Terex RL4000 User manual

Operator'sManual First Edition • Second Printing
RL4000•TML-4000 PartNo.116692
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
SymbolandHazardPictorialsDefinitions .............3
GeneralSafety......................................................5
Work Area Safety .................................................9
Legend ................................................................13
Controls ..............................................................16
Pre-operationInspection .....................................18
FunctionTests ....................................................20
Inspections .........................................................23
OperatingInstructions.........................................28
TransportandLiftingInstructions ........................33
Maintenance .......................................................35
Specifications .....................................................37
ReportingSafetyDefects ....................................38
Contact us:
Internet:www.genielift.com
e-mail:[email protected]
Copyright © 2009 by Terex
Terex
18340 NE 76th Street
PO Box 97030
Redmond, WA 98073-9730
First Edition: Second Printing, July 2009
Printed on recycled paper
Printed in U.S.A.

Operator'sManual
First Edition • Second Printing
PartNo.116692 RL4000•TML-4000 1
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.genielift.com

Operator'sManual First Edition • Second Printing
2 RL4000•TML-4000 PartNo.116692
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

Operator'sManual
First Edition • Second Printing
PartNo.116692 RL4000•TML-4000 3
Symbol and Hazard Pictorials Definitions
Electrocution
hazard.
Maintain required
clearance.
Read the
operator’s
manual.
Do not use ether
or other high
energy starting
aids on machines
equipped with
glow plugs.
Explosion hazard.
Electrocution
hazard.
STOP
Stop the engine. Earth ground.
Read the service
manual.
Electrocution/
burn hazard.
Crush hazard.
Only trained and
qualified personnel
may access this
compartment.
No open flame.
Burn hazard.
Disconnect the
batteries.
Explosion/burn
hazard.
Corrosive acid.
No smoking.
No open flame. Explosion/burn
hazard.

Operator'sManual First Edition • Second Printing
4 RL4000•TML-4000 PartNo.116692
Lifting eye.
Crushing hazard. Stay clear of
descending tower.
Tie-down point.
Crushing hazard. Keep away from
moving parts.
Wheel load.
Carbon Monoxide
hazard.
Wear protective
clothing.
Burn hazard Stay clear of hot
exhaust.
Symbol and Hazard Pictorials Definitions
Stay clear of hot
surfaces.
Burn hazard Keep away from
moving parts.
Deploy outriggers
before raising
mast.
Burn hazard Stay clear of hot
surfaces. Burn hazard Shattering glass
hazard Tip-over hazard
Tip-over hazard

Operator'sManual
First Edition • Second Printing
PartNo.116692 RL4000•TML-4000 5
General Safety
Safety Signs and Locations (Word Decals)

Operator'sManual First Edition • Second Printing
6 RL4000•TML-4000 PartNo.116692
General Safety
Safety Signs and Locations (Word Decals)

Operator'sManual
First Edition • Second Printing
PartNo.116692 RL4000•TML-4000 7
General Safety
Safety Signs and Locations (Symbol Decals)

Operator'sManual First Edition • Second Printing
8 RL4000•TML-4000 PartNo.116692
General Safety
Safety Signs and Locations (Symbol Decals)

Operator'sManual
First Edition • Second Printing
PartNo.116692 RL4000•TML-4000 9
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 perform 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.
Do not refuel the machine while it
is hot. Allow to cool for several
minutes before refueling.
Do not spill fuel inside the engine
compartment.
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.

Operator'sManual First Edition • Second Printing
10 RL4000•TML-4000 PartNo.116692
Work Area Safety
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.
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.
Be sure the tires are in good conditionand the lug
nuts are properly tightened.
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.
Collision Hazard
Check the work area for overhead obstructions or
other possible hazards.
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.

Operator'sManual
First Edition • Second Printing
PartNo.116692 RL4000•TML-4000 11
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.
Do not use where people will remain close to the
lamps for more than a few minutes unless adequate
shielding or other safety precautions are used.
Stay clear of the moving tower.
Do not grasp the cable.
Use proper lifting techniques when lifting and
positioning the tongue of the machine.
Always replace the protective lamp cover after
replacing the lamp bulbs.
Fall Hazards
Do not climb or stand on any part of the light tower.
Traffic Hazards
Stand clear of traffic when starting or checking the
unit along the road.
Damaged Machine Hazards
Do not use a damaged or malfunctioning machine.
Do not use a machine with a worn, frayed, kinked
or damaged cable.
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.
Work Area Safety
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.
Note: Lamp bulbs contain mercury (Hg). Dispose of
lamp bulbs according to local, state and federal
laws.
Be sure lamp fixture connections are properly
tightened before turning lights on.
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.
Do not use any battery charger greater than 12V to
charge the battery.
Do not remove the vent caps from the battery when
charging.
Do not expose the battery or the charger to water or
rain.

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12 RL4000•TML-4000 PartNo.116692
Explosion Hazard
Keep sparks, flames and lighted
tobacco away from batteries.
Batteries emit explosive gas.
Electrocution/Burn Hazards
Avoid contact with electrical terminals.
Inspect the power cord for damage prior to each
use. Replace any damaged cord before operating.
Do not allow the power cord to become caught or
crushed while raising, lowering or rotating the mast.
Avoid electrical shock from contact with battery
terminals. Remove all rings, watches and other
jewelry.
Towing Hazards
Read, understand and obey all of your tow vehicle
manufacturer’s recommendations, warnings and
instructions before towing this machine.
Do not tow machine unless mast is retracted and
lowered to horizontal position and locking pin on
mast is securely in place.
Do not tow machine unless travel lock pin is
securely in place.
Do not tow machine unless all outriggers have been
retracted and stowed.
Do not overload your tow vehicle. Check the Gross
Vehicle Weight Rating (GVWR). The total weight of
the tow vehicle, its occupants, cargo and the
tongue weight of the trailer must not exceed the
GVWR.
Work Area Safety
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.
Note: Do not tow machine when engine is running!
This can cause severe engine/radiator damage and
WILL NOT BE COVERED UNDER WARRANTY!
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.

Operator'sManual
First Edition • Second Printing
PartNo.116692 RL4000•TML-4000 13
1 Coil cord
2 Coil cord sleeve
3 Leveling jack
4 Fender
5 Tire
6 Ballast (located inside cabinet)
7 Raise/lower winch
8 Tongue
9 Road side door
10 Extent/retract winch
11 Forklift pockets
12 Lifting eye
13 Lamps
14 Upper retaining pin
15 Muffler
16 Outrigger
17 Curb side door
18 Light bar
19 Lower retaining pin
20 Control panel (located inside cabinet)
21 Spring pin
22 Tie-downs
Legend - RL4000 model

Operator'sManual First Edition • Second Printing
14 RL4000•TML-4000 PartNo.116692
1 Coil cord
2 Coil cord sleeve
3 Leveling jack
4 Fender
5 Tire
6 Ballast (located inside cabinet)
7 Raise/lower winch
8 Tongue
9 Road side door
10 Extend/retract winch
11 Forklift pockets
12 Lifting eye
13 Lamps
14 Upper retaining pin
15 Muffler
16 Outrigger
17 Curb side door
18 Light bar
19 Control panel (located inside cabinet)
20 Lower retaining pin
21 Outrigger release pin
22 Tie-downs
Legend - TML-4000 model

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First Edition • Second Printing
PartNo.116692 RL4000•TML-4000 15
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16 RL4000•TML-4000 PartNo.116692
Control Panel
1 Light switches
2 Main circuit breaker
3 Hour meter
4 Ignition switch for engine
Controls - Both Models
5 Engine prime button
6 Alternator failure light
7 Mini breaker, 120V
8 Duplex receptacle with GFI, 120V/20A
9 T-lock receptacle, 240V/30A

Operator'sManual
First Edition • Second Printing
PartNo.116692 RL4000•TML-4000 17
Controls - Both Models
Control Panel
1 Light switches
Move each light switch up to turn on the
indicated light. Move each light switch down to
turn off the indicated light.
2 Main circuit breaker
Move the main circuit breaker switch up on the
control panel before turning the individual light
switches on or before attempting to use the
convenience receptacles.
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 ACC position and hold the
engine prime button to prime the fuel pump.
Turn the switch to the run position and hold the
engine prime button down to prime the engine.
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
Primes the engine before starting.
6 Alternator failure light
Light on indicates that the engines DC alternator
isn’t producing enough voltage.
7 Mini breaker
Pop-out style breaker. Push in button to insure
GFI receptacle is ready for use.
8 Duplex receptacle with GFI
Convenience duplex receptacle with Ground
Fault Interrupter (GFI).
9 T-lock receptacle

Operator'sManual First Edition • Second Printing
18 RL4000•TML-4000 PartNo.116692
Pre-operation Inspection
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.