Terex RL4000 Bedienungsanleitung

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June 2013

RL4000 • TML-4000 Part No. 116694

Important

Read, understand and obey the safety rules and

operating instructions in the appropriate

Operator's Manual on your machine before

attempting any maintenance procedure.

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.

Technical Publications

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.

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.

116694 June 2013

First Edition, Second Printing

TEREX and "Super Quiet" are registered

trademarks of TEREX USA LLC in the USA and

many other countries.

Printed on recycled paper

Printed in U.S.A.

Introduction

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June 2013

Part No. 116694 RL4000 • TML-4000

iii

Revision History

Revision Date Section Procedure / Schematic Page / Description

B 6/2013 6 - Schem. Updates and additions.

REFERENCE EXAMPLES:

Kubota Engine_Section 2_Specifications.

A-6,B-3,C-7_Section 3_Maintenance Procedure.

3-2, 6-4, 9-1_Section 4_Repair Procedure.

Fault Codes_Section 5.

6-35, 6-56, 6-104_Section 6_Schematic Page #.

Electronic Version

Click on any procedure or page number

highlighted in blue to view the update.

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June 2013

RL4000 • TML-4000 Part No. 116694

REVISION HISTORY, CONTINUED

Revision Date Section Procedure / Schematic Page / Description

REFERENCE EXAMPLES:

Kubota Engine_Section 2_Specifications.

A-6,B-3,C-7_Section 3_Maintenance Procedure.

3-2, 6-4, 9-1_Section 4_Repair Procedure.

Fault Codes_Section 5.

6-35, 6-56, 6-104_Section 6_Schematic Page #.

Electronic Version

Click on any procedure or page number

highlighted in blue to view the update.

Discount-Equipment.com

June 2013

Part No. 116694 RL4000 • TML-4000

Serial Number Legend

The serial number plate on your

RL4000/TML-4000 is located on the cabinet next

to the light tower mast.

How to Read Your Serial Number

RL4 08 - 1003

Model

Model year

Sequence

number

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June 2013

RL4000 • TML-4000 Part No. 116694

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.

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.

Safety Rules

Section 1 • Safety Rules

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June 2013

Part No. 116694 RL4000 • TML-4000

SAFETY RULES

Be sure to wear protective eye wear and

other protective clothing if the situation

warrants it.

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.

Section 1 • Safety Rules

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 .

vii

Discount-Equipment.com

June 2013

RL4000 • TML-4000 Part No. 116694

Table of Contents

Introduction

Important Information - Introduction ..................................................................

Revision History ................................................................................................

iii

How to Read Your Serial Number ....................................................................

Section 1 Safety Rules

General Safety Rules .......................................................................................

Section 2 Specifications

Model - RL4000 and TML-4000 ................................................................... 2 - 1

RL4000 ........................................................................................................ 2 - 2

TML-4000 .................................................................................................... 2 - 3

SAE and Metric Fastener Torque Charts..................................................... 2 - 4

Section 3 Scheduled Maintenance Procedures

Introduction .................................................................................................. 3 - 1

Pre-delivery Preparation Report .................................................................. 3 - 3

Maintenance Schedules

Kubota Lubrication and Maintenance Service Intervals............................... 3 - 5

Perkins Lubrication and Maintenance Service Intervals .............................. 3 - 6

Marathon Generators Maintenance Schedule ............................................. 3 - 7

Section 4 Troubleshooting

Introduction .................................................................................................. 4 - 1

Troubleshooting Guide ................................................................................ 4 - 2

viii

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June 2013

Part No. 116694 RL4000 • TML-4000

TABLE OF CONTENTS

Section 5 Schematics

Introduction .................................................................................................. 5 - 1

DC Wiring, Kubota ....................................................................................... 5 - 2

Engine Harness, Kubota.............................................................................. 5 - 3

DC Wiring, Perkins ...................................................................................... 5 - 4

Engine Harness, Perkins ............................................................................. 5 - 5

Wire Harness, Inside Control Box, DC ........................................................ 5 - 6

MH Light Fixture .......................................................................................... 5 - 7

1000 MH Ballast .......................................................................................... 5 - 8

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