Terex RL4000 User manual

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June 2013
RL4000 • TML-4000 Part No. 116694 ii
Important
Read, understand and obey the safety rules and
operating instructions in the appropriate
Operator's Manual on your machine before
attempting any maintenance procedure.
Basic mechanical, hydraulic and electrical
skills are required to perform most procedures.
However, several procedures require specialized
skills, tools, lifting equipment and a suitable
workshop. In these instances, we strongly
recommend that maintenance and repair be
performed at an authorized TEREX dealer
service center.
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 printings of this and all other manuals.
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.
Introduction
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June 2013
Part No. 116694 RL4000 • TML-4000
iii
Revision History
Revision Date Section Procedure / Schematic Page / Description
B 6/2013 6 - Schem. Updates and 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.
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June 2013
RL4000 • TML-4000 Part No. 116694
iv
REVISION HISTORY, CONTINUED
Revision Date Section Procedure / Schematic Page / Description
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.
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June 2013
Part No. 116694 RL4000 • TML-4000
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
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June 2013
RL4000 • TML-4000 Part No. 116694
Personal Safety
Any person working on or around a machine must
be aware of all known safety hazards. Personal
safety and the continued safe operation of the
machine should be your top priority.
Read each procedure thoroughly. This
manual and the decals on the machine,
use signal words to identify the following:
Safety alert symbol—used to alert
personnel to potential personal
injury hazards. Obey all safety
messages that follow this symbol
to avoid possible injury or death.
Red—used to indicate the
presence of an imminently
hazardous situation which, if not
avoided, will result in death or
serious injury.
Orange—used to indicate the
presence of a potentially
hazardous situation which, if not
avoided, could result in death or
serious injury.
Yellow with safety 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 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.
Do Not Perform Maintenance
Unless:
You are trained and qualified to perform
maintenance on this machine.
You read, understand and obey:
- manufacturer’s instructions and safety rules
- employer’s safety rules and worksite
regulations
- applicable governmental regulations
You have the appropriate tools, lifting
equipment and a suitable workshop.
Safety Rules
Section 1 • Safety Rules
vi
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June 2013
Part No. 116694 RL4000 • TML-4000
SAFETY RULES
Be sure to wear protective eye wear and
other protective clothing if the situation
warrants it.
Be aware of potential crushing hazards
such as moving parts, free swinging or
unsecured components when lifting or
placing loads. Always wear approved steel-toed
shoes.
Section 1 • Safety Rules
Workplace Safety
Be sure to keep sparks, flames and
lighted tobacco away from flammable and
combustible materials like battery gases
and engine fuels. Always have an approved fire
extinguisher within easy reach.
Be sure that all tools 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 straps that
are in good condition and of ample capacity.
Be sure that fasteners intended for one
time use (i.e., cotter pins and self-locking
nuts) are not reused. 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 .
vii
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June 2013
RL4000 • TML-4000 Part No. 116694
Table of Contents
Introduction
Important Information - Introduction .................................................................. ii
Revision History ................................................................................................ iii
How to Read Your Serial Number .................................................................... v
Section 1 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 .................................................................................................. 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
Troubleshooting Guide ................................................................................ 4 - 2
viii
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June 2013
Part No. 116694 RL4000 • TML-4000
TABLE OF CONTENTS
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
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