Parts Manual

RL4000D2

First Edition
YZ 7X 40 RL

Rev A Part No. 116444 September 2008

September 2008

Introduction
Important
Read, understand and obey the safety rules and operating instructions in the appropriate Operator's Manual on your machine before attempting any maintenance procedure. Basic mechanical, hydraulic and electrical skills are required to perform most procedures. However, several procedures require specialized skills, tools, lifting equipment and a suitable workshop. In these instances, we strongly recommend that maintenance and repair be performed at an authorized TEREX dealer service center.

REV A

Serial Number Information

TEREX Corporation offers the following manuals for these models:
Title Part No.

TEREX RL4000 Operator's Manual ................... 116417 First Edition TEREX RL4000 Service Manual ........................ 116473 First Edition TEREX RL4000 Part's Manual ........................... 116444 First Edition Leroy Somer Manual .......................................... 116118 Kubota Engine Manual ....................................... 893020

Technical Publications
TEREX Corporation has endeavored to deliver the highest degree of accuracy possible. However, continuous improvement of our products is a TEREX policy. Therefore, product specifications are subject to change without notice. Readers are encouraged to notify TEREX of errors and send in suggestions for improvement. All communications will be carefully considered for future printings of this and all other manuals.

Axis Manual ........................................................ 116117 Marathon Manual ............................................... 116188

Contact Us:
www.TEREX.com

Copyright 2008 by TEREX Corporation 116444 Rev A September 2008 First Edition, Second Printing "TEREX" is a registered trademark of TEREX Corporation in the USA and many other countries. "Super Quiet" is a trademark of TEREX Corporation. Printed on recycled paper Printed in U.S.A.

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How to Read Your Serial Number

Serial Number Legend

The serial number plate on your RL4000 is located on the cabinet next to the light tower mast.

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Section 1 Safety Rules

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Safety Rules

Danger
Failure to obey the instructions and safety rules in this manual and the appropriate Operator's Manual on your machine will result in death or serious injury. Many of the hazards identified in the operators manual are also safety hazards when maintenance and repair procedures are performed.

Do Not Perform Maintenance Unless:

You are trained and qualified to perform maintenance on this machine. You read, understand and obey: - manufacturers instructions and safety rules - employers safety rules and worksite regulations - applicable governmental regulations You have the appropriate tools, lifting equipment and a suitable workshop.

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Section 1 Safety Rules

September 2008

SAFETY RULES

REV A

Personal Safety
Any person working on or around a machine must be aware of all known safety hazards. Personal safety and the continued safe operation of the machine should be your top priority.

Be sure to wear protective eye wear and other protective clothing if the situation warrants it. Be aware of potential crushing hazards such as moving parts, free swinging or unsecured components when lifting or placing loads. Always wear approved steel-toed shoes.

Read each procedure thoroughly. This manual and the decals on the machine, use signal words to identify the following: Safety alert symbolused to alert personnel to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death. Redused to indicate the presence of an imminently hazardous situation which, if not avoided, will result in death or serious injury. Orangeused to indicate the presence of a potentially hazardous situation which, if not avoided, could result in death or serious injury. Yellow with safety alert symbol used to indicate the presence of a potentially hazardous situation which, if not avoided, may cause minor or moderate injury. Yellow without safety alert symbolused to indicate the presence of a potentially hazardous situation which, if not avoided, may result in property damage. Greenused to indicate operation or maintenance information.

Workplace Safety
Be sure to keep sparks, flames and lighted tobacco away from flammable and combustible materials like battery gases and engine fuels. Always have an approved fire extinguisher within easy reach.

Be sure that all tools and working areas are properly maintained and ready for use. Keep work surfaces clean and free of debris that could get into machine components and cause damage.

Be sure that your workshop or work area is properly ventilated and well lit.

Be sure any forklift, overhead crane or other lifting or supporting device is fully capable of supporting and stabilizing the weight to be lifted. Use only chains or straps that are in good condition and of ample capacity.

Be sure that fasteners intended for one time use (i.e., cotter pins and self-locking nuts) are not reused. These components may fail if they are used a second time.

Be sure to properly dispose of old oil or other fluids. Use an approved container. Please be environmentally safe .

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REV A

Table of Contents
Important Information - Introduction .................................................................... ii How to Read Your Serial Number ...................................................................... iii Parts Stocking List ............................................................................................ ix How to Order Parts ............................................................................................ xi Service Parts Fax Order Form ......................................................................... xii

Introduction

Section 1

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

Section 100

Rev A

Decals Figure 101.1 Decals .............................................................................. 100 - 2

Section 200

Rev A A

Chassis Components Figure 201.1 Figure 202.1 Light Tower Chassis ......................................................... 200 - 2 Fuel Tank Assembly ......................................................... 200 - 4

Section 300

Rev A

Cabinet Components Figure 301.1 Cabinet Components ......................................................... 300 - 2

Section 400

Rev A A A A

Electrical Components Figure 401.1 Figure 402.1 Figure 403.1 Figure 404.1 Electrical Control Box ....................................................... 400 - 2 Ballast Box Assembly ...................................................... 400 - 4 Light Fixture ...................................................................... 400 - 6 Coil Cord & Junction Box .................................................. 400 - 8

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TABLE OF CONTENTS

REV A

Section 500

Rev Engine & Generator A A A Figure 501.1 Figure 502.1 Figure 503.1 Engine - Kubota ................................................................ 500 - 2 Marathon Generator - 6 kW ............................................... 500 - 4 Leroy Somer Generator - 6 kW .......................................... 500 - 6

Section 600

Rev Mast Components A Figure 601.1 Tower Assembly ............................................................... 600 - 2

Section 700

Rev Options A Figure 701.1 Options ............................................................................. 700 - 2

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Parts Stocking List

Required Parts
The following parts are required to perform maintenance procedures as outlined in the TEREX RL4000Parts and Service Manual.
Description Kubota Models Oil Filter .............................................................. 866050 Air Filter .............................................................. 866127 Fuel Filter ........................................................... 839200 V-belt ................................................................. 839209 Part No.

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How To Order Parts

Genie Industries 18340 NE 76th Street P.O. Box 97030 Redmond, WA 98073-9730 Telephone (877) 367-5606 Fax (888) 274-6192 genieindustries.com

Please be prepared with the following information when ordering replacement parts for your TEREX product: Machine model number Machine serial number Terex part number Part description and quantity Purchase order number "Ship to" address Desired method of shipment Name and telephone number of the authorized TEREX Distributor in your area Use the Service Parts Fax Order Form on the next page and fax your order to our Parts Department. If you don't know the name of your authorized distributor, or if your area is not currently serviced by an authorized distributor, please call TEREX Corporation.

Machine Information
Model Serial Number Date of Purchase Authorized TEREX Distributor Phone Number

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Service Parts fax Order Form

FAX TO: (888) 274-6192 OR TOLL FREE: 877-367-5606

Please fill out completely Date _________________________________ Account Number _______________________________ Your Fax Number _____________________________ Your Phone Number ____________________________ Ship To ___________________________________ ___________________________________ ___________________________________ ___________________________________ Ship Via ___________________________________
remove this page and make copies remove this page and make copies

Your Name ______________________________ _________________________________ Bill To _________________________________ _________________________________ _________________________________ _________________________________ Purchase Order Number ____________________

Model(s) ______________________________________________________ Serial No.(s) _________________ Optional Equipment __________________________________________________________________________ Part Number Description Quantity Price

All backordered parts will be shipped when available via the same ship method as the original order unless noted below: o o o Ship complete order only - no backorders Ship all available parts and contact customer on disposition of backordered parts Other (please specify)

FOR TEREX USE ONLY Order Number ______________ Date Scheduled ____________ Order Total ________________ Origin Code ________________ Ship Condition ______________ Terms Code ________________

AL4000 Light Tower

Comments _________________________

__________________________________

Part No. 833002

__________________________________

September 2008

Section 100 Decals

Section 100

Decals

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Section 100 Decals

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Figure 101.1
Decals

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100 - 2

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Section 100 Decals

REV A

FIGURE 101.1

ITEM #
1 2 3 4 5 6 7 8 9 10 11 12

PARTS #
109055 850155 CU51A112 853316 853792 CR51A101 CU51A102 C52100100 CU51A116 CU51A111 CR51A101 CR51A311

DESCRIPTION
KIT: DECALS FOR MODEL 04000RL RITE LITE DECAL: DIESEL FUEL ONLY DECAL: DANGER HOT EXHAUST DECAL:RL4000 W/STRIPE OP/BOTTOM 2.25"TALL DECAL: TEREX 4.5"X43" DECAL:WARNING-IMPROPER GROUNDING. DECAL: NOTICE-NO ETHER DECAL: CALIF.PROP 65 DECAL: TEREX POWER MOVING INSTRUCTION DECAL: WARNING-BOOM DROP DECAL:WARNING-IMPROPER GROUNDING. DECAL:WARNING-IMPROPER GROUNDING.

QTY.
1 1 1 1 2 1 1 1 1 1 1 1

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Section 200 Chassis Components

Section 200

Chassis Components

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200 - 1

Section 200 Chassis Components

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Figure 201.1
LIght Tower Chassis

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200 - 2

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Section 200 Chassis Components

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FIGURE 201.1

ITEM #
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40

PART #
160270 Z112300 174170 182330 851820 840222 841430 CR82C000 841473 840394 840395 CS62C012 721051 C83100900 CTRD-111A C2201-DC 840376 C82100600 C82200104 C33612 111936 CS82A020 CS62A011 CR51A102 840120 851310 840221 C61100200 930950 CU63B054 CR21A000 C42200220 CR59B035 51600200 990150 990200 991650 993860 994200 995310

DESCRIPTION
BATTERY CABLE SET 24 4GA MBT TERM P&N R&B BATTERY WET 12V GR24 460 CCA STD-DUTY L/A BATTERY HOLD DOWN BATTERY HOLD DOWN ROD 1/4" X 10-1/4" DECAL, SYMBOL FOR GROUND JACK SNAP RING JACK SIDEWIND LONG 3KLB TRAILER BASE AXLE SHACKLE 4-5/8" LG 2000LB/3500LB AXLE SPRING BOLT 2000LB/3500LB AXLE SPRING NUT 2000LB/3500LB OUTRIGGER LEG CAPLUG, TUBE PLUG 2-1/2" X 2-1/2" TIRE, ST175/80-13 LOAD B W/13" BLACK RIM HUB W/RACE/BEARINGS/NUTS/STUDS/CAP/WASHER DUST CAP FOR 2000LB AXLE AXLE WHEEL NUT 2000LB/3500LB AXLE 2000LB, 36" SC U-BOLT, AXLE 2000LB SPRING-LEAF SPRING-2000LB CHAIN SAFETY 3000LB 3/8" X 30" W/S-HOOK TONGUE, B-O-H W/JACK BRACKET OUTRIGGER HOUSING DECAL, WARNING ALL OUTRIGGER COUPLER, 2", BOLT ON DECAL, WARNING ALL JACKS MUST BE SWIVELED JACK BRACKET SWIVEL WELD-ON WINCH, BRAKE, 1500LB W/HANDLE WEATHERSTRIP ADHESIVE 1/4" THK X 1/2" WIDE CABLE, TOWER TILT TANK FUEL 30GAL RL FUEL CAP FUEL TANK SUPPORT BRACKET LATCH, OUTRIGGER NUT NUT, LOCK, NYLON INSERT WASHER, LOCK 1/2" WASHER, FLAT 1/2" SCREW, 1/2-13NC X 5-1/2" SCREW, 1/2-13NC X 4"

QTY.
1 1 1 2 1 4 4 1 4 6 6 2 2 2 2 2 10 1 4 2 2 1 1 1 1 3 1 1 8FT 1 1 1 1 2 4 2 4 2 1 1

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Section 200 Chassis Components

September 2008

Figure 202.1
Fuel Tank Assembly

REV A

200 - 4

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Section 200 Chassis Components

REV A

FIGURE 202.1

ITEM #
1 2 3 4 5 6 7 8 9 10 11 12 13 14

PARTS #
CR21A000 CR59B035 C42200220 660320 890795 792750 740620 898590 C91100300 891520 891550 891560 890785 C90200400

DESCRIPTION
FUEL TANK, 30 GALLON BRACKET, FUEL TANK SUPPORT CAP, FUEL TANK FUEL PUMP HOSE, FUEL 5/16" X 7FT CLAMP, HOSE FILTER, IN-LINE FUEL FITTING, STRAIGHT TO BARB 5/16" HOSE, NYLON FUEL FITTING, 90 DEGREE ELBOW, RETURN ADAPTOR, STRAIGHT FITTING, STRAIGHT TO BARB 1/8" HOSE, FUEL 1/8" FITTING, 90 DEGREE ELBOW, PICKUP

QTY.
1 1 1 1 1 5 1 1 1 1 1 1 AR 1

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RL4000 Light Tower

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Section 300 Cabinet Components

Section 300

Cabinet Components

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300 - 1

Section 300 Cabinet Components

September 2008

Figure 301.1
Cabinet Components

REV A

300 - 2

RL4000 Light Tower

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Section 300 Cabinet Components

REV A

FIGURE 301.1

ITEM #
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27

PART #
CU63A040 C61300501 C61300502 CU51A118 24514 865307 CR54B050 C51100200 C51100300 C42200203 C83400100 CR56C050 C51500200 930950 C61400100 CS63C080 C61300502 C61300501 CR58C011 C51400301 CR59C010 796610 990670 CR54B040 CR56C040 116215 CR63A040

DESCRIPTION
SUPPORT, PLASTIC, 2HOLE 3.5" X 2.5" X 1" PIN, 3/4" X 7" ZINC CLIP, HITCH PIN DECAL, PIN WITH ARROW LITERATURE BOX BLACK, PLASTIC COOLANT RECOVERY TANK DOOR, ROADSIDE CAM, DOOR HANDLE T-HANDLE, BLACK W/ KEYS DOOR HANDLE KEYS FENDER CABINET, UNDERDOOR PANEL RS PROP DOOR 10" TELESCOPIC WEATHERSTRIP ADHESIVE 1/4" THK X 1/2" WIDE PULLEY, 3" TOWER BASE CLIP, HITCH PIN PIN, 3/4" X 7" CABINET, FRONT PANEL CUSHION PANEL, TOP HINGE PIANO 1.5" X 51.75" RIVET POP 3/16" X 1/2" DOOR, CURBSIDE CABINET, UNDERDOOR PANEL CS CABINET, REAR PANEL REAR TOWER SUPPORT

QTY.
1 1 1 1 1 1 1 2 2 2 2 1 2 14FT 1 1 1 1 1 2 1 2 36 1 1 1 1

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Section 300 Cabinet Components

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Section 400 Electrical Components

Section 400

Electrical Components

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400 - 1

Section 400 Electrical Components

September 2008

Figure 401.1
Electrical Control Box

REV A

400 - 2

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Section 400 Electrical Components

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FIGURE 401.1

ITEM #
1 2 3 4 5 6 7 8 9 10 10A 11 12 13 14 15 16 16A 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 31A 32 33 34 35 36 37 37A 38

PART #
853294 683680 186546 709133 683870 684640 683970 684450 C54100600 684380 116815 680030 685672 685674 800003 686220 709032 680060 680290 116770 680250 663890 186542 186540 260361 853289 186544 996340 995300 994420 R660010 682715 186543 R661490 116121 993310 116820 800004 116805

DESCRIPTION
DECAL: AL/RL CONTROL BOX AC "POWER & LIGHT" BREAKER 2P 30A 240V CONTROL BOX,FACE PLATE TERMINAL,RING BREAKER 1P 15A 277VAC RECEPTACLE 20A 120V DUPLEX W/GFI BREAKER MINI 1P 20A RECEPTACLE 30A 240V NUT, NYLOCK, 8-32 ZINC SWITCH, IGNITION LEVER OPERATED included with item 10 WIRE HARNESS,DC ENGINE CONNECTOR,2 SCREW,3/4" CONNECTOR 9P,FEMALE SOCKETS, FEMALE CONNECTOR WITH WIRES (includes 13 and 14) CONNECTOR,2 SCREW,1.25 included with item 16 TERMINAL,CLOSED END WRAP CAP CRIMP SLEEVE WIRE HARNESS LOCKNUT, CONDUIT 3/4" CORD SET FEMALE 6FT 5P CONTROL BOX,REAR PANEL CONTROL BOX BODY HOURMETER, DIGITAL DECAL: AL/RL CONTROL BOX DC "ENGINE CONTROLS" CONTROL BOX,FRONT PANEL SCREW,#10-16X3/4 PH ZP SCREW,#6-32X1/4 PAN HD WASHER,LOCK,#6 SWITCH PUSH-BUTTON included with item 31 LIGHT INDICATOR 12V RED CONTROL BOX,TOP PANEL RELAY 12V DC 30A BRACKET, E-BOX HANGER NUTSERT,1/4-20UNC WIRING HARNESS, FROM ENGINE KUBOTA SOLENOID PIGTAIL COMPLETE ELECTRICAL CONTROL BOX, includes 1-36

QTY.
1 1 1 2 4 1 1 1 5 1 1 1 1 9 1 1 2 1 1 1 1 4 1 1 1 1 1 12 12 12 1 1 1 1 2 8 1 1 1

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Section 400 Electrical Components

September 2008

Figure 402.1
Ballast Box Assembly

REV A

400 - 4

RL4000 Light Tower

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Section 400 Electrical Components

REV A

FIGURE 402.1

ITEM #
1 2 3 4 5 6 7 8 9 10 11

PART #
114355 663860 160030 160032 995490 850130 851691 851692 851693 851694 189346

DESCRIPTION
BALLAST BOX, MH CONNECTOR, 5P, MALE MH TRANSFORMER AND CAPACITOR CAPACITOR, 24uF, MH, 60Hz, 480V SCREW, 1/4-20NC X 5/8 DECAL: DANGER HIGH VOLTAGE DECAL: 1 DECAL: 2 DECAL: 3 DECAL: 4 SPACER

QTY.
1 1 1 1 8 1 1 1 1 1 4

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Section 400 Electrical Components

September 2008

Figure 403.1
Light Fixture

REV A

400 - 6

RL4000 Light Tower

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Section 400 Electrical Components

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FIGURE 403.1

ITEM #
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35

PART #
663850 709034 833567 995970 991650 990810 833566 833573 981640 833564 833569 833585 833568 833570 990675 833524 833543 833574 833581 833578 NPN 160071 833571 160140 833565 833563 833577 833584 833583 833582 683950 680020 682470 22120102 C41100720

DESCRIPTION
CORD SET MALE 5FT. 3P TERMINAL STRIP, 2P CASTING FOR NEW FIXTURE WASHER LOCK STAR 1/2 WASHER LOCK 1/2 SCREW 1/2-13NCX1-1/2 HHC GR 2 ZP TRUNION T-HANDLE SCREW 1/2-13NCX1-1/4 HHC GRADE 5 SOCKET BASE-MOGUL GASKET FOR REFLECTOR LABEL, FIXTURE CSA APPROVED REFLECTOR RING,REINFORCING FOR REFLECTOR RIVET POP 1/8X.390 GR-1/4-5/16 LENS W/ GASKET CLAMP;LENS TO REFLECTOR SCREW,8-32X1" HH SLOT WASHER, FIBER FOR BAND NUTSERT FOR BAND,8-32 X 1/4 included with item 17 LAMP MH 1000W SCREW,10-24X5/8 LAMP HPS 1000W SCREW 8-32X3/8 PH SOCKET BRACKET SCREW,8-32X5/8 LABEL,105C CORD RATING LABEL,WET LOCATION FIBERGLASS WIRE SLEEVE GASKET 1/2 S/R CONN LOCKNUT CONDUIT 1/2 CONNECTOR STRAINRELIEF LAMP SUPPORT COMPLETE FIXTURE ASSEMBLY (includes items 1-34)

QTY.
1 2 1 2 2 2 1 1 1 1 1 1 1 1 2 1 1 1 1 1 1 1 4 1 2 1 2 1 1 1 1 1 1 1 1

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Section 400 Electrical Components

September 2008

Figure 404.1
Coil Cord & Junction Box

REV A

ITEM #
1 2 3 4 5 6 7 8 9 10 11 12 13 14

PART #
685674 685671 660287 663870 663880 C48300108 680190 852800 680080 720440 186280 994380 22112580 22112575

DESCRIPTION
SOCKET CONNECTOR 9P, PLUG COIL CORD, RETRACT, 14/7 CONNECTOR, 3P, FEMALE DUST CAP W/CHAIN JUNCTION BOX BOX COVER, 2GANG W/GASKET DECAL: CAUTION TIGHTEN FIXTURE CONNECTOR GRIP, HUBBLE WEATHERSTRIP ADHESIVE PLATE, COIL CORD, CABINET MOUNT SCREW, #6-32 X 5/8", RD HD, SLOT, S/S JUNCTION BOX, COMPLETE WITH COIL CORD includes 1-12 COIL CORD ASSEMBLY includes 1, 2 and 3

QTY.
9 1 1 4 4 1 1 1 1 AR 1 4 1 1

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Section 500 Engine & Generator

Section 500

Engine & Generator

Part No. 116444

RL4000 Light Tower

500 - 1

Section 500 Engine & Generator

September 2008

Figure 501.1
Engine- Kubota D1105

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500 - 2

RL4000 Light Tower

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September 2008

Section 500 Engine & Generator

REV A

FIGURE 501.1

ITEM #
1 2 3 4 5 6 7 8

PART #
732205PP 995380 991650 990415 80379 124016 124017 124025 839190 741140 866125 866126 866127 866128 866129 866050 740620 839107 839200 660320 866101 866090 866044 866040 839209 839261 839134 866113 839154 865276 190150 832128 996330 990460 125395 741970 792750 897110 866110 866120 839109 839110 865307 893020

DESCRIPTION
KUBOTA D1105 ENGINE, POWERPACK, BUILD EBG2 SCREW, 1/2-13NC X 4HHC, GR 2, ZP WASHER, LOCK 1/2" WASHER, FLAT, SNUBBER, 1/2 X 2-3/4", ZP VIBRATION MOUNT, 40 DUROMETER ENGINE MOUNT, L-BRACKET - CURBSIDE ENGINE MOUNT, L-BRACKET - ROADSIDE GENSET RISER, 6KW ONLY LOW OIL PRESSURE SWITCH HIGH TEMPERATURE SWITCH AIR CLEANER ASSEMBLY AIR CLEANER BODY AIR CLEANER ELEMENT AIR CLEANER COVER AIR CLEANER VALVE OIL FILTER FUEL FILTER, IN-LINE, 5/16 FUEL FILTER ASSEMBLY FUEL FILTER ELEMENT FUEL PUMP STARTER ALTERNATOR 2 WIRE STOP SOLENOID GASKET, SOLENOID V-BELT WATER PUMP FAN, PUSHER FAN GUARD OIL DIPSTICK MUFFLER, D1105 SPACER, MUFFLER MUFFLER GASKET SCREW, M8 X 1.25 X 45MM, HHC, ZP, MUFFLER WASHER, LOCK, 5/16, MUFFLER MUFFLER TAILPIPE, D1105 OIL DRAIN VALVE CLAMP 7/16 TO 25/32 HOSE, OIL, 3/8, 0-250PSI RADIATOR CAP FOR RADIATOR HOSE, TOP HOSE, BOTTOM COOLANT RECOVERY TANK OPERATION MANUAL D1105

QTY.
1 2 2 2 2 1 1 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 3 4 4 1 1 1 3 1 1 1 1 1 1

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500 - 3

Section 500 Engine & Generator

September 2008

Figure 502.1
Marathon Generator - 6 kW - 201CSA5411

REV A

500 - 4

RL4000 Light Tower

Part No. 116444

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Section 500 Engine & Generator

REV A

FIGURE 502.1

ITEM # PART #
1 2 3 4 5 6 7 8 85206 189347 990220 990415 80379 991761 990470 981120 116167 116168 116169 116172 116174 116176 116177 116178 116179 116182 116183 116184 116187 836853 836856 116188

DESCRIPTION
GENERATOR, MARATHON, PANCAKE, 6KW GENERATOR MOUNT BRACKET SCREW, 1/2-13NC X 3-1/2 HHC, GR 2, ZP WASHER, FLAT SNUBBER, 1/2 X 2-3/4 X 7GA, ZINC ISOLATOR, ENGINE MOUNT, 40 DURO SCREW, 3/8-16NC X 1-1/4 HHC, GRADE 5, ZP WASHER, LOCK, 3/8 WASHER, FLAT, 3/8 FAN, 8LHD435044 BEARING, ODE, A-90006R-30 BEARING, BRACKET, ODE(5412), 8LHD013096 O-RING, 8LHD766012 POT COVER, 8LHD310316 SCREEN ASY W/SPGS, 8LHD336030 DRIVE DISC (C-107), 702326-01 HUB SPACER, 725334-01 CONN. BOX BASE, 8LHD354045 CONN. BOX COVER, 8LHD354044 CAPACITOR 25MF, 8LHD5990012 CLAMP, CAPACITOR, 8LHD086034 TERMINAL BLOCK, TS-6005 DIODE SURGE PROTECTOR, SUPPRESSOR/VARISITOR MANUAL, MARATHON PANCAKE GENERATOR

QTY.
1 1 2 2 2 4 4 4 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

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Section 500 Engine & Generator

September 2008

Figure 503.1
Leroy Somer Generator - 6 kW - LSA 36, M6

REV A

500 - 6

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Section 500 Engine & Generator

REV A

FIGURE 503.1

ITEM #
1 2 3 4 5 6 7 8 9 10 11 12 13 14

PART #
836704 836705 836706 836707 836708 836709 836710 836711 996290 990415 740925 996496 189344 630905

DESCRIPTION
NDE BEARING DIODE KIT (includes 2 diodes) ROTOR BOLT (8 X 245) TOP COVER END CAP FAN TERMINAL BLOCK KIT: CAPACITOR, 22.5mf, (Includes two capacitors) SCREW, M10X1.5X90MM HHC, GRADE 8.8, ZP WASHER, FLAT SNUBBER VIBRATION MOUNT, 30 DUR NUT LOCK NYLON INSERT M10 X 1.5 HEX ZP GENERATOR MOUNT BAR GENERATOR L-S 6KW 120/240 C106 SAE5 LSA36

QTY.
1 1 1 1 1 1 1 2 1 2 3 1 1 1

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Section 600 Mast Components

Section 600

Mast Components

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600 - 1

Section 600 Mast Components

September 2008

Figure 601.1
Tower Assembly

REV A

600 - 2

RL4000 Light Tower

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September 2008

Section 600 Mast Components

REV A

FIGURE 601.1

ITEM #
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25

PART #
C48300108 CR61C018 CR61A017 990610 CU61A090 CS63C080 CR61C010 CR61C020 CR61C030 CS61C060 CU51A103 CR51A107 C61100200 CR64C010 CR51A103 CU51A121 CU61A025 CU51A117 CS61A053 C41135000 CU61A035 C61400100 C54200300 C54300400 C54100200

DESCRIPTION
JUNCTION BOX, WITH QUICK CONNECTIONS COIL CORD COVER SLEEVE WIRE GUIDE BRACKET BOLT TEE 1/2-20NF SPRING,KICKOUT TOWER BASE TOWER, 4" SECTION TOWER, 3" SECTION TOWER, 2" SECTION SWIVEL, BOOM(TOWER) DECAL: AVOID BOOM SWING DECAL: ALIGN ARROWS BEFORE LOWERING WINCH,BRAKE,1500LB W/HANDLE CROSSHEAD DECAL: WARNING-TAIL HOOK MUST BE PROPERLY DECAL: LIFT HERE W/ ARROW CABLE UPPER EXTEND 19' DECAL: CAUTION LAMPS GET HOT SLIDE BLOCK, TOWER GUIDE RIVET,POP,1/4" X 1/2" CABLE LOWER EXTEND 11' PULLEY,3" BOLT WASHER NUT

QTY.
1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 6 24 1 1 1 1 1

Part No. 116444

RL4000 Light Tower

600 - 3

Section 600 Mast Components

September 2008

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September 2008

Section 700 Options

Section 700

Options

Part No. 116444

RL4000 Light Tower

700 - 1

Section 700 Options

September 2008

Figure 701.1
Options

REV A

700 - 2

RL4000 Light Tower

Part No. 116444

September 2008

Section 700 Options

REV A

FIGURE 701.1

ITEM # PART #
1 2 3 4 5 6 7 683970 684640 940000 174170 161085 182331 660420

DESCRIPTION
BREAKER MINI 1P 20A RECEPTACLE 20A 120V DUPLEX W/GFI COMBO HITCH KIT OPTION BATTERY HOLDOWN ANGLE 14.50" BATTERY, WET, 12V GR24, 700 AMP HEAVY-DUTY L/A BATTERY HOLDOWN ROD, 1/4 X 11-1/4" LIGHT, TRAILER KIT M540, WITH RIGHT & LEFT SIDE

QTY.
1 1 1 1 1 2 1

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RL4000 Light Tower

700 - 3

Section 700 Options

September 2008

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RL4000 Light Tower

Part No. 116444

California Proposition 65

Warning
The exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects or other reproductive harm.

Towing Checklist
(Use at each stop)
Before Towing Boom hold-down latch is securely locked in place Towing hitch is properly secured to tow vehicle 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

Before Driving

On The Road

Genie North America

Phone 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 China
Phone +86 21 53852570 Fax +86 21 53852569

Genie Scandinavia
Phone +46 31 575100 Fax +46 31 579020

Genie Malaysia
Phone +65 98 480 775 Fax +65 67 533 544

Genie France
Phone +33 (0)2 37 26 09 99 Fax +33 (0)2 37 26 09 98

Genie Japan
Phone +81 3 3453 6082 Fax +81 3 3453 6083

Genie Iberica
Phone +34 93 579 5042 Fax +34 93 579 5059

Genie Korea
Phone +82 25 587 267 Fax +82 25 583 910

Genie Germany
Phone +49 (0)4202 88520 Fax +49 (0)4202 8852-20

Genie Brasil
Phone +55 11 41 665 755 Fax +55 11 41 665 754

Genie U.K.
Phone +44 (0)1476 584333 Fax +44 (0)1476 584334

Genie Holland
Phone +31 183 581 102 Fax +31 183 581 566

Genie Mexico City

Phone +52 55 5666 5242 Fax +52 55 5666 3241

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