Home

RL4 Vertical Mast (PN 1266665)

1. oo S falojn NN as S N Io o o A 2lolo 157 214 210 285 420 570 56 762 583 791 778 1055 682 925 1233 Genie Part No 1266665 RL4 Vertical Mast 5 August 2015 V Specifications This page intentionally left blank Genie 6 RL4 Vertical Mast Part No 1266665 August 2015 Service Manual 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 A WARNING Failure to perform each procedure as presented and scheduled may cause death serious injury or substantial damage 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 WN AW Machines that have been out of service for a period longer than 3 months must complete the quarterly inspection Genie Machine Configuration Unless otherwise specified perfor
2. Daily or every 8 hours A D 3 Coupler Quarterly or every 250 hours Semi annually or A B C every 500 hours Annually or A B C D every 1000 hours Two yearor A B C D E every 2000 hours e Place a check in the appropriate box after each inspection procedure is completed e Use the step by step procedures in this section to learn how to perform these inspections If any inspection receives tag and remove the machine from service repair and re inspect it After repair place a check in the R box Legend Y yes acceptable no remove from service R repaired Genie 12 RL4 Vertical Mast Part No 1266665 August 2015 Service Manual 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 operators 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
3. 83 RL4 DC Control Box Timed Oil Switch 84 RL4 DC Control Box Low Fuel Shut Down 85 RL4 DC Control Box Low Fuel Shut Down 86 RL4 Running Lights Front Fairing 87 RL4 Running Lights Front Fairing 88 RL4 Running Lights Rear Fairing 89 RL4 Running Lights Rear Fairing 90 RL4 Electrical Winch Option 1 uu uusha adii 91 RL4 Electrical Winch Option 92 Genie RL4 Vertical Mast Part No 1266665 August 2015 Service Manual Machine Specifications Specifications Generator Options Total lighting wattage 4 x 1000 watts Coliseum 6 kW 1CBCO06 TX Fuel capacities Generator rpm full load 60Hz 1800 rpm Single tank 45 gallons Temperature ambient maximum 104 F 170 liters 40 C Tires and wheels Power 6 kW Tire size ST175 80D13 Coliseum 7 kW 1CBC07 TX Load range C Generator rpm Q full load 60 Hz 1800 rpm Lug nut torque dry 90 ft lbs Temperature ambient maximum 104 F 122 Nm 40 C Lug nut torque lubricated 67 5 ft lbs Power 7 kW 91 5 Nm Performance Specifications Tongue weight maximum With fuel 45 gallon tank 203 16 92 kg Run time 45 g
4. 240V 30 AMP RECEPTACLE WHITE 12 AWG GREEN TO GROUND 12 AWG WHI J5 ON TG350 D A PHASE B PHASE p NEUTRAL DYNAGEN GRN BLACK 120 BLK TRANSFORMER 1000W METAL c1 COM HALIDE BALLAST 24 MF m 480V s 5 gt gt WHITE gt RED 120V RED TRANSFORMER COM 1000W METAL c1 HALIDE BALLAST 24 MF 480V WHITE gt TRANSFORMER 1000W METAL BROWN 12 HALIDE BALLAST 1 T C1 24 480V WHITE 120V 20AMP TRANSFORMER lt GFI PROTECTED 1000W METAL BLUE 120V HALIDE BALLAST C1 COM 24 MF 480V 74 LIGHT CONNECTION JUNCTION BOX HIGH TEMPERATURE ZONE ALL WIRING AND COMPONENTS MUST MEET MIN TEMP PROTECTION OF 1500 DEGREES CELSIUS August 2015 Service Manual RL4 DC Control Box Wiring Standard 75 August 2015 RL4 DC CONTROL BOX STANDARD ALTERNATOR m m FAILURE GE LIGHT YEL 10 AWG YEL 10 AWG PREHEAT RELAY 12V PUSH BUTTON SPST V py BBN Lo P1 RED 1 e 3 WHT 4 P AWG y 7 8 O 9 O O O O WHT 12 AWG m zx RED 10 AWG HOUR METER BLK 1 12V DC OPERATION N August 2015 Service Manual RL4 DC Control Box Wiring DynaGe
5. 49 2 3 How to Replace the Mast Lift 51 2 4 How to Remove the Manual Winoh essen 52 2 5 How to Remove the Electric Winch 53 Kohler KDW1003 Engine nnn nnne J J nnn 54 3 1 Timing Adjustment Kohler 54 3 2 Glow Plugs Kohler Engines 54 3 3 Coolant Temperature and Oil Pressure Switches Kohler Engines 54 Kubota D1105 E Engine J eene u u nnn nnns 55 4 1 Timing Adjustment Kubota Engines 55 4 2 Glow Plugs Kubota Engines L 55 4 3 Coolant Temperature and Oil Pressure Switches Kubota Engines 55 Generator sce RE 56 Cerco 56 5 2 How to Check a Generator Capacitor sess 57 5 3 How to Check a Generator 20 004 0 0 00 0 57 Light Ballas boneeo Een 59 6 1 Ground 59 6 2 Light Ballast titt tre io re 60 Fuel 61 FA 61 Genie Part No 1266665 RL4 Vertical Mast ix August 2015
6. RL4 DC Engine Components Kubota 81 Service Manual August 2015 RL4 DC ENGINE COMPONENTS KUBOTA 12VDC OPERATION BLK RED 12 VOLT STARTER 12 fe TELEMATICS GLOW PLUGS TELEMATICS PIN CKT TEL BAT TEL GND BK TEL SIG BRN PLUG PLUG REMOTE ENABLE LT BLU PLUG PLUG BRN FUEL PUMP HARNESS PART NUMBER 116820 82 FUEL SOLENOID LOW OIL PRESSURE NC ORG BLK HIGH COOLANT TEMPERATURE NO August 2015 Service Manual RL4 DC Control Box Timed Oil Switch 83 Service Manual August 2015 4 DC CONTROL BOX TIMED OIL SWITCH ALTERNATOR YEL 10 AWG FAILURE GEN YEL 10 AWG PREHEAT LIGHT RELAY 12V PUSH BUTTON YEL 100K uf 16VDC CAPACITOR WHT 12 AWG RED 10 AWG 12VDC OPERATION 84 August 2015 Service Manual RL4 DC Control Box Low Fuel Shut Down 85 August 2015 4 DC CONTROL BOX LOW FUEL SHUT DOWN ALTERNATOR FAILURE GRN YEL 10 AWG YEL 10 AWG PREHEAT RELAY 12V PUSH BUTTON LIGHT 100K uf 16VDC CAPACITOR LOW FUEL WARNING TO LOW FUEL CUT OFF YEL FUEL LEVEL SWITCH REED SWITCH RED 10 AWG 12VDC OPERATION 86
7. Inspection Checklist Daily or every 8 hours A Quarterly or every 250 hours 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 Genie RL4 Vertical Mast 9 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 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 Genie A TEREX BRA
8. a _ o 5 JO 4 zs to t j Ny a alo Ajo 2l lola alw alo S se o JA colo a a alele Ls alo NI T No sale eio gt mi gt N D N A W m 2 lt W m 2 lt 2 lt gt 2 lt gt w oo z 5 o gjoja ajo o o co o to co AER on co o N N N N O o AJN co gt hare eo eo o gt N 5 N un N w N o 5 T N _ 1o to NI Os 4 m alni I COINS ojo N a a o A N N o N a N N N PILIS gt ojo ala lol 4 co halo lol o mlo mv 5 o gt o 411 9 Aon olo e o N AJOJN RISIN SEIS Ni 6o oo jojn S N jojn sN ol 5 gt
9. LUBED DRY LUBED LUBED in Ibs Nm 1 4 in Ibs Nm in Ibs Nm in Ibs Nm in lbs _ 5 10 1 120 120 13 5 15 8 LUBED DRY LUBED LUBED Nm ftis Nm ftis Nm 24 13 44 23 26 37 41 57 64 17 6 19 31 2 35 2 50 1 55 5 77 3 86 7 108 4 122 149 176 271 298 433 474 650 718 800 908 1138 1260 17 19 31 35 49 55 75 85 110 120 150 170 270 300 430 470 640 710 790 890 1120 1240 23 25 7 42 47 4 66 4 74 5 101 6 115 149 162 203 230 366 406 583 637 867 962 1071 1206 1518 1681 100 110 124 14 7 5 16 24 25 339 21 284 813 80 1084 68 921 120 130 160 180 280 310 450 500 680 750 1016 990 1342 840 1139 970 1080 7 7 1360 4 1510 1460 1979 1950 2643 2370 2670 2 1640 2223 2190 2969 2670 3000 FASTENER TORQUE CHART This chart is to be used as a guide only unless noted elsewhere in this manual 96 DRY 18 20 33 37 716 50 9 16 1 I 110 130 200 220 320 350 480 530 590 670 840 930 2 228 18 24 48 24 14 20 43 20 12 18 141 18 140 16 9 14 8 412 412 7 412 6 12 Q o o gt m 2 lt 0 2 lt i c m z B Uu m aje D gt o Q q EN o orn
10. August 2015 Service Manual RL4 Running Lights Front Fairing Section 87 Service Manual August 2015 1 pmess DEUTSCH CONNECTOR PLUG SPN Lt L3 wss DEUTScHCONNECTOR WEDGES o4e2 204 16 DEUTSCH CONNEGTOR socer 3 4 rne BLACK PLASTIC WIRE LooMWSLIT a5 s escue NEW RL4 RUNNING LIGHTS 5 press DEUTSCH CONNECTOR REGEPTAGLESPN 1 FRONT SECTION we 1_ s 026 DEUTSCHCONNECTOR PN 9 d 1 4 MALE NYLON INSULATED TERMINAL 10 7 46 14 1 4 RING NYLON INSULATED TERMINAL E 1 WIRE 18 GA WHITE WIRE 18 GA GREEN BROWN 14 2 18 GA YELLOW BROWN 15 18 GA YELLOW 16 TIE WRAP EE 4 WAY FLAT TAILER END CONNECTOR POSITION COLOR 4 WHITE 3 YLLW BRN 3 YLLW 2 GRN BRN 1 POSITION A WE e 6 WELGRN SOLDERED JOINT 18 AWG WHITE 18 AWG YELLOW BRN 18 AWG YELLOW 18 AWG GREEN BRN 18 AWG GREEN Millas 88 August 2015 Service Manual RL4 Running Lights Rear Fairing Section 89 August 2015 press DEUTSCH CONNECTOR PLUG sem 2 was pewrscecowecronwenge Ta 0462 201 16 DEUTSCH CONNECTOR SOCKET Cee
11. Genie 70 RL4 Vertical Mast Part No 1266665 August 2015 Service Manual RL4 Control Box AC Voltage Wiring Standard 71 August 2015 240 VAC FROM GENERATOR U1 DC CONTROL BOX VOLTAGE WIRING STANDARD MAIN BREAKER KOHLER GENSET CAPACITOR NEUTRAL BONDED TO GROUND 12 AWG GREEN 12 AWG WHITE GRN BLACK 120V BLK TRANSFORMER COM 1000W METAL HALIDE BALLAST M2Vv 18 ZL RED 120V TRANSFORMER 1000W METAL HALIDE BALLAST LIGHT CONNECTION JUNCTION BOX TRANSFORMER 1000W METAL HALIDE BALLAST HIGH TEMPERATURE ZONE ALL WIRING AND COMPONENTS MUST MEET MIN TEMP PROTECTION OF 1500 DEGREES CELSIUS BROWN 120V 120 20 GFI PROTECTED RECEPTACLES TRANSFORMER 1000W METAL HALIDE BALLAST 20AMP BREAKER 480V WHITE 240V 30 AMP RECEPTACLE 72 August 2015 Service Manual RL4 Control Box AC Voltage Wiring Autostart 73 Service Manual August 2015 RL4 DC CONTROL BOX AC VOLTAGE WIRING AUTOSTART MAIN BREAKER RELAY A 12VDC DYNAGEN CONTROLLED U1 240 VAC FROM GENERATOR V2 GENSET CAPACITOR NEUTRAL BONDED 18 5 14 1 CORD 4 0
12. 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 Besure 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 Part No 1266665 Genie RL4 Vertical Mast 25 Checklist B Procedures 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 Puton 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
13. Radiator or cooling system clogged or corroded Inspect and repair as needed 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 Unsuitable fuel used Crankcase oil level is too high Tighten or replace fan belt Drain fuel system and replace with specified fuel Drain oil to the proper level Low compression Inspect for broken seized piston rings or inspect valve clearance Injector nozzle faulty Replace injector Combustion incomplete due to faulty timing Inspect and repair as needed poor valve adjustment or poor compression Genie Part No 1266665 RL4 Vertical Mast 63 Service Manual August 2015 Diagnostics Problem Engine runs rough Engine turns over but will not start or is difficult to start Possible Cause Air or contaminated fuel in fuel system Solution Inspect and repair as needed Clogged or leaking fuel system Clogged exhaust system Clogged air filter Replace fuel lines tighten all connections inspect the fuel pickup tube and inspect the fuel filter Inspect and repair as needed Inspect and repair or replace as needed Clogged or stuck fuel injectors Inspect and repair as needed Faulty governor or fuel pump Empty fuel tank Inspect and repair as needed Add fuel to tank
14. T gt 7 DEUTSCH CONNECTOR REGEFTACLESAIN 1 7 w3p 7 DEUTSCH CONNECTOR WEDGE 0460 202 16 DEUTSCH CONNECTOR PIN RUE 9 1 4 MALE NYLON INSULATED TERMINAL 10 16 14 1 4 RING NYLON INSULATED TERMINAL WIRE 18 GA WHITE pw 777 WRESGAYELOWBRONN Q WE E NEW RL4 RUNNING LIGHTS REAR SECTION 18 AWG WHITE 18 AWG YELLOWIBRN 18 AWG YELLOW d 18 AWG WHITE 18 AWG GREEN BRN gt 18 AWG GREEN y SOLDERED JOINT 4 a r B GREEN a Z Z NN 90 August 2015 Service Manual RL4 Electrical Winch Option Wiring 91 Service Manual August 2015 4 ELECTRICAL WINCH OPTION WIRING RL4 CON CONTROL B BOX WINCH CONTROL SWITCH RED 14 AWG pem SPDT MOMENTARY CENTER RETURN 12V SUPPLY KEY SWITCH BAT SUPERWINCH COMPONENTS 12VDC FWDIRVS WINCH CONTACTOR 12VDC WINCH MOTOR FWD 2 HARNESS 1267114 aiie YELLOW C RED RED HEAT SHRINK CURRENT LIMIT BLACK 12V BATTERY 92 August 2015 Service Manual This page intentionally left blank Genie Part No 1266665 RL4 Vertical Mast 93 Genie Sweden Phone 0046 3157 5101 Fax 0046 3157 5104 Genie France Phone 003
15. 39 D 1 Perform Engine 39 D 2 Perform Generator 40 D 3 Perform Coupler Maintenance 4 nennen 40 Checklist E 41 E 1 Inspect the Cable and Cable 2 41 E 2 Perform Engine 42 E 3 Perform Engine 43 4 Perform Generator Maintenance 43 E 5 Perform Generator 2 4 422 0 0 44 E 6 Perform Generator Maintenancoe 0 44 Section 4 Repair Procedures J J J u l J J J J 45 DRE 45 E u E shasqa qasaq sss au usq 47 1 1 How to Remove ullu l 47 1 2 How to Check Line Voltage 0000 47 1 3 How to Check the Open Circuit 2 48 Genie viii RL4 Vertical Mast Part No 1266665 August 2015 ssmaOOop rr Table of Contents Malu S 49 2 1 How to Remove the Mast 49 2 2 How to Disassemble the Mast
16. Kubota D 1105 and V 1505 Operator s Manual Checklist A Procedures A 15 Perform Engine Maintenance Engine specifications require that this procedure be performed every 200 hours e Change engine oil e Replace oil filter e Inspect radiator hoses and clamps e 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 OR the Kohler KDW1003 Engine Owner s Manual Kohler part number 0053028440 Kohler KDW1003 Engine Owner s Manual Genie part number 1268769 Genie part number 893020 Kubota D 1105 and V 1505 Operator s Manual Genie part number 893020 Genie Part No 1266665 RL4 Vertical Mast 21 August 2015 Checklist Procedures A 16 A 17 Perform Generator Maintenance Drain the Fuel Filter Water Separator Generator specifications require that this procedure be performed every 200 hours or quarterly whichever comes first Clean and inspect the generator exterior e Check for loose or damaged wires and components A WARNING Electrocution burn hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry Coliseum Manual Genie part number 1268770 a generator Genie 22 RL4 Vertical Mast Terex specifications require that this
17. Leaking or pinched fuel lines Inspect and repair as needed Clogged fuel filter Replace filter Air or water mixed in fuel 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 Fuel injection nozzle clogged Inspect and repair as needed Fuel injection pump faulty Fuel solenoid valve faulty Faulty glow plug Faulty relay or wiring connection in control box Battery is discharged or low Inspect and repair as needed Inspect and repair as needed Inspect and repair as needed Inspect and repair as needed Charge or replace battery Air cleaner is dirty Clean or replace more frequently 64 Genie RL4 Vertical Mast Part No 1266665 August 2015 Problem Engine battery quickly discharged Engine runs but battery voltage is low Engine runs but lights will not operate Lamp light output low Light heads are flashing on off Light head will not illuminate Unusual noise from the generator Possible Cause Battery electrolyte low Service Manual Diagnostics Solution Add distilled water and charge Fan belt slips Inspect and repair as needed Wiring loose or disconnected Inspect and repair as needed Faulty alternator rectifier or diode Inspect and repair as needed Faulty battery Faulty alternator Circuit breaker has t
18. 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 Placealifting 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 Genie 24 RL4 Vertical Mast 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 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 6 Move the tip of the adjuster too
19. On the timer move the mode switch upper left switch to AUTO and the set switch upper right switch to RUN 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 Move the set switch to the left clock icon to set the present day and time A default time of AM 12 00 will appear on the display screen Press the day button 1 7 repeatedly until the arrow points to the actual day of the week Press the hour button h repeatedly until the actual hour of the day is displayed Press the minute button m repeatedly until the minute of the present hour is displayed Part No 1266665 10 11 Service Manual Light Ballast Move the Set switch to the program position 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 Use the day hour and minute buttons to set the timer to the desired start day and time 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 13 Genie RL4 Vertical Mast 59 Use the day hour and minute buttons to set the timer to the desired shut off day and time Move the set switch to RUN Service Manual August 2015 Light Ballas
20. Vertical Mast Part No 1266665 August 2015 Service Manual Mast 4 Pullthe cable to unwind it from the winch 2 5 How to Remove the Electric Winch drum 1 the mast assembly to the stowed 5 Loosen the set screw securing the cable position 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 2 Remove the fasteners and winch covers from the 4 inch 10 cm mast assembly and set aside Refer to the illustration below 3 Onthe electric winch turn the yellow cap to 6 Remove the fasteners securing the electric the free spool position winch to the 4 inch 10 cm mast assembly CAUTION Bodily injury hazard Cables can fray Always wear adequate hand protection when handling the cable a winch covers b electric winch c engaged free spool lock d 4 inch 10 cm mast assembly Genie Part No 1266665 RL4 Vertical Mast 53 Service Manual August 2015 Kohler KDW1003 Engine 3 1 Timing Adjustment Kohler Engines Complete information to perform this procedure is available in the Kohler KDW 702 1003 1404 Workshop Manual Kohler part number 00053029340 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 Connectthe leads from
21. 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 Genie 30 RL4 Vertical Mast 12 Fully loosen the castle nut Do not rotate the hub 13 Finger tighten the castle nut until snug 14 Install a new cotter pin Bend the cotter 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
22. a person trained and qualified on the repair of this machine V Immediately tag and remove from service a About This Section There are two groups of schematics in this section Electrical Schematics Electrocution burn hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry damaged or malfunctioning machine Hydraulic Schematics Repair any machine damage or malfunction A WARNING 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 Genie 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 68 RL4 Vertical Mast Part No 1266665 August 2015 Service Manual 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 Genie Part No 1266665 RL4 Vertical Mast 69 Service Manual August 2015 Wire Color Legend This page intentionally left blank
23. 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 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 19 Move the tip of the adjuster tool ina downwards direction 3 to 5 clicks to loosen the brakes only until the wheel spins freely with little drag Part No 1266665 August 2015 Service Manual 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 gt 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 Liftthe 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 Part No 1266665 Genie RL4 Vert
24. an ohmmeter between each glow plug terminal and ground 9 Result The resistance should be approximately 1 ohm Result The resistance is 0 ohm or greater than 1 ohm The glow plug is faulty Genie 54 RL4 Vertical Mast 3 3 Coolant Temperature and Oil Pressure Switches Kohler Engines 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 August 2015 Service Manual 4 1 Timing Adjustment 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
25. be performed every 8 hours or daily whichever comes first e Engine oil level check e Coolant level check add Fuel system filter water separator drain e Engine tightness check for leaks e Exhaust system check for leaks e 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 OR the Kohler KDW1003 Engine Owner s Manual Kohler part number 0053028440 Kohler KDW1003 Engine Owner s Manual Genie part number 1268769 Kubota D 1105 and V 1505 Operator s Manual Checklist A Procedures 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 poc
26. glow plug terminal and ground Result The resistance should be approximately 1 ohm mi Result The resistance is 0 ohm or greater than 1 ohm The glow plug is faulty Part No 1266665 Genie RL4 Vertical Mast 55 Kubota D1105 E Engine 4 3 Coolant Temperature and Oil Pressure Switches Kubota Engines 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 Service Manual August 2015 Generator 5 1 Generator ADANGER High voltage Exposure to A DANGER 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 discharg
27. 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 AWARNING Bodily injury hazard An over inflated tire can explode and could cause death or serious injury AWARNING hazard Do not use temporary flat tire repair products 1 Check tire surface and sidewalls for cuts cracks punctures and unusual wear 2 Check each wheel for damage bends and cracks 3 Check the pressure in each air filled tire Refer to Specifications Machine Specifications Part No 1266665 Genie RL4 Vertical Mast 17 Checklist A Procedures A 9 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 clamp 2 cannister end cap 3 dust discharge valve Service Manual August 2015 Checklist A Procedures 2
28. lift the rear fairing assembly off the 13 Pull the generator away from the engine just unit and set aside enough to reach the fasteners securing the enerator rotor to the engine flywheel 6 p the left side cabinet weldment and 2 the fasteners 9 y 14 Remove the generator from the machine CAUTION Crushing hazard The generator may become unbalanced and fall if not properly supported when removed from the machine Genie 56 RL4 Vertical Mast Part No 1266665 August 2015 Service Manual 5 2 How to Check a Generator Capacitor 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 A 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 capacito
29. serious injury Turn off all power when not needed for testing Use extreme caution when working with high voltage electrical components ADANGER 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 9 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 amp 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 e Normal end of life failure e Overheated due to light fixture heat or high ambient temperature Incorrect capacitor voltage rating Capacitor becomes loose in ballast box Part No 1266665 August 2015 Service Manual 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 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 f
30. then dry with a soft cloth Genie 34 RL4 Vertical Mast 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 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 Part No 1266665 August 2015 E 10 11 Remove the castle nut and washer Pull the hub off of the spindle The washer and outer bearing should fall loose from the hub Place the hub on a flat surface and gently pry the bearing seal out of the hub Remove the rear bearing Pack both
31. 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 Service Manual August 2015 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 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 a specific gravity of 1 277 or greater The battery is fully charged Proceed to step 11 Result One or more battery cells display 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 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 Genie 26
32. 3 237 260 986 Fax 0033 237 260 998 Genie Iberica Phone 0034 900 808 110 Fax 0034 935 725 080 Genie Germany Phone 0800 180 9017 Phone 0049 4221 491 810 Fax 0049 4221 491 820 Genie North America Phone 425 881 1800 Toll Free USA and Canada 800 536 1800 Fax 425 883 3475 Genie Australia Pty Ltd Phone 61 7 3375 1660 Fax 61 7 3375 1002 Genie China Phone 86 21 53853768 Fax 86 21 53852569 Genie Singapore Phone 65 67533544 65 67533544 Genie Japan Phone 81 3 6436 2020 81 3 5445 1231 Genie Korea Phone 82 2 558 7267 Fax 82 2 558 3910 Genie U K Phone 0044 1476 584 333 Fax 0044 1476 584 330 Genie Brasil Phone 55 11 4082 5600 Fax 55 22 4082 5630 Genie Mexico City Phone 52 55 5666 5242 52 55 5666 3241 Genie Holland Phone 31 183 581 102 Fax 31 183 581 566 California Proposition 65 Warning The exhaust from this product contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm
33. EO ee Table of Contents Section 5 Section 6 DBIERLDOrjlcp 62 ror 2 E 62 ric e 68 au u M 68 Wire Color Legend n nnne nnne en 69 RL4 Control AC Voltage Wiring 71 RL4 Control AC Voltage Wiring 72 RL4 Control AC Voltage Wiring Autostart 738 RL4 Control Box AC Voltage Wiring Autostart 74 RL4 DC Control Box Standard nens 75 RL4 DC Control Box Standard 76 RL4 DC Engine Components DynaGen 77 RL4 DC Engine Components DynaGen 78 RL4 DC Engine Components 2 2 4 44 79 RL4 DC Engine Components 2 4 4 4 4 80 RL4 DC Engine Components 81 RL4 DC Engine Components Kubota 82 RL4 DC Control Box Timed Oil Switch
34. Iu rr i Table of Contents Checklist A Procedures 13 A 1 Inspect the Manuals and 13 A 2 Perform Pre operation 14 Perform Function Tests rete e e iba f eni 14 4 Perform Engine 2 15 5 Perform Coupler 0022 0 15 A 6 Test the Brakes if 16 A 7 Torque the Wheel Lug 16 A 8 Check the Tires and 17 A 9 Inspect the Engine Air 17 A 10 Perform Generator 2 4 0 0 10 0 18 A 11 Perform Engine 19 A 12 Perform Engine 19 A 13 Inspect the Cable and Cable 20 A 14 Perform Engine 21 A 15 Perform Engine 21 A 16 Perform Generator Maintenance 2 22 A 17 Drain the Fuel Filter Water 2 22 A 18 Adjust the Brakes 24 Checklist B Procedures l u u u u u 25 B 1 Inspect the Engin
35. 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 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 36 Genie RL4 Vertical Mast With the engine running press down on the brake pedal and use a multimeter to measure the total amp draw of the b
36. ND Genie UK The Maltings Wharf Road Grantham Lincolnshire NG31 6BH England 44 1476 584333 Terex South Dakota Inc USA 500 Oak Wood Road PO Box 1150 Watertown SD 57201 6150 605 882 4000 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 no remove from service repaired Comments Pre delivery Preparation Y N R 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 August 2015 Service Manual Maintenance Inspection Report Model Checklist A N Checklist B R A 1 Inspect the manuals B 1 Batteries Serial number and decals B 2 El
37. RL4 Vertical Mast B 2 Inspect the Electrical Wiring 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 Electrocution burn hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry AWARNING 1 Inspect the following areas for burnt chafed corroded pinched and loose wires e Ground controls e Battery e Engine e Mast e Lighting junction box e Trailer lighting wire harness 2 Inspectfor a liberal coating of dielectric grease in the following locations Lighting junction box Ground controls e All wire harness connectors Part No 1266665 August 2015 Service Manual 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 Checklist B Procedures B 4 Perform Engine Maint
38. Release the latches on the air cleaner cap Remove the end cap from the air cleaner canister Remove the filter element 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 A 10 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 Genie 18 RL4 Vertical Mast Part No 1266665 August 2015 Service Manual A 11 Perform Engine Maintenance 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 OR the Kohler KDW1003 Engine Owner s Manual Kohler part number 0053028440 Kohler KDW1003 Engine Owner s Manual Checklist A Procedures A 12 Perform Engine Maintenance Engine specifications require that this procedure be perf
39. allon tank 110 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 Part No 1266665 Genie RL4 Vertical Mast 1 Coliseum 8 kW 1CBC08 TX Generator rpm full load 60 Hz 1800 rom Temperature ambient maximum 104 F 40 C 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 Service Manual August 2015 Specifications Kohler KDW1003 Engine Displacement 62 7 cu in 1 3 liters Number of cylinders 3 Bore and Stroke 2 95 x 3 1 inches 75 x 77 6 mm Horsepower 26 1 3600 19 5 kW Firing order 1 2 3 Compression ratio 22 8 1 Compression pressure 412 to 469 psi 28 4 to 32 3 bar Engine speed Governor Valve Clearance cold Engine coolant Capacity Lubrication system Oil pressure Oil capacity including filter Oil pressure switch engine shutoff pressure 7 psi viscosity requirements Unit ships with 10W 30 Extreme operating temperatures may require the use of alternative engine oils For oil requirements refer to the Engine Operator Manual for your engine Injection system Injection pum
40. anual 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 Part No 1266665 August 2015 Service Manual E 3 Perform Engine Maintenance Engine specifications require that this procedure be performed every 3000 hours e Inspect injection pump e 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 OR the Kohler KDW1003 Engine Owner s Manual Kohler part number 0053028440 Kohler KDW1003 Engine Owner s Manual Checklist E Procedures 4 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 e Replace the generator shaft bearing Consult a trained Coliseum service professional Coliseum Manual Genie part number 1268769 Genie pam number 1208770 Kubota 0 1105 and V 1505 Operator s Manual Genie part number 893020 Genie Part No 1266665 RL4 Vertical Mast 43 Service Manual August 2015 Checklist E Procedures E 5 Perform Generator Maintenance Generator specifications require that th
41. ast or wiring Genie 48 RL4 Vertical Mast Part No 1266665 August 2015 Service Manual UE 2 1 How to Remove the Mast Assembly Mast 2 2 How to Disassemble the Mast Assembly ilv ini 1 Remove the mast assembly See 1 1 How to IN Bodily injury hazard The A WARNING procedures in this section Remove the Mast Assembly require specific repalr skills Remove the T bolt from the mast base lifting equipment and a suitable assembly workshop Attempting this procedure without these skills 3 Remove the nut from the bottom of the mast and tools could result in death or base Remove the mast base assembly from serious injury and significant the 4 inch mast section component damage Dealer ue service is required CAUTION Bodily injury hazard Cables can fray Always wear adequate ilv ini hand protection when handling Bodily injury hazard Cables CAUTION can fray Always wear adequate the cable Anen banding Component damage hazard Cables be damaged if they Tag and remove the light heads from the mast are kinked or pinched Remove the junction box from the light bar 4 Remove the light bar assembly and hardware Remove and retain the coil cord clamp and from the 1 5 inch 3 8 cm mast section and set hardware from the base section of the mast aside Remove the 1 5 inch 3 8 cm mast Lay the coil cord junction box and lamp heads section from the 2 inch 5 cm mast section to the side Disconne
42. azard 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 Service Manual August 2015 Diagnostics 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 e Machine parked on a firm level surface e 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 Before Troubleshooting A WARNING 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 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 Electrocution burn hazard Contact with electrically charged circuits could r
43. 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 A personnel to potential personal 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 AWARNING Indicates a potentially hazardous situation which if not avoided could result in death or serious injury ndicates 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 Mi Indicates that an incorrect result has occurred after performing a series of steps Genie 46 RL4 Vertical Mast Part No 1266665 August 2015 Service Manual 1 1 How to Remove a Lamp A WARNING 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
44. bearings with clean fresh grease Inspect the hub for wear Replace if necessary Place the large inner bearing into the rear of the hub 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 13 Inspect the brake lining for wear if equipped Inspect the brake cylinder for leaks if equipped 17 18 19 20 21 22 Service Manual Checklist C Procedures 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 Place the outer bearing into the hub Install the washer and the castle nut Tighten the castle nut to 50 ft lbs 68 Nm to seat the bearings Fully loosen the castle nut Do not rotate the hub Finger tighten the castle nut until snug 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 14 Inspect the brake springs for wear or loss of Specifications arch if equipped 15 Inspect the brake wiring hoses for wear if equipped Genie Part No 1266665 RL4 Vertical Mast 35 Service Manual August 2015 Checklist C Procedures C 4 Inspect the Electric Brake
45. 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 Placea 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 Pullthe hub off of the spindle The washer and outer bearing should fall loose from the hub Service Manual August 2015 Checklist B Procedures N 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 gt 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
46. ct the cable from the 2 inch 5 cm Remove the fasteners securing the mast base m section by removing Ihe Tabie to the chassis pin Attach a lifting strap from an overhead crane Working top ofthe a mehi 79 em masi section use a drill to remove the rivets to the mast base beneath the rotating section sec rina the wear pads i BOSili n and T bolt Remove the mast from the 9 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 Genio Part No 1266665 RL4 Vertical Mast 49 August 2015 Mast 7 X 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
47. d 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 V You are trained and qualified to perform maintenance on this machine You read understand and obey e manufacturer s instructions and safety rules employer s safety rules and worksite regulations e applicable governmental regulations V You have the appropriate tools lifting equipment and a suitable workshop Genie iv RL4 Vertical Mast Part No 1266665 August 2015 Service Manual 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 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 A WARNING Indicates a potentially hazardous situation which if not avoided could result in death or serious injury CAUTION Indicates a potentially hazardous si
48. e Genie 28 RL4 Vertical Mast B 6 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 Part No 1266665 August 2015 Checklist Procedures B 7 B 8 Lubricate the T bolt Inspect and Adjust the Brakes if 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 Usingthe 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 oil residue from the threaded surfaces of the T bolt and apply a few drops of light oil or thread lubricant onto the threaded surfaces 3 Fully install the T bolt into the mast a T bolt Part No 1266665 Genie RL4 Vertical Mast 29 equipped Axle specifications require that this procedure be performed every 3000 miles or quarterly whichever
49. e ii RL4 Vertical Mast Contact Us Internet www genielift com E mail awp techpub Copyright 2015 by Terex Corporation 1266665 Rev A August 2015 First Edition First Printing and AWP are registered trademarks of Terex USA LLC in the U S A and many other countries Part No 1266665 August 2015 Service Manual Serial Number Legend TEREX MODEL RL4 SERIAL NUMBER RL4 15 105 MANUFACTURE DATE 07 14 15 MODEL YEAR 2015 ELECTRICAL SCHEMATIC NUMBER Es0528 MACHINE UNLADEN WEIGHT 1208 Ibs 548 kg AXLE WEIGHT 3500 Ibs 1588 kg TONGUE WEIGHT 100 Ibs 50 kg TIRE PRESSURE 50 psi 345 MAXIMUM TOW SPEED Position 50 KVA HZ 60 Hz KW VOLTS 48V RPM AMPS MAX AMBIENT TEMPERA TURE 104 F 40 C INSULATION SYSTEM Class F Country of manufacture USA Manufacturer Terex USA LLC 590 Huey Road PO Box 3147 Rock Hill SC 29732 USA Serial label 1 Model 2 Model year 3 Sequence number 4 Serial label located on cabinet 5 Serial number stamped on chassis ATEREX BRAND a Introduction RL4 15 1105 Model Sequence number Model year Serial number stamped on chassis Part No 1266665 RL4 Vertical Mast August 2015 Safety Rules Danger Failure to obey the instructions and safety rules in this manual an
50. e Start Battery 25 B 2 Inspect the Electrical 26 B 3 Torque the Wheel Lug eene 27 B 4 Perform Engine 27 B 5 Perform Jack 28 B 6 Inspect and Lubricate the 28 B 7 Lubricate the 29 B 8 Inspect and Adjust the Brakes if 29 B 9 Inspect the Suspension a 31 B 10 Perform Engine 32 Genie Part No 1266665 RL4 Vertical Mast vii August 2015 Table of Contents Checklist 1 33 C 1 Perform Engine 2 20 00 00 nennen 33 C 2 Clean the Light 34 Grease the Wheel Bearings 34 C 4 Inspect the Electric Brake Magnets 36 C 5 Perform Engine nennen 37 C 6 Perform Generator nene 38 Checklist D u uu u u u
51. e are 4 or more broken wires on any 2 or more strands The cable must immediately be replaced Genie Part No 1266665 RL4 Vertical Mast 41 Service Manual August 2015 Checklist E Procedures 5 Visually inspect the winch cable for the following e nicks partial strand cut through e kinks in the cable permanent bends e 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 e crushed spot on the cable Result A crushed spot on the cable measuring 12596 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 If the mast cables need replacing refer to Repair Procedure 1 1 How to Replace the Mast Lift Cables Genie 42 RL4 Vertical Mast E 2 Perform Engine Maintenance Engine specifications require that this procedure be performed every 2000 hours or bi annually whichever comes first e Replace coolant e Replace radiator hoses and clamps e Replace fuel hoses and clamps e 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 OR the Kohler KDW1003 Engine Owner s M
52. ectrical wiring A 2 Pre operation Date inspection B 3 Lug nuts A 3 Function tests B 4 Engine maintenance Hour meter Perform after 8 hours B 5 Jack A 4 Engine maintenance B 6 Winch Machine owner Perform before towing B 7 T bolt Inspected by print A 5 Coupler Perform every 3000 miles Inspector signature A 6 Brakes if equipped B 8 Brakes if equipped Inspector title Perform after 10 miles B 9 Suspension Inspector company A 7 Lug nuts Perform every 400 hours Perform weekly B 10 Engine maintenance Instructions A 8 Tires and wheels Make copies of this report to use for each inspection A 9 Engine air filter Comments Select the appropriate checklist s for A 10 Generator the type of inspection s to perform maintenance Daily or every 8 hours A A 11 Engine maintenance Quarterly or every Perform after 50 hours 250 hours Semi annually or A B C A 12 Engine maintenance every 500 hours Perform monthly Annually or A B C D A 13 Cables and pulleys every 1000 hours Perform every 100 hours 0 14 maintenance 2000 hours Perform every 200 hours Place a check in the appropriate box A 15 Engine maintenance after each inspection procedure is completed A 16 Generator maintenance Use the step by step procedures in this section to learn how to perform A 17 Fuel Water these inspections separator f any inspection receives an tag A 18 Brake
53. ed will result in death or serious injury 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 7 CAUTION 8 Remove the screws and washers securing the generator pedestal to the chassis Burn hazard Beware of hot engine components Contact with hot engine components may result in severe burns 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 Using an insulated conductor or a screwdriver with an insulated handle discharge the capacitor by shorting across the capacitor terminals ADANGER 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 2 Disconnect the rear fairing wiring harnesses located along side the roadside lift bar 10 Tag and disconnect all external wires from the generator 3 Disconnect the gas struts on the rear fairing assembly from the lift bar 11 Support the generator using the lifting eye 4 Remove the screws from the hinges attaching 12 Remove the fasteners securing the generator the rear fairing assembly to the lift bar to the engine bellhousing 5 Carefully
54. enance Engine specifications require that this procedure be performed every 250 hours or six months whichever comes first e 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 OR the Kohler KDW1003 Engine Owner s Manual Kohler part number 0053028440 Kohler KDW1003 Engine Owner s Manual Genie part number 1268769 Kubota D 1105 and V 1505 Operator s Manual Genie part number 893020 Genie Part No 1266665 RL4 Vertical Mast 27 Service Manual August 2015 Checklist B Procedures B 5 Perform Jack Maintenance Jack specifications require that this procedure be performed every 250 hours or quarterly whichever comes first Maintaining the jack is essential to good machine performance and safe operation An unsafe working condition exists if the jack has excessive wear and or does not operate smoothly free of hesitation and binding 1 Select a jack Remove the cover from the top of the jack Apply a small amount of automotive grease to the internal gearing and rotate the handle several times to evenly distribute the grease 4 Appl a few drops of light oil to the jack handle where it makes contact with the outside of the jack tube Securely install the cover onto the jack Repeat this procedure beginning with step 1 for the other jackson the machin
55. enance 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 No 1266665 Genie part number 1268769 Kubota D 1105 and V 1505 Operator s Manual Genie part number 893020 RL4 Vertical Mast 39 Service Manual August 2015 Checklist D Procedures 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 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 coupl
56. enie A TEREX BRAND RL4 Vertical Mast Part No 1266665 Rev A August 2015 Service Manual August 2015 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 Compliance Machine Classification Group A Type 1 as defined by ISO 16368 Machine Design Life Unrestricted with proper operation inspection and scheduled maintenance Geni
57. er welds and mounting bolt torque Torque the fasteners to 35 ft Ibs 48 Nm Result 1 5 full threads of the locking bolt must be exposed beyond the lock nut after the adjustment Coliseum Manual 2 Apply automotive grease to the coupler ball Genie part number 1268770 pocket 3 coupler pivot points using SAE 30 motor oil Genie 40 RL4 Vertical Mast Part No 1266665 August 2015 Service Manual 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 e broken or damaged pulleys e unusual or excessive pulley wear Result pulley is broken or damaged or shows unusual or excessive pulley wear The pulley must immediately be replaced Put on protective leather gloves and eye wear 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 e frayed or broken wire strands Result In any given one foot of cable length ther
58. ertical Mast Part No 1266665 August 2015 Service Manual Observe and Obey Repair procedures shall be completed by a person trained and qualified on the repair of this machine V 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 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 Genie RL4 Vertical Mast 45 Repair Procedures 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 e All external AC power supply disconnected from the machine August 2015 Eee Repair Procedures About This Section Most of the procedures in this section should only
59. esult 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 CAUTION Burn hazard Beware of hot e Wheels chocked engine components Contact with hot engine components Light switches in the off position may cause severe burns Use All external AC power supply disconnected caution when working around from the machine lamps or a hot engine Genie 62 RL4 Vertical Mast Part No 1266665 August 2015 Service Manual Problem Mast will not rise to the operating position Engine will not turn over Engine overheats Engine runs but produces a dense smoke Possible Cause Faulty cable or pulley Diagnostics Solution Inspect and repair as needed Faulty winch Inspect and repair as needed No power 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 Low coolant level 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 Radiator blocked Clear the radiator fins
60. ginning with step 6 for the other side of the machine Genie Part No 1266665 RL4 Vertical Mast 37 Service Manual August 2015 Checklist C Procedures C 6 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 e 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 38 RL4 Vertical Mast Genie Part No 1266665 August 2015 Service Manual Checklist D Procedures D 1 Perform Engine Maintenance Engine specifications require that this procedure be performed every 1500 hours or bi annually whichever comes first e Injectors Required maint
61. ical Mast 31 Checklist B Procedures B 9 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 Service Manual August 2015 Checklist B Procedures B 10 Perform Engine Maintenance Engine specifications require that this procedure be performed every 400 hours or semi annually whichever comes first e Replace oil filter e 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 OR the Kohler KDW1003 Engine Owner s Manual Kohler part number 0053028440 Kohler KDW1003 Engine Owner s Manual Genie part number 1268769 Kubota D 1105 and V 1505 Operator s Manual Genie part number 893020 32 RL4 Vertical Mast Genie Part No 1266665 August 2015 Service Manual Checklist C Procedures C 1 Perform Engine Maintenance Engine specifications require that this pr
62. il if they are used a second time Be sure to properly dispose of old oil or 2 other fluids Use an approved container Please be environmentally safe 7 Be sure that your workshop or work area TD is properly ventilated and well lit EN August 2015 Table of Contents Introduction IMEFOGDUCUION Re net ii Important Information essen ii Serial Number Legend teet edt ee tt red eed ved red antc iii Serial Number Legend iii Section 1 Civ cc iv General Safety Rules iter tiec iv Section 2 Specifications 5 1 xe uec teu u edite tasca a 1 Machine Specifications a 1 Performance 1 Performance Specifications 4 4 0 0100 1 Machine Specifications riter e e t RED A 1 Machine Specifications a 2 Machine Torque Specifications L 4 SAE and Metric Fasteners Torque 5 Section 3 Scheduled Maintenance Procedures eene 7 laiia alt e Lm 7 Pre Delivery Preparation u u 10 Maintenance Inspection 11 Genie vi RL4 Vertical Mast Part No 1266665 August 2015
63. ing 125 of the cable diameter or more is found OR there is a broken wire at the 1 Visually inspect the electric winch and cable crush point The cable must immediately be pulleys for the following replaced e broken or damaged pulleys 7 Wind cable onto the winch ensuring that the cable is correctly installed onto each of the e unusual or excessive pulley wear pulleys Result A pulley is broken or damaged or shows unusual or excessive pulley wear The pulley must immediately be replaced Put on protective leather gloves and eye wear Fully unwind the cable from the winch Wearing leather gloves run a hand up and down a length of the cable inspecting the cable and components for the following e 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 August 2015 Service Manual A 14 Perform Engine Maintenance Engine specifications require that this procedure be performed every 100 hours e Clean air filter e Clean the fuel filter e 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 OR the Kohler KDW1003 Engine Owner s Manual Kohler part number 0053028440 Kohler KDW1003 Engine Owner s Manual Genie part number 1268769
64. ire extinguisher within easy reach ADANGER 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 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 Part No 1266665 Genie RL4 Vertical Mast 61 Fuel Tank Remove the front fairing assembly 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 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 h
65. is 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 e Inspect and clean the generator and windings for oil or dirt contamination Coliseum Manual E 6 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 removal Inspect and clean generator components including generator windings Genie part number 1268770 Replace the generator shaft bearings Consult a trained Coliseum service professional Coliseum Manual Genie part number 1268770 Genie 44 RL4 V
66. ket and the pin is inserted behind the collar or latch 3 Check mounting bracket hardware for wear Genie part number 893020 and proper tightness gt Result Replace bent broken or worn hardware Genie 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 Genie 16 RL4 Vertical Mast 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 Part No 1266665 August 2015 Service Manual A 8 Check the Tires and Wheels Axle specifications require that this procedure be performed weekly Maintaining the tires and wheels
67. l 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 Liftthe 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 Part No 1266665 August 2015 Service Manual 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 Electrocution burn hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry A WARNING Bodily injury hazard Batteries contain acid Avoid spilling or contacting battery acid Neutralize battery acid spills with baking soda and water A WARNING
68. m 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 Part No 1266665 RL4 Vertical Mast 7 August 2015 E 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 Indicates a imminently hazardous situation which if not avoided will result in death or serious injury A 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 ma
69. maintenance information An illegible decal will fail to alert personnel of a procedure or hazard and could result in unsafe operating conditions 1 Checkto make sure that the operator s and safety manuals are present and complete in the storage container inside the cabinet Part No 1266665 Genie RL4 Vertical Mast 13 Checklist A Procedures 2 Examine the pages of each manual to be sure that they are legible and in good condition 9 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 operators 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 gt 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 Service Manual August 2015 Checklist A Procedures A 2 Perform Pre
70. ments refer to the engine Operator Engine speed 1800 rpm Manual for your engine Governor centrifugal Battery mechanical C T 12V D Valve Clearance cold 0 005710 0 0072 in 0 145 0 185 mm Group 27 Engine coolant Quantity 1 Capacity 3 27 quarts Cold cranking ampere 500 3 1 liters Reserve capacity 75 rate 105 minutes Lubrication system Alternator Oil pressure 28 to 64 psi Alternator output 40A 12V DC 1 93 to 4 41 bar m Fan belt deflection 1 4 to 3 8 inch Oil capacity including filter 5 4 quarts 7109 mm 5 1 liters Genie Part No 1266665 RL4 Vertical Mast 3 August 2015 F Specifications Machine Torque Specifications Generator Flex plate to flywheel 15 ft Ibs 20 Nm Generator case to bell housing 30 ft Ibs 41 Nm Generator isolators 75 ft Ibs 102 Nm Wheel lugs Lug nut torque lubricated 67 5 ft lbs 91 5 Nm Lug nut torque dry 90 ft lbs 122 Nm Engine vibration isolators Mounting bolts dry 60 ft lbs 81 Nm Mounting bolts lubricated 45 ft lbs 61 Nm Continuous improvement of our products is a Genie policy Product specifications are subject to change without notice or obligation Genie 4 RL4 Vertical Mast Part No 1266665 August 2015 Specifications SAE FASTENER TORQUE CHART This chart is to be used as a guide only unless noted elsewhere in this manual A574 High Strength Grades Grade
71. n 77 Service Manual August 2015 RL4 WITH DYNAGEN TG350 AUTOSTART 12V DC OPERATION SENSOR INPUT B LOW IMPEDANCE TEMP AND OIL OFF MODULE POWER 12V RED 1 iv 2 TEMP OIL PRESSURE SWITCH OFF ALT D QPHOTOCELL J5 FROM GENERATOR WHT 4 STARTER A PHASE 5 BATTERY B PHASE 6 GLOW PLUGS 7 p FUEL PUMP NEUTRAL 8 O TELEMATICS REMOTE ENABLE 9 DYNAGEN TG350 MODULE 295 11 12 PHOTO CELL BLK BATTERY RED 12 u BLU 70 46 ae oO AUTOSTART WARNING B GLOW PLUGS RELY PAK RP100 MAINS CONTACTORS B PHASE TELEMATICS NO ACTIVE LOW Lame TELEMATICS ACTIVE HIGH 78 August 2015 Service Manual RL4 DC Engine Components Kohler 79 Service Manual August 2015 RL4 DC ENGINE COMPONENTS KOHLER 12VDC OPERATION RED BATTERY 12 VOLT STARTER FUEL SOLENOID 4004 N L ORG RESISTORS TN 110 OHM BA PRESSURE 110 EHI vod HIGH i FUEL PUMP COOLANT TEMPERATURE TELEMATICS GLOW NO PLUGS HARNESS PART NUMBER 1264847 TELEMATICS TEL BAT TEL GND TEL SIG PLUG PLUG REMOTE ENABLE PLUG PLUG 80 August 2015 Service Manual
72. ocedure be performed every 500 hours e Replace fan belts e 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 0053028440 Kohler KDW1003 Engine Owner s Manual Genie part number 1268769 Kubota D 1105 and V 1505 Operator s Manual Genie part number 893020 Genie Part No 1266665 RL4 Vertical Mast 33 Service Manual August 2015 Checklist C Procedures 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 3 Thoroughly rinse
73. one Note During assembly carefully install the mast cable Refer to the illustration on the following page for cable routing Genie 50 RL4 Vertical Mast Part No 1266665 August 2015 Mast Note Refer to the illustration below for cable 2 3 How to Replace the Mast Lift Cables routing detail See 2 2 How to Disassemble the Mast Assembly IV g rel ET Mast Lift Mast Lift Cable 2 Cable 3 t Mast Lift Cable 1 Y Mast Lift Mast Lift Mast Lift Cable 1 Cable 2 N Cable 3 Winch 3 inch T 2 inch 1 5 inch Mast Mast Mast Section Section Section 4inch Mast Section Genio Part No 1266665 RL4 Vertical Mast 51 Service Manual August 2015 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 Bodily injury hazard Cables can fray Always wear adequate hand protection when handling the cable 4 Remove the winch from the machine Genie 52 RL4
74. 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 Genie 14 RL4 Vertical Mast 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 Part No 1266665 August 2015 Service Manual 4 Perform Engine Maintenance Engine specifications require that this procedure
75. or 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 August 2015 E Generator Locate the diode at the end of the generator 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 Ibs 2 2 to 3 4 Nm Genie 58 RL4 Vertical Mast Part No 1266665 August 2015 LC UE 6 1 Ground Controls The timer is used to automatically start the engine and turn on the lights at a preset time 1 2 Move the engine start switch to timed start
76. ormed every 200 hours e Change engine oil e Replace oil 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 OR the Kohler KDW1003 Engine Owner s Manual Kohler part number 0053028440 Genie part number 1268769 Kohler KDW1003 Engine Owner s Manual Kubota D 1105 and V 1505 Operator s Manual Genie part number 1268769 Genie part number 893020 Kubota D 1105 and V 1505 Operator s Manual Genie part number 893020 Genie Part No 1266665 RL4 Vertical Mast 19 Service Manual August 2015 Checklist A Procedures A 13 5 Visually inspect the winch cable for the following Inspect the Cables and Cable e nicks partial strand cut through Pulleys e kinks in the cable permanent bends e weld splatter Terex specifications require that this procedure be Result Nicks kinks in the cable or weld performed monthly splatter are The cable must immediately be replaced Detection of damage to the cables or pulleys is essential for safe machine operation An unsafe 5 2 Inspec the wineh pable tarihe working condition exists if these components are a damaged and do not operate smoothly Regular crushed spot on the cable inspection of this system allows the inspector to identify changes in the operating condition that may Result A crushed spot on the cable indicate damage measur
77. p Bosch MD mini Injection timing 19 BTDC Injection pump pressure 1991 psi maximum 137 bar Fuel requirement 3600 rpm For fuel requirements refer to the engine Operator centrifugal Manual for your engine mechanical Battery 0 0057 to 0 0072 in Type 12V DC 0 145 to 0 185 mm Group 27TM Quantity 1 1 37 quarts 1 3 liters Cold cranking ampere 500 Reserve capacity 75 rate 105 minutes 28 to 64 psi Alternator 1 93 to 4 41 bar Alternator output 40A 12V DC 2 54 quarts Fan belt deflection 1 4 to 3 8 inch 2 4 liters 7 to 9 mm Genie RL4 Vertical Mast Part No 1266665 August 2015 Service Manual Kubota D1105 E Engine Specifications Oil pressure switch engine 7 psi shutoff pressure Cil viscosity requirements Displacement 68 53 cu in 1 12 liters Unit ships with 10W 30 Extreme operating Numb f cvlind 3 temperatures may require the use of alternative engine oils For requirements refer to the Engine Operator Bore and Stroke 3 07 x 3 09 inches Manual for your engine TRO SII Injection system Horsepower 13 6 Ms e Injection pump Bosch MD mini Firing order 1 2 3 Injection timing 19 BTDC Injection pump pressure 1991 psi Compression ratio 23 1 E PP 137 Compression pressure 412 to 469 psi Fuel t 28 4 to 32 3 bar requiremen 5 For fuel require
78. 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 A 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 Part No 1266665 August 2015 Service Manual 2 Loosen the drain plug located at the bottom of the bowl Allow the water to drain into suitable container until fuel starts to come out Immediately tighten the drain plug a head bolt b vent plug 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 Startthe engine from the electrical control 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
79. r terminals A DANGER 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 3 Tag and disconnect the wires attached to the capacitor Part No 1266665 Genie RL4 Vertical Mast 57 Generator 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 gt Result The meter indicates a very high resistance which does not decrease The capacitor is faulty and should be replaced mi 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 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 Note Be sure the engine has been turned off f
80. rake 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 Stop the engine of the tow vehicle Select a wheel Chock the front and rear of the tire at the opposite side of the machine Loosen the wheel lug nuts Do not remove them 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 Remove the dust cap from the hub Remove the cotter pin from the castle nut Remove the castle nut and washer Pull the hub off of the spindle The washer and outer bearing should fall loose from the hub Part No 1266665 August 2015 Service Manual 11 Locate the brake magnet Inspect the surface of the magnet for pitting and any irregular surface wear R 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 amp Result Replace the magnets and magnet springs on both
81. ripped Loose wiring connections Replace battery Inspect and repair as needed Reset circuit breaker Inspect and repair as needed Faulty generator Dirty light fixture Batteries low Inspect and repair as needed Clean light fixture Charge batteries Short in power supply cable Inspect and repair as needed Power supply cable connector faulty End of life Inspect and repair as needed 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 Generator has a faulty bearing or faulty fan blade Part No 1266665 Inspect and repair as needed Genie RL4 Vertical Mast 65 Service Manual August 2015 Diagnostics Problem Generator produces full voltage at no load or voltage drops at full load Generator voltage too high Generator produces no voltage at no load or at full load Generator will not hold voltage loss of residual magnetism Possible Cause Loose or broken lead wires Rotor open or shorted Solution Inspect lead wires and connections for broken wires and loose connections Measure resistance between leads Stator grounded or shorted High engine speed Faulty surge suppressor Faulty capacitor Loss of residual magnetism Open winding Machine has been unused for a significant length of time Contact
82. s if equipped and remove the machine from service repair and re inspect it After repair place a check in the R box Legend Y yes acceptable no remove from service repaired Genie Part No 1266665 RL4 Vertical Mast 11 August 2015 RV Maintenance Inspection Report Checklist E Y NR Model Checklist C Y NR C 1 Engine maintenance E 1 Cable Serial number C 2 Lights Perform every 2000 hours Date Perform every 6000 miles E 2 Engine maintenance C 3 Wheel bearings Perform every 3000 hours Hour meter Machine owner C 4 Brakes if equipped Perform every 800 hours E 3 Engine maintenance Perform every 10 000 hours C 5 Engine maintenance E 4 Generator maintenance Perform every 2000 hours Inspected by print Perform every 20 000 hours C 6 Generator maintenance Checklist D Y NR Perform every 1500 hours Inspector signature 5 Generator maintenance Inspector title Inspector company Perform every 30 000 hours E 6 Generator maintenance Instructions D 1 Engine maintenance Perform every 8000 hours Make copies of this report to use for each inspection D 2 Select the appropriate checklist s for the type of inspection s to perform Generator maintenance Comments Perform annually
83. 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 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 Checklist C Procedures 5 Perform Engine Maintenance Engine specifications require that this procedure be performed every 800 hours or annually whichever comes first e Replace air filter e Inspect wiring e 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 OR the Kohler KDW1003 Engine Owner s Manual Kohler part number 0053028440 Kohler KDW1003 Engine Owner s Manual Genie part number 1268769 Kubota D 1105 and V 1505 Operator s Manual Genie number 893020 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 be
84. t 6 2 Light Ballast 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 ADANGER 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 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 capacitor Remove the plastic terminal cover and disconnect the wire harness connector from the capacitor 3 Usingan 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 Genie 60 RL4 Vertical Mast High voltage Exposure to electrical wires or electrical current will result in death or
85. 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 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 Note Required maintenance procedures and additional engine information is available in the Kubota D1105 E and V1505 E Operators Manual Kubota 16683 89169 part number OR the Kohler KDW1003 Engine Owner s Manual Kohler part number 0053028440 Kohler KDW1003 Engine Owner s Manual Genie part number 1268769 Kubota D 1105 and V 1505 Operator s Manual panel and check the fuel filter water separator Genie part number 899020 for leaks Genie Part No 1266665 RL4 Vertical Mast 23 Service Manual August 2015 Checklist A Procedures 18 Test the Brakes equipped Axle specifications require that this procedure be performed initially at 250 miles of use Maintaining the axle brakes in good condition is essential to safe operation and good performance
86. the Genie Service Department Adjust the rpm Refer to Section 2 Specifications Disconnect suppressor from circuit If there is an obvious increase in voltage replace the suppressor Replace capacitor Flash the rotor Replace the generator Flash the rotor Rotor shorting out when the unit gets hot Inspect rotor windings for broken and or burned wires Pinched leads Inspect and repair as needed Faulty capacitor Replace the capacitor Faulty diode Faulty surge suppressor 66 Replace the diode Replace the surge suppressor Genie RL4 Vertical Mast Part No 1266665 August 2015 Service Manual Problem Generator voltage spikes Generator voltage low Possible Cause Incorrect engine adjustment fuel line or faulty fuel Diagnostics Solution Change fuel filter and check engine speed Loose connection Faulty ground connection Inspect all connections and repair as needed Inspect all ground connections and repair as needed Load induced Loss of residual magnetism Filter load Flash the rotor Low engine speed Adjust idle See Repair Section Faulty capacitor Replace the capacitor Faulty diode Part No 1266665 Replace the diode Genie RL4 Vertical Mast 67 Service Manual August 2015 Schematics Observe and Obey A WARNING V Troubleshooting and repair procedures shall be completed by
87. 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 Genie RL4 Vertical Mast 47 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 August 2015 m r h Lighting 1 3 How to Check the Open Circuit Voltage Correct line voltage at the lamp socket is essential for proper operation of the lighting system AWARNING 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 allmachine power 2 Locate the electrical cable of the lamp to be tested Disconnect the cable from the junction box attached to the light bar Seta voltmeter to read 0 to 750V AC Insert the leads of the voltmeter into pins A and B of the electrical connector socket at the junction box Start the engine Turn the appropriate circuit breaker light switch to the ON position and observe the reading on the voltmeter Refer to the following chart Open Circuit Voltage 375V AC to 465V AC Specification Note If there is no reading on the meter Repair or replace the capacitor ball
88. tuation 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 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 Part No 1266665 Genie RL4 Vertical Mast Safety Rules Workplace 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 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 N 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 Be sure that fasteners intended for one time use i e cotter pins and self locking nuts are not reused These components may fa
89. with hot lamp components may result in severe burns CAUTION 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 Part No 1266665 Lighting 1 2 How to Check Line Voltage Correct line voltage at the lamp socket is essential for proper operation of the lighting system Electrocution burn hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry A WARNING 1 Turn off all machine power 2 Remove the cover from the lamp junction box 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 Connecta voltmeter to the lamp wires Start the engine 4 Turnthe 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
90. y result in property damage Indicates that a specific result is expected after performing a series of steps W Indicates that an incorrect result has occurred after performing a series of steps Genie 8 RL4 Vertical Mast Part No 1266665 August 2015 Service Manual Scheduled Maintenance Procedures Maintenance Symbols Legend Note The following symbols have been usedi 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 E Indicates that dealer service will be required to perform this procedure s Indicates that a cold engine will be required to perform this procedure Indicates that a warm engine will be required to perform this procedure 1266665 Pre delivery Preparation Report 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

RL4 Vertical Mast (PN 1266665)

Contents

Download Pdf Manuals

Related Search

Related Contents