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November 2006
November 2006
OPERATOR/SERVICE
OPERATOR/SERVICE
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RTS
RTS
Series
Series
RL400
RL4000D2
Light Tower
Light Tower
PART NUMBER 833005
PART NUMBER 833005
REVISION A
REVISION A
November 2006
November 2006
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MANUAL
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.O. BOX
.O. BOX
3147
3147
ROCK HILL, S.C. 29732 USA
ROCK HILL, S.C. 29732 USA
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Table of Contents
Troubleshooting
Related Manuals for Terex RL4000D2 Series
Summary of Contents for Terex RL4000D2 Series
- Page 1 November 2006 November 2006 OPERATOR/SERVICE OPERATOR/SERVICE & & MANUA MANUAL Series Series RL400 RL4000D2 Light Tower Light Tower PART NUMBER 833005 PART NUMBER 833005 REVISION A REVISION A November 2006 November 2006 .O. BOX .O. BOX 3147 3147 ROCK HILL, S.C. 29732 USA ROCK HILL, S.C.
- Page 2 November 2006 November 2006 TABLE OF CONTENTS TABLE OF CONTENTS OPERATOR’S MANUAL OPERATOR’S MANUAL the Operato Operator ..............................................Safe Safety Alert ty Alert Symb Symbols ..........................................Genera eral Safety ....
- Page 3 November 2006 November 2006 TABLE OF CONTENTS TABLE OF CONTENTS OPERATOR’S MANUAL OPERATOR’S MANUAL the Operato Operator ..............................................Safe Safety Alert ty Alert Symb Symbols ..........................................Genera eral Safety ....
- Page 4 If this manual becomes lost, order a new one from T If this manual becomes lost, order a new one from Terex erex so future operation and maintenance so future operation and maintenance personnel may read these personnel may read these instructions.
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Page 5: Safety Alert Symbols
November 2006 SAFETY ALERT SYMBOLS MEANS: ATTENTION! BE ALERT! YOUR SAFETY IS INVOLVED THIS SAFETY SYMBOL IS USED FOR IMPORTANT SAFETY MES- SAGES. WHEN YOU SEE THIS SYMBOL, FOLL OW THE SAFETY MESSAGE TO AVOID PERSONAL INJURY OR PROPERTY DAMAGE. UNDERSTANDING SIGNAL WORDS A signal word - DANGER, WARNING or CAUTION is used with the safety alert symbol. -
Page 6: General Safety
November 2006 GENERAL SAFETY DO NOT OPERATE THE RL4000 LIGHT TOWER WITHOUT READING THIS OPERATOR’S MANUAL. DO NOT WORK ON OR OPERATE THE LIGHT TOWER WHILE UNDER THE INFLU- ENCE OF PERFORMANCE IMPAIRING DRUGS OR ALCOHOL. SAFETY ALERT SYMBOL Stop and take time to read ALL Safety alert mes- sages. - Page 7 November 2006 GENERAL SAFETY FUELING handle fuel with care. It is highly flam- ALWAYS mable. stop engine before refueling. Fill fuel ALWAYS tank outdoors. Be sure the fuel supply has a positive shut-off valve . replace fuel lines with materials different DO NOT from those supplied as original equipment.
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Page 8: Electrical Safety
November 2006 GENERAL SAFETY EXHAUST GASES ARE TOXIC. DO NOT USE INDOORS UNLESS PROPERLY VENTILATED OR AN EXHAUST SCRUBBER IS USED. Check exhaust system regularly for leaks and ensure that the exhaust manifolds are secure and not warped. Make sure the unit is well ventilated. ELECTRICAL SAFETY This equipment utilizes high voltage circuits. -
Page 9: Battery Hazards
November 2006 GENERAL SAFETY BATTERY HAZARDS Lead acid batteries can be dangerous. The sulfuric acid in the battery can cause severe skin and eye burns. The hydrogen gas emitted during charging can explode if an arc or flame is present. smoke while servicing the battery. -
Page 10: Beware Of Traffic Hazards
November 2006 GENERAL SAFETY BEWARE OF TRAFFIC HAZARDS Stand clear of traffic when starting or checking the unit along the road. Check the fuel tank, oil pan, and fuel and oil lines for leaks that would spill fuel or oil on the road. Check fasteners and mounting brackets periodically to insure all are tight and nothing is in danger of falling off during transit. -
Page 11: Receipt Of Delivery Checklist
November 2006 RECEIPT OF DELIVERY CHECKLIST The tower will be serviced, tested and ready for operation upon delivery. Terex recommends the following checks: Insure there is no freight handling damage which should be charged against the carrier. Make sure the telescoping boom is secure. -
Page 12: Transport & Towing
8. Make sure all doors are closed and tightly locked. 9. Remove tire chocks. Towing o f a Terex lig ht tow er is approved with t he light f ix- tures in pl ace on the cros shead assembly for all o ff road... - Page 13 November 2006 SETUP A. Move the light tower to desired location keeping the following in mind: 1. The light tower should not be placed where those working under the light are either: a. Forced to look into the light regularly. b.
- Page 14 November 2006 SETUP F. When applicable, drive grounding rod into earth. (Grounding rod not included) 1. Drive the rod into the ground and secure the grounding wire to the lug located on the trailer frame. Towing Chain Tongue Jack Outrigger Pin Outrigger Jack Rear Jack FIRM AND LEVEL AREA...
- Page 15 November 2006 SETUP H. Raising the tower as follows: 1. Remove the tower travel locking pin from the cradle at the rear of the cabinet. 2. Remove the tower locking pin from the tower base. Using the lower pivot winch, raise the tower to the vertical position.
- Page 16 November 2006 SETUP THE AUTOMATIC BRAKE MUST BE WORKING ON THE UPPER TELESCOPING WINCH. THE WINCH SHOULD NOT ALLOW THE TOWER TO DROP DOWN WHEN THE HANDLE IS RELEASED. UNDER NO CIRCUMSTANCES SHOULD THE LIGHT TOWER BE TOWED OR MOVED WHEN THE BOOM IS IN A VERTICAL POSITION.
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Page 17: Starting The Engine/Generator Set
45 seconds. 5. Start the engine and listen for any unusual sounds or vibrations. Should unusual sounds be detected, contact Terex Light Construction Service Manager. 6. Once the engine has been started and running smoothly, place the light switches in the “ON”... -
Page 18: Shutdown Procedures
November 2006 OPERATING INSTRUCTIONS LIGHT TOWER AUXILIA RY POWER: 1. One 20 amp, 120 VAC GFI receptacle and one 30 amp, 240 VAC receptacle are provided for auxiliary power. 2. Total auxiliary power cannot exceed main circuit breaker rating. Each lamp operating consumes 9.5 amps of 120 volt power. - Page 19 November 2006 OPERATING INSTRUCTIONS LOWERING THE TOWER (Conti nued): 2. Loosen the rotational lock and rotate the tower into its nesting position. The upper telescoping winch should be pointing forward, towards the tongue. 3. Remove the travel locking pin (located on cradle). 4.
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Page 20: Maintenance
MAINTENANCE MINIMUM MAINTENANCE PROCEDURES: The following maintenance intervals are only suggested by Terex. You should always check your engine owner’s manual for specific information. Should you find any discrepancies between the Terex Manual and the Engine Manufacturer’s Manual always follow the Engine Manufacturer’s Manual. - Page 21 November 2006 MAINTENANCE CLEANING: The Light Tower employs various electronic controls that may be damaged by liquid spray washing or high pressure washing. Follow these procedures to prevent any damage to these components. DO NOT SPRAY WATER INTO THE UNIT WHILE IT IS RUNNING.
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Page 22: Noise Level
November 2006 MAINTENANCE MANUAL WINCH Maintain a light film of automotive-type grease on the pinion, drum gear, and the O.D. of the drum bearing at all times. Keep the ratchet pawl pivot, pinion shaft bushings, and pinion threads lubri cated with automotive engine oil at all times. Before each use, check the brake friction discs for wear. -
Page 23: Specifications And Dimensions
November 2006 SPECIFICATIONS & DIMENSIONS RL4000 Light Tower Part No. 833005 Rev A... - Page 24 November 2006 SPECIFICATIONS & DIMENSIONS TEREX model RL4000 series light tower provides mobile; trailer mounted floodlighting for night- time maintenance, construction, mining, and emergency work. It consists of a trailer with a diesel powered 6 kW 60Hz (50 Hz units available) generator, and a 30 foot cable actuated tower with four (4) 1000 watt floodlight fixtures.
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Page 25: Torque Specifications
November 2006 TORQUE SPECIFICATIONS MISCELLANEOUS SPECIFICATIONS The Amida RL4000 light tower is built to NEC standards. FASTENER TORQUE SPECIFICATIONS All fasteners should be torqued to the following specifications in lb-ft (lb-in): SAE FAST ENER TORQUE CHART • This char t is to be us ed as a guide only unless noted elsewher e in this manual • A574 High St r en gt h Grade 5 Grade 8... -
Page 26: Troubleshooting
November 2006 TROUBLESHOOTING The engine and generator are set at the factory. These units are tested and set to 1800 RPM at 60 HZ for proper operation in the field. These units should never require additional adjustments in the field. Adjustments should only be made by a qualified service technician, otherwise the manufacturer’s warranty may become void. - Page 27 November 2006 TROUBLESHOOTING 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. Inspect valve clearances 7.Engine overheats a.Blocked cooling air intakes a.Inspect the front and rear intakes...
- Page 28 November 2006 TROUBLESHOOTING 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.
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Page 29: Light Fixture Troubleshooting
November 2006 TROUBLESHOOTING 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. 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 30 November 2006 LIGHT FIXTURE TROUBLESHOOTING TRACEABLE NUMBERED WIRING SYSTEM (Using plug in ballasts to troubleshoot) When troubleshooting the preceeding problems, minimize down time by following the traceable numbered wiring system, always follow these steps: STEP1: Insure all ballasts, which are numbered, are plugged into lead wires with corresponding numbers.
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Page 31: Warranty Procedure
After inspecting the defective part(s), and it is determined that warranty is due, we will then, at the discretion of TEREX LIGHT CONSTRUCTION , credit the applicants account or send replacement parts. -
Page 32: Manufacturer's Limited Warranty
Rock Hill, S.C. 29732 MANUFACTURER’S LIMITED WARRANTY TEREX LIGHT CONSTRUCTION (“TLC”) warrants to the original purchaser that such equipment, accessories, parts and other products manufactured by TLC will be free from defects in workmanship and material for a period of one (1) year after the date of first delivery or for two thousand (2,000 ) hours of use, whichever comes first;... -
Page 33: Serial Number Record
. When ord ering parts , PLEASE INCLUDE THE MODEL AND SERIAL NUMBER located on the nameplate of the tow er. For major repair and servic e or other info rmation, contact yo ur loc al Terex dealer or write to: Terex Light Construc tion P.O. -
Page 34: Model Number Identification
November 2006 MODEL NUMBER IDENTIFICATION Part No. 833005 Rev A RL4000 Light Tower... - Page 35 November 2006 RECOMENDED ENGINE OIL & FUEL KUBOTA D1105 DIESEL ENGINE Engine oil should be MIL-L-2104C or have properties of API classification of CD grades or higher. Change the type of engine oil according to the ambient operating tempera ture: Above 77°F (25°C) SAE 30 32°F to 77°F (0 to 25°C)
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Page 36: Wire Rope Replacement
When used properly, the wire ropes should give years of trouble-free service, depending on how often the masts are raised and lowered. The rule of thumb at TEREX is that if the tower is raised and lowered an average of once per day, that the cables should be replaced every two years of service. - Page 37 RL4000 CABLE ROUTING INSTRUCTONS These instructions deal with the assembly and routing of cable for the Terex RL4000 boom, and should aid in making this a smooth assembly. Each boom consists of three separate stages: referred to here as the tower (1), the second stage (2), and the upper (3) boom tubes (see Figure 1).
- Page 38 November 2006 Wiring Diagrams Section Part No. 833005 Rev A RL4000 Light Tower...
- Page 39 November 2006 Fixture Wiring Diagram RL4000 Light Tower Part No. 833005 Rev A...
- Page 40 November 2006 1000MH Ballast Diagram Part No. 833005 Rev A RL4000 Light Tower...
- Page 41 November 2006 1000HPS Ballast Diagram RL4000 Light Tower Part No. 833005 Rev A...
- Page 42 November 2006 AC Wiring For A Light Tower Diagram Part No. 833005 Rev A RL4000 Light Tower...
- Page 43 November 2006 DC Engine Wiring Diagram RL4000 Light Tower Part No. 833005 Rev A...
- Page 44 November 2006 Consolidated Coil Cord With Plug End Part No. 833005 Rev A RL4000 Light Tower...
- Page 45 November 2006 This page intentionally left blank. RL4000 Light Tower Part No. 833005 Rev A...
- Page 46 November 2006 Parts Catalog Section Part No. 833005 Rev A RL4000 Light Tower...
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Page 47: Identification Of Parts
NOTES and DESIGNATIONS This manual is compiled from information available and current at time of approval for printing. Terex reserves the right to improve its product without notice to follow its policy of constantly striving to manufacture a better product. -
Page 48: Parts Ordering Information
When ordering parts for a specific unit, follow the instructions listed below. By doing so, you will be assured of receiving the correct part in the shortest period of time. 1. Send your order to the nearest Terex distributor in your area. 2. Give the light tower model and serial number. - Page 49 November 2006 This page intentionally left blank. RL4000 Light Tower Part No. 833005 Rev A...
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Page 50: Decal Layout
DECAL:RL4000 W/STRIPE OP/BOTTOM 2.25"TALL 853792 DECAL: TEREX 4.5"X43" CR51A101 DECAL:WARNING-IMPROPER GROUNDING. CU51A102 DECAL: NOTICE-NO ETHER C52100100 DECAL: CALIF.PROP 65 CU51A116 DECAL: TEREX POWER MOVING INSTRUCTION CU51A111 DECAL: WARNING-BOOM DROP CR51A101 DECAL:WARNING-IMPROPER GROUNDING. CR51A101 DECAL:WARNING-IMPROPER GROUNDING. Part No. 833005 Rev A RL4000 Light Tower... -
Page 51: Frame Assembly
November 2006 FRAME ASSEMBLY RL4000 Light Tower Part No. 833005 Rev A... - Page 52 November 2006 ITEM # PART # DESCRIPTION QTY. 160270 BATTERY CABLE SET 24 4GA MBT TERM P&N R&B 160110 BATTERY WET 12V GR24 525 CCA STD-DUTY L/A 174170 BATTERY HOLD DOWN 182330 BATTERY HOLD DOWN ROD 1/4" X 10-1/4" 851820 DECAL, SYMBOL FOR GROUND 840222 JACK SNAP RING...
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Page 53: Cabinet Assembly
November 2006 CABINET ASSEMBLY RL4000 Light Tower Part No. 833005 Rev A... - Page 54 November 2006 ITEM # PART # DESCRIPTION QTY. CU63A040 SUPPORT, PLASTIC, 2HOLE 3.5" X 2.5" X 1" C61300501 PIN, 3/4" X 7" ZINC C61300502 CLIP, HITCH PIN CU51A118 DECAL, PIN WITH ARROW C53200100 LITERATURE BOX BLACK, PLASTIC 865307 COOLANT RECOVERY TANK CR54B050 DOOR, ROADSIDE C51100200...
- Page 55 November 2006 November 2006 TOWE TOWER A ASSEMBLY SSEMBLY...
- Page 56 November 2006 November 2006 I I T T E E M M # # P P A A R R T T # # D D E E S S C C R R I I P P T T I I O O N N Q Q T T Y Y .
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Page 57: Electrical Control Box
November 2006 November 2006 ELECTRICAL CONTROL BOX ELECTRICAL CONTROL BOX... - Page 58 November 2006 ITEM # PART # DESCRIPTION QTY. 853294 DECAL: AL/RL CONTROL BOX AC "POWER & LIGHT" 683680 BREAKER 2P 30A 240V 186546 CONTROL BOX,FACE PLATE 709133 TERMINAL,RING 683870 BREAKER 1P 15A 277VAC 684640 RECEPTACLE 20A 120V DUPLEX W/GFI 683970 BREAKER MINI 1P 20A 684450 RECEPTACLE 30A 240V...
- Page 59 November 2006 COIL CORD & JUNCTION BOX ITEM # PART # DESCRIPTION QTY. 685673 PIN, MALE 685671 CONNECTOR 9P,MALE 660287 CORD RETRACT 14/7 663870 CONNECTOR 3P FEMALE 663880 DUST CAP W/CHAIN C48300108 JUNCTION BOX 680190 BOX COVER 2GANG W/GASKET 852800 DECAL: CAUTION TIGHTEN FIXTURE CONNECTOR 680080 GRIP-HUBBLE...
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Page 60: Ballast Assembly
November 2006 BALLAST ASSEMBLY ITEM # PART # DESCRIPTION QTY. 850130 DECAL: DANGER HIGH VOLTAGE 851691 DECAL: 1 851692 DECAL: 2 851693 DECAL: 3 851694 DECAL: 4 189346 BALLAST SPACER 160030 BALLAST TRANSFORMER 160032 CAPACITOR 24uF MH 60Hz 663860 CONNECTOR,5P,MALE 114355 BALLAST BOX MH JOY 1000W/120V/60HZ (Complete Assembly includes items 1 - 9) - Page 61 November 2006 FIXTURE ASSEMBLY RL4000 Light Tower Part No. 833005 Rev A...
- Page 62 November 2006 ITEM # PART # DESCRIPTION QTY. 663850 CORD SET MALE 5FT. 3P 709034 TERMINAL STRIP, 2P 833567 CASTING FOR NEW FIXTURE 995970 WASHER LOCK STAR 1/2 991650 WASHER LOCK 1/2 990810 SCREW 1/2-13NCX1-1/2 HHC GR 2 ZP 833566 TRUNION 833573 T-HANDLE...
- Page 63 November 2006 ENGINE/GENSET ASSEMBLY (KUBOTA D1105) ITEM # PART # DESCRIPTION QTY. 732205PP KUBOTA D1105 ENGINE POWERPACK BUILD EBG2 839190 LOW OIL PRESSURE SWITCH 741140 HIGH TEMPERATURE SWITCH 866125 AIR CLEANER ASSEMBLY 866126 AIR CLEANER BODY 866127 AIR CLEANER ELEMENT 866128 AIR CLEANER COVER 866129...
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Page 64: Radiator Assembly
November 2006 RADIATOR ASSEMBLY ITEM # PARTS # DESCRIPTION QTY. 866114 RADIATOR 866120 CAP FOR RADIATOR 839109 HOSE, TOP 839110 HOSE, BOTTOM 866113 FAN GUARD 865307 COOLANT RECOVERY TANK 890790 HOSE FUEL 1/4X1/2 200# Part No. 833005 Rev A RL4000 Light Tower... - Page 65 November 2006 ENGINE/RADIATOR MOUNTING BRACKET ITEM # PART # DESCRIPTION QTY. 995380 SCREW, 1/2-13NC X 6-1/2 HHC, GRADE 5, ZP 990210 WASHER FLAT 1/2 990415 WASHER, FLAT SNUBBER 740925 VIBRATION MOUNT, 30 DUR 740770 VIBRATION MOUNT 35 LB 124015 ENG.FT/RAD SUPPORT ROADSIDE, D1105/LSA36 (shown) 124016 ENG.FT/RAD SUPPORT CURBSIDE D1105/LSA36 (not shown) 124025...
- Page 66 November 2006 GENERATOR MOUNTING BAR ITEM # PART # DESCRIPTION QTY. 836704 NDE BEARING 836705 DIODE KIT (includes 2 diodes) 836706 ROTOR BOLT (8 X 245) 836707 TOP COVER 836708 END CAP 836709 836710 TERMINAL BLOCK 836711 CAPACITOR, 22.5mf, (two per unit required) 996290 SCREW, M10 X 1.5 X 90MM HHC, GRADE 8.8, ZP 990415...
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Page 67: Trailer Hitches
November 2006 TRAILER HITCHES ITEM # PART # DESCRIPTION QTY. 940000 KIT: COMBO HITCH, includes items 2-6 840120 COUPLER, 2", BOLT ON 176336 COMBO HITCH SIDE SPACER 176335 COMBO HITCH SIDE PLATE 840470 BALL, 2" 121572 COMBO HITCH RING, 16" LONG 213770 RING HITCH BOLT-ON, 2-1/2 ID 124450... - Page 68 November 2006 OPTIONS ITEM # PART # DESCRIPTION QTY. R82A150 SPARE TIRE MOUNT R82A160 CLAMP,SPARE TIRE BRKT,TONGUE MNT. C83100900 TIRE, B78-13B W/13", BLACK RIM 160530 BATTERY BLANKET THERMO 284-4001 36"LG C41101100 LIGHT DOME WITH SWITCH 741690 FUEL LINE HEATER, DIESEL,12V,150W 683970 BREAKER MINI 1P 20A 684640...