RL4000 Parts Manual-116444-08-05-2008 - k2dt.com

1 Parts ManualFirst EditionRev APart No. 116444 September 2008RL4000 Light TowerPart No. 116444 REV AiiImportantRead, understand and obey the safety rules andoperating instructions in the appropriate Operator'sManual on your machine before attempting anymaintenance mechanical, hydraulic and electricalskills are required to perform most , several procedures require specializedskills, tools, lifting equipment and a suitableworkshop. In these instances, we stronglyrecommend that maintenance and repair beperformed at an authorized TEREX dealerservice PublicationsTEREX Corporation has endeavored to deliver thehighest degree of accuracy possible. However,continuous improvement of our products is aTEREX policy. Therefore, product specificationsare subject to change without are encouraged to notify TEREX of errorsand send in suggestions for improvement.

2 Allcommunications will be carefully considered forfuture printings of this and all other 2008 by TEREX Corporation116444 Rev A September 2008 First Edition, Second Printing"TEREX" is a registered trademark of TEREXC orporation in the USA and many other countries."Super Quiet" is a trademark of TEREXC orporation. Printed on recycled paperPrinted in Number InformationTEREX Corporation offers the following manuals forthese models:TitlePart RL4000 Operator's manual ..116417 First EditionTEREX RL4000 Service manual ..116473 First EditionTEREX RL4000 part 's manual .. 116444 First EditionLeroy Somer manual ..116118 Kubota Engine manual ..893020 Axis manual ..116117 Marathon manual .. 2008 part No. 116444RL4000 Light TowerREV ASerial Number LegendThe serial number plate on your RL4000 is locatedon the cabinet next to the light tower to Read Your Serial 2008RL4000 Light TowerPart No.

3 116444 REV AThis page intentionally left 2008 part No. 116444RL4000 Light TowerREV AvDangerFailure to obey the instructions and safety rulesin this manual and the appropriate Operator'sManual on your machine will result in death orserious of the hazards identified in theoperator s manual are also safety hazardswhen maintenance and repair proceduresare Not Perform MaintenanceUnless:You are trained and qualified to performmaintenance on this read, understand and obey:- manufacturer s instructions and safety rules- employer s safety rules and worksiteregulations- applicable governmental regulationsYou have the appropriate tools, liftingequipment and a suitable RulesSection 1 Safety 2008RL4000 Light TowerPart No. 116444 REV ASAFETY RULESP ersonal SafetyAny person working on or around a machine mustbe aware of all known safety hazards.

4 Personalsafety and the continued safe operation of themachine should be your top each procedure thoroughly. Thismanual and the decals on the machine,use signal words to identify the following:Safety alert symbol used to alertpersonnel to potential personalinjury hazards. Obey all safetymessages that follow this symbolto avoid possible injury or used to indicate thepresence of an imminentlyhazardous situation which, if notavoided, will result in death orserious used to indicate thepresence of a potentiallyhazardous situation which, if notavoided, could result in death orserious with safety alert symbol used to indicate the presence of apotentially hazardous situationwhich, if not avoided, may causeminor or moderate without safety alertsymbol used to indicate thepresence of a potentiallyhazardous situation which, if notavoided, may result in used to indicate operationor maintenance sure to wear protective eye wear andother protective clothing if the situationwarrants aware of potential crushing hazardssuch as moving Parts .

5 Free swinging orunsecured components when lifting orplacing loads. Always wear approved SafetyBe sure to keep sparks, flames andlighted tobacco away from flammable andcombustible materials like battery gasesand engine fuels. Always have an approved fireextinguisher within easy sure that all tools and working areasare properly maintained and ready foruse. Keep work surfaces clean and free ofdebris that could get into machine components andcause sure that your workshop or work areais properly ventilated and well sure any forklift, overhead crane orother lifting or supporting device is fullycapable of supporting and stabilizing theweight to be lifted. Use only chains or straps thatare in good condition and of ample sure that fasteners intended for onetime use ( , cotter pins and self-lockingnuts) are not reused.

6 These componentsmay fail if they are used a second sure to properly dispose of old oil orother fluids. Use an approved be environmentally safe .viSection 1 Safety is your online resource for commercial and industrial quality equipment sales and rentals. We sell worldwide for the brands Genie, Terex, stihl , JLG, Multiquip, Mayco, Stone, Diamond Products, Airman, Mustang, Power Blanket. Locations: Florida (West Palm Beach) 561-964-4949 Outside Florida TOLL FREE: 877-690-3101 Need Parts ? Check out our website at Can t find what you need? Click on this link: and fill out t he request form. Make sure you have your machines model and serial number available in order to help us get you the correct Parts . One of our experienced staff members will get back to you with a quote for the right part that your machine 2008 part No.

7 116444RL4000 Light TowerREV ATable of ContentsIntroductionImportant Information - Introduction ..iiHow to Read Your Serial Stocking List ..ixHow to Order Parts ..xiService Parts Fax Order Form ..xiiSection 1 Safety RulesGeneral Safety Rules ..vSection 100 RevDecalsAFigure 100 - 2 Section 200 RevChassis ComponentsAFigure Tower Chassis .. 200 - 2 AFigure Tank Assembly ..200 - 4 Section 300 RevCabinet ComponentsAFigure 300 - 2 Section 400 RevElectrical ComponentsAFigure Control 400 - 2 AFigure Box 400 - 4 AFigure 400 - 6 AFigure Cord & Junction 400 - 2008RL4000 Light TowerPart No. 116444 REV ATABLE OF CONTENTSS ection 500 Rev Engine & GeneratorAFigure - 500 - 2 AFigure Generator - 6 kW .. 500 - 4 AFigure Somer Generator - 6 kW .. 500 - 6 Section 600 RevMast ComponentsAFigure 600 - 2 Section 700 RevOptionsAFigure 700 - 2008 part No.

8 116444RL4000 Light TowerREV AixParts Stocking ListRequired PartsThe following Parts are required to performmaintenance procedures as outlined in theTEREX RL4000 Parts and Service ModelsOil Filter ..866050 Air Filter ..866127 Fuel Filter .. 2008RL4000 Light TowerPart No. 116444 REV AxThis page intentionally left Section 100 DecalsPart No. 116444RL4000 Light Tower100 - 1 September 2008 Section 100 DecalsREV A100 - 2RL4000 Light TowerPart No. 116444 September 2008 Figure Section 100 DecalsREV APart No. 116444RL4000 Light Tower100 - 3 September 2008 FIGURE # Parts # : DECALS FOR MODEL 04000RL RITE LITE12850155 DECAL: DIESEL FUEL ONLY13CU51A112 DECAL: DANGER HOT EXHAUST14853316 DECAL: RL4000 W/STRIPE OP/BOTTOM "TALL15853792 DECAL: TEREX "X43"26CR51A101 DECAL:WARNING-IMPROPER : NOTICE-NO ETHER18C52100100 DECAL: 6519CU51A116 DECAL: TEREX POWER MOVING INSTRUCTION110CU51A111 DECAL: WARNING-BOOM DROP111CR51A101 DECAL:WARNING-IMPROPER :WARNING-IMPROPER 100 Decals100 - 4RL4000 Light TowerPart No.

9 116444 September 2008 This page intentionally left Section 200 Chassis ComponentsPart No. 116444RL4000 Light Tower200 - 1 September 2008 Section ASection 200 Chassis Components200 - 2RL4000 Light TowerPart No. 116444 September 2008 Figure Tower A Section 200 Chassis ComponentsPart No. 116444RL4000 LIght Tower200 - 3 September 2008 FIGURE # part # CABLE SET 24 4GA MBT TERM P&N R&B12Z112300 BATTERY WET 12V GR24 460 CCA STD-DUTY L/A13174170 BATTERY HOLD DOWN14182330 BATTERY HOLD DOWN ROD 1/4" X 10-1/4"25851820 DECAL, SYMBOL FOR GROUND16840222 JACK SNAP RING47841430 JACK SIDEWIND LONG 3 KLB48CR82C000 TRAILER BASE19841473 AXLE SHACKLE 4-5/8" LG 2000LB/3500LB410840394 AXLE SPRING BOLT 2000LB/3500LB611840395 AXLE SPRING NUT 2000LB/3500LB612CS62C012 OUTRIGGER LEG213721051 CAPLUG, TUBE PLUG 2-1/2" X 2-1/2"214C83100900 TIRE, ST175/80-13 LOAD B W/13" BLACK RIM215 CTRD-111 AHUB W/RACE/BEARINGS/NUTS/STUDS/CAP/WASHER216 C2201-DCDUST CAP FOR 2000LB AXLE217840376 AXLE WHEEL NUT 2000LB/3500LB1018C82100600 AXLE 2000LB, 36" SC119C82200104U-BOLT.

10 AXLE 2000LB420C33612 SPRING-LEAF SPRING-2000LB221111936 CHAIN SAFETY 3000LB 3/8" X 30" W/S-HOOK222CS82A020 TONGUE, B-O-H W/JACK BRACKET123CS62A011 OUTRIGGER HOUSING124CR51A102 DECAL, WARNING ALL OUTRIGGER125840120 COUPLER, 2", BOLT ON126851310 DECAL, WARNING ALL JACKS MUST BE SWIVELED327840221 JACK BRACKET SWIVEL WELD-ON128C61100200 WINCH, BRAKE, 1500LB W/HANDLE129930950 WEATHERSTRIP ADHESIVE 1/4" THK X 1/2" WIDE8FT30CU63B054 CABLE, TOWER TILT131CR21A000 TANK FUEL 30 GAL132C42200220RL FUEL CAP133CR59B035 FUEL TANK SUPPORT BRACKET13451600200 LATCH, OUTRIGGER235990150 NUT436990200 NUT, LOCK, NYLON INSERT237991650 WASHER, LOCK 1/2"438993860 WASHER, FLAT 1/2"239994200 SCREW, 1/2-13NC X 5-1/2"140995310 SCREW, 1/2-13NC X 4" ASection 200 Chassis Components200 - 4RL4000 Light TowerPart No. 116444 September 2008 Figure Tank A Section 200 Chassis ComponentsPart No.