RL4000D2 LIGHT TOWER
Contents
1. 38 965mm 61 1 2 54 1562mm 1372mm 71 124 126 3150mm 3200mm OPERATING POSITION 22 RL4000 Light Tower Part No 833005 Rev A November 2006 TEREX SPECIFICATIONS amp DIMENSIONS TEREX model RL4000 series light tower provides mobile trailer mounted floodlighting for night time maintenance construction mining and emergency work It consists of a trailer with a diesel powered 6 kW 60Hz 50 Hz units available generator and a 30 foot cable actuated tower with four 4 1000 watt floodlight fixtures It is ideally suited for heavy duty use and is built to meet the following specification DIMENSIONS Overall length travel position w fixtures amp tongue 170 5 4331 mm Overall length tower vertical w tongue amp jacks 124 3150 mm Trailer frame length 61 5 1562 mm Overall height floodlighting position 30 9114 mm Overall height travel position 69 5 1765 mm Overall width with fenders 54 1372 mm Overall width with outriggers pulled out 126 8200 mm Trailer frame width 38 965 mm Tongue length 62 5 1588 mm Wheel size 13 330mm Axle Rating 2000 Ib 907 kg Tongue weight travel position 130 Ib 59 kg Total weight no fuel 1760 Ib 798 kg Fuel Capacity 30 gal 114 kg Unit weight with full fuel tank 1960 Ib 888 kg Max High2. HOLVH3N39 9 Nid HOLVH3N3O Lev TIV8 Y3MOd OVAOZZ Z Nid L Nid HOLO3NNOO 13S 9305 S 91n JlOd S ALdW3 2 ALdW3 8 m 9 m 2 Y Nid o z m A NONA H0103NN09 Nid 6N Y 310d v 319V19V4 138 MOLONJONODL rk NHO E LSVTIVd ania 4 TAA ALIHM 5 ge E a m 3 ISYTIVA L Xog 319V1d3938 e 0 9 Adve SHON TOAINOD a MO103NNOO 01 1 io ose voz LSYTIVA MOLVMJNJO JO 931 1V8LN3N OL YOVS3N39 ANNOYS OL 3335 1 MOLVNJNJO JO SGISNI 931 OL MOIVNJNJO JO 931 OL 9r wy 1 41 RL4000 Light Tower Part No 833005 Rev A Novembe
3. SLINANOdNOD 3NION3 1 Part No 833005 Rev A RL4000 Light Tower 42 ij TEREX idated Coil Cord With Plug End Consol 09 NO HO LO3NNOO ONA NO 13M9VYr YALNO 440 ul 414158 c C 409 MOV 18 f Nid H 9 MOTNA 3 3018 NMOX8 Alda NJJAO V Nid YOLOANNOD Nid 6 S96 6 9 HOS LN3G 5 0 071213 JA LSNW SNOILO3NNOO 9 ONIM OV3YHL DILSVId M HOLO3NNOO 3 VIN vL HOLOnNOO 6 WON 8407 SS3NMOIH L TIVM YINOLSVI3 DILSVIdONAAHL LANADOT Z L 020089 alvid OVAHMINA 01028542 Z lddiN 3SVHO Z l 08 289 3SVHO v 07 589 43 RL4000 Light Tower November 2006 1 Y3LNO OILSVIdOWYIHL 1 tr 052089 NOLLVINSNI YOLONGNOD 4 97 das 0897 MONIA 4095 HOlVuvd3s mA L 052 11 11 HLONJI 0319W8138 9 5 re HLON37 9NDIHOM 0 92 Part No 833005 Rev A November 2006 TEREX This page intentionally left blank 44 RL4000 Light Tower Part No 833005 Rev A November 2006
4. 56 Coil Cord and Junction BOX fM 58 A 59 Fikture Assembly a 60 Engine Genset Assembly 62 Radiator Assembly 63 Engine Radiator Mounting Bracket 64 Generator Mounting Bar ani 65 01 52 66 Do 67 68 2 RL4000 Light Tower Part No 833005 Rev A November 2006 TEREX TO THE OPERATOR DO NOT ATTEMPT TO SETUP OPERATE OR WORK ON THE LIGHT TOWER UNLESS YOU HAVE READ AND STUDIED THIS MANUAL AND THE ENGINE AND GENERATOR MANUALS CAREFULLY READING THESE MANUALS WILL TEACH YOU HOW TO SAFELY SETUP OPERATE AND PROPERLY MAINTAIN THE TOWER AND ITS COMPONENTS REMEMBER THAT YOU ARE THE KEY TO SAFETY GOOD SAFETY PRACTICES NOT ONLY PROTECT YOU BUT ALSO THOSE WORKING AROUND YOU MAKE THIS MANUAL A WORKING PART OF YOUR SAFETY PROGRAM An operator should never use drugs alcohol or any other substance which can change his alertness or coordination Do not work on this equipment when mentally or physically fatigued This manual is compiled from information available and current at time of approval for printing Terex reserves the right to improve its products without giving prior notice or incurring any obliga tion If this manual becomes lost order a new on
5. TEREX NENNEN OPERATOR SERVICE amp PARTS MANUAL Series RL4000D2 Light Tower PART NUMBER 833005 REVISION A November 2006 TOLL FREE 800 433 3026 P O BOX 31 FAX Parts Dept 800 633 5534 ROCK HILL S C 29732 USA November 2006 TEREX TABLE OF CONTENTS OPERATOR S MANUAL TO 3 Safety Alert Symbols 4 General Safe 5 9 Receipt of Delivery Checklist teens 10 Elie TWIN eri De ee 11 SOLID M MEME 12 15 Operating Instructions pa tica 16 18 Maintenance PP 19 21 Specifications and Dimensions s s seve cenene priora er tne xU naa rv ck 22 23 Torque Specifications Pet 24 cl 25 29 e e oo A 30 31 Serial Number Record es 32 Model Number Identification sosa 33 Recomended 8 Mec m 34 Wire Rope Replacement sesos 35 36 PARTS MANUAL Winnog Diagrams NET 38 43 General Information Parts Manual escocia 46 Parts COPS o 47 81 18 11 i A 49 Frame Assembly 50 Cabinet PP 52 TEA SS MON ee A 54 Electrical Control BOX
6. 4 Part No 833005 Rev RL4000 Light Tower 53 November 2006 TEREX TOWER ASSEMBLY Part No 833005 Rev A RL4000 Light Tower 54 November 2006 TEREX 4 PARTA DESCRIPTION JUNCTION BOX WITH QUICK CONNECTIONS COIL CORD COVER SLEEVE WIRE GUIDE BRACKET BOLT TEE 1 2 20NF SPRING KICKOUT TOWER BASE TOWER 4 SECTION TOWER 3 SECTION TOWER 2 SECTION SWIVEL BOOM TOWER DECAL AVOID BOOM SWING DECAL ALIGN ARROWS BEFORE LOWERING WINCH BRAKE 1500LB W HANDLE CROSSHEAD DECAL WARNING TAIL HOOK MUST BE PROPERLY DECAL LIFT HERE W ARROW CABLE UPPER EXTEND 19 DECAL CAUTION LAMPS GET HOT SLIDE BLOCK TOWER GUIDE RIVET POP 1 4 X 1 2 CABLE LOWER EXTEND 11 PULLEY 3 o gt a m m m m m m m m m m m m 1 1 Part No 833005 Rev A RL4000 Light Tower 55 November 2006 ELECTRICAL CONTROL BOX TEREX ff 2 2 38 Complete Control Box 37A Kubota Solenoid Pigtail 37 Wiring Harness Part No 833005 Rev A RL4000 Light Tower 56 November 2006 TEREX 4 PARTE DESCRIPTION 5 DECAL AL RL CONTROL BOX AC POWER amp LIGHT BREAKER 2P 30A 240V CONTROL BOX FACE PLATE TERMINAL RING BREAKER 1P 15A 277VAC RECEPTACLE 20A 120 DUPLEX W GFI
7. BALLASTS ENGINES HYDRAULIC PUMPS FUEL PUMPS ALTERNATORS GENERATORS WINCHES TIRES AND ELECTRICAL COMPONENTS Accessories assemblies and components included in products of TLC which are not manufactured by TLC are subject 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 shall not cover misuse alteration abuse negligence accident acts of God sabotage or any item in which serial numbers have been altered defaced or removed but shall be limited to repair or replacement of those parts which upon inspection by TLC appear to have been defective in material or workmanship TLC s liability and Buyer s sole and exclusive remedy for a failure of goods to perform as warranted and or for any and all other claims arising out of the purchase and use of the goods including negligence on the part of TLC shall be limited to the repair or replacement of defective parts returned transportation prepaid to TLC TLC shall in no event be liable for incidental or consequential or other damages or losses resulting from a breach of warranty such as but not by way of limitation labor costs loss of profits loss of use of other than equipment third party repairs personal injury emotional or mental distress improper performance of work penalties of any kind loss of service of personnel or any other damages o
8. Nm in ibs Nm in Ibs Nm Nm in ibs Nm 5 6 i 407 69 7 87 93 105 100 11 3 132 15 7 3 6 83 116 1 95 An anti seize lubricant MUST be used on all stainless steel hardware 24 RL4000 Light Tower Part No 833005 Rev A November 2006 TEREX TROUBLESHOOTING The engine and generator are set at the factory These units are tested and set to 1800 RPM at 60 HZ for proper operation in the field These units should never require additional adjustments in the field Adjustments should only be made by a qualified service technician otherwise the manufacturer s warranty may become void TROUBLE POSSIBLE CAUSE REMEDY 1 Boom will not rise to the operating position b Defective cable b Have a trained or pulley mechanic examine and repair as needed c Defective winch c Have a trained and replace as needed 2 Boom will not telescope a Defective winch a Have a trained and replace as needed b Broken cable or pulley b Have a trained and replace as needed c Telescope lock pin closed c 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 as needed 4 Engine turns over but will a Empty fuel tank a Fill tank with 2 diesel fuel system as needed _ of prime and tighten connections d Heater elements burned out d Replace heater eleme
9. TEREX Parts Catalog Section Part No 833005 Rev A RL4000 Light Tower 45 November 2006 TEREX GENERAL INFORMATION PARTS MANUAL INTRODUCTION 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 46 RL4000 Light Tower Part No 833005 Rev A November 2006 TEREX PARTS ORDERING INFORMATION IMPORTANT When a part fails and needs to be replaced only use equivalent parts of equal perfor mance and strength Contact your local Terex dealer for parts and service When ordering parts for a
10. 0 SAE 10W SAE 10W 30 Use 2 diesel fuel NOTES 1 The temperatures in the table are the ambient temperatures at the time when the engine is started If the running ambient temperatures are much higher than the starting tem peratures 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 or API CD must also be used if the sulfur content of the fuel exceeds 0 5 3 Always use a reputable brand of diesel fuel The sulfur content should be below 0 5 higher sulfur content would require more frequent oil changes Observe strict cleanli ness when filling the fuel tank 4 Check the engine oil level before starting the engine or more than five minutes after it has been stopped Remove the dipstick wipe clean reinsert it take it out again and check the oil level If the oil level is too low remove the oil filler cap and add new oil until the FULL line on the dipstick is reached 34 RL4000 Light Tower Part No 833005 Rev A November 2006 TEREX WIRE ROPE REPLACEMENT CRITERIA FOR REPLACEMENT OF WIRE ROPE TEREX LIGHT TOWERS The wire ropes used to raise and lower the masts on a TEREX Light Tower are probably some of the most important mechanical parts used in day to day operation of the machinery It is there fore very important that the cables be inspected on a frequent basis once a month f
11. 1 1 2 1 1 1 1 1 1 1 4 1 2 1 2 1 1 1 1 1 1 2 1 Part No 833005 Rev A RL4000 Light Tower 61 TEREX November 2006 ENGINE GENSET ASSEMBLY KUBOTA D1105 All items listed are service parts that Terex stocks Additional engine parts breakdowns are available through the Service and Sales Department KUBOTA D1105 ENGINE POWERPACK BUILD EBG2 LOW OIL PRESSURE SWITCH HIGH TEMPERATURE SWITCH AIR CLEANER ASSEMBLY AIR CLEANER BODY FUEL FILTER IN LINE 5 16 FUEL FILTER ASSEMBLY ELEMENT FUEL PUMP 2 WIRE STOP SOLENOID V BELT WATER PUMP FAN PUSHER 62 RL4000 Light Tower Part No 833005 Rev A November 2006 TEREX RADIATOR ASSEMBLY 98 5 ei 3 ios Coolant Overflow RADIATOR CAP FOR RADIATOR HOSE TOP HOSE BOTTOM FAN GUARD COOLANT RECOVERY TANK HOSE FUEL 1 4X1 2 2004 Part No 833005 Rev A RL4000 Light Tower 63 November 2006 TEREX ENGINE RADIATOR MOUNTING BRACKET 6 Roadside 7 Curbside ITEM PART DESCRIPTION ENG FT RAD SUPPORT ROADSIDE D1105 LSA36 shown ENG FT RAD SUPPORT CURBSIDE D1105 LSA36 not shown ENGINE RISER 2 75 HIGH FOR 1 2 BOLT NUT LOCK NYLON INSERT 1 2 13NC GR 2 ZPIN F 64 RL4000 Light Tower Part No 833005 Rev A November 2006 GENERAT
12. 1 Remove the light fixtures from their packing boxes and install them on the crossarm with the lens facing upward as shown above 2 The cord on the fixture should be on the side closest to the trailer so the cord entry is beneath the fixture when the tower is raised this reduces moisture problems and insures the water weep hole in the fixture 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 horizontally by adjusting the fixtures and tighten ing the mounting nut 5 The light fixtures may be left on the unit when towed around the job site 6 Plug each fixture into the receptacles provided Plug into the numbered receptacles in a clockwise rotation starting at the upper or 1 00 o clock position This makes trouble shooting easy without lowering the tower ACAUTION If Tungsten Halogen lamps are used the cord must be routed and secured away from the fixture Failure to do so may result in cord burn through and short circuit due to the high fixture temperature Part No 833005 Rev A RL4000 Light Tower 13 November 2006 TEREX SETUP H Raising the tower as follows 1 Remove the tower travel locking pin from the cradle at the rear of the cabinet 2 Remove the tower locking pin from the tower base Using the lower pivot winch raise the tower to the vertical position
13. 2 25 TALL DECAL TEREX 4 5 X43 DECAL WARNING IMPROPER GROUNDING DECAL NOTICE NO ETHER DECAL CALIF PROP 65 DECAL TEREX POWER MOVING INSTRUCTION DECAL WARNING BOOM DROP DECAL WARNING IMPROPER GROUNDING DECAL WARNING IMPROPER GROUNDING yd TEREX Part No 833005 Rev A RL4000 Light Tower 49 November 2006 TEREX FRAME ASSEMBLY 50 RL4000 Light Tower Part No 833005 Rev A November 2006 TEREX 4 PARTE DESCRIPTION 562 012 721051 83100900 CTRD 111A C2201 DC 840376 C82100600 C82200104 C33612 111936 CS82A020 562 011 CR51A102 840120 851310 840221 C61100200 CR59B035 BATTERY CABLE SET 24 4GA MBT TERM P amp N R amp B BATTERY WET 12V GR24 525 CCA STD DUTY L A BATTERY HOLD DOWN BATTERY HOLD DOWN ROD 1 4 X 10 1 4 DECAL SYMBOL FOR GROUND JACK SNAP RING JACK SIDEWIND LONG 3KLB TRAILER BASE RL4000 2006 REDESIGN AXLE SHACKLE 4 5 8 LG 2000LB 3500LB AXLE SPRING BOLT 2000LB 3500LB AXLE SPRING NUT 2000LB 3500LB OUTRIGGER LEG CAPLUG TUBE PLUG 2 1 2 X 2 1 2 TIRE B78 13B W 13 BLACK RIM HUB W RACE BEARINGS NUTS STUDS CAP WASHER DUST CAP FOR 2000LB AXLE AXLE WHEEL NUT 2000LB 3500LB AXLE 2000LB 36 SC U BOLT AXLE 2000LB SPRING LEAF SPRING 2000LB CHAIN SAFETY 3000LB 3 8 X 30 W S HOOK TONGUE B O H W JACK BRACKET OUTRIGGER HOUSING DECAL WARNING ALL OUTRIGGER COUPLER 2 BOLT ON DECAL WARNING ALL JACKS MU
14. 833005 Rev A November 2006 TEREX BALLAST ASSEMBLY 10 Ballast Box Assembly Complete includes items 1 9 ITEM PART DESCRIPTION DECAL DANGER HIGH VOLTAGE A BALLAST SPACER BALLAST TRANSFORMER CAPACITOR 24uF MH 60Hz CONNECTOR 5P MALE BALLAST BOX MH JOY 1000W 120V 60HZ Complete Assembly includes items 1 9 C n 4 Part No 833005 Rev RL4000 Light Tower 59 November 2006 TEREX FIXTURE ASSEMBLY NOTE FOR COMPLETE MH ASSEMBLY ORDER PART C41100720 60 RL4000 Light Tower Part No 833005 Rev A November 2006 TEREX 4 PARTA DESCRIPTION CORD SET MALE 5FT 3P TERMINAL STRIP 2P CASTING FOR NEW FIXTURE WASHER LOCK STAR 1 2 WASHER LOCK 1 2 SCREW 1 2 13NCX1 1 2 HHC GR 2 ZP TRUNION T HANDLE SCREW 1 2 13NCX1 1 4 HHC GRADE 5 GASKET FOR REFLECTOR SOCKET BASE MOGUL LABEL FIXTURE CSA APPROVED REFLECTOR RING REINFORCING FOR REFLECTOR RIVET POP 1 8X 390 GR 1 4 5 16 LENS W GASKET CLAMP LENS TO REFLECTOR SCREW 8 32X1 HH SLOT WASHER FIBER FOR BAND NUTSERT FOR BAND 8 32 X 1 4 included with item 17 SCREW 8 32X3 8 PH SOCKET BRACKET SCREW 8 32X5 8 LABEL 105C CORD RATING LABEL WET LOCATION FIBERGLASS WIRE SLEEVE CONNECTOR STRAINRELIEF LAMP SUPPORT COMPLETE FIXTURE ASSEMBLY Includes items 1 34 1 2 1 2 2 2 1 1 1 1 1 1
15. SPARE TIRE BRKT TONGUE MNT C83100900 TIRE B78 13B W 13 BLACK RIM 160530 BATTERY BLANKET THERMO 284 4001 36 LG C41101100 LIGHT DOME WITH SWITCH 741690 FUEL LINE HEATER DIESEL 12V 150W 683970 BREAKER MINI 1P 20A 684640 RECEPTACLE 20A 120V DUPLEX W GFI 842084 AXLE 3500LB W ELECTRIC BRAKES 48 HF 36 SC RL4 0 0 A c Part No 833005 Rev A RL4000 Light Tower 67 TEREX November 2006 OPTIONS CONTINUED 11 Battery 700 Amp Option Trailer Lights Option 4 PART DESCRIPTION BATTERY HOLDOWN ANGLE 14 50 BATTERY WET 12V GR24 700 AMP HEAVY DUTY L A BATTERY HOLD DOWN ROD 1 4 11 1 4 LIGHT TRAILER KIT M540 WITH RIGHT LEFT SIDE 68 RL4000 Light Tower Part No 833005 Rev A
16. electrical equipment from being damaged 1 Unlock and open the access doors 2 Check the oil fuel and coolant levels 3 Check that the tower has been properly grounded 4 Preheat the unit for 10 30 seconds A CAUTION Never preheat for more than 30 seconds 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 ACAUTION 9 than 45 seconds 5 Start the engine and listen for any unusual sounds or vibrations Should unusual sounds be detected contact Terex Light Construction Service Manager 6 Once the engine has been started and running smoothly place the light switches in the ON positions one at a time 7 Check each flood light for proper operation 8 Close and latch the access doors NOTICE Vaporous lights require a warm up period of 5 10 minutes before they will produce a full output Breakers Light Hourmeter Duplex Receptacle Mini Breaker T Lock Receptacle Switch Switch Push Button Light Indicator 16 RL4000 Light Tower Part No 833005 Rev A November 2006 TEREX OPERATING INSTRUCTIONS LIGHT TOWER AUXILIARY POWER 1 One 20 amp 120 receptacle and one 30 amp 240 receptacle are provided for auxiliary power Total auxiliary power cannot exceed main circuit breaker rating Each lamp oper
17. higher than the work area B Use tire chocks in front of and behind each tire whenever possible Always use tire chocks on 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 vehicle E Level the trailer using the jacks as follows 1 Extend the front outriggers until the outrigger pins lock into place Rotate the jack on each outrigger into vertical position and lock into place 2 Rotate the rear jack and lock into the vertical position 3 Start at the highest jack position Rotate the jack handle until the jack foot touches the ground 4 Raise the other jacks to level trailer OUTRIGGERS ARE NOT DESIGNED TO LIFT THE TIRES OFF THE GROUND ACAUTION Insure that all jacks are down to prevent the tower from tipping over backwards when raised NEVER ATTEMPT TO MOVE THE TOWER WHILE THE LEV ELLING JACKS ARE DOWN SERIOUS MACHINE DAMAGE WILL RESULT 12 RL4000 Light Tower Part No 833005 Rev A November 2006 ij TEREX SETUP F When applicable drive grounding rod into earth Grounding rod not included 1 Drive the rod into the ground and secure the grounding wire to the lug located on the trailer frame Outrigger Pin Outrigger Jack Rear Jack FIRM AND LEVELAREA G When applicable install the floodlights on the crossarm
18. is properly maintained and be familiar with its use Extinguishers rated ABC by the NFPA are appropriate for all applications 6 RL4000 Light Tower Part No 833005 Rev A November 2006 TEREX GENERAL SAFETY AWARNING EXHAUST GASES ARE TOXIC DO NOT USE INDOORS UNLESS PROPERLY VENTILATED OR AN EXHAUST SCRUBBER IS USED Check exhaust system regularly for leaks and ensure that the exhaust manifolds are secure and not warped Make sure the unit is well ventilated ELECTRICAL SAFETY This equipment utilizes high voltage circuits Always exercise extreme caution when trouble shooting or repairing any electrical circuit The electrical circuits in this light tower complete their paths back to the generator within the equipment The neutral conductor at the generator 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 convenience Disconnect electrical power and turn off engine before removing protective covers on high voltage electrical closures Beware of a cut or damaged power cord Have a qualified electrician replace immediately When troubleshooting indicates a malfunction in the high voltage AC system pass the task to a qualified and trained electrician DO NOT TOUCH HOT PARTS The exhaust manifold and tail pipe are very hot Parts of the engine
19. specific unit follow the instructions listed below By doing so you will be assured of receiving the correct part in the shortest period of time 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 specific shipping instructions to whom and where parts are to be shipped also whether shipment is to go parcel post express freight or truck prepaid or collect We want your order to reach you as quickly and as economically as possible 5 Confirm all telephone orders in writing via mail or fax confirmation PART NUMBERS AND PRICES ARE SUBJECT TO CHANGE WITHOUT NOTICE Part No 833005 Rev A RL4000 Light Tower 47 November 2006 TEREX This page intentionally left blank 48 RL4000 Light Tower Part No 833005 Rev A November 2006 DECAL LAYOUT TOP PANEL 1 109055 DECAL KIT FRONT PANEL REAR PANEL 12 9 11 10 4 LEFT ACCESS DOOR RIGHT ACCESS DOOR 5 8 TEREX 4 TEREX 109055 850150 CU51A112 853316 853792 CR51A101 CU51A102 C52100100 CU51A116 CU51A111 CR51A101 CR51A101 8 U51A102 INSIDE DOOR DESCRIPTION KIT DECALS FOR MODEL 04000RL RITE LITE DECAL DIESEL FUEL ONLY DECAL DANGER HOT EXHAUST DECAL RL4000 W STRIPE OP BOTTOM
20. the lower pivot winch lower the tower into the cradle Verify that the tailhook is latched or hooked over the tower cradle This prevents the tower sections from telescoping out while traveling Replace the travel locking pin If required remove the light fixtures and crosshead assembly Secure all locking pins and verify that the tailhook is properly latched 10 Close and lock both doors Pivot Lower Winch Telescoping Upper Winch Travel Locking Pin Rotational Lock V Kick out Spring pas ESA c 2 Tower Locking Pin 18 RL4000 Light Tower Part No 833005 Rev A November 2006 TEREX MAINTENANCE MINIMUM MAINTENANCE PROCEDURES The following maintenance intervals are only suggested by Terex You should always check your engine owner s manual for specific information Should you find any discrepancies between the Terex Manual and the Engine Manufacturer s Manual always follow the Engine Manufacturer s Manual Twice Daily Check the crankcase oil and fill as required Daily Check the engine and generator for any loose bolts connections and fittings Check the coolant 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 clogging Bi weekly Check the engine oil quality and change as required Bi Monthly or every 250 hour
21. 1101 When returning parts for credit please contact the factory for Return of Goods Authorization Terex Model Number Serial Number Engine Model Number Serial Number Generator Model Number Serial Number Sold to Ship to Options Production Date Work Order Number Shipping Date In Service Date When this unit left the factory the engine was filled with engine oil grade 32 RL4000 Light Tower Part No 833005 Rev A November 2006 TEREX MODEL NUMBER IDENTIFICATION IMPORTANT WHEN REQUESTING TECHNICAL HELP AND ORDERING REPLACEMENT PARTS THE MODEL AND SERIAL NUMBER ARE NECESSARY REFER TO THE TEREX SERIAL NUMBER TAG ON THE UNIT FOR CORRECT MODEL NUMBER AND SERIAL NUMBER MODEL NUMBER IDENTIFICATION Sample Light Tower Product Line RL4 060 D 2 4 MH Tower 111111 RL4000 RL4 lt 30 Foot Basic Tower KW Diesel D 2nd Generation Number of Lights Type of Lights HPS High Pressure Sodium MH Metal Halide TH Tungsten Halogen Part No 833005 Rev A RL4000 Light Tower 33 November 2006 TEREX RECOMENDED ENGINE OIL amp FUEL KUBOTA D1105 DIESEL ENGINE Engine oil should be MIL L 2104C or have properties of API classification of CD grades or higher Change the type of engine oil according to the ambient operating temperature Above 77 F 25 SAE 30 32 to 77F 0 to 25 C SAE 20 Below 32 F
22. BREAKER MINI 1P 20A RECEPTACLE 30A 240V NUT NYLOCK 8 32 ZINC SWITCH IGNITION LEVER OPERATED included with item 10 WIRE HARNESS DC ENGINE CONNECTOR 2 SCREW 3 4 CONNECTOR WITH WIRES includes 13 and 14 CONNECTOR 2 SCREW 1 25 included with item 16 TERMINAL CLOSED END LOCKNUT CONDUIT 3 4 CORD SET FEMALE 6FT 5P CONTROL BOX REAR PANEL CONTROL BOX BODY HOURMETER DIGITAL DECAL AL RL CONTROL BOX DC ENGINE CONTROLS CONTROL BOX FRONT PANEL SCREW 10 16X3 4 PH ZP SCREW H6 32X1 4 PAN HD WASHER LOCK 6 SWITCH PUSH BUTTON included with item 31 LIGHT INDICATOR 12V RED CONTROL BOX TOP PANEL RELAY 12V DC 30A BRACKET E BOX HANGER NUTSERT 1 4 20UNC WIRING HARNESS FROM ENGINE KUBOTA SOLENOID PIGTAIL COMPLETE ELECTRICAL CONTROL BOX includes 1 36 ome ADN 2 1 1 1 1 4 1 1 1 1 1 Part No 833005 Rev A RL4000 Light Tower 57 November 2006 TEREX COIL CORD amp JUNCTION BOX 12 Junction Box Complete with Coil Cord Includes items 1 11 13 Coil Cord Assembly Includes items 1 2 amp 3 1 9 1 1 4 4 1 1 1 1 DUST CAP W CHAIN JUNCTION BOX BOX COVER 2GANG W GASKET DECAL CAUTION TIGHTEN FIXTURE CONNECTOR GRIP HUBBLE WEATHERSTRIP ADHESIVE COIL CORD BULKHEAD JUNCTION BOX COMPLETE WITH COIL CORD includes 1 11 COIL CORD ASSEMBLY Includes items 1 2 and 3 gt 20 k mk 2 58 RL4000 Light Tower Part No
23. EX LIGHT CONSTRUCTION credit the applicants account or send replacement parts TEREX LIGHT CONSTRUCTION warranty reimbursements 1 40 00 for each hour s labor we allow toward a repair 2 Distributors cost of parts not more than the price currently available from TEREX LIGHT CONSTRUCTION 3 One way surface freight charges on parts returned to TEREX LIGHT CONSTRUCTION Many repairs are assigned a predetermined labor schedule which is an average time in which a skilled technician should be able to make a repair TEREX LIGHT CONSTRUCTION will reimburse not to exceed the predetermined number of hours for a particular repair TEREX LIGHT CONSTRUCTION does not reimburse for 1 Travel travel time nor travel labor 2 Mileage 3 Excessive diagnostic time 4 Repairs of defects malfunctions or failures resulting from accidents abuse misuse modifica tions alterations improper servicing or lack of performance of required maintenance service 5 Repairs where defective parts were not shipped back when requested by TEREX LIGHT CON STRUCTION 6 Regular maintenance such as parts or labor for oil changes filter changes or filters 7 Repairs where defective parts were not received by TEREX LIGHT CONSTRUCTION after TEREX LIGHT CONSTRUCTION issued a return authorization TEREX Light Construction P O Box 3147 Rock Hill S C 29731 USA Phone 803 324 3011 Fax 803 366 1101 30 RL4000 Light Tower Part No 833005 Rev A N
24. ING THIS UNIT SHUT IT DOWN IMMEDIATELY HAVE THE UNIT INSPECTED BY A TRAINED ELECTRICIAN LIGHT FIXTURE TROUBLESHOOTING DO NOT OPEN FIXTURES WHILE LIGHT CIRCUIT BREAKER is on ALLOW LAMP TO COOL BEFORE TOUCHING Take extra precautions when troubleshooting electrical ACAUTION problems Only qualified electricians should troubleshoot this equipment A Only use a voltmeter with two well insulated pin probes rated for 600 volts B Treat all conductors as potentially hot C Proceed through circuits 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 ballasts are receiving power suspect burned out power cable 28 RL4000 Light Tower Part No 833005 Rev A November 2006 TEREX LIGHT FIXTURE TROUBLESHOOTING TRACEABLE NUMBERED WIRING SYSTEM Using plug in ballasts to troubleshoot When troubleshooting the preceeding problems minimize down time by following the traceable numbered wiring system always follow 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 each fixture into the appropriately numbered plug at the top of the tower By adhering to the traceable numbered wiring system troubleshooting f
25. OO 3n18 1H911 3LIHM 1INOMID 3009 3009 Nva3douna OILSINOG SJANIXId NJLSONNL 303 AWVS SI NOLIVHOOIJNOO Nid ALON NMONA MOVIE CHA NHO NSSHO 3018 3LIHM em 524 Part No 833005 Rev A RL4000 Light Tower 38 TEREX November 2006 1000MH Ballast Diagram N33H9 NOWINOO JONVHO LOH NOININOO LNdNI ALIHM LAdNI Movid 319W1d3938 310d S LSYTIVA M0001 Hal HOJSNVHL A9V la JONVHO 39 RL4000 Light Tower Part No 833005 Rev A November 2006 TEREX 1000HPS Ballast Diagram ISYTIVA WNIGOS SYNSS3Yd HDIH M0001 N33H9 NOINIWOO dWY1 LOH NOWWOS INdNI ALIHM LAdNI MOV ld 1 319V1d3938Y JlOd S CX LX HOLINDI Part No 833005 Rev A RL4000 Light Tower 40 November 2006 X 14 For A Light Tower Diagram AC Wiring S96 6 9LOH Co d96 6 0LOH LO ONAOZZ LSVTIVE 18 OVAOZZ LSVTIVS it Nid TVALNJN ISVTIVA 9 TVALNIN LSVTIVE v 9 18 4 LSVTIVE Z 3 OVAOZZ LSVTIVA vi
26. OR MOUNTING BAR Items 1 thru 8 are not shown For detail break down see Leroy Somer Parts amp Service Manual supplied with unit ITEM PART DESCRIPTION NDE BEARING DIODE KIT includes 2 diodes ROTOR BOLT 8 X 245 TERMINAL BLOCK CAPACITOR 22 5mf two per unit required SCREW M10 X 1 5 X 90MM HHC GRADE 8 8 ZP WASHER FLAT SNUBBER VIBRATION MOUNT 30 DUR NUT LOCK NYLON INSERT M10 X 1 5 HEX ZP GENERATOR MOUNT BAR GENERATOR L S 6KW 120 240 C106 SAE5 LSA36 AH AH do od TEREX Part No 833005 Rev A RL4000 Light Tower 65 November 2006 TEREX TRAILER HITCHES o O OO UO 0 UD D UU O O gt co 0 DESCRIPTION KIT COMBO HITCH includes items 2 6 COUPLER 2 BOLT ON COMBO HITCH SIDE SPACER COMBO HITCH SIDE PLATE BALL 2 COMBO HITCH RING 16 LONG RING HITCH BOLT ON 2 1 2 ID ADJUSTABLE HEIGHT HITCH 24 ADJUSTABLE HEIGHT HITCH 18 TO 36 RING HITCH FOR ADJ HEIGHT HITCH 2 1 2 ID RING HITCH FOR ADJ HEIGHT HITCH 3 ID A dl gt 66 RL4000 Light Tower Part No 833005 Rev A November 2006 TEREX OPTIONS Tire Mount Option Dome Light Option Fuel Heater Option GFI Option Electric Brake Option R82A150 SPARE TIRE MOUNT R82A160 CLAMP
27. Reinsert the tower locking pin into the tower base A CAUTION 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 TOWER ALOSS OF FINGERS OR LIMBS MAY RESULT FROM UNSAFE PRACTICES A CAUTION Do not attempt to lean the tower down when it is extended Serious damage may occur Telescoping Upper Winch Travel Locking Pin Rotational Lock 2 Kick out Spring Pivot Lower Winch Tower Locking Pin WHEN RAISING THE BOOM MAKE SURE THE BOOM WIRING DOES NOT BECOME ENTANGLED 14 RL4000 Light Tower Part No 833005 Rev A November 2006 2 TEREX SETUP THE AUTOMATIC BRAKE MUST WORKING ON THE UPPER TELESCOPING 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 INA VERTICAL POSITION 3 Release the tower rotational lock and adjust the lights to the desired area Once positioned correctly retighten the rotational lock Part No 833005 Rev A RL4000 Light Tower 15 November 2006 TEREX OPERATING INSTRUCTIONS STARTING THE ENGINE GENERATOR SET ACAUTION Insure the light switches are turned off This prevents the engine from starting under load and prevents
28. ST BE SWIVELED JACK BRACKET SWIVEL WELD ON WINCH BRAKE 1500LB W HANDLE WEATHERSTRIP ADHESIVE 1 4 THK X 1 2 WIDE FUEL TANK SUPPORT BRACKET AA Part No 833005 Rev RL4000 Light Tower 51 November 2006 TEREX CABINET ASSEMBLY 53200100 Manual Box Right Side Not Shown For Clarity 24 R54B040 Right RL Access Door 25 R56C040 Right RL Underdoor Panel 52 RL4000 Light Tower Part No 833005 Rev A November 2006 TEREX ITEM PART DESCRIPTION CU63A040 C61300501 C61300502 CU51A118 C53200100 865307 CR54B050 C51100200 C51100300 C42200203 C83400100 CR56C050 C51500200 930950 C61400100 CS63C080 C61300502 C61300501 CR58C011 C51400300 CR59C010 796610 990670 CR54B040 CR56C040 CR58C020 CR63A040 SUPPORT PLASTIC 2HOLE 3 5 X 2 5 X 1 PIN 3 4 X 7 ZINC CLIP HITCH PIN DECAL PIN WITH ARROW LITERATURE BOX BLACK PLASTIC COOLANT RECOVERY TANK DOOR ROADSIDE CAM DOOR HANDLE T HANDLE BLACK W KEYS DOOR HANDLE KEYS FENDER CABINET UNDERDOOR PANEL RS PROP DOOR 10 TELESCOPIC WEATHERSTRIP ADHESIVE 1 4 THK X 1 2 WIDE PULLEY 3 TOWER BASE CLIP HITCH PIN PIN 3 4 X 7 CABINET FRONT PANEL CUSHION PANEL TOP HINGE PIANO 1 5 X 51 75 RIVET POP 3 16 X 1 2 DOOR CURBSIDE CABINET UNDERDOOR PANEL CS CABINET REAR PANEL REAR TOWER SUPPORT PO PO JS AH m m m TI
29. Y SECURE THE TRAILER TO THE TOWING VEHICLE MAY RESULT IN SERIOUS INJURY OR DEATH 3 Retract and rotate the front leveling jack 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 fixtures are secure and ready for transport 7 Secure all loose locking pins and retainers 8 Make sure all doors are closed and tightly locked 9 Remove tire chocks A CAUTION Towing of a Terex light tower is approved with the light fix tures in place on the crosshead assembly for all off road terrain and highway towing as long as the following speed limits are followed Highway towing 60 MPH Off road towing 10 MPH max Severe damage may occur from excessive speeds Damage created by abuse will void the manufacturer s warranty Part No 833005 Rev A RL4000 Light Tower 11 November 2006 ij TEREX SETUP A Move the light tower to desired location keeping the following in mind 1 The light tower should not be placed where those working under the light are either a Forced to look into the light regularly b Forced to work with their backs to the light shadows will block the light from the work area 2 The area where the tower is positioned should be relatively level for safe and proper operation of the unit 3 The light tower should be located on the same level or on ground
30. are also hot Use protective gloves when handling hot parts The light fixtures become very hot during operations To avoid burns always allow any fixture to cool before handling Part No 833005 Rev A RL4000 Light Tower 7 November 2006 TEREX GENERAL SAFETY BATTERY HAZARDS Lead acid batteries can be dangerous The sulfuric acid in the battery can cause severe skin and eye burns The hydrogen gas emitted during charging can explode if an arc or flame is present DO NOT smoke while servicing the battery DO NOT allow tools to touch battery terminals and create an arc Disconnect the negative terminal of the battery when working on the engine or other parts to prevent accidental arcing Disconnect the negative cable at the end away from the battery DO NOT remove the vent caps when charging the battery Always wear eye protection when servicing the battery If acid gets on skin or eyes 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 ENVELOPE OF THE LAMP IS BROKEN OR PUNCTURED DO NOT use where people will remain close to the lamps for more than a few minutes unless adequate shielding or other safety precautions are used KEEP ALL BODY PARTS AND CLOTHING AWAY FROM MOVING PARTS Loose jackets shirts sleeves and especially neckties
31. ating consumes 9 5 amps of 120 volt power Co Before plugging in auxiliary power cords feed them up through the trailer frame and attach to receptacles Close the cabinet doors to protect control panel and other components from weather 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 The AC generator ACAUTION may become damaged After being shut down the lights must be allowed to cool NOTICE S down before trying to restart the lights This cool down period can be between 10 25 minutes depending on the ambient temperature LOWERING THE TOWER 1 Using the upper telescoping winch telescope the tower down to its fully retracted position The boom should lower smoothly and evenly to its lowest ACAUTION position If it does not contact a qualified mechanic Insure the coil cord does not become entangled with the ACAUTION 9 lower tower sections Part No 833005 Rev A RL4000 Light Tower 17 TEREX November 2006 OPERATING INSTRUCTIONS LOWERING THE TOWER Continued 2 8 9 Loosen the rotational lock and rotate the tower into its nesting position The upper telescoping winch should be pointing forward towards the tongue Remove the travel locking pin located on cradle Remove the tower locking pin located on tower base Using
32. e from Terex so future operation and maintenance personnel may read these instructions Rotational Lock Telescoping Upper Winch Winch Access Door Electrical Box Light Fixtures Trailer Frame Part No 833005 Rev A RL4000 Light Tower 3 November 2006 TEREX SAFETY ALERT SYMBOLS MEANS ATTENTION BE ALERT YOUR SAFETY IS INVOLVED THIS SAFETY SYMBOL IS USED FOR IMPORTANT SAFETY MES SAGES WHEN YOU SEE THIS SYMBOL FOLLOW THE SAFETY MESSAGE TO AVOID PERSONAL INJURY OR PROPERTY DAMAGE 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 A DANGER WARNING Identifies the hazard or unsafe practice AWAR N N that could result in severe injury or death CAUTION Identifies the hazard or unsafe practice A CA U TI O N that could result in minor injury or property damage NOTICE Identifies important installation operation or maintenance information RL4000 Light Tower Part No 833005 Rev A November 2006 TEREX GENERAL SAFETY DO OPERATE THE RL4000 LIGHT TOWER WITHOUT READING THIS OPERATOR S MANUAL DO NOT WORK ON OR OPERATE THE LIGHT TOWER WHILE UNDER THE INFLU ENCE OF PERFORMANCE IMPAIRING DRUGS OR ALCOHOL SAFETY ALERT SYMBOL Stop and take time to read ALL Safety a
33. he generator bearing or damaged fan blade the generator 11 Lamp will not start a Lamp loose in socket a Inspect lamp base to see if there is arcing at center contact button Tighten lamp Check socket for damage Replace if needed b Floodlight plugs not tight b Check plug and receptacle Tighten if needed c Defective ballast c Interchange ballast plugs If lamp starts replace ballast Check for swollen capacitors charred wiring core and coil or other signs of excessive heat d Low voltage d Check line voltage at ballast input Voltage should be within 10 of rating when operating at normal load Increase supply voltage or remove external load 26 RL4000 Light Tower Part No 833005 Rev A November 2006 TEREX TROUBLESHOOTING POSSIBLE CAUSE 11 Lamp will not start e Improper ballast e The ballast name plate data should agree with the line voltage and lamp used If not replace the ballast down time insufficient to cool 12 Lamp starts slowly arc does a Defective lamp a Lamp may glow for an extended not strike when switch is first period of time Replace after turned on checking voltage and ballast 13 Circuit breaker trips on lamp a Short circuit or ground a Check wiring against diagram inspect for shorts or ground Fix as needed 14 Lamp light output low c Defective ballast c Interchange ballast plugs If lamp starts replace ballast Check for swollen capacitors charred wiring core and coil or other
34. ia 42 33 44 596 55 a 352 5 RI 9 64 4 583 me 14 3 50 1 49 664 5 678 947 827 20 41 555 5 745 5 513 toed 6 91 gt 75 1016 80 1084 110 9 93 126 64 857 8 15 50 12 10 162 105 142 as az s 1084 mo 149 120 162 160 203 10 176 18 12 0 162 130 76 370 250 1 1 58 1 no 149 150 203 6 27 20 284 10 24 18 130 176 230 180 24 50 35 0 1 2 10 200 271_ 20 366 280 379 380 55 30 3 16 220 298 30 406 30 40 40 55 35 44 78 9 320 433 430 588 450 60 60 827 50 69 14 350 474 40 637 50 68 60 08 560 759 7 e 480 650 60 867 680 922 910 123 70 1044 78 962 75 1016 990 132 80 1 1155 12 50 908 890 1206 1080 1464 1240 1952 120 1654 125 12 50 1960 1240 1681 1510 2047 2010 2725 1700 5304 is 6 1460 1979 1950 2643 2370 3213 3160 4284 2670 3620 12 1640 2223 2190 2969 2670 3620 3560 4826 300 4067 METRIC FASTENER TORQUE CHART This chart is to be used as a guide only unless noted elsewhere in this manual 12 9 LUBED LUBED LUBED LUBED in ibs Nm in Ibs Nm in ibs Nm in Ibs
35. ixture aiming and fixture control will follow a standard predictable pattern Part No 833005 Rev A RL4000 Light Tower 29 November 2006 TEREX WARRANTY WARRANTY PROCEDURE The specific language of this warranty will determine TEREX LIGHT CONSTRUCTION s obligation in connection with its product The information presented below should be used as a general guide for imple mentation of policy In the event of a component failure during the warranty period it should be repaired as soon as possible preferably at an authorized TEREX LIGHT CONSTRUCTION service center If component is manufactured by a company other than TEREX LIGHT CONSTRUCTION such as Deutz Honda Isuzu Kubota Leroy Somer Lister Petter Lombardini Wisconsin etc the applicant should pursue repair and or reimbursement through that manufacturer and its dealer distributor network To file a claim with TEREX LIGHT CONSTRUCTION an APPLICATION FOR WARRANTY ADJUSTMENT AWA form must be completed in it s entirety Return the completed form within fourteen days of the repair to ATTENTION WARRANTY TEREX LIGHT CONSTRUCTION 590 Huey Road Rock Hill Industrial Park Rock Hill SC 29730 TEREX LIGHT CONSTRUCTION will review the AWA form Should we desire to inspect the defective parts we will issue you a return authorization for the defective parts After inspecting the defective part s and it is determined that warranty is due we will then at the discretion of TER
36. lert mes sages Follow the safety messages to avoid personal injury or property damage ACCIDENT PREVENTION Use protective clothing 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 and belted where required UNAUTHORIZED WELDING UNAUTHORIZED WELDING CAN CAUSE STRUCTURAL FAILURE OR PERSONAL INJURY DO NOT weld on any structural member Any unauthorized welding or repair procedure will void the warranty Part No 833005 Rev A RL4000 Light Tower 5 November 2006 TEREX GENERAL SAFETY ALWAYS handle fuel with care It is highly flam mable ALWAYS stop engine before refueling Fill fuel tank outdoors Be sure the fuel supply has a positive shut off valve DO NOT replace fuel lines with materials different from those supplied as original equipment FIRES CAN CAUSE A CAUTION SEVERE PERSONAL INJURY OR MACHINE DAMAGE Fuel Fill 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 hot Allow to cool for several minutes before refueling DO NOT spill fuel inside the engine compartment If fuel has leaked wipe it up and have leak re paired before next use Have a fire extinguisher nearby Be sure the extinguisher
37. nts e Fuel line solenoid is not open e Replace fuel line solenoid 5 Engine runs rough a Clogged or leaking fuel system a Replace fuel lines tighten all connections inspect the pickup tube and inspect the fuel filter b Clogged exhaust system b Clear the exhaust system c Clogged air filter c Clear air filter d Clogged or stuck fuel injectors d Have a trained mechanic examine e Valve clearances are out of e Have a trained adjustment or the valve spring mechanic examine may be damaged f Defective governor or fuel pump f Have a trained mechanic examine Part No 833005 Rev A RL4000 Light Tower 25 November 2006 TEREX TROUBLESHOOTING TROUBLE POSSIBLE CAUSE REMEDY 6 Engine runs but produces a dense smoke b Low compression b Have a trained mechanic inspect for broken or seized rings Inspect valve clearances and clear as needed water coolant solution clogged d Fan belt is loose d Tighten fan belt 8 Engine runs but the battery a Alternator has failed a Have a trained mechanic inspect voltage is low the alternator 9 Engine runs but the light will a Circuit breakers are tripped a Reset the circuit breaker not operate b Loose connections in the wiring b Have a trained electrician inspect system the ballast box wiring system Leroy Somers Generator the capacitor the generator f Engine speed is too low f Have a trained mechanic inspect the engine speed and reset to 1800rpm 60hz the ballast and capacitors t
38. or wear and tear and immediately in the event of possible damage due to operator error in using the winch or possible damage from other equipment NORMAL WEAR AND TEAR When used properly the wire ropes should give years of trouble free service depending on how often the masts are raised and lowered The rule of thumb at TEREX is that if the tower is raised and lowered an average of once per day that the cables should be replaced 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 wadded up cloth or heavy leather gloves to avoid being pricked by a broken wire run a hand up and down a length of the cable If any exterior wires are broken they will lift up from main body of the cable and become visible For any given 1 foot of cable length if there are 4 or more wires each on any 2 or more strands broken the suspect rope should be replaced immediately DAMAGE INSPECTION If any nicks partial strand cut through kinks permanent bends or weld spatter on the cable from field service are observed the suspect wire rope should be changed immediately If there is a crushed spot somewhere on the wire rope it should be replaced only if the width of the crushed spot exceeds 1 1 4 times the nominal diameter of the cable 5 16 on a 1 4 cable and 7 32 on a 3 16 cable or if there are broken
39. ovember 2006 TEREX WARRANTY TEREX LIGHT CONSTRUCTION P O Box 3147 Rock Hill S C 29732 MANUFACTURER S LIMITED WARRANTY TEREX LIGHT CONSTRUCTION TLC warrants to the original purchaser that such equipment accessories parts and other products manufactured by TLC will be free from defects in workmanship and material for a period of one 1 year after the date of first delivery or for two thousand 2 000 hours of use whichever comes first provided that Buyer sends TLC notice of such defect within thirty 30 days of its discovery Should defects be discovered the Buyer must clearly establish that I the equipment parts etc have been properly installed and set up maintained and operated within the limits of rated and normal usage and 11 the defect did not result in any manner from the intentional or negligent action or inaction of Buyer Buyer must also return the defective item or items to TLC Rock Hill SC for inspection at TLC s request If Buyer cannot establish that conditions 1 and ll have been met then this warranty shall not cover the alleged defect Failure to give notice of defect within such period shall be a waiver of this Warranty and any assistance rendered thereafter shall not extend or revive it THIS WARRANTY IS LIMITED TO THE BUYER AND IS NOT ASSIGNABLE OR OTHERWISE TRANSFERABLE TLC MAKES NO WARRANTY WITH RESPECT TO PARTS COMPONENTS EQUIPMENT AND ACCESSORIES NOT MANUFACTURED BY TLC SUCH AS FIXTURES
40. ower Part No 833005 Rev A November 2006 TEREX MAINTENANCE MANUAL WINCH Maintain a light film of automotive type grease on the pinion drum gear and the O D of the drum bearing at all times Keep the ratchet pawl pivot pinion shaft bushings and pinion threads lubri cated with automotive engine oil at all times 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 be alert for any fraying of ca bles and replace any damaged cables IMMEDIATELY Never stand under any object lifted by the winch NON le Brake disc should be free of oil and grease NOISE LEVEL Mean SPL sound pressure level hemispherically at 7 meters 63dBA Sound Power Level 63 dBA 20 log d 7 8 90 0 LWA re 1 pW D 7 meters Part No 833005 Rev A RL4000 Light Tower 21 November 2006 TEREX SPECIFICATIONS amp DIMENSIONS De Ogri VJ ost GA im 170 1 2 4331 TRAVEL POSITION NOTES WHEEL SIZE 13 330mm AXLE RATING 2000lbs 907kg TONGUE WEIGHT TRAVEL POSITION 130lbs 59kg TOTAL WEIGHT NO FUEL 1760lbs 798kg FUEL CAPACITY 30 GAL 1021 360 9144mm
41. r 2006 TEREX DC Engine Wiring Diagram x pee Bus gu NO 2 3 sona PMS ojojejo Mee 0 gt v x JANIVHIdNIL o gt 1NY1002 m a9 Pa E L Yalan 2 ollo A HNOH u HOLIMS a elle a 6 6 15 a 1 Nua Nua Nua THM iva on 2 T Taal 1 2 1 29 2 5 ona MOT 5 e e 2 1HM s LHM lt i m 1845 i AVIJA DUO oyo e euo eje o 18 am z 2 M se T A Sica aay 1 m o TT HILHVLS NYD kd 44 e 0 Nyg i 1108 Grain NYG ow GION310S A re i ana is g LHM a 7 H 2 oL e y e asna 1 ME T cL te TJA ikon E E 5 H NOLLNA IUNTIVJ ii 1V3H3Yd YOLVNYALIV kd NYD
42. r losses which may be experienced by the Buyer A product warranty certificate must be filled out in its entirety and returned to TLC in order to process any warranty claims submitted THIS WARRANTY IS EXPRESSLY IN LIEU OF AND EXCLUDES ALL OTHER WARRANTIES EX PRESSED OR IMPLIED INCLUDING ANY WARRANTY OF MERCHANTABILITY AND FITNESS OF ANY PRODUCT OR GOODS FOR A PARTICULAR PURPOSE AND ALL OTHER OBLIGATIONS OR LIABILITIES ON TLC S PART AND NEITHER ASSUMES NOR AUTHORIZES ANY OTHER PER SONTO ASSUME FORTLC ANY OTHER LIABILITY IN CONNECTION WITH THE SALE OFTLC S PRODUCTS THERE ARE NO WARRANTIES WHICH EXTEND BEYOND THE DESCRIPTION ON THE FACE Part No 833005 Rev A RL4000 Light Tower 31 November 2006 TEREX SERIAL NUMBER RECORD TEREX LIGHT CONSTRUCTION PORTABLE LIGHT TOWER OPERATION AND SERVICE MANUAL This Operation and Service Manual contains information pertaining to the operation and maintenance of your Terex Light Tower We suggest that you read this manual carefully prior to operating the tower This manual should be retained and referred to for operation mainte nance and ordering parts When ordering parts PLEASE INCLUDE THE MODEL AND SERIAL NUMBER located on the nameplate of the tower For major repair and service or other information contact your local Terex dealer or write to Terex Light Construction P O Box 3147 590 Huey Road Rock Hill SC 29730 Telephone 803 324 3011 FAX 803 366
43. s Change the engine crankcase oil Six months or every 500 hours Replace the oil filter Check valve clearances consult Manufacturer s Manual Check electrical components and clean as required Check electrical wiring for chafing wear and replace as needed Yearly or every 1 000 hours Clean or replace the fuel filter Clean or replace the fuel pump strainer if equipped Check the head and manifold bolts for tightness Replace air filter element Part No 833005 Rev A RL4000 Light Tower 19 November 2006 TEREX MAINTENANCE CLEANING The Light Tower employs various electronic controls that may be damaged by liquid spray washing or high pressure washing Follow these procedures to prevent any damage to these components DO NOT SPRAY WATER INTO THE UNIT WHILE IS RUNNING THIS MAY RESULT IN INJURY 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 Interior Cleaning 1 Using a damp cloth covered with a mild soap carefully clean around any electric controls generator and thermostats Light Fixture Cleaning 1 The light fixtures and bulbs may be cleaned using any window cleaner THE LIGHT FIXTURES ARE VERY ALLOW TO COOL BEFORE PERFORMING ANY CLEANING TO THE FIXTURE BULBS OR LENSES 20 RL4000 Light T
44. serviced tested and ready for operation upon delivery Terex recommends the following checks O Q 1 HOC E Insure there is no freight handling damage which should be charged against the carrier Make sure the telescoping boom is secure Make sure the crosshead assembly is secure Check the front and rear jacks for security and proper operation 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 connections or leaks Check the control panel for damage or loose connections Check the boom wires for obvious damage or loose connections Check the light fixtures for damage to the lamps lenses reflector or etc Check the winches cables and pulleys for damage and proper operation Check the exhaust system for damage Check all fluid levels battery radiator and engine oils Insure manuals are in the pocket provided inside the unit 10 RL4000 Light Tower Part No 833005 Rev A November 2006 TEREX TRANSPORT amp TOWING 1 Using the front leveling jack securely attach the light tower to the transporting vehicle 2 Insure that the coupler is properly secured to the towing vehicle and attach the safety chains ALWAYS USE THE PROPER TRAILER HITCH AND SAFETY CHAINS OBEY ALL LOCAL OR STATE D O T LAWS WHEN TOWING A LIGHT TOWER FAILURE TO PROPERL
45. should not be worn while working on or running the unit Only remove guards or protective devices from unit temporarily to gain access for maintenance Always replace guards immediately after servicing Never remove guards while unit is operating Keep your hands away from moving parts particularly clear of the radiator fan and alternator belts when the engine is running 8 RL4000 Light Tower Part No 833005 Rev A November 2006 TEREX GENERAL SAFETY Roj JIH BEWARE OF TRAFFIC HAZARDS Stand clear of traffic when starting or checking the unit along the road Check the fuel tank oil pan and fuel and oil lines for leaks that would spill fuel or oil on the road Check fasteners and mounting brackets periodically to insure all are tight and nothing is in danger of falling off during transit ACAUTION Be careful when lifting Never suspend any other eguipment from the shipping tie downs Use the lifting eye or forklift pockets on the tower for lifting the trailer and tower assembly only Make sure any tie downs at the bottom of the trailer are released and the cradle retaining pin is inserted and secured prior to lifting Forklift Pockets Cradle Retaining Pin Tie Down Tie Down NEVER CLIMB ON TOP OF THE CABINET AND OR TOWER WHEN ERECTED OR RETRACTED Part No 833005 Rev A RL4000 Light Tower 9 TEREX November 2006 RECEIPT OF DELIVERY CHECKLIST The tower will be
46. signs of excessive heat d Wrong voltage d Check line voltage at ballast input Voltage should be within 10 of rating when operating at normal load Check wiring connections for voltage loss Check socket contact point e Improper ballast e Check ballast name plate against lamp data 15 Lamp colors different a Normal lamp depreciation 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 a Check voltage at ballast for current or voltage surges for shorted capacitors and replace as needed b b Check ballast name plate against lamp data a 17 Short lamp life Lamp damaged a Check for outer bulb cracks cracks where lamp meets base and for broken arc tube or loose metal parts Replace as needed b Check ballast name plate against lamp data 18 Lamp flickers or goes out a Check ballast name plate against intermittent or cycling lamp data b New lamp b Under certain conditions new lamps may cycle Usually after 3 tries to start at 30 to 60 second intervals lamp will stabilize and operate normal Part No 833005 Rev A RL4000 Light Tower 27 November 2006 TEREX TROUBLESHOOTING TROUBLE POSSIBLE CAUSE REMEDY 18 Lamp flickers or goes out intermittent or cycling d High spike ballast d Ballast produces high spike current IF YOU FEEL AN ELECTRIC SHOCK AT ANY TIME WHILE OPERAT
47. way Speed 60 mph 97 kmh DO NOT USETOWER IN WIND SPEEDS ABOVE 62 MPH 100 KMH This section details specifications and maintenance not covered in the operators and trouble shooting sections of this manual and the RL4000 specification sheets OIL AIR SERVICE The engine oil should initially be changed after the first 50 hours of use and then every 250 hours thereafter The oil filter should be replaced after every 500 hours of use The air filter element should be replaced once every year or after six cleanings see manufacturer s operation manual for details Part No 833005 Rev A RL4000 Light Tower 23 November 2006 TEREX TORQUE SPECIFICATIONS MISCELLANEOUS SPECIFICATIONS The Amida RL4000 light tower is built to NEC standards FASTENER TORQUE SPECIFICATIONS All fasteners should be torqued to the following specifications in Ib ft Ib in SAE FASTENER TORQUE CHART This chart is to be used as a guide only unless noted elsewhere in this manual A574 High Strength SIZE THREAD Grade 5 E Grade 8 65 in ibs Nm in ibs Nm in ibs Nm in ibs Nm in ibs Nm va 39 3 13 80 9 m0 158 124 130 147 2 30 101 140 158 21 LUBED UBED DRY LUBED UBED DRY LUBED UBED tis Wm Nm fis Nm fis Nm se 3 23 18124 339 21 284 1 257 29 271 2 366 325 38 15 s
48. wires at the point of damage Part No 833005 Rev A RL4000 Light Tower 35 TEREX November 2006 WIRE ROPE REPLACEMENT Figure 1 Boom Components RL4000 CABLE ROUTING INSTRUCTONS These instructions deal with the assembly and routing of cable for the Terex RL4000 boom and should aid in making this a smooth assembly Each boom consists of three separate stages referred to here as the tower 1 the second stage 2 and the upper 3 boom tubes see Figure 1 ASSEMBLY 1 Feed cable up 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 the tower boom tube 3 Run the cable over the upper pulley on the tower boom tube as shown here and in Figure 2 Figure 3 Winch Clevis Pin Figure 2 Cable Routed Through Pulley 3 Attach opposite end of cable to the winch on the tower boom tube See Figure 3 4 Repeat Steps 1 3 for the upper boom tube and attach cable to the clevis pin on the second stage boom tube shown in Figure 2 36 RL4000 Light Tower Part No 833005 Rev A November 2006 TEREX Wiring Diagrams Section Part No 833005 Rev A RL4000 Light Tower 37 November 2006 TEREX iagram D iring Fixture W 1 MOTIJA M N3339 N33H9 LS v Tiva NONA LOH NMONA ISVTIVE NOWW
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