Terex RL4000 Operator's Manual
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Terex RL4000 Operator's Manual

Terex RL4000 Operator's Manual

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Summary of Contents for Terex RL4000

  • Page 2: Table Of Contents

    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 Symbol and Hazard Pictorials Definitions .....

  • Page 3: Introduction

    First Edition • Second Printing Introduction 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...
  • Page 4 First Edition • Second Printing Introduction Hazard Classification Intended Use Terex uses symbols, color coding and signal words This machine is intended to be used only to provide to identify the following: lighting and electrical power to a work site.

  • Page 5: Symbol And Hazard Pictorials Definitions

    Only trained and Explosion hazard. energy starting No smoking. qualified personnel aids on machines may access this equipped with compartment. glow plugs. No open flame. No open flame. Explosion/burn Corrosive acid. Explosion/burn hazard. hazard. Part No. 116692 RL4000 • TML-4000...
  • Page 6 Deploy outriggers Stay clear of hot Keep away from Burn hazard Tie-down point. before raising surfaces. moving parts. mast. Stay clear of hot Shattering glass Burn hazard Burn hazard Tip-over hazard surfaces. hazard Tip-over hazard RL4000 • TML-4000 Part No. 116692...

  • Page 7: General Safety

    Operator's Manual First Edition • Second Printing General Safety Safety Signs and Locations (Word Decals) Part No. 116692 RL4000 • TML-4000...
  • Page 8 Operator's Manual First Edition • Second Printing General Safety Safety Signs and Locations (Word Decals) RL4000 • TML-4000 Part No. 116692...
  • Page 9 Operator's Manual First Edition • Second Printing General Safety Safety Signs and Locations (Symbol Decals) Part No. 116692 RL4000 • TML-4000...
  • Page 10 Operator's Manual First Edition • Second Printing General Safety Safety Signs and Locations (Symbol Decals) RL4000 • TML-4000 Part No. 116692...

  • Page 11: Work Area Safety

    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. Part No. 116692 RL4000 • TML-4000...
  • Page 12 Do not work on this equipment when mentally or the machine. physically fatigued. Do not use the machine on a Do not work on this equipment when under the moving or mobile surface or influence of drugs or alcohol. vehicle. RL4000 • TML-4000 Part No. 116692...
  • Page 13 Do not remove the vent caps from the battery when and in the storage container located on the machine. charging. Be sure all decals are legible and in place. Do not expose the battery or the charger to water or rain. Part No. 116692 RL4000 • TML-4000...
  • Page 14 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. RL4000 • TML-4000 Part No. 116692...

  • Page 15: Legend

    Operator's Manual First Edition • Second Printing Legend - RL4000 model 1 Coil cord 12 Lifting eye 2 Coil cord sleeve 13 Lamps 3 Leveling jack 14 Upper retaining pin 4 Fender 15 Muffler 5 Tire 16 Outrigger 6 Ballast (located inside cabinet)
  • Page 16 7 Raise/lower winch 18 Light bar 8 Tongue 19 Control panel (located inside cabinet) 9 Road side door 20 Lower retaining pin 10 Extend/retract winch 21 Outrigger release pin 11 Forklift pockets 22 Tie-downs RL4000 • TML-4000 Part No. 116692...
  • Page 17 Operator's Manual First Edition • Second Printing This page intentionally left blank. Part No. 116692 RL4000 • TML-4000...

  • Page 18: Controls

    5 Engine prime button 1 Light switches 6 Alternator failure light 2 Main circuit breaker 7 Mini breaker, 120V 3 Hour meter 8 Duplex receptacle with GFI, 120V/20A 4 Ignition switch for engine 9 T-lock receptacle, 240V/30A RL4000 • TML-4000 Part No. 116692...
  • Page 19 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 Part No. 116692 RL4000 • TML-4000...

  • Page 20: Pre-Operation Inspection

    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. RL4000 • TML-4000 Part No. 116692...
  • Page 21 Outriggers, leveling jacks and foot pads o Nuts, bolts and other fasteners o Lamp fixtures, connections and bulbs o Cable (kinks, frays and abrasions) o Safety chains (if required) o Engine and related components o Fuel tank o Generator Part No. 116692 RL4000 • TML-4000...

  • Page 22: Function Tests

    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. RL4000 • TML-4000 Part No. 116692...
  • Page 23 Result: A clicking sound should be heard as the enough to clear the tow vehicle. winch handle is turned. 7 RL4000: Release the spring pin on the side 10 Release the winch handle. outriggers and slide them out into the deployed Result: The winch brake should hold when the position.
  • Page 24 24 Turn the winch handle counterclockwise until the mast reaches horizontal position. 25 Insert the lower retaining pin into the mast support and install the cotter pin to secure. RL4000 • TML-4000 Part No. 116692...

  • Page 25: Inspections

    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. Part No. 116692 RL4000 • TML-4000...
  • Page 26 Label - Ground 28162 Warning - Bodily injury hazard 133148 Danger - Electrocution hazard 31788 Danger - Battery safety 133225 Cosmetic - Terex logo 38149 Label - Patents 133455 Danger - General safety 52475 Label - Tie-down point 133457 Instruction - Mast stowage...
  • Page 27 Operator's Manual First Edition • Second Printing Inspections Part No. 116692 RL4000 • TML-4000...
  • Page 28 Warning - Explosion hazard 114251 Danger - No smoking 133149 Danger - Electrocution hazard 114391 Warning - Bodily injury hazard 133225 Cosmetic - Terex logo 114448 Cosmetic - Terex logo 133487 Cosmetic - RL4000 116893 Warning - Tow speed 851691...
  • Page 29 Operator's Manual First Edition • Second Printing Inspections Part No. 116692 RL4000 • TML-4000...

  • Page 30: Operating Instructions

    3 Always perform function tests prior to use. inspection before using the machine. 4 Inspect the workplace. 5 Only use the machine as it was intended. RL4000 • TML-4000 Part No. 116692...
  • Page 31 2 Allow the engine to run for 1 to 5 minutes under no load. Note: Never shut the engine down while under load. This can damage the AC generator. 3 Turn the ignition switch to the engine off position. Part No. 116692 RL4000 • TML-4000...
  • Page 32 4 Before lowering the mast sections, the blue arrows on the mast must be aligned. 5 Release the mast rotation lock and rotate the mast to align the arrows. 6 Tighten the T-handle to secure the mast. RL4000 • TML-4000 Part No. 116692...
  • Page 33 Consult the local electrical codes or 9 RL4000: Release the spring pin on the side authority having jurisdiction in the area where the outriggers and slide the outriggers into the machine will be used for specific requirements.
  • Page 34 All tires must be properly inflated. Do not overinflate the tires. Tire pressures go up during Avoid sudden movements when turning. driving. Checking the tire pressure when the tires are warm will give you an inaccurate pressure reading. RL4000 • TML-4000 Part No. 116692...

  • Page 35: Transport And Lifting Instructions

    Terex customers needing to containerize any Raise and stow the outriggers. Terex product should source a qualified freight forwarder with expertise in preparing, loading and securing construction and lifting equipment for international shipment.
  • Page 36 Close and secure the cabinet doors. Use the lifting eye on the tower to lift the machine, attach a lifting hook to the lifting eye. RL4000 model shown RL4000 • TML-4000 Part No. 116692...

  • Page 37: Maintenance

    5.4 quarts / 5.1 liters Cold conditions and the requirements specified in the use SAE 5W-20 responsibilities manual. Perkins 13.8 HP Use only Terex approved replacement parts. Oil requirement SAE 10W-40 4.66 quarts / 4.41 liters Cold conditions Maintenance Symbols Legend...
  • Page 38 Note: Tires and wheels must be replaced with tires and wheels of the specifications listed. 3 Check each tire with an air pressure gauge and add air as needed. 4 Check the torque of each lug nut. RL4000 • TML-4000 Part No. 116692...

  • Page 39: Specifications

    Operator's Manual First Edition • Second Printing Specifications Model - RL4000 & TML-4000 Height, stowed 5 ft 9.5 in 1.765 m Length, stowed 14 ft 2 in 4.331 m Width, stowed 4 ft 6 in 1.372 m Extended tower height 30 ft 9.114 m...

  • Page 40: Reporting Safety Defects

    Safety Hotline toll-free at 1-800-424-9393 (366-0123 in Washington DC area) or write to: NHTSA U.S. Department of Transportation 400 7th Street SW, (NSA-11) Washington DC 20590 You can also obtain information about motor vehicle safety from the Hotline. RL4000 • TML-4000 Part No. 116692...
  • Page 42 California Proposition 65 California Proposition 65 Warning Warning Battery post terminals and related The exhaust from this product accessories contain lead compounds, contains chemicals known to chemicals known to the State of the State of California to California to cause cancer cause cancer, birth defects and other reproductive harm.

This manual is also suitable for:

Tml-4000

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