Page 1
S
t
RL4 Vertical Mas
ervice Manual
Part No. 1266665
Rev A
August 2015
Page 2
Service Manual August 2015
Introduction
Introduction Introduction
Important
Read, understand and obey the safety rules and
operating instructions in the appropriate Operator's
Manual on your machine before attempting any
maintenance procedure.
This manual provides detailed scheduled
maintenance information for the machine owner
and user. It also provides troubleshooting and
repair procedures for qualified service
professionals.
Basic mechanical, hydraulic and electrical skills are
required to perform most procedures. However,
several procedures require specialized skills, tools,
lifting equipment and a suitable workshop. In these
instances, we strongly recommend that
maintenance and repair be performed at an
authorized Terex dealer service center.
Technical Publications
Terex has endeavored to deliver the highest
degree of accuracy possible. However, continuous
improvement of our products is a Terex policy.
Therefore, product specifications are subject to
change without notice.
Readers are encouraged to notify Terex of errors
and send in suggestions for improvement. All
communications will be carefully considered for
future printings of this and all other manuals.
Contact Us:
Internet: www.genielift.com
E-mail: awp.techpub@terex.com
Compliance
Machine Design Life
Unrestricted with proper operation, inspection and
scheduled maintenance.
Copyright © 2015 by Terex Corporation
1266665 Rev A, August 2015
First Edition, First Printing
'Terex' and 'AWP' are registered trademarks of Terex USA, LLC
in the U.S.A. and many other countries.
ii RL4 Vertical Mast Part No. 1266665
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August 2015 Service Manual
Introduction
Serial Number Legend
Part No. 1266665 RL4 Vertical Mast iii
Page 4
Service Manual August 2015
Safety Rules
Section 1 Safety Rules
Danger
Failure to obey the instructions and safety rules in
this manual and the appropriate Operator's Manual
on your machine will result in death or serious
injury.
Many of the hazards identified in the operator's
manual are also safety hazards when maintenance
and repair procedures are performed.
Do Not Perform Maintenance
Unless:
You are trained and qualified to perform
maintenance on this machine.
You read, understand and obey:
manufacturer's instructions and safety rules
employer's safety rules and worksite
regulations
applicable governmental regulations
You have the appropriate tools, lifting
equipment and a suitable workshop.
iv RL4 Vertical Mast Part No. 1266665
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August 2015 Service Manual
NOTICE
Safety Rules
Workplace Safety
Personal Safety
Any person working on or around a machine must
be aware of all known safety hazards. Personal
safety and the continued safe operation of the
machine should be your top priority.
Read each procedure thoroughly. This
manual and the decals on the machine,
use signal words to identify the following:
Safety alert symbol–used to alert
personnel to potential personal
DANGER
WARNING
injury hazards. Obey all safety
messages that follow this symbol
to avoid possible injury or death.
Indicates a imminently hazardous
situation which, if not avoided, will
result in death or serious injury.
Indicates a potentially hazardous
situation which, if not avoided,
could result in death or serious
injury.
Any person working on or around a machine must
be aware of all known safety hazards. Personal
safety and the continued safe operation of the
machine should be your top priority.
Be sure to keep sparks, flames and
lighted tobacco away from flammable and
combustible materials like battery gases
and engine fuels. Always have an
approved fire extinguisher within easy
reach.
Be sure that all tools and working areas
are properly maintained and ready for
use. Keep work surfaces clean and free of
debris that could get into machine
components and cause damage.
Be sure any forklift, overhead crane or
other lifting or supporting device is fully
capable of supporting and stabilizing the
weight to be lifted. Use only chains or
straps that are in good condition and of
ample capacity.
CAUTION
Be sure to wear protective eye wear and
other protective clothing if the situation
warrants it.
Be aware of potential crushing hazards
such as moving parts, free swinging or
unsecured components when lifting or
placing loads. Always wear approved
steel-toed shoes.
Indicates a potentially hazardous
situation which, if not avoided,
may cause minor or moderate
injury.
Indicates a potentially hazardous
situation which, if not avoided,
may result in property damage.
Be sure that fasteners intended for one
time use (i.e., cotter pins and self-locking
nuts) are not reused. These components
may fail if they are used a second time.
Be sure to properly dispose of old oil or
other fluids. Use an approved container.
Please be environmentally safe.
Be sure that your workshop or work area
is properly ventilated and well lit.
Part No. 1266665 RL4 Vertical Mast v
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August 2015
Table of Contents
Introduction Introduction .......................................................................................................... ii
Important Information .............................................................................................. ii
Serial Number Legend ........................................................................................... iii
Serial Number Legend ........................................................................................... iii
Section 1 Safety Rules ......................................................................................................... iv
General Safety Rules ............................................................................................. iv
Section 2 Specifications ....................................................................................................... 1
Machine Specifications .......................................................................................... 1
Performance Specifications ................................................................................... 1
Performance Specifications ................................................................................... 1
Kohler KDW1003GE Engine Specifications ......................................................... 1
Machine Specifications .......................................................................................... 2
Machine Torque Specifications .............................................................................. 4
SAE and Metric Fasteners Torque Charts ............................................................. 5
Section 3 Scheduled Maintenance Procedures ................................................................. 7
Introduction ............................................................................................................ 7
Pre-Delivery Preparation Report .......................................................................... 10
Maintenance Inspection Report ........................................................................... 11
vi RL4 Vertical Mast Part No. 1266665
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August 2015
Table of Contents
Checklist A Procedures ..................................................................................... 13
A-1 Inspect the Manuals and Decals ................................................................... 13
A-2 Perform Pre-operation Inspection .................................................................. 14
A-3 Perform Function Tests ................................................................................. 14
A-4 Perform Engine Maintenance - Kubota ......................................................... 15
A-5 Perform Coupler Maintenance ....................................................................... 15
A-6 Test the Brakes (if equipped) ......................................................................... 16
A-7 Torque the Wheel Lug Nuts ........................................................................... 16
A-8 Perform Engine Maintenance - Kohler .......................................................... 17
A-9 Check the Tires and Wheels .......................................................................... 17
A-10 Inspect the Engine Air Filter ......................................................................... 18
A-11 Perform Generator Maintenance ................................................................. 19
A-12 Perform Engine Maintenance - Kubota ....................................................... 19
A-13 Perform Engine Maintenance - Kohler ........................................................ 20
A-14 Inspect the Cable and Cable Pulleys ........................................................... 20
A-15 Perform Engine Maintenance - Kubota ....................................................... 21
A-16 Perform Engine Maintenance - Kubota ....................................................... 22
A-17 Perform Generator Maintenance ................................................................. 22
A-18 Drain the Fuel Filter/Water Separator .......................................................... 23
A-19 Adjust the Brakes (if equipped) ................................................................... 24
A-20 Perform Engine Maintenance - Kohler ........................................................ 25
Checklist B Procedures ..................................................................................... 26
B-1 Inspect the Engine Start Battery .................................................................... 26
B-2 Inspect the Electrical Wiring .......................................................................... 27
B-3 Torque the Wheel Lug Nuts ........................................................................... 28
B-4 Perform Engine Maintenance - Kubota ......................................................... 28
B-5 Inspect and Lubricate the Winch ................................................................... 29
Part No. 1266665 RL4 Vertical Mast vii
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August 2015
Table of Contents
B-6 Lubricate the T-bolt ....................................................................................... 29
B-7 Inspect and Adjust the Brakes (if equipped) ................................................. 30
B-8 Inspect the Suspension ................................................................................. 32
B-9 Perform Engine Maintenance - Kohler .......................................................... 32
B-10 Perform Engine Maintenance - Kubota ....................................................... 33
Checklist C Procedures ..................................................................................... 34
C-1 Perform Engine Maintenance........................................................................ 34
C-2 Clean the Light Assemblies ........................................................................... 34
C-3 Grease the Wheel Bearings .......................................................................... 35
C-4 Inspect the Electric Brake Magnets .............................................................. 36
C-6 Perform Engine Maintenance - Kohler .......................................................... 37
C-6 Perform Engine Maintenance - Kubota ......................................................... 38
C-7 Perform Engine Maintenance - Kohler .......................................................... 38
C-8 Perform Generator Maintenance................................................................... 39
Checklist D Procedures ..................................................................................... 40
D-1 Perform Engine Maintenance - Kubota ......................................................... 40
D-2 Perform Generator Maintenance................................................................... 40
D-3 Perform Coupler Maintenance ...................................................................... 41
Checklist E Procedures ..................................................................................... 42
E-1 Inspect the Cable and Cable Pulleys ............................................................ 42
E-2 Perform Engine Maintenance - Kubota ......................................................... 43
E-3 Perform Engine Maintenance - Kubota ......................................................... 43
E-4 Perform Engine Maintenance - Kohler .......................................................... 44
E-5 Perform Engine Maintenance - Kohler .......................................................... 44
E-6 Perform Engine Maintenance - Kohler .......................................................... 45
E-7 Perform Generator Maintenance ................................................................... 45
E-8 Perform Generator Maintenance ................................................................... 46
E-9 Perform Generator Maintenance ................................................................... 46
viii RL4 Vertical Mast Part No. 1266665
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August 2015
Table of Contents
Section 4 Repair Procedures ............................................................................................. 47
Introduction ........................................................................................................... 47
Lighting ............................................................................................................... 49
1-1 How to Remove a Lamp ................................................................................. 49
1-2 How to Check Line Voltage ............................................................................ 49
Mast ..................................................................................................................... 50
2-1 How to Remove the Mast Assembly .............................................................. 50
2-2 How to Disassemble the Mast Assembly ....................................................... 50
2-3 How to Replace the Mast Lift Cables ............................................................. 52
2-4 How to Remove the Manual Winch ................................................................ 53
2-5 How to Remove the Electric Winch ................................................................ 54
2-6 How to Disengage the Tower Lock ................................................................ 55
Kohler KDW1003GE Engine .............................................................................. 57
3-1 Timing Adjustment-Kohler Engines ................................................................ 57
3-2 Glow Plugs-Kohler Engines ........................................................................... 57
3-3 Coolant Temperature and Oil Pressure Switches-Kohler Engines ................ 57
Kubota D1105-E4BG Engine ............................................................................. 58
4-1 Timing Adjustment-Kubota Engines ............................................................... 58
4-2 Glow Plugs-Kubota Engines .......................................................................... 58
4-3 Coolant Temperature and Oil Pressure Switches-Kubota Engines ............... 58
Generator ............................................................................................................ 59
5-1 Generator ....................................................................................................... 59
5-2 How to Check a Generator Capacitor ............................................................ 60
5-3 How to Check a Generator Diode .................................................................. 60
Light Ballast ........................................................................................................ 62
6-1 Ground Controls ............................................................................................. 62
6-2 Light Ballast .................................................................................................... 63
Fuel Tank ............................................................................................................. 64
7-1 Fuel Tank ....................................................................................................... 64
Part No. 1266665 RL4 Vertical Mast ix
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August 2015
Table of Contents
Section 5 Diagnostics ......................................................................................................... 65
Introduction .......................................................................................................... 65
Section 6 Schematics ......................................................................................................... 71
Introduction .......................................................................................................... 71
Wire Color Legend ............................................................................................... 72
RL4 Control Box AC Voltage Wiring - Standard .................................................. 73
RL4 Control Box AC Voltage Wiring - Standard .................................................. 74
RL4 Control Box AC Voltage Wiring - Autostart .................................................. 75
RL4 Control Box AC Voltage Wiring - Autostart .................................................. 76
RL4 DC Control Box - Standard ........................................................................... 77
RL4 DC Control Box - Standard ........................................................................... 78
RL4 DC Engine Components - DynaGen Autostart ............................................. 79
RL4 DC Engine Components - DynaGen Autostart ............................................. 80
RL4 DC Engine Components - Kohler ................................................................. 81
RL4 DC Engine Components - Kohler ................................................................. 82
RL4 DC Engine Components - Kubota ................................................................ 83
RL4 DC Engine Components - Kubota ................................................................ 84
RL4 DC Control Box - Timed Oil Switch .............................................................. 85
RL4 DC Control Box - Timed Oil Switch .............................................................. 86
RL4 DC Control Box - Low Fuel Shut Down ........................................................ 87
RL4 DC Control Box - Low Fuel Shut Down ........................................................ 88
RL4 Running Lights - Front Fairing Section ......................................................... 89
RL4 Running Lights - Front Fairing Section ......................................................... 90
RL4 Running Lights - Rear Fairing Section ......................................................... 91
RL4 Running Lights - Rear Fairing Section ......................................................... 92
RL4 Electrical Winch Option ................................................................................ 93
RL4 Electrical Winch Option ................................................................................ 94
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August 2015 Service Manual
Specifications
Section 2 Specifications
Machine Specifications
Total lighting wattage
Fuel capacities
Single tank
Tires and wheels
Tire size ST175/80D13
Load range C
Lug nut torque, dry
Lug nut torque, lubricated
4 x 1000 watts
45 gallons
170 liters
90 ft-lbs
122 Nm
67.5 ft-lbs
91.5 Nm
Performance Specifications
Tongue weight, maximum
With fuel (45 gallon tank)
Run time
45 gallon tank 90 hours
For operational specifications, refer to the
Operator's Manual.
Continuous improvement of our products is a
Genie policy. Product specifications are
subject to change without notice or obligation.
203 lbs
92 kg
Generator Options
Coliseum 6 kW 1CBC06-TX
Generator rpm @ full load 60Hz, 1800 rpm
Temperature, ambient maximum
Power 6 kW
Coliseum 7 kW 1CBC07-TX
Generator rpm @ full load 50 Hz, 1500 rpm
Temperature, ambient maximum
Power 7 kW
Coliseum 8 kW 1CBC08-TX
Generator rpm @ full load 60 Hz, 1800 rpm
Temperature, ambient maximum
Power 8 kW
For operational specifications, refer to the
Operator's Manual.
Continuous improvement of our products is a
Genie policy. Product specifications are
subject to change without notice or obligation.
104° F
40° C
104° F
40° C
104° F
40° C
Part No. 1266665 RL4 Vertical Mast 1
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Service Manual August 2015
Specifications
Kohler KDW1003GE Engine
Displacement
Number of cylinders
Bore and Stroke
Horsepower
Firing order
Compression ratio
Compression pressure
Engine speed
Governor
Valve Clearance, cold
Engine coolant
Capacity
Lubrication system
Oil pressure
Oil capacity (including filter)
2.95 x 3.1 inches
75 x 77.6 mm
10.7 @ 1800
412 to 469 psi
28.4 to 32.3 bar
0.00787402 in
28.8 to 50.6 psi
62.7 cu in
1.03 liters
8 kW
1 - 3 - 2
22.8:1
1800 rpm
centrifugal
mechanical
0.20 mm
4.5 quarts
4.3 liters
3 to 4.5 bar
5 quarts
4.7 liters
Oil pressure switch (engine
shutoff pressure)
Oil viscosity requirements
Unit ships with 10W-30. Extreme operating
3
temperatures may require the use of alternative engine
oils. For oil requirements, refer to the Engine Operator
Manual for your engine.
Injection system
Injection pump Bosch
Injection timing 9° BTDC
Injection pump pressure,
maximum
Fuel requirement
For fuel requirements, refer to the engine Operator
Manual for your engine.
Battery
Type 12V DC
Group 27TM
Quantity 1
Cold cranking ampere 500
Reserve capacity @ 75A rate 105 minutes
Alternator
Alternator output 45A, 12V DC
Fan belt deflection
1/4 to 3/8 inch
20 psi
2233 psi
155 bar
7 to 9 mm
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August 2015 Service Manual
Specifications
Kubota D1105-E4BG Engine
Displacement
Number of cylinders
Bore and Stroke
Horsepower
Firing order
Compression ratio
Compression pressure
Engine speed
Governor
Valve Clearance, cold
Engine coolant
Capacity
Lubrication system
Oil pressure
Oil capacity (including filter)
0.0057 to 0.0072 in
0.145 to 0.185 mm
68.53 cu in
3.07 x 3.09 inches
78 x 78.4 mm
13.6 @ 1800
397 to 454 psi
28.4 to 32.3 bar
mechanical
3.27 quarts
28 to 64 psi
1.93 to 4.41 bar
1.12 liters
10.1 kW
1 - 2 - 3
24:1
1800 rpm
centrifugal
3.1 liters
5.4 quarts
5.1 liters
Oil pressure switch (engine
shutoff pressure)
Oil viscosity requirements
Unit ships with 10W-30. Extreme operating
3
temperatures may require the use of alternative engine
oils. For oil requirements, refer to the Engine Operator
Manual for your engine.
Injection system
Injection pump Bosch MD mini
Injection timing 16.5° BTDC
Injection pump pressure,
maximum
Fuel requirement
For fuel requirements, refer to the engine Operator
Manual for your engine.
Battery
Type 12V DC
Group 27TM
Quantity 1
Cold cranking ampere 500
Reserve capacity @ 75A rate 105 minutes
Alternator
Alternator output 30A, 12V DC
Fan belt deflection
1/4 to 3/8 inch
7 psi
1991 psi
137 bar
7 to 9 mm
Part No. 1266665 RL4 Vertical Mast 3
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Service Manual August 2015
Specifications
Machine Torque Specifications
Generator
Flex plate to flywheel
Generator case to bell housing
Generator isolators
Wheel lugs
Lug nut torque, lubricated
Lug nut torque, dry
Engine vibration isolators
Mounting bolts, dry
Mounting bolts, lubricated
25 ft-lbs
34 Nm
44 ft-lbs
60 Nm
37 ft-lbs
50.5 Nm
67.5 ft-lbs
91.5 Nm
90 ft-lbs
122 Nm
75 ft-lbs
102 Nm
57 ft-lbs
77 Nm
Continuous improvement of our products is a
Genie policy. Product specifications are
subject to change without notice or obligation.
4 RL4 Vertical Mast Part No. 1266665
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August 2015 Service Manual
Specifications
Part No. 1266665 RL4 Vertical Mast 5
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Service Manual August 2015
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6 RL4 Vertical Mast Part No. 1266665
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August 2015 Service Manual
Scheduled Maintenance Procedures
Section 3 Scheduled Maintenance Procedures
Observe and Obey:
Maintenance inspections shall be completed
by a person trained and qualified on the
maintenance of this machine.
Scheduled maintenance inspections shall be
completed daily, quarterly, semi-annually,
annually and every 2 years as specified of the
Maintenance inspection Report. The frequency
and extent of periodic examinations and tests
may also depend on national regulations.
WARNING
Failure to perform each
procedure as presented and
scheduled may cause death,
serious injury or substantial
damage.
Machine Configuration:
Unless otherwise specified, perform each
procedure with the machine in the following
configuration:
Machine parked on a firm, level surface
Mast in the stowed position
Key switch in the off position with the key
removed
The red Emergency Stop button in the off
position on the electrical control box
Wheels chocked
Light switches in the off position
All external AC power supply disconnected
from the machine
Boom in the stowed position
Turntable secured with the turntable rotation
lock
Immediately tag and remove from service a
damaged or malfunctioning machine.
Repair any machine damage or malfunction
before operating the machine.
Use only Terex approved replacement parts.
Machines that have been out of service for a
period longer than 3 months must complete the
quarterly inspection.
Part No. 1266665 RL4 Vertical Mast 7
Page 18
Service Manual August 2015
NOTICE
Scheduled Maintenance Procedures
About This Section
This section contains detailed procedures for each
scheduled maintenance inspection.
Each procedure includes a description, safety
warnings and step-by-step instructions.
Symbols Legend
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.
DANGER
Indicates a imminently hazardous
situation which, if not avoided, will
result in death or serious injury.
WARNING
Indicates a potentially hazardous
situation which, if not avoided,
could result in death or serious
injury.
CAUTION
Indicates a potentially hazardous
situation which, if not avoided,
may cause minor or moderate
injury.
Indicates a potentially hazardous
situation which, if not avoided,
may result in property damage.
Indicates that a specific result is expected
after performing a series of steps.
Indicates that an incorrect result has occurred
after performing a series of steps.
8 RL4 Vertical Mast Part No. 1266665
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August 2015 Service Manual
Scheduled Maintenance Procedures
Maintenance Symbols Legend
Pre-delivery Preparation Report
Note: 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.
Indicates that tools will be required to
perform this procedure.
Indicates that new parts will be required to
perform this procedure.
Indicates that dealer service will be
required to perform this procedure.
Indicates that a cold engine will be
required to perform this procedure.
Indicates that a warm engine will be
required to perform this procedure.
The pre-delivery preparation report contains
checklists for each type of scheduled inspection.
Make copies for each inspection. Store completed
forms as required.
Maintenance Schedule
The Scheduled Maintenance Procedures section
and the Maintenance Inspection Report have been
divided into subsections. Use the following chart to
determine which group(s) of procedures are
required to perform a scheduled inspection.
Inspection Checklist
Daily or every 8 hours A
Quarterly or every 250 hours A + B
Semi-annually or every 500 hours A + B + C
Annually or every 1000 hours A + B + C + D
Two-year or every 2000 hours A + B + C + D + E
Maintenance Inspection Report
The maintenance inspection report contains
checklists for each type of scheduled inspection.
Make copies of the Maintenance Inspection Report
to use for each inspection. Maintain completed
forms for a minimum of 4 years or in compliance
with your employer, jobsite and governmental
regulations and requirements.
Part No. 1266665 RL4 Vertical Mast 9
Page 20
Service Manual August 2015
Pre-Delivery Preparation Report
Fundamentals
It is the responsibility of the dealer to perform the
Pre-delivery Preparation.
The Pre-delivery Preparation is performed prior to
each delivery. The inspection is designed to
discover if anything is apparently wrong with a
machine before it is put into service.
A damaged or modified machine must never be
used. If damage or any 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.
Scheduled maintenance inspections shall be
performed by qualified service technicians,
according to the manufacturer's specifications and
the requirements listed in the responsibilities
manual.
Terex South Dakota, Inc USA
500 Oak Wood Road
PO Box 1150
Watertown, SD 57201-6150
(605) 882-4000
The Maltings, Wharf Road
Grantham, Lincolnshire
NG31- 6BH England
Genie UK
(44) 1476-584333
Instructions
Use the operator’s manual on your machine.
The Pre-delivery Preparation consists of
completing the Pre-operation Inspection, the
Maintenance items and the Function Tests.
Use this form to record the results. Place a check in
the appropriate box after each part is completed.
Follow the instructions in the operator’s manual.
If any inspection receives an N, remove the
machine from service, repair and re-inspect it. After
repair, place a check in the R box.
Legend
Y = yes, acceptable
N = no, remove from service
R = repaired
Comments
Pre-delivery Preparation
Pre-operation inspection completed
Maintenance items completed
Function tests completed
Model
Serial number
Date
Machine owner
Inspected by (print)
Inspector signature
Inspector title
Inspector company
Y N R
Page 21
August 2015 Service Manual
Maintenance Inspection Report
Model
Serial number
Date
Hour meter
Machine owner
Inspected by (print)
Inspector signature
Inspector title
Inspector company
Instructions
Make copies of this report to use for
each inspection.
Select the appropriate checklist(s) for
the type of inspection(s) to perform.
Daily or every 8 hours A
Quarterly or every
250 hours
Semi-annually or
every 500 hours
Annually or
every
1000 hours
Two-year or
every
2000 hours
Place a check in the appropriate box
after each inspection procedure is
completed.
Use the step-by-step procedures in
this section to learn how to perform
these inspections.
If any inspection receives an "N," tag
and remove the machine from service,
repair and re-inspect it. After repair,
place a check in the "R" box.
A + B + C + D + E
Legend
Y = yes, acceptable
N = no, remove from service
R = repaired
A + B
A + B + C
A + B + C + D
Checklist A Y N R
A-1 Inspect the manuals
and decals
A-2 Pre-operation
inspection
A-3 Function tests
Perform after 8 hours:
A-4 Engine maintenance -
Kubota
Perform before towing:
A-5 Coupler
A-6 Brakes (if equipped)
Perform after 10 miles:
A-7 Lug nuts
Perform after 10 hours:
A-8 Engine maintenance -
Kohler
Perform weekly:
A-9 Tires and wheels
A-10 Engine air filter
A-11 Generator
maintenance
A-12 Engine maintenance -
Kubota
Perform after 50 hours:
A-13 Engine maintenance -
Kohler
Perform monthly:
A-14 Cables and pulleys
Perform every 100 hours:
A-15 Engine maintenance -
Kubota
Perform every 200 hours:
A-16 Engine maintenance -
Kubota
A-17 Generator
maintenance
A-18 Fuel/Water separator
A-19 Brakes (if equipped)
Perform every 250 hours:
A-20 Engine maintenance -
Kohler
Checklist B Y N R
B-1 Batteries
B-2 Electrical wiring
B-3 Lug nuts
B-4 Engine maintenance -
Kubota
B-5 Winch
B-6 T-bolt
Perform every 3000 miles:
B-7 Brakes (if equipped)
B-8 Suspension
Perform every 300 hours:
B-10 Engine maintenance -
Kohler
Perform every 400 hours:
B-11 Engine maintenance -
Kubota
Comments
Part No. 1266665 RL4 Vertical Mast 11
Page 22
Service Manual August 2015
Maintenance Inspection Report
Model
Serial number
Date
Hour meter
Machine owner
Inspected by (print)
Inspector signature
Inspector title
Inspector company
Instructions
Make copies of this report to use for
each inspection.
Select the appropriate checklist(s) for
the type of inspection(s) to perform.
Daily or every 8 hours A
Quarterly or every
250 hours
Semi-annually or
every 500 hours
Annually or
every
1000 hours
Two-year or
every
2000 hours
Place a check in the appropriate box
after each inspection procedure is
completed.
Use the step-by-step procedures in
this section to learn how to perform
these inspections.
If any inspection receives an "N," tag
and remove the machine from service,
repair and re-inspect it. After repair,
place a check in the "R" box.
A + B + C + D + E
Legend
Y = yes, acceptable
N = no, remove from service
R = repaired
A + B
A + B + C
A + B + C + D
Checklist C Y N R
C-1 Engine maintenance
C-2 Lights
Perform every 6000 miles:
C-3 Wheel bearings
C-4 Brakes (if equipped)
Perform every 500 hours:
C-5 Engine maintenance -
Kohler
Perform every 800 hours:
C-6 Engine maintenance -
Kubota
Perform every 1000 hours:
C-7 Engine maintenance -
Kohler
Perform every 2000 hours:
C-8 Generator
maintenance
Checklist D Y N R
Perform every 1500 hours:
D-1 Engine maintenance -
Kubota
Perform every 8000 hours:
D-2 Generator
maintenance
Perform annually:
D-3 Coupler
Checklist E Y N R
E-1 Cable
Perform every 2000 hours:
E-2 Engine maintenance -
Kubota
Perform every 3000 hours:
E-3 Engine maintenance -
Kubota
Perform every 4000 hours:
E-4 Engine maintenance -
Kohler
Perform every 5000 hours:
E-5 Engine maintenance -
Kohler
Perform every 10,000 hours:
E-6 Engine maintenance -
Kohler
E-7 Generator
maintenance
Perform every 20,000 hours:
E-8 Generator
maintenance
Perform every 30,000 hours:
E-9 Generator
maintenance
Comments
12 RL4 Vertical Mast Part No. 1266665
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August 2015 Service Manual
Checklist A Procedures
A-1
Inspect the Manuals and Decals
Terex specifications require that this procedure be
performed every 8 hours or daily, whichever comes
first.
Maintaining the operator’s and safety manuals in
good condition is essential to safe machine
operation. Manuals are included with each
machine and should be stored in the container
provided in the platform. An illegible or missing
manual will not provide safety and operational
information necessary for a safe operating
condition.
In addition, maintaining all of the safety and
instructional decals in good condition is mandatory
for safe machine operation. Decals alert operators
and personnel to the many possible hazards
associated with using this machine. They also
provide users with operation and maintenance
information. An illegible decal will fail to alert
personnel of a procedure or hazard and could
result in unsafe operating conditions.
1 Check to make sure that the operator's and
safety manuals are present and complete in
the storage container inside the cabinet.
2 Examine the pages of each manual to be sure
that they are legible and in good condition.
Result: The operator's manual is appropriate
for the machine and all manuals are legible
and in good condition.
Result: The operator's manual is not
appropriate for the machine or all manuals are
not in good condition or is illegible. Remove
the machine from service until the manual is
replaced.
3 Open the operator's manual to the decals
inspection section. Carefully and thoroughly
inspect all decals on the machine for legibility
and damage.
Result: The machine is equipped with all
required decals, and all decals are legible and
in good condition.
Result: The machine is not equipped with all
required decals, or one or more decals are
illegible or in poor condition. Remove the
machine from service until the decals are
replaced.
4 Always return the manuals to the storage
container after use.
Note: Contact your authorized Terex distributor or
Terex if replacement manuals or decals are
needed.
Part No. 1266665 RL4 Vertical Mast 13
Page 24
Service Manual August 2015
Checklist A Procedures
A-2
Perform Pre-operation Inspection
Terex specifications require that this procedure be
performed every 8 hours or daily, whichever comes
first.
Completing a Pre-operation Inspection is essential
to safe machine operation. 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.
Complete information to perform this procedure is
available in the appropriate operator's manual.
Refer to the Operator's Manual on your machine.
A-3
Perform Function Tests
Terex specifications require that this procedure be
performed every 8 hours or daily, whichever comes
first.
Completing the function tests is essential to safe
machine operation. Function tests are designed to
discover any malfunctions before the machine is
put into service. A malfunctioning machine must
never be used. If malfunctions are discovered, the
machine must be tagged and removed from
service.
Complete information to perform this procedure is
available in the appropriate operator's manual.
Refer to the Operator's Manual on your machine.
14 RL4 Vertical Mast Part No. 1266665
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August 2015 Service Manual
Checklist A Procedures
A-4
Perform Engine Maintenance Kubota
Engine specifications require that this procedure be
performed every 8 hours or daily, whichever comes
first.
Engine oil level — check
Coolant level — check/add
Fuel system filter/water separator — drain
Engine tightness — check for leaks
Exhaust system — check for leaks
Loose or missing fasteners
Required maintenance procedures and additional
engine information is available in the Kubota
D1105-E and V1505-E Operator's Manual (Kubota
16683-89169 part number )
Kubota D-1105 and V-1505 Operator's Manual
Genie part number 893020
A-5
Perform Coupler Maintenance
Coupler specifications require that this procedure
be performed before towing.
Maintaining the coupler in good condition is
essential to safe operation and good performance.
Coupler failure could result in a machine tip-over
during transport, and component damage may also
result if problems are not discovered and repaired
in a timely fashion.
1 Check vehicle, mounting bracket, hitch ball
and coupler for signs of wear or damage and
that the coupler handle opens and closes
freely.
Result: if coupler and/or mounting bracket is
deformed or damaged, replace complete
coupler and mounting bracket. Replace bent,
broken or worn parts before use.
2 Close coupler securely by ensuring that the
hitch ball is fully seated in the coupler ball
pocket and the pin is inserted behind the collar
or latch.
3 Check mounting bracket hardware for wear
and proper tightness.
Result: Replace bent, broken or worn
hardware.
Part No. 1266665 RL4 Vertical Mast 15
Page 26
Service Manual August 2015
Checklist A Procedures
A-6
Test the Brakes (if equipped)
Axle specifications require that this procedure be
performed before towing.
Maintaining the axle brakes in good condition is
essential to safe operation and good performance.
Brakes which are out of adjustment can result in
longer stopping distances and excessive brake
wear on the towing vehicle. Component damage
may also result if problems are not discovered and
repaired in a timely fashion.
Test the brakes for proper function. Repair or
replace any faulty components as needed.
A-7
Torque the Wheel Lug Nuts
Axle specifications require that this procedure be
performed initially at 10, 25 and 50 miles of use, or
after reinstallation of a tire.
Maintaining the wheel lug nuts at proper torque is
essential to safe operation and good service life of
the tires, wheel and axle.
1 Check each lug nut for proper torque. Refer to
Specifications, Machine Specifications.
16 RL4 Vertical Mast Part No. 1266665
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August 2015 Service Manual
Checklist A Procedures
A-8
Perform Engine Maintenance Kohler
Engine specifications require that this procedure be
performed every 10 hours or daily, whichever
comes first.
Engine oil level — check
Coolant level — check/add
Radiator — clean
Air filter
fuel line
Alternator/Fan Belt - Inspect Tension
Required maintenance procedures and additional
engine information is available in the Kohler
KDW1003 Engine Owner's Manual (Kohler part
number ED0053028440).
Kohler KDW1003 Engine Owner's Manual
Genie part number 1268769
A-9
Check the Tires and Wheels
Axle specifications require that this procedure be
performed weekly.
Maintaining the tires and wheels in good condition
and the tires at the correct pressure is essential to
safe operation and good performance. Tire and/or
wheel failure could result in a machine tip-over.
Component damage may also result if problems
are not discovered and repaired in a timely fashion.
WARNING
WARNING
1 Check tire surface and sidewalls for cuts,
cracks, punctures and unusual wear.
2 Check each wheel for damage, bends and
cracks.
Bodily injury hazard. An
over-inflated tire can explode
and could cause death or serious
injury.
Tip-over hazard. Do not use
temporary flat tire repair
products.
3 Check the pressure in each air-filled tire. Refer
to Specifications, Machine Specifications.
Part No. 1266665 RL4 Vertical Mast 17
Page 28
Service Manual August 2015
Checklist A Procedures
A-10
Inspect the Engine Air Filter
Terex specifications require that this procedure be
performed every 40 hours or weekly, whichever
comes first.
Maintaining the engine air filter in good condition is
essential to good engine performance and service
life. Failure to perform this procedure can lead to
poor engine performance and component damage.
Note: Perform this procedure with the engine off.
1 Open the engine side cover. Empty the dust
discharge valve by pressing together the sides
of the discharge slot. Clean the discharge slot
as needed.
1
2 Release the latches on the air cleaner cap.
Remove the end cap from the air cleaner
canister.
3 Remove the filter element.
4 Use a damp cloth to wipe the filter sealing
surface and the inside of the outlet tube. Make
sure that all contaminant is removed before
the filter is inserted.
5 Check new filter element gasket for damage
before installing.
6 Install the new filter element.
7 Install the end cap on the canister and secure.
Note: Be sure the discharge slot is pointing down.
2
3
1 clamp
2 cannister end cap
3 dust discharge valve
18 RL4 Vertical Mast Part No. 1266665
Page 29
August 2015 Service Manual
Checklist A Procedures
A-11
Perform Generator Maintenance
Generator specifications require that this
procedure be performed every 40 hours or weekly,
whichever comes first.
Clean and inspect the generator exterior
Clean and replace the generator air filters -
(if equipped)
Coliseum Manual
Genie part number 1268770
A-12
Perform Engine Maintenance Kubota
Engine specifications require that this procedure be
performed every 100 hours.
Check fuel lines and clamps
Required maintenance procedures and additional
engine information is available in the Kubota
D1105-E and V1505-E Operator's Manual (Kubota
16683-89169 part number )
Kubota D-1105 and V-1505 Operator's Manual
Genie part number 893020
Part No. 1266665 RL4 Vertical Mast 19
Page 30
Service Manual August 2015
Checklist A Procedures
A-13
Perform Engine Maintenance Kohler
Engine specifications require that this procedure be
performed after 50 hours.
Engine oil and filter — change
Required maintenance procedures and additional
engine information is available in the Kohler
KDW1003 Engine Owner's Manual (Kohler part
number ED0053028440).
Kohler KDW1003 Engine Owner's Manual
Genie part number 1268769
A-13
Inspect the Cables and Cable
Pulleys
Terex specifications require that this procedure be
performed monthly.
Detection of damage to the cables or pulleys is
essential for safe machine operation. An unsafe
working condition exists if these components are
damaged and do not operate smoothly. Regular
inspection of this system allows the inspector to
identify changes in the operating condition that may
indicate damage.
1 Visually inspect the electric winch and cable
pulleys for the following:
broken or damaged pulleys
unusual or excessive pulley wear
Result: A pulley is broken or damaged, or
shows unusual or excessive pulley wear. The
pulley must immediately be replaced.
2 Put on protective leather gloves and eye wear.
3 Fully unwind the cable from the winch.
4 Wearing leather gloves, run a hand up and
down a length of the cable, inspecting the
cable and components for the following:
frayed or broken wire strands
Result: In any given one-foot of cable length
there are 4 or more broken wires on any 2 or
more strands. The cable must immediately be
replaced.
20 RL4 Vertical Mast Part No. 1266665
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August 2015 Service Manual
Checklist A Procedures
5 Visually inspect the winch cable for the
following:
nicks (partial strand cut through)
kinks in the cable (permanent bends)
A-15
Perform Engine Maintenance Kubota
weld splatter
Result: Nicks, kinks in the cable or weld
splatter are. The cable must immediately be
replaced.
6 Visually inspect the winch cable for the
following:
crushed spot on the cable
Result: A crushed spot on the cable
measuring 125% of the cable diameter or
more is found OR there is a broken wire at the
crush point. The cable must immediately be
replaced.
7 Wind cable onto the winch, ensuring that the
cable is correctly installed onto each of the
pulleys.
Engine specifications require that this procedure be
performed every 100 hours.
Clean air filter
Clean the fuel filter
Inspect fan belt
Required maintenance procedures and additional
engine information is available in the Kubota
D1105-E and V1505-E Operator's Manual (Kubota
16683-89169 part number )
Kubota D-1105 and V-1505 Operator's Manual
Genie part number 893020
Part No. 1266665 RL4 Vertical Mast 21
Page 32
Service Manual August 2015
Checklist A Procedures
A-16
Perform Engine Maintenance Kubota
Engine specifications require that this procedure be
performed every 200 hours.
Change engine oil
Replace oil filter
Inspect radiator hoses and clamps
Inspect air intake hose
Required maintenance procedures and additional
engine information is available in the Kubota
D1105-E and V1505-E Operator's Manual (Kubota
16683-89169 part number )
Kubota D-1105 and V-1505 Operator's Manual
Genie part number 893020
A-17
Perform Generator Maintenance
Generator specifications require that this
procedure be performed every 200 hours or
quarterly, whichever comes first.
Clean and inspect the generator exterior
Check for loose or damaged wires and
components.
WARNING
Coliseum Manual
Genie part number 1268770
Electrocution/burn hazard.
Contact with electrically charged
circuits could result in death or
serious injury. Remove all rings,
watches and other jewelry.
a
a generator
22 RL4 Vertical Mast Part No. 1266665
Page 33
August 2015 Service Manual
Checklist A Procedures
A-18
Drain the Fuel Filter/Water
Separator
Terex specifications require that this procedure be
performed every 200 hours or monthly, whichever
comes first.
Proper maintenance of the fuel filter/water
separator is essential for good engine performance.
Failure to perform this procedure can lead to poor
engine performance and component damage.
2 Loosen the drain plug located at the bottom of
the bowl. Allow the water to drain into a
suitable container until fuel starts to come out.
Immediately tighten the drain plug.
a
b
c
DANGER
Explosion and fire hazard.
Engine fuels are combustible.
Perform this procedure in an
open, well-ventilated area away
from heaters, sparks, flames and
lighted tobacco. Always have an
approved fire extinguisher within
easy reach.
1 Locate the fuel filter/water separator and
loosen the vent plug located on the fuel
filter/water separator head.
d
e
a head bolt
b vent plug
c separator head
d filter bowl
e drain plug
3 Tighten the vent plug and clean up any spills
or wet surfaces.
Note: If the fuel bowl is completely drained,
you must prime, or bleed, the fuel filter/water
separator before starting the engine. See step
5.
4 Start the engine from the electrical control
panel and check the fuel filter/water separator
for leaks.
Part No. 1266665 RL4 Vertical Mast 23
Page 34
Service Manual August 2015
Checklist A Procedures
Bleed the fuel system:
5 Loosen the vent plug/screw located on the
filter head.
6 Operate the hand primer until fuel, free of air,
flows from the vent plug/screw. Tighten the
vent plug/screw on the filter head.
7 Loosen the vent screw, located on top of the
fuel injection pump.
8 Operate the hand primer until fuel, free of air,
flows from the vent plug/screw. Tighten the
vent plug/screw on the injection pump.
9 Clean up any fuel that may have spilled.
10 Attempt to start the engine using the starter
motor for a maximum of 15 seconds, resting
the starter for 30 seconds before trying again.
11 Inspect the fuel filter/water separator for leaks.
DANGER
Note: Required maintenance procedures and
additional engine information is available in the
Kubota D1105-E and V1505-E Operator's Manual
(Kubota 16683-89169 part number ) OR the Kohler
KDW1003 Engine Owner's Manual (Kohler part
number ED0053028440).
Kohler KDW1003 Engine Owner's Manual
Genie part number 1268769
Kubota D-1105 and V-1505 Operator's Manual
Genie part number 893020
Explosion and fire hazard. If a
fuel leak is discovered, keep any
additional personnel from
entering the area and do not
operate the machine. Repair the
leak immediately.
A-19
Test the Brakes (if equipped)
Axle specifications require that this procedure be
performed initially at 200 miles of use.
Maintaining the axle brakes in good condition is
essential to safe operation and good performance.
Brakes which are out of adjustment can result in
longer stopping distances and excessive brake
wear on the towing vehicle. Component damage
may also result if problems are not discovered and
repaired in a timely fashion.
Note: Perform this procedure with the machine on
a firm, level surface with the machine in the stowed
position.
1 Select a wheel. Chock the front and rear of the
tire at the opposite side of the machine.
2 Place a lifting jack under the axle near the
brake to be adjusted. Lift the axle until the
wheel is off the ground and place a jack stand
under the axle. Lower the axle onto the jack
stand.
3 Working from the back side of the wheel at the
brake backing plate, locate and remove the
small rubber plug from the lower side of the
backing plate to access the star-shaped brake
adjuster wheel. Set the plug to the side.
4 Insert a brake adjuster tool into the opening of
the brake backing plate, engaging it with the
teeth of the brake adjuster wheel. Move the tip
of the adjuster tool in an upwards direction to
tighten the brakes.
Note: It may be helpful to use a flashlight when
locating the brake adjuster wheel.
24 RL4 Vertical Mast Part No. 1266665
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August 2015 Service Manual
Checklist A Procedures
5 Repeatedly move the tip of the adjuster tool in
an upwards direction to tighten the brakes until
the wheel locks up and will no longer turn.
Note: This centers the brake shoes on the brake
drum, ensuring the shoes are positioned correctly.
A-20
Perform Engine Maintenance Kohler
6 Move the tip of the adjuster tool in a
downwards direction 3 to 5 clicks to loosen the
brakes only until the wheel spins freely with
little drag.
7 Securely install the small rubber plaug into the
brake backing plate.
8 Check the wheel bearing wear by attempting
to move wheel hub side to side, then up and
down.
There is no side to side or up and down
movement. The bearing is good.
There is side to side or up and down
movement. The bearing must be adjusted or
replaced. See B-8, Inspect and Adjust the
Brakes (if equipped).
9 Lift the axle slightly. Remove the jack stand
and lower the machine to the ground. Chock
the front and rear of the tire.
10 Repeat this procedure, beginning with step 2,
for the other wheel.
Engine specifications require that this procedure be
performed every 200 hours.
Inspect radiator hoses and clamps
Inspect air intake hose
Change engine oil - add oil if necessary
Replace fuel filter
Required maintenance procedures and additional
engine information is available in the Kohler
KDW1003 Engine Owner's Manual (Kohler part
number ED0053028440).
Kohler KDW1003 Engine Owner's Manual
Genie part number 1268769
Part No. 1266665 RL4 Vertical Mast 25
Page 36
Service Manual August 2015
Checklist B Procedures
B-1
Inspect the Engine Start Battery
Terex specifications require that this procedure be
performed every 250 hours or quarterly, whichever
comes first.
Proper battery condition is essential to good engine
performance and operational safety. Improper fluid
levels or damaged cables and connections can
result in engine component damage and
hazardous conditions.
WARNING
WARNING
Note: Fully charge the batteries and allow the
batteries to rest 24 hours before performing this
procedure to allow the battery cells to equalize.
1 Open the side covers.
2 Be sure that the battery cable connections are
free of corrosion.
Note: Adding terminal protectors and a corrosion
preventative sealant will help eliminate corrosion
on the battery terminals and cables.
Electrocution/burn hazard.
Contact with electrically charged
circuits could result in death or
serious injury. Remove all rings,
watches and other jewelry.
Bodily injury hazard. Batteries
contain acid. Avoid spilling or
contacting battery acid.
Neutralize battery acid spills with
baking soda and water.
3 Be sure that the battery retainers and cable
connections are tight.
4 Be sure that the battery separator wire
connections are tight (if equipped).
Models without maintenance-free or sealed
batteries:
5 Put on protective clothing and eye wear.
6 Remove the battery vent caps and check the
specific gravity of each battery cell with a
hydrometer. Note the results.
7 Check the ambient air temperature and adjust
the specific gravity reading for each cell as
follows:
Add 0.004 to the reading of each cell for
every 10° F / 5.5° C above 80° F / 26.7° C.
Subtract 0.004 from the reading of each cell
for every 10° F / 5.5° C below 80° F / 26.7°
C.
Result: All battery cells display an adjusted
specific gravity of 1.277 or higher. The battery
is fully charged. Proceed to step 11.
Result: One or more battery cells display a
specific gravity of 1.276 or below. Proceed to
step 8.
8 Perform an equalizing charge OR fully charge
the battery(s) and allow the battery(s) to rest at
least 6 hours.
9 Remove the battery vent caps and check the
specific gravity of each battery cell with a
hydrometer. Note the results.
26 RL4 Vertical Mast Part No. 1266665
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August 2015 Service Manual
Checklist B Procedures
10 Check the ambient air temperature and adjust
the specific gravity reading for each cell as
follows:
Add 0.004 to the reading of each cell for
every 10° F / 5.5° C above 80° F / 26.7° C.
B-2
Inspect the Electrical Wiring
Subtract 0.004 from the reading of each cell
for every 10° F / 5.5° C below 80° F / 26.7°
C.
Result: All battery cells display a specific
gravity of 1.277 or greater. The battery is fully
charged. Proceed to step 11.
Result: One or more battery cells display a
specific gravity from 1.218 to 1.269. The
battery is still usable, but at a lower
performance. The battery will need to be
recharged more often. Proceed to step 11.
Result: One or more battery cells display a
specific gravity from 1.217 to 1.173. The
battery is approaching the end of it's life.
Proceed to step 11.
Result: The difference in specific gravity
readings between cells is greater than 0.1 OR
the specific gravity of one or more cells is less
than 1.177. Replace the battery.
11 Check the battery acid level. If needed,
replenish with distilled water to 1/8 inch / 3 mm
below the bottom of the battery fill tube. Do not
overfill.
12 Install the vent caps and neutralize any
electrolyte that may have spilled.
13 Close the side covers.
Terex specifications require that this procedure be
performed every 250 hours or quarterly, whichever
comes first.
Maintaining electrical wiring in good condition is
essential to safe operation and good machine
performance. Failure to find and replace burnt,
chafed, corroded or pinched wires could result in
unsafe operating conditions and may cause
component damage.
WARNING
1 Inspect the following areas for burnt, chafed,
corroded pinched and loose wires:
Ground controls
Battery
Engine
Mast
Lighting junction box
Trailer lighting wire harness
2 Inspect for a liberal coating of dielectric grease
in the following locations:
Lighting junction box
Electrocution/burn hazard.
Contact with electrically charged
circuits could result in death or
serious injury. Remove all rings,
watches and other jewelry.
Part No. 1266665 RL4 Vertical Mast 27
Ground controls
All wire harness connectors
Page 38
Service Manual August 2015
Checklist B Procedures
B-3
Torque the Wheel Lug Nuts
Axle specifications require that this procedure be
performed initially at 10, 25 and 50 miles of use, or
after reinstallation of a tire.
Maintaining the wheel lug nuts at proper torque is
essential to safe operation and good service life of
the tires, wheel and axle.
1 Check each lug nut for proper torque. Refer to
Specifications, Machine Specifications.
B-4
Perform Engine Maintenance Kubota
Engine specifications require that this procedure be
performed every 250 hours or six months,
whichever comes first.
Inspect alternator and fan belts
Required maintenance procedures and additional
engine information is available in the Kubota
D1105-E and V1505-E Operator's Manual (Kubota
16683-89169 part number )
Kubota D-1105 and V-1505 Operator's Manual
Genie part number 893020
28 RL4 Vertical Mast Part No. 1266665
Page 39
August 2015 Service Manual
Checklist B Procedures
B-5
Inspect and Lubricate the Winch
Terex specifications require that this procedure be
performed every 250 hours or quarterly, whichever
comes first.
Maintaining the winch is essential to good machine
performance and safe operation. An unsafe
working condition exists if the winch has excessive
wear and/or does not operate smoothly, free of
hesitation and binding.
1 Carefully lubricate the winch.
B-6
Lubricate the T-bolt
Terex specifications require that this procedure be
performed every 250 hours or quarterly, whichever
comes first.
Maintaining the T-bolt is essential to good machine
performance and safe operation. An unsafe
working condition exists if the T-bolt has excessive
wear and/or does not operate smoothly, free of
hesitation and binding.
1 Using the illustration as a guide, locate the
T-bolt at the bottom of the mast assembly.
Remove the T-bolt from the mast.
2 Remove all dust, dirt and copper anti-seize
from the threaded surfaces of the T-bolt, and
apply a few drops of light oil or copper
anti-seize lubricant onto the threaded
surfaces.
3 Fully install the T-bolt into the mast.
Part No. 1266665 RL4 Vertical Mast 29
a
a T-bolt
Page 40
Service Manual August 2015
NOTICE
Checklist B Procedures
B-7
Inspect and Adjust the Brakes (if
equipped)
Axle specifications require that this procedure be
performed every 3000 miles or quarterly,
whichever comes first.
Maintaining the axle brakes in good condition is
essential to safe operation and good performance.
Brakes which are out of adjustment can result in
longer stopping distances and excessive brake
wear on the towing vehicle. Component damage
may also result if problems are not discovered and
repaired in a timely fashion.
Note: Perform this procedure with the machine on
a firm, level surface with the machine in the stowed
position.
1 Select a wheel. Chock the front and rear of the
tire at the opposite side of the machine.
2 Loosen the wheel lug nuts. Do not remove
them.
3 Place a lifting jack under the axle near the
wheel to be removed. Lift the axle until the
wheel is off the ground and place a jack stand
under the axle. Lower the axle onto the jack
stand and remove the wheel.
4 Remove the dust cap from the hub. Remove
the cotter pin from the castle nut.
5 Remove the castle nut and washer.
6 Pull the hub off of the spindle. The washer and
outer bearing should fall loose from the hub.
7 Inspect the brake lining for wear (if equipped).
Result: the thickness of the brake lining is
greater than 1/16 inch / 1.6 mm. The brake
shoes are good.
Result: the thickness of the brake lining is
1/16 inch / 1.6 mm or less. The brake shoes
must be replaced and the brake drums must
be inspected for wear, scoring and other
damage.
Note: The maximum bore of a good brake drum
shall not be greater than 0.090 inch / 2.29 mm in
excess of the drum diameter.
Note: If drum resurfacing is required, the brake
drum should be resurfaced to a 120 micron finish.
Note: If replacing the brake shoes, apply a light
coat of grease or anti-seize compound to the
anchor pin, arm bushing and pin, and areas of the
backing plate which contact the magnet arm and
brake shoes frame. Apply a small amount of lube to
the actuating cam at the top of the magnet arm. Do
not allow grease or oil to contact the brakes shoes
or the inside of the drum.
8 Slide the hub onto the yoke spindle.
Component damage hazard. Do
not apply excessive force or
damage to the lip of the seal may
occur.
9 Place the outer bearing into the hub.
10 Install the washer and the castle nut.
11 Tighten the castle nut to 50 ft-lbs / 68 Nm to
seat the bearings.
12 Fully loosen the castle nut. Do not rotate the
hub.
30 RL4 Vertical Mast Part No. 1266665
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August 2015 Service Manual
Checklist B Procedures
13 Finger tighten the castle nut until snug.
14 Install a new cotter pin. Bend the cotter pin to
lock it in place.
Note: Always replace the cotter pin with a new one
when removing the castle nut.
15 Install the dust cap, then the tire and wheel
assembly. Torque the wheel lug nuts to
specification. Refer to Section 2,
Specifications.
16 Working from the back side of the wheel at the
brake backing plate, locate and remove the
small rubber plug from the lower side of the
backing plate to access the star-shaped brake
adjuster wheel. Set the plug to the side.
17 Insert a brake adjuster tool into the opening of
the brake backing plate, engaging it with the
teeth of the brake adjuster wheel. Move the tip
of the adjuster tool in an upwards direction to
tighten the brakes.
Note: It may be helpful to use a flashlight when
locating the brake adjuster wheel.
19 Move the tip of the adjuster tool in a
downwards direction 3 to 5 clicks to loosen the
brakes only until the wheel spins freely with
little drag.
20 Securely install the small rubber plug into the
brake backing plate.
21 Check the wheel bearing wear by attempting
to move wheel hub side to side, then up and
down.
There is no side to side or up and down
movement. The bearing is good.
There is side to side or up and down
movement. The bearing must be adjusted or
replaced. See B-8, Inspect and Adjust the
Brakes (if equipped).
22 Lift the axle slightly. Remove the jack stand
and lower the machine to the ground. Chock
the front and rear of the tire.
23 Repeat this procedure, beginning with step 2,
for the other wheel.
18 Repeatedly move the tip of the adjuster tool in
an upwards direction to tighten the brakes until
the wheel locks up and will no longer turn.
Note: This centers the brake shoes on the brake
drum, ensuring the shoes are positioned correctly.
Part No. 1266665 RL4 Vertical Mast 31
Page 42
Service Manual August 2015
Checklist B Procedures
B-8
Inspect the Suspension
Axle specifications require that this procedure be
performed every 3000 miles or quarterly,
whichever comes first.
Maintaining the axle suspension in good condition
is essential to safe operation and good
performance. Towing the machine with worn or
damaged suspension components could result in a
tip-over. Component damage may also result if
problems are not discovered and repaired in a
timely fashion.
1 Working with a flashlight or in a well lit shop,
carefully inspect all suspension components
and fasteners. Replace as necessary.
B-9
Perform Engine Maintenance Kohler
Engine specifications require that this procedure be
performed every 300 hours.
Inspect radiator hoses and clamps
Inspect air intake hose
Inspect alternator and fan belts
Required maintenance procedures and additional
engine information is available in the Kohler
KDW1003 Engine Owner's Manual (Kohler part
number ED0053028440).
Kohler KDW1003 Engine Owner's Manual
Genie part number 1268769
32 RL4 Vertical Mast Part No. 1266665
Page 43
August 2015 Service Manual
Checklist B Procedures
B-10
Perform Engine Maintenance Kubota
Engine specifications require that this procedure be
performed every 400 hours or semi-annually,
whichever comes first.
Replace oil filter
Replace fuel filter
Required maintenance procedures and additional
engine information is available in the Kubota
D1105-E and V1505-E Operator's Manual (Kubota
16683-89169 part number )
Kubota D-1105 and V-1505 Operator's Manual
Genie part number 893020
Part No. 1266665 RL4 Vertical Mast 33
Page 44
Service Manual August 2015
NOTICE
Checklist C Procedures
C-1
Perform Engine Maintenance
Engine specifications require that this procedure be
performed every 500 hours.
Kohler engine only:
Check valve clearance
Kubota engine only:
Replace fan belts
Flush coolant system
Clean fuel tank
Required maintenance procedures and additional
engine information is available in the Kubota
D1105-E and V1505-E Operator's Manual (Kubota
16683-89169 part number ) OR the Kohler
KDW1003 Engine Owner's Manual (Kohler part
number ED0053028440).
Kohler KDW1003 Engine Owner's Manual
Genie part number 1268769
Kubota D-1105 and V-1505 Operator's Manual
Genie part number 893020
C-2
Clean the Light Assemblies
Terex specifications require that this procedure be
performed every 500 hours or semi-annually,
whichever comes first.
Maintaining the light assemblies is essential to
good machine performance. Failure to regularly
clean the light assemblies may result in less light
than expected and, over time, could result in
damage to the machine.
Note: Perform this procedure with the light
assemblies out of direct sunlight and cool to the
touch.
1 Use clean, cool water to rinse the surface of
each light assembly.
2 Clean each light assembly using a soft cloth,
water and a mild dishwashing detergent.
Component damage hazard.
Harsh checmcals and cleaning
agents will damage the surface
of the light assembly. Do not
allow harsh cleaning agents to
make contact with the light
surface..
34 RL4 Vertical Mast Part No. 1266665
3 Thoroughly rinse, then dry with a soft cloth.
Page 45
August 2015 Service Manual
NOTICE
Checklist C Procedures
C-3
Grease the Wheel Bearings
Axle specifications require that this procedure be
performed every 6,000 hours or semi-annually,
whichever comes first.
Maintaining the axle wheel bearings is essential to
safe machine operation and service life. Operating
a machine with loose or worn wheel bearings may
cause an unsafe operating condition and continued
use may result in component damage. Extremely
wet or dry conditions or regular steam cleaning and
pressure washing of the machine may require that
this procedure be performed more often.
Note: Perform this procedure with the machine on
a firm, level surface with the machine in the stowed
position.
9 Inspect the hub for wear. Replace if
necessary.
10 Place the large inner bearing into the rear of
the hub.
11 Install a new bearing grease seal into the hub
by pressing it evenly into the hub until it is
flush.
Note: Always replace the bearing grease seal when
removing the hub.
12 Inspect the brake lining for wear (if equipped).
13 Inspect the brake cylinder for leaks (if
equipped).
14 Inspect the brake springs for wear or loss of
arch (if equipped).
15 Inspect the brake wiring/hoses for wear (if
equipped).
16 Slide the hub onto the yoke spindle.
1 Select a wheel. Chock the front and rear of the
tire at the opposite side of the machine.
2 Loosen the wheel lug nuts. Do not remove
them.
3 Place a lifting jack under the axle near the
wheel to be removed. Lift the axle until the
wheel is off the ground and place a jack stand
under the axle. Lower the axle onto the jack
stand and remove the wheel.
4 Remove the dust cap from the hub. Remove
the cotter pin from the castle nut.
5 Remove the castle nut and washer.
6 Pull the hub off of the spindle. The washer and
outer bearing should fall loose from the hub.
7 Place the hub on a flat surface and gently pry
the bearing seal out of the hub. Remove the
rear bearing.
8 Pack both bearings with clean, fresh grease.
Component damage hazard. Do
not apply excessive force or
damage to the lip of the seal may
occur.
17 Place the outer bearing into the hub.
18 Install the washer and the castle nut.
19 Tighten the castle nut to 50 ft-lbs / 68 Nm to
seat the bearings.
20 Fully loosen the castle nut. Do not rotate the
hub.
21 Finger tighten the castle nut until snug.
22 Install a new cotter pin. Bend the cotter pin to
lock it in place.
Note: Always replace the cotter pin with a new one
when removing the castle nut.
23 Install the dust cap, then the tire and wheel
assembly. Torque the wheel lug nuts to
specification. Refer to Section 2,
Specifications.
Part No. 1266665 RL4 Vertical Mast 35
Page 46
Service Manual August 2015
Checklist C Procedures
C-4
Inspect the Electric Brake
Magnets (if equipped)
Axle specifications require that this procedure be
performed every 6,000 hours or semi-annually,
whichever comes first.
Maintaining the axle brakes in good condition is
essential to safe operation and good performance.
A faulty brake magnet can severely impact the
stopping power of a trailer. While some magnet
problems will be apparent upon visual inspection,
there may also be electrical problems that can
impact performance. A failing or faulty brake
magnet can lead to weak or surging brakes, or
cause the brakes to pull to one side. It is important
to inspect and test the magnets at regular intervals
to ensure maximum effectiveness.
1 Connect the electric brake wire harness to a
tow vehicle capable of towing the machine.
2 Start the engine of the tow vehicle, and press
down on the brake pedal.
Result: An audible 'click' is noted at each
brake when the brake magnet is activated and
pulls itself into contact with the brake drum.
The brake circuit is functioning correctly.
Result: An audible 'click' is not noted at each
brake because the brake magnet is not
activated and does not make contact with the
brake drum. The brake circuit is faulty. Inspect
the wire harness and harness connections
and repair as required, and repeat this
procedure beginning with step 2.
3 With the engine running, press down on the
brake pedal and use a multimeter to measure
the total amp draw of the brake circuit by
positioning an amp clamp around the brake
wire lead near the trailer connector. Note the
reading.
Result: The total amp draw measures 5.5 to
6.0 amps. The brake circuit is functioning
correctly.
Result: The total amp draw measures less
than 5.5 amps. Replace the magnets and
magnet springs on both sides of the axle, and
resurface the brake drums. Repeat this
procedure beginning with step 4.
4 Stop the engine of the tow vehicle.
5 Select a wheel. Chock the front and rear of the
tire at the opposite side of the machine.
6 Loosen the wheel lug nuts. Do not remove
them.
7 Place a lifting jack under the axle near the
wheel to be removed. Lift the axle until the
wheel is off the ground and place a jack stand
under the axle. Lower the axle onto the jack
stand and remove the wheel.
8 Remove the dust cap from the hub. Remove
the cotter pin from the castle nut.
9 Remove the castle nut and washer.
10 Pull the hub off of the spindle. The washer and
outer bearing should fall loose from the hub.
36 RL4 Vertical Mast Part No. 1266665
Page 47
August 2015 Service Manual
NOTICE
Checklist C Procedures
11 Locate the brake magnet. Inspect the surface
of the magnet for pitting and any irregular
surface wear.
Result: Replace the magnets and magnet
springs on both sides of the axle if pitting or
any irregular surface wear is detected, and
resurface the brake drums.
12 Inspect the copper coil at the center of the
magnet.
Result: Replace the magnets and magnet
springs on both sides of the axle if the
exposed copper coil is visible in any way, and
resurface the brake drums.
13 Slide the hub onto the yoke spindle.
C-5
Perform Engine Maintenance Kohler
Engine specifications require that this procedure be
performed every 500 hours.
Change engine oil
Required maintenance procedures and additional
engine information is available in the Kohler
KDW1003 Engine Owner's Manual (Kohler part
number ED0053028440).
Component damage hazard. Do
not apply excessive force or
damage to the lip of the seal may
occur.
14 Place the outer bearing into the hub.
15 Install the washer and the castle nut.
16 Tighten the castle nut to 50 ft-lbs / 68 Nm to
seat the bearings.
17 Fully loosen the castle nut. Do not rotate the
hub.
18 Finger tighten the castle nut until snug.
19 Install a new cotter pin. Bend the cotter pin to
lock it in place.
Note: Always replace the cotter pin with a new one
when removing the castle nut.
20 Install the dust cap, then the tire and wheel
assembly. Torque the wheel lug nuts to
specification. Refer to Section 2,
Specifications.
21 Repeat this procedure, beginning with step 6,
for the other side of the machine.
Kohler KDW1003 Engine Owner's Manual
Genie part number 1268769
Part No. 1266665 RL4 Vertical Mast 37
Page 48
Service Manual August 2015
Checklist C Procedures
C-6
Perform Engine Maintenance Kubota
Engine specifications require that this procedure be
performed every 800 hours or annually, whichever
comes first.
Replace air filter
Inspect wiring
Check valve clearance
Required maintenance procedures and additional
engine information is available in the Kubota
D1105-E and V1505-E Operator's Manual (Kubota
16683-89169 part number )
Kubota D-1105 and V-1505 Operator's Manual
Genie part number 893020
C-7
Perform Engine Maintenance Kohler
Engine specifications require that this procedure be
performed every 1000 hours.
Injector cleaning and adjustment
Flush coolant system
Clean fuel tank
Replace coolant
Replace fuel hoses and clamps
Replace air intake hose and clamps
Replace radiator hoses and clamps
Required maintenance procedures and additional
engine information is available in the Kohler
KDW1003 Engine Owner's Manual (Kohler part
number ED0053028440).
Kohler KDW1003 Engine Owner's Manual
Genie part number 1268769
38 RL4 Vertical Mast Part No. 1266665
Page 49
August 2015 Service Manual
Checklist C Procedures
C-8
Perform Generator Maintenance
Generator specifications require that this
procedure be performed every 2000 hours or
semi-annually, whichever comes first.
Maintaining the generator in good condition is
essential to safe operation and long service life.
Storing the generator in a harsh environment may
require this procedure be performed more
frequently. Loose or damaged connections or
components may result in a generator to lose
efficiency, and reduce the life of the generator.
Inspect stator output leads and insulation
for cracking and damage.
Inspect exposed electrical for loose or
damaged connections.
Inspect transformers, fuses, capacitors and
lighting arrestors for loose or damaged
component connections.
Inspect all wire and electrical connections
for proper clearance..
Inspect and clean inside of outlet box, air
screens and air baffles with compressed air.
Inspect for machine vibration and bearing
wear.
Coliseum Manual
Genie part number 1268770
Part No. 1266665 RL4 Vertical Mast 39
Page 50
Service Manual August 2015
Checklist D Procedures
D-1
Perform Engine Maintenance Kubota
Engine specifications require that this procedure be
performed every 1500 hours or bi-annually,
whichever comes first.
Injectors
Required maintenance procedures and additional
engine information is available in the Kubota
D1105-E and V1505-E Operator's Manual (Kubota
16683-89169 part number )
Kubota D-1105 and V-1505 Operator's Manual
Genie part number 893020
D-2
Perform Generator Maintenance
Generator specifications require that this
procedure be performed every 8000 hours or
annually, whichever comes first.
Maintaining the generator in good condition is
essential to safe operation and long service life.
Storing the generator in a harsh environment may
require this procedure be performed more
frequently. Poor resistance may result in a
generator to lose efficiency, and reduce the life of
the generator.
Check resistance to ground on generator
windings, main rotating assembly, stator,
exciter field and armature.
Coliseum Manual
Genie part number 1268770
40 RL4 Vertical Mast Part No. 1266665
Page 51
August 2015 Service Manual
Checklist D Procedures
D-3
Perform Coupler Maintenance
Coupler specifications require that this procedure
be performed annually.
Maintaining the coupler in good condition is
essential to safe operation and good performance.
Coupler failure could result in a machine tip-over
during transport, and component damage may also
result if problems are not discovered and repaired
in a timely fashion.
1 Check coupler welds and mounting bolt
torque. Torque the fasteners to 35 ft-lbs / 48
Nm.
Result: 1.5 full threads of the locking bolt must
be exposed beyond the lock nut after the
adjustment.
2 Apply automotive grease to the coupler ball
pocket.
3 Oil coupler pivot points using SAE 30 motor
oil.
Part No. 1266665 RL4 Vertical Mast 41
Page 52
Service Manual August 2015
Checklist E Procedures
E-1
Inspect the Cables and Cable
Pulleys
Terex specifications require that this procedure be
performed every two years.
Detection of damage to the cables or pulleys is
essential for safe machine operation. An unsafe
working condition exists if these components are
damaged and do not operate smoothly. Regular
inspection of this system allows the inspector to
identify changes in the operating condition that may
indicate damage.
1 Visually inspect the electric winch and cable
pulleys for the following:
broken or damaged pulleys
unusual or excessive pulley wear
Result: A pulley is broken or damaged, or
shows unusual or excessive pulley wear. The
pulley must immediately be replaced.
2 Put on protective leather gloves and eye wear.
3 Fully unwind the cable from the winch.
4 Wearing leather gloves, run a hand up and
down a length of the cable, inspecting the
cable and components for the following:
frayed or broken wire strands
Result: In any given one-foot of cable length
there are 4 or more broken wires on any 2 or
more strands. The cable must immediately be
replaced.
5 Visually inspect the winch cable for the
following:
nicks (partial strand cut through)
kinks in the cable (permanent bends)
weld splatter
Result: Nicks, kinks in the cable or weld
splatter are. The cable must immediately be
replaced.
6 Visually inspect the winch cable for the
following:
crushed spot on the cable
Result: A crushed spot on the cable
measuring 125% of the cable diameter or
more is found OR there is a broken wire at the
crush point. The cable must immediately be
replaced.
7 Wind cable onto the winch, ensuring that the
cable is correctly installed onto each of the
pulleys.
42 RL4 Vertical Mast Part No. 1266665
If the mast cables need replacing, refer to Repair
Procedure 1-1, How to Replace the Mast Lift
Cables.
Page 53
August 2015 Service Manual
Checklist E Procedures
E-2
Perform Engine Maintenance Kubota
Engine specifications require that this procedure be
performed every 2000 hours or bi-annually,
whichever comes first.
Replace coolant
Replace radiator hoses and clamps
Replace fuel hoses and clamps
Replace air intake hose and clamps
Required maintenance procedures and additional
engine information is available in the Kubota
D1105-E and V1505-E Operator's Manual (Kubota
16683-89169 part number )
Kubota D-1105 and V-1505 Operator's Manual
Genie part number 893020
E-3
Perform Engine Maintenance Kubota
Engine specifications require that this procedure be
performed every 3000 hours.
Inspect injection pump
Inspect injection timing
Required maintenance procedures and additional
engine information is available in the Kubota
D1105-E and V1505-E Operator's Manual (Kubota
16683-89169 part number )
Kubota D-1105 and V-1505 Operator's Manual
Genie part number 893020
Part No. 1266665 RL4 Vertical Mast 43
Page 54
Service Manual August 2015
Checklist E Procedures
E-4
Perform Engine Maintenance Kohler
Engine specifications require that this procedure be
performed every 4000 hours.
Replace timing belt
Replace air filter
Required maintenance procedures and additional
engine information is available in the Kohler
KDW1003 Engine Owner's Manual (Kohler part
number ED0053028440).
Kohler KDW1003 Engine Owner's Manual
Genie part number 1268769
E-5
Perform Engine Maintenance Kohler
Engine specifications require that this procedure be
performed every 5000 hours.
Partial engine overhaul
Required maintenance procedures and additional
engine information is available in the Kohler
KDW1003 Engine Owner's Manual (Kohler part
number ED0053028440).
Kohler KDW1003 Engine Owner's Manual
Genie part number 1268769
44 RL4 Vertical Mast Part No. 1266665
Page 55
August 2015 Service Manual
Checklist E Procedures
E-6
Perform Engine Maintenance Kohler
Engine specifications require that this procedure be
performed every 10,000 hours.
Total engine overhaul
Required maintenance procedures and additional
engine information is available in the Kohler
KDW1003 Engine Owner's Manual (Kohler part
number ED0053028440).
Kohler KDW1003 Engine Owner's Manual
Genie part number 1268769
E-7
Perform Generator Maintenance
Generator specifications require that this
procedure be performed every 10,000 hours.
Maintaining the generator in good condition is
essential to safe operation and long service life.
Regular replacement of the shaft bearing will
extend the life of the generator.
Replace the generator shaft bearing.
Consult a trained Coliseum service
professional.
Coliseum Manual
Genie part number 1268770
Part No. 1266665 RL4 Vertical Mast 45
Page 56
Service Manual August 2015
Checklist E Procedures
E-8
Perform Generator Maintenance
Generator specifications require that this
procedure be performed every 20,000 hours or
3 years, whichever comes first.
Maintaining the generator in good condition is
essential to safe operation and long service life.
Storing the generator in a harsh environment may
require this procedure be performed more
frequently. Allowing dirt and grease to build up on
the generator may result in a generator which will
run hotter, lose efficiency, and reduce the life of the
generator.
Inspect and clean the generator and
windings for oil or dirt contamination.
Coliseum Manual
Genie part number 1268770
E-9
Perform Generator Maintenance
Generator specifications require that this
procedure be performed every 30,000 hours or
5 years, whichever comes first.
Maintaining the generator in good condition is
essential to safe operation and long service life.
Storing the generator in a harsh environment may
require this procedure be performed more
frequently. Allowing dirt and grease to build up on
the generator may result in a generator which will
run hotter, lose efficiency, and reduce the life of the
generator. Regular replacement of the shaft
bearing will extend the service life of the generator.
Disassemble the generator, including rotor
Coliseum Manual
Genie part number 1268770
removal.
Inspect and clean generator components
including generator windings.
Replace the generator shaft bearings.
Consult a trained Coliseum service
professional.
46 RL4 Vertical Mast Part No. 1266665
Page 57
August 2015 Service Manual
Repair Procedures
Section 4 Repair Procedures
Observe and Obey:
Repair procedures shall be completed by a
person trained and qualified on the repair of
this machine.
Immediately tag and remove from service a
damaged or malfunctioning machine.
Repair any machine damage or malfunction
before operating the machine.
Before Repairs Start:
Read, understand and obey the safety rules
and operating instructions in the appropriate
operator's manual on your machine.
Machine Configuration:
Unless otherwise specified, perform each
repair procedure with the machine in the
following configuration:
Machine parked on a firm, level surface
Mast in the stowed position
Key switch in the off position with the key
removed
The red Emergency Stop button in the off
position on the electrical control box
Wheels chocked
Light switches in the off position
All external AC power supply disconnected
from the machine
Be sure that all necessary tools and parts are
available and ready for use.
Use only Terex approved replacement parts.
Read each procedure completely and adhere
to the instructions. Attempting shortcuts may
produce hazardous conditions.
Part No. 1266665 RL4 Vertical Mast 47
Page 58
Service Manual August 2015
NOTICE
Repair Procedures
About This Section
Most of the procedures in this section should only
be performed by trained service professional in a
suitably equipped workshop. Select the appropriate
repair procedure after troubleshooting the problem.
Perform disassembly procedures to the point
where repairs can be completed. Then to
re-assemble, perform the disassembly steps in
reverse order.
Symbols Legend
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.
DANGER
Indicates a imminently hazardous
situation which, if not avoided, will
result in death or serious injury.
WARNING
Indicates a potentially hazardous
situation which, if not avoided,
could result in death or serious
injury.
CAUTION
Indicates a potentially hazardous
situation which, if not avoided,
may cause minor or moderate
injury.
Indicates a potentially hazardous
situation which, if not avoided,
may result in property damage.
Indicates that a specific result is expected
after performing a series of steps.
Indicates that an incorrect result has occurred
after performing a series of steps.
48 RL4 Vertical Mast Part No. 1266665
Page 59
August 2015 Service Manual
NOTICE
Lighting
1-2 How to Check Line Voltage
1-1 How to Remove a Lamp
WARNING
CAUTION
Electrocution/burn hazard.
Contact with electrically charged
circuits could result in death or
serious injury. Remove all rings,
watches and other jewelry.
Burn hazard. Beware of hot
lamp components. Contact
with hot lamp components
may result in severe burns.
Correct line voltage at the lamp socket is essential
for proper operation of the lighting system.
WARNING
Electrocution/burn hazard.
Contact with electrically charged
circuits could result in death or
serious injury. Remove all rings,
watches and other jewelry.
1 Turn off all machine power.
2 Remove the cover from the lamp junction box.
1 Turn off all machine power.
2 Remove the light lens mounting fasteners and
remove the lens.
3 Remove the spring securing the lamp to the
lamp retainer.
Component damage hazard.
Contacting the lamp with bare
skin can cause damage to the
lamp. Do not allow bare skin
contact with the lamps.
4 Wrap a clean cloth around the lamp and
remove it from the socket.
Note: Be sure to wrap a clean cloth around the
lamp when installing it into the lamp socket.
Note: The junction box is located between the light
housings at the top of the mast.
1 Locate the correct wiring for the lamp to be
tested.
2 Connect a voltmeter to the lamp wires.
3 Start the engine.
4 Turn the appropriate circuit breaker light
switch to the "ON" position.
5 Observe the voltage as the lamps warm up.
Refer to the following chart.
Note: It can take up to 5 minutes for the lights to
reach full intensity. If the lights are turned off and
then turned back on while they are still warm, they
may not light up again for 10 to 20 minutes.
Time Line Voltage
Initial ignition 415V AC
30 seconds 412V AC
1 minute 413V AC
2 minutes 416V AC
5 minutes 246V AC
10 minutes 251V AC
Note: If voltage reading remains high during warm up,
check for loose or broken wire connections or the lamp
may be faulty.
Note: The voltage readings provided in the chart
are averages, voltage on your machine may vary.
Part No. 1266665 RL4 Vertical Mast 49
Page 60
Service Manual August 2015
NOTICE
Mast
2-2 How to Disassemble the Mast
2-1 How to Remove the Mast Assembly
Assembly
WARNING
CAUTION
1 Tag and remove the light heads from the mast.
2 Remove the junction box from the light bar.
Remove and retain the coil cord clamp and
hardware from the base section of the mast.
Lay the coil cord, junction box and lamp heads
to the side.
3 Remove the fasteners securing the mast base
to the chassis.
4 Attach a lifting strap from an overhead crane
to the mast base beneath the rotating section
and T-bolt. Remove the mast from the
machine.
Bodily injury hazard. The
procedures in this section
require specific repair skills,
lifting equipment and a suitable
workshop. Attempting this
procedure without these skills
and tools could result in death or
serious injury and significant
component damage. Dealer
service is required.
Bodily injury hazard. Cables
can fray. Always wear adequate
hand protection when handling
the cable.
1 Remove the mast assembly. See 1-1, How to
Remove the Mast Assembly.
2 Remove the T-bolt from the mast base
assembly.
3 Remove the nut from the bottom of the mast
base. Remove the mast base assembly from
the 4" inch mast section.
CAUTION
4 Remove the light bar assembly and hardware
from the 1.5 inch / 3.8 cm mast section and set
aside. Remove the 1.5 inch / 3.8 cm mast
section from the 2 inch / 5 cm mast section.
Disconnect the cable from the 2 inch / 5 cm
mast section by removing the cable retention
pin.
5 Working at the top of the 3 inch / 7.5 cm mast
section, use a drill to remove the rivets
securing the wear pads in position.
6 Remove the 2 inch / 5 cm mast section from
the 3 inch / 7.5 cm mast section. Disconnect
the cable from the 3 inch / 7.5 cm mast section
by removing the cable retention pin.
Bodily injury hazard. Cables
can fray. Always wear adequate
hand protection when handling
the cable.
Component damage hazard.
Cables can be damaged if they
are kinked or pinched.
50 RL4 Vertical Mast Part No. 1266665
Page 61
August 2015 Service Manual
Mast
7 Working at the top of the 4 inch / 10 cm mast
section, use a drill to remove the rivets
securing the wear pads in position.
8 Remove the 3 inch / 7.5 cm mast section from
the 4 inch / 10 cm mast section. Disconnect
the cable from the 4 inch / 10 mast section by
removing the cable retention pin.
9 Remove the clevis pin and sheave from the
2 inch / 5 cm mast section.
10 Remove the clevis pin and sheave from the
3 inch / 7.5 cm mast section.
11 Remove the clevis pin and sheave from the
4 inch / 10 cm mast section.
Note: For ease of assembly, note the location
where each wear pad is removed.
Note: To ensure that the mast extends properly
after assembly, carefully measure the cable to
confirm that the new cable is the same length as
the old one.
Note: During assembly, carefully install the mast
cable. Refer to the illustration on the following page
for cable routing.
Part No. 1266665 RL4 Vertical Mast 51
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Service Manual August 2015
Mast
2-3 How to Replace the Mast Lift Cables
See 2-2, How to Disassemble the Mast Assembly.
Note: Refer to the illustration below for cable
routing detail.
Winch
Mast Lift
Cable #1
4 inch
Mast
Section
Mast Lift
Cable #1
Mast Lift
Cable #2
Mast Lift
Cable #2
3 inch
Mast
Section
Mast Lift
Cable #3
Mast Lift
Cable #3
2 inch
Mast
Section
1.5 inch
Mast
Section
52 RL4 Vertical Mast Part No. 1266665
Page 63
August 2015 Service Manual
Mast
2-4 How to Remove the Manual Winch
1 Turn the handle of the mast pivot winch and
fully loosen the mast pivot cable. Remove the
handle from the winch.
2 Open the cabinet doors and locate the winch.
Remove the fasteners securing the handle to
the winch, and remove the handle.
3 Remove the cable retaining fastener securing
the cable to the winch drum. Unwind the cable
from the winch drum.
CAUTION
4 Remove the winch from the machine.
Bodily injury hazard. Cables
can fray. Always wear adequate
hand protection when handling
the cable.
Part No. 1266665 RL4 Vertical Mast 53
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Service Manual August 2015
Mast
2-5 How to Remove the Electric Winch
1 Lower the mast assembly to the stowed
position.
2 Remove the fasteners and winch covers from
the 4 inch / 10 cm mast assembly and set
aside. Refer to the illustration below.
3 On the electric winch, turn the yellow cap to
the free spool position.
CAUTION
Bodily injury hazard. Cables
can fray. Always wear adequate
hand protection when handling
the cable.
4 Pull the cable to unwind it from the winch
drum.
5 Loosen the set screw securing the cable.
Note: Before removing the cable from the winch
drum, make note of the cable routing. The cable
must be routed the same way when installing the
electric winch.
6 Remove the fasteners securing the electric
winch to the 4 inch / 10 cm mast assembly.
A
B
C
D
a winch covers
b electric winch
c engaged/free spool lock
d 4 inch / 10 cm mast assembly
54 RL4 Vertical Mast Part No. 1266665
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August 2015 Service Manual
Mast
2-6 How to Disengage the Tower Lock
To disengage the light tower lock so the tower can
be lowered to the stowed position and towed to a
suitable workshop for repairs follow the steps
below.
Remove the front fairing:
1 Raise the rear hatch fairing. Disconnect the
gas struts and close the rear hatch fairing.
2 Remove the hinge bolts that go through the
front fairing.
WARNING
CAUTION
Bodily injury hazard. This
procedure requires specific repair
skills, lifting equipment and a
suitable workshop. Attempting
this procedure without these skills
and tools could result in death or
serious injury and significant
component damage. Dealer
service is strongly recommended.
Bodily injury hazard. Cables
can fray. Always wear
adequate hand protection
when handling the cable.
3 Next remove the remaining front fairing
fasteners and loosen the front fairing enough
to access the trailer wiring harness
connectors.
4 Disconnect the two connectors at the roll bar
located on the upper road side of the light
tower.
5 Feed the draw bar wiring up through the hole
then remove the front fairing and set aside.
Part No. 1266665 RL4 Vertical Mast 55
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Service Manual August 2015
Mast
Unlock the tower:
6 Loosen the T-bolt and rotate the tower so that
the lock holes are facing forward. Re-tighten
T-bolt to secure the tower.
7 Using the figure below, attach a lifting strap
around the first movable tower section (1) as
shown.
8 Using a Telehandler or construction forklift
slowly begin lifting up the first movable tower
section (2) until the tower lock lever (3)
disengages.
9 Slowly begin lowering the tower while using a
pry bar to push in on the tower lock lever to
prevent it from engaging the lock hole.
10 Repeat step 9 until the tower is completely
down in the stowed position.
Transport the light tower to be repaired:
11 Once the light tower mast has been lowered to
the stowed position reinstall the front fairing
using the fasteners removed in the "Remove
the front fairing" section above.
12 The light tower can now be towed to the
nearest dealer service center for complete
tower disassembly and rebuild.
1
3
2
4
56 RL4 Vertical Mast Part No. 1266665
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August 2015 Service Manual
Kohler KDW1003GE Engine
3-3 Coolant Temperature and Oil Pressure
3-1 Timing Adjustment-Kohler Engines
Switches-Kohler Engines
Complete information to perform this procedure is
available in the Kohler KDW 702 - 1003 - 1404
Workshop Manual (Kohler part number:
ED0053029340).
Kohler KDW 702 - 1003 - 1404 Workshop Manual
Genie part number 1268828
3-2 Glow Plugs-Kohler Engines
1 Disconnect the wiring and buss bar from the
glow plugs.
2 Connect the leads from an ohmmeter between
each glow plug terminal and ground.
Result: The resistance should be
approximately 1 ohm.
Result: The resistance is 0 ohm or greater
than 1 ohm. The glow plug is faulty.
The engine coolant temperature switch is a
normally open switch. The switch contacts close at
approximately 235°F / 113°C. If the coolant
temperature rises above the switch point, the
switch contacts close and the engine will shut off to
prevent damage. The engine will not start until the
temperature drops below the switch point.
Additionally a low coolant level can cause the
coolant temperature switch to not work properly.
Make sure that the coolant system is at proper
level.
The engine oil pressure switch is a normally closed
switch. The switch contacts open at approximately
6.5 psi / 0.45 bar. If the oil pressure drops below
the switch point, the contacts open and the engine
will shut off to prevent damage.
Part No. 1266665 RL4 Vertical Mast 57
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Service Manual August 2015
Kubota D1105-E4BG Engine
4-3 Coolant Temperature and Oil Pressure
4-1 Timing Adjustment-Kubota Engines
Switches-Kubota Engines
Complete information to perform this procedure is
available in the Kubota 05 Series Workshop
Manual (Kubota part number: 97897-02432).
Kubota 05 Series Workshop Manual
Genie part number 31742
4-2 Glow Plugs-Kubota Engines
1 Disconnect the wiring and buss bar from the
glow plugs.
2 Connect the leads from an ohmmeter between
each glow plug terminal and ground.
Result: The resistance should be
approximately 1 ohm.
Result: The resistance is 0 ohm or greater
than 1 ohm. The glow plug is faulty.
The engine coolant temperature switch is a
normally open switch. The switch contacts close at
approximately 225°F / 107°C. If the coolant
temperature rises above the switch point, the
switch contacts close and the engine will shut off to
prevent damage. The engine will not start until the
temperature drops below the switch point.
Additionally a low coolant level can cause the
coolant temperature switch to not work properly.
Make sure that the coolant system is at proper
level.
The engine oil pressure switch is a normally closed
switch. The switch contacts open at approximately
7 psi / 0.48 bar. If the oil pressure drops below the
switch point, the contacts open and the engine will
shut off to prevent damage.
58 RL4 Vertical Mast Part No. 1266665
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Generator
7 Remove the screws and washers securing the
5-1 Generator
DANGER
DANGER
High voltage. Exposure to
electrical wires or electrical
current will result in death or
serious injury. Turn off all power
when not needed for testing. Use
extreme caution when working
with high voltage electrical
components.
Electrocution/burn hazard.
Attempting to service the
machine before the capacitor is
fully discharged will result in
death or serious injury.
generator pedestal to the chassis.
CAUTION
8 Open the control box by removing the two
upper screws of the control panel. Tilt the
control panel forward in order to access the
generator wiring located on the inside of the
control box.
9 Using an insulated conductor or a screwdriver
with an insulated handle, discharge the
capacitor by shorting across the capacitor
terminals.
Burn hazard. Beware of hot
engine components. Contact
with hot engine components
may result in severe burns.
Note: Be sure the engine has been turned off for at
least 15 minutes before servicing the machine. Use
a voltmeter to confirm there is no residual voltage
in the capacitor.
1 Deploy the outriggers and level the machine.
2 Disconnect the rear fairing wiring harnesses
located along side the roadside lift bar.
3 Disconnect the gas struts on the rear fairing
assembly from the lift bar.
4 Remove the screws from the hinges attaching
the rear fairing assembly to the lift bar.
5 Carefully lift the rear fairing assembly off the
unit and set aside.
6 Remove the left side cabinet weldment and
fender.
DANGER
10 Tag and disconnect all external wires from the
generator.
11 Support the generator using the lifting eye.
12 Remove the fasteners securing the generator
to the engine bellhousing.
13 Pull the generator away from the engine just
enough to reach the fasteners securing the
generator rotor to the engine flywheel.
Remove the fasteners.
14 Remove the generator from the machine.
CAUTION
High voltage. Exposure to
electrical wires or electrical
current will result in death or
serious injury. Use extreme
caution when working with high
voltage electrical components.
Crushing hazard. The generator
may become unbalanced and fall
if not properly supported when
removed from the machine.
Part No. 1266665 RL4 Vertical Mast 59
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Service Manual August 2015
Generator
5-2 How to Check a Generator Capacitor
DANGER
DANGER
Note: Be sure the engine has been turned off for at
least 15 minutes before servicing the machine. Use
a voltmeter to confirm there is no residual voltage
in the capacitor.
1 Open the control box by removing the two
upper screws of the control panel. Tilt the
control panel forward in order to access the
generator wiring located on the inside of the
control box.
2 Using an insulated conductor or a screwdriver
with an insulated handle, discharge the
capacitor by shorting across the capacitor
terminals.
DANGER
3 Tag and disconnect the wires attached to the
capacitor.
High voltage. Exposure to
electrical wires or electrical
current will result in death or
serious injury. Turn off all power
when not needed for testing. Use
extreme caution when working
with high voltage electrical
components.
Electrocution/burn hazard.
Attempting to service the
machine before the capacitor is
fully discharged will result in
death or serious injury.
High voltage. Exposure to
electrical wires or electrical
current will result in death or
serious injury. Use extreme
caution when working with high
voltage electrical components.
4 With an ohmmeter set to its highest resistance
scale, connect the ohmmeter leads to the
capacitor terminals and observe the reading
on the meter. Then, reverse the connections
and observe the reading on the meter.
Result: The meter indicates a very low
resistance which then gradually increases
AND a very high resistance which then
gradually decreases. The capacitor is working.
Result: The meter indicates a very high
resistance which does not decrease. The
capacitor is faulty and should be replaced.
Result: The meter indicates a very low
resistance which does not increase. The
capacitor is faulty and should be replaced.
5-3 How to Check a Generator Diode
DANGER
DANGER
Note: Be sure the engine has been turned off for at
least 15 minutes before servicing the machine. Use
a voltmeter to confirm there is no residual voltage
in the capacitor.
1 Remove the fasteners securing the end
cover/bearing housing to the generator.
Remove the cover.
High voltage. Exposure to
electrical wires or electrical
current will result in death or
serious injury. Turn off all power
when not needed for testing. Use
extreme caution when working
with high voltage electrical
components.
Electrocution/burn hazard.
Attempting to service the
machine before the capacitor is
fully discharged will result in
death or serious injury.
60 RL4 Vertical Mast Part No. 1266665
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August 2015 Service Manual
Generator
2 Locate the diode at the end of the generator.
3 Tag and disconnect the positive wire lead from
the diode.
4 With a multimeter set to test diodes, connect
one multimeter lead to the diode terminal and
the other multimeter lead to the 'Q' lead
terminal of the generator. Note the results.
Note: Refer to the instructions which are provided
for your multimeter to ensure the diode is
accurately tested.
5 Reverse the multimeter lead connections.
Note the results.
Result: The two readings are at a ratio of
3000:1 or higher. The diode is good.
Result: The two readings are at a ratio of less
than 3000:1. The diode is faulty and should be
replaced.
Note: Before installing a new diode, clean the
surface of the exciter rotor core, and run a bead of
a thermal-electrical compound around the base of
the diode (the threads of the diode should not be
coated). Torque to 20 to 30 in-lbs / 2.2 to 3.4 Nm.
Part No. 1266665 RL4 Vertical Mast 61
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Service Manual August 2015
Light Ballast
9 Move the Set switch to the program position
6-1 Ground Controls
The timer is used to automatically start the engine
and turn on the lights at a preset time.
(P) to set the desired stop and start time. A
default time of AM 12:00 will appear. A small
1 will appear to the right of the time with a
lamp symbol above it.
1 Move the engine start switch to timed start.
2 On the timer, move the mode switch (upper
left switch) to AUTO and the set switch (upper
right switch) to RUN.
3 Using the tip of a pencil or pen, press the
Reset button (R). A blinking display will show
0:00 for the time and an arrow under the day 7
(for Sunday).
4 Move the set switch to the left (clock icon) to
set the present day and time.
5 A default time of AM 12:00 will appear on the
display screen.
6 Press the day button (1..7) repeatedly until the
arrow points to the actual day of the week.
7 Press the hour button (h) repeatedly until the
actual hour of the day is displayed.
8 Press the minute button (m) repeatedly until
the minute of the present hour is displayed.
10 Use the day, hour and minute buttons to set
the timer to the desired start day and time.
11 Press the program button (P) to set the timer
for the desired shut-off time. AM 12:00 will
appear in the display with a small 2 to the
right.
Note: The lamp symbol will not appear above the 2.
12 Use the day, hour and minute buttons to set
the timer to the desired shut-off day and time.
13 Move the set switch to RUN.
62 RL4 Vertical Mast Part No. 1266665
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August 2015 Service Manual
Light Ballast
6-2 Light Ballast
DANGER
DANGER
Note: Be sure the engine has been turned off for at
least 15 minutes before servicing the machine. Use
a voltmeter to confirm there is no residual voltage
in the capacitor.
High voltage. Exposure to
electrical wires or electrical
current will result in death or
serious injury. Turn off all power
when not needed for testing. Use
extreme caution when working
with high voltage electrical
components.
Electrocution/burn hazard.
Attempting to service the
machine before the capacitor is
fully discharged will result in
death or serious injury.
DANGER
4 With an ohmmeter set to its highest resistance
scale, connect the ohmmeter leads to the
capacitor terminals and observe the reading
on the meter. Then, reverse the connections
and observe the reading on the meter.
Result: The meter indicates a resistance
which then gradually decreases. The capacitor
is working.
Result: The meter indicates a very high
resistance which does not decrease. The
capacitor is faulty and should be replaced.
High voltage. Exposure to
electrical wires or electrical
current will result in death or
serious injury. Turn off all power
when not needed for testing. Use
extreme caution when working
with high voltage electrical
components.
Note: This procedure is only for the capacitors
which are attached to the lighting ballasts. To test a
generator capacitor, see 5-2, How to Check a
Generator Capacitor.
1 Open the control box by removing the two
upper screws of the control panel. Tilt the
control panel forward to access the ballast
capacitors located on the inside of the control
box.
2 Choose a capacitor. Remove the plastic
terminal cover and disconnect the wire
harness connector from the capacitor.
3 Using an insulated conductor or a screwdriver
with an insulated handle, discharge the
capacitor by shorting across the capacitor
terminals.
Note: Refer to the instructions which are provided
for your multimeter to ensure the diode is
accurately tested.
Result: The meter indicates a very low
resistance which does not increase. The
capacitor is faulty and should be replaced.
5 Repeat the above procedure for each ballast
capacitor.
Probable causes of capacitor failure:
Normal end-of-life failure.
Overheated due to light fixture heat or high
ambient temperature.
Incorrect capacitor voltage rating.
Capacitor becomes loose in ballast box.
Part No. 1266665 RL4 Vertical Mast 63
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Service Manual August 2015
NOTICE
NOTICE
Fuel Tank
Remove the front fairing assembly:
7-1 Fuel Tank
1 Remove the fuel filler cap from the tank. Using
an approved hand-operated pump, drain the
fuel tank into a container of suitable capacity.
Refer to Section 2, Specifications.
7 Remove the fasteners securing the front
fairing assembly to the chassis.
8 Carefully lift the front fairing assembly off the
chassis and set aside.
DANGER
DANGER
Explosion and fire hazard.
Engine fuels are combustible.
Perform this procedure in an
open, well-ventilated area away
from heaters, sparks, flames
and lighted tobacco. Always
have an approved fire
extinguisher within easy reach.
Explosion and fire hazard. When
transferring fuel, connect a
grounding wire between the
machine and pump or container.
Be sure to only use a hand
operated pump suitable for use
with diesel fuel.damage hazard.
Be sure not to cut the power to
the platform wiring.
Remove the rear fairing assembly:
2 Deploy the outriggers and level the machine.
3 Disconnect the rear fairing wiring harnesses
located along side the roadside lift bar.
4 Disconnect the gas struts on the rear fairing
assembly from the lift bar.
Remove the lift bar assembly:
9 Remove the fasteners securing the lift bar
assembly to the chassis.
10 Remove the fasteners securing the lift
structure cross brace to the light tower mast.
11 Carefully remove the lift bar assembly off the
chassis and set aside.
Remove the fuel tank assembly:
12 Tag, disconnect and plug the fuel hoses from
the fuel tank.
13 Carefully remove the fuel tank assembly from
the chassis and set aside.
Component damage hazard. The
fuel tank is plastic and may
become damaged if allowed to
fall.
14 Clean up any fuel that may have spilled.
Note: Clean the fuel tank and inspect for cracks
and other damage before installing it onto the
machine.
5 Remove the screws from the hinges attaching
the rear fairing assembly to the lift bar.
6 Carefully lift the rear fairing assembly off the
unit and set aside.
64 RL4 Vertical Mast Part No. 1266665
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August 2015 Service Manual
Diagnostics
Section 5 Diagnostics
Before Troubleshooting:
Read, understand and obey the safety rules
and operating instructions in the appropriate
operator's manual on your machine.
Be sure that all necessary tools and test
equipment are available and ready for use.
Observe and Obey:
Troubleshooting and repair procedures shall
be completed by a person trained and qualified
on the repair of this machine
Immediately tag and remove from service a
damaged or malfunctioning machine.
Repair any machine damage or malfunction
before operating the machine.
Unless otherwise specified, perform each
procedure with the machine in the following
configuration:
Machine parked on a firm, level surface
Mast in the stowed position
Key switch in the off position with the key
removed
The red Emergency Stop button in the off
position on the electrical control box
Wheels chocked
Light switches in the off position
All external AC power supply disconnected
from the machine
Read each appropriate fault code thoroughly.
Attempting short cuts may produce hazardous
conditions.
Be aware of the following hazards and follow
generally accepted safe workshop practices.
WARNING
DANGER
CAUTION
Electrocution/burn hazard.
Contact with electrically charged
circuits could result in death or
serious injury. Remove all rings,
watches and other jewelry.
High voltage. Exposure to
electrical wires or electrical
current will result in death or
serious injury. Turn off all power
when not needed for testing. Use
extreme caution when working
with high voltage electrical
components.
Burn hazard. Beware of hot
engine components. Contact
with hot engine components
may cause severe burns. Use
caution when working around
lamps or a hot engine.
Part No. 1266665 RL4 Vertical Mast 65
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Service Manual August 2015
Diagnostics
Problem Possible Cause Solution
Mast will not rise to the
operating position
Engine will not turn over No power
Faulty cable or pulley Inspect and repair as needed.
Faulty winch Inspect and repair as needed.
Inspect and repair battery cables and
connections as needed. Inspect and
charge or replace battery as needed.
Inspect and replace fuse.
Faulty starter Inspect and repair as needed
Faulty starter switch
Engine overheats Low coolant level
Radiator blocked Clear the radiator fins.
Radiator or cooling system clogged or
corroded
Engine runs but produces a
Fan or radiator cap faulty Inspect and repair as needed.
Thermostat faulty Inspect and repair as needed.
Head gasket faulty Inspect and repair as needed.
Fan belt is loose Tighten or replace fan belt.
Unsuitable fuel used
Crankcase oil level is too high Drain oil to the proper level.
dense smoke
Low compression
Injector nozzle faulty Replace injector.
Inspect and repair switch and/or
switch wiring as needed
Top off radiator and coolant overflow
tank with correct coolant mixture per
engine operator's manual.
Inspect and repair as needed.
Drain fuel system and replace with
specified fuel.
Inspect for broken/seized piston rings
or inspect valve clearance.
66 RL4 Vertical Mast Part No. 1266665
Combustion incomplete due to faulty timing,
poor valve adjustment or poor compression
Inspect and repair as needed.
Page 77
August 2015 Service Manual
Diagnostics
Problem Possible Cause Solution
Engine runs rough Air or contaminated fuel in fuel system Inspect and repair as needed.
Clogged or leaking fuel system
Clogged exhaust system Inspect and repair as needed.
Replace fuel lines, tighten all
connections, inspect the fuel pickup
tube and inspect the fuel filter.
Engine turns over but will not
start or is difficult to start
Clogged air filter
Clogged or stuck fuel injectors Inspect and repair as needed.
Faulty governor or fuel pump Inspect and repair as needed.
Empty fuel tank Add fuel to tank.
Leaking or pinched fuel lines Inspect and repair as needed.
Clogged fuel filter Replace filter.
Air or water mixed in fuel
Fuel injection nozzle clogged Inspect and repair as needed.
Fuel injection pump faulty Inspect and repair as needed.
Fuel solenoid valve faulty Inspect and repair as needed.
Faulty glow plug Inspect and repair as needed.
Inspect and repair or replace as
needed.
Air: Tighten fule lines and vent fuel
system air at injection pump.
Water: Drain fuel and replace filter;
inspect and clean or replace injector
as needed.
Part No. 1266665 RL4 Vertical Mast 67
Faulty relay or wiring connection in control
box
Battery is discharged or low Charge or replace battery.
Air cleaner is dirty Clean or replace more frequently.
Inspect and repair as needed.
Page 78
Service Manual August 2015
Diagnostics
Problem Possible Cause Solution
Engine battery quickly
discharged
Battery electrolyte low Add distilled water and charge.
Fan belt slips Inspect and repair as needed.
Engine runs but battery voltage
Wiring loose or disconnected Inspect and repair as needed.
Faulty alternator, rectifier or diode Inspect and repair as needed.
Faulty battery Replace battery.
Faulty alternator Inspect and repair as needed.
is low
Engine runs but lights will not
Circuit breaker has tripped Reset circuit breaker.
operate
Loose wiring connections Inspect and repair as needed.
Faulty generator Inspect and repair as needed.
Lamp light output low Dirty light fixture Clean light fixture.
Light head will not illuminate End of life Replace lamp or light head.
Short in power supply cable Inspect and repair as needed.
Power supply cable connector faulty or poor
Inspect and repair as needed.
connection
Unusual noise from the
generator
Generator has a faulty bearing or faulty fan
blade
Inspect and repair as needed.
68 RL4 Vertical Mast Part No. 1266665
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August 2015 Service Manual
Diagnostics
Problem Possible Cause Solution
Generator produces full voltage
at no load or voltage drops at
full load
Loose or broken lead wires
Rotor open or shorted Measure resistance between leads..
Inspect lead wires and connections for
broken wires and loose connections.
Stator grounded or shorted
Generator voltage too high High engine speed
Generator produces no voltage
Faulty capacitor Replace capacitor.
at no load or at full load
Generator will not hold voltage
(loss of residual magnetism)
Generator voltage spikes
Loss of residual magnetism Flash the rotor.
Open winding Replace the generator.
Machine has been unused for a significant
length of time
Rotor shorting out when the unit gets hot
Pinched leads Inspect and repair as needed.
Faulty capacitor Replace the capacitor.
Faulty diode Replace the diode.
Incorrect engine adjustment, fuel line or
faulty fuel
Loose connection
Faulty ground connection
Load induced Filter load.
Contact the Genie Service
Department.
Adjust the rpm
Refer to Section 2, Specifications
Flash the rotor.
Inspect rotor windings for broken
and/or burned wires.
Change fuel filter and check engine
speed.
Inspect all connections and repair as
needed.
Inspect all ground connections and
repair as needed.
Part No. 1266665 RL4 Vertical Mast 69
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Service Manual August 2015
Diagnostics
Problem Possible Cause Solution
Generator voltage low Loss of residual magnetism Flash the rotor.
Low engine speed Adjust idle. See Repair Section.
Faulty capacitor Replace the capacitor.
Faulty diode Replace the diode.
70 RL4 Vertical Mast Part No. 1266665
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August 2015 Service Manual
Schematics
Section 6 Schematics
Observe and Obey:
Troubleshooting and repair procedures shall
be completed by a person trained and qualified
on the repair of this machine
Immediately tag and remove from service a
damaged or malfunctioning machine.
Repair any machine damage or malfunction
before operating the machine.
Before Troubleshooting:
Read, understand and obey the safety rules
and operating instructions in the appropriate
operator's manual on your machine.
Be sure that all necessary tools and test
equipment are available and ready for use.
About This Section
There are two groups of schematics in this section.
Electrical Schematics
WARNING
Hydraulic Schematics
WARNING
Electrocution/burn hazard.
Contact with electrically charged
circuits could result in death or
serious injury. Remove all rings,
watches and other jewelry.
Bodily injury hazard. Spraying
hydraulic oil can penetrate and
burn skin. Loosen hydraulic
connections very slowly to allow
the oil pressure to dissipate
gradually. Do not allow oil to
squirt or spray.
Part No. 1266665 RL4 Vertical Mast 71
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Service Manual August 2015
Wire Color Legend
Wire Color Legend
BL Blue
BK Black
BR Brown
GR Green
OR Orange
VI Violet
RD Red
WH White
YL Yellow
OR/BK Orange/Black
WH/BK White/Black
WH/RD White/Red
GR/YL Green/Yellow
RD/BK Red/Black
YL/RD Yellow/Red
BL/WH Blue/White
72 RL4 Vertical Mast Part No. 1266665
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August 2015 Service Manual
73
RL4 Control Box AC Voltage Wiring - Standard
Page 84
Service Manual August 2015
74
RL4 DC CONTROL BOX, AC VOLTAGE WIRING, STANDARD
LIGHT CONNECTION JUNCTION BOX
HIGH TEMPERATURE ZONE
ALL WIRING AND COMPONENTS MUST MEET
MIN. TEMP, PROTECTION OF 1500 DEGREES CELSIUS
MAIN
BREAKER
LIGHT
BREAKERS
25 AMP
KOHLER
GENSET
CAPACITOR
12 AWG GREEN
12 AWG WHITE
BLACK 120V
RED 120V
12 AWG RED
12 AWG BLACK
BROWN 120V
BLUE 120V
COM
COM
COM
COM
WHITE
GRN
BLK
132
4
RED
WHT
BLU
BRN
GRN
BLK
RED
BRN
BLUE
WHITE
18/5, 14/1 CORD
WHITE
WHITE
TRANSFORMER
(1000W METAL
HALIDE BALLAST)
TRANSFORMER
(1000W METAL
HALIDE BALLAST)
TRANSFORMER
(1000W METAL
HALIDE BALLAST)
TRANSFORMER
(1000W METAL
HALIDE BALLAST)
120V-20AMP
GFI PROTECTED
RECEPTACLES
20AMP
BREAKER
240V
30 AMP
RECEPTACLE
(V1)
(U1) (U1)
240 VAC FROM GENERATOR
(V1)
(C1) (C1)
(U2)
(V2) (V2)
(U2)
(C2)
C1
24 MF
480V
C1
24 MF
480V
C1
24 MF
480V
C1
24 MF
480V
(C2)
NEUTRAL BONDED
TO GROUND
12
Page 85
August 2015 Service Manual
75
RL4 Control Box AC Voltage Wiring - Autostart
RL4 Control Box AC Voltage Wiring - Autostart
Page 86
Service Manual August 2015
76
RL4 DC CONTROL BOX, AC VOLTAGE WIRING, AUTOSTART
LIGHT CONNECTION JUNCTION BOX
HIGH TEMPERATURE ZONE
ALL WIRING AND COMPONENTS MUST MEET
MIN. TEMP, PROTECTION OF 1500 DEGREES CELSIUS
MAIN
BREAKER
RELAY B
J5 ON TG350
A PHASE
B PHASE
NEUTRAL
DYNAGEN
RELAY A
12VDC
DYNAGEN
CONTROLLED
LIGHT
BREAKERS
25 AMP
GENSET
CAPACITOR
12 AWG GREEN
12 AWG WHITE
18 AWG BLACK
18 AWG RED
BLACK 120V
RED 120V
12 AWG RED
12 AWG BLACK
BROWN 120V
BLUE 120V
COM
COM
COM
COM
WHITE
GRN
BLK
1
1
2
3
4
324
RED
WHT
BLU
BRN
GRN
BLK
RED
BRN
BLUE
WHITE
18/5, 14/1 CORD
WHITE
WHITE
120V-20AMP
GFI PROTECTED
RECEPTACLES
20AMP
BREAKER
240V
30 AMP
RECEPTACLE
(V1)
(U1)
(U1)
240 VAC FROM GENERATOR
(V1)
(C1)
(C1)
(U2)
(V2)
(V2)
(U2)
(C2)
(C2)
NEUTRAL BONDED
TO GROUND
12
TRANSFORMER
(1000W METAL
HALIDE BALLAST)
TRANSFORMER
(1000W METAL
HALIDE BALLAST)
TRANSFORMER
(1000W METAL
HALIDE BALLAST)
TRANSFORMER
(1000W METAL
HALIDE BALLAST)
C1
24 MF
480V
C1
24 MF
480V
C1
24 MF
480V
C1
24 MF
480V
Page 87
August 2015 Service Manual
77
RL4 DC Control Box - Standard
Page 88
Service Manual August 2015
78
RL4 DC CONTROL BOX, STANDARD
ALTERNATOR
FAILURE
LIGHT
PREHEAT
PUSH BUTTON
12V DC OPERATION
HOUR
METER
GRN
BRN
ORG
YEL
IGN
ACC
BAT
ST
YEL 10 AWG
WHT
BRN
BLK
BLK
WHT 12 AWG
RED 10 AWG
RED
YEL
GRN
RELAY 12V
SPST
BRN
YEL 10 AWG
YEL 10 AWG
RED
P1
P1
13
2
46
79
1012
1
2
3
4
5
6
7
8
9
10
11
12
87a
(NC)
87
30
8685
11
ORG
GRN
WHT
BLK
YEL
BRN
Page 89
August 2015 Service Manual
79
RL4 DC Control Box Wiring - DynaGen
Page 90
Service Manual August 2015
80
RL4 WITH DYNAGEN TG350 AUTOSTART
12V DC OPERATION
P1
P1
13
2
46
79
1012
11
RED
RED
BLK
BLU
1
1
1
10
10
11
12
13
14
5
5
9
5
9
4
4
4
7
7
7
2
2
2
6
8
6
1
1
1
8
6
8
3
3
3
2
2
3
3
4
4
12V + BATTERY
ON - OFF
TELEMATICS REMOTE ENABLE
FUEL PUMP
GLOW PLUGS
BATTERY -
BATTERY -
PHOTO CELL
AUTOSTART WARNING
MAINS CONTACTORS
A PHASE
A PHASE
J5 FROM GENERATOR
J7
5 AMP
FUSE
J6
J3
J4
J1
B PHASE
MODULE POWER +12V
TIMER
OFF
PHOTOCELL
CLOCK TIMER
SENSOR INPUT B - LOW IMPEDANCE - TEMP AND OIL
NEUTRAL
B
GLOW PLUGS
D
MAINS
C
CRANK
A
FUEL PUMP
B PHASE
12V + BATTERY
TO J4 P6
STARTER
ALT D+
TEMP/OIL PRESSURE SWITCH
2
3
4
5
6
7
8
9
10
11
12
4
1
TELEMATICS
(NC)
(NO)
12VDC
TELEMATICS
ACTIVE LOW
TELEMATICS
ACTIVE HIGH
6
3
5
2
4
1
J1
5
2
6
3
ORG
GRN
WHT
BLK
YEL
BRN
YLLW/BRN
RELY PAK (RP100)
DYNAGEN TG350 MODULE
RED/BLK
RED/BLK
WHT/BLK
BLU
BLU
LT BLU
ORG/BLK
Page 91
August 2015 Service Manual
81
RL4 DC Engine Components - Kohler
Page 92
Service Manual August 2015
82
RL4 DC ENGINE COMPONENTS (KOHLER)
12VDC OPERATION
HARNESS PART NUMBER = 1264847
P1
P1
13
2
46
79
1012
11
RED
BLK RED
E-STOP
OPTION
FUSE
50A
RED
GRN
BRN
BRN
IN4004
FUEL PUMP
GLOW
PLUGS
LOW OIL
PRESSURE
(NC)
HIGH
COOLANT
TEMPERATURE
(NO)
TELEMATICS
TELEMATICS
584
1
PIN#
1
2
3
4
5
6
7
8
RD
BK
BRN
-
LT BLU
-
-
TEL BAT
TEL GND
TEL SIG
PLUG
PLUG
REMOTE ENABLE
PLUG
PLUG
CKT# COLOR
ORG
ORG/BLK
VLT
WHT
B+
B
ST
STARTER
ALTERNATOR
BATTERY
12 VOLT
FUEL
SOLENOID
1
2
3
4
5
6
7
8
9
10
11
12
ORG
N.C.
RESISTORS
110 OHM110 OHM
GRN
WHT
BLK
YEL
BRN
LT BLU
Page 93
August 2015 Service Manual
83
RL4 DC Engine Components - Kubota
Page 94
Service Manual August 2015
84
RL4 DC ENGINE COMPONENTS (KUBOTA)
12VDC OPERATION
HARNESS PART NUMBER = 116820
P1
P1
13
2
46
79
1012
11
RED
BLK RED
E-STOP
OPTION
FUSE
50A
RED
GRN
BRN
BRN
FUEL PUMP
GLOW
PLUGS
LOW OIL
PRESSURE
(NC)
HIGH
COOLANT
TEMPERATURE
(NO)
TELEMATICS
TELEMATICS
584
1
PIN#
1
2
3
4
5
6
7
8
RD
BK
BRN
-
LT BLU
-
-
TEL BAT
TEL GND
TEL SIG
PLUG
PLUG
REMOTE ENABLE
PLUG
PLUG
CKT# COLOR
ORG
ORG/BLK
VLT
WHT
B+
B
ST
STARTER
ALTERNATOR
BATTERY
12 VOLT
FUEL
SOLENOID
1
2
3
4
5
6
7
8
9
10
11
12
ORG
N.C.
GRN
WHT
BLK
YEL
BRN
LT BLU
Page 95
August 2015 Service Manual
85
RL4 DC Control Box - Timed Oil Switch
Page 96
Service Manual August 2015
86
RL4 DC CONTROL BOX, TIMED OIL SWITCH
C
P1
P1
ALTERNATOR
FAILURE
LIGHT
100K /16VDC
CAPACITOR
uf
1
1
4
7
10
3
2
11
6
9
12
2
3
4
5
6
7
8
9
10
86
_
+
86
87
87
(NC)
(NC)
87a
87a
30
30
85
85
11
12
HOUR
METER
12VDC OPERATION
RELAY 12V
SPST
PREHEAT
PUSH BUTTON
BLK
BLK
BRN
YEL
BLK
WHT
GRN
ORG
RED
RED
YEL 10 AWG
YEL 10 AWG
YEL 10 AWG
WHT 12 AWG
RED 10 AWG
BRN
BRN
BRN
GRN
ORG
WHT
YEL
YEL
GRN
ACC
ST
BAT
IGN
Page 97
August 2015 Service Manual
87
RL4 DC Control Box - Low Fuel Shut Down
Page 98
Service Manual August 2015
88
RL4 DC CONTROL BOX, LOW FUEL SHUT DOWN
C
P1
ALTERNATOR
FAILURE
LIGHT
FUEL LEVEL SWITCH
(REED SWITCH)
TO LOW FUEL CUT-OFF
100K /16VDC
CAPACITOR
uf
1
2
3
4
5
6
7
8
9
10
86
_
+
86
87
87
(NC)
(NC)
87a
87a
30
30
85
85
11
12
HOUR
METER
12VDC OPERATION
RELAY 12V
SPST
PREHEAT
PUSH BUTTON
BLK
BLK
BRN
YEL
BLK
WHT
GRN
ORG
RED
LOW FUEL
WARNING
RED
YEL 10 AWG
YEL 10 AWG
YEL 10 AWG
WHT 12 AWG
RED 10 AWG
BRN
BRN
BRN
GRN
ORG
WHT
YEL
YEL
GRN
ACC
ST
BAT
IGN
Page 99
August 2015 Service Manual
89
RL4 Running Lights - Front Fairing Section
Page 100
Service Manual August 2015
90
NEW RL4 RUNNING LIGHTS
FRONT SECTION
ITEM PART NUMBER DESCRIPTION QTY
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
1
1
3
85"
24"
1
1
3
4
0
182"
149"
126"
149"
126"
12
1
DEUTSCH CONNECTOR, PLUG, 3-PIN
DEUTSCH CONNECTOR, WEDGE
DEUTSCH CONNECTOR, SOCKET
7/16" BLACK PLASTIC WIRE LOOM W SLIT, .413 ID
ELECTRICAL TAPE
DEUTSCH CONNECTOR, RECEPTACLE 3-PIN
DEUTSCH CONNECTOR, WEDGE
DEUTSCH CONNECTOR, PIN
1/4" MALE NYLON INSULATED TERMINAL
16-14 1/4" RING NYLON INSULATED TERMINAL
WIRE, 18 GA, WHITE
TIE WRAP
4-WAY, FLAT TAILER END CONNECTOR
WIRE, 18 GA, GREEN/BROWN
WIRE, 18 GA, GREEN
WIRE, 18 GA, YELLOW/BROWN
WIRE, 18 GA, YELLOW
DT06-3S
W3S
0462-201-16
DT04-3P
W3P
0460-202-16
18 AWG WHITE
18 AWG YELLOW/BRN
18 AWG GREEN/BRN
18 AWG GREEN
SOLDERED JOINT
18 AWG YELLOW
POSITION
4
3
3
2
1
COLOR
WHITE
YLLW/BRN
YLLW
GRN/BRN
GRN
1
2
3
9
17
5
4
9
6
7
8
A
A
B
B
C
C
POSITION
A
B
C
POSITION
A
B
C
COLOR
WHITE
YELLOW
YEL/GRN
COLOR
WHITE
GREEN
GRN/BRN
4
3
2
1
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