Parts Manual
RL4000D2
First Edition Rev A Part No. 116444 September 2008
September 2008
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 Operator's Manual ......... ...................11 ..........11641 6417 7 First Edition
Title
Part No.
TEREX RL4000 RL4000 Service Manual Manual .......... ..................... .............. ...116 116473 473 First Edition TEREX RL4000 Part's Part's Manual .......... .................... .................1 .......1164 16444 44 First Edition Leroy Somer Manual ........... ..................... ..................... .....................11 ..........11611 6118 8 Kubota Engine Manual............................. Manual.......................................89 ..........89302 3020 0
Technical Publications
Axis Manual .......... .................... .................... ..................... ..................... ...............1 .....1 161 16117 17
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.
Marathon Manual ........... ..................... .................... ..................... ................1 .....1 161 16188 88
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 © 2008 by TEREX Corporation
www.TEREX.com
116444 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.
ii
RL4000 Light Tower
Par t No. 116444
September 2008
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 Operator's Manual ......... ...................11 ..........11641 6417 7 First Edition
Title
Part No.
TEREX RL4000 RL4000 Service Manual Manual .......... ..................... .............. ...116 116473 473 First Edition TEREX RL4000 Part's Part's Manual .......... .................... .................1 .......1164 16444 44 First Edition Leroy Somer Manual ........... ..................... ..................... .....................11 ..........11611 6118 8 Kubota Engine Manual............................. Manual.......................................89 ..........89302 3020 0
Technical Publications
Axis Manual .......... .................... .................... ..................... ..................... ...............1 .....1 161 16117 17
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.
Marathon Manual ........... ..................... .................... ..................... ................1 .....1 161 16188 88
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 © 2008 by TEREX Corporation
www.TEREX.com
116444 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.
ii
RL4000 Light Tower
Par t No. 116444
September 2008
REV A
How to Read Your Serial Number
Serial Number Legend The serial number plate on your RL4000 is i s located on the cabinet next to the light tower mast.
Par t No. 116444
RL4000 Light Tower
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September 2008
REV A
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iv
RL4000 Light Tower
Par t No. 116444
September 2008
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.
Par t No. 116444
RL4000 Light Tower
v
Section 1 • Safety Rules
SAFETY RULES
September 2008
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 Light Tower
Part No. 116444
September 2008
Table of Contents
REV A
Introduction
Section 1
Important Information - Introduction ....................................................................
ii
How to Read Your Serial Number ......................................................................
iii
Parts Stocking List ............................................................................................
ix
How to Order Parts ............................................................................................
xi
Service Parts Fax Order Form .........................................................................
xii
Safety Rules General Safety Rules ........................................................................................
Section 100
Rev A
Section 200
Section 300
Rev
Part No. 116444
Decals Figure 101.1
Decals ..............................................................................100 - 2
Chassis Components
A
Figure 201.1
Light Tower Chassis .........................................................200 - 2
A
Figure 202.1
Fuel Tank Assembly ......................................................... 200 - 4
Rev A
Section 400
v
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 ......................................................................400 - 6
A
Figure 404.1
Coil Cord & Junction Box ..................................................400 - 8
RL4000 Light Tower
vii
September 2008
TABLE OF CONTENTS
Section 500
Section 600
Rev
Figure 501.1
Engine - Kubota ................................................................500 - 2
A
Figure 502.1
Marathon Generator - 6 kW ...............................................500 - 4
A
Figure 503.1
Leroy Somer Generator - 6 kW ..........................................500 - 6
Rev
Rev A
viii
Engine & Generator
A
A Section 700
REV A
Mast Components Figure 601.1
Tower Assembly ...............................................................600 - 2
Options Figure 701.1
Options .............................................................................700 - 2
RL4000 Light Tower
Part No. 116444
September 2008
Parts Stocking List
REV A
Required Parts The following parts are required to perform maintenance procedures as outlined in the TEREX RL4000Parts and Service Manual.
Description
Part No.
Kubota Models Oil Filter .............................................................. 866050 Air Filter .............................................................. 866127 Fuel Filter ...........................................................8 39200 V-belt ................................................................. 839209
Part No. 116444
RL4000 Light Tower
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September 2008
REV A
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x
RL4000 Light Tower
Part No. 116444
September 2008
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. 116444
RL4000 Light Tower
xi
September 2008
Service Parts fax Order Form FAX TO: (888) 274-6192 OR TOLL FREE: 877-367-5606
Please fill out completely Date
_________________________________
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 __________________________________________________________________________ Part Number
Description
Quantity
s e i p o c e k a m d n a e g a p s i h t e v o m e r
Price
s e i p o c e k a m d n a e g a p s i h t e v o m e r
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 ________________
__________________________________
AL4000 Light Tower
Part No. 833002
September 2008
Section 100 • Decals
Section 100
Decals
Part No. 116444
RL4000 Light Tower
100 - 1
Section 100 • Decals
Figure 101.1
September 2008
REV A
Decals
100 - 2
RL4000 Light Tower
Part No. 116444
September 2008
Section 100 • Decals
REV A
ITEM # 1 2 3 4 5 6 7 8 9 10 11 12
FIGURE 101.1
PARTS # 109055 850155 CU51A112 853316 853792 CR51A101 CU51A102 C52100100 CU51A116 CU51A111 CR51A101 CR51A311
Part No. 116444
DESCRIPTION KIT: DECALS FOR MODEL 04000RL RITE LITE DECAL: DIESEL FUEL ONLY DECAL: DANGER HOT EXHAUST DECAL:RL4000 W/STRIPE OP/BOTTOM 2.25"TALL DECAL: TEREX 4.5"X43" DECAL:WARNING-IMPROPER GROUNDING. DECAL: NOTICE-NO ETHER DECAL: CALIF.PROP 65 DECAL: TEREX POWER MOVING INSTRUCTION DECAL: WARNING-BOOM DROP DECAL:WARNING-IMPROPER GROUNDING. DECAL:WARNING-IMPROPER GROUNDING.
RL4000 Light Tower
QTY. 1 1 1 1 2 1 1 1 1 1 1 1
100 - 3
Section 100 • Decals
September 2008
RL4000 Light Tower
Part No. 116444
This page intentionally left blank.
100 - 4
September 2008
Section 200 •Chassis Components
Section 200
Chassis Components
Part No. 116444
RL4000 LightTower
200 - 1
Section 200 •Chassis Components
Figure 201.1
September 2008
REV A
LIght Tower Chassis
200 - 2
RL4000 LightTower
Part No. 116444
Section 200 •Chassis Components
September 2008
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 # 160270 Z112300 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 MBT TERM P&N R&B 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 J ACK SNAP RING J ACK 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/J ACK BRACKET OUTRIGGER HOUSING DECAL, WARNING ALL OUTRIGGER COUPLER, 2", BOLT ON DECAL, WARNING ALL J ACKS MUST BE SWIVELED J ACK 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 LIghtTower
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 202.1
September 2008
REV A
Fuel Tank Assembly
200 - 4
RL4000 LightTower
Part No. 116444
September 2008
Section 200 •Chassis Components
REV A
ITEM # 1 2 3 4 5 6 7 8 9 10 11 12 13 14
FIGURE 202.1
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" X 7FT 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 LIghtTower
QTY. 1 1 1 1 1 5 1 1 1 1 1 1 AR 1
200 - 5
Section 200 •Chassis Components
September 2008
REV A
This page intentionally left blank.
200 - 6
RL4000 LightTower
Part No. 116444
September 2008
Section 300 • Cabinet Components
Section 300
Cabinet Components
Part No. 116444
RL4000 LightTower
300 - 1
Section 300 • Cabinet Components
Figure 301.1
September 2008
REV A
Cabinet Components
300 - 2
RL4000 Light Tower
Part No. 116444
Section 300 • Cabinet Components
September 2008
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
PART # CU63A040 C61300501 C61300502 CU51A118 24514 865307 CR54B050 C51100200 C51100300 C42200203 C83400100 CR56C050 C51500200 930950 C61400100 CS63C080 C61300502 C61300501 CR58C011 C51400301 CR59C010 796610 990670 CR54B040 CR56C040 116215 CR63A040
Part No. 116444
DESCRIPTION SUPPORT, PLASTIC, 2HOLE 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 DOOR, ROADSIDE CAM, DOOR HANDLE T-HANDLE, BLACK W/ KEYS DOOR HANDLE KEYS FENDER CABINET, UNDERDOOR PANEL RS PROP DOOR 10" TELESCOPIC WEATHERSTRIP ADHESIVE 1/4" THK X 1/2" WIDE PULLEY, 3" TOWER BASE CLIP, HITCH PIN PIN, 3/4" X 7" CABINET, FRONT PANEL CUSHION PANEL, TOP HINGE PIANO 1.5" X 51.75" RIVET POP 3/16" X 1/2" DOOR, CURBSIDE CABINET, UNDERDOOR PANEL CS CABINET, REAR PANEL REAR TOWER SUPPORT
RL4000 Light Tower
QTY. 1 1 1 1 1 1 1 2 2 2 2 1 2 14FT 1 1 1 1 1 2 1 2 36 1 1 1 1
300 - 3
Section 300 • Cabinet Components
September 2008
RL4000 LightTower
Part No. 116444
This page intentionally left blank.
300 - 4
September 2008
Section 400 •Electrical Components
Section 400
Electrical Components
Part No. 116444
RL4000 LIghtTower
400 - 1
Section 400 • Electrical Components
Figure 401.1
September 2008
REV A
Electrical Control Box
400 - 2
RL4000 Light Tower
Part No. 116444
Section 400 • Electrical Components
September 2008
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
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 116805
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 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 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 KUBOTA SOLENOID PIGTAIL COMPLETE ELECTRICAL CONTROL BOX, includes 1-36
RL4000 Light Tower
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
400 - 3
Section 400 • Electrical Components
Figure 402.1
September 2008
REV A
Ballast Box Assembly
400 - 4
RL4000 Light Tower
Part No. 116444
Section 400 • Electrical Components
September 2008
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 Light Tower
QTY. 1 1 1 1 8 1 1 1 1 1 4
400 - 5
Section 400 • Electrical Components
Figure 403.1
September 2008
REV A
Light Fixture
400 - 6
RL4000 Light Tower
Part No. 116444
Section 400 • Electrical Components
September 2008
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 35
PART #
DESCRIPTION
663850 709034 833567 995970 991650 990810 833566 833573 981640 833564 833569 833585 833568 833570 990675 833524 833543 833574 833581 833578 NPN 160071 833571 160140 833565 833563 833577 833584 833583 833582 683950 680020 682470 22120102 C41100720
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 SOCKET BASE-MOGUL GASKET FOR REFLECTOR 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 LAMP HPS 1000W 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)
Part No. 116444
RL4000 Light Tower
QTY. 1 2 1 2 2 2 1 1 1 1 1 1 1 1 2 1 1 1 1 1 1 1 4 1 2 1 2 1 1 1 1 1 1 1 1
400 - 7
Section 400 • Electrical Components
September 2008
Figure 404.1
REV A
Coil Cord & Junction Box
ITEM # 1 2 3 4 5 6 7 8 9 10 11 12 13 14
400 - 8
PART # 685674 685671 660287 663870 663880 C48300108 680190 852800 680080 720440 186280 994380 22112580 22112575
DESCRIPTION
QTY.
SOCKET CONNECTOR 9P, PLUG COIL CORD, RETRACT, 14/7 CONNECTOR, 3P, FEMALE DUST CAP W/CHAIN J UNCTION 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 J UNCTION BOX, COMP LE TE WITH COIL CORD includes 1-12 COIL CORD ASSEMBLY includes 1, 2 and 3
RL4000 Light Tower
9 1 1 4 4 1 1 1 1 AR 1 4 1 1
Part No. 116444
September 2008
Section 500 •Engine & Generator
Section 500
Engine & Generator
Part No. 116444
RL4000 LightTower
500 - 1
Section 500 • Engine & Generator
Figure 501.1
September 2008
REV A
Engine- Kubota D1105
500 - 2
RL4000 Light Tower
Part No. 116444
Section 500 • Engine & Generator
September 2008
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 792750 897110 866110 866120 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 CLAMP 7/16 TO 25/32 HOSE, OIL, 3/8, 0-250PSI RADIATOR CAP FOR RADIATOR HOSE, TOP HOSE, BOTTOM COOLANT RECOVERY TANK OPERATION MANUAL D1105
RL4000 Light Tower
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 1 3 1 1 1 1 1 1
500 - 3
Section 500 • Engine & Generator
Figure 502.1
September 2008
REV A
Marathon Generator - 6 kW - 201CSA5411
500 - 4
RL4000 Light Tower
Part No. 116444
September 2008
Section 500 • Engine & Generator
REV A
FIGURE 502.1
ITEM # PART # 1 2 3 4 5 6 7 8
85206 189347 990220 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 BRACKET SCREW, 1/2-13NC X 3-1/2 HHC, GR 2, ZP WASHER, FLAT SNUBBER, 1/2 X 2-3/4 X 7GA, ZINC ISOLATOR, ENGINE MOUNT, 40 DURO SCREW, 3/8-16NC X 1-1/4 HHC, GRADE 5, ZP WASHER, LOCK, 3/8 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 Light Tower
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 - 5
Section 500 • Engine & Generator
Figure 503.1
September 2008
REV A
Leroy Somer Generator - 6 kW - LSA 36, M6
500 - 6
RL4000 Light Tower
Part No. 116444
Section 500 • Engine & Generator
September 2008
REV A
FIGURE 503.1
ITEM # 1 2 3 4 5 6 7 8 9 10 11 12 13 14
PART # 836704 836705 836706 836707 836708 836709 836710 836711 996290 990415 740925 996496 189344 630905
Part No. 116444
DESCRIPTION NDE BEARING DIODE KIT (includes 2 diodes) ROTOR BOLT (8 X 245) TOP COVER END CAP FAN TERMINAL BLOCK KIT: CAPACITOR, 22.5mf, (Includes two capacitors) SCREW, M10X1.5X90MM HHC, GRADE 8.8, ZP WASHER, FLAT SNUBBER VIBRATION MOUNT, 30 DUR NUT LOCK NYLON INSERT M10 X 1.5 HEX ZP GENERATOR MOUNT BAR GENERATOR L-S 6KW 120/240 C106 SAE5 LSA36
RL4000 Light Tower
QTY. 1 1 1 1 1 1 1 2 1 2 3 1 1 1
500 - 7
Section 500 •Engine & Generator
September 2008
RL4000 LightTower
Part No. 116444
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500 - 8
September 2008
Section 600 • Mast Components
Section 600
Mast Components
Part No. 116444
RL4000 LightTower
600 - 1
Section 600 • Mast Components
Figure 601.1
September 2008
REV A
Tower Assembly
600 - 2
RL4000 Light Tower
Part No. 116444
Section 600 • Mast Components
September 2008
REV A
FIGURE 601.1
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
PART # C48300108 CR61C018 CR61A017 990610 CU61A090 CS63C080 CR61C010 CR61C020 CR61C030 CS61C060 CU51A103 CR51A107 C61100200 CR64C010 CR51A103 CU51A121 CU61A025 CU51A117 CS61A053 C41135000 CU61A035 C61400100 C54200300 C54300400 C54100200
Part No. 116444
DESCRIPTION J UNCTION BOX, WITH QUICK CONNECTIONS COIL CORD COVER SLEEVE WIRE GUIDE BRACKET BOLT TEE 1/2-20NF SPRING,KICKOUT TOWER BASE TOWER, 4" SECTION TOWER, 3" SECTION TOWER, 2" SECTION SWIVEL, BOOM(TOWER) DECAL: AVOID BOOM SWING DECAL: ALIGN ARROWS BEFORE LOWERING WINCH,BRAKE,1500LB W/HANDLE CROSSHEAD DECAL: WARNING-TAIL HOOK MUST BE PROPERLY DECAL: LIFT HERE W/ ARROW CABLE UPPER EXTEND 19' DECAL: CAUTION LAMPS GET HOT SLIDE BLOCK, TOWER GUIDE RIVET,POP,1/4" X 1/2" CABLE LOWER EXTEND 11' PULLEY,3" BOLT WASHER NUT
RL4000 Light Tower
QTY. 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 6 24 1 1 1 1 1
600 - 3
Section 600 • Mast Components
September 2008
REV A
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600 - 4
RL4000 Light Tower
Part No. 116444
September 2008
Section 700 • Options
Section 700
Options
Part No. 116444
RL4000 LightTower
700 - 1
Section 700 • Options
Figure 701.1
September 2008
REV A
Options
700 - 2
RL4000 Light Tower
Part No. 116444
September 2008
Section 700 • Options
REV A
FIGURE 701.1
ITEM # PART # 1 2 3 4 5 6 7
683970 684640 940000 174170 161085 182331 660420
Part No. 116444
DESCRIPTION BREAKER MINI 1P 20A RECEPTACLE 20A 120V DUPLEX W/GFI COMBO HITCH KIT OPTION BATTERY HOLDOWN ANGLE 14.50" BATTERY, WET, 12V GR24, 700 AMP HEAVY-DUTY L/A BATTERY HOLDOWN ROD, 1/4 X 11-1/4" LIGHT, TRAILER KIT M540, WITH RIGHT & LEFT SIDE
RL4000 Light Tower
QTY. 1 1 1 1 1 2 1
700 - 3
Section 700 • Options
September 2008
RL4000 LightTower
Part No. 116444
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700 - 4
