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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