Terex RL4000 User manual

Operator'sManual First Edition • First Printing
RL4000LightTowers PartNo.116417
Important
Read, understand and obey these safety rules and
operating instructions before operating this
machine.
Only trained and authorized personnel shall be
permitted to operate this machine. This manual
should be considered a permanent part of your
machine and should remain with the machine at all
times. If you have any questions, call Terex.
Contents
Page
Introduction ...........................................................1
GeneralSafety......................................................3
Work Area Safety .................................................4
Legend ..................................................................7
Controls ................................................................8
Inspections .........................................................10
OperatingInstructions.........................................16
TransportandLiftingInstructions ........................19
Maintenance .......................................................21
Specifications .....................................................23
ReportingSafetyDefects ....................................24
Contact us:
Internet:www.TEREX.com
Copyright © 2008 by Terex
Terex Light Construction Division
590 Huey Road
RockHill, SC 29730
First Edition: First Printing, November 2008
Printed on recycled paper
Printed in U.S.A.

PartNo.116417 RL4000LightTowers 1
Operator'sManual
First Edition • First Printing
Introduction
Danger
Failure to obey the instructions and
safety rules in this manual will
result in death or serious injury.
Do Not Operate Unless:
You learn and practice the principles of safe
machine operation contained in this operator's
manual.
1 Avoid hazardous situations.
Know and understand the safety rules before
going on to the next section.
2 Always perform a pre-operation inspection.
3 Always perform function tests prior to use.
4 Inspect the workplace.
5 Only use the machine as it was intended.
You read, understand and obey the
manufacturer's instructions and safety rules—
safety and operator's manuals and machine
decals.
You read, understand and obey employer's
safety rules and worksite regulations.
You read, understand and obey all applicable
governmental regulations.
You are properly trained to safely operate the
machine.
Owners, Users and Operators:
Terex appreciates your choice of our machine for
your application. Our number one priority is user
safety, which is best achieved by our joint efforts.
We feel that you make a major contribution to
safety if you, as the equipment users and
operators:
1 Comply with employer, job site and
governmental rules.
2 Read, understand and follow the instructions
in this and other manuals supplied with this
machine.
3 Use good safe work practices in a common
sense way.
4 Only have trained/certified operators, directed
by informed and knowledgeable supervision,
running the machine.
If there is anything in this manual that is not clear
or which you believe should be added, please
contact us.
Internet: www.TEREX.com

Operator'sManual First Edition • First Printing
2 RL4000LightTowers PartNo.116417
Intended Use
This machine is intended to be used only to provide
lighting and electrical power to a work site.
Introduction
Safety Sign Maintenance
Replace any missing or damaged safety signs.
Keep operator safety in mind at all times. Use mild
soap and water to clean safety signs. Do not use
solvent-based cleaners because they may damage
the safety sign material.
Hazard Classification
Terex uses symbols, color coding and signal words
to identify the following:
Safety alert symbol—used to alert
personnel to potential personal
injury hazards. Obey all safety
messages that follow this symbol
to avoid possible injury or death.
Indicates a hazardous situation
which, if not avoided, will result in
death or serious injury.
Indicates a hazardous situation
which, if not avoided, could result
in death or serious injury.
Indicates a hazardous situation
which, if not avoided, could result
in minor or moderate injury.
Indicates a property damage
message.
Red
Orange
Yellow
Blue

PartNo.116417 RL4000LightTowers 3
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First Edition • First Printing
General Safety
Safety signs
and locations
Shading indicates decal is hidden
from view, i.e. under covers

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4 RL4000LightTowers PartNo.116417
Work Area Safety
Electrocution Hazards
This machine is not electrically insulated and will
not provide protection from contact with or
proximity to electrical current.
Maintain required clearances from electrical
power lines and apparatus in accordance with
applicable governmental regulations and the
following chart.
Line Voltage Required Clearance
0 to 50KV 10 ft 3.0 m
50 to 200KV 15 ft 4.6 m
200 to 350KV 20 ft 6.1 m
350 to 500KV 25 ft 7.6 m
500 to 750KV 35 ft 10.6 m
750 to 1000KV 45 ft 13.7 m
Allow for tower movement and electrical line sway
or sag, and beware of strong or gusty winds.
Do not operate the machine during lightning or
storms.
Do not use the machine as a ground for welding.
Keep away from the
machine if it contacts
energized power lines.
Personnel must not touch or
operate the machine until
power lines are shut off.
Do not connect wires directly to the generator.
Connect auxiliary equipment only to the power
outlets provided.
Do not service or replace the lamps with the
engine/generator running.
This machine should be grounded in accordance
with all local electrical codes. Consult the local
electrical codes or Authority Having Jurisdiction
in the area where the machine will be used for
specific requirements.
Explosion and Fire Hazards
Do not start the engine if you smell or detect diesel
fuel or other explosive substances.
Do not refuel the machine with the engine running.
Refuel the machine and charge the battery only in
an open, well-ventilated area away from sparks,
flames and lighted tobacco.
Do not operate the machine in hazardous locations
or locations where potentially flammable or
explosive gases or particles may be present.
Do not spray ether into engines equipped with glow
plugs.
Tip-over Hazards
Do not raise the tower unless all outriggers are
properly deployed, the foot pads are in firm contact
with the ground and the machine is level.
Do not set the machine up on a surface where it
cannot be leveled using only the leveling jacks.
Do not hang any objects from the lights or the
tower.
Do not use the tower to raise material or
personnel.
Do not move the machine unless the tower is
lowered to the horizontal position.
Do not raise the tower when
wind speeds may exceed 62
mph / 100 km/h.

PartNo.116417 RL4000LightTowers 5
Operator'sManual
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Work Area Safety
Do not alter or disable machine components that
in any way affect safety and stability.
Do not adjust or stow the outriggers when the
tower is raised.
Do not place ladders or
scaffolds against any part of
the machine.
Do not use the machine on
a moving or mobile surface
or vehicle.
Crushing Hazards
Do not lower the tower
unless the area below is
clear of personnel and
obstructions.
Keep hands and fingers
away from any potential
pinch points.
Burn Hazards
Do not touch the lamp
fixtures while they are
turned on. Turn the lamps
off and allow them to cool
before touching.
Do not touch hot parts of the
engine or tailpipe. Use
protective gloves when
handling hot parts.
Bodily Injury Hazards
Do not use the machine indoors unless properly
ventilated.
Do not breathe exhaust fumes.
Do not work on this equipment when mentally or
physically fatigued.
Do not work on this equipment when under the
influence of drugs or alcohol.
Do not use the machine if the protective barrier on
any of the lamps is broken or punctured. Metal
halide lamps produce shortwave ultra-violet
radiation and can cause serious skin burns or eye
inflammation if the protective barrier is not in
place.
Stay clear of the moving tower.
Fall Hazards
Do not climb or stand on any part of the light
tower.
Damaged Machine Hazards
Do not use a damaged or malfunctioning machine.
Be sure the operator's manual is complete, legible
and in the storage container located on the
machine.
Be sure all decals are legible and in place.
Component Damage Hazard
Do not turn the lights on unless the engine is
running. Always turn the lights off before shutting
down the engine.
Do not tow the light tower while the lamps are hot.
Hot lamps will break if moved.
Do not replace lamp bulbs with any bulbs other
than those specified on the machine and in this
manual.

Operator'sManual First Edition • First Printing
6 RL4000LightTowers PartNo.116417
Battery Safety
Burn Hazards
Batteries contain acid. Always
wear protective clothing and
eye wear when working with
batteries.
Avoid spilling or contacting
battery acid. Neutralize battery
acid spills with baking soda and
water.
Explosion Hazard
Keep sparks, flames and lighted
tobacco away from batteries.
Batteries emit explosive gas.
Electrocution/Burn Hazards
Avoid contact with electrical terminals.
Avoid electrical shock from contact with battery
terminals. Remove all rings, watches and other
jewelry.
Lockout
When leaving the machine unattended, secure
from unauthorized use. Unauthorized personnel
may attempt to operate the machine without
proper instruction, creating an unsafe condition.
Work Area Safety
Towing Hazards
Read, understand and obey all of your tow vehicle
manufacturer’s recommendations, warnings and
instructions before towing this machine.
Do not tow the machine unless the tower is lowered
to the horizontal position and the travel lock is
secured.
Do not overload your tow vehicle. Check the
manufacturer's Gross Vehicle Weight Rating
(GVWR). To obtain the gross vehicle weight, add
the tongue weight of the trailer to the vehicle
weight (including vehicle, passengers and cargo).
Do not load cargo on the machine. The light tower
is not designed to carry any extra cargo.
Be sure the hitch is securely attached to the tow
vehicle.
Be sure the safety chains (if required) are securely
attached to the tow vehicle.
Be sure that all driving lights are operational.
Be sure all hitch components, lights and mirrors
and methods of attaching the trailer to the tow
vehicle conform to local, state and federal
regulations.
Do not tow the machine on public roads unless it
meets all governmental regulations for towing.
Do not exceed 60 mph / 97 km/h. Obey all local
and national towing speed laws.
Be sure to chock the wheels when parking on a hill.
DO NOT TOW MACHINE WHEN ENGINE IS
RUNNING! This can cause severe engine/
radiator damage and WILL NOT BE COVERED
UNDERWARRANTY!

PartNo.116417 RL4000LightTowers 7
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1 Tower, 2 inch section
2 Coil cord
3 Tower, 4 inch section
4 Coil cord sleeve
5 Leveling jack
6 Fender
7 Tire
8 Ballast (located inside cabinet)
9 Tower winch
10 Tongue
11 Road side door
12 Mast winch
13 Forklift pockets
14 Lifting eye
15 Tower, 3 inch section
16 Lamps
17 Travel lock pin
18 Muffler
19 Outrigger
20 Curb side door
21 Light bar
Legend

Operator'sManual First Edition • First Printing
8 RL4000LightTowers PartNo.116417
Control Panel
1 Light switches
2 Main circuit breaker
3 Hour meter
4 Ignition switch for engine
Controls
5 Engine prime button
6 Alternator failure light
7 Mini breaker
8 Duplex receptacle with GFI
9 T-lock receptacle

PartNo.116417 RL4000LightTowers 9
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Controls
Control Panel
1 Light switches
Move each switch to turn on the indicated
light(s).
2 Main circuit breaker
Flip the main circuit breaker switch on before
turning the individual light switches on.
3 Hour meter
The hour meter displays the number of hours the
machine has operated.
4 Ignition switch for engine
Turn the switch to the run position and hold the
engine prime button down to prime the engine.
Hold the prime button down and turn the switch
to the start position to start the engine.
Turn the switch to the off position to turn the
engine off.
5 Engine prime button
With the switch in the run position, press and
hold the prime button for 15 seconds before
starting the engine.
6 Alternator failure light
Light on indicates that the alternator isn’t
producing enough voltage.
7 Mini breaker
8 Duplex receptacle with GFI
9 T-lock receptacle

Operator'sManual First Edition • First Printing
10 RL4000LightTowers PartNo.116417
Inspections
Do Not Operate Unless:
You learn and practice the principles of safe
machine operation contained in this operator's
manual.
1 Avoid hazardous situations.
2 Always perform a pre-operation
inspection.
Know and understand the pre-operation
inspection before going on to the next section.
3 Always perform function tests prior to use.
4 Inspect the workplace.
5 Only use the machine as it was intended.
Pre-operation Inspection
Fundamentals
It is the responsibility of the operator to perform a
pre-operation inspection and routine maintenance.
The pre-operation inspection is a visual inspection
performed by the operator prior to each work shift.
The inspection is designed to discover if anything
is apparently wrong with a machine before the
operator performs the function tests.
The pre-operation inspection also serves to
determine if routine maintenance procedures are
required. Only routine maintenance items specified
in this manual may be performed by the operator.
Refer to the list on the next page and check each
of the items.
If damage or any unauthorized variation from
factory delivered condition is discovered, the
machine must be tagged and removed from
service.
Repairs to the machine may only be made by a
qualified service technician, according to the
manufacturer's specifications. After repairs are
completed, the operator must perform a
pre-operation inspection again before going on to
the function tests.
Scheduled maintenance inspections shall be
performed by qualified service technicians,
according to the manufacturer's specifications.
manual.

PartNo.116417 RL4000LightTowers 11
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Inspections
Pre-operation Inspection
oBe sure that the operator’s manual is complete,
legible and in the storage container located on
the machine.
oBe sure that all decals are legible and in place.
See Inspections section.
oCheck for engine oil leaks and proper fluid level.
Add oil if needed. See Maintenance section.
oCheck for engine coolant leaks and proper
coolant level. Add coolant if necessary. See
Maintenance section.
oCheck for battery fluid leaks and proper fluid
level. Add distilled water if needed. See
Maintenance section.
oCheck for proper tire pressure and lug nut
torque. Add air to tires if needed. See
Maintenance section.
Check the following components or areas for
damage, improperly installed or missing parts and
unauthorized modifications:
oElectrical components, wiring and electrical
cables
oTower components
oLatches and pins
oTires and wheels
oTrailer lights and reflectors
oOutriggers, leveling jacks and foot pads
oNuts, bolts and other fasteners
oLamp fixtures and bulbs
oSafety chains (if required)
oEngine and related components
oFuel tank(s)
oGenerator
Check entire machine for:
oCracks in welds or structural components
oDents or damage to machine
oExcessive rust, corrosion or oxidation
oBe sure that all structural and other critical
components are present and all associated
fasteners and pins are in place and properly
tightened.
oBe sure that the battery is in place and properly
connected.

Operator'sManual First Edition • First Printing
12 RL4000LightTowers PartNo.116417
Do Not Operate Unless:
You learn and practice the principles of safe
machine operation contained in this operator's
manual.
1 Avoid hazardous situations.
2 Always perform a pre-operation
inspection.
3 Always perform function tests prior to
use.
Know and understand the function tests before
going on to the next section.
4 Inspect the workplace.
5 Only use the machine as it was intended.
Function Test Fundamentals
The function tests are designed to discover any
malfunctions before the machine is put into service.
The operator must follow the step-by-step
instructions to test all machine functions.
A malfunctioning machine must never be used. If
malfunctions are discovered, the machine must be
tagged and removed from service. Repairs to the
machine may only be made by a qualified service
technician, according to the manufacturer's
specifications.
After repairs are completed, the operator must
perform a pre-operation inspection and function
tests again before putting the machine into service.
Inspections

PartNo.116417 RL4000LightTowers 13
Operator'sManual
First Edition • First Printing
Setup
1 Position the light tower at the desired work site.
2 Chock the wheels.
3 Disconnect the trailer lights and safety chains.
4 Pull the release pin on the tongue jack and
rotate into place.
5 Turn the jack handle to lower the foot pad and
raise the tongue of the machine enough to clear
the tow vehicle.
6 Release the spring pin on the front and back
outriggers and slide each outrigger out until the
spring pin engages. Rotate the outriggers into
position.
7 Turn the outrigger jack handles to level the
machine and raise the wheels off the ground.
Level the machine using only the leveling jacks.
8 Drive the grounding rod into the ground
and connect to the grounding lug on
the chassis near the base of the tower.
9 Manually start the engine. See
Operating Instructions section.
Inspections
Test the Lights
Note: Make sure the engine is running.
10 Turn on the main circuit breaker switch.
11 Turn on the light switches.
Result: All lights should come on.
Note: If the lights are already hot from being
operated, they will require 5-10 minutes to cool
before they will come on again.

Operator'sManual First Edition • First Printing
14 RL4000LightTowers PartNo.116417
Workplace Inspection
Be aware of and avoid the following hazardous
situations:
•drop-offs or holes
•bumps, floor obstructions or debris
•sloped surfaces
•unstable or slippery surfaces
•overhead obstructions and high voltage
conductors
•hazardous locations
•inadequate surface support to withstand all load
forces imposed by the machine
•wind and weather conditions
•the presence of unauthorized personnel
•other possible unsafe conditions
Do Not Operate Unless:
You learn and practice the principles of safe
machine operation contained in this operator's
manual.
1 Avoid hazardous situations.
2 Always perform a pre-operation
inspection.
3 Always perform function tests prior to use.
4 Inspect the workplace.
Know and understand the workplace inspection
before going on to the next section.
5 Only use the machine as it was intended.
Fundamentals
The workplace inspection helps the operator
determine if the workplace is suitable for safe
machine operation. It should be performed by the
operator prior to moving the machine to the
workplace.
It is the operator's responsibility to read and
remember the workplace hazards, then watch for
and avoid them while moving, setting up and
operating the machine.
Inspections

PartNo.116417 RL4000LightTowers 15
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Inspections
Part No. Description Quantity
850130 Danger - High Voltages 4
850155 Label - Diesel Fuel Only 1
851310 Label - All Jacks Must Be Swiveled 3
851820 Label - Ground Lug 1
852800 Caution - Tighten Fixture Connector 1
853316 Cosmetic - RL4000 1
853792 Cosmetic - Terex 2
C52100100Label - Proposition 65 2
CR51A101 Warning - Improper Grounding 1
CR51A102 Warning - Tipping Condition 1
CR51A103 Warning - Tail Hook Latch 2
Part No. Description Quantity
CR51A107 Label - Align Arrows Before Locking 1
CU51A101 Notice - Before Operating 2
CU51A102 Warning - No Ether 1
CU51A103 Warning - Boom Swing Area 2
CU51A111 Warning - Boom Drop 2
CU51A112 Danger - Hot Exhaust 1
CU51A116 Label - Operation Instructions 1
CU51A117 Caution - Lamps Get Hot 2
CU51A118 Label - Pin 2
CU51A121 Label - Lift Here 2
CU51A311 Warning - Electric Shock Hazard 1
Inspection for Decals with Words
Determine whether the decals on your machine
have words or symbols. Use the appropriate
inspection to verify that all decals are legible and in
place.
Shading indicates decal is hidden
from view, i.e. under covers

Operator'sManual First Edition • First Printing
16 RL4000LightTowers PartNo.116417
Operating Instructions
Do Not Operate Unless:
You learn and practice the principles of safe
machine operation contained in this operator's
manual.
1 Avoid hazardous situations.
2 Always perform a pre-operation
inspection.
3 Always perform function tests prior to use.
4 Inspect the workplace.
5 Only use the machine as it was intended.
Fundamentals
The Operating Instructions section provides
instructions for each aspect of machine operation.
It is the operator's responsibility to follow all the
safety rules and instructions in the operator's
manual.
Only trained and authorized personnel should be
permitted to operate a machine. If more than one
operator is expected to use a machine at different
times in the same work shift, they must all be
qualified operators and are all expected to follow all
safety rules and instructions in the operator's,
safety and responsibilities manuals. That means
every new operator should perform a pre-operation
inspection, function tests, and a workplace
inspection before using the machine.

PartNo.116417 RL4000LightTowers 17
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Setup
Make sure the machine is set up according to the
Setup procedure in the Function Tests section.
Start the Engine
Note: The main circuit breaker and the light
switches must be off before starting the engine.
Note: There must be fuel in the fuel tank in order to
start the engine.
Manual Engine Start
1 Move the ignition switch to the run
position.
2 Press and hold the prime button for 15
seconds.
3 While holding down the prime button,
move the ignition switch to engine start.
Operation of Tower
1 Remove the tower travel lock pin from the cradle
located on the rear of the cabinet.
2 Remove the tower locking pin from the tower
base.
3 Using the lower pivot winch, raise the tower to
the vertical position.
4 Reinsert the tower locking pin into the tower
base.
5 Raise the light tower mast to the desired height
using the winch located on the light tower mast.
Operating Instructions
Operation of Lights
Note: The engine must be running before the lights
are turned on.
1 Turn on the main circuit breaker switches on the
control panel.
2 Turn on the lights using the individual light
switches.
Models with four lights: Each switch turns on one of
the lights.
3 Turn the lights off using the individual light
switches. Make sure the lights are turned off
before shutting down the engine.
Grounding
An optional grounding rod may be
used to ground the light tower.
Consult your local codes for
information.
Drive the rod into the ground and
connect it to the grounding lug
located on the chassis near the
base of the tower.
Electrical Outlets
Electrical outlets are located on the control panel
inside light tower cabinet.

Operator'sManual First Edition • First Printing
18 RL4000LightTowers PartNo.116417
Operating Instructions
Towing
1 Lower the light bar to the stowed position.
2 Fully retract and lower the tower.
3 Make sure the travel lock pin is securely locked
in place.
4 Make sure the covers are closed and secured.
5 Pull the spring pins on each outrigger to rotate
the outrigger up and slide it into the stowed
position.
6 Raise the tongue of the machine by turning the
tongue jack handle.
7 Position the transport vehicle under the coupler
on the tongue of the machine.
8 Open the latch on the coupler.
7 Turn the tongue jack handle to lower the tongue.
9 Close the latch on the coupler.
10 Rotate the tongue jack to the stowed position
and secure with the lock pin.
11 Attach the safety chains (if required).
12 Connect and test the trailer lights.
Towing Information
Driving a vehicle/trailer combination is different
from driving a vehicle alone.
Inspect all connections at each stop.
All tires must be properly inflated. Do not
overinflate the tires. Tire pressures go up during
driving. Checking the tire pressure when the tires
are warm will give you an inaccurate pressure
reading.
Increase the distance between your vehicle and the
vehicle in front of you to twice the normal following
distance when towing a trailer. Allow more following
distance in adverse weather.
Slow down for downgrades and shift your
transmission into a lower gear.
Slow down for curves, hazardous road conditions,
freeway exits, and when driving in adverse weather.
Heavy winds, excessive speed, load shifting or
passing vehicles can cause a trailer to sway while
driving. If this occurs, do not brake, speed up or
turn the steering wheel. Turning the steering wheel
or applying the brakes can cause the vehicle and
trailer to jackknife. Let up on the gas pedal and
keep the steering wheel straight.
If the vehicle and/or trailer travels off the paved
road, hold the steering wheel firmly and let up on
the gas pedal. Do not apply the brakes. Do not turn
sharply. Slow down to under 25 mph / 40 km/h.
Gradually turn the steering wheel to get back on the
road. Proceed with caution when entering traffic.
When passing other vehicles, be sure to leave
enough room for the extra length of the trailer. You
will need to go much farther beyond the passed
vehicle before you can return to your lane.
Avoid jerky or sudden movements when turning.