Terex RL4 LED User manual

Operator's Manual
RL™4 LED from SN RL4LEDJ-101 ANSI/CSA
North America
South America
Asia
with
Maintenance
Information
First Edition
First Printing
Part No. 1286390GT

Operator's Manual First Edition • First Printing
RL4LED™ Vertical Mast Part No. 1286390GT
FrontMatter
Contents
Introduction ........................................................... 1
Symbol and Hazard Pictorials Definitions............. 4
General Safety ...................................................... 6
Work Area Safety................................................ 10
Legend ................................................................ 16
Controls............................................................... 17
Inspections.......................................................... 19
Operating Instructions......................................... 30
Transport and Lifting Instructions ....................... 40
Maintenance ....................................................... 42
Specifications...................................................... 45
Reporting Safety Defects .................................... 46
Copyright © 2018 Terex Corporation
First Edition: First Printing, March 2018
"Terex" is a registered trademark of Terex USA, LLC in the
USA and many other countries.

First Edition • First Printing Operator's Manual
Introduction
Part No. 1286390GT RL4LED™ Vertical Mast 1
Introducti on
About this manual
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.
This book is an operation and daily maintenance
manual for the user or operator of a Terex
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,
contact Terex.
Product Identification
The machine serial number is located on the serial
label.
Intended Use
This machine is intended to be used only to provide
lighting and electrical power to a work site. Use of
this product in any other way is prohibited and
contrary to its intended use.
Bulletin Distribution and
Compliance
Safety of product users is of paramount importance
to Terex. Various bulletins are used by Terex to
communicate important safety and product
information to dealers and machine owners.
The information contained in the bulletins is tied to
specific machines using the machine model and
serial number.
Distribution of bulletins is based on the most
current owner on record along with their associated
dealer, so it is important to register your machine
and keep your contact information up to date.
To ensure safety of personnel and the reliable
continued operation of your machine, be sure to
comply with the action indicated in a respective
bulletin.

Operator's Manual First Edition • First Printing
Introduction
2 RL4LED™ Vertical Mast Part No. 1286390GT
Contacting the Manufacturer
At times it may be necessary to contact Terex.
When you do, be ready to supply the model
number and serial number of your machine, along
with your name and contact information. At
minimum, Terex should be contacted for:
Accident reporting
Questions regarding product applications and
safety
Standards and regulatory compliance information
Current owner updates, such as changes in
machine ownership or changes in your contact
information. See Transfer of Ownership, below.
Transfer of Machine Ownership
Taking a few minutes to update owner information
will ensure that you receive important safety,
maintenance and operating information that
applies to your machine.
Please register your machine by visiting us on the
web at www.genielift.com or by calling us toll free
at 1-800-536-1800.
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.

First Edition • First Printing Operator's Manual
Introduction
Part No. 1286390GT RL4LED™ Vertical Mast 3
Hazard Classification
Decals on this machine use symbols, color coding,
and signal words to identify the following:
Safety alert symbol–used to alert
you 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.
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.
DANGER
WARNING
CAUTION
NOTICE

Operator's Manual First Edition • First Printing
Symbol and Hazard Pictorials Definitions
4 RL4LED™ Vertical Mast Part No. 1286390GT
Symbol and Hazard Pic torials Definiti ons
Read the operator’s
manual
Electrocution hazard Stop engine Earth ground Electrocution hazard
Maintain required
clearance
Explosion / Burn
hazard
Disconnect battery
Read the service
manual
Keep away from
moving parts
Keep away from
moving parts
Explosion / Burn
hazard
Explosion / Burn
hazard
Corrosive acid. Explosion hazard Do not use high
energy starting aids
on machines
equipped with glow
plugs or grid heater.
No smoking No flame No flame Burn hazard Stay clear of hot
surfaces and
components

First Edition • First Printing Operator's Manual
Symbol and Hazard Pictorials Definitions
Part No. 1286390GT RL4LED™ Vertical Mast 5
Carbon Monoxide
hazard
Do not use light tower
indoors
Wear protective
clothing
Lifting point Tie-down point
Tip-over hazard Deploy outriggers
before raising mast
Tip-over hazard, tow
speed
Electrocution/
entanglement hazard
Electrocution/
entanglement hazard
Flashing beacon
indicates engine may
start at any time
Access by trained
and authorized
personnel only

Operator's Manual First Edition • First Printing
General Safety
6 RL4LED™ Vertical Mast Part No. 1286390GT
General Safety
1266884
1266884
1266647
1266647
1266650
1266650
1266661
1266661
1266648
1266648
Electrocution Hazar d
Contact with electric power lines will result in
death or serious injury.
Before operating the machine, contact the
electric power line owner to disconnect, move,
or insulate power lines.
Line voltage
0to50kv
>
50 to 200 kv
> 200 to 350 kv
> 350 to 500 kv
>
500 to 750 kv
>
750 to 1000 kv
Maintain Clearance Listed
Required clearance
10 ft (3 m)
15 ft (4.6 m)
20 ft (6.1 m)
25 ft (7.6 m)
35 ft (10.7 m)
45 ft (13.7 m)
> 1000 kv
Refer to Operator’s Manual
1266647 A
1266884 A
WARNING
Ti p Over Hazar d
Improper towing can result in death
or serious injury
.
60 mph
97 km/h
Read and understand manuals.
Slow down for curves, adverse weather ,
hazardous road conditions, road construction,
towing vehicle limitations and expressway exits.
Obey all local and national towing speed laws.
WARNING
Ti p Over Hazar d
Improper operation can result in death
or serious injury
.
1. Deploy stabilizers.
2. Raise mast.
1266648 A
DANGER
1266650 A
Explosion/Burn Hazard
Fuel and fumes can ex-
plode and burn, resulting in
death or serious injury.
No smoking.
Keep all open ames and
sparks away.
Stop engine before adding
fuel.
Explosion Hazard
Death or serious injury ca n
result from the use of high
energy starting aids.
1266661 A
WARNING
Do not use high
energy starting aids
on machines equipped
with glow plugs or
grid heater.

First Edition • First Printing Operator's Manual
General Safety
Part No. 1286390GT RL4LED™ Vertical Mast 7
Shading indicates decal is hidden from view, i.e. under covers
1266653
1266888
1266655
1266661
1266657
1266883
1266887
1266881
1266888
1266655
1266653 1266657
1266883
Electrocution Hazard
Contact with electrical power will result
in death or serious injury.
Shut down engine/ generator and
disconnect battery before performing
maintenance.
Read and understand manuals.
1266657 A
WARNING
Burn Hazard
Contact with hot surfaces can result in death
or serious injury.
Stay clear of hot surfaces. Allow machine to
cool before servicing.
1266653 A
DANGER
Explosion/Burn Hazar d
Battery explosion and/or contact with
corrosive acid will result in death or serious
injury.
Wear appropriate personal protective
equipment, including gloves, face shield
and long sleeve shirt.
Read manuals. If you do not understand
the information in the manuals, consult your
supervisor, the owner or the manufacturer.
Keep all open flames
and sparks away.
1266888 A
Improper operation or maintenance of this
equipment can result in death or serious
injury.
Read and understand operator’s manual
and all safety signs before using or
maintaining machine.
If you do not understand the information in
the manuals, consult your supervisor, the
owner or the manufacturer.
WARNING
1266655 A
1266887
DANGER
Electrocution/Entanglement Hazard
This machine can start automatically. Contact
with electrical power or moving components
will result in death or serious injury.
Flashing beacon indicates engine may
start at any time. Stay clear of machine.
Access to this compartment by trained
and authorized personnel only.
1266887 A
DANGER
1266883 A
STOP
1
2
3
4
Electrocutio n
Hazard
Contact with
electrical power
will result in
death or serious
injury.
Shut down
engine/generator
and disconnect
battery before
performing
maintenance.
Read and
understand
manuals.
1266881
Inhalation Hazard
Engine exhaust contains carbon monoxide,
a poison that you cannot see or smell.
Breathing carbon monoxide can result in
death or serious injury.
Do not operate this machine indoors.
Use only outside, far from open windows,
doors, and vents.
1266881 A
WARNING
1266661
Explosion Hazar d
Death or serious injury can
result from the use of high
energy starting aids.
1266661 A
WARNING
Do not use high
energy starting aids
on machines equipped
with glow plugs or
grid heater.

Operator's Manual First Edition • First Printing
General Safety
8 RL4LED™ Vertical Mast Part No. 1286390GT
1266679 A
0to50kv
>
50 to 200 kv
>
200 to 350 kv
>
350 to 500 kv
>
500 to 750 kv
>
750 to 1000 kv
10 ft (3 m)
15 ft (4.6 m)
20 ft (6.1 m)
25 ft (7.6 m)
35 ft (10.7 m)
45 ft (13.7 m)
>
1000 kv
60 mph
97 km/h
1266678 A
1266676 A
1266678
1266678
1266676
1266676
1266679
1266679
1266675
1266675
1.
2.
1266675 A
1266889
1266889
1266889 A

First Edition • First Printing Operator's Manual
General Safety
Part No. 1286390GT RL4LED™ Vertical Mast 9
Shading indicates decal is hidden from view, i.e. under covers
1266923
1266923
1266886
1266886
1267103
1267102
1267103 A
1266973 A
1266883 A
STOP
1
4
2
3
1267102
1267102 A

Operator's Manual First Edition • First Printing
Work Area Safety
10 RL4LED™ Vertical Mast Part No. 1286390GT
WorkArea Safety
Electrocution Hazards
This machine is not electrically insulated and will
not provide protection from contact with or
proximity to electrical current.
Before operating the machine, contact the electric
power line owner to disconnect, move, or insulate
power lines.
Obey all local and governmental regulations
regarding required clearance from electrical power
lines. At a minimum, the required clearance
contained in the chart below must be followed.
Line Voltage Required Clearance
0 to 50KV 10 ft 3.05 m
>50 to 200KV 15 ft 4.60 m
>200 to 350KV 20 ft 6.10 m
>350 to 500KV 25 ft 7.62 m
>500 to 750KV 35 ft 10.67 m
>750 to 1000KV 45 ft 13.72 m
over 1000KV see below
For power lines over 1000kV, the minimum
clearance distance must be established by the
utility owner or operator or by a registered
professional engineer who is a qualified person
with respect to electrical power transmission and
distribution.
Allow for mast movement, 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 energized 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 LED modules
with the engine/generator running or batteries
connected.
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.
There is a permanent conductor between the
generator (static winding) and the frame.

First Edition • First Printing Operator's Manual
Work Area Safety
Part No. 1286390GT RL4LED™ Vertical Mast 11
Explosion and Fire Hazards
Do not start the engine if you smell or detect liquid
petroleum gas (LPG), gasoline, diesel fuel or other
explosive substances.
Stop engine before adding fuel.
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 use high energy starting
aids on machines.
Tip-over Hazards
Do not raise the mast 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
j
acks.
Do not hang objects from the lights or the mast.
Do not use the mast to raise material or personnel.
Do not move the machine unless the mast is
lowered to the stowed position.
Do not raise the mast
when wind speeds may
exceed 50 mph / 81 km/h.
Do not alter or disable
machine components that
in any way affect safety
and stability.

Operator's Manual First Edition • First Printing
Work Area Safety
12 RL4LED™ Vertical Mast Part No. 1286390GT
Do not alter or disable machine components that in
any way affect safety and stability.
Do not adjust or stow the outriggers when the mast
is raised.
Be sure the tires are in good condition and the lug
nuts 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 Hazard
Do not lower the mast unless
the area below is clear of
personnel and obstructions.
Keep hands and fingers away
from any potential pinch points.
Collision Hazards
Check the work area for overhead obstructions or
other possible hazards.
Ensure that the collision area around the mast and
light fixtures is clear before rotating the mast.
Stay clear of moving mast.
Always use the light fixture bar rotation lock before
replacing light fixtures.
Burn Hazards
Stay clear of hot components and surfaces.
Allow machine to cool before servicing.
Do not touch hot parts of the
generator engine or tailpipe, Use
protective gloves when handling
hot parts.

First Edition • First Printing Operator's Manual
Work Area Safety
Part No. 1286390GT RL4LED™ Vertical Mast 13
Bodily Injury Hazard
Breathing carbon monoxide can result in death or
serious injury. Do not use the machine indoors.
Use only outside, far from open windows, doors
and vents.
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 grasp the cable.
Use proper lifting techniques when lifting and
positioning the tongue of the machine.
Read manuals. If you do not understand the
information in the manuals consult your supervisor,
the owner or the manufacturer.
Fall Hazards
Do not climb or stand on any part of the light tower
during maintenance or operation.
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.
Conduct a thorough pre-operation inspection of the
machine and test all functions before each work
shift. Immediately tag and remove from service a
damaged or malfunctioning machine.
Be sure all maintenance has been performed as
specified in this manual and the appropriate Terex
service manual.
Be sure the operator's manual is complete, legible
and in the storage container located on the
machine.
Be sure all decals are in place and legible.
Do not modify or alter the light tower without the
prior written permission of the manufacturer.

Operator's Manual First Edition • First Printing
Work Area Safety
14 RL4LED™ Vertical Mast Part No. 1286390GT
Component Damage Hazards
Do not replace LED modules with any other than
those specified on the machine and in this manual.
Be sure LED module 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 remove the vent caps from the battery when
charging.
Do not expose the batteries or the charger to water
or rain during charging.
Explosion Hazards
Keep sparks, flames, and lighted
tobacco away from batteries.
Batteries emit explosive gas.
Do not contact the battery terminals
or the cable clamps with tools that
may cause sparks.
Electrocution/Burn Hazards
Connect the battery charger to
a grounded, AC 3-wire
electrical outlet only.
Inspect daily for damaged
cords, cables and wires.
Replace damaged items before
operating.
Avoid electrical shock from contact with battery
terminals. Remove all rings, watches and other
jewelry.
Component Damage Hazards
Do not use any battery charger greater than 6V to
charge the batteries.
Lifting Hazard
Use the appropriate number of people and proper
lifting techniques when lifting batteries.

First Edition • First Printing Operator's Manual
Work Area Safety
Part No. 1286390GT RL4LED™ Vertical Mast 15
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 mast is
retracted to the stowed position and is secured.
Do not tow the machine unless rear outriggers and
all jacks have been retracted and stowed.
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 are securely attached to
the tow vehicle. Safety chains should be crossed
below hitch.
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.
Use extreme care and slow speeds while towing
across uneven terrain, debris, holes or drop-offs.
Note: Do not tow machine when engine is running!
This can cause severe engine damage and WILL
NOT BE COVERED UNDER WARRANTY!
Lockout After Each Use
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's Manual First Edition • First Printing
Legend
16 RL4LED™ Vertical Mast Part No. 1286390GT
Legend
1LED modules
2Winch
3Control panel (located under access door)
4Manual storage (located inside cabinet)
5Leveling jack
6Kickstand
7Tie-downs
8Tongue with trailer hitch
9T-handle for mast rotation lock
10 Outrigger
11 Forklift pockets
12 Control panel access door
13 Lifting eye
14 Mast

First Edition • First Printing Operator's Manual
Controls
Part No. 1286390GT RL4LED™ Vertical Mast 17
Controls
Control Panel - Standard
1Ignition switch
Push ignition switch to the on position and hold
until engine starts.
2Battery switch
Turn the battery switch to the on position.
3Choke button
Push choke button in when starting engine.
4Hour meter
The hour meter displays the number of hours
the machine has operated.
5Light switch
Move the light switch up to turn on the lights.
Move the light switch down to turn off the lights.
6Low oil light
Light on indicates the machine is low on oil and
will not run when the indicator is lit.
7Current overload light
Light on indicates the current inverter is
overloaded and will cut power to receptacles.
8Engine OK light
Light remains on during normal operating
conditions.
4
5
7
3
2
1
8
6

Operator's Manual First Edition • First Printing
Controls
18 RL4LED™ Vertical Mast Part No. 1286390GT
Control Panel - Standard
1Air Cleaner
2Connectors A, B, C
Interface between generator and light tower.
312VDC 9AH Battery
Used to power starter during remote starting.
4Wireless Rest Button
Used to reset or pair remote fob.
5Wireless Reset Indicator
6Hour meter
The hour meter displays the number of hours
the machine has operated.
7120VAC, 30 Amp Receptacle (L5-30R)
8Oil Fill Port
9Oil Drain
23
4
8
1
9
5
6
7