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1 L 7X YZ R 40 Parts Manual RL4000D2 First Edition Rev A Part No September 2008

2 Introduction 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: Serial Number Information September 2008 Copyright 2008 by TEREX Corporation Rev A September 2008 First Edition, Second Printing TEREX Corporation offers the following manuals for these models: "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. ii RL4000 Light Tower Part No Title Part No. TEREX RL4000 Operator's Manual First Edition TEREX RL4000 Service Manual First Edition TEREX RL4000 Part's Manual First Edition Leroy Somer Manual Kubota Engine Manual Axis Manual Marathon Manual

3 September 2008 Serial Number Legend How to Read Your Serial Number The serial number plate on your RL4000 is located on the cabinet next to the light tower mast. Part No RL4000 Light Tower iii

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5 September 2008 Section 1 Safety Rules Danger Safety Rules 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 RL4000 Light Tower v

6 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 operation of the machine should be your top priority. Read each procedure thoroughly. This manual and the decals on the machine, use signal words to identify the following: Safety alert symbol used to alert personnel to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death. Red used to indicate the presence of an imminently hazardous situation which, if not avoided, will result in death or serious injury. Orange used to indicate the presence of a potentially hazardous situation which, if not avoided, could result in death or serious injury. Yellow with safety alert symbol used to indicate the presence of a potentially hazardous situation which, if not avoided, may cause minor or moderate injury. Yellow without safety alert symbol used to indicate the presence of a potentially hazardous situation which, if not avoided, may result in property damage. Green used to indicate operation or maintenance information. Section 1 Safety Rules September 2008 Be sure to wear protective eye wear and other protective clothing if the situation warrants it. Be aware of potential crushing hazards such as moving parts, free swinging or unsecured components when lifting or placing loads. Always wear approved steel-toed shoes. Workplace Safety Be sure to keep sparks, flames and lighted tobacco away from flammable and combustible materials like battery gases and engine fuels. Always have an approved fire extinguisher within easy reach. Be sure that all tools and working areas are properly maintained and ready for use. Keep work surfaces clean and free of debris that could get into machine components and cause damage. Be sure that your workshop or work area is properly ventilated and well lit. Be sure any forklift, overhead crane or other lifting or supporting device is fully capable of supporting and stabilizing the weight to be lifted. Use only chains or straps that are in good condition and of ample capacity. Be sure that fasteners intended for one time use (i.e., cotter pins and self-locking nuts) are not reused. These components may fail if they are used a second time. Be sure to properly dispose of old oil or other fluids. Use an approved container. Please be environmentally safe. vi RL4000 Light Tower Part No

7 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) Outside Florida TOLL FREE: Need parts? Check out our website at Can t find what you need? Click on this link: and fill out the 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 needs.

8 September 2008 Introduction Section 1 Table of Contents Important Information - Introduction... ii How to Read Your Serial Number... iii Parts Stocking List... ix How to Order Parts... xi Service Parts Fax Order Form... xii Safety Rules Section 100 Rev Decals General Safety Rules... v A Figure Decals Section 200 Rev Chassis Components A Figure Light Tower Chassis A Figure Fuel Tank Assembly Section 300 Rev Cabinet Components A Figure Cabinet Components Section 400 Rev Electrical Components A Figure Electrical Control Box A Figure Ballast Box Assembly A Figure Light Fixture A Figure Coil Cord & Junction Box Part No RL4000 Light Tower vii

9 TABLE OF CONTENTS Section 500 Rev Engine & Generator September 2008 A Figure Engine - Kubota A Figure Marathon Generator - 6 kw A Figure Leroy Somer Generator - 6 kw Section 600 Rev Mast Components Section 700 Rev Options A Figure Tower Assembly A Figure Options viii RL4000 Light Tower Part No

10 September 2008 Required Parts The following parts are required to perform maintenance procedures as outlined in the TEREX RL4000Parts and Service Manual. Description Kubota Models Part No Part No. Oil Filter Air Filter Fuel Filter V-belt RL4000 Light Tower Parts Stocking List ix

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12 September 2008 Section 100 Decals Decals Section 100 Part No RL4000 Light Tower 100-1

13 Figure Decals Section 100 Decals September RL4000 Light Tower Part No

14 September 2008 Section 100 Decals FIGURE ITEM # PARTS # DESCRIPTION QTY KIT: DECALS FOR MODEL 04000RL RITE LITE DECAL: DIESEL FUEL ONLY 1 3 CU51A112 DECAL: DANGER HOT EXHAUST DECAL:RL4000 W/STRIPE OP/BOTTOM 2.25"TALL DECAL: TEREX 4.5"X43" 2 6 CR51A101 DECAL:WARNING-IMPROPER GROUNDING. 1 7 CU51A102 DECAL: NOTICE-NO ETHER 1 8 C DECAL: CALIF.PROP CU51A116 DECAL: TEREX POWER MOVING INSTRUCTION 1 10 CU51A111 DECAL: WARNING-BOOM DROP 1 11 CR51A101 DECAL:WARNING-IMPROPER GROUNDING CR51A311 DECAL:WARNING-IMPROPER GROUNDING. 1 Part No RL4000 Light Tower 100-3

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16 September 2008 Section 200 Chassis Components Section 200 Chassis Components Part No RL4000 Light Tower 200-1

17 Figure LIght Tower Chassis Section 200 Chassis Components September RL4000 Light Tower Part No

18 September 2008 Section 200 Chassis Components FIGURE ITEM # PART # DESCRIPTION QTY BATTERY CABLE SET 24 4GA MBT TERM P&N R&B 1 2 Z BATTERY WET 12V GR 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 4 8 CR82C000 TRAILER BASE AXLE SHACKLE 4-5/8" LG 2000LB/3500LB AXLE SPRING BOLT 2000LB/3500LB AXLE SPRING NUT 2000LB/3500LB 6 12 CS62C012 OUTRIGGER LEG CAPLUG, TUBE PLUG 2-1/2" X 2-1/2" 2 14 C TIRE, ST175/80-13 LOAD B W/13" BLACK RIM 2 15 CTRD-111A HUB W/RACE/BEARINGS/NUTS/STUDS/CAP/WASHER 2 16 C2201-DC DUST CAP FOR 2000LB AXLE AXLE WHEEL NUT 2000LB/3500LB C AXLE 2000LB, 36" SC 1 19 C U-BOLT, AXLE 2000LB 4 20 C33612 SPRING-LEAF SPRING-2000LB CHAIN SAFETY 3000LB 3/8" X 30" W/S-HOOK 2 22 CS82A020 TONGUE, B-O-H W/JACK BRACKET 1 23 CS62A011 OUTRIGGER HOUSING 1 24 CR51A102 DECAL, WARNING ALL OUTRIGGER COUPLER, 2", BOLT ON DECAL, WARNING ALL JACKS MUST BE SWIVELED JACK BRACKET SWIVEL WELD-ON 1 28 C WINCH, BRAKE, 1500LB W/HANDLE WEATHERSTRIP ADHESIVE 1/4" THK X 1/2" WIDE 8FT 30 CU63B054 CABLE, TOWER TILT 1 31 CR21A000 TANK FUEL 30GAL 1 32 C RL FUEL CAP 1 33 CR59B035 FUEL TANK SUPPORT BRACKET LATCH, OUTRIGGER NUT NUT, LOCK, NYLON INSERT WASHER, LOCK 1/2" WASHER, FLAT 1/2" SCREW, 1/2-13NC X 5-1/2" SCREW, 1/2-13NC X 4" 1 Part No RL4000 LIght Tower 200-3

19 Figure Fuel Tank Assembly Section 200 Chassis Components September RL4000 Light Tower Part No

20 September 2008 Section 200 Chassis Components FIGURE ITEM # PARTS # DESCRIPTION QTY. 1 CR21A000 FUEL TANK, 30 GALLON 1 2 CR59B035 BRACKET, FUEL TANK SUPPORT 1 3 C CAP, FUEL TANK FUEL PUMP HOSE, FUEL 5/16" X 7FT CLAMP, HOSE FILTER, IN-LINE FUEL FITTING, STRAIGHT TO BARB 5/16" 1 9 C HOSE, NYLON FUEL FITTING, 90 DEGREE ELBOW, RETURN ADAPTOR, STRAIGHT FITTING, STRAIGHT TO BARB 1/8" HOSE, FUEL 1/8" AR 14 C FITTING, 90 DEGREE ELBOW, PICKUP 1 Part No RL4000 LIght Tower 200-5

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22 September 2008 Section 300 Cabinet Components Section 300 Cabinet Components Part No RL4000 Light Tower 300-1

23 Figure Cabinet Components Section 300 Cabinet Components September RL4000 Light Tower Part No

24 September 2008 Section 300 Cabinet Components FIGURE ITEM # PART # DESCRIPTION QTY. 1 CU63A040 SUPPORT, PLASTIC, 2HOLE 3.5" X 2.5" X 1" 1 2 C PIN, 3/4" X 7" ZINC 1 3 C CLIP, HITCH PIN 1 4 CU51A118 DECAL, PIN WITH ARROW LITERATURE BOX BLACK, PLASTIC COOLANT RECOVERY TANK 1 7 CR54B050 DOOR, ROADSIDE 1 8 C CAM, DOOR HANDLE 2 9 C T-HANDLE, BLACK W/ KEYS 2 10 C DOOR HANDLE KEYS 2 11 C FENDER 2 12 CR56C050 CABINET, UNDERDOOR PANEL RS 1 13 C PROP DOOR 10" TELESCOPIC WEATHERSTRIP ADHESIVE 1/4" THK X 1/2" WIDE 14FT 15 C PULLEY, 3" 1 16 CS63C080 TOWER BASE 1 17 C CLIP, HITCH PIN 1 18 C PIN, 3/4" X 7" 1 19 CR58C011 CABINET, FRONT PANEL 1 20 C CUSHION 2 21 CR59C010 PANEL, TOP HINGE PIANO 1.5" X 51.75" RIVET POP 3/16" X 1/2" CR54B040 DOOR, CURBSIDE 1 25 CR56C040 CABINET, UNDERDOOR PANEL CS CABINET, REAR PANEL 1 27 CR63A040 REAR TOWER SUPPORT 1 Part No RL4000 Light Tower 300-3

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26 September 2008 Section 400 Electrical Components Section 400 Electrical Components Part No RL4000 LIght Tower 400-1

27 Figure Electrical Control Box Section 400 Electrical Components September RL4000 Light Tower Part No

28 September 2008 Section 400 Electrical Components FIGURE ITEM # PART # DESCRIPTION QTY DECAL: AL/RL CONTROL BOX AC "POWER & LIGHT" BREAKER 2P 30A 240V CONTROL BOX,FACE PLATE TERMINAL,RING BREAKER 1P 15A 277VAC RECEPTACLE 20A 120V DUPLEX W/GFI BREAKER MINI 1P 20A RECEPTACLE 30A 240V 1 9 C NUT, NYLOCK, 8-32 ZINC SWITCH, IGNITION LEVER OPERATED 1 10A included with item WIRE HARNESS,DC ENGINE CONNECTOR,2 SCREW,3/4" CONNECTOR 9P,FEMALE SOCKETS, FEMALE CONNECTOR WITH WIRES (includes 13 and 14) CONNECTOR,2 SCREW, A included with item TERMINAL,CLOSED END WRAP CAP CRIMP SLEEVE WIRE HARNESS 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,#6-32X1/4 PAN HD WASHER,LOCK,# R SWITCH PUSH-BUTTON 1 31A included with item LIGHT INDICATOR 12V RED CONTROL BOX,TOP PANEL 1 34 R RELAY 12V DC 30A BRACKET, E-BOX HANGER NUTSERT,1/4-20UNC WIRING HARNESS, FROM ENGINE 1 37A KUBOTA SOLENOID PIGTAIL COMPLETE ELECTRICAL CONTROL BOX, includes Part No RL4000 Light Tower 400-3

29 Figure Ballast Box Assembly Section 400 Electrical Components September RL4000 Light Tower Part No

30 September 2008 Section 400 Electrical Components FIGURE ITEM # PART # DESCRIPTION QTY BALLAST BOX, MH CONNECTOR, 5P, MALE MH TRANSFORMER AND CAPACITOR CAPACITOR, 24uF, MH, 60Hz, 480V SCREW, 1/4-20NC X 5/ DECAL: DANGER HIGH VOLTAGE DECAL: DECAL: DECAL: DECAL: SPACER 4 Part No RL4000 Light Tower 400-5

31 Figure Light Fixture Section 400 Electrical Components September RL4000 Light Tower Part No

32 September 2008 Section 400 Electrical Components FIGURE ITEM # PART # DESCRIPTION QTY CORD SET MALE 5FT. 3P TERMINAL STRIP, 2P CASTING FOR NEW FIXTURE WASHER LOCK STAR 1/ WASHER LOCK 1/ SCREW 1/2-13NCX1-1/2 HHC GR 2 ZP TRUNION T-HANDLE SCREW 1/2-13NCX1-1/4 HHC GRADE SOCKET BASE-MOGUL GASKET FOR REFLECTOR LABEL, FIXTURE CSA APPROVED REFLECTOR RING,REINFORCING FOR REFLECTOR RIVET POP 1/8X.390 GR-1/4-5/ LENS W/ GASKET CLAMP;LENS TO REFLECTOR SCREW,8-32X1" HH SLOT WASHER, FIBER FOR BAND NUTSERT FOR BAND,8-32 X 1/ NPN included with item LAMP MH 1000W SCREW,10-24X5/ LAMP HPS 1000W SCREW 8-32X3/8 PH SOCKET BRACKET SCREW,8-32X5/ LABEL,105C CORD RATING LABEL,WET LOCATION FIBERGLASS WIRE SLEEVE GASKET 1/2 S/R CONN LOCKNUT CONDUIT 1/ CONNECTOR STRAINRELIEF LAMP SUPPORT 1 35 C COMPLETE FIXTURE ASSEMBLY 1 (includes items 1-34) Part No RL4000 Light Tower 400-7

33 Figure Coil Cord & Junction Box Section 400 Electrical Components September 2008 ITEM # PART # DESCRIPTION QTY SOCKET CONNECTOR 9P, PLUG COIL CORD, RETRACT, 14/ CONNECTOR, 3P, FEMALE DUST CAP W/CHAIN 4 6 C JUNCTION BOX BOX COVER, 2GANG W/GASKET DECAL: CAUTION TIGHTEN FIXTURE CONNECTOR GRIP, HUBBLE WEATHERSTRIP ADHESIVE AR PLATE, COIL CORD, CABINET MOUNT SCREW, #6-32 X 5/8", RD HD, SLOT, S/S JUNCTION BOX, COMPLETE WITH COIL CORD includes COIL CORD ASSEMBLY includes 1, 2 and RL4000 Light Tower Part No

34 September 2008 Section 500 Engine & Generator Engine & Generator Section 500 Part No RL4000 Light Tower 500-1

35 Figure Engine- Kubota D1105 Section 500 Engine & Generator September RL4000 Light Tower Part No

36 September 2008 Section 500 Engine & Generator FIGURE ITEM # PART # DESCRIPTION QTY PP KUBOTA D1105 ENGINE, POWERPACK, BUILD EBG SCREW, 1/2-13NC X 4HHC, GR 2, ZP WASHER, LOCK 1/2" WASHER, FLAT, SNUBBER, 1/2 X 2-3/4", ZP VIBRATION MOUNT, 40 DUROMETER ENGINE MOUNT, L-BRACKET - CURBSIDE ENGINE MOUNT, L-BRACKET - ROADSIDE GENSET RISER, 6KW ONLY LOW OIL PRESSURE SWITCH HIGH TEMPERATURE SWITCH AIR CLEANER ASSEMBLY AIR CLEANER BODY AIR CLEANER ELEMENT AIR CLEANER COVER AIR CLEANER VALVE OIL FILTER FUEL FILTER, IN-LINE, 5/ FUEL FILTER ASSEMBLY FUEL FILTER ELEMENT FUEL PUMP STARTER ALTERNATOR WIRE STOP SOLENOID GASKET, SOLENOID V-BELT WATER PUMP FAN, PUSHER FAN GUARD OIL DIPSTICK MUFFLER, D SPACER, MUFFLER MUFFLER GASKET SCREW, M8 X 1.25 X 45MM, HHC, ZP, MUFFLER WASHER, LOCK, 5/16, MUFFLER MUFFLER TAILPIPE, D OIL DRAIN VALVE CLAMP 7/16 TO 25/ HOSE, OIL, 3/8, 0-250PSI RADIATOR CAP FOR RADIATOR HOSE, TOP HOSE, BOTTOM COOLANT RECOVERY TANK OPERATION MANUAL D Part No RL4000 Light Tower 500-3

37 Section 500 Engine & Generator Figure Marathon Generator - 6 kw - 201CSA5411 September RL4000 Light Tower Part No

38 September 2008 Section 500 Engine & Generator FIGURE ITEM # PART # DESCRIPTION QTY GENERATOR, MARATHON, PANCAKE, 6KW GENERATOR MOUNT BRACKET SCREW, 1/2-13NC X 3-1/2 HHC, GR 2, ZP WASHER, FLAT SNUBBER, 1/2 X 2-3/4 X 7GA, ZINC ISOLATOR, ENGINE MOUNT, 40 DURO SCREW, 3/8-16NC X 1-1/4 HHC, GRADE 5, ZP WASHER, LOCK, 3/ WASHER, FLAT, 3/ FAN, 8LHD BEARING, ODE, A-90006R BEARING, BRACKET, ODE(5412), 8LHD O-RING, 8LHD POT COVER, 8LHD SCREEN ASY W/SPGS, 8LHD DRIVE DISC (C-107), HUB SPACER, CONN. BOX BASE, 8LHD CONN. BOX COVER, 8LHD CAPACITOR 25MF, 8LHD CLAMP, CAPACITOR, 8LHD TERMINAL BLOCK, TS DIODE SURGE PROTECTOR, SUPPRESSOR/VARISITOR MANUAL, MARATHON PANCAKE GENERATOR 1 Part No RL4000 Light Tower 500-5

39 Section 500 Engine & Generator Figure Leroy Somer Generator - 6 kw - LSA 36, M6 September RL4000 Light Tower Part No

40 September 2008 Section 500 Engine & Generator FIGURE ITEM # PART # DESCRIPTION QTY NDE BEARING DIODE KIT (includes 2 diodes) ROTOR BOLT (8 X 245) TOP COVER END CAP FAN TERMINAL BLOCK KIT: CAPACITOR, 22.5mf, (Includes two capacitors) SCREW, M10X1.5X90MM 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 1 Part No RL4000 Light Tower 500-7

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42 September 2008 Section 600 Mast Components Section 600 Mast Components Part No RL4000 Light Tower 600-1

43 Figure Tower Assembly Section 600 Mast Components September RL4000 Light Tower Part No

44 September 2008 Section 600 Mast Components FIGURE ITEM # PART # DESCRIPTION QTY. 1 C JUNCTION BOX, WITH QUICK CONNECTIONS 1 2 CR61C018 COIL CORD COVER SLEEVE 1 3 CR61A017 WIRE GUIDE BRACKET BOLT TEE 1/2-20NF 1 5 CU61A090 SPRING,KICKOUT 1 6 CS63C080 TOWER BASE 1 7 CR61C010 TOWER, 4" SECTION 1 8 CR61C020 TOWER, 3" SECTION 1 9 CR61C030 TOWER, 2" SECTION 1 10 CS61C060 SWIVEL, BOOM(TOWER) 1 11 CU51A103 DECAL: AVOID BOOM SWING 1 12 CR51A107 DECAL: ALIGN ARROWS BEFORE LOWERING 1 13 C WINCH,BRAKE,1500LB W/HANDLE 1 14 CR64C010 CROSSHEAD 1 15 CR51A103 DECAL: WARNING-TAIL HOOK MUST BE PROPERLY 1 16 CU51A121 DECAL: LIFT HERE W/ ARROW 1 17 CU61A025 CABLE UPPER EXTEND 19' 1 18 CU51A117 DECAL: CAUTION LAMPS GET HOT 1 19 CS61A053 SLIDE BLOCK, TOWER GUIDE 6 20 C RIVET,POP,1/4" X 1/2" CU61A035 CABLE LOWER EXTEND 11' 1 22 C PULLEY,3" 1 23 C BOLT 1 24 C WASHER 1 25 C NUT 1 Part No RL4000 Light Tower 600-3

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46 September 2008 Section 700 Options Options Section 700 Part No RL4000 Light Tower 700-1

47 Figure Options Section 700 Options September RL4000 Light Tower Part No

48 September 2008 Section 700 Options FIGURE ITEM # PART # DESCRIPTION QTY BREAKER MINI 1P 20A RECEPTACLE 20A 120V DUPLEX W/GFI COMBO HITCH KIT OPTION BATTERY HOLDOWN ANGLE 14.50" BATTERY, WET, 12V GR24, 700 AMP HEAVY-DUTY L/A BATTERY HOLDOWN ROD, 1/4 X 11-1/4" LIGHT, TRAILER KIT M540, WITH RIGHT & LEFT SIDE 1 Part No RL4000 Light Tower 700-3