RL-TML-4000 Service Manual
Contents
1. Xii Section 1 Safety Rules General Safety Rules snanar nanna Section 2 Rev Specifications A 2 1 Specifications 2 2 Specifications Continued nanna nanna 2 3 A Torque Specifications 2 4 Section 3 Rev Scheduled Maintenance Procedures e EHE 3 1 Pre delivery Preparation 3 2 A Maintenance Schedules Kubota Lubrication and Maintenance Service Intervals 3 3 Perkins Lubrication and Maintenance Service Intervals 3 4 Marathon Generators Maintenance Schedule 3 5 Section 4 Rev Troubleshooting Introduction EE 4 1 A Troubleshooting Guide nn 4 2 116694 14000 TML 4000 Vii First Edition 7 First Printing TABLE OF CONTENTS Section 5 Rev Schematics A WTO 5 1 Wining KUDO 5 2 A Wire Harness Inside Control Box DC 5 9 A Milani DEEP 5 4 A a Rr PEE 5 5 viii RL4000 TML 4000 Part No 116694 First Edition First Printing Required Parts The following parts are required to perform maintenance procedures as outlined in the TE2. 131661 Kubota Engine Manual 893020 5 rrr 116117 Marathon Manual 116188 Copyright O 2009 by TEREX Corporation 116694 May 2009 First Edition First Printing TEREX is a registered trademark of TEREX Corporation in the USA and many other countries Super Quiet is a trademark of TEREX Corporation Printed on recycled paper Printed in U S A li RL4000 TML 4000 Part No 116694 First Edition First Printing TEREX How to Read Your Serial Number Serial Number Legend The serial number plate on your RL4000 TML 4000 is located on the cabinet next to the light tower mast TEREX ROCK HILL 590 Huey Road Rock Hill SC 29732 DATE FEBRUARY 2008 GVWR PNBV GAWR PNBE TIRES PNEU RIMS JANTE COLD TIRES INFL MODEL RL4000 SERIAL NUMBER RL408 1003 MODEL YEAR 2008 MANUFACTURED BY FABRIQUE PAR PRESS DE GONFL A FROID SINGLE THIS VEHICLE CONFORMS TO ALL APPLICABLE U S FEDERAL MOTOR VEHICLE SAFETY STANDARDS IN EFFECT ON THE DATE OF MANUFACTURE SHOWN ABOVE THIS VEHICLE CONFORMS TO ALL APPLICABLE STANDARDS PRESCRIBED UNDER THE CANADIAN MOTOR VEHICLE SAFETY REGULATIONS IN EFFECT ON THE DATE MANUFACTURE CE VEHICULE EST CONFORME A TOUTES LES NORMES QUI LUI SONT APPLICABLES EN VERTU DU REGLEMENT SUR LA SECURITE
3. 4000 TML 4000 Introduction First Edition First Printing 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 Contact Us www TEREX com Serial Number Information TEREX Corporation offers the following manuals for these models Title Part No TEREX RL4000 TML 4000 Operator s Manual 116692 First Edition TEREX RL4000 TML 4000 Service Manual 116694 First Edition TEREX RL4000 TML 4000 Part s Manual 116693 First Edition Perkins Operations Manual
4. MOTISA vL 3LIHM MOTIJA SMV vl II vL MOVIA NMOSS MOVIE SISSVHO SNVrLNSSHS LAS yOOTLSIML YOE ANNOYS owr LAS 142 VOZ utu Ha JW YNOH NMOSA woFLYVLS NMOHS HOLIMSAgy v OL ALIHM HLIM SNOT YOLVOICNI IN PI NINS HOLIMSA3M SONVEO RDUM L 3 NOLLINSI vL gt qQ3AOIN3H 38 LSNW HOLIMSAZSP JHIM NZNSI 9 HO LIMSAZJM NMOHA 1 1 LSVTIVd OL SAIL CYS voz 3LIHM RL4000 TML 4000 Part No 116694 REVA First Edition First Printing ANNOYS LSV11Vd WO 4 LOH 15 NOWWOO LINDYION MOTISA M Nvadouna NSLSONNL 1 AWVS AHL SI NOLIVHOOIJNOO ALON Movia
5. SILSAWOG MOVIE Section 5 Schematics MH Light Fixture Drawing 2985A TEREX 3LIHM Part No 116694 RL4000 e TML 4000 TEREX Section 5 Schematics First Edition First Printing 1000 MH Ballast Drawing 42986 REVA N33H9 NOININOO dAV1 JONVHO LOH NOININOO ALIHM 1 1 8 15 3anvH TVLIW M0001 W3INHOJSNVHL JOVIA JONVHO RL4000 TML 4000 PartNo 116694 Genie North America Phone 425 881 1800 Toll Free USA and Canada 800 536 1800 Fax 425 883 3475 Genie Australia Pty Ltd Phone 61 7 3375 1660 Fax 61 7 3375 1002 California Proposition 65 AWarning Battery post terminals and related accessories contain lead compounds chemicals known to the State of California to cause cancer and other reproductive harm California Proposition 65 AWarning The exhaust from this product contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm Towing Checklist Use at each stop Before Towing Towing hitch is properly secured to tow vehicle Safety chains if required are properly attached and secure chains are cross
6. 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 unable to complete R repaired Comments 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 First Edition First Printing Section Scheduled Maintenance Procedures TEREX Maintenance Schedules REVA Kubota Lubrication and Maintenance Service Intervals Every Every Every Every Every Every Every Every ITEM 100 200 400 500 piat 800 1500 3000 Two Hours Hours Hours Hours Hours Hours Hours Years Check of fuel pipes and clamp bands T T Check engine oilandcoolantlevel gt Cleaning of air cleaner elemet f _ Check of fan belt Check of fan tightness si Check of radiator hoses and clamp cc TI Check of intake airline of intake air _ RE ERI A Fiera esae Removal of sediment infueltank L Cleaning of water jacket radiator interior Replacement of fan belt Replacement of air cleaner element 4 Check of damage in electric wiring an
7. 6 9 320 433 430 583 450 610 610 827 510 en 4 o 474 470 687 500 678 670 908 560 759 e 480 50 640 867 680 922 910 1283 770 1044 12 530 718 962 750 1016 990 1342 840 1139 12 870 908 s0 1206 1080 1464 1440 1952 1220 6 12 930 1260 1240 1681 1510 2047 2010 2725 1700 2304 6 1460 1979 1950 2643 2370 3213 3160 4284 2670 3620 1640 2223 2190 2969 2670 3620 3560 4826 3000 4087 METRIC FASTENER TORQUE CHART This chart is to be used as a guide only unless noted elsewhere in this manual Class4 6 15 Class 8 8 Class 10 9 Class 12 9 DRY DRY DRY 854 68 775 91 103 R DRY 830 1055 682 925 909 1233 0 1 if Ek if 559 f Ek D N P Nol D a al mn At oO DIF A x D e NI m 0 lt il 0 1 lt 00 i zal as o oo oO S BA BLA cof Oo x AJ ge ojo D Co
8. Co M o N Co o OO NINI OL 5 QAS oy CO rN S B oj ny BIER NI NIS Ol a ala M 5 15 elo pv eo NI v 99 zs ob tal IT nb RIN ofj fn Kes Oo A m FS 9 2 4 4000 TML 4000 Part No 116694 First Edition First Printing Section 3 Scheduled Maintenance Procedures TEREX Scheduled Maintenance Procedures REVA 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 AWARNING 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 quarter
9. D 2 5 3 5 5 0 lt 5 2 8153 S 515 9 D 6 lt lt lt o I 2 6 5 1 5 8 F 1 B 5 Cooling svstem supplemental coolant additive SCA test add Engine air cleaner element dual element clean replace Engine air cleaner element single element inspect replace ngine oil and filter change oses and clamps inspect replace Radiator clean Iternator and fan belts replace urbocharger inspect Iternator inspect ngine crankcase breather replace tarter motor inspect uel injector test change Water pump inspect Cooling system coolant commercial heavy duty change Cooling system coolant extender ELC add ooling system coolant change 2 2 5 3 lt 5 o 1 2 pe 1 gt o 8 5 0 ct w c o jet pum 3 4 RL4000 TML 4000 Part No 116694 First Edition First Printing Section 3 Scheduled Maintenance Procedures TEREX MAINTENANCE SCHEDULES CONTINUED REVA Marathon Generators Maintenance Schedule 10000 Visual inspection ST 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 e
10. DES VEHICULES AUTOMOBILES DU CANADA EN VIGUEUR LA DATE DE SA FABRICATION TYPE OF VEHICLE TYPE DE VEHICULE TRAILER REMORQUE N TEREX 1 244 KG 2 743 LBS 1 244 KG 2 743 LBS ST205 75D13 LOAD RANGE C 15 0 X 4 5 5H 35 PSI 250 KPA RL4XXXXX Serial number is stamped into frame Part No 116694 RL4000 TML 4000 lii First Edition First Printing TEREX This page intentionally left blank iv RL4000 TML 4000 Part No 116694 First Edition First Printing Section 1 Safety Rules TEREX Safety Rules 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 Part No 116694 RL4000 TML 4000 TEREX SAFETY RULES Personal Safety Any person working on or around a machine must be aware of all known safety hazards Personal safety and the continued safe o
11. 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 Part No 116694 RL4000 TML 4000 3 5 Section 3 Scheduled Maintenance Procedures First Edition First Printing TEREX REVA This page intentionally left blank 3 6 RL4000 e TML 4000 PartNo 116694 First Edition First Printing REVA Observe and Obey Troubleshooting and repair procedures shall be completed by a person trained and qualified on the repair of this machine M 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 Section 4 Troubleshooting TEREX Troubleshooting 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 ADANGER Electrocution hazard Exposure to electrically charged circu
12. mechanic inspect voltage is low the alternator 9 Engine runs but the lights 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 the 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 if needed Make sure power is off 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 Part No 116694 RL4000 TML 4000 4 3 Section 4 Troubleshooting First Edition First Printing TEREX TROUBLESHOOTING REVA POSSIBLE CAUSE 11 Lamp will not start e Improper ballast e The ballast name plate data should a 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 l
13. 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 4 4 RL4000 e TML 4000 PartNo 116694 First Edition First Printing Section 4 Troubleshooting TEREX REVA TROUBLESHOOTING TROUBLE POSSIBLE CAUSE REMEDY 18 Lamp flickers or goes out intermittent or cycling d High spike ballast d Ballast produces high spike current Measure with oscilloscope Replace ballast as required IF YOU FEEL AN ELECTRIC SHOCK AT ANY TIME WHILE OPERATING THIS UNIT SHUT IT DOWN IMMEDIATELY HAVE THE UNIT INSPECTED BY A TRAINED ELECTRICIAN THIS ENGINE GENERATOR SET IS FACTORY INSTALLED TESTED AND SET FOR FIELD OPERATION ANY DAMAGE TO THE ENGINE OR GENERATOR UNITS OCCURRING AFTER ADJUSTMENTS ARE MADE IN THE FIELD BY UNAUTHORIZED PERSONNEL WILL NOT BE COVERED BY YOUR MANUFACTURER S WARRANTY AND WILL ALSO VOID THE MANUFACTURER S WARRANTY ON THIS PARTICULAR UNIT IF YOU CAN NOT REACH YOUR LOCAL DEALER CONTACT THE FACTORY SERVICE MANAGER TOLL FREE AT 1 800 433 3026 Light Fixture Troubleshooting DO NOT OPENFIXTURE WHILE LIGHT CIRCUIT BREAKER IS ON ALLOW LAMP TO COOL BEFORE TOUCHING TAKE EXTRA PRECAUTIONS WHEN TROUBLESHOOTING ELECTRICAL PROBLEMS A Only use a voltmeter with two well insu lated pin probes rated for 600 volts B Treat all conductors as potentially ho
14. A 98073 9730 Telephone 877 367 5606 Fax 888 274 6192 genieindustries com Part No 116694 RL4000 7 TML 4000 xi First Edition 7 First Printing TEREX Service Parts fax Order Form FAX TO 888 274 6192 OR TOLL FREE 877 367 5606 Please fill out completely Date Account Number Your Name Your Fax Number Your Phone Number Bill To Ship To Purchase Order Number Ship Via Model s Serial No s Optional Equipment Part Number Description Quantity Price All backordered parts will be shipped when available via the same ship method as the original order unless noted below o Ship complete order only no backorders o Ship all available parts and contact customer on disposition of backordered parts o Other please specify For TEREX Use Order Number Origin Code Comments Date Scheduled Ship Condition Order Total Terms Code remove this page and make copies remove this page and make copies First Edition First Printing Section 2 Specifications TEREX Specifications REVA Model RL4000 amp 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 105 783 kg Machine weights vary with option configurations See serial label for specific machine weight Maximum tongue w
15. ECIFICATIONS REVA SAE FASTENER TORQUE CHART e This chart is to be used as a guide only unless noted elsewhere in this manual A574 High Strength THREAD Grade 5 Grade 8 LUBED LUBED LUBED in ibs Nm in lbs Nm in ibs Nm Nm in ibs Nm 14 20 100 113 80 9 140 158 110 124 190 147 28 90 101 120 135 120 135 160 18 140 f 158 EN 4 LUBED UBED DRY LUBED DRY LUBED Nm bs Nm mis Nm iss Nm nis su 38 13 76 17 23 38 24 25 339 21 284 24 4 19 5 7 271 7 66 24 88 se L B 2 312 42 6 447 6 6 515 24 352 5 7 64 48 8 me 4 37 501 40 004 5 678 70 947 827 8 55 5 745 6 813 80 108 4 68 921 a L B 7 75 1016 60 1084 310 149 B 0 867 115 90 122 3120 362 one 12 80 110 49 120 162 3150 203 130 176 8 90 122 230 176 130 ss n no 149 150 203 1601 217 210 284 180 244 8 130 176 170 280 3180 244 20 5 271 sa L 10 20 27 270 366 280 379 5 46 403 _ 16 20 298 300 306 310 420 420 569 474
16. REX RL4000 TML 4000 Parts and Service Manuals Description Part No Kubota Models ii e a iaa 866050 Air Filter 866127 dc ERES TITULI 839200 jc 839209 Perkins Models 94762 Air cto 97474 Fille pet roa e e 62421 Be 85071 TEREX Parts Stocking List Part No 116694 RL4000 TML 4000 First Edition First Printing TEREX This page intentionally left blank RL4000 TML 4000 Part No 116694 First Edition First Printing Please be prepared with the following information when ordering replacement parts for your TEREX product Machine model number Machine serial number Terex part number Part description and quantity Purchase order number Ship to address Desired method of shipment Name and telephone number of the authorized TEREX Distributor in your area 8 8 8 Use the Service Parts Fax Order Form on the next page and fax your order to our Parts Department If you don t know the name of your authorized distributor or if your area is not currently serviced by an authorized distributor please call TEREX Corporation Machine Information Model Serial Number Date of Purchase Authorized TEREX Distributor Phone Number TEREX How To Order Parts Genie Industries 18340 NE 76th Street P O Box 97030 Redmond W
17. amp 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 a Normal lamp depreciation b Dirty lamp or fixture b Clean lamp and fixture 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 Check line voltage at ballast input Voltage should be within 1096 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 a Replace lamp b Dirty lamp or fixture b Clean lamp and fixture 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 Improper ballast b Check ballast name plate against lamp data 17 Short lamp life a 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
18. ccurred after performing a series of steps Part No 116694 RL4000 TML 4000 3 1 Pre Delivery Preparation 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 TEREX TEREX Rock Hill P O BOX 3147 Rock Hill SC 29732 USA Toll Free 800 433 3026 in U S A and Canada Copyright 2006 by TEREX Corporation TEREX is a registered trademark of TEREX Corporation RevB 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
19. d loose connections Check of valve clearance sd of valve clearance Check of fuel injection nozzle L of turbo Check of turbo charger ee Check of injectiontimer f j fef of radiator coolant L L C Replacement of battery H Replacement of radiator hoses 77 Replacement of fuel pipes and clamp Replacement of intake air line 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 Part No 116694 RL4000 TML 4000 3 3 Section 3 Scheduled Maintenance Procedures First Edition First Printing TEREX MAINTENANCE SCHEDULES CONTINUED REVA Perkins Lubrication and Maintenance Service Intervals Every 50 Every Every Every Every Every Every Every ITEM Daily H Hi 250 500 1000 2000 3000 6000 12000 2 Hours Hours Hours Hours Hours Hours Hours Cooling system coolant level check Driven equipment check EE Engine air cleaner service indicator inspect Engine air precleaner check clean Em separator drain inspect adjust uel system filter replace gt lt T og o E lt 8 eo 5 o lt O
20. ed below hitch All lights are connected and working Tires are properly inflated Before Driving Fasten safety restraints Properly adjust mirrors On The Road Do not exceed 60 mph 97 km h Obey all local and national towing speed laws Check connections and tire pressure at each stop Slow down for hazardous conditions Allow extra distance for following and passing other vehicles Genie China Phone 86 21 53852570 Fax 86 21 53852569 Genie Scandinavia Phone 46 31 575100 Fax 46 31 579020 Genie Malaysia Phone 65 98 480 775 Fax 65 67 533 544 Genie France Phone 33 0 2 37 26 09 99 Fax 33 0 2 37 26 09 98 Genie Japan Phone 81 3 3453 6082 Fax 81 3 3453 6083 Genie Korea Phone 82 25 587 267 Fax 82 25 583 910 Genie Iberica Phone 34 93 579 5042 Fax 34 93 579 5059 Genie Gerfnany Phone 49 0 4202 88520 Fax 49 0 4202 8852 20 Genie Brasil Phone 55 11 41 665 755 Fax 55 11 41 665 754 Genie U K Phone 44 0 1476 584333 Fax 44 0 1476 584334 Genie Holland Phone 31 183 581 102 Fax 31 183 581 566 Genie Mexico City Phone 52 55 5666 5242 Fax 52 55 5666 3241
21. eight 199 Ibs 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 71dbaQ 23ft 7m Part No 116694 RL4000 TML 4000 2 1 Section 2 Specifications First Edition First Printing TEREX SPECIFICATIONS REVA RL4000 las 170 1 2 4331mm TRAVEL POSITION 360 9144mm 38 965mm 54 1372mm 1562mm 124 126 3150mm 3200mm OPERATING POSITION 2 2 RL4000 TML 4000 PartNo 116694 First Edition First Printing Section 2 Specifications TEREX REVA SPECIFICATIONS TML 4000 170 1 2 J 4331mm TRAVEL POSITION Wy Wy 360 9144mm 38 965mm 1562mm 54 1372mm 126 3200mm 124 3150mm OPERATING POSITION Part No 116694 RL4000 TML 4000 2 3 Section 2 Specifications First Edition First Printing TEREX SP
22. its could result in death or serious injury Remove all rings watches and other jewelry ADANGER Electrocution 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 ACAUTION Burn hazard Contact with hot engine components may cause severe burns Use caution when working around a hot engine Part No 116694 RL4000 TML 4000 4 1 TEREX Section 4 Troubleshooting First Edition First Printing REVA Troubleshooting Guide The engine generator set is tested and set at the factory for proper operation in the field These units should never require additional adjustments in the field If needed 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 2 Boom will not telescope 3 Engine will not turn over 4 Engine turns over but will not start 5 Engine runs rough b Defective cable b Have a trained or pulley mechanic examine and repair as needed c Defective winch c Have a trained mechanic examine and replace as
23. ly 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 AWARNING Orange used to indicate the presence of a potentially hazardous situation which if not avoided could result in death or serious injury ADANGER Yellow with safety alert symbol ACAUTION 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 CAUTION Green used to indicate operation or maintenance information Indicates that a specific result is expected after performing a series of steps W Indicates that an incorrect result has o
24. needed a Defective winch a Have a trained and replace as needed b Broken cable or pulley b Have a trained and replace as needed loose cables b Engine has seized due to loss b Have a trained of fluids mechanic examine and repair as needed b Check and clean the fuel system as needed of prime and tighten connections d Heater elements burned out d Replace heater elements e Fuel line solenoid is not open e Replace fuel line solenoid 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 e Valve clearances are out of e Have a trained adjustment or the valve spring may be damaged f Defective governor or fuel pump f Have a trained 4000 TML 4000 Part 116694 First Edition First Printing Section 4 Troubleshooting TEREX REVA 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 c Clogged air cleaner c Replace air cleaner element and clear as needed b Replace the coolant with a 5096 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
25. obacco 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 ama that your workshop or work area p is properly ventilated and well lit 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 any forklift overhead crane 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 5 other fluids Use an approved container Please be environmentally safe vi RL4000 TML 4000 Part No 116694 First Edition First Printing TEREX Table of Contents Introduction Important Information li How to Read Your iii Parts Stocking ix How to Order Pans xi Service Parts Fax Order Form
26. peration 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 1 Red used to indicate the presence of an imminently hazardous situation which if not avoided will result in death or serious injury AWARNING 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 ACAUTION 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 CAUTION Green used to indicate operation or maintenance information Section 1 Safety Rules First Edition 7 First Printing Be sure to wear protective eye wear and other protective clothing if the situation warrants it Be aware of potential crushing hazards 5 such as moving parts free swinging or unsecured components when lifting or placing loads Always wear approved steel toed shoes Workplace Safety Be sure to keep sparks flames and W lighted t
27. ral Repair Process Malfunction Identify discovered symptoms Troubleshoot problem still exists Perform repair Return to service 7 problem solved Part No 116694 4000 TML 4000 5 1 REVA Section 5 Schematics First Edition First Printing DC Wiring Kubota Drawing 116814 TEREX 4 MO19 ON 1 1 I H9IH X18 LHM YILIN dnd o 2 UNOH 2 Ko 2 5 Z 8 8 Nua IHNSSIHA Io E o 8 v 940 L GION31OS x d a NOlLdO e K e to LHM 0153 5 1545 HSNd 9 oy 8 2 c r 0 el SLN3NOdMWOO lOHINOO Part No 116694 RL4000 e TML 4000 TEREX Wire Harness Inside Control Box DC Section 5 Schematics First Edition First Printing Drawing 116815 REVA NOILVNIWYSL wHALHVLS HO LIMSA3 AHOSS300V Cm NI uoirinausnd LNO HO LIMSA3 HollMsA34 NINOLLNSHSNd GL
28. t 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 Part No 116694 RL4000 TML 4000 4 5 Section 4 Troubleshooting First Edition First Printing TEREX This page intentionally left blank 4 6 RL4000 e TML 4000 PartNo 116694 First Edition First Printing REVA 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 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 Section 5 Schematics TEREX Schematics About This Section There are two groups of schematics in this section An illustration legend precedes each group of drawings Electrical Schematics AWARNING Electrocution hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry Gene
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