SERIES RL4000D1 LIGHT TOWER OPERATION/SERVICE & PARTS MANUAL After Serial Number : FOF-15979 PART NUMBER SFMRL4D1 REVISION A FEBRUARY 2006 1
TABLE OF CONTENTS OPERATOR’S MANUAL To the Operator -----------------------------------------------------------------------------------------3 Safety Alert Symbols ----------------------------------------------------------------------------------4 General Safety ------------------------------------------------------------------------------------------5-9 Receipt of Delivery Checklist -----------------------------------------------------------------------10 Transport & Towing --------------------------------
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.
SAFETY ALERT SYMBOLS MEANS: ATTENTION! BE ALERT! YOUR SAFETY IS INVOLVED THIS SAFETY SYMBOL IS USED FOR IMPORTANT SAFETY MESSAGES. WHEN YOU SEE THIS SYMBOL, FOLLOW THE SAFETY MESSAGE TO AVOID PERSONAL INJURY OR PROPERTY DAMAGE. UNDERSTANDING SIGNAL WORDS A signal word - DANGER, WARNING or CAUTION is used with the safety alert symbol. DANGER Identifies the hazard or unsafe practice that will result in severe injury or death.
GENERAL SAFETY DO NOT SETUP OR OPERATE THE LIGHT TOWER WITHOUT READING THIS OPERATOR’S MANUAL. DO NOT WORK ON OR OPERATE THE LIGHT TOWER WHILE UNDER THE INFLUENCE OF PERFORMANCE IMPAIRING DRUGS OR ALCOHOL. SAFETY ALERT SYMBOL Stop and take time to read ALL Safety alert messages. Follow the safety messages to avoid personal injury or property damage. ACCIDENT PREVENTION Use protective clothing and safety equipment.
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 FIRES CAN CAUSE SEVERE PERSONAL INJURY OR MACHINE DAMAGE. Prevent fires by keeping the light tower and its surrounding area clean. DO NOT refuel while smoking or when near open flame or sparks.
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.
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.
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. Be careful when lifting. Never suspend any other equipment from the shipping tie downs.
RECEIPT OF DELIVERY CHECKLIST The tower will be serviced, tested and ready for operation upon delivery. Terex recommends the following checks: ( ) Insure there is no freight handling damage which should be charged against the carrier. ( ) Make sure the telescoping boom is secure. ( ) Make sure the crosshead assembly is secure. ( ) Check the front and rear jacks for security and proper operation. ( ) Check the outriggers for security and proper operation.
Transport & Towing 1) Using the front leveling jack, securely attach the light tower to the transporting vehicle. 2) Insure that the coupler is properly secured to the towing vehicle and attach the safety chains. ALWAYS USE THE PROPER TRAILER HITCH AND SAFETY CHAINS. OBEY ALL LOCAL OR STATE D.O.T. LAWS WHEN TOWING A LIGHT TOWER. FAILURE TO PROPERLY SECURE THE TRAILER TO THE TOWING VEHICLE MAY RESULT IN SERIOUS INJURY OR DEATH. 3) Retract and rotate the front leveling jack into its stowed position.
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.
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 FIRM AND LEVEL AREA G. When applicable, install the floodlights on the crossarm. 1) Remove the light fixtures from their packing boxes and install them on the crossarm with the lens facing the ground.
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.
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.
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. Never preheat for more than 30 seconds, damage may be done to the heating elements.
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.
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.
MAINTENANCE MINIMUM MAINTENANCE PROCEDURES: The following maintenance intervals are only suggested by Terex. You should always check your engine owner’s manual for specific information. Should you find any discrepancies between the Terex Manual and the Engine Manufacturer’s Manual always follow the Engine Manufacturer’s Manual. Twice Daily: -Check the crankcase oil and fill as required. Daily: -Check the engine and generator for any loose bolts, connections, and fittings.
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. DO NOT SPRAY WATER INTO THE UNIT WHILE IT IS RUNNING. THIS MAY RESULT IN INJURY OR DEATH BY ELECTRIC SHOCK. Exterior Cleaning: 1. The exterior housing may be washed by most conventional cleaners and methods. 2. The exterior housing may be waxed using any conventional automotive wax.
Model: Title: RL4000 Light Tower Specifications and Dimensions Specifications and Dimensions 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
TROUBLE SHOOTING GUIDE The engine and generator are set at the factory. These units are tested and set to 1800 RPM at 60 HZ for proper operation in the field. These units should never require additional adjustments in the field. Adjustments should only be made by a qualified service technician, otherwise the manufacturer’s warranty may become void. TROUBLE 1.Boom will not rise to the operating position. POSSIBLE CAUSE a.Yoke pin is in place b.Defective cable or pulley c.Tailhook is latched d.
TROUBLE SHOOTING GUIDE 7.Engine overheats a.Blocked cooling air intakes b.Low coolant levels 8.Engine runs but the battery voltage is low 9.Engine runs but the light will not operate c.Radiator fins have become clogged d.Fan belt is loose a.Alternator has failed a.Circuit breakers are tripped b.Loose connections in the wiring system c.Burned out bulb d.Defective capacitor (Leroy Somers Generator) e.Defective rectifier (Newage generator) f.Defective AC generator g.Engine speed is too low h.
TROUBLE SHOOTING GUIDE 12.Lamp starts slowly (arc does not strike when switchis first turned on 13.Circuit breaker trips on lamp startup a.Defective lamp 14.Lamp light output low a.Normal lamp depreciation b.Dirty lamp or fixture c.Defective ballast a.Short circuit or ground d.Wrong voltage e.Improper ballast 15.Lamp colors different a.Normal lamp depreciation b.Dirty lamp or fixture c.Wrong lamp a.Lamp may glow for an extended period of time. Replace after checking voltage and ballast a.
1 2 3 4 D TEREX LIGHT CONSTRUCTION
D TEREX LIGHT CONSTRUCTION
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.
TEREX LIGHT CONSTRUCTION P.O. Box 3147 Rock Hill, S.C.
TEREX LIGHT CONSTRUCTION PORTABLE LIGHT TOWER OPERATION AND SERVICE MANUAL This Operation and Service Manual contains information pertaining to the operation and maintenance of your Terex Light Tower. We suggest that you read this manual carefully prior to operating the tower. This manual should be retained and referred to for operation, maintenance, and ordering parts When ordering parts, PLEASE INCLUDE THE MODEL AND SERIAL NUMBER located on the nameplate of the tower.
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.
RECOMMENDED ENGINE OIL & FUEL KUBOTA D905 DIESEL ENGINE Engine oil should be MIL-L-2104C or have properties of API classification of CD grades or higher. Change the type of engine oil according to the ambient operating temperature: Above 77°F (25°C) 32°F to 77°F (0 to 25°C) SAE 30 SAE 20 Below 32°F (0°) SAE 10W SAE 10W-30 Use #2 diesel fuel. NOTES: 1. The temperatures in the table are the ambient temperatures at the time when the engine is started.
CRITERIA FOR REPLACEMENT OF WIRE ROPE – TEREX-AMIDA LIGHT TOWERS The wire ropes used to raise and lower the masts on a TEREX Light Tower are probably some of the most important mechanical parts used in day-to-day operation of the machinery. It is therefore very important that the cables be inspected on a frequent basis (once a month) for wear and tear, and immediately in the event of possible damage due to operator error in using the winch, or possible damage from other equipment.
RL4000 CABLE ROUTING INSTRUCTONS These instructions deal with the assembly and routing of cable for the Terex RL4000 boom, and should aid in making this a smooth assembly. Each boom consists of three separate stages: referred to here as the tower (1), the second stage (2), and the upper (3) boom tubes (see Figure 1). ASSEMBLY 1. Feed cable up through the hole on the bottom of the second stage boom tube with the crimped end at the bottom and lay the cable along the length of the tube as shown here. 2.
GENERAL INFORMATION-PARTS MANUAL 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.
PARTS ORDERING INFORMATION IMPORTANT When a part fails and needs to be replaced, only use equivalent parts of equal performance and strength. Contact your local Terex dealer for parts and service. When ordering parts for a specific unit, follow the instructions listed below. By doing so, you will be assured of receiving the correct part in the shortest period of time. 1. Send your order to the nearest Terex distributor in your area. 2. Give the light tower model and serial number. 3.
Model: RL4000 Light Tower Title: Cabinet Decal Layout TOP PANEL 109055 DECAL KIT 850150 U51A112 REAR PANEL FRONT PANEL U51A311 R51A101 U51A111 U51A116 RL 4000 U51A109 853316 LEFT ACCESS DOOR RIGHT ACCESS DOOR 853792 853792 R51A101 853736 AND 853737 INSIDE DOOR 52100100 U51A102 INSIDE DOOR RIGHT UNDERDOOR PANEL LEFT UNDERDOOR PANEL U51A105 U51A105 41
Model: RL4000 Light Tower Title: Frame Assembly 160270 Battery Cable Set R59B035 Fuel Tank Strap 42200220 Fuel Cap R21A000, Fuel Tank 160110, Battery 174170, Battery Clamp 182330 Threaded Rod 851820 Decal U63B054, Boom Tilt Cable 1/4X9'-8" 840222 Snap Ring 841430, Jack 930950 Weatherstrip 61100200, 1500# Brake Winch Lower Pivot R82C000, Base Assembly 841430, Jack 840222 Ring 840221 Bracket 841473, Standard Shackle 840394, Spring Bolt 851310 Decal 840395, Spring Bolt Nut R51A102 Decal S62A011,
Model: RL4000 Light Tower Title: Cabinet Assembly U63A040, Boom Yoke Crosshead Plastic Support 61300501, PIN 61300502 Clip R63A040, RL Boom Yoke Right Side Not Shown For Clarity: R54B040, Right RL Access Door R56C040, Right RL Underdoor Panel R58C020, RL Rear Panel Assembly U51A118 Decal (2)796610, S.S.
Model: Title: RL4000 Light Tower Tower Assembly 44
Model: RL4000 LIGHT TOWER Title: Electrical Control Box 116805, COMPLETE ASSEMBLY NOT SHOWN 116775 WIRING HARNESS 116765 WIRING HARNESS RECEPTACLE (2) 186548, Mount Bracket 186543, Top Plate 186546, Front Plate 186542, Rear Panel 683680, Breaker 2P-30A 186540, Box Body (4) 683870, Breaker 1P-15A 260360, Hour Meter 684640, Duplex Receptacle W/ GFI 684380, Switch R660010, Push-Button Switch 683970, Mini-Breaker R661490, Relay 684450, T-Lock Receptacle 853294, Decal 663890, Cordset 682715, Light 1
Model: Title: RL4000 Light Tower Ballast Assembly 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 182330, Ballast Hold Down Rod (2) / Unit, use only where Ballasts are stacked 990381, Self Tapping Screw with Rubber Washer 114355, Ballast Box, Metal Halide Assembly 663860, 5 Pin Connector 160032, Capacitor MH Only 160030 Transformer and Capacitor Kit 46
Model: Title: RL4000 Light Tower Fixture Assembly 47
Model: Title: RL4000 LIGHT TOWER Genset, Kub-D905/L-S 6KW 866120, Radiator Cap 866125, Air Cleaner Assembly 866126, Air Cleaner Body 866127, Air Cleaner Element 866128, Air Cleaner Cover 866129, Air Cleaner Valve 741140, Temp.
Model: Title: 839109 Hose RL4000 Light Tower Genset, Kub-D905/L-S 6KW 866090, Alternator 839190, Low Oil Press.
Model: RL4000 Light Tower Title: Radiator 839157, Overflow Hose Assembly 839109, Upper Radiator Hose 866120, Radiator Cap 866110, Radiator 865307, Coolant Recovery Tank 839110, Lower Radiator Hose 50
Model: RL4000 Light Tower 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.
Model: RL4000 LIGHT TOWER Title: Trailer Hitches 840120, Coupler, 2" 176336, Spacer 176335, Plate 840470, Ball, 2" SAE-2 121572, Combo Hitch Ring 16" Long 940000, Kit, Combo Hitch 213770, Ring Hitch 2-1/2" I.D. 124450, Hitch, 24" Height 221580, Hitch, Adj. Height 211410, 2-1/2" I.D.Ring Hitch for Adj Height 841200, Hitch, Pintle Ring, 3" I.D.
