Terex RL4 LED Parts Manual
V
t
Parts Manual
Serial Number Range
RL4 LED
ertical Mas
from SN RL4LEDJ-101
Part No. 1287640GT
Rev: A3
October 2019
T
October 2019
2
RL 4 LED Vertical Mast
Part No. 1287640G
October 2019
Part No. 1287640GT
RL 4 LED Vertical Mast
3
T
October 2019
4
RL 4 LED Vertical Mast
Part No. 1287640G
October 2019
5
Part No. 1287640GT
RL 4 LED Vertical Mast
T
October 2019
6
RL 4 LED Vertical Mast
Part No. 1287640G
October 2019
7
Description Page
Table of Contents
001 Parts Stocking List ........................................................................
001.1 Parts Stocking List .............................................................................
100 Decals .......................................................................................
101.1 Decals with Words .............................................................................
102.1 Decals with Symbols ...........................................................................
200 Chassis Components ......................................................................
201.1 Chassis Components ...........................................................................
202.1 Fuel Tank and Hoses ...........................................................................
203.1 Axle ...........................................................................................
204.1 Hitches . . ......................................................................................
205.1 Cabinet, Front Fairing . . . .......................................................................
206.1 Cabinet, Rear Fairing ...........................................................................
300 Engines and Generators ..................................................................
301.1 Champion Model 100467 .......................................................................
400 Electrical Components ....................................................................
401.1 Control Box Assembly . . . .......................................................................
402.1 Electrical Wiring and Power Cables ..............................................................
8
8
10
10
14
16
16
22
24
26
28
30
36
36
38
38
40
500 Mast Components . . .......................................................................
501.1 Mast Assembly and Cable Routing (to SN RL4LJ-400) .............................................
501.2 Mast Assembly and Cable Routing (from SN RL4LJ-401) . .........................................
502.1 Tower Base and Mast Assembly, 4" Inch (to SN RL4LJ-400) ........................................
502.2 Tower Base and Mast Assembly, 4" Inch (from SN RL4LJ-401) .....................................
503.1 Mast Assembly, 3" Inch (to SN RL4LJ-400) .......................................................
503.2 Mast Assembly, 3" Inch (from SN RL4LJ-401) .....................................................
504.1 Mast Assembly, 2" Inch (to SN RL4LJ-400) .......................................................
504.2 Mast Assembly, 2" Inch (from SN RL4LJ-401) .....................................................
505.1 Mast Assembly, 1.5" Inch (to SN RL4LJ-400) ......................................................
505.2 Mast Assembly, 1.5" Inch (from SN RL4LJ-401) . . . . ...............................................
506.1 LED Light Assembly ............................................................................
507.1 Winch . . . ......................................................................................
Part Number Index .............................................................................
42
42
44
46
50
52
54
56
58
60
62
64
66
68
Part No. 1287640GT
RL 4 LED Vertical Mast
T
001 Parts Stocking List
001.1 Parts Stocking List
October 2019
RL 4 LED Vertical Mast8
Part No. 1287640G
A
A-
A-
A-
A-
A-
A-
A-
A-
A-
A-
A-
A-
October 2019
t
001 Parts Stocking Lis
001.1 Parts Stocking List
Item Part No. Description Qty.
— GENERAL SERVICE PARTS — .. ...................................................
1484GT PAINT,AEROSOL,BRIGHT BLUE***
12-ounce spray paint
1268GT PAINT,AEROSOL,GENIE GRAY***
12-ounce spray paint
1258567GT PAINT, AEROSOL, TRAFFIC BLACK
12-ounce spray paint
32150GT PAINT,WET,GENIE BLUE (1 GL)**
1-gallon
32151GT PAINT,WET,GENIE GRAY (1 GL)**
1-gallon
66399GT GREASE,DIELECTRIC 4 OZ** .........................................................
1283776GT SEAL MARKER,CROSS CHECK,BLUE,TUBE ..........................................
93500GT PARKER DIGITAL PRESSURE GAUGE ................................................
49612GT O-RING KIT (ORFS FITTINGS)
O-ring kit, ORFS
49613GT PLUG AND CAP KIT-SERVICE,ORFS*
Plug and cap kit, ORFS
28750GT O-RING KIT,FIELD SVC,ALL PROD*
O-ring kit, SAE
33994GT PLUG AND CAP KIT-SERVICE,37 **
Plug and cap kit, SAE
......................................................................................
1 — MANUALS — .......................................................................
....................................................
.....................................................
..................................................
.....................................................
....................................................
........................................................
.................................................
...................................................
...................................................
1- 27581GT MANUAL,AEM SAFETY ...............................................................
1- 1286390GT MANUAL, OPERATOR'S, RL4LED .. ...................................................
1- 1287632GT MANUAL, SERVICE, RL4LED .........................................................
1- 1287640GT MANUAL, PARTS, RL4LED .. ..........................................................
......................................................................................
2 — INVERTOR, CHAMPION — .........................................................
3- 1287253GT GASKET,VALVE COVER,INVERTER,RL4LED GAS ....................................
4- 1287254GT SPARK PLUG F6RTC, INVERTER,Rl4LED GAS ........................................
5- 1287255GT ELEMENT,AIR CLEANER,INVERTER,RL4LED GAS ....................................
Part No. 1287640GT
RL 4 LED Vertical Mast 9
T
100 Decals
101.1 Decals with Words
October 2019
RL 4 LED Vertical Mast10
Part No. 1287640G
A
October 2019
100 Decals
101.1 Decals with Words
Item Part No. Description Qty.
1288980GT DECAL,EMISSION CONTROL INFORMATION,RL4LED GAS ........................... 1
1 52475GT DECAL,LABEL,TRANSPORT TIEDOWN* .. ............................................ 3
2 72086GT DECAL,LABEL,LIFTING EYE .......................................................... 1
3 133062GT Decal, Label, Ground .................................................................. 1
4 133211GT DECAL, PHOTO CELL ................................................................ 1
5 133461GT DECAL,TIRE SPECIFICATION ......................................................... 1
6 229102GT DECAL, LABEL, ARROW .............................................................. 2
7 1266647GT DECAL, DANGER, ELECTROCUTION HAZARD ........................................ 1
8 1266648GT DECAL, WARNING, TIP-OVER HAZARD, OUTRIGGERS . .. ............................ 1
9 1266650GT DECAL, DANGER, NO SMOKING . .. ................................................... 1
10 1266652GT DECAL, LABEL, TRANSPORT DIAGRAM .. ............................................ 1
11 1266653GT DECAL, DANGER, ELECTROCUTION HAZARD ........................................ 2
12 1266655GT DECAL, WARNING, IMPROPER OPERATION .......................................... 1
13 1266657GT DECAL, DANGER, ELECTROCUTION HAZARD ........................................ 1
14 1266658GT DECAL, COSMETIC, TEREX LOGO, FRONT FAIRING ................................. 1
15 1266659GT DECAL, COSMETIC, GENIE LOGO, FRONT FAIRING .................................. 1
16 1266661GT DECAL, WARNING, EXPLOSION HAZARD ............................................ 1
17 1266667GT DECAL, INSTRUCTIONS, TONGUE DEPLOYMENT .................................... 1
18 1266881GT DECAL, DANGER, INHALATION HAZARD .. ........................................... 1
19 1266883GT DECAL, DANGER, ELECTROCUTION HAZARD ........................................ 1
20 1266884GT DECAL, WARNING, TOW SPEED ..................................................... 1
21 1266885GT DECAL, WARNING, EXPLOSION/BURN HAZARD .. .................................... 1
22 1266887GT DECAL, DANGER, AUTO-START HAZARD ............................................ 1
23 1266888GT DECAL, DANGER, EXPLOSION HAZARD, BATTERY ................................... 1
24 1280819GT DECAL,WARNING,CANCER AND REPRODUCTIVE HARM, PROP 65 .................. 1
25 1280820GT DECAL,FUEL,DIESEL EXHAUST, PROP 65 ............................................ 1
26 1286300GT DECAL, GASOLINE ONLY ... .......................................................... 1
27 1286537GT DECAL, COSMETIC, GENIE LOGO, RL4, REAR DOOR ................................ 1
Part No. 1287640GT
RL 4 LED Vertical Mast 11
T
100 Decals
101.1 Decals with Words
October 2019
RL 4 LED Vertical Mast12
Part No. 1287640G
October 2019
100 Decals
101.1 Decals with Words
Item Part No. Description Qty.
28 1286538GT DECAL, COSMETIC, GENIE LOGO, RL4 ............................................... 2
29 1286540GT DECAL, COSMETIC, TEREX LOGO, RL4, REAR DOOR ................................ 1
30 1286541GT DECAL, COSMETIC, TEREX LOGO, RL4 . .. ........................................... 2
31 1287638GT DECAL, OPERATING INSTRUCTIONS ................................................. 1
Part No. 1287640GT
RL 4 LED Vertical Mast 13
T
100 Decals
102.1 Decals with Symbols
October 2019
RL 4 LED Vertical Mast14
Part No. 1287640G
A
October 2019
5
100 Decals
102.1 Decals with Symbols
Item Part No. Description Qty.
1288980GT DECAL,EMISSION CONTROL INFORMATION,RL4LED GAS ........................... 1
1 28158GT DECAL,LABEL,UNLEADED GAS ONLY ................................................ 1
2 52475GT DECAL,LABEL,TRANSPORT TIEDOWN* .. ............................................ 3
3 72086GT DECAL,LABEL,LIFTING EYE .......................................................... 1
4 133062GT Decal, Label, Ground .................................................................. 1
5 229102GT DECAL, LABEL, ARROW .............................................................. 2
6 1266652GT DECAL, LABEL, TRANSPORT DIAGRAM .. ............................................ 1
7 1266658GT DECAL, COSMETIC, TEREX LOGO, FRONT FAIRING ................................. 1
8 1266659GT DECAL, COSMETIC, GENIE LOGO, FRONT FAIRING .................................. 1
9 1266668GT DECAL, INSTRUCTIONS, TONGUE DEPLOYMENT .................................... 1
10 1266675GT DECAL, WARNING, TIP-OVER HAZARD, OUTRIGGERS . .. ............................ 1
12 1266677GT DECAL, WARNING, BURN HAZARD ................................................... 1
13 1266678GT DECAL, LABEL, TOW SPEED ......................................................... 1
14 1266679GT DECAL, DANGER, ELECTROCUTION HAZARD ........................................ 1
15 1266886GT DECAL, LABEL, ELECTROCUTION HAZARD .......................................... 1
16 1266889GT DECAL, WARNING, EXPLOSION HAZARD ............................................ 1
17 1266923GT DECAL, LABEL, READ THE MANUAL .................................................. 1
18 1267102GT DECAL, DANGER, INHALATION HAZARD .. ........................................... 1
19 1267103GT DECAL, DANGER, ELECTROCUTION HAZARD ........................................ 1
20 1267104GT DECAL, LABEL, BATTERY/CHARGER SAFETY ........................................ 1
21 1268278GT DECAL, WARNING, AUTO-START HAZARD ........................................... 1
22 1286537GT DECAL, COSMETIC, GENIE LOGO, RL4, REAR DOOR ................................ 1
23 1286538GT DECAL, COSMETIC, GENIE LOGO, RL4 ............................................... 2
24 1286540GT DECAL, COSMETIC, TEREX LOGO, RL4, REAR DOOR ................................ 1
25 1286541GT DECAL, COSMETIC, TEREX LOGO, RL4 . .. ........................................... 2
Part No. 1287640GT
RL 4 LED Vertical Mast 1
T
200 Chassis Components
201.1 Chassis Components
October 2019
RL 4 LED Vertical Mast16
Part No. 1287640G
A
A
October 2019
7
200 Chassis Components
201.1 Chassis Components
Item Part No. Description Qty.
1 1271645GT SCREW .............................................................................. 4
2 1255760GT WASHER,FLAT,1/2,USS,ZAG ......................................................... 4
3 1289714GT KIT, REPLACEMENT, MAST, COMPLETE, RL4 ........................................ 1
4 995310GT SCREW,HHC,1/2-13 X 4 G . ........................................................... 4
5 1255760GT WASHER,FLAT,1/2,USS,ZAG ......................................................... 4
6 1264555GT WELDMENT, LIFT, RL4 ............................................................... 1
7 1284127GT
8 1264101GT SCREW,HHC,5/16-18X1,8,ZAG ........................................................ 2
9 825358GT WASHER,FLAT,5/16,USS,ZAG ........................................................ 2
10 1265317GT
11 1254805GT BOLT,U-BOLT,LATCH STRIKER,TRAY ................................................ 1
12 825358GT WASHER,FLAT,5/16,USS,ZAG ........................................................ 2
13 1255804GT NUT,JAM,1/2-13,A,ZAG ............................................................... 2
14 1264101GT SCREW,HHC,5/16-18X1,8,ZAG ........................................................ 2
15 825358GT WASHER,FLAT,5/16,USS,ZAG ........................................................ 2
16 790965GT PIN,PLUNGER,OUTRIGGER, KIT
16B- 1284486GT PIN, POP, 1.5IN BARREL
17 RELEASE, OUTRIGGER .............................................................. 1
18 PIN, COTTER ......................................................................... 1
19 WASHER ............................................................................. 1
SSY,RECPT BOX,RL4 ............................................................... 1
SSEMBLY, LATCH, U-BOLT, RL4 . ................................................... 1
.............................................. 1
kit includes items 17-20; to SN RL4J-6144
..............................................................
from SN RL4J-6145
20 SPRING .............................................................................. 1
21 1283911GT WELDMENT,OR, REAR,RL4 W/PLATE ................................................ 2
22 1280323GT JACK,EAGLE,PN CGEQ20-ASM, 1200 LBS ............................................ 3
22- 1283137GT KIT,HANDLE,JACK,RL
22- 1283138GT KIT,LOCK PIN,JACK,RL
23 993245GT NUT, WING .. ......................................................................... 1
24 1271665GT WASHER ............................................................................. 1
25 1264517GT PLATE, SHACKLE, AXLE, RL4 ........................................................ 4
Part No. 1287640GT
for 1280323 Jack Assembly
for 1280323 Jack Assembly
RL 4 LED Vertical Mast 1
............................................................ 1
............................................................ 1
T
200 Chassis Components
201.1 Chassis Components
October 2019
RL 4 LED Vertical Mast18
Part No. 1287640G
6
6
0
A
A
A
A
A
October 2019
200 Chassis Components
201.1 Chassis Components
Item Part No. Description Qty.
26 1264511GT BOLT, SHACKLE, RL4 ................................................................
27 1264512GT NUT, FLANGE, SHACKLE, RL4 ........................................................
28 116021GT WHEEL/TIRE ASSY,13",175/80 LRB ................................................... 2
29 840376GT NUT,WHEEL, 1/2 X 20 ................................................................. 1
30 1264508GT
31 1266197GT BOLT, SHOULDER, DIA .75 X 6.0 . .. ................................................... 1
32 1255761GT WASHER,FLAT,3/4,USS,HRD,ZAG .................................................... 2
33 1258049GT NUT,TL,5/8-11,C,ZAG ................................................................. 1
34 1265729GT CHASSIS, KICKSTEP, WELDMENT, ................................................... 1
35 1267867GT
36 1266256GT WELDMENT, BRACKET, RECEIVER, D ................................................ 1
37 1256844GT SCREW,HHC,1/2-13X1.5,8,ZAG ....................................................... 2
38 1255760GT WASHER,FLAT,1/2,USS,ZAG ......................................................... 2
39 1261639GT WELDMENT: DRAWBAR: RL4 ......................................................... 1
40 57332GT COUPLER,BALL,2" CLASS II .......................................................... 1
41 995310GT SCREW,HHC,1/2-13 X 4 G . ........................................................... 2
42 990200GT NUT,NYLOCK,1/2-13 GR2 .. .......................................................... 2
43 1266144GT BOLT, SHOULDER DIA .75 X 4.0 L .................................................... 1
SSEMBLY, AXLE, RL4 ............................................................... 1
SSEMBLY, PIN AND CLIP, 1/2" X 6-1/2" .. ............................................ 1
44 1255761GT WASHER,FLAT,3/4,USS,HRD,ZAG .................................................... 2
45 1258049GT NUT,TL,5/8-11,C,ZAG ................................................................. 1
46 1267868GT
47 1263088GT WELDMENT, CHASSIS, RL4
47B 1278511GT WELDMENT, CHASSIS, RL4
47B 1288151GT
47B 1288152GT
47B 36456GT SPRING CLIP,5/16-18,.025-.15X.
48 162160GT CHAIN, SAFETY, SNAP HOOK ........................................................ 2
48B 1297928GT SCREW,HHF,3/8-16X4.5,8,ZAG ....................................................... 1
Part No. 1287640GT
SSEMBLY, PIN AND CLIP, 3/4" X 4-3/4" .. ............................................ 1
to SN RL4LJ-292 (includes deck)
from SN RL4LJ-293
SSEMBLY, SKIN, FRONT, RL4
from SN RL4LJ-293
SSEMBLY, SKIN, REAR, RL4
from SN RL4LJ-293
for 1288151, 1288152
....................................................... 1
..........................................................
.......................................................
........................................................
......................................................
RL 4 LED Vertical Mast 19
T
200 Chassis Components
201.1 Chassis Components
October 2019
RL 4 LED Vertical Mast20
Part No. 1287640G
October 2019
200 Chassis Components
201.1 Chassis Components
Item Part No. Description Qty.
48B 61975GT RETAINER,SPRING,1.21 X .375 ....................................................... 2
48B 6097GT WASHER,FLAT,USS,3/8",Y ............................................................ 2
48B 1274322GT NUT,NYLOCK FLG,3/8-16,G,ZAG .. .................................................... 1
49 Ref., WINCH
refer to 507.1
..........................................................................
Part No. 1287640GT
RL 4 LED Vertical Mast 21
T
200 Chassis Components
202.1 Fuel Tank and Hoses
October 2019
RL 4 LED Vertical Mast22
Part No. 1287640G
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