38
June 2013
RL4000 • TML-4000 Part No. 116694ii
Important
Read, understand and obey the safety rules andoperating instructions in the appropriateOperator's Manual on your machine beforeattempting any maintenance procedure.
Basic mechanical, hydraulic and electricalskills are required to perform most procedures.However, several procedures require specializedskills, tools, lifting equipment and a suitableworkshop. In these instances, we stronglyrecommend that maintenance and repair beperformed at an authorized TEREX dealerservice center.
Technical Publications
TEREX Corporation has endeavored to deliver thehighest degree of accuracy possible. However,continuous improvement of our products is aTEREX policy. Therefore, product specificationsare subject to change without notice.
Readers are encouraged to notify TEREX of errorsand send in suggestions for improvement. Allcommunications will be carefully considered forfuture printings of this and all other manuals.
Copyright © 2009 by TEREX Corporation
116694 June 2013First Edition, Second Printing
TEREX and "Super Quiet" are registeredtrademarks of TEREX USA LLC in the USA andmany other countries.
Printed on recycled paper
Printed in U.S.A.
Contact Us:
Introduction
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 numberhighlighted in blue to view the update.
June 2013
RL4000 • TML-4000 Part No. 116694iv
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 numberhighlighted in blue to view the update.
June 2013
Part No. 116694 RL4000 • TML-4000
Serial Number Legend
The serial number plate on yourRL4000/TML-4000 is located on the cabinet nextto the light tower mast.
v
How to Read Your Serial Number
RL4 08 - 1003
Model
Model year
Sequencenumber
June 2013
RL4000 • TML-4000 Part No. 116694
Personal SafetyAny person working on or around a machine mustbe aware of all known safety hazards. Personalsafety and the continued safe operation of themachine should be your top priority.
Read each procedure thoroughly. Thismanual and the decals on the machine,use signal words to identify the following:
Safety alert symbol—used to alertpersonnel to potential personalinjury hazards. Obey all safetymessages that follow this symbolto avoid possible injury or death.
Red—used to indicate thepresence of an imminentlyhazardous situation which, if notavoided, will result in death orserious injury.
Orange—used to indicate thepresence of a potentiallyhazardous situation which, if notavoided, could result in death orserious injury.
Yellow with safety alert symbol—used to indicate the presence of apotentially hazardous situationwhich, if not avoided, may causeminor or moderate injury.
Yellow without safety alertsymbol—used to indicate thepresence of a potentiallyhazardous situation which, if notavoided, may result in propertydamage.
DangerFailure to obey the instructions and safety rulesin this manual and the appropriate Operator'sManual on your machine will result in death orserious injury.
Many of the hazards identified in theoperator’s manual are also safety hazardswhen maintenance and repair proceduresare performed.
Do Not Perform MaintenanceUnless:
You are trained and qualified to performmaintenance 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, liftingequipment and a suitable workshop.
Safety Rules
Section 1 • Safety Rules
vi
June 2013
Part No. 116694 RL4000 • TML-4000
SAFETY RULES
Be sure to wear protective eye wear andother protective clothing if the situationwarrants it.
Be aware of potential crushing hazardssuch as moving parts, free swinging orunsecured components when lifting or
placing loads. Always wear approved steel-toedshoes.
Section 1 • Safety Rules
Workplace SafetyBe sure to keep sparks, flames andlighted tobacco away from flammable andcombustible materials like battery gases
and engine fuels. Always have an approved fireextinguisher within easy reach.
Be sure that all tools and working areasare properly maintained and ready foruse. Keep work surfaces clean and free
of debris that could get into machine componentsand cause damage.
Be sure that your workshop or work areais properly ventilated and well lit.
Be sure any forklift, overhead crane orother lifting or supporting device is fullycapable of supporting and stabilizing the
weight to be lifted. Use only chains or straps thatare in good condition and of ample capacity.
Be sure that fasteners intended for onetime use (i.e., cotter pins and self-lockingnuts) are not reused. These components
may fail if they are used a second time.
Be sure to properly dispose of old oil orother fluids. Use an approved container.Please be environmentally safe .
vii
June 2013
RL4000 • TML-4000 Part No. 116694
Table of Contents
Introduction
Important Information - Introduction .................................................................. ii
Revision History ................................................................................................ iii
How to Read Your Serial Number .................................................................... v
Section 1 Safety Rules
General Safety Rules ....................................................................................... vi
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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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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RL4000 • TML-4000 Part No. 116694
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x
Section 2 • Specifications
Part No. 116694 RL4000 • TML-4000 2 - 1
June 2013
Specifications
Model - RL4000 & TML-4000
Height, stowed 5 ft 9.5 in 1.765 m
Length, stowed 14 ft 2 in 4.331 m
Width, stowed 4 ft 6 in 1.372 m
Extended tower height 30 ft 9.114 m
Weight 1725 lbs 783 kg(Machine weights vary with option configurations. Seeserial label for specific machine weight.)
Maximum tongue weight 199 lbs 91 kg
Tire size, U.S. P175/80D13 Load B
Engine type Kubota 13.6 HPPerkins 13.8 HP
Fuel capacity 30 gallons 114 liters
Run time Kubota 38.3 hoursPerkins 37.9 hours
Generator Marathon 6 kW, 60 Hz
Total lighting wattageFour lights 4000 watts
Replacement bulbs 1000 wattsType BT-37 Metal Halide
Tower rotation 359 degrees,non-continuous
Maximum towing speed 60 mph 97 km/h
Maximum wind speed rating 62 mph 100 km/h
Sound level (dba rating) 71 dba @ 23 ft / 7 m
Section 2 • Specifications
2 - 2 RL4000 • TML-4000 Part No. 116694
June 2013
SPECIFICATIONS
69 1/2"(1765mm)
126"(3200mm)
360"(9144mm)
54"(1372mm)
38"(965mm)
124"(3150mm)
61 1/2"(1562mm)
OPERATING POSITION
170 1/2"(4331mm)
TRAVEL POSITION
RL4000
Section 2 • Specifications
Part No. 116694 RL4000 • TML-4000 2 - 3
June 2013
SPECIFICATIONS
TML-4000
69 1/2"(1765mm)
126"(3200mm)
360"(9144mm)
54"(1372mm)
38"(965mm)
124"(3150mm)
61 1/2"(1562mm)
OPERATING POSITION
170 1/2"(4331mm)
TRAVEL POSITION
Section 2 • Specifications
2 - 4 RL4000 • TML-4000 Part No. 116694
June 2013
SPECIFICATIONS
10.9 12.98.84.6
Section 3 • Scheduled Maintenance Procedures
Part No. 116694 RL4000 • TML-4000 3 - 1
June 2013
Scheduled Maintenance Procedures
Observe and Obey:
Maintenance inspections shall be completed bya person trained and qualified on themaintenance of this machine.
Scheduled maintenance inspections shall becompleted as specified using the suppliedLubrication and Maintenance Service IntervalCharts provided in this section.
Failure to perform each procedureas presented and scheduled couldresult in death, serious injury orsubstantial damage.
Immediately tag and remove from service adamaged or malfunctioning machine.
Repair any machine damage or malfunctionbefore operating the machine.
Keep records on all inspections for three years.
Machines that have been out of service for aperiod longer than 3 months must complete thequarterly inspection.
Unless otherwise specified, perform eachmaintenance procedure with the machine inthe following configuration:
• Machine parked on a firm, level surface
• Toggle switch in the off position
• Wheels chocked
About This Section
This section contains detailed procedures for eachscheduled maintenance inspection.
Each procedure includes a description, safetywarnings and step-by-step instructions.
Symbols Legend
Safety alert symbol—used to alertpersonnel to potential personalinjury hazards. Obey all safetymessages that follow this symbolto avoid possible injury or death.
Red—used to indicate thepresence of an imminentlyhazardous situation which, if notavoided, will result in death orserious injury.
Orange—used to indicate thepresence of a potentiallyhazardous situation which, if notavoided, could result in death orserious injury.
Yellow with safety alert symbol—used to indicate the presence of apotentially hazardous situationwhich, if not avoided, may causeminor or moderate injury.
Yellow without safety alertsymbol—used to indicate thepresence of a potentiallyhazardous situation which, if notavoided, may result in propertydamage.
Indicates that a specific result is expected afterperforming a series of steps.
Indicates that an incorrect result has occurredafter performing a series of steps.
Section 3 • Scheduled Maintenance Procedures
3 - 2 RL4000 • TML-4000 Part No. 116694
June 2013
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Copyright © 2006 by TEREX Corporation. TEREX® is a registered trademark of TEREX USA,LLC.Rev C
Pre-DeliverPre-DeliverPre-DeliverPre-DeliverPre-Delivery Preparationy Preparationy Preparationy Preparationy Preparation
Pre-Delivery Preparation Y N R
Pre-operation inspection completed
Maintenance items completed
Function tests completed
Model
Serial number
Date
Machine owner
Inspected by (print)
Inspector signature
Inspector title
Inspector company
Instructions
Use the operator’s manual on your machine.
The Pre-delivery Preparation consists of completing thePre-operation Inspection, the Maintenance items and theFunction Tests.
Use this form to record the results. Place a check in theappropriate box after each part is completed. Follow theinstructions in the operator’s manual.
If any inspection receives an N, remove the machine fromservice, repair and re-inspect it. After repair, place a checkin the R box.
LegendY = yes, completedN = no, unable to completeR = repaired
Comments
Fundamentals
It is the responsibility of the dealer to perform thePre-delivery Preparation.
The Pre-delivery Preparation is performed prior to eachdelivery. The inspection is designed to discover if anythingis apparently wrong with a machine before it is put intoservice.
A damaged or modified machine must never be used. Ifdamage or any variation from factory delivered conditionis discovered, the machine must be tagged and removedfrom service.
Repairs to the machine may only be made by a qualifiedservice technician, according to the manufacturer'sspecifications.
Scheduled maintenance inspections shall be performedby qualified service technicians, according to themanufacturer's specifications and the requirements listedin the responsibilities manual.
TEREX USA, LLCNyala Farm RoadWestport, CT 06880 USAToll Free (800) 433-3026 in U.S.A. and Canada
Section 3 • Scheduled Maintenance Procedures
3 - 4 RL4000 • TML-4000 Part No. 116694
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Section 3 • Scheduled Maintenance Procedures
Part No. 116694 RL4000 • TML-4000 3 - 5
June 2013
Maintenance Schedules
ITEM Every 50 Hours
Every 100
Hours
Every 200
Hours
Every 400
Hours
Every 500
Hours
Every Year
Every 800
Hours
Every 1500
Hours
Every 3000
Hours
Every Two
Years
Check of fuel pipes and clamp bands •Check engine oil and coolant level •Cleaning of air cleaner element •Check of battery electrolyte level •Check of fan belt tightness •Check of radiator hoses and clamp bands •Check of intake air line •Replacement of oil filter cartridge •Replacement of fuel filter cartridge •Removal of sediment in fuel tank •Cleaning of water jacket (radiator interior) •Replacement of fan belt •Replacement of air cleaner element •Check of damage in electric wiring and loose connections •
Check of valve clearance •Check of fuel injection nozzle injection pressure •
Check of turbo charger •Check of injection pump •Check of injection timer •Change of radiator coolant (L.L.C.) •Replacement of battery •Replacement of radiator hoses and clamp bands •Replacement of fuel pipes and clamp bands •Replacement of intake air line •
Kubota Lubrication and Maintenance Service Intervals
*Refer to the manufacturer's manuals for detailed maintence intervals and instructions. If the information in the manufacturer's manual differs from that in this manual the manufacturer's manual should take precedence.
Kubota Engine ManualGenie part number 893020
Section 3 • Scheduled Maintenance Procedures
3 - 6 RL4000 • TML-4000 Part No. 116694
June 2013
MAINTENANCE SCHEDULES CONTINUED
ITEM Daily Every 50 Hours
Every 250
Hours
Every 500
Hours
Every 1000
Hours
Every 2000
Hours
Every 3000
Hours
Every 6000
Hours
Every 12000 Hours
Cooling system coolant level - check •Driven equipment - check •Engine air cleaner service indicator - inspect •
Engine air precleaner - check/clean •Engine oil level - check •Fuel system primary filter/water separator - drain •
Walk around inspection •Fuel tank water and sediment - drain •Alternator and fan belts - inspect/adjust •
Fuel system filter - replace •Battery electrolyte level - check •Cooling system supplemental coolant additive (SCA) - test/add •
Engine air cleaner element (dual element) - clean/replace •
Engine air cleaner element (single element) - inspect/replace •
Engine oil and filter - change •Hoses and clamps- inspect/replace •Radiator - clean •Alternator and fan belts - replace •Engine valve lash - inspect/adjust •Turbocharger - inspect •Alternator - inspect •Engine crankcase breather - replace •Engine mounts - inspect •Starter motor - inspect •Fuel injector - test/change •Water pump - inspect •Cooling system coolant (commercial heavy-duty) - change •Cooling system coolant extender (ELC) - add •Cooling system coolant (ELC) - change •
Perkins Lubrication and Maintenance Service Intervals
Perkins Operations Manual
Section 3 • Scheduled Maintenance Procedures
Part No. 116694 RL4000 • TML-4000 3 - 7
June 2013
MAINTENANCE SCHEDULES CONTINUED
ITEM DAILY 200 Hours 10000 Hours
Visual inspection •Clean and inspect after every 200 hours of normal operating time. If generator is housed in a harsh environment, it is advisable to clean and inpect the unit more frequently. •Replace the bearing •
Marathon Generators Maintenance Schedule
*Refer to the manufacturer's manuals for detailed maintence intervals and instructions. If the information in the manufacturer's manual differs from that in this manual the manufacturer's manual should take precedence.
Marathon ManualGenie part number 116188
Section 3 • Scheduled Maintenance Procedures
3 - 8 RL4000 • TML-4000 Part No. 116694
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Section 4 • TroubleshootingJune 2013
Part No. 116694 RL4000 • TML-4000 4 - 1
Before Troubleshooting:
Read, understand and obey the safety rulesand operating instructions in the appropriateoperator's manual on your machine.
Be sure that all necessary tools and testequipment are available and ready for use.
Be aware of the following hazards and followgenerally accepted safe workshop practices.
Electrocution/burn hazard.Exposure to electrically chargedcircuits could result in death orserious injury. Remove all rings,watches and other jewelry.
Electrocution/burn hazard.Attempting to sevice the machinebefore the capacitors are fullydischarged will result in death orserious injury.
High voltage. Exposure toelectrical wires or electricalcurrent will result in death orserious injury. Remove all rings,watches and other jewelry. Turnoff all power when not needed fortesting. Use extreme cautionwhen working with high voltageelectrical components.
Burn hazard. Contact with hotengine components may causesevere burns. Use caution whenworking around a hot engine.
Troubleshooting
Observe and Obey:
Troubleshooting and repair procedures shall becompleted by a person trained and qualified onthe repair of this machine.
Immediately tag and remove from service adamaged or malfunctioning machine.
Repair any machine damage or malfunctionbefore operating the machine.
Unless otherwise specified, perform eachrepair procedure with the machine in thefollowing configuration:
• Machine parked on a firm, level surface.
• Wheels chocked.
• Toggle switch in off position.
Section 4 • Troubleshooting June 2013
4 - 2 RL4000 • TML-4000 Part No. 116694
Troubleshooting Guide
The engine/generator set is tested and set at the factory for proper operation in the field. These unitsshould never require additional adjustments in the field. If needed, adjustments should only be made bya qualified service technician, otherwise the manufacturer’s warranty may become void.
TROUBLE POSSIBLE CAUSE REMEDY1.Boom will not rise to a.Upper retaining pin is in place a.Remove upper retaining pinthe operating position. b.Defective cable b.Have a trained
or pulley mechanic examine and repair as needed
c.Defective winch c.Have a trainedmechanic examineand replace as needed
2.Boom will not telescope. a.Defective winch a.Have a trainedmechanic examineand replace as needed
b.Broken cable or pulley b.Have a trainedmechanic examineand replace as needed
3.Engine will not turn over a.Dead battery a.Check the battery voltage orloose cables
b.Engine has seized due to loss b.Have a trainedof fluids mechanic examine and
repair as needed4.Engine turns over but will a.Empty fuel tank a.Fill tank with #2 diesel fuelnot start b.Clogged fuel lines or filter b.Check and clean the fuel
system as neededc.Leaking fuel lines or a loss c.Replace any leaking fuel linesof prime and tighten connectionsd.Heater elements burned out d.Replace heater elementse.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 allconnections, inspect the pickuptube and inspect the fuel filter
b.Clogged exhaust system b.Clear the exhaust systemc.Clogged air filter c.Clear air filterd.Clogged or stuck fuel injectors d.Have a trained
mechanic examinee.Valve clearances are out of e.Have a trainedadjustment or the valve spring mechanic examinemay be damagedf.Defective governor or fuel pump f.Have a trained
mechanic examine
Section 4 • TroubleshootingJune 2013
Part No. 116694 RL4000 • TML-4000 4 - 3
TROUBLESHOOTING
TROUBLE POSSIBLE CAUSE REMEDY6.Engine runs but produces a a.Crankcase oil level is too high a.Drain oil to its proper leveldense smoke b.Low compression b.Have a trained mechanic
inspect for broken or seizedrings. Inspect valve clearances
c. Clogged air cleaner c. Replace air cleaner element7.Engine overheats a.Blocked cooling air intakes a.Inspect the front and rear intakes
and clear as neededb.Low coolant levels b.Replace the coolant with a 50%
water/coolant solutionc.Radiator fins have become c.Clear the radiator finscloggedd.Fan belt is loose d.Tighten fan belt
8.Engine runs but the battery a.Alternator has failed a.Have a trained mechanic inspectvoltage is low the alternator9.Engine runs but the lights will a.Circuit breakers are tripped a.Reset the circuit breakernot operate b.Loose connections in the wiring b.Have a trained electrician inspect
system the ballast box wiring systemc.Burned out bulb c.Replace the bulbs as neededd.Defective capacitor d.Have a trained electrician inspect(Leroy Somers Generator) the capacitore.Defective AC generator e.Have a trained electrician inspect
the generatorf.Engine speed is too low f.Have a trained mechanic inspect
the engine speed and reset to1800rpm @ 60hz
g.Defective ballast and capacitors g.Have a trained electrician inspectthe ballast and capacitors
10.Unusual noise coming from a.The generator has a defective a.Have a trained electrician inspectthe generator bearing or damaged fan blade the generator11.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 fordamage. Replace if needed.
b.Floodlight plugs not tight
c.Defective ballast c.Interchange ballast plugs. If lampstarts, replace ballast. Check forswollen capacitors, charred wiring,core and coil, or other signs ofexcessive heat.
d.Low voltage d.Check line voltage at ballast input.Voltage should be within 10% of
b.Check plug and receptacle. Tighten if needed. Make sure power is off.
rating when operating at normal load. Increase supply voltage or remove external load.
Section 4 • Troubleshooting June 2013
4 - 4 RL4000 • TML-4000 Part No. 116694
TROUBLESHOOTING
TROUBLE POSSIBLE CAUSE REMEDY11.Lamp will not start e.Improper ballast e.The ballast name plate data should
agree with the line voltage and lampused. If not, replace the ballast.
f.Lamp has been operating; cool f.Switch off breaker and allow lampdown time insufficient to cool.
12.Lamp starts slowly (arc does a.Defective lamp a.Lamp may glow for an extendednot strike when switch is first period of time. Replace after turned on checking voltage and ballast13.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 fixturec.Defective ballast c.Interchange ballast plugs. If lamp
starts, replace ballast. Check forswollen capacitors, charred wiring,core and coil, or other signs ofexcessive heat.
d.Wrong voltage d.Check line voltage at ballast input.Voltage should be within 10% of
e.Improper ballast e.Check ballast name plate againstlamp data
15.Lamp colors different a.Normal lamp depreciation a.Replace lampb.Dirty lamp or fixture b.Clean lamp and fixturec.Wrong lamp c.Check data on lamps and replace
as needed.16.Arc tube discolored or swollen a.Over voltage from power supply
b.Improper ballast b.Check ballast name plate againstlamp data
17.Short lamp life a.Lamp damaged a.Check for outer bulb cracks,cracks where lamp meets base, andfor broken arc tube or loose metalparts. Replace as needed.
b.Improper ballast b.Check ballast name plate againstlamp data
18.Lamp flickers or goes out- a.Improper Ballast a.Check ballast name plate againstintermittent or cycling lamp data
b.New lamp b.Under certain conditions new lamps may "cycle". Usually after 3 tries to start at 30 to 60 second intervals, lamp will stabilize and operate normal
rating when operating at normal load. Check wiring connections for voltage loss. Check socket contact point.
a.Check voltage at ballast, for current or voltage surges, for shorted capacitors and replace as needed
Section 4 • TroubleshootingJune 2013
Part No. 116694 RL4000 • TML-4000 4 - 5
TROUBLESHOOTING
TROUBLE POSSIBLE CAUSE REMEDY18.Lamp flickers or goes out- c.Defective lamp c.Replace lampintermittent or cycling d.High spike ballast d.Ballast produces high spike current.
Measure with oscilloscope. Replace ballast as required.
IF YOU FEEL AN ELECTRIC SHOCK AT ANY TIME WHILE OPERATING THIS UNIT, SHUT ITDOWN IMMEDIATELY! HAVE THE UNIT INSPECTED BY A TRAINED ELECTRICIAN.
THIS ENGINE/GENERATOR SET IS FACTORY INSTALLED, TESTED, AND SET FOR FIELDOPERATION. ANY DAMAGE TO THE ENGINE OR GENERATOR UNITS OCCURRING AFTERADJUSTMENTS ARE MADE IN THE FIELD BY UNAUTHORIZED PERSONNEL WILL NOT BECOVERED BY YOUR MANUFACTURER’S WARRANTY AND WILL ALSO VOID THEMANUFACTURER’S WARRANTY ON THIS PARTICULAR UNIT. IF YOU CAN NOT REACH YOURLOCAL DEALER, CONTACT THE FACTORY SERVICE MANAGER TOLL FREE AT 1-800-433-3026.
DO NOT OPEN FIXTURE WHILE LIGHTCIRCUIT BREAKER IS “ON”. ALLOWLAMP TO COOL BEFORE TOUCHING.
**TAKE EXTRA PRECAUTIONS WHENTROUBLESHOOTING ELECTRICAL PROBLEMS**
A. Only use a voltmeter with two well-insu-lated pin probes rated for 600 volts.
B. Treat all conductors as potentially hot.
C. Proceed through circuits systematically,operating only one section at a time.
D. Before disconnecting ballast, turn off circuitbreaker and wait 30 seconds for capacitorto discharge.
E. If all the lights are out and all the ballastsare receiving power, suspect burned outpower cable.
Light Fixture Troubleshooting
Section 4 • Troubleshooting June 2013
4 - 6 RL4000 • TML-4000 Part No. 116694
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Section 5 • Schematics
Part No. 116694 RL4000 • TML-4000 5 - 1
June 2013
Schematics
Observe and Obey:
Troubleshooting and repair procedures shall becompleted by a person trained and qualified onthe repair of this machine.
Immediately tag and remove from service adamaged or malfunctioning machine.
Repair any machine damage or malfunctionbefore operating the machine.
Before Troubleshooting:
Read, understand and obey the safety rulesand operating instructions in the appropriateoperator's manual on your machine.
Be sure that all necessary tools and testequipment are available and ready for use.
About This SectionThere are two groups of schematics in this section.An illustration legend precedes each group ofdrawings.
Electrical Schematics
Electrocution/burn hazard. Contactwith electrically charged circuitscould result in death or seriousinjury. Remove all rings, watchesand other jewelry.
General Repair Process
Malfunctiondiscovered
Identifysymptoms
Troubleshoot
Performrepair
Return toservice problem
solved
problemstill exists
Inspectand test
Section 5 • Schematics
5 - 2 RL4000 • TML-4000 Part No. 116694
June 2013
DC Wiring, KubotaDrawing #116814C
WH
T
YE
L
BR
N
BL
K
GR
N
OR
G
RE
D
85
30
WH
T
WH
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BR
N
RE
D
HO
UR
ME
TE
R
BR
N
BL
K
86
87
87
aB
RN
RE
LA
Y1
2V
SP
ST
(NC
)
ALT
ER
NA
TO
RF
AIL
UR
EL
IGH
T
CO
NT
RO
LB
OX
PR
EH
EA
TP
US
H B
UT
TO
N
YE
L
GR
N
RE
DY
EL
RE
DW
HT
WH/BK
STA
RT
ER
FU
EL
PU
MP
12
12
11109
11109
PL
UG
SG
LO
W
WH
/BK
WH
T
GR
N
OR
G
YE
L
BR
N
BL
K
876
876
543
543
21
21N
.C.
RE
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BR
N
ALT
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NA
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R
B
GR
NL IG
VIO
OR/BK
TE
MP
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(N
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BLK
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RED
OIL
PR
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S.
SW
ITC
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B+
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PU
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HO
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FU
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SO
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FU
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30
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BA
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10
74
2P1
31
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RN
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81
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11
68
20
Section 5 • Schematics
Part No. 116694 RL4000 • TML-4000 5 - 3
June 2013
P1
E-STOP(OPTION)
TEMPERATURESWITCH
GLOW PLUGS
FUEL PUMP
GROUND
FUEL SOLENOID
STARTERSOLENOID
STARTERSOLENOID
STARTERBATT +
ALTERNATOR(IG)
ALTERNATOR(B+)
OIL PRESSURESWITCH
FUSE30A
Engine Harness, KubotaDrawing #116820B
Section 5 • Schematics
5 - 4 RL4000 • TML-4000 Part No. 116694
June 2013
DC Wiring, PerkinsDrawing #116819B
WH
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Section 5 • Schematics
Part No. 116694 RL4000 • TML-4000 5 - 5
June 2013
Engine Harness, PerkinsDrawing #116822B
FUEL SOLENOID
OIL PRESSURE SWITCH
TEMPERSTURESWITCH
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GROUND
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VOLTAGE REGULATOR
GLOW PLUGS
GROUND
E-STOP(OPTION)
(WIRE ENTRY VIEW)
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PERKINS ENGINECONNECTOR REFERENCE
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Section 5 • Schematics
5 - 6 RL4000 • TML-4000 Part No. 116694
June 2013
Wire Harness, Inside Control Box, DCDrawing #116815F
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Section 5 • Schematics
Part No. 116694 RL4000 • TML-4000 5 - 7
June 2013
MH Light FixtureDrawing #2985A
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Section 5 • Schematics
5 - 8 RL4000 • TML-4000 Part No. 116694
June 2013
1000 MH BallastDrawing #2986
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Section 5 • Schematics
Part No. 116694 RL4000 • TML-4000 5 - 9
June 2013
This page intentionally left blank.
Dis
trib
ute
d B
y:
Genie North AmericaPhone 425.881.1800
Toll Free USA and Canada
800.536.1800
Fax 425.883.3475
Genie Australia Pty Ltd.Phone +61 7 3375 1660
Fax +61 7 3375 1002
Genie ChinaPhone +86 21 53852570
Fax +86 21 53852569
Genie MalaysiaPhone +65 98 480 775
Fax +65 67 533 544
Genie JapanPhone +81 3 3453 6082
Fax +81 3 3453 6083
Genie KoreaPhone +82 25 587 267
Fax +82 25 583 910
Genie BrasilPhone +55 11 41 665 755
Fax +55 11 41 665 754
Genie HollandPhone +31 183 581 102
Fax +31 183 581 566
Genie ScandinaviaPhone +46 31 575100
Fax +46 31 579020
Genie FrancePhone +33 (0)2 37 26 09 99
Fax +33 (0)2 37 26 09 98
Genie IbericaPhone +34 93 579 5042
Fax +34 93 579 5059
Genie GermanyPhone +49 (0)4202 88520
Fax +49 (0)4202 8852-20
Genie U.K.Phone +44 (0)1476 584333
Fax +44 (0)1476 584334
Genie Mexico CityPhone +52 55 5666 5242
Fax +52 55 5666 3241
Before Driving
On The Road
Before Towing ·
· Safety chains (if required) are properly attached and secure (chains are crossed below hitch)
· All lights are connected and working
· Tires are properly inflated
· Fasten safety restraints
· Properly adjust mirrors
· Do not exceed 60 mph / 97 km/h. Obey all local and national towing speed laws
· Check connections and tire pressure at each stop
· Slow down for hazardous conditions
· Allow extra distance for following and passing other vehicles
Towing hitch is properly secured to tow vehicle
Towing Checklist(Use at each stop)
California Proposition 65
WarningThe exhaust from this product
contains chemicals known to
the State of California to
cause cancer, birth defects
or other reproductive harm.
California Proposition 65
WarningBattery post terminals and related
accessories contain lead compounds,
chemicals known to the State of
California to cause cancer
and other reproductive harm.
