May 2009
Introduction
REV A
Important
Serial Number Information
Read, understand and obey the safety rules and operating instructions in the appropriate Operator's Manual on your machine before attempting any maintenance procedure.
TEREX Corporation offers the following manuals for these models:
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.
TEREX RL4000/TML-4000 ................................ 116692 Operator's Manual First Edition
Title
Part No.
TEREX RL4000/TML-4000 ................................ 116694 Service Manual First Edition TEREX RL4000/TML-4000 ................................ 116693 Part's Manual First Edition Perkins Operations Manual ................................ 131661
Technical Publications
Kubota Engine Manual ....................................... 893020
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.
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:
Copyright © 2009 by TEREX Corporation
www.TEREX.com
116693 Rev A 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.
ii
RL4000 • TML-4000
Part No. 116693
May 2009
REV A
How to Read Your Serial Number
Serial Number Legend The serial number plate on your RL4000 or TML-4000 is located on the cabinet next to the light tower mast.
Part No. 116693
RL4000 • TML-4000
iii
May 2009
REV A
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iv
RL4000 • TML-4000
Part No. 116693
May 2009
Section 1 • Safety Rules
Safety Rules
REV A
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. 116693
RL4000 • TML-4000
v
Section 1 • Safety Rules
SAFETY RULES
May 2009
REV A
Be sure to wear protective eye wear and other protective clothing if the situation warrants it.
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 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 • TML-4000
Part No. 116693
May 2009
Table of Contents
REV A
Introduction 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 Section 1
Safety Rules General Safety Rules ........................................................................................ v
Section 100
Rev A
Section 200
Section 300
Rev
Part No. 116693
Figure 101.1
Decals .............................................................................. 100 - 2
Chassis Components
A
Figure 201.1
Light Tower Chassis ......................................................... 200 - 2
A
Figure 202.1
Quick Deploy Outriggers - TML-4000 ................................ 200 - 6
A
Figure 203.1
Fuel Tank Assembly ......................................................... 200 - 8
Rev A
Section 400
Decals
Rev
Cabinet Components Figure 301.1
Cabinet Components ......................................................... 300 - 2
Electrical Components
A
Figure 401.1
Electrical Control Box ....................................................... 400 - 2
A
Figure 402.1
Ballast Box Assembly ...................................................... 400 - 4
A
Figure 403.1
Light Fixture - Round ......................................................... 400 - 6
A
Figure 404.1
Light Fixture - Rectangle ................................................... 400 - 8
A
Figure 405.1
Coil Cord & Junction Box ................................................ 400 - 10
RL4000 • TML-4000
vii
May 2009
TABLE OF CONTENTS
Section 500
Section 600
Section 700
Rev Engine & Generator A
Figure 501.1
Engine - Kubota ................................................................ 500 - 2
A
Figure 502.1
Engine - Perkins ............................................................... 500 - 4
A
Figure 503.1
Marathon Generator - 6 kW ............................................... 500 - 6
Rev Mast Components A
Figure 601.1
Lower Mast Assembly ...................................................... 600 - 2
A
Figure 602.1
Middle Mast Assembly ..................................................... 600 - 4
A
Figure 603.1
Upper Mast Assembly - RL4000 ....................................... 600 - 6
A
Figure 603.2
Upper Mast Assembly - TML-4000 .................................... 600 - 8
Rev Options A
viii
REV A
Figure 701.1
Options ............................................................................. 700 - 2
RL4000 • TML-4000
Part No. 116693
May 2009
Parts Stocking List
REV A
Required Parts The following parts are required to perform maintenance procedures as outlined in the TEREX RL4000/TML-4000 Parts and Service Manuals. Description
Part No.
Kubota Models
Oil Filter .............................................................. 866050 Air Filter .............................................................. 866127 Fuel Filter ........................................................... 839200 V-belt ................................................................. 839209 Perkins Models
Oil Filter ................................................................ 94762 Air Filter ................................................................ 97474 Fuel Filter ............................................................. 62421 V-belt ................................................................... 85071
Part No. 116693
RL4000 • TML-4000
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May 2009
REV A
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x
RL4000 • TML-4000
Part No. 116693
May 2009
How To Order Parts
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
Genie Industries 18340 NE 76th Street P.O. Box 97030 Redmond, WA 98073-9730 Telephone (877) 367-5606 Fax (888) 274-6192 genieindustries.com
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
Part No. 116693
RL4000 • TML-4000
xi
May 2009
Service Parts fax Order Form FAX TO: (888) 274-6192 OR TOLL FREE: 877-367-5606
Please fill out completely _________________________________
Account Number _______________________________
Your Name ______________________________
Your Fax Number _____________________________
_________________________________
Your Phone Number ____________________________
_________________________________
Ship To
Bill To
___________________________________
_________________________________
___________________________________
_________________________________
___________________________________
_________________________________ Purchase Order Number ____________________
___________________________________ Ship Via
___________________________________
Model(s) ______________________________________________________ Serial No.(s) _________________ Optional Equipment __________________________________________________________________________ Description
Quantity
Price
remove this page and make copies
Part Number
remove this page and make copies
Date
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 ________________
RL4000 • TML-4000
Comments _________________________
Date Scheduled ____________
Ship Condition ______________
__________________________________
Order Total ________________
Terms Code ________________
__________________________________
Part No. 116444
May 2009
Section 100 • Decals
Section 100
Decals
Part No. 116444
RL4000 • TML-4000
100 - 1
Section 100 • Decals
Figure 101.1
May 2009
REV A
Decals
100 - 2
RL4000 • TML-4000
Part No. 116444
May 2009
Section 100 • Decals
REV A
Part No. 116444
FIGURE 101.1
RL4000 • TML-4000
100 - 3
Section 100 • Decals
May 2009
RL4000 • TML-4000
Part No. 116444
Figure 101.1 Decals
100 - 4
May 2009
Section 200 • Chassis Components
Section 200
Chassis Components
Part No. 116444
RL4000 • TML-4000
200 - 1
Section 200 • Chassis Components
Figure 201.1
May 2009
REV A
Light Tower Chassis - RL4000
200 - 2
RL4000 • TML-4000
Part No. 116444
Section 200 • Chassis Components
May 2009
REV A
FIGURE 201.1
ITEM # 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40
PART # 160276 112300 174170 182330 851820 840222 841430 CR82C000 841473 840394 840395 CS62C012 721051 C83100900 CTRD-111A C2201-DC 840376 C82100600 C82200104 C33612 111936 CS82A020 CS62A011 CR51A102 840120 851310 840221 C61100200 930950 CU63B054 CR21A000 C42200220 CR59B035 51600200 990150 990200 991650 993860 994200 995310
Part No. 116444
DESCRIPTION BATTERY CABLE SET 24 4GA R&B-3/8 RING TERMINAL BATTERY WET 12V GR24 460 CCA STD-DUTY L/A BATTERY HOLD DOWN BATTERY HOLD DOWN ROD 1/4" X 10-1/4" DECAL, SYMBOL FOR GROUND JACK SNAP RING JACK SIDEWIND LONG 3KLB TRAILER BASE AXLE SHACKLE 4-5/8" LG 2000LB/3500LB AXLE SPRING BOLT 2000LB/3500LB AXLE SPRING NUT 2000LB/3500LB OUTRIGGER LEG CAPLUG, TUBE PLUG 2-1/2" X 2-1/2" TIRE, ST175/80-13 LOAD B W/13" BLACK RIM HUB W/RACE/BEARINGS/NUTS/STUDS/CAP/WASHER DUST CAP FOR 2000LB AXLE AXLE WHEEL NUT 2000LB/3500LB AXLE 2000LB, 36" SC U-BOLT, AXLE 2000LB SPRING-LEAF SPRING-2000LB CHAIN SAFETY 3000LB 3/8" X 30" W/S-HOOK TONGUE, B-O-H W/JACK BRACKET OUTRIGGER HOUSING DECAL, WARNING ALL OUTRIGGER COUPLER, 2", BOLT ON DECAL, WARNING ALL JACKS MUST BE SWIVELED JACK BRACKET SWIVEL WELD-ON WINCH, BRAKE, 1500LB W/HANDLE WEATHERSTRIP ADHESIVE 1/4" THK X 1/2" WIDE CABLE, TOWER TILT TANK FUEL 30GAL RL FUEL CAP 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"
RL4000 • TML-4000
QTY. 1 1 1 2 1 4 4 1 4 6 6 2 2 2 2 2 10 1 4 2 2 1 1 1 1 3 1 1 8FT 1 1 1 1 2 4 2 4 2 1 1
200 - 3
Section 200 • Chassis Components
Figure 201.1
May 2009
REV A
Light Tower Chassis - RL4000
200 - 4
RL4000 • TML-4000
Part No. 116444
Section 200 • Chassis Components
May 2009
FIGURE 201.1
REV A
ITEM # 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59
PART # C51600600 930950 993180 C54200800 993860 990200 990160 C51601462 CS63C080 C54201300 C61400100 C61300501 C61300502 990820 990200 C54200300 C54300400 C54100200 213770
Part No. 116444
DESCRIPTION NUT, CLIP, 3/8"-16 X 3/4" WEATHERSTRIP, ADHESIVE, 1/4" THICK X 1/2" WIDE NUT, LOCK, NYLON INSERT, 3/4-10NC, GR 2, ZP BOLT, 3/4"-10 X 5", Z, G5 WASHER, FLAT, 1/2, S/S, ST, 18-8 NUT, LOCK, NYLON INSERT, 1/2-13NC, GR 2, ZPIN SCREW, 3/8-16NC X 3-3/4, HHC, GRADE 2, ZP NUT, FLANGE, 3/8"-16, Z TOWER BASE SCREW, FLANGE, 1/2"-13 X 1.5", PATCH PULLEY, 3" CABLE PIN, 3/4" X 7", ZINC CLIP, HITCH PIN SCREW, 1/2-13NC X 2HHC, GR 8, Y-ZINC NUT, LOCK, NYLON INSERT, 1/2-13NC, GR 2, ZPIN BOLT, HEX, 7/8"-9 X 7", Z, G5 WASHER, FLAT, 7/8", Z NUT, NYLOCK, 7/8"-9 Z RING HITCH, BOLT-ON, 2-1/2 ID
RL4000 • TML-4000
QTY. 9 8 1 1 2 2 3 3 1 6 1 1 1 1 1 1 1 1 1
200 - 5
Section 200 • Chassis Components
Figure 202.1
May 2009
REV A
Quick Deploy Outriggers - TML-4000
200 - 6
RL4000 • TML-4000
Part No. 116444
Section 200 • Chassis Components
May 2009
FIGURE 202.1
REV A
ITEM # 1 2 3 4 5 6 7 8 9 10 11 12 13 14 14 15 15 16 17 17 18 19 20 21 22 23 24 25 26 27 28
PART # 32499 33373 38028 42191 51131 69800 69813 69814 69815 80000 80003 80203 80323 116563 116564 116674 116686 120222 166667 166668 790710 840222 841430 981660 990200 990210 990650 990660 991650 995320 995810
Part No. 116444
DESCRIPTION E CLIP, .875 IN., SL LEG WASHER, SHIM, 1.50 X .890 X .09 NUT, LP NYLOCK, 5/8-11 WASHER, FLAT, .640 X 1.160 X .09 SCREW, HHC, 5/8-11 X 2.5 WELDMENT, OUTRIGGER HANDLE BUSHING, .875 X .507 X 2.04 SPRING, TORSION, .875 ID X .50 SPACER, SLEEVE, .63 X .75 X .50 WELDMENT, STRUT GUIDE STRUT BAR, OUTRIGGER BUSHING, OUTRIGGER, MAIN SPACER, STRUT BRACKET, ROADSIDE, OUTRIGGER MOUNT BRACKET,CURBSIDE, OUTRIGGER MOUNT STRIKER PLATE, ROADSIDE STRIKER PLATE, CURBSIDE PIN, 1/2 X 1-1/4 X 7-1/4, SLIDE LOCK WELDMENT, OUTRIGGER, CURBSIDE WELDMENT, OUTRIGGER, ROADSIDE SPRING, COIL, 1/2 X 2.25 X .060 WIRE JACK SNAP RING JACK, SIDEWIND, LONG, 3K LB FT, L-PIN ZP SCREW, 1/2-13NC X 1-1/2 HHC, GRADE 5, ZP NUT, LOCK, NYLON INSERT, 1/2-13NC, GR 2, ZPIN WASHER, FLAT, 1/2 COTTER PIN, 1/8 X 1, SS ROLL PIN, 1/4 X 1-5/8, EXPANDING, ZP WASHER, LOCK, 1/2 SCREW, 1/2-13NC X 4-1/2, HHC, GRADE 8, Y-ZINC SCREW, 1/4-20NC X 5/8, HWH, ROLLOK, ULTRA SEALN
RL4000 • TML-4000
QTY. 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 2 5 1 1 2 2 2
200 - 7
Section 200 • Chassis Components
Figure 203.1
May 2009
REV A
Fuel Tank Assembly
200 - 8
RL4000 • TML-4000
Part No. 116444
Section 200 • Chassis Components
May 2009
REV A
ITEM # 1 2 3 4 5 6 7 8 9 10 11 12 13 14
FIGURE 203.1
PARTS # CR21A000 CR59B035 C42200220 660320 890795 792750 740620 898590 C91100300 891520 891550 891560 890785 C90200400
Part No. 116444
DESCRIPTION FUEL TANK, 30 GALLON BRACKET, FUEL TANK SUPPORT CAP, FUEL TANK FUEL PUMP HOSE, FUEL 5/16" CLAMP, HOSE FILTER, IN-LINE FUEL FITTING, STRAIGHT TO BARB 5/16" HOSE, NYLON FUEL FITTING, 90 DEGREE ELBOW, RETURN ADAPTOR, STRAIGHT FITTING, STRAIGHT TO BARB 1/8" HOSE, FUEL 1/8" FITTING, 90 DEGREE ELBOW, PICKUP
RL4000 • TML-4000
QTY. 1 1 1 1 7 5 1 1 AR 1 1 1 AR 1
200 - 9
Section 200 • Chassis Components
May 2009
REV A
This page intentionally left blank.
200 - 10
RL4000 • TML-4000
Part No. 116444
May 2009
Section 300 • Cabinet Components
Section 300
Cabinet Components
Part No. 116444
RL4000 • TML-4000
300 - 1
Section 300 • Cabinet Components
Figure 301.1
May 2009
REV A
Cabinet Components
300 - 2
RL4000 • TML-4000
Part No. 116444
Section 300 • Cabinet Components
May 2009
REV A
FIGURE 301.1
ITEM # 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33
PART # CU63A040 C61300501 C61300502 CU51A118 24514 865307 NPN CR54B050 C51100200 C51100300 C42200203 C83400100 CR56C050 C51500200 930950 C51400301 C51601520 CR58C011 CR56C040 CR54B040 CR59C010 796610 990670 116215 CR63A040 C51601442 993850 C51600800 C54201200 993850 C51601441 C51601450 C51601451
Part No. 116444
DESCRIPTION SUPPORT, PLASTIC, 2 HOLE, 3.5" X 2.5" X 1" PIN, 3/4" X 7" ZINC CLIP, HITCH PIN DECAL, PIN WITH ARROW LITERATURE BOX, BLACK, PLASTIC COOLANT RECOVERY TANK, INCLUDES ITEM 7 INCLUDED IN ITEM 6 DOOR, ROADSIDE CAM, DOOR HANDLE T-HANDLE, BLACK W/ KEYS DOOR HANDLE KEYS FENDER CABINET, UNDERDOOR PANEL, ROADSIDE PROP, DOOR, 10" TELESCOPIC WEATHERSTRIP, ADHESIVE, 1/4" THICK X 1/2" WIDE CUSHION SCREW, FLANGE, 3/8"-16 X 1.25", PATCH CABINET, FRONT PANEL CABINET, UNDERDOOR PANEL, CURBSIDE DOOR, CURBSIDE PANEL, TOP HINGE, PIANO, 1.5" X 51.75" RIVET, POP, 3/16" X 1/2" CABINET, REAR PANEL REAR TOWER SUPPORT SCREW, FLANGE, 1/4"-20 WASHER, FLAT, 1/4 NUT, CLIP, 1/4"-20 X 3/4" SCREW, CARRIAGE, 1/4"-20 X 3/4" WASHER, FLAT, 1/4 NUT, FLANGE, 1/4"-20 SCREW, FLANGE, 5/16"-18 X 1", PATCH NUT, FLANGE, 5/16"-18
RL4000 • TML-4000
QTY. 1 1 1 1 1 1 1 1 2 2 2 2 1 2 14 2 2 1 1 1 1 2 36 1 1 14 14 14 43 4 4 4 4
300 - 3
Section 300 • Cabinet Components
May 2009
This page intentionally left blank.
300 - 4
RL4000 • TML-4000
Part No. 116444
May 2009
Section 400 • Electrical Components
Section 400
Electrical Components
Part No. 116444
RL4000 • TML-4000
400 - 1
Section 400 • Electrical Components
Figure 401.1
May 2009
REV A
Electrical Control Box
400 - 2
RL4000 • TML-4000
Part No. 116444
Section 400 • Electrical Components
May 2009
REV A
FIGURE 401.1
ITEM # 1 2 3 4 5 6 7 8 9 10 10A 11 12 13 14 15 16 16A 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 31A 32 33 34 35 36 37 37A 38 39
PART # 853294 683680 186546 709133 683870 684640 683970 684450 C54100600 684380 116815 680030 685672 685674 800003 686220 709032 680060 680290 116770 680250 663890 186542 186540 260361 853289 186544 996340 995300 994420 R660010 682715 186543 R661490 116121 993310 116820 800004 116808 R660715
Part No. 116444
DESCRIPTION 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 NUT, NYLOCK, 8-32 ZINC SWITCH, IGNITION LEVER OPERATED included with item 10 WIRE HARNESS,DC ENGINE, INSIDE CONTROL BOX CONNECTOR,2 SCREW,3/4" CONNECTOR 9P,FEMALE SOCKETS, FEMALE CONNECTOR WITH WIRES (includes 13 and 14) CONNECTOR,2 SCREW,1.25 included with item 16 TERMINAL,CLOSED END WRAP CAP CRIMP SLEEVE WIRE HARNESS, AC 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,#6 SWITCH PUSH-BUTTON included with item 31 LIGHT INDICATOR 12V RED CONTROL BOX,TOP PANEL RELAY 12V DC 30A BRACKET, E-BOX HANGER NUTSERT,1/4-20UNC WIRING HARNESS, FROM ENGINE, DC WIRING KUBOTA SOLENOID PIGTAIL COMPLETE ELECTRICAL CONTROL BOX, includes 1-36 DIODE, 6 AMP-50 PIV, 2 WIRE
RL4000 • TML-4000
QTY. 1 1 1 2 4 1 1 1 5 1 1 1 1 9 1 1 2 1 1 1 1 4 1 1 1 1 1 12 12 12 1 1 1 1 2 8 1 1 1 1
400 - 3
Section 400 • Electrical Components
Figure 402.1
May 2009
REV A
Ballast Box Assembly
400 - 4
RL4000 • TML-4000
Part No. 116444
Section 400 • Electrical Components
May 2009
REV A
FIGURE 402.1
ITEM # 1 2 3 4 5 6 7 8 9 10 11
PART # 114355 663860 160030 160032 995490 850130 851691 851692 851693 851694 189346
Part No. 116444
DESCRIPTION BALLAST BOX, MH CONNECTOR, 5P, MALE MH TRANSFORMER AND CAPACITOR CAPACITOR, 24uF, MH, 60Hz, 480V SCREW, 1/4-20NC X 5/8 DECAL: DANGER HIGH VOLTAGE DECAL: 1 DECAL: 2 DECAL: 3 DECAL: 4 SPACER
RL4000 • TML-4000
QTY. 1 1 1 1 8 1 1 1 1 1 4
400 - 5
Section 400 • Electrical Components
Figure 403.1
May 2009
REV A
Light Fixture - Round
400 - 6
RL4000 • TML-4000
Part No. 116444
Section 400 • Electrical Components
May 2009
REV A
FIGURE 403.1
ITEM # 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34
PART # 663850 709034 833567 995970 991650 990810 833566 833573 981640 833569 833564 833585 833568 833570 990675 833524 833543 833574 833581 833578 NPN 160071 833571 833565 833563 833577 833584 833583 833582 683950 680020 682470 120102 C41100720
Part No. 116444
DESCRIPTION CORD SET MALE 5FT. 3P TERMINAL STRIP, 2P CASTING FOR NEW FIXTURE WASHER LOCK STAR 1/2 WASHER LOCK 1/2 SCREW 1/2-13NCX1-1/2 HHC GR 2 ZP TRUNION T-HANDLE SCREW 1/2-13NCX1-1/4 HHC GRADE 5 GASKET FOR REFLECTOR SOCKET BASE-MOGUL LABEL, FIXTURE CSA APPROVED REFLECTOR RING,REINFORCING FOR REFLECTOR RIVET POP 1/8X.390 GR-1/4-5/16 LENS W/ GASKET CLAMP;LENS TO REFLECTOR SCREW,8-32X1" HH SLOT WASHER, FIBER FOR BAND NUTSERT FOR BAND,8-32 X 1/4 included with item 17 LAMP MH 1000W SCREW,10-24X5/8 SCREW 8-32X3/8 PH SOCKET BRACKET SCREW,8-32X5/8 LABEL,105C CORD RATING LABEL,WET LOCATION FIBERGLASS WIRE SLEEVE GASKET 1/2 S/R CONN LOCKNUT CONDUIT 1/2 CONNECTOR STRAINRELIEF LAMP SUPPORT COMPLETE FIXTURE ASSEMBLY (Includes items 1-34)
RL4000 • TML-4000
QTY. 1 2 1 2 2 2 1 1 1 1 1 1 1 1 2 1 1 1 1 1 1 1 4 2 1 2 1 1 1 1 1 1 2 1
400 - 7
Section 400 • Electrical Components
Figure 404.1
May 2009
REV A
Light Fixture - Rectangle
400 - 8
RL4000 • TML-4000
Part No. 116444
Section 400 • Electrical Components
May 2009
REV A
FIGURE 403.1
ITEM # PART # 1 2 3 4 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19
116107 116049 116048 116051 116052 80101 116047 116045 116046 116057 116056 116044 116059 116053 116108 116043 116112 116109 116058 116061
Part No. 116444
DESCRIPTION TOP FRAME, HOUSING BASE GASKET, RECTANGULAR GLASS/LENS GLASS/LENS, RECTANGULAR PSI RETAINER CLIP, GLASS/LENS COVER, GLASS/LENS RETAINER CLIP LAMP, 1000W (CONTAINS MERCURY) REFLECTOR, LAMP SIDE REFLECTOR, BASE REFLECTOR, SIDE LIGHT SOCKET, PSI RECT 5 KV LIGHT SOCKET, PSI RECT 5 KV BRACKET, SOCKET MOUNT FIBERGLASS PAD, RECT LAMP FIXTURE GASKET, HOUSING BASE, TOP FRAME FIXTURE HOUSING BASE, 1KW RECT CLEVIS PIN, 4.6 X 60MM CORD, 16/3, STW 60", QUICK CONNECT GROMMET ASSEMBLY LAMP CLIP, PSI RECT HOUSING SPRING, LAMP RETAINER
RL4000 • TML-4000
QTY. 1 1 1 8 8 1 1 1 1 1 1 1 1 1 1 2 1 1 1 1
400 - 9
Section 400 • Electrical Components
May 2009
Figure 405.1
REV A
Coil Cord & Junction Box
ITEM # 1 2 3 4 5 6 7 8 9 10 11 12 13 14
400 - 10
PART # 685674 685671 660287 663870 663880 C48300108 680190 133488 680080 720440 186280 994380 22112580 22112575
DESCRIPTION
QTY.
SOCKET CONNECTOR 9P, PLUG COIL CORD, RETRACT, 14/7 CONNECTOR, 3P, FEMALE DUST CAP W/CHAIN JUNCTION BOX BOX COVER, 2GANG W/GASKET DECAL: CAUTION TIGHTEN FIXTURE CONNECTOR GRIP, HUBBLE WEATHERSTRIP ADHESIVE PLATE, COIL CORD, CABINET MOUNT SCREW, #6-32 X 5/8", RD HD, SLOT, S/S JUNCTION BOX, COMPLETE WITH COIL CORD includes 1-12 COIL CORD ASSEMBLY includes 1, 2 and 3
RL4000 • TML-4000
9 1 1 4 4 1 1 1 1 AR 1 4 1 1
Part No. 116444
May 2009
Section 500 • Engine & Generator
Section 500
Engine & Generator
Part No. 116444
RL4000 • TML-4000
500 - 1
Section 500 • Engine & Generator
Figure 501.1
May 2009
REV A
Engine- Kubota D1105
500 - 2
RL4000 • TML-4000
Part No. 116444
Section 500 • Engine & Generator
May 2009
REV A
FIGURE 501.1
ITEM # 1 2 3 4 5 6 7 8
PART # 732205PP 995380 991650 990415 80379 124016 124017 124025 839190 741140 866125 866126 866127 866128 866129 866050 740620 839107 839200 660320 866101 866090 866044 866040 839209 839261 839134 866113 839154 865276 190150 832128 996330 990460 125395 741970 897110 866110 866120 116638 839109 839110 865307 893020
Part No. 116444
DESCRIPTION KUBOTA D1105 ENGINE, POWERPACK, BUILD EBG2 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, 5/16 FUEL FILTER ASSEMBLY FUEL FILTER ELEMENT FUEL PUMP STARTER ALTERNATOR 2 WIRE STOP SOLENOID GASKET, SOLENOID V-BELT WATER PUMP FAN, PUSHER FAN GUARD OIL DIPSTICK MUFFLER, D1105 SPACER, MUFFLER MUFFLER GASKET SCREW, M8 X 1.25 X 45MM, HHC, ZP, MUFFLER WASHER, LOCK, 5/16, MUFFLER MUFFLER TAILPIPE, D1105 OIL DRAIN VALVE HOSE, OIL, 3/8, 0-250PSI RADIATOR CAP FOR RADIATOR, TO SN RL408-000100 CAP FOR RADIATOR, FROM SN RL408-000101 HOSE, TOP HOSE, BOTTOM COOLANT RECOVERY TANK OPERATION MANUAL D1105
RL4000 • TML-4000
QTY. 1 2 2 2 2 1 1 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 3 4 4 1 1 3 1 1 1 1 1 1 1
500 - 3
Section 500 • Engine & Generator
Figure 502.1
May 2009
REV A
Engine- Perkins 403D-11G
500 - 4
RL4000 • TML-4000
Part No. 116444
Section 500 • Engine & Generator
May 2009
REV A
FIGURE 502.1
ITEM # 1 2 3 4 5 6 7 8
PART # 116541 990270 991650 990415 80379 116518 116519 R981095 116756-1 189292 101321 97473 134456 97407 97474 94762 740620 94889 62421 72348 85103 85089 97404 95071 101322 97476 101320 112291 58291 97428 58292 131661 131662
Part No. 116444
DESCRIPTION ENGINE, PERKINS, GJ65598-1, 403D-11G SCREW, 1/2-13NC X 3-1/2 HHC, GR 8, ZP WASHER, LOCK 1/2" WASHER, FLAT, SNUBBER, 1/2 X 2-3/4", ZP VIBRATION MOUNT, 40 DUROMETER ENGINE MOUNT, L-BRACKET - ROADSIDE ENGINE MOUNT, L-BRACKET - CURBSIDE SCREW, M12 X 1.25 X 30MM, HHCS, GR.9.8, CAD&YELLOW DC WIRING HARNESS BRACKET, REGULATOR MOUNTING, PERKINS LOW OIL PRESSURE SWITCH HIGH TEMPERATURE SWITCH, 2 TERMINAL HIGH TEMPERATURE SWITCH, 1 TERMINAL AIR CLEANER ASSEMBLY AIR CLEANER ELEMENT OIL FILTER FUEL FILTER, IN-LINE, 5/16 FUEL FILTER ASSEMBLY FUEL FILTER ELEMENT FUEL PUMP STARTER ALTERNATOR STOP SOLENOID V-BELT WATER PUMP FAN OIL DIPSTICK MUFFLER RADIATOR HOSE, TOP HOSE, BOTTOM OPERATION MANUAL 403D WORKSHOP MANUAL 403D
RL4000 • TML-4000
QTY. 1 2 2 2 2 1 1 4 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
500 - 5
Section 500 • Engine & Generator
Figure 503.1
May 2009
REV A
Marathon Generator - 6 kW - 201CSA5411
500 - 6
RL4000 • TML-4000
Part No. 116444
Section 500 • Engine & Generator
May 2009
REV A
FIGURE 503.1
ITEM # PART # 1 2 2 3 4 5 6 7 8
85206 189347 116517 990270 990415 80379 991761 990470 981120 116167 116168 116169 116172 116174 116176 116177 116178 116179 116182 116183 116184 116187 836853 836856 116188
Part No. 116444
DESCRIPTION GENERATOR, MARATHON, PANCAKE, 6KW GENERATOR MOUNT BAR, KUBOTA GEN MOUNT BAR FOR PERKINS 403D-11G T4 SCREW, 1/2-13NC X 3-1/2 HHC, GR 8, 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, 3/8 WASHER, FLAT, 3/8 FAN, 8LHD435044 BEARING, ODE, A-90006R-30 BEARING, BRACKET, ODE(5412), 8LHD013096 O-RING, 8LHD766012 POT COVER, 8LHD310316 SCREEN ASY W/SPGS, 8LHD336030 DRIVE DISC (C-107), 702326-01 HUB SPACER, 725334-01 CONN. BOX BASE, 8LHD354045 CONN. BOX COVER, 8LHD354044 CAPACITOR 25MF, 8LHD5990012 CLAMP, CAPACITOR, 8LHD086034 TERMINAL BLOCK, TS-6005 DIODE SURGE PROTECTOR, SUPPRESSOR/VARISITOR MANUAL, MARATHON PANCAKE GENERATOR
RL4000 • TML-4000
QTY. 1 1 2 2 2 4 4 4 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
500 - 7
Section 500 • Engine & Generator
May 2009
This page intentionally left blank.
500 - 8
RL4000 • TML-4000
Part No. 116444
May 2009
Section 600 • Mast Components
Section 600
Mast Components
Part No. 116444
RL4000 • TML-4000
600 - 1
Section 600 • Mast Components
Figure 601.1
May 2009
REV A
Lower Mast Assembly
600 - 2
RL4000 • TML-4000
Part No. 116444
Section 600 • Mast Components
May 2009
REV A
FIGURE 601.1
ITEM # 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
PART # CR61C010 990200 990650 CU61A025 C61400100 CS61A053 992760 C54200200 C41135000 CR61C018 CR61A017 C51600800 990610 CU61A090 CS61C060 C61100200
Part No. 116444
DESCRIPTION TOWER, 4" SECTION NUT, LOCK, NYLON INSERT, 1/2-13NC, GR 2, ZP COTTER PIN, 1/8 X 1, SS CABLE, UPPER, EXTEND, 19' PULLEY, 3" SLIDE BLOCK, TOWER GUIDE CLEVIS PIN, 1/2 X 1.5, SS SCREW, 1/2"-13 X 2" RIVET, POP, 1/4" X 1/2" COIL CORD COVER SLEEVE WIRE GUIDE BRACKET NUT, CLIP, 1/4"-20 X 3/4" BOLT, TEE, 1/2-20NF SPRING, KICKOUT SWIVEL, BOOM (TOWER) WINCH, BRAKE, 1500LB, W/HANDLE
RL4000 • TML-4000
QTY. 1 1 1 1 1 3 1 1 12 1 1 4 1 1 1 1
600 - 3
Section 600 • Mast Components
Figure 602.1
May 2009
REV A
Middle Mast Assembly
600 - 4
RL4000 • TML-4000
Part No. 116444
Section 600 • Mast Components
May 2009
REV A
FIGURE 602.1
ITEM # 1 2 3 4 5 6 7 8 9
PART # CR61C020 990200 990650 C61400100 CU61A035 CS61A053 992760 C54200200 C41135000
Part No. 116444
DESCRIPTION TOWER, 3" SECTION NUT, LOCK, NYLON INSERT, 1/2-13NC, GR 2, ZP COTTER PIN, 1/8 X 1, SS PULLEY, 3" CABLE, UPPER, EXTEND, 11' SLIDE BLOCK, TOWER GUIDE CLEVIS PIN, 1/2 X 1.5, SS SCREW, 1/2"-13 X 2" RIVET, POP, 1/4" X 1/2"
RL4000 • TML-4000
QTY. 1 1 1 1 1 3 1 1 12
600 - 5
Section 600 • Mast Components
Figure 603.1
May 2009
REV A
Upper Mast Assembly - RL4000
600 - 6
RL4000 • TML-4000
Part No. 116444
Section 600 • Mast Components
May 2009
REV A
FIGURE 603.1
ITEM # 1 2 3 4 5 6 7 8 9 10 11 12
PART # CR61C030 C48300108 CR64C010 C41100720 993180 990230 116073 116055 161095 990880 123080 116064
Part No. 116444
DESCRIPTION TOWER, 2" SECTION JUNCTION BOX WITH QUICK CONNECTIONS CROSSHEAD FIXTURE ASSY, 1000W , MH, QUICK CONNECT NUT, LOCK, NYLON INSERT, 3/4-10NC, GR 2, ZP WASHER, FLAT, 3/4 CROSSARM ASSY, RECTLIGHT FIXTURE YOKE, PSI RECTANGULAR LIGHT FIXTURE FIXTURE, MH, 1000W , NEMA 7, W/YOKE, W /QUICK CONN WASHER, LOCK STAR, 3/4 EXT.TOOTH, ZP FIXTURE MOUNTING WING NUT HANDLE, ADJUSTMENT
RL4000 • TML-4000
QTY. 1 1 1 4 4 4 1 4 4 4 4 4
600 - 7
Section 600 • Mast Components
Figure 603.2
May 2009
REV A
Upper Mast Assembly - TML-4000
600 - 8
RL4000 • TML-4000
Part No. 116444
Section 600 • Mast Components
May 2009
REV A
FIGURE 603.2
ITEM # 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
PART # CR61C030 C48300108 116591 990230 993180 720495 124461 80409 990230 993180 134415 6021 6097 161075 CR64C010
Part No. 116444
DESCRIPTION TOWER, 2" SECTION JUNCTION BOX, QUICK CONNECT HALF CROSSARM WASHER, FLAT, 3/4 NUT, LOCK, NYLON INSERT, 3/4-10NC, GR 2, ZP WASHER, UHMW, BLACK, 13/16 ID X 3.0 OD X 1/8 BRACKET, FIXTURE,YAW ADJUSTMENT, 3/4 HOLE BRACKET, LIGHT PITCH ADJUSTMENT WASHER, FLAT, 3/4 NUT, LOCK, NYLON INSERT, 3/4-10NC, GR 2, ZP SCREW, 3/8-16 X 3/4, S/S, HEX WASHER, LOCK, 3/8 WASHER, FLAT, 3/8 FIXTURE, MH, 1000W , NEMA 7, NO YOKE, W/QUICK CONN CROSSHEAD
RL4000 • TML-4000
QTY. 1 1 2 4 4 4 4 4 4 4 12 12 12 4 1
600 - 9
Section 600 • Mast Components
May 2009
REV A
This page intentionally left blank.
600 - 10
RL4000 • TML-4000
Part No. 116444
May 2009
Section 700 • Options
Section 700
Options
Part No. 116444
RL4000 • TML-4000
700 - 1
Section 700 • Options
Figure 701.1
May 2009
REV A
Options
700 - 2
RL4000 • TML-4000
Part No. 116444
Section 700 • Options
May 2009
REV A
FIGURE 701.1
ITEM # 1
2
3
4
5
6
PART #
DESCRIPTION
QTY.
TR-0LTY0422 OPTION LT: ENGINE BLOCK HEATER, KUBOTA 741993 HEATER, ENGINE BLOCK, 3100003, ZERO START
1
116216 116154 116151
1 1
OPTION LT: FUEL/WATER SEPARATOR, RACOR, KUBOTA FILTER, WATER SEPARATOR, DIESEL FUEL, STANADYNE ELEMENT, 30 MICRON, FUEL WATER
TR0LTX0481RLOPTION LT: TAIL LIGHTS, RECESSED 663515 LIGHT WIRING HARNESS, RECESSED LIGHTS 663520 LIGHT, LICENSE TAG W/BRACKET 663527 LIGHT, SIDE MARKER, AMBER, 2.5" DIAMETER, RECESSED 663528 LIGHT, SIDE MARKER, RED, 2.5" DIAMETER, RECESSED 663529 GROMMET, RECESSED LIGHT KIT, W/PLUG AND WIRES 663843 TRAILER HARNESS, 4 POLE, RUN/BRAKE LIGHTS 663840 LIGHT, TRAILER, RECESSED, STOP, TURN, TAIL LIGHTS
1 1 2 2 4 1 1
TR-0LTX0180 OPTION LT: CONNECTOR 7-POLE, RUN LIGHTS, ROUND 663400 CONNECTOR, TAIL LIGHT 663405 CONNECTOR, TAIL LIGHT, 7POLE CABLE GUARD
1 1
TR-0LTX0040 940000 840120 176336 176335 121572 840470
OPTION LT: HITCH, COMBO, BALL & RING, BOLT-ON KIT: COMBINATION HITCH, BALL & RING, COMPLETE COUPLER FOR 2" BALL COMBO HITCH SIDE SPACER, BOLT-ON COMBO HITCH SIDE PLATE, BOLT-ON COMBO HITCH RING, 16" LONG, BOLT-ON BALL, 2"
1 1 2 2 1 1
TR-0LTX0222 161085 174170 182331
OPTION LT: BATTERY, 700A, HEAVY DUTY BATTERY, 700AMP, GP24, 12V, POST/TERMINAL BATTERY, HOLDOWN ANGLE, 14.50 BATTERY, HOLD-DOWN ROD, 1/4 X 11-1/4
1 1 2
Part No. 116444
RL4000 • TML-4000
700 - 3
Section 700 • Options
Figure 701.1
May 2009
REV A
Options
700 - 4
RL4000 • TML-4000
Part No. 116444
Section 700 • Options
May 2009
REV A
FIGURE 701.1
ITEM # 7
PART #
DESCRIPTION
QTY.
TR-0LTX0210 OPTION LT: RECEPTACLE, EXTRA GFI, DUPLEX 684640 RECEPTACLE, 20A, 120V, DUPLEX W/GFI 683970 BREAKER, MINI, 1P, 20A
1 1
8
TR-OLTX0271 LIGHT DOME W ITH SWITCH C41101100 DOME LIGHT W ITH SWITCH
1 1
9
116217 116154 116144
1 1
OPTION LT: INLINE FUEL HEATER W/SEPARATOR AY, DSL FUEL/WATER SEPARATOR, STANADYNE HEATER, TOPLOAD, FUEL, 100W/12V, STANADYNE
NOTE: OPTION NUMBERS CANNOT BE SOLD AS SPARE PARTS.
Part No. 116444
RL4000 • TML-4000
700 - 5
California Proposition 65
California Proposition 65
Warning Battery post terminals and related accessories contain lead compounds, chemicals known to the State of California to cause cancer and other reproductive harm.
Warning 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 crossed 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
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