towing ·...