Terex RL4000D2 Service Manual
Service Manual
RL4000D2
First Edition
First Printing
Part No. 116473
September 2008
Courtesy of Machine.Market
Introduction
September 2008
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.
Serial Number Information
TEREX Corporation offers the following manuals
for these models:
Title Part No.
TEREX RL4000 Operator's Manual .................... 116417
First Edition
TEREX RL4000 Service Manual ........................ 116473
First Edition
TEREX RL4000 Part's Manual ........................... 116444
First Edition
Leroy Somer Manual ........................................... 116118
Kubota Engine Manual ....................................... 893020
Axis Manual ........................................................ 116117
Marathon Manual ................................................ 116188
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
Copyright © 2008 by TEREX Corporation
116473 Rev A September 2008
First Edition, Second 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.
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How to Read Your Serial Number
Serial Number Legend
The serial number plate on your RL4000 is located
on the cabinet next to the light tower mast.
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Section 1 • Safety Rules
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.
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Section 1 • Safety Rules
September 2008
REV ASAFETY 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.
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 .
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REV A
Introduction
Important Information - Introduction ...................................................................
How to Read Your Serial Number ..................................................................... iii
Parts Stocking List ............................................................................................ ix
How to Order Parts ........................................................................................... xi
Service Parts Fax Order Form ......................................................................... xii
Section 1 Safety Rules
General Safety Rules ........................................................................................
Section 2 Rev Specifications
A Specifications .............................................................................................. 2 - 1
A Specifications (Continued) ........................................................................... 2 - 2
A Specifications (Continued) ........................................................................... 2 - 3
Table of Contents
ii
v
A Torque Specifications .................................................................................. 2 - 4
Section 3 Rev Scheduled Maintenance Procedures
Introduction .................................................................................................. 3 - 1
Pre-delivery Preparation Report................................................................... 3 - 2
A Maintenance Schedules
Kubota Lubrication and Maintenance Service Intervals................................ 3 - 3
Leroy Somer Generators Maintenance Schedule ........................................ 3 - 4
Marathon Generators Maintenance Schedule .............................................. 3 - 5
Section 4 Rev Troubleshooting
Introduction .................................................................................................. 4 - 1
A Troubleshooting Guide................................................................................. 4 - 2
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Section 5 Rev Schematics
A Introduction .................................................................................................. 5 - 1
A AC Light Tower Wiring ................................................................................. 5 - 2
A Wire Harness, Control Box, European, DC .................................................. 5 - 3
A DC Wiring, European, Kubota ...................................................................... 5 - 4
A DC Wiring, Kubota ....................................................................................... 5 - 5
A Wire Harness, Inside Control Box, DC ......................................................... 5 - 6
A MH or HPS Light Fixture .............................................................................. 5 - 7
A 1000 MH Ballast .......................................................................................... 5 - 8
A 1000 HPS Ballast ......................................................................................... 5 - 9
September 2008
REV ATABLE OF CONTENTS
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REV A
Required Parts
The following parts are required to perform
maintenance procedures as outlined in the
TEREX RL4000 Parts and Service Manuals.
Description Part No.
Kubota Models
Oil Filter .............................................................. 866050
Air Filter .............................................................. 866127
Fuel Filter ........................................................... 839200
V-belt .................................................................. 839209
Parts Stocking List
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REV A
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REV A
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
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.
How To Order Parts
Genie Industries
18340 NE 76th Street
P.O. Box 97030
Redmond, WA 98073-9730
Telephone (877) 367-5606
Fax (888) 274-6192
genieindustries.com
Machine Information
Model
Serial Number
Date of Purchase
Authorized TEREX Distributor
Phone Number
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Service Parts fax Order Form
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) _________________
FAX TO: (888) 274-6192 OR TOLL FREE: 877-367-5606
Optional Equipment __________________________________________________________________________
Part Number Description Quantity Price
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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 ONLY
Order Number ______________ Origin Code ________________ Comments _________________________
Date Scheduled ____________ Ship Condition ______________ __________________________________
Order Total ________________ Terms Code ________________ __________________________________
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