SERIES RL4000D1 Light Tower: Operation/Service & Parts Manual
SERIES RL4000D1 Light Tower: Operation/Service & Parts Manual
LIGHT TOWER
OPERATION/SERVICE
& PARTS MANUAL
After Serial Number :
FOF-15979
PART NUMBER SFMRL4D1
REVISION A
FEBRUARY 2006
TABLE OF CONTENTS
OPERATORS MANUAL
To the Operator -----------------------------------------------------------------------------------------3
Safety Alert Symbols ----------------------------------------------------------------------------------4
General Safety ------------------------------------------------------------------------------------------5-9
Receipt of Delivery Checklist -----------------------------------------------------------------------10
Transport & Towing ------------------------------------------------------------------------------------11
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
Tower 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
TO THE OPERATOR
DO NOT ATTEMPT TO SETUP, OPERATE, OR WORK ON THE LIGHT TOWER UNLESS
YOU HAVE 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
Pivot (Lower)
Winch
Telescoping (Upper)
Winch
Access Door
Safety Chain
Boom
Electrical Box
Jack
Outrigger Leg
Trailer Housing
Light Fixtures
Trailer Frame
MEANS:
ATTENTION! BE ALERT!
YOUR SAFETY IS INVOLVED
DANGER Identifies the hazard or unsafe practice 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.
GENERAL SAFETY
DO NOT SETUP OR OPERATE THE LIGHT TOWER WITHOUT
READING THIS OPERATORS MANUAL.
DO NOT WORK ON OR OPERATE THE LIGHT TOWER WHILE UNDER THE INFLUENCE OF PERFORMANCE IMPAIRING DRUGS OR ALCOHOL.
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.
GENERAL SAFETY
FUELING
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 shutoff valve.
DO NOT replace fuel lines with materials
different from those supplied as original
equipment.
Fuel Fill
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.
GENERAL SAFETY
BATTERY 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 medical attention.
GENERAL SAFETY
BEWARE 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 nothing is in danger of falling off during transit.
Tie-Down
Tiie-Down
10
11
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.
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
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.
Rotational Lock
Kick-out Spring
Pivot Lower
Winch
Tower Locking
Pin
14
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.
15
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.
Switch
16
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.
17
OPERATING INSTRUCTIONS
2) Loosen the rotational lock and rotate the tower into its nesting position. The upper telescoping 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.
Telescoping
Upper Winch
Rotational Lock
Kick-out Spring
Pivot Lower
Winch
Coupler
Tower Locking
Pin
Outrigger
Jack
18
MAINTENANCE
MINIMUM MAINTENANCE PROCEDURES:
The following maintenance intervals are only suggested by Terex. You should always
check your engine owners manual for specific information. Should you find any discrepancies between the Terex Manual and the Engine Manufacturers Manual always follow the
Engine Manufacturers 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 Manufacturers 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.
19
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.
20
Model:
Title:
TRAVEL POSITION
NOTES:
WHEEL SIZE: 13" (330mm)
AXLE RATING: 2000lbs (907kg)
TONGUE WEIGHT TRAVEL POSITION: 130lbs (59kg)
TOTAL WEIGHT, NO FUEL: 1760lbs (798kg)
FUEL CAPACITY: 27 GAL (102L)
OPERATING POSITION
21
POSSIBLE CAUSE
a.Yoke pin is in place
b.Defective cable
or pulley
c.Tailhook is latched
d.Defective winch
a.Defective winch
a.Dead battery
b.Engine has seized due to loss
of fluids
22
REMEDY
a.Remove yoke pin
b.Have a trained
mechanic examine and
repair as needed
c.Loosen boom cable
and push in crosshead
assembly
d.Have a trained
mechanic examine
and replace as needed
a.Have a trained
mechanic examine
and replace as needed
b.Have a trained
mechanic examine
and replace as needed
a.Check the battery voltage or
loose cables
b.Have a trained
mechanic examine and
repair as needed
a.Fill tank with #2 diesel fuel
b.Check and clean the fuel
system as needed
c.Replace any leaking fuel lines
and tighten connections
d.Replace heater elements
e.Replace fuel line solenoid
a.Replace fuel lines, tighten all
connections, inspect the pickup
tube and inspect the fuel filter
b.Clear the exhaust system
c.Clear air filter
d.Have a trained
mechanic examine
e.Have a trained
mechanic examine
f.Have a trained
mechanic examine
a.Drain oil to its proper level
b.Have a trained mechanic
inspect for broken or seized
rings. Inspect valve clearances
7.Engine overheats
d.Low voltage
e.Improper ballast
23
a.Defective lamp
d.Wrong voltage
e.Improper ballast
15.Lamp colors different
24
25
26
27
28
29
TEREX
LIGHT CONSTRUCTION
30
D
TEREX
LIGHT CONSTRUCTION
31
D
LIGHT CONSTRUCTION
TEREX
WARRANTY PROCEDURE
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 network.
To file a claim with TEREX LIGHT CONSTRUCTION, an APPLICATION FOR WARRANTY ADJUSTMENT (AWA) form must be completed in its 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 hours 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 charges 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
predetermined number of hours for a particular repair.
TEREX LIGHT CONSTRUCTION does not reimburse for:
1.
2.
3.
4.
32
33
Sold to:
_____________________________
_____________________________
_________________________
_____________________________
_________________________
_____________________________
_____________________________
_____________________________
_____________________________
Options:
_____________________________
_____________________________
When this unit left the factory the engine was filled with engine oil grade __________
34
IMPORTANT
WHEN REQUESTING TECHNICAL HELP AND ORDERING REPLACEMENT PARTS THE
MODEL AND SERIAL NUMBER ARE NECESSARY.
REFER TO THE TEREX SERIAL NUMBER TAG ON THE UNIT FOR CORRECT MODEL NUMBER
AND SERIAL NUMBER.
______________________________________________________________________________
MODEL NUMBER IDENTIFICATION
Sample:
Light Tower Product Line
RL4
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)
Number of Lights
Type of Lights
HPS = High Pressure Sodium
MH = Metal Halide
TH = Tungsten Halogen
European Version (AL4000 Only)
35
060 D
MH
CE
SAE 30
SAE 20
SAE 10W
SAE 10W-30
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.
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.
36
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.
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.
37
Figure 3. Winch
Clevis Pin
Figure 1.
Boom Components
38
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.
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.
39
40
Model:
Title:
109055
DECAL KIT
850150
U51A112
REAR PANEL
FRONT PANEL
U51A311
R51A101
U51A111
U51A116
RL 4000
U51A109
853316
853792
853792
R51A101
52100100
U51A105
U51A105
41
Model:
Title:
Frame Assembly
160110, Battery
840222
Snap Ring
841430, Jack
930950
Weatherstrip
R82C000, Base
Assembly
841430, Jack
840222 Ring
840221
Bracket
841473, Standard
Shackle
840394, Spring Bolt
851310
Decal
S82A020, Tongue
Assembly
(4)82200104, U-Bolts
82100600, 2000# Idler Axle
Complete Assembly
42
Model:
Title:
Cabinet Assembly
53200100
Manual
Box
(2)51400300, Cushion
865307, Radiator OverFlow Bottle Assembly
R58C011, RL Front Panel
51100200, T-Handle
Cam
61300502, Clip
S63C080, Boom
Support
930950
Weather Strip
43
Model:
Title:
44
Model:
Title:
684380, Switch
R660010, Push-Button
Switch
683970, Mini-Breaker
R661490, Relay
684450, T-Lock Receptacle
853294, Decal
663890, Cordset
682715, Light
45
Model:
Title:
850130
Decal
114355, Ballast Box,
Metal Halide
Assembly
Numbered Decals
851691
851692
851693
1
851694
130890, Ballast Spacer Tube
(2) / Unit, use only where
Ballasts are stacked
160032, Capacitor MH
Only
46
Model:
Title:
47
Model:
Title:
Capacitor
109350, LSA37, 6KW
866030, Soleniod
866040, Gasket
836857, Diode
Generator
630930 LSA37, 6KW
48
Model:
Title:
839109 Hose
866090, Alternator
839190, Low Oil Press. Sensor
865276, Muffler
832128, Muffler Gaslket
839110, Hose
866394, Pipe
865054, Hose
836832, O-Ring
866100, Starter
49
Model:
Title:
Radiator
866110, Radiator
50
Model:
Title:
Generator
6 3 0 9 3 0 , G e n e rato r
(4 ) 9 9 02 0 0
L o ck N u t
(2) 9 90 1 9 0 , S cre w
(2 ) 9 9 1 6 5 0 , L o ck W a sh e r
(2) 9 90 41 0 , F e n d e r W a sh e r
1 8 9 33 5, G e n e ra to r
M o u n tin g B a r
1 13 40 0, G ro u n d W ire A ssy.
(4) 9 90 21 0 , F la t W a sh e r
(2 ) 7 4 0 9 2 0 , V ib ra tio n M o u n t A ssy.
(2 ) 9 9 0 8 2 0 , B o lt
T h ru T ra ile r
D e ck
(2 ) 9 9 0 20 0, L o ckn ut
(2 ) 9 9 0 21 0, F la tw ash e r
E n g in e B lock
(4 ) R 98 01 75 , F la t W ashe r
(4 ) 9 9 4 8 3 0 , L o ckw a sh e r
(4 ) 9 9 5 1 1 0 , S cre w
R a d ia to r M o u n ting B ra cke t
(2 ) 9 9 0 1 9 0 , S cre w
1 8 4 32 5, G e n se t S p a ce r - 9/16 "
51
Model:
Title:
Trailer Hitches
840120, Coupler, 2"
176336, Spacer
176335, Plate
221580, Hitch,
Adj. Height
52
53
54
55
56
57
58
59
60