Genie RL4 Vertical Mast Service Manual
S
t
RL4 Vertical Mas
ervice Manual
Part No. 1266665
Rev A
August 2015
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
August 2015 Service Manual
Introduction
Serial Number Legend
Part No. 1266665 RL4 Vertical Mast iii
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
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
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
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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
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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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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
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
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
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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Specifications
Part No. 1266665 RL4 Vertical Mast 5
Service Manual August 2015
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6 RL4 Vertical Mast Part No. 1266665
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
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
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
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
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
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
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
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
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
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
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
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
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
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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