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 ------------------------------------------------------------------------------------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

2
 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 COM-
PONENTS.

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 mainte-
nance personnel may read these instructions.

Rotational Lock

Telescoping (Upper) Pivot (Lower)

Winch Winch

Access Door

Boom Safety Chain

Electrical Box Jack

Outrigger Leg

Trailer Housing
Light Fixtures Trailer Frame

3
 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 prac-

tice that will result in severe injury or death.

WARNING Identifies the hazard or unsafe prac-

tice that could result in severe injury or death.

CAUTION Identifies the hazard or unsafe prac-

tice that could result in minor injury or property
damage.

NOTICE Identifies important installation, opera-

tion or maintenance information.

4
 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 INFLU-
ENCE 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 equip-

ment. Always wear approved safety equip-
ment 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.

5
 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 shut-

off valve.

DO NOT replace fuel lines with materials

different from those supplied as original
Fuel Fill equipment.

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.

DO NOT refuel the engine when it is hot.

Allow to cool for several minutes before
refueling.

DO NOT spill fuel inside the engine compart-

ment.

If fuel has leaked, wipe it up and have leak

repaired before next use.

Have a fire extinguisher nearby. Be sure the

extinguisher is properly maintained and be
familiar with its use. Extinguishers rated ABC
by the NFPA are appropriate for all applica-
tions.

6
 GENERAL SAFETY

EXHAUST GASES ARE TOXIC. DO NOT USE IN-

DOORS 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 equip-
ment 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 imme-
diately.

When troubleshooting indicates a malfunction in the high voltage AC system, pass

the task to a qualified and trained electrician.

DO NOT TOUCH HOT PARTS

The exhaust manifold and tail pipe are very hot. Parts of the engine are also hot.
Use protective gloves when handling hot parts.

The light fixtures become very hot during operations. To avoid burns, always allow
any fixture to cool before handling.

7
 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 medi-
cal attention.

METAL HALIDE LAMPS PRODUCE SHORTWAVE

ULTRAVIOLET RADIATION AND CAN CAUSE SERI-
OUS SKIN AND EYE BURNS OR INFLAMMATION IF
THE OUTER ENVELOPE OF THE LAMP IS BRO-
KEN OR PUNCTURED.
DO NOT use where people will remain close to the lamps for more than a few min-
utes unless adequate shielding or other safety precautions are used.

KEEP ALL BODY PARTS AND CLOTHING AWAY

FROM MOVING PARTS
Loose jackets, shirts, sleeves, and especially neckties should not be worn while
working on or running the unit.

Only remove guards or protective devices from unit temporarily to gain access for
maintenance. Always replace guards immediately after servicing. Never remove
guards while unit is operating.

Keep your hands away from moving parts, particularly clear of the radiator fan and
alternator belts when the engine is running.

8
 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 noth-
ing is in danger of falling off during transit.

Be careful when lifting. Never suspend any other

equipment from the shipping tie downs.

Use the lifting eye or forklift pockets on the tower for lifting the trailer and tower
assembly only (with tower and cabinet).

Make sure any tie-downs at the bottom of the trailer are released, and the cradle
retaining pin is inserted and secured, prior to lifting.

Forklift Pockets
Cradle Retaining Pin

Tie-Down
Tiie-Down

NEVER CLIMB ON TOP OF THE CABINET AND/OR

TOWER WHEN ERECTED OR RETRACTED.

9
 RECEIPT OF DELIVERY CHECKLIST

The tower will be serviced, tested and ready for operation upon delivery. Terex recom-
mends 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.

( ) Check that the tires are not damaged, under inflated or that any lugs are loose.

( ) Check the engine/generator for obvious damage, loose connections, or leaks.

( ) Check the control panel for damage or loose connections.

( ) Check the boom wires for obvious damage or loose connections.

( ) Check the light fixtures for damage to the lamps, lenses, reflector or etc.

( ) Check the winches, cables and pulleys for damage and proper operation.

( ) Check the exhaust system for damage.

( ) Check all fluid levels; battery, radiator, and engine oils.

( ) Insure manuals are in the pocket provided inside the unit.

10
 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 SERI-
OUS INJURY OR DEATH.
3) Retract and rotate the front leveling jack into its stowed position.

4) Check the tires for proper inflation (32psi) and verify the lug nuts are tight.

5) Position all outriggers and jacks into the stowed or travel position.

6) Verify that the fixtures are secure and ready for transport.

7) Secure all loose locking pins and retainers.

8) Make sure all doors are closed and tightly locked.

9) Remove tire chocks.

Towing of a Terex light tower is approved with the

light fixtures in place on the crosshead assembly
for all off road terrain and highway towing as long
as the following speed limits are followed:
Highway towing- 45 MPH max
Off road towing- 10 MPH max
Severe damage may occur from excessive
speeds. Damage created by abuse will void the
manufacturer’s warranty.

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.

OUTRIGGERS ARE NOT DESIGNED TO LIFT THE
TIRES OFF THE GROUND.
Insure that all jacks are down to prevent the tower
from tipping over backwards when raised.
NEVER ATTEMPT TO MOVE THE TOWER WHILE
THE LEVELLING JACK ARE DOWN. SERIOUS
MACHINE DAMAGE WILL RESULT.
12
 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.

2) The cord on the fixture should be on the side closest to the trailer so the cord entry is
beneath the fixture when the tower is raised (this reduces moisture problems and
insures the water weep hole in the fixture is down).

3) Set the vertical aim for each light fixture by adjusting the light fixtures and tightening
the lower bolt.

4) Set the spread between the fixtures horizontally by adjusting the fixtures and tighten
ing the mounting nut.

5) The light fixtures may be left on the unit when towed around the job site. They can be
removed and stowed for highway towing.

6) Plug each fixture into the receptacles provided. Plug into the numbered receptacles in
a clockwise rotation starting at the upper or 1:00 o’clock position. This makes trouble
shooting easy without lowering the tower.

If Tungsten Halogen lamps are used, the cord

must be routed and secured away from the fix-
ture. Failure to do so may result in cord burn-
through and short circuit due to the high fixture
temperature.
13
 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 verti-
cally, 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.

BEWARE OF PINCH POINTS WHEN ERECTING

OR STOWING THE TELESCOPING TOWER. A
LOSS OF DIGITS OR LIMBS MAY RESULT FROM
UNSAFE PRACTICES.
Do not attempt to lean the tower down below 45
degrees when it is extended - serious damage
may occur.

Telescoping
Upper Winch Travel Locking Pin

Rotational Lock

Kick-out Spring
Pivot Lower
Winch

Tower Locking
Pin
WHEN RAISING THE BOOM, MAKE SURE THE
BOOM WIRING DOES NOT BECOME EN-
TANGLED.

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 dam-
aged.
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.
4) Turn the key switch towards the start side of the key switch. On most units this is to-
wards the right.

To avoid start damage, never operate the starter

for more than 45 seconds.
5) Start the engine and listen for any unusual sounds or vibrations. Should unusual sounds
be detected, contact Terex Light Construction Service Manager.

6) Once the engine has been started and running smoothly, place the light switches in the
“ON” positions, one at a time.

7) Check each flood light for proper operation.

8) Close and latch the access doors.

Vaporous lights require a warm up period of 5-10
minutes before they will produce a full output.
Breaker, Main

Breakers, Light

Duplex Receptacle
W/ GFI
Hourmeter

Mini-Breaker

T-Lock Receptacle Switch

Switch, Push Button
Light, Indicator

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 compo-
nents 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”.
Never shut the unit down while under load. The
AC generator may become damaged.

After being shut down, the lights must be allowed

to cool down before trying to restart the lights.
This cool down period can be between 10-25 min-
utes, depending on the ambient temperature.

LOWERING THE TOWER:

1) Using the upper telescoping winch, telescope the tower down to its fully retracted posi-
tion.
The boom should lower smoothly and evenly to
its lowest position. If it does not, contact a quali-
fied mechanic.
Insure the coil cord does not become entangled
with the lower tower sections.

17
 OPERATING INSTRUCTIONS

2) Loosen the rotational lock and rotate the tower into its nesting position. The upper tele-
scoping 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 Travel Locking Pin

Rotational Lock

Kick-out Spring
Pivot Lower
Winch

Coupler

Tower Locking
Outrigger
Pin
Jack

18
 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 discrepan-
cies 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.
-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 Manufacturer’s 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.

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.

Interior Cleaning:
1. Using a damp cloth covered with a mild soap, carefully clean around any electric con-
trols, generator, and thermostats.

2. The base and housing foam may be cleaned with a damp cloth covered with mild soap.

Light Fixture Cleaning:

1. The light fixtures and bulbs may be cleaned using any window cleaner.

THE LIGHT FIXTURES ARE VERY HOT, ALLOW TO

COOL BEFORE PERFORMING ANY CLEANING TO
THE FIXTURE, BULBS OR LENSES.

20
 Model:
RL4000 Light Tower
Title:
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 techni-
cian, otherwise the manufacturer’s warranty may become void.

TROUBLE POSSIBLE CAUSE REMEDY

1.Boom will not rise to a.Yoke pin is in place a.Remove yoke pin
the operating position. b.Defective cable b.Have a trained
or pulley mechanic examine and
repair as needed
c.Tailhook is latched c.Loosen boom cable
and push in crosshead
assembly
d.Defective winch d.Have a trained
mechanic examine
and replace as needed
2.Boom will not telescope. a.Defective winch a.Have a trained
mechanic examine
and replace as needed
b.Broken cable or pulley b.Have a trained
mechanic examine
and replace as needed
3.Engine will not turn over a.Dead battery a.Check the battery voltage or
loose cables
b.Engine has seized due to loss b.Have a trained
of fluids mechanic examine and
repair as needed
4.Engine turns over but will a.Empty fuel tank a.Fill tank with #2 diesel fuel
not start b.Clogged fuel lines or filter b.Check and clean the fuel
system as needed
c.Leaking fuel lines or a loss c.Replace any leaking fuel lines
of prime and tighten connections
d.Heater elements burned out d.Replace heater elements
e.Fuel line solenoid is not open e.Replace fuel line solenoid
5.Engine runs rough a.Clogged or leaking fuel system a.Replace fuel lines, tighten all
connections, inspect the pickup
tube and inspect the fuel filter
b.Clogged exhaust system b.Clear the exhaust system
c.Clogged air filter c.Clear air filter
d.Clogged or stuck fuel injectors d.Have a trained
mechanic examine
e.Valve clearances are out of e.Have a trained
adjustment or the valve spring mechanic examine
may be damaged
f.Defective governor or fuel pump f.Have a trained
mechanic examine
6.Engine runs but produces a a.Crankcase oil level is too high a.Drain oil to its proper level
dense smoke b.Low compression b.Have a trained mechanic
inspect for broken or seized
rings. Inspect valve clearances

22
 TROUBLE SHOOTING GUIDE

7.Engine overheats a.Blocked cooling air intakes a.Inspect the front and rear intakes
and clear as needed
b.Low coolant levels b.Replace the coolant with a 50%
water/coolant solution
c.Radiator fins have become c.Clear the radiator fins
clogged
d.Fan belt is loose d.Tighten fan belt
8.Engine runs but the battery a.Alternator has failed a.Have a trained mechanic inspect
voltage is low the alternator
9.Engine runs but the light will a.Circuit breakers are tripped a.Reset the circuit breaker
not operate b.Loose connections in the wiring b.Have a trained electrician inspect
system the ballast box wiring system
c.Burned out bulb c.Replace the bulbs as needed
d.Defective capacitor d.Have a trained electrician inspect
(Leroy Somers Generator) the capacitor
e.Defective rectifier e.Have a trained electrician inspect
(Newage generator) the rectifier
f.Defective AC generator f.Have a trained electrician inspect
the generator
g.Engine speed is too low g.Have a trained mechanic inspect
the engine speed and reset to
1800rpm @ 60hz
h.Defective ballast and capacitors h.Have a trained electrician inspect
the ballast and capacitors
10.Unusual noise coming from a.The generator has a defective a.Have a trained electrician inspect
the generator bearing or damaged fan blade the generator
11.Lamp will not start a.Lamp loose in socket a.Inspect lamp base to see if there
is arcing at center contact button.
Tighten lamp. Check socket for
damage. Replace if needed.
b.Floodlight plugs not tight b.Check plug and receptacle. Tighten
if needed
c.Defective ballast c.Interchange ballast plugs. If lamp
starts, replace ballast. Check for
swollen capacitors, charred wiring,
core and coil, or other signs of
excessive heat.
d.Low voltage d.Check line voltage at ballast input.
Voltage should be within 10% of
rating when operating at normal load.
Increase supply voltage or remove
external load.
e.Improper ballast e.The ballast name plate data should
agree with the line voltage and lamp
used. If not, replace the ballast.
f.Improper lamp operating position f.Operating position should agree
with lamp etch.
g.Lamp has been operating; cool g.Switch off breaker and allow lamp
down time insufficient to cool.

23
 TROUBLE SHOOTING GUIDE

12.Lamp starts slowly (arc does a.Defective lamp a.Lamp may glow for an extended
not strike when switchis first period of time. Replace after
turned on checking voltage and ballast
13.Circuit breaker trips on lamp a.Short circuit or ground a.Check wiring against diagram.
startup inspect for shorts or ground. Fix as
needed.
14.Lamp light output low a.Normal lamp depreciation a.Replace lamp
b.Dirty lamp or fixture b.Clean lamp and fixture
c.Defective ballast c.Interchange ballast plugs. If lamp
starts, replace ballast. Check for
swollen capacitors, charred wiring,
core and coil, or other signs of
excessive heat.
d.Wrong voltage d.Check line voltage at ballast input.
Voltage should be within 10% of
rating when operating at normal load.
Check wiring connections for voltage
loss. Check socket contact point.
e.Improper ballast e.Check ballast name plate against
lamp data
15.Lamp colors different a.Normal lamp depreciation a.Replace lamp
b.Dirty lamp or fixture b.Clean lamp and fixture
c.Wrong lamp c.Check data on lamps and replace
as needed.

IF YOU FEEL AN ELECTRIC SHOCK AT ANY TIME

WHILE OPERATING THIS UNIT, SHUT IT DOWN
IMMEDIATELY! HAVE THE UNIT INSPECTED BY A
TRAINED ELECTRICIAN.

DO NOT OPEN FIXTURES WHILE LIGHT CIRCUIT

IS “ON”.

NO USER SERVICEABLE PARTS INSIDE! THIS IS

ONLY A GUIDE. UNIT TO BE SERVICED BY A
QUALIFIED ELECTRICIAN!

24
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TEREX
LIGHT CONSTRUCTION

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TEREX
LIGHT CONSTRUCTION

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31
TEREX
LIGHT CONSTRUCTION

D
 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 ADJUST-
MENT (AWA) form must be completed in it’s 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 hour’s 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. Travel, travel time, nor travel labor.

2. Mileage.
3. Excessive diagnostic time.
4. Repairs of defects, malfunctions, or failures resulting from accidents, abuse, misuse, modifica-
tions, alterations, improper servicing or lack of performance of required maintenance service.
5. Repairs where defective parts were not shipped back when requested by TEREX LIGHT CON-
STRUCTION.
6. Regular maintenance such as parts or labor for oil changes, filter changes or filters.
7. Repairs where defective parts were not received by TEREX LIGHT CONSTRUCTION after TEREX
LIGHT CONSTRUCTION issued a return authorization.
TEREX Light Construction P.O.Box 3147• Rock Hill, S.C. 29731 USA • Phone 803-324-3011 • Fax 803-366-1101

32
 TEREX LIGHT CONSTRUCTION
P.O. Box 3147
Rock Hill, S.C. 29732

MANUFACTURER’S LIMITED WARRANTY

TEREX LIGHT CONSTRUCTION (“TLC”) warrants to the original purchaser that such equipment,
accessories, parts and other products manufactured by TLC will be free from defects in workmanship and material
for a period of one (1) year after the date of first delivery or for one thousand (1,000) hours of use, whichever
comes first; provided that Buyer sends TLC notice of such defect within thirty (30) days of its discovery. Should
defects be discovered, the Buyer must clearly establish that (I) the equipment, parts, etc. have been properly
installed and set up, maintained and operated within the limits of rated and normal usage and (II) the defect did not
result in any manner from the intentional or negligent action or inaction of Buyer. Buyer must also return the
defective item or items to TLC, Rock Hill, SC for inspection at TLC’s request. If Buyer cannot establish that
conditions (I) and (II) have been met, then this warranty shall not cover the alleged defect. Failure to give notice
of defect within such period shall be a waiver of this Warranty and any assistance rendered thereafter shall not
extend or revive it. THIS WARRANTY IS LIMITED TO THE BUYER AND IS NOT ASSIGNABLE OR
OTHERWISE TRANSFERABLE.

TLC MAKES NO WARRANTY WITH RESPECT TO PARTS, COMPONENTS, EQUIPMENT AND

ACCESSORIES NOT MANUFACTURED BY TLC SUCH AS FIXTURES, BALLASTS, ENGINES,
HYDRAULIC PUMPS, FUEL PUMPS, ALTERNATORS, GENERATORS, WINCHES, TIRES AND
ELECTRICAL COMPONENTS. Accessories, assemblies and components included in products of TLC, which
are not manufactured by TLC, are subject only to the warranty of their respective manufacturers. TLC makes no
other warranty, express or implied, and makes no warranty of merchantability or fitness for any particular purpose.
This warranty shall not cover misuse, alteration, abuse, negligence, accident, acts of God, sabotage or any item in
which serial numbers have been altered, defaced or removed, but shall be limited to repair or replacement of those
parts which, upon inspection by TLC, appear to have been defective in material or workmanship.

TLC’s liability and Buyer’s sole and exclusive remedy for a failure of goods to perform as warranted and/or for
any and all other claims arising out of the purchase and use of the goods, including negligence on the part of TLC,
shall be limited to the repair or replacement of defective parts returned, transportation prepaid to TLC. TLC shall
in no event be liable for incidental or consequential or other damages or losses resulting from a breach of warranty
such as, but not by way of limitation, labor costs, loss of profits, loss of use of other than equipment, third party
repairs, personal injury, emotional or mental distress, improper performance of work, penalties of any kind, loss of
service of personnel, or any other damages or losses which may be experienced by the Buyer.

A product warranty certificate must be filled out in its entirety and returned to TLC in order to process any
warranty claims submitted.

THIS WARRANTY IS EXPRESSLY IN LIEU OF AND EXCLUDES ALL OTHER WARRANTIES,

EXPRESSED OR IMPLIED (INCLUDING ANY WARRANTY OF MERCHANTABILITY AND
FITNESS OF ANY PRODUCT OR GOODS FOR A PARTICULAR PURPOSE) AND ALL OTHER
OBLIGATIONS OR LIABILITIES ON TLC’S PART, AND TLC NEITHER ASSUMES NOR
AUTHORIZES ANY OTHER PERSON TO ASSUME FOR TLC ANY OTHER LIABILITY IN
CONNECTION WITH THE SALE OF TLC’S PRODUCTS. THERE ARE NO WARRANTIES WHICH
EXTEND BEYOND THE DESCRIPTION ON THE FACE HEREOF.

33
 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.

For major repair and service or other information, contact your local Terex dealer or write to:

Terex Light Construction

P.O. Box 3147
590 Huey Road
Rock Hill, SC 29730
Telephone: (803) 324-3011
FAX: (803) 366-1101

When returning parts for credit please contact the factory for Return of Goods Authorization.

Terex Model Number _______________________ Serial Number ____________________

Engine Model Number _______________________ Serial Number ____________________

Generator Model Number ____________________ Serial Number ____________________

Sold to: _____________________________ Ship to: _________________________

_____________________________ _________________________

_____________________________ _________________________

Options: _____________________________ Production Date: _________________

_____________________________ Work Order Number ______________

_____________________________ Shipping Date ___________________

_____________________________ In Service Date __________________

_____________________________

_____________________________

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 060 D 4 MH CE

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
 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) SAE 30

32°F to 77°F (0 to 25°C) 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. 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. MIL-L-2104B or MIL-L-2104C or API CD must also be used if the sulfur content
of the fuel exceeds 0.5%.

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
 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 impor-
tant 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 dam-
age due to operator error in using the winch, or possible damage from other equipment.

NORMAL WEAR AND TEAR

When used properly, the wire ropes should give years of trouble-free service, depending on how often the masts
are raised and lowered. The rule of thumb at TEREX is that if the tower is raised and lowered an average of once
per day, that the cables should be replaced every two years of service.

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.

OPERATOR ERROR – OTHER MACHINERY DAMAGE

One of the most common reasons for failure of a Light Tower wire rope is due to operator error in using the
winch, or damage to the cable by tools or other machinery. The most common operator error happens when the
mast is telescoping down. When the upper telescoping lock engages, the operator does not pull the lower pivot lock
out (located on the tower base) and keeps on cranking the winch. This results in the cable becoming loose around
the drum due to the tower not pivoting down. This can result in three problems: the loose cable can get trapped
underneath itself, resulting in a sudden or partial “drop” of the mast when the loose section releases at a later time,
thus damaging the cable; or the cable can jump off the winch drum and be damaged by the gears of the winch. The
loose cable can also cause the drum to spin to take up the slack cable. If there is enough friction in the threaded
parts of the winch, the drum can cause the crank handle to start spinning. This can cause the tower to “freefall”
and the results can be catastrophic for anyone standing underneath the tower. A spinning crank handle can also
break bones. Other reasons damage can occur are due to some outside force such as forklift blade nicking or
crushing a cable when moving a unit, or an accidental blow or damage by a hand tool, etc.

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 diam-
eter 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
 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. Slide the second stage boom tube into the tower boom tube.

3. Run the cable over the upper pulley on the tower boom tube as shown here and
in Figure 2.

Figure 3. Winch
Clevis Pin

Figure 2. Cable Routed Through Pulley

3. Attach opposite end of cable to the winch on the tower boom

tube (See Figure 3).

4. Repeat Steps 1 – 3 for the upper boom tube, and attach cable
to the clevis pin on the second stage boom tube shown in Figure 2.

Figure 1.
Boom Components
38
 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 quanti-
ties 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.

NOTES and DESIGNATIONS

This manual is compiled from information available and current at time of approval for
printing. Terex reserves the right to improve its product without notice to follow its policy of
constantly striving to manufacture a better product.

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
 PARTS ORDERING INFORMATION

IMPORTANT

When a part fails and needs to be replaced, only use equivalent parts of equal perfor-
mance 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. Write the quantity required, part number, and description of the parts wanted.

4. Give the specific shipping instructions, to whom and where parts are to be shipped, also
whether shipment is to go parcel post, express freight, or truck, prepaid or collect. We want
your order to reach you as quickly and as economically as possible.

5. Confirm all telephone orders in writing via main or fax confirmation.

PART NUMBERS AND PRICES ARE SUBJECT TO CHANGE WITHOUT NOTICE.

40
 Model:
RL4000 Light Tower
Title:
Cabinet Decal Layout

TOP PANEL
109055
DECAL KIT

850150

FRONT PANEL REAR PANEL U51A112

U51A311
R51A101

U51A111

U51A116
RL 4000

U51A109
853316

LEFT ACCESS DOOR

853792 RIGHT ACCESS DOOR

853792

R51A101

853736 AND 853737 INSIDE DOOR U51A102 INSIDE DOOR

52100100

LEFT UNDERDOOR PANEL RIGHT 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
840222 841430, Jack
U63B054, Boom Tilt Cable Snap Ring
1/4X9'-8"
61100200, 1500# Brake Winch 930950
Lower Pivot Weatherstrip R82C000, Base
Assembly
841430, Jack
840222 Ring 841473, Standard
Shackle
840221
Bracket 840394, Spring Bolt

851310 840395, Spring Bolt Nut

Decal
R51A102
Decal
S62A011, Outrigger
840120, 2" Coupler Slide Housing

S82A020, Tongue
110870, 36" Safety Assembly S62C012 Outrigger Leg
Chain w/ Hook Sq. Mount
721051, Sq. Plastic
End Cap

C33612, Leaf Spring

83100900, B78-13B Tire w/ 13"
White Spoke Rim

TRD-111A, Hub Assembly

(4)82200104, U-Bolts
2201-DC, Dust Cap
82100600, 2000# Idler Axle 840376, Wheel Nut
Complete Assembly

42
 Model:
RL4000 Light Tower
Title:
Cabinet Assembly

U63A040, Boom Yoke

Crosshead
Plastic Support
61300501, PIN
R63A040, RL Boom Yoke
61300502
Clip
Right Side Not Shown For Clarity: R58C020, RL Rear Panel Assembly
R54B040, Right RL Access Door
R56C040, Right RL Underdoor Panel U51A118
Decal
(2)796610, S.S. Hinge
53200100
Manual
Box
R59C010, RL Top Panel

(2)51400300, Cushion
865307, Radiator Over-
Flow Bottle Assembly
R58C011, RL Front Panel
R54B050, Left Access
Door
61300501, 7" Boom Pin
Assembly 51100200, T-Handle
Cam
61300502, Clip
51100300, T-Handle w/ Keys
42200203, Keys
(2)83400100, Fender
S63C080, Boom
Support 930950
Weather Strip

61400100, 3" Cable

Pulley R56C050, Left RL Underdoor
Panel
(2)51500200, 10" Telescopic
Door Stop

43
Model:
RL4000 Light Tower
Title:
Tower Assembly

44
 Model:
RL4000 LIGHT TOWER
Title:
Electrical Control Box

116805, COMPLETE ASSEMBLY

NOT SHOWN
116775 WIRING HARNESS
(2) 186548, Mount Bracket 116765 WIRING HARNESS RECEPTACLE

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
683970, Mini-Breaker Switch
R661490, Relay
684450, T-Lock Receptacle
663890, Cordset
853294, Decal 682715, Light
186544, Sub Panel
853289, Decal

45
 Model:
RL4000 Light Tower
Title:
Ballast Assembly

850130 Numbered Decals

Decal 851691
114355, Ballast Box, 851692
Metal Halide 851693
Assembly 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
114355, Ballast Box, with Rubber Washer
Metal Halide
Assembly

663860, 5 Pin Connector

160032, Capacitor MH
Only

160030 Transformer and

Capacitor Kit

46
Model:
RL4000 Light Tower
Title:
Fixture Assembly

47
 Model:
RL4000 LIGHT TOWER
Title:
Genset, Kub-D905/L-S 6KW

866125, Air Cleaner Assembly 866120, Radiator Cap

866126, Air Cleaner Body
866127, Air Cleaner Element
866128, Air Cleaner Cover
741140, Temp. Sender
866129, Air Cleaner Valve

Capacitor
109350, LSA37, 6KW

866030, Soleniod
866040, Gasket

836857, Diode
Generator
630930 LSA37, 6KW
866050, Oil Filter
866080, V-Belt
839200, Fuel Filter
866110, Radiator

865223, Electric Fuel Pump

Mounted to Trailer Frame

740620, In-line
Fuel Filter

48
 Model:
RL4000 Light Tower
Title:
Genset, Kub-D905/L-S 6KW

839109 Hose
866090, Alternator
839190, Low Oil Press. Sensor

865276, Muffler
832128, Muffler Gaslket

839110, Hose

866394, Pipe
865054, Hose 836831, Bearing Housing

836832, O-Ring
866100, Starter
836833, Rear Bearing

49
 Model:
RL4000 Light Tower
Title:
Radiator

839157, Overflow Hose Assembly

866120, Radiator Cap 839109, Upper Radiator Hose

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.
(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

(2) 1 89 29 0, E ng in e M o un tin g B ra cke t

(2 ) 9 9 1 6 5 0 , L ock W a she r

(2 ) 9 9 0 4 1 0 , F en de r W a sh er

(2 ) 7 4 0 9 2 0 , V ib ra tio n M o u n t A ssy.

1 8 4 32 5, G e n se t S p a ce r - 9/16 "

51
 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.

52
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