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SERIES RL4000D1
LIGHT TOWER
OPERATION/SERVICE
& PARTS MANUAL
PART NUMBER SFMRL4D1
REVISION A
FEBRUARY 2006
After Serial Number :
FOF-15979
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TABLE OF CONTENTS
OPERATOR’S MANUAL
T o the Operator -----------------------------------------------------------------------------------------3
Safety Alert Symbols ----------------------------------------------------------------------------------4
General Safety ------------------------------------------------------------------------------------------5-9
Receipt of Delivery Checklist -----------------------------------------------------------------------10
Transport & Towing ------------------------------------------------------------------------------------1 1
Setup ------------------------------------------------------------------------------------------------------12-15
Operating Instructions -------------------------------------------------------------------------------- 16-18
Maintenance -------------------------------------------------------------------------------------------- 19-20
Specifications and Dimensions----------------------------------------------------------------------21
Trouble Shooting ---------------------------------------------------------------------------------------22-24
Wiring Diagrams ----------------------------------------------------------------------------------------25-31
Warrranty--------------------------------------------------------------------------------------------------32-33
Serial Number Record --------------------------------------------------------------------------------34
Model Number Identification ------------------------------------------------------------------------35
Reccomended Oil --------------------------------------------------------------------------------------36
Wire Rope Replacement -----------------------------------------------------------------------------37-38
PARTS MANUAL
General Information Parts Manual------------------------------------------------------------------39
Parts Ordering Information---------------------------------------------------------------------------40
Decal Layout---------------------------------------------------------------------------------------------41
Frame Assembly----------------------------------------------------------------------------------------42
Cabinet Assembly---------------------------------------------------------------------------------------43
T ower Assembly ----------------------------------------------------------------------------------------44
Control Box and Junction Box ----------------------------------------------------------------------45
Ballast Assembly ---------------------------------------------------------------------------------------46
Fixture Assembly----------------------------------------------------------------------------------------47
Genset-----------------------------------------------------------------------------------------------------48-49
Radiator Assembly ------------------------------------------------------------------------------------50
Generator------------------------------------------ ------------------------------------------------------51
Hitches ----------------------------------------------------------------------------------------------------52
Options ----------------------------------------------------------------------------------------------------53-60
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TO THE OPERATOR
DO NOT ATTEMPT TO SETUP, OPERATE, OR WORK ON THE LIGHT TOWER UNLESS
YOU HA VE 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 obligation.
If this manual becomes lost, order a new one from Terex so future operation and maintenance personnel may read these instructions.
Rotational Lock
Telescoping (Upper)
Winch
Access Door
Boom
Electrical Box
Pivot (Lower)
Winch
Safety Chain
Jack
Outrigger Leg
Light Fixtures
Trailer Housing
Trailer Frame
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SAFETY ALERT SYMBOLS
MEANS:
ATTENTION! BE ALERT!
YOUR SAFETY IS INVOLVED
THIS SAFETY SYMBOL IS USED FOR IMPORTANT SAFETY MESSAGES.
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 prac-
tice that will result in severe injury or death.
WARNING Identifies the hazard or unsafe practice that could result in severe injury or death.
CAUTION Identifies the hazard or unsafe practice that could result in minor injury or property
damage.
NOTICE Identifies important installation, operation or maintenance information.
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GENERAL SAFETY
DO NOT SETUP OR OPERATE THE LIGHT TOWER WITHOUT
READING THIS OPERA TOR’S MANUAL.
DO NOT WORK ON OR OPERATE THE LIGHT TOWER WHILE UNDER THE INFLUENCE OF PERFORMANCE IMPAIRING DRUGS OR ALCOHOL.
SAFETY ALERT SYMBOL
Stop and take time to read ALL Safety alert
messages. 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.
Always wear a hard hat when operating
the light tower!
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.
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Fuel Fill
GENERAL SAFETY
ALWAYS handle fuel with care. It is highly
flammable.
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.
SEVERE PERSONAL INJURY OR
MACHINE DAMAGE.
.
FUELING
FIRES CAN CAUSE
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
repaired before next use.
Have a fire extinguisher nearby. Be sure the
extinguisher is properly maintained and be
familiar with its use. Extinguishers rated ABC
by the NFPA are appropriate for all applica-
tions.
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GENERAL SAFETY
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 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.
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GENERAL SAFETY
BA TTER Y 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 medi-
cal attention.
METAL HALIDE LAMPS PRODUCE SHORTWAVE
ULTRAVIOLET 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 min-
utes unless adequate shielding or other safety precautions are used.
KEEP ALL BODY P ARTS AND CLOTHING AW AY
FROM MOVING PARTS
Loose jackets, shirts, sleeves, and especially neckties 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.
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GENERAL SAFETY
BEW ARE 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 noth-
ing is in danger of falling off during transit.
Be careful when lifting. Never suspend any other
equipment from the shipping tie downs.
Use the lifting eye or forklift pockets on the tower for lifting the trailer and tower
assembly only (with tower and cabinet).
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
Tiie-Down
NEVER CLIMB ON TOP OF THE CABINET AND/OR
TOWER WHEN ERECTED OR RETRACTED.
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RECEIPT OF DELIVERY CHECKLIST
The tower will be serviced, tested and ready for operation upon delivery. Terex recommends the following checks:
( ) 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.
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Transport & 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 ST ATE
D.O.T. LAWS WHEN TOWING A LIGHT TOWER.
FAILURE TO PROPERLY 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.
Towing of a Terex light tower is approved with the
light fixtures 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- 45 MPH max
Off road towing- 10 MPH max
Severe damage may occur from excessive
speeds. Damage created by abuse will void the
manufacturer’s warranty.
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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 there 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 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.
Insure that all jacks are down to prevent the tower
from tipping over backwards when raised.
NEVER ATTEMPT TO MOVE THE TOWER WHILE
THE LEVELLING JACK ARE DOWN. SERIOUS
MACHINE DAMAGE WILL RESULT.
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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.
Towing Chain
Tongue Jack
Outrigger Pin
Outrigger Jack
Rear Jack
G. When applicable, install the floodlights on the crossarm.
1) Remove the light fixtures from their packing boxes and install them on the crossarm
with the lens facing the ground.
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 lower bolt.
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. They can be
removed and stowed for highway towing.
FIRM AND LEVEL AREA
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.
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 burnthrough and short circuit due to the high fixture
temperature.
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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. Reinsert the tower locking pin into the tower base.
If there is any difficulty in tilting the boom vertically, check the tailhook and hook. The tailhook
may need to be released. Release the tailhook by
pushing in on the crosshead assembly until the
tailhook is cleared from the hook angle.
BEWARE OF PINCH POINTS WHEN ERECTING
OR STOWING THE TELESCOPING TOWER. A
LOSS OF DIGITS OR LIMBS MAY RESULT FROM
UNSAFE PRACTICES.
Do not attempt to lean the tower down below 45
degrees when it is extended - serious damage
may occur .
Rotational Lock
Kick-out Spring
Pivot Lower
Winch
Tower Locking
Pin
WHEN RAISING THE BOOM, MAKE SURE THE
BOOM WIRING DOES NOT BECOME ENTANGLED.
Telescoping
Upper Winch
Travel Locking Pin
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SETUP
THE AUTOMATIC BRAKE MUST BE 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
TOWER BE REPOSITIONED WHEN THE BOOM IS
IN A VERTICAL POSITION.
4) Release the tower rotational lock and adjust the lights to the desired area. Once
positioned correctly, retighten the rotational lock.
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OPERATING INSTRUCTIONS
STARTING THE ENGINE/GENERATOR SET
Insure the light switches are turned “off”. This
prevents the engine from starting under load and
prevents 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) Place the key into the ignition switch and preheat the unit for 10-30 seconds.
Never preheat for more than 30 seconds, damage
may be done to the heating elements.
4) Turn the key switch towards the start side of the key switch. On most units this is to-
wards the right.
To avoid start damage, never operate the starter
for more 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.
Vaporous lights require a warm up period of 5-10
minutes before they will produce a full output.
Breaker, Main
Breakers, Light
Duplex Receptacle
W/ GFI
Mini-Breaker
Hourmeter
T-Lock Receptacle
Swit c h , Push Button
16
Switch
Light, In dicator
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OPERATING INSTRUCTIONS
LIGHT TOWER AUXILIARY POWER:
1) One 15 amp, 125 VAC GFI receptacle is provided for auxiliary power.
2) Total auxiliary power cannot exceed main circuit breaker rating. Each lamp operating
consumes 9.5 amps of 110 volt power.
3) 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 may become damaged.
After being shut down, the lights must be allowed
to cool 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 position. If it does not, contact a qualified mechanic.
Insure the coil cord does not become entangled
with the lower tower sections.
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OPERATING INSTRUCTIONS
2) Loosen the rotational lock and rotate the tower into its nesting position. The upper tele-
scoping winch should be pointing forward, towards the tongue.
3) Remove the travel locking pin (located on cradle).
4) Remove the tower locking pin (located on tower base).
5) Using the lower pivot winch, lower the tower into the cradle.
6) Verify that the tailhook is “latched” or hooked over the tower cradle. This prevents the
tower sections from telescoping out while traveling.
7) Replace the travel locking pin.
8) If required, remove the light fixtures and crosshead assembly.
9) Secure all locking pins and verify that the tailhook is properly latched.
10) Close and lock both doors.
Rotational Lock
Kick-out Spring
Pivot Lower
Winch
Coupler
Tower Locking
Pin
Telescoping
Upper Winch
Outrigger
Jack
Travel Locking Pin
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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 hours:
-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.
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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 IT
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 con-
trols, generator, and thermostats.
2. The base and housing foam may be cleaned with a damp cloth covered with mild soap.
Light Fixture Cleaning:
1. The light fixtures and bulbs may be cleaned using any window cleaner.
THE LIGHT FIXTURES ARE VERY HOT, ALLOW TO
COOL BEFORE PERFORMING ANY CLEANING TO
THE FIXTURE, BULBS OR LENSES.
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Model:
Title:
RL4000 Light Tower
Specifications and Dimensions
Specifications and Dimensions
TRAVEL POSITION
NOTES:
WHEEL SIZE: 13" (330mm)
AXLE RATING: 2000lbs (907kg)
TONGUE WEIGHT TRAVEL POSITION: 130lbs (59kg)
TO TAL WEIGH T, NO FUEL: 1 7 6 0 lbs (798kg )
FUEL CAPACITY: 27 GAL (102L)
OPERATING POSITION
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TROUBLE SHOOTING GUIDE
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 a.Yoke pin is in place a.Remove yoke pin
the operating positi on. b.Defective cable b.Have a trained
or pulley mechanic examin e and
repair as need ed
c.Tailhook is l atched c.Loosen boom c able
and push in crosshead
assembly
d.Defective winch d.Have a trained
mechanic examine
and replace as needed
2.Boom will not t el escope. a.Defective winch a.Have a trained
mechanic examine
and replace as needed
b.Broken cable or pulley b.Have a trained
mechanic examine
and replace as needed
3.Engine will not turn over a.D ead bat tery a.Check the bat tery voltage or
loose cables
b.Engine has seized due to loss b.Have a trained
of fluids mechanic examine and
repair as need ed
4.Engine turns over but will a.Empty fu el tank a.Fill tank with #2 diesel fuel
not s tart b.Clogg ed fuel lines or fil ter b.Check and c l ean the fuel
system as needed
c.Leakin g fuel lines or a l oss c.Replace any leaking fuel lines
of prime and tighten connections
d.Heater elements bur ned out d.Replace heater elem ents
e.Fuel line solenoid is n o t open e.Replace fuel line sol enoid
5.Engine runs rough a.Clogged or leaking fuel system a.Replace fuel lines, tighten all
connections, inspect the pickup
tube and ins pect the fuel filter
b.Clogged exhaust system b.Clear the exhaust system
c.Cl ogged air filt er c.Cl ear air filter
d.Clogg ed or st uck fuel injectors d.H ave a t rained
mechanic examine
e.Val ve clearances are out of e.Have a trained
adjustment or the valve spring mech anic exam i ne
may be damaged
f.Defective governor or fuel pump f.Have a trained
mechanic examine
6.Engine runs but produces a a.Crankcase oil level is too high a.Drain oil to its proper level
dense smoke b.Low compression b.Have a trained mec hanic
ins pect for broken or seized
rings. Inspect valve clear ances
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TROUBLE SHOOTING GUIDE
7.Engine overh eats a.Bl ocked c ooling air intakes a.In spect the front an d rear in takes
and clear as n eeded
b.Low coolant levels b .Repl ace the coolant with a 5 0%
water/cool ant sol ution
c.Radiator fins have becom e c.Clear the radiator fins
clogged
d.Fan belt is loose d.Tighten fan belt
8.Engine runs but the battery a.Al ternator has fail ed a.Have a trai ned mechanic inspect
voltage i s low the al ternator
9.Engine runs but the light wil l a.Circuit breakers are tripped a.Reset the circu it breaker
not operate b.Loose connections in the wiring b.Have a trained electrician i nsp ect
system the ballast box wiring system
c.Burn ed out bul b c.Rep lace the bul bs as needed
d.Defective capacitor d.Have a trained electrician i nsp ect
(Leroy Somers Generator) the capacitor
e.Defective rectifi er e.Have a trai ned electrician in spect
(Newage generator) the recti fi er
f.Defective AC g enerator f.Have a trai ned electrici a n ins pect
the generator
g.Engine speed is too low g.Have a trained mec hanic inspect
the engine speed and reset to
1800rpm @ 60hz
h.Defective ballast and capacitors h.Have a trained electrician inspect
the ballast and capacitors
10.Unusual noise comin g from a. Th e generator has a defective a.H ave a trained electrician i nspect
the generator bearing or damaged fan blade the generator
11.Lamp will not st ar t a.Lamp loose in s ocket a.Inspect lamp base to see if there
is arci ng at cent er contact button.
Tighten lamp. Check socket for
damage. R eplace if needed.
b.Floodlight plugs not tight b.Check plug and receptacle. Tighten
if need ed
c.Defec tive ballast c.In terchange ballast plugs. If lamp
starts, replace b al last. C heck for
swollen capacitors, ch arred wiring,
core and coil, or other signs of
excessive h eat.
d.Low voltage d.Check line voltage at ballast input.
Volt age sh ould be withi n 10% of
rating when operat i ng at norm al l oad.
Increase supply voltage or remove
external l oad.
e.Improper ball ast e.The ballast name plate dat a should
agree with th e line voltage and lamp
used. If not, replace t he ballast.
f.Improper lam p operating position f.Operating p osition should agree
with lamp etch.
g.Lamp has been operating; c ool g.Switch off breaker and allow lamp
down time insufficient to cool.
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TROUBLE SHOOTING GUIDE
12.Lamp starts slowly (arc does a.Defective lamp a.Lamp may glow for an extended
not s trike wh en switchis first period of time. Rep l ace after
tur ned on checking voltag e and ballast
13.Circuit breaker t r i ps on l amp a.Short c i r cuit or ground a.Check wiring against d iagram.
startup ins pect for short s or ground. Fix as
needed.
14.Lamp light output l ow a.Normal lamp deprec iation a.Replace lamp
b.Dirty la mp or fi xture b.Cle a n la mp and fixture
c.Defec tive ballast c.In terch ange ballast plugs. If lamp
starts, replace ballast. Chec k for
swollen capacitors, ch arred wiring,
core and coil, or other signs of
excessive h eat.
d.Wrong volt age d.C heck li ne voltage at bal l ast in put.
Volt age sh ould be withi n 10% of
rating when operat i ng at norm al load.
Check wiring connections for voltage
loss. Check socket contact point.
e.Improper ballast e.Check ballast name plate against
lamp data
15.Lamp col or s different a.Normal l amp deprec iation a.Replace lamp
b.Dirty la mp or fi xture b.Cle a n la mp and fixture
c.Wrong lamp c.Check data on l amps and r eplace
as needed.
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.
DO NOT OPEN FIXTURES WHILE LIGHT CIRCUIT
IS “ON”.
NO USER SERVICEABLE PARTS INSIDE! THIS IS
ONLY A GUIDE. UNIT TO BE SERVICED BY A
QUALIFIED ELECTRICIAN!
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TEREX
LIGHT CONSTRUCTION
D
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D
TEREX
LIGHT CONSTRUCTION
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LIGHT CONSTRUCTION
TEREX
D
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WARRANTY PROCEDURE
p
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
implementation 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, Leroy Somer, Lister Petter, Lombardini, Wisconsin, etc., the applicant should pursue repair
and/or reimbursement through that manufacturer, and its dealer/distributor networ
To file a claim with TEREX LIGHT CONSTRUCTION, an APPLICAT ION FOR WARRANTY ADJUST-
MENT (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 TEREX 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 char ges 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
redetermined 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
k.
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Page 33
TEREX LIGHT CONSTRUCTION
p
y
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 one thousand (1,000) 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 (II) 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 (I) and (II) 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, BALLAS TS, ENGINES,
HYDRAULIC PUMPS, FUEL PUMPS, ALTERNATORS, GENER ATORS, 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
arts 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 or 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 an
warranty claims submitted.
THIS WARRANTY IS EXPRESSLY IN LIEU OF AND EXCLUDE S ALL OTHER WARRANTIES,
EXPRESSED 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 TLC NEITHER ASSUMES NOR
AUTHORIZES ANY OTHER PERSON TO ASSUME FOR TLC ANY OTHER LIABILITY IN
CONNECTION WITH THE SALE OF TLC’S PRODUCTS. THERE ARE NO WARRANTIES WHICH
EXTEND BEYOND THE DESCRIPTION ON THE FACE HEREOF.
33
Page 34
TEREX LIGHT CONSTRUCTION
e
e
PORTABLE LIGHT TOWER
OPERATION AND SERVICE MANUAL
This Operation and Service Manual contains information pertaining to the operation and maintenanc
of your Ter ex Ligh t T ower. W e s u g gest th at you read this m an u al c a re fully prio r to o p erating the
tower. This manual should be retained and referred to for operation, maintenance, and ordering parts
When ordering parts, PLEASE INCLUDE THE MODEL AND SERIAL NUMBE R lo cated on th
nameplate of the tower.
For major rep air and s erv ice o r oth er information, co nta ct your local Terex dealer or write to :
Terex Lig ht Constru cti on
P.O. Box 3147
590 Huey Road
Rock Hill, SC 29730
Telephone: (803) 324-3011
FAX: (803) 366-1101
When retur n ing p ar ts for cred it p leas e co nt act th e fa ctor y for R etu rn of Goods Auth or iza tio n .
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 __________________
_____________________________
_____________________________
Wh en this unit left the factory the engine was filled with engine oil grade __________
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IMPORTANT
_
N
WHEN REQUESTING TECHNICAL HELP AND ORDERING REPLACEMENT PARTS THE
MODEL AND SERIAL NUMBER ARE NEC ESSARY.
REFER TO THE TEREX SERIAL NUMBER TAG ON THE UNIT FOR CORRECT MODEL NUMBER
AND SERIAL NUMBER.
_____________________________________________________________________________
MODEL NUMBER IDENT IFICATION
Sample:
Light Tower Product Line RL4 060 D 4 MH CE
Tower Series
RL4000 (RL4) = 30 Foot Basic Tower with double winch
AL5000 (AL5) = 30 Foot Basic Tower with in-cabinet light
storage and door insulation
LT7000 (LT7) = 30 Foot Deluxe Hydraulic Tower w/optional Acoustic
Enclosure and Complete Instrumentation
kW Rating
(060 is 6.0 kW)
Diesel (D)
umber of Lights
Type of Lights
HPS = High Pressure Sodium
MH = Metal Halide
TH = Tungsten Halogen
European Version (AL4000 Only)
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RECOMMENDED ENGINE OIL & FUEL
KUBOTA D905 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°C) SAE 30
32°F to 77°F (0 to 25°C) SAE 20
Below 32°F (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 temperatures, 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 cleanliness 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.
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CRITERIA FOR REPLACEMENT OF WIRE ROPE – TEREX-AMIDA 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 therefore very important that the cables
be inspected on a frequent basis (once a month) for 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.
OPERATOR ERROR – OTHER MACHINERY DAMAGE
One of the most common reasons for failure of a Light Tower wire rope is due to operator error in using the
winch, or damage to the cable by tools or other machinery. The most common operator error happens when the
mast is telescoping down. When the upper telescoping lock engages, the operator does not pull the lower pivot lock
out (located on the tower base) and keeps on cranking the winch. This results in the cable becoming loose around
the drum due to the tower not pivoting down. This can result in three problems: the loose cable can get trapped
underneath itself, resulting in a sudden or partial “drop” of the mast when the loose section releases at a later time,
thus damaging the cable; or the cable can jump off the winch drum and be damaged by the gears of the winch. The
loose cable can also cause the drum to spin to take up the slack cable. If there is enough friction in the threaded
parts of the winch, the drum can cause the crank handle to start spinning. This can cause the tower to “freefall”
and the results can be catastrophic for anyone standing underneath the tower. A spinning crank handle can also
break bones. Other reasons damage can occur are due to some outside force such as forklift blade nicking or
crushing a cable when moving a unit, or an accidental blow or damage by a hand tool, etc.
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 wires at the point of
damage.
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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 th e c r imped e n d a t th e b o tto m and lay the cable along the leng th of the tub e
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 F ig u re 2 .
Figure 3. Winch
Cle v is P in
Figure 2. Cable Routed Through Pulley
3. A ttach opposite end of cable to the winch on the tower boom
tube (See Fig ure 3 ).
4. R epeat 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.
Figure 1.
Boom Com ponents
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Page 39
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 number 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.
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Page 40
PARTS ORDERING INFORMATION
IMPORTANT
When a part fails and needs to be replaced, only use equivalent parts of equal performance and strength.
Contact your local Terex dealer for parts and service.
When ordering parts for a 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 main or fax confirmation.
PART NUMBERS AND PRICES ARE SUBJECT TO CHANGE WITHOUT NOTICE.
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Page 41
Model:
RL4000 Light Tower
109055
DECAL KIT
FRONT PANEL
U51A116
U51A109
Title:
U51A311
U51A111
R51A101
Cabinet Decal Layout
TOP PANEL
850150
REAR PANEL
RL 4000
853316
U51A112
LEFT ACCESS DOOR
853792
853736 AND 853737 INSIDE DOOR
LEFT UNDERDOOR PANEL
U51A105
52100100
U51A105
RIGHT ACCESS DOOR
853792
R51A101
U51A102 INSIDE DOOR
RIGHT UNDERDOOR PANEL
41
Page 42
Model:
Title:
RL4000 Light Tower
Frame Assembly
R59B035 Fuel Tank Strap
42200220 Fuel Cap
R21A000, Fuel Tank
U63B054, Boom Tilt Cable
61100200, 1500# Brake Winch
851310
Decal
840120, 2" Coupler
1/4X9'-8"
Lower Pivot
841430, Jack
840222 Ring
840221
Bracket
930950
Weatherstrip
R51A102
Decal
S62A011, Outrigger
Slide Housing
160270
160110, Battery
851820
Decal
Battery Cable Set
840222
Snap Ring
174170, Battery Clamp
182330 Threaded Rod
841430, Jack
R82C000, Base
Assembly
841473, Standard
Shackle
840394, Spring Bolt
840395, Spring Bolt Nut
110870, 36" Safety
Chain w/ Hook
C33612, Leaf Spring
S82A020, Tongue
Assembly
(4)82200104, U-Bolts
82100600, 2000# Idler Axle
Complete Assembly
S62C012 Outrigger Leg
Sq. Mount
721051, Sq. Plastic
End Cap
83100900, B78-13B Tire w/ 13"
White Spoke Rim
TRD-111A, Hub Assembly
2201-DC, Dust Cap
840376, Wheel Nut
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Page 43
Model:
Title:
RL4000 Light Tower
Cabinet Assembly
Right Side Not Shown For Clarity:
R54B040, Right RL Access Door
R56C040, Right RL Underdoor Panel
R59C010, RL Top Panel
(2)51400300, Cushion
R58C011, RL Front Panel
61300501, 7" Boom Pin
Assembly
61300502, Clip
S63C080, Boom
Support
(2)796610, S.S. Hinge
930950
Weather Strip
U63A040, Boom Yoke
Plastic Support
R63A040, RL Boom Yoke
R58C020, RL Rear Panel Assembly
53200100
Manual
Box
Crosshead
61300501, PIN
865307, Radiator Over-
Flow Bottle Assembly
R54B050, Left Access
51100200, T-Handle
51100300, T-Handle w/ Keys
42200203, Keys
(2)83400100, Fender
Door
Cam
61300502
Clip
U51A118
Decal
61400100, 3" Cable
Pulley
R56C050, Left RL Underdoor
Panel
(2)51500200, 10" Telescopic
Door Stop
43
Page 44
Model:
Title:
RL4000 Light Tower
Tower Assembly
44
Page 45
Model:
Title:
RL4000 LIGHT TOWER
Electrical Control Box
116805, COMPLETE ASSEMBLY
(2) 186548, Mount Bracket
186543, Top Plate
186546, Front Plate
683680, Breaker 2P-30A
(4) 683870, Breaker 1P-15A
684640, Duplex Receptacle
W/ GFI
683970, Mini-Breaker
684450, T-Lock Receptacle
853294, Decal
682715, Light
186544, Sub Panel
853289, Decal
NOT SHOWN
116775 WIRING HARNESS
116765 WIRING HARNESS RECEPTACLE
186542, Rear Panel
186540, Box Body
260360, Hour Meter
684380, Switch
R660010, Push-Button
Switch
R661490, Relay
663890, Cordset
45
Page 46
Model:
Title:
RL4000 Light Tower
Ba lla s t Assem bly
114355, Ballast Box,
Metal Halide
Assembly
182330, Ballast Hold Down R od
(2) / U n it, u s e o n ly wher e
Ballasts are stacked
114355, Ballast Box,
Metal Halide
Assembly
663860, 5 Pin Connector
160032, Capacitor MH
Only
850130
Decal
Num bered D ecals
851691
851692
851693
1
851694
130890, Ballast Spacer Tube
990381, Self Tapping Screw
(2) / U n it, u s e o n ly wher e
Ballasts are stacked
with Rubber Washer
46
160030 Transformer and
Capacitor Kit
Page 47
Model:
Title:
RL4000 Light Tower
Fixture Assembly
47
Page 48
Model:
Title:
RL4000 LIGHT TOWER
Genset, Kub-D905/L-S 6KW
866125, Air Cleaner Assembly
866126, Air Cleaner Body
866127, Air Cleaner Element
866128, Air Cleaner Cover
866129, Air Cleaner Valve
Capacitor
109350, LSA37, 6KW
866030, Soleniod
866040, Gasket
866120, Radiator Cap
741140, Temp. Sender
836857, Diode
Generator
630930 LSA37, 6KW
839200, Fuel Filter
865223, Electric Fuel Pump
Mounted to Trailer Frame
740620, In-line
Fuel Filter
866050, Oil Filter
866080, V-Belt
866110, Radiator
48
Page 49
Model:
Title:
RL4000 Light Tower
Genset, Kub-D905/L-S 6KW
839109 Hose
866090, Alternator
839190, Low Oil Press. Sensor
865276, Muffler
832128, Muffler Gaslket
839110, Hose
866394, Pipe
865054, Hose
866100, Starter
836831, Bearing Housing
836832, O-Ring
836833, Rear Bearing
49
Page 50
Model:
RL4000 Light Tower
866120, Radiator Cap
866110, Radiator
Title:
Radiator
839157, Overflow Hose Assembly
839109, Upper Radiator Hose
839110, Lower Radiator Hose
50
865307, Coolant Recovery
Tank
Page 51
(2) 991650, Lock Washer
(2) 990410, Fender Washer
113400, Ground Wire Assy.
(4) 990200
Lock Nut
(2) 990190, Screw
Model:
Title:
RL4000 Light Tower
Generator
630930, Generator
189335, Generator
Mounting Bar
(4) 990210, Flat Washer
(2) 740920, Vibration Mount Assy.
Radiator Mounting Bracket
(2) 189290, Engine Mounting Bracket
Th r u T railer
Engine Block
(2) 990820, B olt
Deck
(2) 990200, Locknut
(2) 990210, F latwasher
(4) R980175, Flat W asher
(4) 994830, Lockwasher
(4) 995110, Screw
(2) 990190, Screw
(2) 991650, Lock Washer
(2) 990410, Fender Washer
(2) 740920, Vibration Mount Assy.
184325, Genset Spacer - 9/16"
51
Page 52
Model:
Title:
840470, Ball, 2"
SAE-2
RL4000 LIGHT TOWER
Trailer Hitches
840120, Coupler, 2"
176336, Spacer
176335, Plate
121572, Combo Hitch Ring
16" Long
940000, Kit, Combo
Hitch
124450, Hitch, 24" Height
211410, 2-1/2" I.D.Ring
Hitch for Adj Height
213770, Ring Hitch
2-1/2" I.D.
221580, Hitch,
Adj. Height
52
841200, Hitch, Pintle Ring, 3" I.D.
Page 53
53545556575859
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