Genie RL4 Vertical Mast User manual

S
ervice Manua
l
RL4 Vertical Mas
t
Part No. 1266665
Rev A
August 2015

Service Manual August 2015
Introduction
ii RL4 Vertical Mast Part No. 1266665
Introducti on 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.
Compliance
Machine Design Life
Unrestricted with proper operation, inspection and
scheduled maintenance.
Technical Publications
Terex has endeavored to deliver the highest
degree of accuracy possible. However, continuous
improvement of our products is a Terex policy.
Therefore, product specifications are subject to
change without notice.
Readers are encouraged to notify Terex of errors
and send in suggestions for improvement. All
communications will be carefully considered for
future printings of this and all other manuals.
Contact Us:
Internet: www.genielift.com
E-mail: [email protected]
Copyright © 2015 by Terex Corporation
1266665 Rev A, August 2015
First Edition, First Printing
'Terex' and 'AWP' are registered trademarks of Terex USA, LLC
in the U.S.A. and many other countries.

August 2015 Service Manual
Introduction
Part No. 1266665 RL4 Vertical Mast iii
Serial Number Legend

Service Manual August 2015
Safety Rules
iv RL4 Vertical Mast Part No. 1266665
Section 1 SafetyRules
Danger
Failure to obey the instructions and safety rules in
this manual and the appropriate Operator's Manual
on your machine will result in death or serious
injury.
Many of the hazards identified in the operator's
manual are also safety hazards when maintenance
and repair procedures are performed.
Do Not Perform Maintenance
Unless:
You are trained and qualified to perform
maintenance on this machine.
You read, understand and obey:
manufacturer's instructions and safety rules
employer's safety rules and worksite
regulations
applicable governmental regulations
You have the appropriate tools, lifting
equipment and a suitable workshop.

August 2015 Service Manual
Safety Rules
Part No. 1266665 RL4 Vertical Mast v
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.
Indicates a potentially hazardous
situation which, if not avoided,
could result in death or serious
injury.
Indicates a potentially hazardous
situation which, if not avoided,
may cause minor or moderate
injury.
Indicates a potentially hazardous
situation which, if not avoided,
may result in property damage.
Be sure 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.
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.
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 fail if they are used a second time.
Be sure to properly dispose of old oil or
other fluids. Use an approved container.
Please be environmentally safe.
Be sure that your workshop or work area
is properly ventilated and well lit.
DANGER
WARNING
CAUTION
NOTICE

August 2015
Table of Contents
vi RL4 Vertical Mast Part No. 1266665
IntroductionIntroduction .......................................................................................................... ii
Important Information..............................................................................................ii
Serial Number Legend ...........................................................................................iii
Serial Number Legend ...........................................................................................iii
Section 1Safety Rules......................................................................................................... iv
General Safety Rules.............................................................................................iv
Section 2Specifications....................................................................................................... 1
Machine Specifications .......................................................................................... 1
Performance Specifications ................................................................................... 1
Performance Specifications ................................................................................... 1
Kohler KDW1003GE Engine Specifications ......................................................... 1
Machine Specifications .......................................................................................... 2
Machine Torque Specifications.............................................................................. 4
SAE and Metric Fasteners Torque Charts............................................................. 5
Section 3Scheduled Maintenance Procedures ................................................................. 7
Introduction ............................................................................................................ 7
Pre-Delivery Preparation Report.......................................................................... 10
Maintenance Inspection Report ........................................................................... 11

August 2015
Table of Contents
Part No. 1266665 RL4 Vertical Mast vii
Checklist A Procedures .....................................................................................13
A-1 Inspect the Manuals and Decals ...................................................................13
A-2 Perform Pre-operation Inspection..................................................................14
A-3 Perform Function Tests .................................................................................14
A-4 Perform Engine Maintenance - Kubota .........................................................15
A-5 Perform Coupler Maintenance.......................................................................15
A-6 Test the Brakes (if equipped).........................................................................16
A-7 Torque the Wheel Lug Nuts...........................................................................16
A-8 Perform Engine Maintenance - Kohler ..........................................................17
A-9 Check the Tires and Wheels..........................................................................17
A-10 Inspect the Engine Air Filter.........................................................................18
A-11 Perform Generator Maintenance .................................................................19
A-12 Perform Engine Maintenance - Kubota .......................................................19
A-13 Perform Engine Maintenance - Kohler ........................................................20
A-14 Inspect the Cable and Cable Pulleys...........................................................20
A-15 Perform Engine Maintenance - Kubota .......................................................21
A-16 Perform Engine Maintenance - Kubota .......................................................22
A-17 Perform Generator Maintenance .................................................................22
A-18 Drain the Fuel Filter/Water Separator..........................................................23
A-19 Adjust the Brakes (if equipped) ...................................................................24
A-20 Perform Engine Maintenance - Kohler ........................................................25
Checklist B Procedures .....................................................................................26
B-1 Inspect the Engine Start Battery....................................................................26
B-2 Inspect the Electrical Wiring ..........................................................................27
B-3 Torque the Wheel Lug Nuts...........................................................................28
B-4 Perform Engine Maintenance - Kubota .........................................................28
B-5 Inspect and Lubricate the Winch ...................................................................29

August 2015
Table of Contents
viii RL4 Vertical Mast Part No. 1266665
B-6 Lubricate the T-bolt ....................................................................................... 29
B-7 Inspect and Adjust the Brakes (if equipped) ................................................. 30
B-8 Inspect the Suspension ................................................................................. 32
B-9 Perform Engine Maintenance - Kohler .......................................................... 32
B-10 Perform Engine Maintenance - Kubota ....................................................... 33
Checklist C Procedures..................................................................................... 34
C-1 Perform Engine Maintenance........................................................................ 34
C-2 Clean the Light Assemblies........................................................................... 34
C-3 Grease the Wheel Bearings .......................................................................... 35
C-4 Inspect the Electric Brake Magnets .............................................................. 36
C-6 Perform Engine Maintenance - Kohler.......................................................... 37
C-6 Perform Engine Maintenance - Kubota......................................................... 38
C-7 Perform Engine Maintenance - Kohler.......................................................... 38
C-8 Perform Generator Maintenance................................................................... 39
Checklist D Procedures..................................................................................... 40
D-1 Perform Engine Maintenance - Kubota......................................................... 40
D-2 Perform Generator Maintenance................................................................... 40
D-3 Perform Coupler Maintenance ...................................................................... 41
Checklist E Procedures..................................................................................... 42
E-1 Inspect the Cable and Cable Pulleys ............................................................ 42
E-2 Perform Engine Maintenance - Kubota ......................................................... 43
E-3 Perform Engine Maintenance - Kubota ......................................................... 43
E-4 Perform Engine Maintenance - Kohler .......................................................... 44
E-5 Perform Engine Maintenance - Kohler .......................................................... 44
E-6 Perform Engine Maintenance - Kohler .......................................................... 45
E-7 Perform Generator Maintenance................................................................... 45
E-8 Perform Generator Maintenance................................................................... 46
E-9 Perform Generator Maintenance................................................................... 46

August 2015
Table of Contents
Part No. 1266665 RL4 Vertical Mast ix
Section 4Repair Procedures .............................................................................................47
Introduction...........................................................................................................47
Lighting ...............................................................................................................49
1-1 How to Remove a Lamp.................................................................................49
1-2 How to Check Line Voltage............................................................................49
Mast .....................................................................................................................50
2-1 How to Remove the Mast Assembly ..............................................................50
2-2 How to Disassemble the Mast Assembly.......................................................50
2-3 How to Replace the Mast Lift Cables.............................................................52
2-4 How to Remove the Manual Winch................................................................53
2-5 How to Remove the Electric Winch................................................................54
2-6 How to Disengage the Tower Lock ................................................................55
Kohler KDW1003GE Engine ..............................................................................57
3-1 Timing Adjustment-Kohler Engines................................................................57
3-2 Glow Plugs-Kohler Engines ...........................................................................57
3-3 Coolant Temperature and Oil Pressure Switches-Kohler Engines ................57
Kubota D1105-E4BG Engine .............................................................................58
4-1 Timing Adjustment-Kubota Engines...............................................................58
4-2 Glow Plugs-Kubota Engines ..........................................................................58
4-3 Coolant Temperature and Oil Pressure Switches-Kubota Engines...............58
Generator ............................................................................................................59
5-1 Generator .......................................................................................................59
5-2 How to Check a Generator Capacitor ............................................................60
5-3 How to Check a Generator Diode ..................................................................60
Light Ballast ........................................................................................................62
6-1 Ground Controls.............................................................................................62
6-2 Light Ballast....................................................................................................63
Fuel Tank.............................................................................................................64
7-1 Fuel Tank .......................................................................................................64

August 2015
Table of Contents
x RL4 Vertical Mast Part No. 1266665
Section 5Diagnostics......................................................................................................... 65
Introduction .......................................................................................................... 65
Section 6Schematics ......................................................................................................... 71
Introduction .......................................................................................................... 71
Wire Color Legend ............................................................................................... 72
RL4 Control Box AC Voltage Wiring - Standard .................................................. 73
RL4 Control Box AC Voltage Wiring - Standard .................................................. 74
RL4 Control Box AC Voltage Wiring - Autostart .................................................. 75
RL4 Control Box AC Voltage Wiring - Autostart .................................................. 76
RL4 DC Control Box - Standard........................................................................... 77
RL4 DC Control Box - Standard........................................................................... 78
RL4 DC Engine Components - DynaGen Autostart............................................. 79
RL4 DC Engine Components - DynaGen Autostart............................................. 80
RL4 DC Engine Components - Kohler................................................................. 81
RL4 DC Engine Components - Kohler................................................................. 82
RL4 DC Engine Components - Kubota................................................................ 83
RL4 DC Engine Components - Kubota................................................................ 84
RL4 DC Control Box - Timed Oil Switch .............................................................. 85
RL4 DC Control Box - Timed Oil Switch .............................................................. 86
RL4 DC Control Box - Low Fuel Shut Down........................................................ 87
RL4 DC Control Box - Low Fuel Shut Down........................................................ 88
RL4 Running Lights - Front Fairing Section......................................................... 89
RL4 Running Lights - Front Fairing Section......................................................... 90
RL4 Running Lights - Rear Fairing Section ......................................................... 91
RL4 Running Lights - Rear Fairing Section ......................................................... 92
RL4 Electrical Winch Option ................................................................................ 93
RL4 Electrical Winch Option ................................................................................ 94

August 2015 Service Manual
Specifications
Part No. 1266665 RL4 Vertical Mast 1
Section 2 Specificati ons
Machine Specifications
Total lighting wattage 4 x 1000 watts
Fuel capacities
Single tank 45 gallons
170 liters
Tires and wheels
Tire size ST175/80D13
Load range C
Lug nut torque, dry 90 ft-lbs
122 Nm
Lug nut torque, lubricated 67.5 ft-lbs
91.5 Nm
Performance Specifications
Tongue weight, maximum
With fuel (45 gallon tank) 203 lbs
92 kg
Run time
45 gallon tank 90 hours
For operational specifications, refer to the
Operator's Manual.
Continuous improvement of our products is a
Genie policy. Product specifications are
subject to change without notice or obligation.
Generator Options
Coliseum 6 kW 1CBC06-TX
Generator rpm @ full load 60Hz, 1800 rpm
Temperature, ambient maximum 104° F
40° C
Power 6 kW
Coliseum 7 kW 1CBC07-TX
Generator rpm @ full load 50 Hz, 1500 rpm
Temperature, ambient maximum 104° F
40° C
Power 7 kW
Coliseum 8 kW 1CBC08-TX
Generator rpm @ full load 60 Hz, 1800 rpm
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
2 RL4 Vertical Mast Part No. 1266665
Kohler KDW1003GE Engine
Displacement 62.7 cu in
1.03 liters
Number of cylinders 3
Bore and Stroke 2.95 x 3.1 inches
75 x 77.6 mm
Horsepower 10.7 @ 1800
8 kW
Firing order 1 - 3 - 2
Compression ratio 22.8:1
Compression pressure 412 to 469 psi
28.4 to 32.3 bar
Engine speed 1800 rpm
Governor centrifugal
mechanical
Valve Clearance, cold 0.00787402 in
0.20 mm
Engine coolant
Capacity 4.5 quarts
4.3 liters
Lubrication system
Oil pressure 28.8 to 50.6 psi
3 to 4.5 bar
Oil capacity (including filter) 5 quarts
4.7 liters
Oil pressure switch (engine
shutoff pressure)
20 psi
Oil 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 pump Bosch
Injection timing 9° BTDC
Injection pump pressure,
maximum
2233 psi
155 bar
Fuel requirement
For fuel requirements, refer to the engine Operator
Manual for your engine.
Battery
Type 12V DC
Group 27TM
Quantity 1
Cold cranking ampere 500
Reserve capacity @ 75A rate 105 minutes
Alternator
Alternator output 45A, 12V DC
Fan belt deflection 1/4 to 3/8 inch
7 to 9 mm

August 2015 Service Manual
Specifications
Part No. 1266665 RL4 Vertical Mast 3
Kubota D1105-E4BG Engine
Displacement 68.53 cu in
1.12 liters
Number of cylinders 3
Bore and Stroke 3.07 x 3.09 inches
78 x 78.4 mm
Horsepower 13.6 @ 1800
10.1 kW
Firing order 1 - 2 - 3
Compression ratio 24:1
Compression pressure 397 to 454 psi
28.4 to 32.3 bar
Engine speed 1800 rpm
Governor centrifugal
mechanical
Valve Clearance, cold 0.0057 to 0.0072 in
0.145 to 0.185 mm
Engine coolant
Capacity 3.27 quarts
3.1 liters
Lubrication system
Oil pressure 28 to 64 psi
1.93 to 4.41 bar
Oil capacity (including filter) 5.4 quarts
5.1 liters
Oil pressure switch (engine
shutoff pressure)
7 psi
Oil 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 pump Bosch MD mini
Injection timing 16.5° BTDC
Injection pump pressure,
maximum
1991 psi
137 bar
Fuel requirement
For fuel requirements, refer to the engine Operator
Manual for your engine.
Battery
Type 12V DC
Group 27TM
Quantity 1
Cold cranking ampere 500
Reserve capacity @ 75A rate 105 minutes
Alternator
Alternator output 30A, 12V DC
Fan belt deflection 1/4 to 3/8 inch
7 to 9 mm

Service Manual August 2015
Specifications
4 RL4 Vertical Mast Part No. 1266665
Machine Torque Specifications
Generator
Flex plate to flywheel 25 ft-lbs
34 Nm
Generator case to bell housing 44 ft-lbs
60 Nm
Generator isolators 37 ft-lbs
50.5 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 75 ft-lbs
102 Nm
Mounting bolts, lubricated 57 ft-lbs
77 Nm
Continuous improvement of our products is a
Genie policy. Product specifications are
subject to change without notice or obligation.

August 2015 Service Manual
Specifications
Part No. 1266665 RL4 Vertical Mast 5

Service Manual August 2015
6 RL4 Vertical Mast Part No. 1266665
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August 2015 Service Manual
Scheduled Maintenance Procedures
Part No. 1266665 RL4 Vertical Mast 7
Section 3 Scheduled Maintenanc e 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.
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.
Machines that have been out of service for a
period longer than 3 months must complete the
quarterly inspection.
Machine Configuration:
Unless otherwise specified, perform each
procedure with the machine in the following
configuration:
Machine parked on a firm, level surface
Mast in the stowed position
Key switch in the off position with the key
removed
The red Emergency Stop button in the off
position on the electrical control box
Wheels chocked
Light switches in the off position
All external AC power supply disconnected
from the machine
Boom in the stowed position
Turntable secured with the turntable rotation
lock
WARNING

Service Manual August 2015
Scheduled Maintenance Procedures
8 RL4 Vertical Mast Part No. 1266665
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.
Indicates a potentially hazardous
situation which, if not avoided,
could result in death or serious
injury.
Indicates a potentially hazardous
situation which, if not avoided,
may cause minor or moderate
injury.
Indicates a potentially hazardous
situation which, if not avoided,
may result in property damage.
Indicates that a specific result is expected
after performing a series of steps.
Indicates that an incorrect result has occurred
after performing a series of steps.
DANGER
WARNING
CAUTION
NOTICE

August 2015 Service Manual
Scheduled Maintenance Procedures
Part No. 1266665 RL4 Vertical Mast 9
Maintenance Symbols Legend
Note: The following symbols have been used in this
manual to help communicate the intent of the
instructions. When one or more of the symbols
appear at the beginning of a maintenance
procedure, it conveys the meaning below.
Indicates that tools will be required to
perform this procedure.
Indicates that new parts will be required to
perform this procedure.
Indicates that dealer service will be
required to perform this procedure.
Indicates that a cold engine will be
required to perform this procedure.
Indicates that a warm engine will be
required to perform this procedure.
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.
Inspection Checklist
Daily or every 8 hours A
Quarterly or every 250 hours A + B
Semi-annually or every 500 hours A + B + C
Annually or every 1000 hours A + B + C + D
Two-year or every 2000 hours A + B + C + D + E
Maintenance Inspection Report
The maintenance inspection report contains
checklists for each type of scheduled inspection.
Make copies of the Maintenance Inspection Report
to use for each inspection. Maintain completed
forms for a minimum of 4 years or in compliance
with your employer, jobsite and governmental
regulations and requirements.

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.
Instructions
Use the operator’s manual on your machine.
The Pre-delivery Preparation consists of
completing the Pre-operation Inspection, the
Maintenance items and the Function Tests.
Use this form to record the results. Place a check in
the appropriate box after each part is completed.
Follow the instructions in the operator’s manual.
If any inspection receives an N, remove the
machine from service, repair and re-inspect it. After
repair, place a check in the R box.
Legend
Y = yes, acceptable
N = no, remove from service
R = repaired
Comments
Pre-delivery Preparation YNR
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
Terex South Dakota, Inc USA
500 Oak Wood Road
PO Box 1150
Watertown, SD 57201-6150
[phone]
Genie UK
The Maltings, Wharf Road
Grantham, Lincolnshire
NG31- 6BH England
(44) 1476-584333