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Terex RL4000, Service Manual

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Terex RL4000 Service Manual Download Page 27

 

Section 5 • Schematics

Part No. 116694

RL4000 • TML-4000

5  -  3

June 2013

P1

E-STOP

(OPTION)

TEMPERATURE

SWITCH

GLOW PLUGS

FUEL PUMP

GROUND

FUEL SOLENOID

STARTER

SOLENOID

STARTER

SOLENOID

STARTER

BATT +

ALTERNATOR

(IG)

ALTERNATOR

(B+)

OIL PRESSURE

SWITCH

FUSE

30A

Engine Harness, Kubota

Drawing #116820B

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Summary of Contents for RL4000

Page 1: ...D i s c o u n t E q u i p m e n t c o m ...

Page 2: ...nie Terex JLG MultiQuip Mayco Toro Stone Diamond Products Magnum Airman Mustang Power Blanket Nifty Lift Atlas Copco Chicago Pneumatic Allmand Brothers Essick Miller Spreader Skyjack Lull Skytrak Tsurumi Husquvarna Target Whiteman Concrete Mortar Stow Concrete Mortar Baldor Wacker Sakai Snorkel Upright Mi T M Sullair Neal Basic Dynapac MBW Weber Bartell Bennar Newman Haulotte Ditch Runner Blaw Kno...

Page 3: ...r Technical Publications 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 printing...

Page 4: ... additions REFERENCE EXAMPLES Kubota Engine_Section 2_Specifications A 6 B 3 C 7_Section 3_Maintenance Procedure 3 2 6 4 9 1_Section 4_Repair Procedure Fault Codes_Section 5 6 35 6 56 6 104_Section 6_Schematic Page Electronic Version Click on any procedure or page number highlighted in blue to view the update D i s c o u n t E q u i p m e n t c o m ...

Page 5: ...RENCE EXAMPLES Kubota Engine_Section 2_Specifications A 6 B 3 C 7_Section 3_Maintenance Procedure 3 2 6 4 9 1_Section 4_Repair Procedure Fault Codes_Section 5 6 35 6 56 6 104_Section 6_Schematic Page Electronic Version Click on any procedure or page number highlighted in blue to view the update D i s c o u n t E q u i p m e n t c o m ...

Page 6: ... Serial Number Legend The serial number plate on your RL4000 TML 4000 is located on the cabinet next to the light tower mast v How to Read Your Serial Number RL4 08 1003 Model Model year Sequence number D i s c o u n t E q u i p m e n t c o m ...

Page 7: ...alert symbol used to indicate the presence of a potentially hazardous situation which if not avoided may cause minor or moderate injury Yellow without safety alert symbol used to indicate the presence of a potentially hazardous situation which if not avoided may result in property damage Danger Failure to obey the instructions and safety rules in this manual and the appropriate Operator s Manual o...

Page 8: ... and working areas are properly maintained and ready for use Keep work surfaces clean and free of debris that could get into machine components and cause damage Be sure that your workshop or work area is properly ventilated and well lit Be sure any forklift overhead crane or other lifting or supporting device is fully capable of supporting and stabilizing the weight to be lifted Use only chains or...

Page 9: ... 2 1 RL4000 2 2 TML 4000 2 3 SAE and Metric Fastener Torque Charts 2 4 Section 3 Scheduled Maintenance Procedures Introduction 3 1 Pre delivery Preparation Report 3 3 Maintenance Schedules Kubota Lubrication and Maintenance Service Intervals 3 5 Perkins Lubrication and Maintenance Service Intervals 3 6 Marathon Generators Maintenance Schedule 3 7 Section 4 Troubleshooting Introduction 4 1 Troubles...

Page 10: ...S Section 5 Schematics Introduction 5 1 DC Wiring Kubota 5 2 Engine Harness Kubota 5 3 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 ix D i s c o u n t E q u i p m e n t c o m ...

Page 11: ...fic machine weight Maximum tongue weight 199 lbs 91 kg Tire size U S P175 80D13 Load B Engine type Kubota 13 6 HP Perkins 13 8 HP Fuel capacity 30 gallons 114 liters Run time Kubota 38 3 hours Perkins 37 9 hours Generator Marathon 6 kW 60 Hz Total lighting wattage Four lights 4000 watts Replacement bulbs 1000 watts Type BT 37 Metal Halide Tower rotation 359 degrees non continuous Maximum towing sp...

Page 12: ...L4000 TML 4000 Part No 116694 June 2013 SPECIFICATIONS 69 1 2 1765mm 126 3200mm 360 9144mm 54 1372mm 38 965mm 124 3150mm 61 1 2 1562mm OPERATING POSITION 170 1 2 4331mm TRAVEL POSITION RL4000 D i s c o u n t E q u i p m e n t c o m ...

Page 13: ...o 116694 RL4000 TML 4000 2 3 June 2013 SPECIFICATIONS TML 4000 69 1 2 1765mm 126 3200mm 360 9144mm 54 1372mm 38 965mm 124 3150mm 61 1 2 1562mm OPERATING POSITION 170 1 2 4331mm TRAVEL POSITION D i s c o u n t E q u i p m e n t c o m ...

Page 14: ...Section 2 Specifications 2 4 RL4000 TML 4000 Part No 116694 June 2013 SPECIFICATIONS 10 9 12 9 8 8 4 6 D i s c o u n t E q u i p m e n t c o m ...

Page 15: ...oggle switch in the off position Wheels chocked 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 Symbols Legend Safety alert symbol used to alert personnel to potential personal injury hazards Obey all safety messages that follow this symbol to avoid possible in...

Page 16: ...pair place a check in the R box Legend Y yes completed N no unable to complete R repaired Comments Fundamentals It is the responsibility of the dealer to perform the Pre delivery Preparation The Pre delivery Preparation is performed prior to each delivery The inspection is designed to discover if anything is apparently wrong with a machine before it is put into service A damaged or modified machin...

Page 17: ...ater jacket radiator interior Replacement of fan belt Replacement of air cleaner element Check of damage in electric wiring and loose connections Check of valve clearance Check of fuel injection nozzle injection pressure Check of turbo charger Check of injection pump Check of injection timer Change of radiator coolant L L C Replacement of battery Replacement of radiator hoses and clamp bands Repla...

Page 18: ... system filter replace Battery electrolyte level check Cooling system supplemental coolant additive SCA test add Engine air cleaner element dual element clean replace Engine air cleaner element single element inspect replace Engine oil and filter change Hoses and clamps inspect replace Radiator clean Alternator and fan belts replace Engine valve lash inspect adjust Turbocharger inspect Alternator ...

Page 19: ...is housed in a harsh environment it is advisable to clean and inpect the unit more frequently Replace the bearing 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 nu...

Page 20: ...xposure to electrical wires or electrical current will result in death or serious injury Remove all rings watches and other jewelry Turn off all power when not needed for testing 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 Troubleshooting Observe and Obey ...

Page 21: ...l not turn over a Dead battery a Check the battery voltage or loose cables b Engine has seized due to loss b Have a trained of fluids mechanic examine and repair as needed 4 Engine turns over but will a Empty fuel tank a Fill tank with 2 diesel fuel not start b Clogged fuel lines or filter b Check and clean the fuel system as needed c Leaking fuel lines or a loss c Replace any leaking fuel lines o...

Page 22: ...ulb c Replace the bulbs as needed d Defective capacitor d Have a trained electrician inspect Leroy Somers Generator the capacitor e Defective AC generator e Have a trained electrician inspect the generator f Engine speed is too low f Have a trained mechanic inspect the engine speed and reset to 1800rpm 60hz g Defective ballast and capacitors g Have a trained electrician inspect the ballast and cap...

Page 23: ...tage d Check line voltage at ballast input Voltage should be within 10 of e Improper ballast e Check ballast name plate against lamp data 15 Lamp colors different a Normal lamp depreciation a Replace lamp b Dirty lamp or fixture b Clean lamp and fixture c Wrong lamp c Check data on lamps and replace as needed 16 Arc tube discolored or swollen a Over voltage from power supply b Improper ballast b C...

Page 24: ...NNEL WILL NOT BE COVERED BY YOUR MANUFACTURER S WARRANTY AND WILL ALSO VOID THE MANUFACTURER S WARRANTY ON THIS PARTICULAR UNIT IF YOU CAN NOT REACH YOUR LOCAL DEALER CONTACT THE FACTORY SERVICE MANAGER TOLL FREE AT 1 800 433 3026 DO NOT OPEN FIXTURE WHILE LIGHT CIRCUIT BREAKER IS ON ALLOW LAMP TO COOL BEFORE TOUCHING TAKE EXTRA PRECAUTIONS WHEN TROUBLESHOOTING ELECTRICAL PROBLEMS A Only use a vol...

Page 25: ...tructions in the appropriate operator s manual on your machine Be sure that all necessary tools and test equipment are available and ready for use About This Section There are two groups of schematics in this section An illustration legend precedes each group of drawings ElectricalSchematics Electrocution burnhazard Contact with electrically charged circuits could result in death or serious injury...

Page 26: ... GRN RED YEL RED WHT WH BK STARTER FUEL PUMP 12 12 11 10 9 11 10 9 PLUGS GLOW WH BK WHT GRN ORG YEL BRN BLK 8 7 6 8 7 6 5 4 3 5 4 3 2 1 2 1 N C RED BRN ALTERNATOR B GRN L IG VIO OR BK TEMPERATURE SWITCH NO BLK ORG RED OIL PRESS SWITCH NC B ST PULL HOLD BRN FUEL SOLENOID RED ENGINE COMPONENTS BLK FUSE 30A BATTERY 12V DC WH RD E STOP OPTION YEL GRN IGN BAT ACC YEL YEL P1 11 12 9 6 10 7 4 2 P1 3 1 HA...

Page 27: ...013 P1 E STOP OPTION TEMPERATURE SWITCH GLOW PLUGS FUEL PUMP GROUND FUEL SOLENOID STARTER SOLENOID STARTER SOLENOID STARTER BATT ALTERNATOR IG ALTERNATOR B OIL PRESSURE SWITCH FUSE 30A Engine Harness Kubota Drawing 116820B D i s c o u n t E q u i p m e n t c o m ...

Page 28: ...9 10 WHT YEL BRN BLK RED GRN ORG 5 6 7 8 9 10 P1 1 2 3 4 6 9 12 3 4 11 7 10 2 P1 1 POWER GND TEMPERATURE SWITCH NO PRESSURE SWITCH NC FUEL SOLENOID STARTER ENGINE COMPONENTS IG GLOW PLUGS B BLU BLK ALTERNATOR FUSE 30A RED BATTERY 12V DC B RED RED ORG VIO WHT ST GRN VOLTAGE REGULATOR BLU YEL VIEW FROM WIRE ENTRY SIDE YEL GRN BLU BLK BLU RED BLU RED YEL GRN BLK 1 2 3 6 5 4 1 2 3 4 5 6 YEL YEL YEL WH...

Page 29: ...CH STARTER SOLENOID GROUND STARTER BATT VOLTAGE REGULATOR GLOW PLUGS GROUND E STOP OPTION WIRE ENTRY VIEW 1 2 BLK RED 1 2 VIO ORN BLK BLK FUEL SOLENOID OIL PRESS SWITCH WATER TEMP SWITCH PERKINS ENGINE CONNECTOR REFERENCE 3 2 BLK 6 5 YEL RED BLU 1 BLU 4 GRN GRN 4 BLU 1 BLU RED YEL 5 6 BLK 2 3 ALTERNATOR P1 FUSE 30A D i s c o u n t E q u i p m e n t c o m ...

Page 30: ...IVE 30A TWISTLOCK GROUND 20A GFCI GROUND GREEN 14 AWG ORANGE 14 AWG KEYSWITCH BATTERY RED 12 AWG KEYSWITCH IGNITION KEYSWITCH STARTER BLACK 14 AWG RED 14 AWG GREEN 14 AWG PUSH BUTTON IN INDICATOR OUT BROWN 14 AWG ORANGE 14 AWG BROWN 14 AWG CHASSIS GROUND STUD BLACK 14 AWG BROWN 14 AWG HOUR METER KEYSWITCH STARTER ISUZU PERKINS THE GREEN WIRE MUST BE REMOVED FROM THE IGNITION SWITCH AND ATTACHED TO...

Page 31: ... BLACK BROWN GREEN GRN YEL WHITE BLUE 14 3 NOTE PIN CONFIGURATION IS THE SAMW FOR TUNGSTEN HALOGEN FIXTURES DOMESTIC COLOR UCODE WHITE BLACK GREEN EUROPEAN COLOR UCODE LIGHT BLUE BROWN GRN YEL UCIRCUIT COMMON FROM BALLAST HOT FROM BALLAST LIVE GROUND EARTH D i s c o u n t E q u i p m e n t c o m ...

Page 32: ... Ballast Drawing 2986 INPUT 120V INPUT COMMON LAMP HOT LAMP COMMON GROUND COM GRN WHITE 5 POLE RECEPTACLE RED C1 24mF 480V BLACK WHITE RED ORANGE GREEN COLOR ORANGE BLACK 120V TRANSFORMER 1000W METAL HALIIDE BALLAST CAPACITOR CIRCUIT D i s c o u n t E q u i p m e n t c o m ...

Page 33: ...r hazardous conditions Allow extra distance for following and passing other vehicles Towing hitch is properly secured to tow vehicle Towing Checklist Use at each stop 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 California Proposition 65 Warning Battery post terminals and...

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