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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Section 2 • Specifications
Part No. 116694 RL4000 • TML-4000 2 - 1
June 2013
Specifications
Model - RL4000 & TML-4000
Height, stowed 5 ft 9.5 in 1.765 m
Length, stowed 14 ft 2 in 4.331 m
Width, stowed 4 ft 6 in 1.372 m
Extended tower height 30 ft 9.114 m
Weight 1725 lbs 783 kg
(Machine weights vary with option configurations. See
serial label for specific 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 speed 60 mph 97 km/h
Maximum wind speed rating 62 mph 100 km/h
Sound level (dba rating) 71 dba @ 23 ft / 7 m
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Section 2 • Specifications
2 - 2 RL4000 • 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
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Section 2 • Specifications
Part No. 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
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Section 2 • Specifications
2 - 4 RL4000 • TML-4000 Part No. 116694
June 2013
SPECIFICATIONS
10.9 12.98.8
4.6
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Section 3 • Scheduled Maintenance Procedures
Part No. 116694 RL4000 • TML-4000 3 - 1
June 2013
Scheduled Maintenance Procedures
Observe and Obey:
Maintenance inspections shall be completed by
a person trained and qualified on the
maintenance of this machine.
Scheduled maintenance inspections shall be
completed as specified using the supplied
Lubrication and Maintenance Service Interval
Charts provided in this section .
Failure to perform each procedure
as presented and scheduled could
result in death, serious injury or
substantial damage.
Immediately tag and remove from service a
damaged or malfunctioning machine.
Repair any machine damage or malfunction
before operating the machine.
Keep records on all inspections for three years.
Machines that have been out of service for a
period longer than 3 months must complete the
quarterly inspection.
Unless otherwise specified, perform each
maintenance procedure with the machine in
the following configuration:
• Machine parked on a firm, level surface
• Toggle 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 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.
Indicates that a specific result is expected after
performing a series of steps.
Indicates that an incorrect result has occurred
after performing a series of steps.
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Pre-DeliverPre-Deliver
Pre-DeliverPre-Deliver
Pre-Delivery Preparationy Preparation
y Preparationy Preparation
y Preparation
Pre-Delivery Preparation Y N R
Pre-operation inspection completed
Maintenance items completed
Function tests completed
Model
Serial number
Date
Machine owner
Inspected by (print)
Inspector signature
Inspector title
Inspector company
Instructions
Use the operator’s manual on your machine.
The Pre-delivery Preparation consists of completing the
Pre-operation Inspection, the Maintenance items and the
Function Tests.
Use this form to record the results. Place a check in the
appropriate box after each part is completed. Follow the
instructions in the operator’s manual.
If any inspection receives an N, remove the machine from
service, repair and re-inspect it. After repair, 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 machine must never be used. If
damage or any variation from factory delivered condition
is discovered, the machine must be tagged and removed
from service.
Repairs to the machine may only be made by a qualified
service technician, according to the manufacturer's
specifications.
Scheduled maintenance inspections shall be performed
by qualified service technicians, according to the
manufacturer's specifications and the requirements listed
in the responsibilities manual.
Copyright © 2006 by TEREX Corporation. TEREX® is a registered trademark of TEREX USA,
LLC.
Rev C
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Section 3 • Scheduled Maintenance Procedures
Part No. 116694 RL4000 • TML-4000 3 - 5
June 2013
Maintenance Schedules
ITEM Every 50
Hours
Every
100
Hours
Every
200
Hours
Every
400
Hours
Every
500
Hours
Every
Year
Every
800
Hours
Every
1500
Hours
Every
3000
Hours
Every
Two
Years
Check of fuel pipes and clamp bands •
Check engine oil and coolant level •
Cleaning of air cleaner element •
Check of battery electrolyte level •
Check of fan belt tightness •
Check of radiator hoses and clamp
bands •
Check of intake air line •
Replacement of oil filter cartridge •
Replacement of fuel filter cartridge •
Removal of sediment in fuel tank •
Cleaning of water 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 •
Replacement of fuel pipes and clamp
bands •
Replacement of intake air line •
Kubota Lubrication and Maintenance Service Intervals
*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.
Kubota Engine Manual
Genie part number 893020
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Section 3 • Scheduled Maintenance Procedures
3 - 6 RL4000 • TML-4000 Part No. 116694
June 2013
MAINTENANCE SCHEDULES CONTINUED
ITEM Daily Every 50
Hours
Every
250
Hours
Every
500
Hours
Every
1000
Hours
Every
2000
Hours
Every
3000
Hours
Every
6000
Hours
Every
12000
Hours
Cooling system coolant level - check •
Driven equipment - check •
Engine air cleaner service indicator -
inspect •
Engine air precleaner - check/clean •
Engine oil level - check •
Fuel system primary filter/water
separator - drain •
Walk around inspection •
Fuel tank water and sediment - drain •
Alternator and fan belts -
inspect/adjust •
Fuel 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 - inspect •
Engine crankcase breather - replace •
Engine mounts - inspect •
Starter motor - inspect •
Fuel injector - test/change •
Water pump - inspect •
Cooling system coolant (commercial
heavy-duty) - change •
Cooling system coolant extender
(ELC) - add •
C
oo
li
ng sys
t
em coo
l
an
t
(ELC)
-
change •
Perkins Lubrication and Maintenance Service Intervals
Perkins Operations Manual
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Section 3 • Scheduled Maintenance Procedures
Part No. 116694 RL4000 • TML-4000 3 - 7
June 2013
MAINTENANCE SCHEDULES CONTINUED
ITEM DAILY 200 Hours 10000
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. •
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 number 116188
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Section 4 • TroubleshootingJune 2013
Part No. 116694 RL4000 • TML-4000 4 - 1
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.
Be aware of the following hazards and follow
generally accepted safe workshop practices.
Electrocution/burn hazard.
Exposure to electrically charged
circuits could result in death or
serious injury. Remove all rings,
watches and other jewelry.
Electrocution/burn hazard.
Attempting to sevice the machine
before the capacitors are fully
discharged will result in death or
serious injury.
High voltage. Exposure 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:
Troubleshooting and repair procedures shall be
completed by a person trained and qualified on
the repair of this machine.
Immediately tag and remove from service a
damaged or malfunctioning machine.
Repair any machine damage or malfunction
before operating the machine.
Unless otherwise specified, perform each
repair procedure with the machine in the
following configuration:
• Machine parked on a firm, level surface.
• Wheels chocked.
• Toggle switch in off position.
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