Terex RL4 LED Operator's Manual
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Terex RL4 LED Operator's Manual

Terex RL4 LED Operator's Manual

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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

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Summary of Contents for Terex RL4 LED

  • Page 1 Operator's Manual RL™4 LED ANSI/CSA from SN RL4LEDJ-101 North America South America Asia with Maintenance Information First Edition First Printing Part No. 1286390GT...

  • Page 2: Table Of Contents

    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. RL4LED™ Vertical Mast Part No. 1286390GT...

  • Page 3: Introduction

    This book is an operation and daily maintenance contrary to its intended use. manual for the user or operator of a Terex machine. Bulletin Distribution and This manual should be considered a permanent...
  • Page 4 First Edition • First Printing Introduction 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...
  • Page 5 First Edition • First Printing Operator's Manual Introduction Hazard Classification Safety Sign Maintenance Replace any missing or damaged safety signs. Decals on this machine use symbols, color coding, Keep operator safety in mind at all times. Use mild and signal words to identify the following: soap and water to clean safety signs.

  • Page 6: Symbol And Hazard Pictorials Definitions

    Operator's Manual First Edition • First Printing Symbol and Hazard Pictorials Definitions Symbol and Hazard Pictorials Definitions Read the operator’s Electrocution hazard Stop engine Earth ground Electrocution hazard manual Maintain required Explosion / Burn Disconnect battery Keep away from Keep away from clearance hazard Read the service...
  • Page 7 First Edition • First Printing Operator's Manual Symbol and Hazard Pictorials Definitions Carbon Monoxide Do not use light tower Wear protective Lifting point Tie-down point hazard indoors clothing Deploy outriggers Tip-over hazard, tow Electrocution/ Electrocution/ Tip-over hazard before raising mast speed entanglement hazard entanglement hazard...

  • Page 8: General Safety

    Operator's Manual First Edition • First Printing General Safety General Safety 1266647 1266648 1266661 1266884 1266650 1266884 WARNING 60 mph 97 km/h Read and understand manuals. Slow down for curves, adverse weather , hazardous road conditions, road construction, Ti p Over Hazar d towing vehicle limitations and expressway exits.
  • Page 9 First Edition • First Printing Operator's Manual General Safety Shading indicates decal is hidden from view, i.e. under covers 1266883 1266881 1266655 1266887 1266661 1266657 1266653 1266888 1266881 1266655 1266888 1266887 1266661 WARNING DANGER DANGER WARNING WARNING Do not use high Explosion/Burn Hazar energy starting aids Battery explosion and/or contact with...
  • Page 10 Operator's Manual First Edition • First Printing General Safety 1266889 1266679 1266675 1266678 1266676 1266678 60 mph 1266889 97 km/h 1266678 A 1266679 1266675 1266889 10 ft (3 m) 0 to 50 kv > 50 to 200 kv 15 ft (4.6 m) >...
  • Page 11 First Edition • First Printing Operator's Manual General Safety Shading indicates decal is hidden from view, i.e. under covers 1266886 1266923 1267102 1266923 1267102 1266886 1267103 STOP 1266883 A 1266973 A 1267103 A 1267102 A Part No. 1286390GT RL4LED™ Vertical Mast...

  • Page 12: Work Area Safety

    Operator's Manual First Edition • First Printing Work Area Safety Work Area Safety Allow for mast movement, electrical line sway or Electrocution Hazards sag, and beware of strong or gusty winds. This machine is not electrically insulated and will Do not operate the machine during lightning or not provide protection from contact with or storms.
  • Page 13 First Edition • First Printing Operator's Manual Work Area Safety Explosion and Fire Hazards Tip-over Hazards Do not start the engine if you smell or detect liquid Do not raise the mast unless all petroleum gas (LPG), gasoline, diesel fuel or other outriggers are properly explosive substances.
  • Page 14 Operator's Manual First Edition • First Printing Work Area Safety Do not alter or disable machine components that in Collision Hazards any way affect safety and stability. Check the work area for overhead obstructions or Do not adjust or stow the outriggers when the mast other possible hazards.
  • Page 15 Use proper lifting techniques when lifting and positioning the tongue of the machine. Be sure all maintenance has been performed as specified in this manual and the appropriate Terex Read manuals. If you do not understand the service manual. information in the manuals consult your supervisor, the owner or the manufacturer.
  • Page 16 Operator's Manual First Edition • First Printing Work Area Safety Explosion Hazards Component Damage Hazards Do not replace LED modules with any other than Keep sparks, flames, and lighted those specified on the machine and in this manual. tobacco away from batteries. Batteries emit explosive gas.
  • Page 17 First Edition • First Printing Operator's Manual Work Area Safety Be sure that all driving lights are operational. Towing Hazards Be sure all hitch components, lights and mirrors Read, understand and obey all of your tow vehicle and methods of attaching the trailer to the tow manufacturer's recommendations, warnings and vehicle conform to local, state and federal instructions before towing this machine.

  • Page 18: Legend

    Operator's Manual First Edition • First Printing Legend Legend LED modules T-handle for mast rotation lock Winch 10 Outrigger Control panel (located under access door) 11 Forklift pockets Manual storage (located inside cabinet) 12 Control panel access door Leveling jack 13 Lifting eye Kickstand 14 Mast...

  • Page 19: Controls

    First Edition • First Printing Operator's Manual Controls Controls Control Panel - Standard Light switch Ignition switch Move the light switch up to turn on the lights. Push ignition switch to the on position and hold Move the light switch down to turn off the lights. until engine starts.
  • Page 20 Operator's Manual First Edition • First Printing Controls Control Panel - Standard Wireless Reset Indicator Air Cleaner Hour meter Connectors A, B, C The hour meter displays the number of hours Interface between generator and light tower. the machine has operated. 12VDC 9AH Battery 120VAC, 30 Amp Receptacle (L5-30R) Used to power starter during remote starting.

  • Page 21: Inspections

    First Edition • First Printing Operator's Manual Inspections Inspections 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. Do Not Operate Unless: The inspection is designed to discover if anything is apparently wrong with a machine before the...
  • Page 22 Operator's Manual First Edition • First Printing Inspections Pre-operation Inspection  Nuts, bolts and other fasteners  LED fixtures and connections  Be sure that the operator’s manual is complete, legible and in the storage container located on  Cable (kinks, frays and abrasions) the machine.
  • Page 23 First Edition • First Printing Operator's Manual Inspections 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 Do Not Operate Unless: tagged and removed from service.
  • Page 24 Operator's Manual First Edition • First Printing Inspections Re-install the locking clip and pin removed in Function Tests step 6 to the new position (8). This will secure the kickstand for light tower operation and Lowering the tongue for use or towing towing.
  • Page 25 First Edition • First Printing Operator's Manual Inspections Release the spring pin on the side outriggers Raising the tongue for storage or shipping and slide them out into the deployed position. Remove the locking clip and pin from located in Make sure the outriggers are locked in place.
  • Page 26 Operator's Manual First Edition • First Printing Inspections Test Machine Functions Test the Lights By raising and lowering the mast back to the 19 Make sure the light switches are in the off stowed position, the following functions will be position.
  • Page 27 First Edition • First Printing Operator's Manual Inspections Workplace Inspection Checklist Be aware of and avoid the following hazardous situations:  drop-offs or holes  bumps, floor obstructions, or debris  sloped surfaces Do Not Operate Unless:  unstable or slippery surfaces ...
  • Page 28 First Edition • First Printing Inspections Inspection for Decals with Words Part No. Decal Description 1266658 Cosmetic — Terex Logo, front fairing Determine whether the decals on your machine 1266659 Cosmetic — Genie Logo, front fairing have words or symbols. Use the appropriate inspection to verify that all decals are legible and in 1266661 Warning —...
  • Page 29 First Edition • First Printing Operator's Manual Inspections Shading indicates decal is hidden from view, i.e. under covers 72086 1266650 1266885 1286300 1266647 1266648 28158 1266661 229102 133461 1266658 1266659 1266652 1286541 1286538 133062 1286541 1286538 1266884 1266667 52475 1266883 1286540 1286537 1287638...
  • Page 30 Label - Arrow Rear door 1266652 Label — Transport Diagram 1286538 Cosmetic — Genie Logo, RL4LED Gas 1266658 Cosmetic — Terex Logo, front fairing 1286540 Cosmetic — Terex Logo, RL4LED Gas, 1266659 Cosmetic — Genie Logo, front fairing Rear door 1266668 Instructions —...
  • Page 31 First Edition • First Printing Operator's Manual Inspections Shading indicates decal is hidden from view, i.e. under covers 72086 1266676 1267099 1266679 28158 1266675 1266889 229102 133122 1266658 1266659 1266649 1266652 1266678 133062 1286541 1286538 52475 1266668 1286540 1266886 1286537 1266923 1267102 1268278...

  • Page 32: Operating Instructions

    Operator's Manual First Edition • First Printing Operating Instructions Operating Instructions 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.
  • Page 33 First Edition • First Printing Operator's Manual Operating Instructions Re-install the locking clip and pin removed in Lowering the tongue for use or towing step 6 to the new position (8). This will secure This light tower is equipped with a deployable the kickstand for light tower operation and tongue to maximize shipping units.
  • Page 34 Operator's Manual First Edition • First Printing Operating Instructions Pull the release pin on the tongue jack and Raising the tongue for storage or shipping rotate into vertical position. Remove the locking clip and pin from located in Turn the leveling jack handle to lower the front position (8).
  • Page 35 First Edition • First Printing Operator's Manual Operating Instructions Starting the Engine How to Connect to Grid Power Note: The light switch must be off before starting Do not start generator if using grid power for the generator's engine. the LED Modules. Note: There must be fuel in the fuel tank in order to Ensure the LED Module Light Switches are in start the engine.
  • Page 36 Operator's Manual First Edition • First Printing Operating Instructions Wireless Remote Control Wireless Remote Star This generator is equipped with a wireless remote Wireless remote starting is only possible within control system for starting and stopping. The 80 feet of the generator. (Wireless signal may not system consists of (4) main components: pass through some solid objects.) Receiver Control Module (RCM)
  • Page 37 First Edition • First Printing Operator's Manual Operating Instructions Push and release the "STOP" button on the Wireless Set Button remote. The red light blinks once to erase the The wireless set button is a feature that lets the remote program. user sync remotes to the generator.
  • Page 38 Operator's Manual First Edition • First Printing Operating Instructions Connect a 10/3 Extension Cord (100 ft. max. Chained Power for Light Tower length) to the GFCI receptacle of Unit #1. Must Units use a second Extension Cord for Unit #3 if desired.
  • Page 39 First Edition • First Printing Operator's Manual Operating Instructions Extending the Mast Operation of Lights Turn the winch handle clockwise until the mast Note: The engine must be running before the lights reaches vertical position. are turned on. Turn the T-handle to release the mast rotation Be sure the position of the lights is adjusted lock.
  • Page 40 Operator's Manual First Edition • First Printing Operating Instructions 12 Turn the tongue jack handle to raise the jack Towing wheel. Pull the spring pin on the tongue jack CAUTION: SHUT ENGINE OFF BEFORE and rotate and secure it into the horizontal travel position.
  • Page 41 First Edition • First Printing Operator's Manual Operating Instructions 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.

  • Page 42: Transport And Lifting Instructions

    Inspect the entire machine for loose or unsecured  Terex customers needing to containerize any items. Terex product should source a qualified freight forwarder with expertise in preparing, loading Use the three tie-down points for anchoring down and securing construction and lifting equipment to the transport surface.
  • Page 43 First Edition • First Printing Operator's Manual Transport and Lifting Instructions Lifting the Machine with a Crane or Forklift Fully lower the mast to the stowed position. Rotate the light bar perpendicular to the tongue of the machine and tighten the T-handle, into the notch, to secure and align the arrows.

  • Page 44: Maintenance

    Engine responsibilities manual. Oil type 10W-30  Use only Terex approved replacement parts. Maintenance Symbols Legend The following symbols have been used in this manual to help communicate the intent of the instructions. When one or more of the symbols appear at the beginning of a maintenance procedure, it conveys the meaning below.
  • Page 45 First Edition • First Printing Operator's Manual Maintenance Check the Batteries Check the Tire Pressure Proper battery condition is essential to good Bodily injury hazard. An over-inflated tire can machine performance and operational safety. explode and may cause death or serious injury. Improper fluid levels or damaged cables and Collision hazard.
  • Page 46 Operator's Manual First Edition • First Printing Maintenance Scheduled Maintenance Maintenance performed quarterly, annually and every two years must be completed by a person trained and qualified to perform maintenance on this machine according to the procedures found in the service manual for this machine. Machines that have been out of service for more than three months must receive the quarterly inspection before they are put back into service.

  • Page 47: Specifications

    50 mph 81 km/h Sound level (dba rating) 58 dba @ 23 ft / 7 m Continuous improvement of our products is a Terex policy. Product specifications are subject to change without notice or obligation. Part No. 1286390GT RL4LED™ Vertical Mast...

  • Page 48: Reporting Safety Defects

    However, NHTSA cannot become involved in any individual problems between you, your dealer or Terex Corporation. To contact NHTSA you may either call the Auto Safety Hotline toll-free at 1-800-424-9393...

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