Terex RL4 Vertical Mast Service Manual 1266665 – PDF DOWNLOAD

Description

Terex RL4 Vertical Mast Service Manual 1266665 – PDF DOWNLOAD

Language : English
Pages : 105
Downloadable : Yes
File Type : PDF

Table of Contents:

Terex RL4 Vertical Mast Service Manual 1266665 – PDF DOWNLOAD

Front Cover.................................................................  1
Important Information.......................................................  2
Serial Number Legend........................................................  3
General Safety Rules........................................................  4
Table of Contents...........................................................  6
Specifications.............................................................. 11
	Machine Specifications.................................................. 11
	Performance Specifications.............................................. 11
	Generator Options....................................................... 11
	Kohler KDW1003GE  Engine Specifications................................. 12
	Kubota D1105-E4BG Engine Specifications................................. 13
	Machine Torque Specifications........................................... 14
	SAE and Metric Fasteners Torque Charts.................................. 15
Scheduled Maintenance Procedures............................................ 17
	Introduction............................................................ 17
	Pre-Delivery Preparation Report......................................... 20
	Maintenance Inspection Report........................................... 21
	Checklist A Procedures.................................................. 23
		A-1 Inspect the Manuals and Decals.................................. 23
		A-2 Perform Pre-operation Inspection................................ 24
		A-3 Perform Function Tests.......................................... 24
		A-4 Perform Engine Maintenance - Kubota............................. 25
		A-5 Perform Coupler Maintenance..................................... 25
		A-6 Test the Brakes (if equipped)................................... 26
		A-7 Torque the Wheel Lug Nuts....................................... 26
		A-8 Perform Engine Maintenance - Kohler............................. 27
		A-9 Check the Tires and Wheels...................................... 27
		A-10 Inspect the Engine Air Filter.................................. 28
		A-11 Perform Generator Maintenance.................................. 29
		A-12 Perform Engine Maintenance - Kubota............................ 29
		A-13 Perform Engine Maintenance - Kohler............................ 30
		A-14 Inspect the Cable and Cable Pulleys............................ 30
		A-15 Perform Engine Maintenance - Kubota............................ 31
		A-16 Perform Engine Maintenance - Kubota............................ 32
		A-17 Perform Generator Maintenance.................................. 32
		A-18 Drain the Fuel Filter/Water Separator.......................... 33
		A-19 Adjust the Brakes (if equipped)................................ 34
		A-20 Perform Engine Maintenance - Kohler............................ 35
	Checklist B Procedures.................................................. 36
		B-1 Inspect the Engine Start Battery................................ 36
		B-2 Inspect the Electrical Wiring................................... 38
		B-3 Torque the Wheel Lug Nuts....................................... 38
		B-4 Perform Engine Maintenance - Kubota............................. 39
		B-5 Inspect and Lubricate the Winch................................. 39
		B-6 Lubricate the T-bolt............................................ 40
		B-7 Inspect and Adjust the Brakes (if equipped)..................... 40
		B-8 Inspect the Suspension.......................................... 42
		B-9 Perform Engine Maintenance - Kohler............................. 43
		B-10 Perform Engine Maintenance - Kubota............................ 43
	Checklist C Procedures.................................................. 44
		C-1 Perform Engine Maintenance...................................... 44
		C-2 Clean the Light Assemblies...................................... 44
		C-3 Grease the Wheel Bearings....................................... 45
		C-4 Inspect the Electric Brake Magnets.............................. 46
		C-5 Perform Engine Maintenance - Kohler............................. 48
		C-6 Perform Engine Maintenance - Kubota............................. 48
		C-7 Perform Engine Maintenance - Kohler............................. 49
		C-8 Perform Generator Maintenance................................... 49
	Checklist D Procedures.................................................. 50
		D-1 Perform Engine Maintenance - Kubota............................. 50
		D-2 Perform Generator Maintenance................................... 50
		D-3 Perform Coupler Maintenance..................................... 51
	Checklist E Procedures.................................................. 52
		E-1 Inspect the Cable and Cable Pulleys............................. 52
		E-2 Perform Engine Maintenance - Kubota............................. 53
		E-3 Perform Engine Maintenance - Kubota............................. 53
		E-4 Perform Engine Maintenance - Kohler............................. 54
		E-5 Perform Engine Maintenance - Kohler............................. 54
		E-6 Perform Engine Maintenance - Kohler............................. 55
		E-7 Perform Generator Maintenance................................... 55
		E-8 Perform Generator Maintenance................................... 56
		E-9 Perform Generator Maintenance................................... 56
Repair Procedures........................................................... 57
	Introduction............................................................ 57
	Lighting................................................................ 59
		1-1 How to Remove a Lamp............................................ 59
		1-2 How to Check Line Voltage....................................... 59
	Mast.................................................................... 60
		2-1 How to Remove the Mast Assembly................................. 60
		2-2 How to Disassemble the Mast Assembly............................ 60
		2-3 How to Replace the Mast Lift Cables............................. 62
		2-4 How to Remove the Manual Winch.................................. 63
		2-5 How to Remove the Electric Winch................................ 64
		2-6 How to Disengage the Tower Lock................................. 65
	Kohler KDW1003GE Engine................................................. 67
		3-1 Timing Adjustment-Kohler Engines................................ 67
		3-2 Glow Plugs-Kohler Engines....................................... 67
		3-3 Coolant Temperature and Oil Pressure Switches-Kohler Engines.... 67
	Kubota D1105-E4BG Engine................................................ 68
		4-1 Timing Adjustment-Kubota Engines................................ 68
		4-2 Glow Plugs-Kubota Engines....................................... 68
		4-3 Coolant Temperature and Oil Pressure Switches-Kubota Engines.... 68
	Generator............................................................... 69
		5-1 Generator....................................................... 69
		5-2 How to Check a Generator Capacitor.............................. 70
		5-3 How to Check a Generator Diode.................................. 71
	Light Ballast........................................................... 72
		6-1 Ground Controls................................................. 72
		6-2 Light Ballast................................................... 73
	Fuel Tank............................................................... 74
		7-1 Fuel Tank....................................................... 74
Diagnostics................................................................. 75
	Introduction............................................................ 75
	Diagnostic Charts....................................................... 76
Schematics.................................................................. 81
	Introduction............................................................ 81
	Wire Color Legend....................................................... 82
	RL4 Control Box AC Voltage Wiring - Standard............................ 84
	RL4 Control Box AC Voltage Wiring - Autostart........................... 85
	RL4 DC Control Box - Standard........................................... 88
	RL4 DC Engine Components - DynaGen Autostart............................ 89
	RL4 DC Engine Components - Kohler....................................... 92
	RL4 DC Engine Components - Kubota....................................... 93
	RL4 DC Control Box - Timed Oil Switch................................... 96
	RL4 DC Control Box - Low Fuel Shut Down................................. 97
	RL4 Running Lights - Front Fairing Section..............................100
	RL4 Running Lights - Rear Fairing Section...............................101
	RL4 Electrical Winch Option.............................................104
Back Cover..................................................................105

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