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Terex RL4000D2, Operator, Service & Parts Manual

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Terex RL4000D2 Operator, Service & Parts Manual Download Page 47

November 2006

46

RL4000  

Light  

Tower

Part  

No.  

833005  

Rev  

A

This manual contains parts ordering information for the Terex RL 4000 light tower.

IDENTIFICATION of PARTS

 All parts are identified with a part number and brief description.  If there are multiple

quantities of the part required, the quantity required will be shown along with part num-
ber and description.  If no quantity is given it is assumed that there is only one part
required.

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.

ILLUSTRATIONS

The illustrations in this manual are intended to show typical construction of the various
parts.  In some instances the shapes or details of the parts illustrated may not exactly
represent their actual appearance.  However, they will serve to show the servicing
methods explained or help to identify parts performing the same function.

INTRODUCTION

GENERAL INFORMATION-PARTS MANUAL

Summary of Contents for RL4000D2

Page 1: ...RTS RTS MANUA MANUAL L Series Series RL400 RL4000D2 0D2 Light Tower Light Tower P P O BOX O BOX 3147 3147 ROCK HILL S C 29732 USA ROCK HILL S C 29732 USA PART NUMBER 833005 PART NUMBER 833005 REVISION...

Page 2: ...r Iden Identific tificatio ation n 33 33 Recome RecomendedOil ndedOil 34 34 WireRope WireRope Replac Replacement ement 35 36 35 36 PARTS MANUAL PARTS MANUAL Wiring Wiring Diagrams Diagrams 38 43 38 43...

Page 3: ...r Iden Identific tificatio ation n 33 33 Recome RecomendedOil ndedOil 34 34 WireRope WireRope Replac Replacement ement 35 36 35 36 PARTS MANUAL PARTS MANUAL Wiring Wiring Diagrams Diagrams 38 43 38 43...

Page 4: ...MANUAL A WORKING PART OF YOUR SAFETY PROGRAM A WORKING PART OF YOUR SAFETY PROGRAM An operator should never An operator should never use drugs alcohol use drugs alcohol or any other subst or any other...

Page 5: ...AGE UNDERSTANDING SIGNAL WORDS A signal word DANGER WARNING or CAUTION is used with the safety alert symbol DANGER Identifies the hazard or unsafe practice that will result in severe injury or death W...

Page 6: ...ing and safety equipment Always wear approved safety equipment such as gloves safety boots safety hard hat goggles ear protection and dust masks when necessary Wear protective clothing that is snug an...

Page 7: ...NAL INJURY OR MACHINE DAMAGE Prevent fires by keeping the light tower and its surrounding area clean DO NOT refuel while smoking or when near open flame or sparks DO NOT refuel the engine when it is h...

Page 8: ...is bonded to the equipment frame Ground wires within the system are also bonded to the equipment frame Always ground the unit when possible A grounding lug has been added to the trailer frame for your...

Page 9: ...immediately flush under running water and obtain medical attention METAL HALIDE LAMPS PRODUCE SHORTWAVE ULTRAVIO LET RADIATION AND CAN CAUSE SERIOUS SKIN AND EYE BURNS OR INFLAMMATION IF THE OUTER EN...

Page 10: ...hing is in danger of falling off during transit Be careful when lifting Never suspend any other equipment from the shipping tie downs BEWARE OF TRAFFIC HAZARDS Use the lifting eye or forklift pockets...

Page 11: ...ration Check the outriggers for security and proper operation Check that the tires are not damaged under inflated or that any lugs are loose Check the engine generator for obvious damage loose connect...

Page 12: ...ck into its stowed position 4 Check the tires for proper inflation 32psi and verify the lug nuts are tight 5 Position all outriggers and jacks into the stowed or travel position 6 Verify that the fixt...

Page 13: ...an incline C Disconnect the towing chain D Unhitch from the towing vehicle as follows 1 Rotate the tongue jack into position 90 degrees release the hitch pin and raise the tongue off the towing vehic...

Page 14: ...xture is down 3 Set the vertical aim for each light fixture by adjusting the light fixtures and tightening the nuts Never adjust fixtures with power on 4 Set the spread between the fixtures horizontal...

Page 15: ...tower base If there is any difficulty in tilting the boom vertically check the tailhook and hook The tailhook may need to be released BEWARE OF PINCH POINTS WHEN ERECTING OR STOW ING THE TELESCOPING T...

Page 16: ...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 3 Release th...

Page 17: ...s damage may be done to the heating elements 5 Turn the switch towards the start side of the switch On most units this is towards the right To avoid start damage never operate the starter for more tha...

Page 18: ...er SHUTDOWN PROCEDURES 1 Place all light switches into their OFF position 2 Allow the engine to run for 1 to 5 minutes under no load then turn the unit OFF Never shut the unit down while under load Th...

Page 19: ...n located on tower base 5 Using the lower pivot winch lower the tower into the cradle 6 Verify that the tailhook is latched or hooked over the tower cradle This prevents the tower sections from telesc...

Page 20: ...ant levels and fill as required Note Use a 50 solution of water and antifreeze for the engine coolant Weekly Check the air cleaner and clean as required Inspect the radiator fins for damage or cloggin...

Page 21: ...RY OR DEATH BY ELECTRIC SHOCK Exterior Cleaning 1 The exterior housing may be washed by most conventional cleaners and methods 2 The exterior housing may be waxed using any conventional automotive wax...

Page 22: ...s Before each use check the brake friction discs for wear If less than 1 16 thick cracked or broken replace IMMEDIATELY Ratchet pawl should click when tower is raised and not when it is lowered Always...

Page 23: ...November2006 22 RL4000LightTower Part No 833005 Rev A SPECIFICATIONS DIMENSIONS...

Page 24: ...h with fenders 54 1372 mm Overall width with outriggers pulled out 126 3200 mm Trailer frame width 38 965 mm Tongue length 62 5 1588 mm Wheel size 13 330mm Axle Rating 2000 lb 907 kg Tongue weight tra...

Page 25: ...23 2190 2969 2670 3620 3560 4826 3000 4067 5 16 3 8 7 16 1 2 1 5 9 16 5 8 3 4 7 8 1 1 125 1 25 LUBED 1 4 LUBED DRY LUBED DRY LUBED DRY LUBED SAE FASTENER TORQUE CHART Grade 5 DRY LUBED This char t is...

Page 26: ...Open telescope lock pin 3 Engine will 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 a...

Page 27: ...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...

Page 28: ...Wrong voltage 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...

Page 29: ...systematically operating only one section at a time 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 ball...

Page 30: ...ow these steps STEP1 Insure all ballasts which are numbered are plugged into lead wires with corresponding numbers STEP 2 Looking at the lights from the glass side and following the diagram below plug...

Page 31: ...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 TEREX LIGHT CONSTRUCTION warranty reimburs...

Page 32: ...only to the warranty of their respective manufacturers TLC makes no other warranty express or implied and makes no warranty of merchantability or fitness for any particular purpose This warranty shal...

Page 33: ...X 803 366 1101 When returning parts for credit please contact the factory for Return of Goods Authorization Terex Model Number _______________________ Serial Number ____________________ Engine Model N...

Page 34: ...November2006 Part No 833005 Rev A RL4000LightTower 33 MODEL NUMBER IDENTIFICATION...

Page 35: ...ratures a compromise must be struck and a higher viscosity oil used Multi grade oils overcome the problem provided they possess a suitable specification 2 MIL L 2104B or MIL L 2104C orAPI CD must also...

Page 36: ...ced every two years of service NORMAL INSPECTION The wire ropes are constructed of 7 strands of 19 plow steel wires each twisted together and then the assembly galvanized to resist corrosion Using a w...

Page 37: ...p through the hole on the bottom of the second stage boom tube with the crimped end at the bottom and lay the cable along the length of the tube as shown here 2 Slide the second stage boom tube into t...

Page 38: ...November 2006 Part No 833005 Rev A RL4000 Light Tower 37 Wiring Diagrams Section...

Page 39: ...November 2006 38 RL4000 Light Tower Part No 833005 Rev A Fixture Wiring Diagram...

Page 40: ...November 2006 Part No 833005 Rev A RL4000 Light Tower 39 1000MH Ballast Diagram...

Page 41: ...November 2006 40 RL4000 Light Tower Part No 833005 Rev A 1000HPS Ballast Diagram...

Page 42: ...November 2006 Part No 833005 Rev A RL4000 Light Tower 41 AC Wiring For A Light Tower Diagram...

Page 43: ...November 2006 42 RL4000 Light Tower Part No 833005 Rev A DC Engine Wiring Diagram...

Page 44: ...November 2006 Part No 833005 Rev A RL4000 Light Tower 43 Consolidated Coil Cord With Plug End...

Page 45: ...November 2006 44 RL4000 Light Tower Part No 833005 Rev A This page intentionally left blank...

Page 46: ...November 2006 Part No 833005 Rev A RL4000 Light Tower 45 Parts Catalog Section...

Page 47: ...nd 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 c...

Page 48: ...1 Send your order to the nearest Terex distributor in your area 2 Give the light tower model and serial number 3 Write the quantity required part number and description of the parts wanted 4 Give the...

Page 49: ...November 2006 48 RL4000 Light Tower Part No 833005 Rev A This page intentionally left blank...

Page 50: ...NGER HOT EXHAUST 1 4 853316 DECAL RL4000 W STRIPE OP BOTTOM 2 25 TALL 1 5 853792 DECAL TEREX 4 5 X43 2 6 CR51A101 DECAL WARNING IMPROPER GROUNDING 1 7 CU51A102 DECAL NOTICE NO ETHER 1 8 C52100100 DECA...

Page 51: ...November 2006 50 RL4000 Light Tower Part No 833005 Rev A FRAME ASSEMBLY...

Page 52: ...2 2 14 C83100900 TIRE B78 13B W 13 BLACK RIM 2 15 CTRD 111A HUB W RACE BEARINGS NUTS STUDS CAP WASHER 2 16 C2201 DC DUST CAP FOR 2000LB AXLE 2 17 840376 AXLE WHEEL NUT 2000LB 3500LB 10 18 C82100600 A...

Page 53: ...November 2006 52 RL4000 Light Tower Part No 833005 Rev A CABINET ASSEMBLY...

Page 54: ...KEYS 2 10 C42200203 DOOR HANDLE KEYS 2 11 C83400100 FENDER 2 12 CR56C050 CABINET UNDERDOOR PANEL RS 1 13 C51500200 PROP DOOR 10 TELESCOPIC 4 14 930950 WEATHERSTRIP ADHESIVE 1 4 THK X 1 2 WIDE 14FT 15...

Page 55: ...November 2006 November 2006 5 54 4 R RL L4 40 00 00 0 L Li ig gh ht t T To ow we er r P Pa ar rt t N No o 8 83 33 30 00 05 5 R Re ev v A A TOWE TOWER A R ASSEMBLY SSEMBLY...

Page 56: ...T TO OW WE ER R 1 1 1 11 1 C CU U5 51 1A A1 10 03 3 D DE EC CA AL L A AV VO OI ID D B BO OO OM M S SW WI IN NG G 1 1 1 12 2 C CR R5 51 1A A1 10 07 7 D DE EC CA AL L A AL LI IG GN N A AR RR RO OW WS S...

Page 57: ...November 2006 November 2006 5 56 6 R RL L4 40 00 00 0 L Li ig gh ht t T To ow we er r P Pa ar rt t N No o 8 83 33 30 00 05 5 R Re ev v A A ELECTRICAL CONTROL BOX ELECTRICAL CONTROL BOX...

Page 58: ...ONNECTOR 2 SCREW 1 25 1 16A included with item 16 17 709032 TERMINAL CLOSED END 2 18 680060 WRAP CAP 1 19 680290 CRIMP SLEEVE 1 20 116770 WIRE HARNESS 1 21 680250 LOCKNUT CONDUIT 3 4 1 22 663890 CORD...

Page 59: ...4 663870 CONNECTOR 3P FEMALE 4 5 663880 DUST CAP W CHAIN 4 6 C48300108 JUNCTION BOX 1 7 680190 BOX COVER 2GANG W GASKET 1 8 852800 DECAL CAUTION TIGHTEN FIXTURE CONNECTOR 1 9 680080 GRIP HUBBLE 1 10...

Page 60: ...DECAL DANGER HIGH VOLTAGE 4 2 851691 DECAL 1 4 3 851692 DECAL 2 4 4 851693 DECAL 3 4 5 851694 DECAL 4 4 6 189346 BALLAST SPACER 4 7 160030 BALLAST TRANSFORMER 4 8 160032 CAPACITOR 24uF MH 60Hz 4 9 66...

Page 61: ...November 2006 60 RL4000 Light Tower Part No 833005 Rev A FIXTURE ASSEMBLY...

Page 62: ...NG FOR REFLECTOR 1 15 990675 RIVET POP 1 8X 390 GR 1 4 5 16 2 16 833524 LENS W GASKET 1 17 833543 CLAMP LENS TO REFLECTOR 1 18 833574 SCREW 8 32X1 HH SLOT 1 19 833581 WASHER FIBER FOR BAND 1 20 833578...

Page 63: ...CLEANER ASSEMBLY 1 5 866126 AIR CLEANER BODY 1 6 866127 AIR CLEANER ELEMENT 1 7 866128 AIR CLEANER COVER 1 8 866129 AIR CLEANER VALVE 1 9 866050 OIL FILTER 1 10 740620 FUEL FILTER IN LINE 5 16 1 11 83...

Page 64: ...0 Light Tower 63 RADIATOR ASSEMBLY ITEM PARTS DESCRIPTION QTY 1 866114 RADIATOR 1 2 866120 CAP FOR RADIATOR 1 3 839109 HOSE TOP 1 4 839110 HOSE BOTTOM 1 5 866113 FAN GUARD 1 6 865307 COOLANT RECOVERY...

Page 65: ...RADE 5 ZP 2 2 990210 WASHER FLAT 1 2 4 3 990415 WASHER FLAT SNUBBER 2 4 740925 VIBRATION MOUNT 30 DUR 2 5 740770 VIBRATION MOUNT 35 LB 2 6 124015 ENG FT RAD SUPPORT ROADSIDE D1105 LSA36 shown 1 7 1240...

Page 66: ...245 1 4 836707 TOP COVER 1 5 836708 END CAP 1 6 836709 FAN 1 7 836710 TERMINAL BLOCK 1 8 836711 CAPACITOR 22 5mf two per unit required 2 9 996290 SCREW M10 X 1 5 X 90MM HHC GRADE 8 8 ZP 1 10 990415 WA...

Page 67: ...R 2 BOLT ON 1 3 176336 COMBO HITCH SIDE SPACER 2 4 176335 COMBO HITCH SIDE PLATE 2 5 840470 BALL 2 1 6 121572 COMBO HITCH RING 16 LONG 1 7 213770 RING HITCH BOLT ON 2 1 2 ID 1 8 124450 ADJUSTABLE HEIG...

Page 68: ...P SPARE TIRE BRKT TONGUE MNT 2 3 C83100900 TIRE B78 13B W 13 BLACK RIM 1 4 160530 BATTERY BLANKET THERMO 284 4001 36 LG 1 5 C41101100 LIGHT DOME WITH SWITCH 1 6 741690 FUEL LINE HEATER DIESEL 12V 150W...

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