Parts Manual

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Summary of content (64 pages)

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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.
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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.
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May 2009 REV A This page intentionally left blank. iv RL4000 • TML-4000 Part No.
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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.
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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.
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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 ............................................................................................
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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 ..................................................
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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 ......................................
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May 2009 REV A This page intentionally left blank. x RL4000 • TML-4000 Part No.
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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.
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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 ___________________________________ _________________________________ _______________
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May 2009 Section 100 • Decals Section 100 Decals Part No.
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Section 100 • Decals Figure 101.1 May 2009 REV A Decals 100 - 2 RL4000 • TML-4000 Part No.
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May 2009 Section 100 • Decals REV A Part No. 116444 FIGURE 101.
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Section 100 • Decals May 2009 RL4000 • TML-4000 Part No. 116444 Figure 101.
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May 2009 Section 200 • Chassis Components Section 200 Chassis Components Part No.
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Section 200 • Chassis Components Figure 201.1 May 2009 REV A Light Tower Chassis - RL4000 200 - 2 RL4000 • TML-4000 Part No.
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Section 200 • Chassis Components May 2009 REV A FIGURE 201.
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Section 200 • Chassis Components Figure 201.1 May 2009 REV A Light Tower Chassis - RL4000 200 - 4 RL4000 • TML-4000 Part No.
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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.
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Section 200 • Chassis Components Figure 202.1 May 2009 REV A Quick Deploy Outriggers - TML-4000 200 - 6 RL4000 • TML-4000 Part No.
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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 .
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Section 200 • Chassis Components Figure 203.1 May 2009 REV A Fuel Tank Assembly 200 - 8 RL4000 • TML-4000 Part No.
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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.
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Section 200 • Chassis Components May 2009 REV A This page intentionally left blank. 200 - 10 RL4000 • TML-4000 Part No.
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May 2009 Section 300 • Cabinet Components Section 300 Cabinet Components Part No.
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Section 300 • Cabinet Components Figure 301.1 May 2009 REV A Cabinet Components 300 - 2 RL4000 • TML-4000 Part No.
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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.
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Section 300 • Cabinet Components May 2009 This page intentionally left blank. 300 - 4 RL4000 • TML-4000 Part No.
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May 2009 Section 400 • Electrical Components Section 400 Electrical Components Part No.
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Section 400 • Electrical Components Figure 401.1 May 2009 REV A Electrical Control Box 400 - 2 RL4000 • TML-4000 Part No.
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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.
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Section 400 • Electrical Components Figure 402.1 May 2009 REV A Ballast Box Assembly 400 - 4 RL4000 • TML-4000 Part No.
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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.
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Section 400 • Electrical Components Figure 403.1 May 2009 REV A Light Fixture - Round 400 - 6 RL4000 • TML-4000 Part No.
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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.
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Section 400 • Electrical Components Figure 404.1 May 2009 REV A Light Fixture - Rectangle 400 - 8 RL4000 • TML-4000 Part No.
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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.
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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.
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May 2009 Section 500 • Engine & Generator Section 500 Engine & Generator Part No.
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Section 500 • Engine & Generator Figure 501.1 May 2009 REV A Engine- Kubota D1105 500 - 2 RL4000 • TML-4000 Part No.
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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.
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Section 500 • Engine & Generator Figure 502.1 May 2009 REV A Engine- Perkins 403D-11G 500 - 4 RL4000 • TML-4000 Part No.
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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.
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Section 500 • Engine & Generator Figure 503.1 May 2009 REV A Marathon Generator - 6 kW - 201CSA5411 500 - 6 RL4000 • TML-4000 Part No.
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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.
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Section 500 • Engine & Generator May 2009 This page intentionally left blank. 500 - 8 RL4000 • TML-4000 Part No.
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May 2009 Section 600 • Mast Components Section 600 Mast Components Part No.
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Section 600 • Mast Components Figure 601.1 May 2009 REV A Lower Mast Assembly 600 - 2 RL4000 • TML-4000 Part No.
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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.
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Section 600 • Mast Components Figure 602.1 May 2009 REV A Middle Mast Assembly 600 - 4 RL4000 • TML-4000 Part No.
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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.
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Section 600 • Mast Components Figure 603.1 May 2009 REV A Upper Mast Assembly - RL4000 600 - 6 RL4000 • TML-4000 Part No.
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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.
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Section 600 • Mast Components Figure 603.2 May 2009 REV A Upper Mast Assembly - TML-4000 600 - 8 RL4000 • TML-4000 Part No.
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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.
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Section 600 • Mast Components May 2009 REV A This page intentionally left blank. 600 - 10 RL4000 • TML-4000 Part No.
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May 2009 Section 700 • Options Section 700 Options Part No.
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Section 700 • Options Figure 701.1 May 2009 REV A Options 700 - 2 RL4000 • TML-4000 Part No.
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Section 700 • Options May 2009 REV A FIGURE 701.1 ITEM # 1 2 3 4 5 6 PART # DESCRIPTION QTY.
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Section 700 • Options Figure 701.1 May 2009 REV A Options 700 - 4 RL4000 • TML-4000 Part No.
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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.
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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.