Service Manual: RL4 Vertical Mast

Service Manual
RL4 Vertical Mast
Part No. 1266665GT

Rev B
August 2022
Service Manual August 2022
Introduction
Intro ductio n Intro ductio n
Impo rtan t Inf or matio n
Important Technical Publications

Read, understand and obey the safety rules and Terex has endeavored to deliver the highest
operating instructions in the appropriate Operator's degree of accuracy possible. However, continuous
Manual on your machine before attempting any improvement of our products is a Terex policy.
maintenance procedure. Therefore, product specifications are subject to
change without notice.
This manual provides detailed scheduled
maintenance information for the machine owner Readers are encouraged to notify Terex of errors
and user. It also provides troubleshooting and and send in suggestions for improvement. All
repair procedures for qualified service communications will be carefully considered for
professionals. future printings of this and all other manuals.
Basic mechanical, hydraulic and electrical skills

are required to perform most procedures. Contact Us:
However, several procedures require specialized
skills, tools, lifting equipment and a suitable Internet: www.genielift.com
workshop. In these instances, we strongly E-mail: [email protected]
recommend that maintenance and repair be
performed at an authorized Terex dealer service
center.
Copyright © 2015 by Terex Corporation
1266665GT Rev B, August 2022

First Edition, Second Printing
'Terex' is a registered trademarks of Terex USA, LLC in the

U.S.A. and many other countries.
ii RL4 Vertical Mast Part No. 1266665GT

August 2022 Service Manual
Safety Rules
Serial Number Legend

To August 31, 2016
1 Model 4 Sequence number

2 Model year 5 Serial number (stamped on chassis)
3 Facility code 6 Serial label
From September 1, 2016
1 Model 3 Sequence number

2 Facility code 4 Serial number (stamped on chassis)
5 Serial label
Part No. 1266665GT RL4 Vertical Mast 3

Safety Rules
Gene ral Saf ety Rul es
Secti on 1 Safety Rul es
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 modify or alter a MEWP without prior
written permission from the manufacturer.
Do Not Perform Maintenance

Unless:
 You are trained and qualified to perform
maintenance on this machine.
 You read, understand and obey:
• manufacturer's instructions and safety rules
• employer's safety rules and worksite
regulations
• applicable governmental regulations
 You have the appropriate tools, lifting
equipment and a suitable workshop.
iv RL4 Vertical Mast Part No. 1266665GT

Safety Rules
Personal Safety Workplace Safety

Any person working on or around a machine must Any person working on or around a machine must
be aware of all known safety hazards. Personal be aware of all known safety hazards. Personal
safety and the continued safe operation of the safety and the continued safe operation of the
machine should be your top priority. machine should be your top priority.
Read each procedure thoroughly. This Be sure to keep sparks, flames and
manual and the decals on the machine, lighted tobacco away from flammable and
use signal words to identify the following: combustible materials like battery gases
and engine fuels. Always have an
Safety alert symbol—used to approved fire extinguisher within easy
alert personnel to potential reach.
personal injury hazards. Obey all
safety messages that follow this Be sure that all tools and working areas
symbol to avoid possible injury or are properly maintained and ready for
death. use. Keep work surfaces clean and free
of debris that could get into machine
Indicates a imminently hazardous components and cause damage.
situation which, if not avoided,
will result in death or serious Be sure any forklift, overhead crane or
injury. other lifting or supporting device is fully
capable of supporting and stabilizing the
Indicates a potentially hazardous weight to be lifted. Use only chains or
situation which, if not avoided, straps that are in good condition and of
could result in death or serious ample capacity.
injury.
Be sure that fasteners intended for one
Indicates a potentially hazardous time use (i.e., cotter pins and self-locking
situation which, if not avoided, nuts) are not reused. These components
may cause minor or moderate may fail if they are used a second time.
injury.
Be sure to properly dispose of old oil or
Indicates a potentially hazardous other fluids. Use an approved container.
situation which, if not avoided, Please be environmentally safe.
may result in property damage.
Be sure that your workshop or work area
Be sure to wear protective eye wear and is properly ventilated and well lit.
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. 1266665GT RL4 Vertical Mast v

August 2022
Table of Contents
Introduction Introduction ...................................................................................................... ii

Important Information ..........................................................................................ii
Serial Number Legend ....................................................................................... 3
Section 1 Safety Rules .................................................................................................... iv

General Safety Rules .........................................................................................iv
Section 2 Specifications................................................................................................... 1
Machine Specifications....................................................................................... 1
Performance Specifications ................................................................................ 1
Generator Options ............................................................................................. 1
Kohler KDW1003GE Engine Specifications...................................................... 2
Kubota D1105-E4BG Engine Specifications ....................................................... 3
Machine Torque Specifications........................................................................... 4
SAE and Metric Fasteners Torque Charts .......................................................... 5
vi RL4 Vertical Mast Part No. 1266665GT

August 2022
Table of Contents
Section 3 Scheduled Maintenance Procedures ............................................................... 7

Introduction ........................................................................................................7
Pre-Delivery Preparation Report ....................................................................... 10
Maintenance Inspection Report ........................................................................ 11
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-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
Part No. 1266665GT RL4 Vertical Mast vii

August 2022
Table of Contents
Checklist B Procedures ................................................................................. 26

B-1 Inspect the Engine Start Battery................................................................. 26
B-2 Inspect the Electrical Wiring ....................................................................... 28
B-3 Torque the Wheel Lug Nuts ....................................................................... 28
B-4 Perform Engine Maintenance - Kubota....................................................... 29
B-5 Inspect and Lubricate the Winch ................................................................ 29
B-6 Lubricate the T-bolt .................................................................................... 30
B-7 Inspect and Adjust the Brakes (if equipped) ............................................... 30
B-8 Inspect the Suspension.............................................................................. 32
B-9 Perform Engine Maintenance - Kohler........................................................ 33
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-5 Perform Engine Maintenance - Kohler ....................................................... 38
C-6 Perform Engine Maintenance - Kubota ...................................................... 38
C-7 Perform Engine Maintenance - Kohler ....................................................... 39
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-7 Perform Generator Maintenance ................................................................ 45
viii RL4 Vertical Mast Part No. 1266665GT

August 2022
Table of Contents
Section 4 Repair Procedures.......................................................................................... 47

Introduction ...................................................................................................... 47
Lighting ........................................................................................................... 49
1-1 How to Remove a Lamp ............................................................................. 49
1-2 How to Check Line Voltage......................................................................... 49
Mast................................................................................................................. 50
2-1 How to Remove the Mast Assembly ........................................................... 50
2-2 How to Disassemble the Mast Assembly..................................................... 50
2-3 How to Replace the Mast Lift Cables .......................................................... 52
2-4 How to Remove the Manual Winch ............................................................. 53
2-5 How to Remove the Electric Winch ............................................................. 54
2-6 How to Disengage the Tower Lock ............................................................. 55
Kohler KDW1003GE Engine ........................................................................... 57

3-1 Timing Adjustment-Kohler Engines ............................................................. 57
3-2 Glow Plugs-Kohler Engines ........................................................................ 57
3-3 Coolant Temperature and Oil Pressure Switches-Kohler Engines ............... 57
Kubota D1105-E4BG Engine .......................................................................... 58

4-1 Timing Adjustment-Kubota Engines ............................................................ 58
4-2 Glow Plugs-Kubota Engines ....................................................................... 58
4-3 Coolant Temperature and Oil Pressure Switches-Kubota Engines .............. 58
Generator ........................................................................................................ 59
5-1 Generator ................................................................................................... 59
5-2 How to Check a Generator Capacitor.......................................................... 60
5-3 How to Check a Generator Diode ............................................................... 61
Light Ballast.................................................................................................... 62
6-1 Ground Controls ......................................................................................... 62
6-2 Light Ballast................................................................................................ 63
Fuel Tank ........................................................................................................ 64

7-1 Fuel Tank ................................................................................................... 64
Part No. 1266665GT RL4 Vertical Mast ix

August 2022
Table of Contents
Section 5 Diagnostics .................................................................................................... 65

Introduction ...................................................................................................... 65
Diagnostic Charts .......................................................................................... 66
Section 6 Schematics ..................................................................................................... 71

Introduction ...................................................................................................... 71
Wire Color Legend ........................................................................................... 72
RL4 Control Box AC Voltage Wiring - Standard ................................................ 74
RL4 Control Box AC Voltage Wiring - Autostart ................................................ 75
RL4 DC Control Box - Standard ....................................................................... 78
RL4 DC Engine Components - DynaGen Autostart........................................... 79
RL4 DC Engine Components - Kohler .............................................................. 82
RL4 DC Engine Components - Kubota ............................................................. 83
RL4 DC Control Box - Timed Oil Switch ........................................................... 86
RL4 DC Control Box - Low Fuel Shut Down ..................................................... 87
RL4 Running Lights - Front Fairing Section ...................................................... 90
RL4 Running Lights - Rear Fairing Section ....................................................... 91
RL4 Electrical Winch Option ............................................................................. 94
x RL4 Vertical Mast Part No. 1266665GT

Specifications
Secti on 2 Specificatio ns
Machine Specifications Generator Options

Machin e Specific atio ns Gene rato r Op tions
Total lighting wattage 4 x 1000 watts Coliseum 6 kW 1CBC06-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 @ full load 50 Hz, 1500 rpm
Lug nut torque, dry 80 ft-lbs Temperature, ambient maximum 104° F
109 Nm 40° C
Lug nut torque, lubricated 67.5 ft-lbs Power 7 kW
91.5 Nm
Coliseum 8 kW 1CBC08-TX
Performance Specifications
Perfor man ce Speci ficatio ns
Generator rpm @ full load 60 Hz, 1800 rpm

Temperature, ambient maximum 104° F
Tongue weight, maximum
40° C
With fuel (45 gallon tank) 203 lbs
92 kg Power 8 kW
Run time For operational specifications, refer to the

Operator's Manual.
45 gallon tank 90 hours
For operational specifications, refer to the Continuous improvement of our products is a
Operator's Manual. Genie policy. Product specifications are
subject to change without notice or obligation.

Specifications
Kohler KDW 1003GE Engine

Kohler KDW1 003GE En gine S pecifica tions
Lubrication system
Oil pressure 28.8 to 50.6 psi
Displacement 62.7 cu in 3 to 4.5 bar
1.03 liters
Oil capacity (including filter) 5 quarts
Number of cylinders 3 4.7 liters
Bore and Stroke 2.95 x 3.1 inches Oil pressure switch (engine 20 psi
75 x 77.6 mm shutoff pressure)
Horsepower 10.7 @ 1800 Oil viscosity requirements
8 kW
Unit ships with 10W-30. Extreme operating
Firing order 1-3-2 temperatures may require the use of alternative engine
Compression ratio 22.8:1 oils. For oil requirements, refer to the Engine Operator
Manual for your engine.
Compression pressure 412 to 469 psi
28.4 to 32.3 bar Injection system
Engine speed 1800 rpm Injection pump Bosch
Governor centrifugal Injection timing 9° BTDC
mechanical Injection pump pressure, 2233 psi
Valve clearance, cold 0.00787402 in maximum 155 bar
0.20 mm Fuel requirement
Engine coolant For fuel requirements, refer to the engine Operator
Capacity 4.5 quarts Manual for your engine.
4.3 liters 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
2 RL4 Vertical Mast Part No. 1266665GT

Specifications
Kubota D1105-E4BG Engine

Kubota D 110 5-E4BG En gine S pecificati ons
Lubrication system
Oil pressure 28 to 64 psi
Displacement 68.53 cu in 1.93 to 4.41 bar
1.12 liters
Oil capacity (including filter) 5.4 quarts
Number of cylinders 3 5.1 liters
Bore and Stroke 3.07 x 3.09 inches Oil pressure switch (engine 7 psi
78 x 78.4 mm shutoff pressure)
Horsepower 13.6 @ 1800 Oil viscosity requirements
10.1 kW
Unit ships with 10W-30. Extreme operating
Firing order 1-2-3 temperatures may require the use of alternative engine
Compression ratio 24:1 oils. For oil requirements, refer to the Engine Operator
Manual for your engine.
Compression pressure 397 to 454 psi
28.4 to 32.3 bar Injection system
Engine speed 1800 rpm Injection pump Bosch MD mini
Governor centrifugal Injection timing 16.5° BTDC
mechanical Injection pump pressure, 1991 psi
Valve clearance, cold 0.0057 to 0.0072 in maximum 137 bar
0.145 to 0.185 mm Fuel requirement
Engine coolant For fuel requirements, refer to the engine Operator
Capacity 3.27 quarts Manual for your engine.
3.1 liters 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

Specifications
Machine Torque Specifications

Machin e T orq ue Sp ecificati ons
Wheel lugs
Lug nut torque, lubricated 67.5 ft-lbs
Generator 91.5 Nm
Flex plate to flywheel 25 ft-lbs Lug nut torque, dry 90 ft-lbs
34 Nm 122 Nm
Generator case to bell housing 44 ft-lbs Engine vibration isolators
60 Nm
Mounting bolts, dry 75 ft-lbs
Generator isolators 37 ft-lbs 102 Nm
50.5 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.

Specifications
SAE and Me tric Fast ene rs T orq ue Ch arts

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Scheduled Maintenance Procedures
Machine Configuration:
Secti on 3 Schedule d M ainte nanc e Proc edu res
Intro ductio n
 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
Observe and Obey:
• Key switch in the off position with the key
 Maintenance inspections shall be completed removed
by a person trained and qualified on the
maintenance of this machine. • The red Emergency Stop button in the off
position on the electrical control box
 Scheduled maintenance inspections shall be
completed daily, quarterly, semi-annually, • Wheels chocked
annually and every 2 years as specified of the
• Light switches in the off position
Maintenance inspection Report. The frequency
and extent of periodic examinations and tests • All external AC power supply disconnected
may also depend on national regulations. from the machine
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.

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

could result in death or serious
injury.

may cause minor or moderate
injury.

Indicates that a specific result is expected

after performing a series of steps.
Indicates that an incorrect result has occurred

Maintenance Symbols Legend Pre-delivery Preparation Report

Note: The following symbols have been used in The pre-delivery preparation report contains
this manual to help communicate the intent of the checklists for each type of scheduled inspection.
instructions. When one or more of the symbols
appear at the beginning of a maintenance Make copies for each inspection. Store completed
procedure, it conveys the meaning below. forms as required.
Indicates that tools will be required to Maintenance Schedule

perform this procedure.
The Scheduled Maintenance Procedures section
and the Maintenance Inspection Report have been
Indicates that new parts will be required to divided into subsections. Use the following chart to
perform this procedure. determine which group(s) of procedures are
required to perform a scheduled inspection.
Indicates that dealer service will be Inspection Checklist

required to perform this procedure. Daily or every 8 hours A
Quarterly or every 250 hours A+B
Indicates that a cold engine will be Semi-annually or every 500 hours A+B+C
required to perform this procedure. Annually or every 1000 hours A+B+C+D
Two-year or every 2000 hours A+B+C+D+E
Indicates that a warm engine will be
required to perform this procedure. 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.

Pre-Delivery Preparation Report
Fundamentals Instructions
Pre-Delive ry Pr epa ratio n Rep ort
It is the responsibility of the owner or dealer to Use the operator’s manual on your machine.
perform the Pre-delivery Preparation.
The Pre-delivery Preparation consists of
The Pre-delivery Preparation is performed prior to completing the Pre-operation Inspection, the
each delivery. The inspection is designed to Maintenance items and the Function Tests.
discover if anything is apparently wrong with a
machine before it is put into service. Use this form to record the results. Place a check
in the appropriate box after each part is
A damaged or modified machine must never be completed. Follow the instructions in the operator’s
used. If damage or any variation from factory manual.
delivered condition is discovered, the machine
must be tagged and removed from service. If any inspection receives an N, remove the
machine from service, repair and re-inspect it.
Repairs to the machine may only be made by a After repair, place a check in the R box.
qualified service technician, according to the
manufacturer's specifications. Legend
Y = yes, acceptable
Scheduled maintenance inspections shall be N = no, remove from service
performed by qualified service technicians, R = repaired
according to the manufacturer's specifications and Comments
the requirements listed in the responsibilities
manual.
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
Maintenance Inspection Report

Maint enan ce In specti on Re por t
Model Checklist A Y N R Checklist B Y N R

Serial number A-1 Inspect the manuals B-1 Batteries
Date and decals
B-2 Electrical wiring
Hour meter A-2 Pre-operation
inspection B-3 Lug nuts
Machine owner
A-3 Function tests B-4 Engine maintenance
Inspected by (print)
- Kubota
Perform after 8 hours:
Inspector signature
B-5 Winch
Inspector title A-4 Engine maintenance
- Kubota B-6 T-bolt
Inspector company
Perform before towing: Perform every 3000 miles:
Instructions A-5 Coupler B-7 Brakes (if equipped)
• Make copies of this report to use for A-6 Brakes (if equipped) B-8 Suspension
each inspection. Perform after 10 miles: Perform every 300 hours:
• Select the appropriate checklist(s) for
the type of inspection(s) to perform. A-7 Lug nuts B-9 Engine maintenance
- Kohler
Daily or every 8 hours A Perform after 10 hours:
Perform every 400 hours:
Quarterly or every A+B A-8 Engine maintenance
250 hours - Kohler B-10 Engine maintenance
Semi-annually or A+B+C - Kubota
Perform weekly:
every 500 hours
A-9 Tires and wheels
Annually or A+B+C+D
every A-10 Engine air filter
1000 hours
A-11 Generator
Two-year or A+B+C+D+E maintenance
every
2000 hours A-12 Engine maintenance
- Kubota
• Place a check in the appropriate box
after each inspection procedure is Perform after 50 hours:
completed.
A-13 Engine maintenance
• Use the step-by-step procedures in - Kohler
this section to learn how to perform
these inspections. Perform monthly:
• If any inspection receives an "N," tag A-14 Cables and pulleys
and remove the machine from service,
repair and re-inspect it. After repair, Perform every 100 hours:
place a check in the "R" box.
- Kubota
Legend Perform every 200 hours:
Y = yes, acceptable
N = no, remove from service
- Kubota
R = repaired
A-17 Generator
maintenance
A-18 Fuel/Water
separator
A-19 Brakes (if equipped)
Perform every 250 hours:

- Kohler

Maintenance Inspection Report
Model Checklist C Y N R Checklist E Y N R

Serial number C-1 Engine maintenance E-1 Cable
Date C-2 Lights Perform every 2000 hours:
Hour meter
Perform every 6000 miles: E-2 Engine maintenance -
Machine owner Kubota
C-3 Wheel bearings
Inspected by (print) Perform every 3000 hours:
C-4 Brakes (if equipped)
Inspector signature E-3 Engine maintenance -
Inspector title Perform every 500 hours: Kubota
Inspector company C-5 Engine maintenance - Perform every 4000 hours:

Kohler
E-4 Engine maintenance -
Instructions Perform every 800 hours: Kohler
C-6 Engine maintenance - Perform every 5000 hours:
• Make copies of this report to use for
Kubota
each inspection. E-5 Engine maintenance -
• Select the appropriate checklist(s) for Perform every 1000 hours: Kohler
the type of inspection(s) to perform. Perform every 10,000 hours:
C-7 Engine maintenance -
Daily or every 8 hours A Kohler
E-6 Engine maintenance -
Quarterly or every A+B Perform every 2000 hours: Kohler
250 hours
C-8 Generator E-7 Generator
Semi-annually or A+B+C maintenance maintenance
every 500 hours
Checklist D Y N R Perform every 20,000 hours:
Annually or A+B+C+D
every Perform every 1500 hours: E-8 Generator
1000 hours maintenance
D-1 Engine maintenance
Two-year or A+B+C+D+E - Kubota Perform every 30,000 hours:
every
Perform every 8000 hours: E-9 Generator
2000 hours
maintenance
• Place a check in the appropriate box D-2 Generator
after each inspection procedure is maintenance
completed. Perform annually:
• Use the step-by-step procedures in
this section to learn how to perform D-3 Coupler
these inspections.
• If any inspection receives an "N," tag
and remove the machine from service,
repair and re-inspect it. After repair,
place a check in the "R" box.
Legend
Y = yes, acceptable
N = no, remove from service
R = repaired

Checklist A Procedures
Chec klis t A Pr oce d ur es
A-1
A-1 Ins pect t he Man uals a nd D ecals
3 Open the operator's manual to the decals

inspection section. Carefully and thoroughly
Inspect the Manuals and Decals inspect all decals on the machine for legibility
and damage.
Result: The machine is equipped with all
Terex specifications require that this procedure be required decals, and all decals are legible and
performed every 8 hours or daily, whichever in good condition.
comes first. Result: The machine is not equipped with all
Maintaining the operator’s and safety manuals in required decals, or one or more decals are
good condition is essential to safe machine illegible or in poor condition. Remove the
operation. Manuals are included with each machine from service until the decals are
machine and should be stored in the container replaced.
provided in the platform. An illegible or missing 4 Always return the manuals to the storage
manual will not provide safety and operational container after use.
information necessary for a safe operating
condition. Note: Contact your authorized Terex distributor or
Terex if replacement manuals or decals are
In addition, maintaining all of the safety and needed.
instructional decals in good condition is mandatory
for safe machine operation. Decals alert operators
and personnel to the many possible hazards
associated with using this machine. They also
provide users with operation and maintenance
information. An illegible decal will fail to alert
personnel of a procedure or hazard and could
result in unsafe operating conditions.
1 Check to make sure that the operator's and
safety manuals are present and complete in
the storage container inside the cabinet.
2 Examine the pages of each manual to be sure
that they are legible and in good condition.
Result: The operator's manual is appropriate
for the machine and all manuals are legible
and in good condition.
Result: The operator's manual is not
appropriate for the machine or all manuals are
not in good condition or is illegible. Remove
the machine from service until the manual is
replaced.

A-2 A-3
A-2 Perf orm Pre- ope rati on In specti on A-3 Perf orm Fu nctio n T ests
Perform Pre-operation Inspection Perform Function Tests
Terex specifications require that this procedure be Terex specifications require that this procedure be
performed every 8 hours or daily, whichever performed every 8 hours or daily, whichever
comes first. comes first.
Completing a Pre-operation Inspection is essential Completing the function tests is essential to safe
to safe machine operation. The Pre-operation machine operation. Function tests are designed to
Inspection is a visual inspection performed by the discover any malfunctions before the machine is
operator prior to each work shift. The inspection is put into service. A malfunctioning machine must
designed to discover if anything is apparently never be used. If malfunctions are discovered, the
wrong with a machine before the operator machine must be tagged and removed from
performs the function tests. The Pre-operation service.
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.
Complete information to perform this procedure is Refer to the Operator's Manual on your machine.
available in the appropriate operator's manual.
Refer to the Operator's Manual on your machine.

A-4 A-5
A-4 Perf orm Engin e M ainte nanc e - Ku bota A-5 Perf orm Cou pler Main tena nce
Perform Engine Maintenance - Perform Coupler Maintenance

Kubota
Coupler specifications require that this procedure

Engine specifications require that this procedure be performed before towing.
be performed every 8 hours or daily, whichever Maintaining the coupler in good condition is
comes first. essential to safe operation and good performance.
Coupler failure could result in a machine tip-over
• Engine oil level – check
during transport, and component damage may
• Coolant level – check/add also result if problems are not discovered and
repaired in a timely fashion.
• Fuel system filter/water separator – drain
1 Check vehicle, mounting bracket, hitch ball
• Engine tightness – check for leaks
and coupler for signs of wear or damage and
• Exhaust system – check for leaks that the coupler handle opens and closes
freely.
• Loose or missing fasteners
Result: if coupler and/or mounting bracket is
Required maintenance procedures and additional deformed or damaged, replace complete
engine information is available in the Kubota coupler and mounting bracket. Replace bent,
D1105-E and V1505-E Operator's Manual (Kubota broken or worn parts before use.
16683-89169 part number )
2 Close coupler securely by ensuring that the
Kubota D-1105 and V-1505 Operator's Manual hitch ball is fully seated in the coupler ball
Genie part number 893020 pocket and the pin is inserted behind the
collar or latch.
3 Check mounting bracket hardware for wear
and proper tightness.
Result: Replace bent, broken or worn
hardware.

A-6 A-7
A-6 T est th e Brak es (if eq uippe d) A-7 T orq ue th e Wh eel L ug Nut s
Test the Brakes (if equipped) Torque the Wheel Lug Nuts
Axle specifications require that this procedure be Axle specifications require that this procedure be
performed before towing. performed initially at 10, 25 and 50 miles of use, or
after reinstallation of a tire.
Maintaining the axle brakes in good condition is
essential to safe operation and good performance. Maintaining the wheel lug nuts at proper torque is
Brakes which are out of adjustment can result in essential to safe operation and good service life of
longer stopping distances and excessive brake the tires, wheel and axle.
wear on the towing vehicle. Component damage
may also result if problems are not discovered and 1 Check each lug nut for proper torque. Refer to
repaired in a timely fashion. Specifications, Machine Specifications.
Test the brakes for proper function. Repair or

replace any faulty components as needed.

A-8 A-9
A-8 Perf orm Engin e M ainte nanc e - Ko hler A-9 Check the Tir es a nd Wh eels
Perform Engine Maintenance - Check the Tires and Wheels

Kohler
Axle specifications require that this procedure be

Engine specifications require that this procedure performed weekly.
be performed every 10 hours or daily, whichever
comes first. Maintaining the tires and wheels in good condition
and the tires at the correct pressure is essential to
• Engine oil level – check safe operation and good performance. Tire and/or
• Coolant level – check/add wheel failure could result in a machine tip-over.
Component damage may also result if problems
• Radiator – clean are not discovered and repaired in a timely
fashion.
• Air filter
• fuel line Bodily injury hazard. An over-
inflated tire can explode and
• Alternator/Fan Belt - Inspect Tension could cause death or serious
Required maintenance procedures and additional injury.
engine information is available in the Kohler
KDW1003 Engine Owner's Manual (Kohler part
number ED0053028440). Tip-over hazard. Do not use
temporary flat tire repair
Kohler KDW1003 Engine Owner's Manual products.
Genie part number 1268769
1 Check all tire treads and sidewalls for cuts,
cracks, punctures and unusual wear.
2 Check each wheel for damage, bends and
cracked welds.
3 Check each lug nut for proper torque. Refer to
Specifications, Machine Specifications.
4 Check the pressure in each air-filled tire.

A-10
A-10 In spect the E ngine Air Filt er
2 Release the latches on the air cleaner cap.

Remove the end cap from the air cleaner
Inspect the Engine Air Filter canister.
3 Remove the filter element.
4 Use a damp cloth to wipe the filter sealing
Terex specifications require that this procedure be
surface and the inside of the outlet tube.
performed every 40 hours or weekly, whichever
Make sure that all contaminant is removed
comes first.
before the filter is inserted.
Maintaining the engine air filter in good condition is 5 Check new filter element gasket for damage
essential to good engine performance and service before installing.
life. Failure to perform this procedure can lead to
poor engine performance and component damage. 6 Install the new filter element.
Note: Perform this procedure with the engine off. 7 Install the end cap on the canister and secure.
Note: Be sure the discharge slot is pointing down.
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 canister end cap
3 dust discharge valve

A-11 A-12
A-11 Per for m Ge ne rato r M ainte nanc e A-12 Per for m Engi ne Maint ena nce - Kubot a
Perform Generator Maintenance Perform Engine Maintenance -

Kubota
Generator specifications require that this

procedure be performed every 40 hours or weekly, Engine specifications require that this procedure
whichever comes first. be performed every 100 hours.
• Clean and inspect the generator exterior • Check fuel lines and clamps
• Clean and replace the generator air filters - Required maintenance procedures and additional
(if equipped) engine information is available in the Kubota
D1105-E and V1505-E Operator's Manual (Kubota
Coliseum Manual
Genie part number 1268770 Kubota D-1105 and V-1505 Operator's Manual

A-13 A-14
A-13 Per for m Engi ne Maint ena nce - Kohle r A-14 In spect the Cable and Cabl e Pulleys
Perform Engine Maintenance - Inspect the Cables and Cable

Kohler Pulleys
Engine specifications require that this procedure Terex specifications require that this procedure be
be performed after 50 hours. performed monthly.
• Engine oil and filter – replace Detection of damage to the cables or pulleys is
essential for safe machine operation. An unsafe
Required maintenance procedures and additional working condition exists if these components are
engine information is available in the Kohler damaged and do not operate smoothly. Regular
KDW1003 Engine Owner's Manual (Kohler part inspection of this system allows the inspector to
number ED0053028440). identify changes in the operating condition that
Kohler KDW1003 Engine Owner's Manual
may indicate damage.
Genie part number 1268769 1 Visually inspect the electric winch and cable
pulleys for the following:
• broken or damaged pulleys
• unusual or excessive pulley wear
Result: A pulley is broken or damaged, or
shows unusual or excessive pulley wear. The
pulley must immediately be replaced.
2 Put on protective leather gloves and eye
wear.
3 Fully unwind the cable from the winch.
4 Wearing leather gloves, run a hand up and
down a length of the cable, inspecting the
cable and components for the following:
• frayed or broken wire strands
Result: In any given one-foot of cable length
there are 4 or more broken wires on any 2 or
more strands. The cable must immediately be
replaced.

A-15
A-15 Per for m Engi ne Maint ena nce - Kubot a
5 Visually inspect the winch cable for the

following:
Perform Engine Maintenance -
• nicks (partial strand cut through) Kubota
• kinks in the cable (permanent bends)
• weld splatter
Result: Nicks, kinks in the cable or weld Engine specifications require that this procedure
splatter are. The cable must immediately be be performed every 100 hours.
replaced.
• Clean air filter
• Clean the fuel filter
following:
• Inspect fan belt
• crushed spot on the cable
Required maintenance procedures and additional
Result: A crushed spot on the cable
engine information is available in the Kubota
measuring 125% of the cable diameter or
more is found OR there is a broken wire at the
crush point. The cable must immediately be 16683-89169 part number )
replaced. Kubota D-1105 and V-1505 Operator's Manual
7 Wind cable onto the winch, ensuring that the Genie part number 893020
cable is correctly installed onto each of the
pulleys.

A-16 A-17
A-16 Per for m Engi ne Maint ena nce - Kubot a A-17 Per for m Ge ne rato r M ainte nanc e
Perform Engine Maintenance - Perform Generator Maintenance

Kubota

Engine specifications require that this procedure procedure be performed every 200 hours or
be performed every 200 hours. quarterly, whichever comes first.
• Change engine oil • Clean and inspect the generator exterior
• Replace oil filter • Check for loose or damaged wires and

components.
• Inspect radiator hoses and clamps
Electrocution/burn hazard.
• Inspect air intake hose Contact with electrically charged
Required maintenance procedures and additional circuits could result in death or
engine information is available in the Kubota serious injury. Remove all rings,
D1105-E and V1505-E Operator's Manual (Kubota watches and other jewelry.
Coliseum Manual
Kubota D-1105 and V-1505 Operator's Manual Genie part number 1268770
a generator

A-18
A-18 Dr ain t he Fuel Filte r/Wate r Sep ara tor
Drain the Fuel Filter/Water

Separator
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.
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 a head bolt
easy reach. b vent plug
c separator head
1 Locate the fuel filter/water separator and
d filter bowl
loosen the vent plug located on the fuel
filter/water separator head. e drain plug
3 Tighten the vent plug and clean up any spills
2 Loosen the drain plug located at the bottom of or wet surfaces.
the bowl. Allow the water to drain into a
suitable container until fuel starts to come out. Note: If the fuel bowl is completely drained,
Immediately tighten the drain plug. you must prime, or bleed, the fuel filter/water
separator before starting the engine. See step
5.
4 Start the engine from the electrical control
panel and check the fuel filter/water separator
for leaks.

A-19
A-19 Adjus t the Brak es (if equi ppe d)
Bleed the fuel system:

5 Loosen the vent plug/screw located on the Adjust the Brakes (if equipped)
filter head.
6 Operate the hand primer until fuel, free of air,
flows from the vent plug/screw. Tighten the
vent plug/screw on the filter head. Axle specifications require that this procedure be
performed initially at 250 miles of use.
7 Loosen the vent screw, located on top of the
fuel injection pump. Maintaining the axle brakes in good condition is
essential to safe operation and good performance.
8 Operate the hand primer until fuel, free of air, Brakes which are out of adjustment can result in
flows from the vent plug/screw. Tighten the longer stopping distances and excessive brake
vent plug/screw on the injection pump. wear on the towing vehicle. Component damage
9 Clean up any fuel that may have spilled. may also result if problems are not discovered and
10 Attempt to start the engine using the starter
motor for a maximum of 15 seconds, resting Note: Perform this procedure on a firm, level
the starter for 30 seconds before trying again. surface with the machine in the stowed position.
11 Inspect the fuel filter/water separator for 1 Select a wheel. Chock the front and rear of
leaks. the tire at the opposite side of the machine.
Explosion and fire hazard. If a 2 Place a lifting jack under the axle near the
fuel leak is discovered, keep any brake to be adjusted. Lift the axle until the
additional personnel from wheel is off the ground and place a jack stand
entering the area and do not under the axle. Lower the axle onto the jack
operate the machine. Repair the stand.
leak immediately.
3 Working from the back side of the wheel at
Note: Required maintenance procedures and the brake backing plate, locate and remove
additional engine information is available in the the small rubber plug from the lower side of
Kubota D1105-E and V1505-E Operator's Manual the backing plate to access the star-shaped
(Kubota 16683-89169 part number ) OR the brake adjuster wheel. Set the plug to the side.
Kohler KDW1003 Engine Owner's Manual (Kohler
part number ED0053028440).

Kubota D-1105 and V-1505 Operator's Manual

A-20
A-20 Per for m Engi ne Maint ena nce - Kohle r
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
Perform Engine Maintenance -
tip of the adjuster tool in an upwards direction Kohler
to tighten the brakes.
Note: It may be helpful to use a flashlight when
locating the brake adjuster wheel.
Engine specifications require that this procedure
5 Repeatedly move the tip of the adjuster tool in be performed every 200 hours.
an upwards direction to tighten the brakes
until the wheel locks up and will no longer
turn. • Inspect air intake hose
Note: This centers the brake shoes on the brake • Change engine oil - add oil if necessary
drum, ensuring the shoes are positioned correctly.
• Replace fuel filter
6 Move the tip of the adjuster tool in a
downwards direction 3 to 5 clicks to loosen
the brakes only until the wheel spins freely engine information is available in the Kohler
with little drag. KDW1003 Engine Owner's Manual (Kohler part
number ED0053028440).
7 Securely install the small rubber plaug into the
brake backing plate. Kohler KDW1003 Engine Owner's Manual
8 Check the wheel bearing wear by attempting
to move wheel hub side to side, then up and
down.
There is no side to side or up and down
movement. The bearing is good.
There is side to side or up and down
movement. The bearing must be adjusted or
replaced. See B-8, Inspect and Adjust the
Brakes (if equipped).
9 Lift the axle slightly. Remove the jack stand
and lower the machine to the ground. Chock
the front and rear of the tire.
10 Repeat this procedure, beginning with step 2,
for the other wheel.

Checklist B Procedures
6 Remove the battery vent caps and check the
Chec klis t B Pr oce d ur es
B-1
B-1 Ins pect t he En gine St art Ba ttery
specific gravity of each battery cell with a

Inspect the Engine Start Battery hydrometer. Note the results.
7 Check the ambient air temperature and adjust
the specific gravity reading for each cell as
follows:
performed every 250 hours or quarterly, whichever • Add 0.004 to the reading of each cell for
comes first. every 10° F / 5.5° C above 80° F / 26.7° C.
Proper battery condition is essential to good • Subtract 0.004 from the reading of each
engine performance and operational safety. cell for every 10° F / 5.5° C below 80° F /
Improper fluid levels or damaged cables and 26.7° C.
connections can result in engine component
Result: All battery cells display an adjusted
damage and hazardous conditions.
specific gravity of 1.277 or higher. The battery
Electrocution/burn hazard. is fully charged. Proceed to step 11.
Contact with electrically charged Result: One or more battery cells display a
circuits could result in death or specific gravity of 1.276 or below. Proceed to
serious injury. Remove all rings, step 8.
watches and other jewelry.
Bodily injury hazard. Batteries

contain acid. Avoid spilling or
contacting battery acid.
Neutralize battery acid spills with
baking soda and water.
Note: Fully charge the batteries and allow the

batteries to rest 24 hours before performing this
procedure to allow the battery cells to equalize.
1 Open the side covers.
2 Be sure that the battery cable connections are
free of corrosion.
Note: Adding terminal protectors and a corrosion
preventative sealant will help eliminate corrosion
on the battery terminals and cables.
3 Be sure that the battery retainers and cable
connections are tight.
4 Be sure that the battery separator wire
connections are tight (if equipped).
Models without maintenance-free or sealed
batteries:
5 Put on protective clothing and eye wear.

8 Perform an equalizing charge OR fully charge 12 Install the vent caps and neutralize any
the battery(s) and allow the battery(s) to rest electrolyte that may have spilled.
at least 6 hours.
13 Close the side covers.
9 Remove the battery vent caps and check the
specific gravity of each battery cell with a
hydrometer. Note the results.
10 Check the ambient air temperature and adjust
the specific gravity reading for each cell as
follows:
• Add 0.004 to the reading of each cell for
every 10° F / 5.5° C above 80° F / 26.7° C.
• Subtract 0.004 from the reading of each
cell for every 10° F / 5.5° C below 80° F /
26.7° C.
Result: All battery cells display a specific
gravity of 1.277 or greater. The battery is fully
charged. Proceed to step 11.
Result: One or more battery cells display a
specific gravity from 1.218 to 1.269. The
battery is still usable, but at a lower
performance. The battery will need to be
recharged more often. Proceed to step 11.
Result: One or more battery cells display a
specific gravity from 1.217 to 1.173. The
battery is approaching the end of its 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.

B-2 B-3
B-2 Ins pect t he Elect rical Wiri ng B-3 T orq ue th e Wh eel L ug Nut s
Inspect the Electrical Wiring Torque the Wheel Lug Nuts
Terex specifications require that this procedure be Axle specifications require that this procedure be
performed every 250 hours or quarterly, whichever performed initially at 10, 25 and 50 miles of use, or
comes first. after reinstallation of a tire.
Maintaining electrical wiring in good condition is Maintaining the wheel lug nuts at proper torque is
essential to safe operation and good machine essential to safe operation and good service life of
performance. Failure to find and replace burnt, the tires, wheel and axle.
chafed, corroded or pinched wires could result in
unsafe operating conditions and may cause 1 Check each lug nut for proper torque. Refer to
component damage. Specifications, Machine Specifications.
Contact with electrically charged
circuits could result in death or
serious injury. Remove all rings,
1 Inspect the following areas for burnt, chafed,

corroded, pinched and loose wires:
• Ground controls
• Battery
• Engine
• Mast
• Lighting junction box
• Trailer lighting wire harness
2 Inspect for a lite, even coating of dielectric
grease in the following locations:
• Lighting junction box
• Ground controls
• All wire harness connectors
Note: Do not apply excessive amounts of dielectric
grease to harness connectors, pins or sockets.
• Note: Do not apply dielectric grease to a
engine ECU/ECM or engine harness
connectors.

B-4 B-5
B-4 Perf orm Engin e M ainte nanc e - Ku bota B-5 Ins pect and Lub ricate the Winch
Perform Engine Maintenance - Inspect and Lubricate the Winch

Kubota

Engine specifications require that this procedure performed every 250 hours or quarterly, whichever
be performed every 250 hours or six months, comes first.
whichever comes first. Maintaining the winch is essential to good machine
performance and safe operation. An unsafe
• Inspect alternator and fan belts
working condition exists if the winch has excessive
Required maintenance procedures and additional wear and/or does not operate smoothly, free of
engine information is available in the Kubota hesitation and binding.
16683-89169 part number ) 1 Carefully lubricate the winch.


B-6 B-7
B-6 Lu bricat e th e T -bol t B-7 Ins pect and Adj ust t he Br akes (if eq uipp ed)
Lubricate the T-bolt Inspect and Adjust the Brakes

(if equipped)

performed every 250 hours or quarterly, whichever Axle specifications require that this procedure be
comes first. performed every 3000 miles or quarterly,
Maintaining the T-bolt is essential to good machine whichever comes first.
performance and safe operation. An unsafe Maintaining the axle brakes in good condition is
working condition exists if the T-bolt has excessive essential to safe operation and good performance.
wear and/or does not operate smoothly, free of Brakes which are out of adjustment can result in
hesitation and binding. longer stopping distances and excessive brake
1 Using the illustration as a guide, locate the T- wear on the towing vehicle. Component damage
bolt at the bottom of the mast assembly. may also result if problems are not discovered and
Remove the T-bolt from the mast. repaired in a timely fashion.
2 Remove all dust, dirt and copper anti-seize Note: Perform this procedure with the machine on
from the threaded surfaces of the T-bolt, and a firm, level surface with the machine in the
apply a few drops of light oil or copper anti- stowed position.
seize lubricant onto the threaded surfaces.
1 Select a wheel. Chock the front and rear of
3 Fully install the T-bolt into the mast. the tire at the opposite side of the machine.
2 Loosen the wheel lug nuts. Do not remove
them.
3 Place a lifting jack under the axle near the
wheel to be removed. Lift the axle until the
wheel is off the ground and place a jack stand
under the axle. Lower the axle onto the jack
stand and remove the wheel.
4 Remove the dust cap from the hub. Remove
the cotter pin from the castle nut.
5 Remove the castle nut and washer.
6 Pull the hub off of the spindle. The washer
and outer bearing should fall loose from the
a T-bolt hub.

7 Inspect the brake lining for wear (if equipped). 14 Install a new cotter pin. Bend the cotter pin to
lock it in place.
Result: the thickness of the brake lining is
greater than 1/16 inch / 1.6 mm. The brake Note: Always replace the cotter pin with a new one
shoes are good. when removing the castle nut.
Result: the thickness of the brake lining is 15 Install the dust cap, then the tire and wheel
1/16 inch / 1.6 mm or less. The brake shoes assembly. Torque the wheel lug nuts to
must be replaced and the brake drums must specification. Refer to Section 2,
be inspected for wear, scoring and other Specifications.
damage.
16 Working from the back side of the wheel at
Note: The maximum bore of a good brake drum the brake backing plate, locate and remove
shall not be greater than 0.090 inch / 2.29 mm in the small rubber plug from the lower side of
excess of the drum diameter. the backing plate to access the star-shaped
brake adjuster wheel. Set the plug to the side.
Note: If drum resurfacing is required, the brake
drum should be resurfaced to a 120 micron finish. 17 Insert a brake adjuster tool into the opening of
the brake backing plate, engaging it with the
Note: If replacing the brake shoes, apply a light teeth of the brake adjuster wheel. Move the
coat of grease or anti-seize compound to the tip of the adjuster tool in an upwards direction
anchor pin, arm bushing and pin, and areas of the to tighten the brakes.
backing plate which contact the magnet arm and
brake shoes frame. Apply a small amount of lube Note: It may be helpful to use a flashlight when
to the actuating cam at the top of the magnet arm. locating the brake adjuster wheel.
Do not allow grease or oil to contact the brakes
18 Repeatedly move the tip of the adjuster tool in
shoes or the inside of the drum.
an upwards direction to tighten the brakes
8 Slide the hub onto the yoke spindle. until the wheel locks up and will no longer
turn.
Component damage hazard. Do
not apply excessive force or Note: This centers the brake shoes on the brake
damage to the lip of the seal drum, ensuring the shoes are positioned correctly.
may occur. 19 Move the tip of the adjuster tool in a
downwards direction 3 to 5 clicks to loosen
9 Place the outer bearing into the hub. the brakes only until the wheel spins freely
10 Install the washer and the castle nut. with little drag.
11 Tighten the castle nut to 50 ft-lbs / 68 Nm to
seat the bearings.
12 Fully loosen the castle nut. Do not rotate the
hub.
13 Finger tighten the castle nut until snug.

B-8
B-8 Ins pect t he Sus pensi on
20 Securely install the small rubber plug into the

brake backing plate.
Inspect the Suspension
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
performed every 3000 miles or quarterly,
movement. The bearing is good.
whichever comes first.
There is side to side or up and down
movement. The bearing must be adjusted or Maintaining the axle suspension in good condition
replaced. See B-8, Inspect and Adjust the is essential to safe operation and good
Brakes (if equipped). performance. Towing the machine with worn or
damaged suspension components could result in a
22 Lift the axle slightly. Remove the jack stand tip-over. Component damage may also result if
and lower the machine to the ground. Chock problems are not discovered and repaired in a
the front and rear of the tire. timely fashion.
23 Repeat this procedure, beginning with step 2, 1 Working with a flashlight or in a well lit shop,
for the other wheel. carefully inspect all suspension components
and fasteners. Replace as necessary.

B-9 B-10
B-9 Perf orm Engin e M ainte nanc e - Ko hler B-10 Per for m Engi ne Maint ena nce - Kubot a
Perform Engine Maintenance - Perform Engine Maintenance -

Kohler Kubota
Engine specifications require that this procedure Engine specifications require that this procedure
be performed every 300 hours. be performed every 400 hours or semi-annually,
• Replace oil filter
• Inspect air intake hose
• Replace fuel filter
• Inspect alternator and fan belts
Required maintenance procedures and additional engine information is available in the Kubota
engine information is available in the Kohler D1105-E and V1505-E Operator's Manual (Kubota
number ED0053028440).

Checklist C Procedures
C-2
Chec klis t C Pr oce d ur es C-2 Clea n th e Lig ht Asse mblies
C-1
C-1 Per for m Engin e M ainte nanc e
Perform Engine Maintenance Clean the Light Assemblies
Engine specifications require that this procedure Terex specifications require that this procedure be
be performed every 500 hours. performed every 500 hours or semi-annually,
Kohler engine only:
Maintaining the light assemblies is essential to
• Check valve clearance good machine performance. Failure to regularly
Kubota engine only: clean the light assemblies may result in less light
than expected and, over time, could result in
• Replace fan belts damage to the machine.
• Flush coolant system Note: Perform this procedure with the light
assemblies out of direct sunlight and cool to the
• Clean fuel tank
touch.
engine information is available in the Kubota 1 Use clean, cool water to rinse the surface of
D1105-E and V1505-E Operator's Manual (Kubota each light assembly.
16683-89169 part number ) OR the Kohler 2 Clean each light assembly using a soft cloth,
KDW1003 Engine Owner's Manual (Kohler part water and a mild dishwashing detergent.
number ED0053028440).
Component damage hazard.
Kohler KDW1003 Engine Owner's Manual Harsh checmcals and cleaning
Genie part number 1268769 agents will damage the surface
of the light assembly. Do not
allow harsh cleaning agents to
Genie part number 893020 make contact with the light
surface..
3 Thoroughly rinse, then dry with a soft cloth.

C-3
C-3 Gr eas e the Whe el Beari ngs
5 Remove the castle nut and washer.

Grease the Wheel Bearings 6 Pull the hub off of the spindle. The washer
and outer bearing should fall loose from the
hub.
7 Place the hub on a flat surface and gently pry
the bearing seal out of the hub. Remove the
performed every 6,000 hours or semi-annually,
rear bearing.
8 Pack both bearings with clean, fresh grease.
Maintaining the axle wheel bearings is essential to
safe machine operation and service life. Operating 9 Inspect the hub for wear. Replace if
a machine with loose or worn wheel bearings may necessary.
cause an unsafe operating condition and 10 Place the large inner bearing into the rear of
continued use may result in component damage. the hub.
Extremely wet or dry conditions or regular steam
cleaning and pressure washing of the machine 11 Install a new bearing grease seal into the hub
may require that this procedure be performed by pressing it evenly into the hub until it is
more often. flush.
Note: Perform this procedure with the machine on Note: Always replace the bearing grease seal
a firm, level surface with the machine in the when removing the hub.
stowed position. 12 Inspect the brake lining for wear (if equipped).
1 Select a wheel. Chock the front and rear of 13 Inspect the brake cylinder for leaks (if
the tire at the opposite side of the machine. equipped).
2 Loosen the wheel lug nuts. Do not remove 14 Inspect the brake springs for wear or loss of
them. arch (if equipped).
3 Place a lifting jack under the axle near the 15 Inspect the brake wiring/hoses for wear (if
wheel to be removed. Lift the axle until the equipped).
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.

C-4
C-4 Ins pect the Ele ctric Br ake Mag nets
16 Slide the hub onto the yoke spindle.

Component damage hazard. Do Inspect the Electric Brake
not apply excessive force or Magnets (if equipped)
damage to the lip of the seal
may occur.
17 Place the outer bearing into the hub. Axle specifications require that this procedure be
18 Install the washer and the castle nut. performed every 6,000 hours or semi-annually,
19 Tighten the castle nut to 50 ft-lbs / 68 Nm to
seat the bearings. Maintaining the axle brakes in good condition is
20 Fully loosen the castle nut. Do not rotate the
A faulty brake magnet can severely impact the
hub.
stopping power of a trailer. While some magnet
21 Finger tighten the castle nut until snug. problems will be apparent upon visual inspection,
there may also be electrical problems that can
22 Install a new cotter pin. Bend the cotter pin to impact performance. A failing or faulty brake
lock it in place. magnet can lead to weak or surging brakes, or
Note: Always replace the cotter pin with a new one cause the brakes to pull to one side. It is important
when removing the castle nut. to inspect and test the magnets at regular intervals
to ensure maximum effectiveness.
Install the dust cap, then the tire and wheel
assembly. Torque the wheel lug nuts to 1 Connect the electric brake wire harness to a
specification. Refer to Section 2, Specifications. tow vehicle capable of towing the machine.
2 Start the engine of the tow vehicle, and press
down on the brake pedal.
Result: An audible 'click' is noted at each
brake when the brake magnet is activated and
pulls itself into contact with the brake drum.
The brake circuit is functioning correctly.
Result: An audible 'click' is not noted at each
brake because the brake magnet is not
activated and does not make contact with the
brake drum. The brake circuit is faulty. Inspect
the wire harness and harness connections
and repair as required, and repeat this
procedure beginning with step 2.

3 With the engine running, press down on the 11 Locate the brake magnet. Inspect the surface
brake pedal and use a multimeter to measure of the magnet for pitting and any irregular
the total amp draw of the brake circuit by surface wear.
positioning an amp clamp around the brake
Result: Replace the magnets and magnet
wire lead near the trailer connector. Note the
springs on both sides of the axle if pitting or
reading.
any irregular surface wear is detected, and
Result: The total amp draw measures 5.5 to resurface the brake drums.
6.0 amps. The brake circuit is functioning
12 Inspect the copper coil at the center of the
correctly.
magnet.
Result: The total amp draw measures less
Result: Replace the magnets and magnet
than 5.5 amps. Replace the magnets and
springs on both sides of the axle if the
magnet springs on both sides of the axle, and
exposed copper coil is visible in any way, and
resurface the brake drums. Repeat this
resurface the brake drums.
procedure beginning with step 4.
13 Slide the hub onto the yoke spindle.
4 Stop the engine of the tow vehicle.
5 Select a wheel. Chock the front and rear of Component damage hazard. Do
the tire at the opposite side of the machine. not apply excessive force or
damage to the lip of the seal
6 Loosen the wheel lug nuts. Do not remove may occur.
them.
7 Place a lifting jack under the axle near the 14 Place the outer bearing into the hub.
wheel to be removed. Lift the axle until the 15 Install the washer and the castle nut.
under the axle. Lower the axle onto the jack 16 Tighten the castle nut to 50 ft-lbs / 68 Nm to
stand and remove the wheel. seat the bearings.
8 Remove the dust cap from the hub. Remove 17 Fully loosen the castle nut. Do not rotate the
the cotter pin from the castle nut. hub.
9 Remove the castle nut and washer. 18 Finger tighten the castle nut until snug.
10 Pull the hub off of the spindle. The washer 19 Install a new cotter pin. Bend the cotter pin to
and outer bearing should fall loose from the lock it in place.
hub. Note: Always replace the cotter pin with a new one
when removing the castle nut.
20 Install the dust cap, then the tire and wheel
assembly. Torque the wheel lug nuts to
specification. Refer to Section 2,
Specifications.
21 Repeat this procedure, beginning with step 6,
for the other side of the machine.

C-5 C-6
C-5 Per for m Engin e M ainte nanc e - Kohle r C-6 Per for m Engin e M ainte nanc e - Kubot a

Kohler Kubota
be performed every 500 hours. be performed every 800 hours or annually,
• Change engine oil
• Replace air filter
engine information is available in the Kohler • Inspect wiring
number ED0053028440). • Check valve clearance
Kohler KDW1003 Engine Owner's Manual engine information is available in the Kubota
Genie part number 1268769 D1105-E and V1505-E Operator's Manual (Kubota


C-7 C-8
C-7 Per for m Engin e M ainte nanc e - Kohle r C-8 Per for m Ge ner ato r M ainte nanc e

Kohler

Engine specifications require that this procedure procedure be performed every 2000 hours or
be performed every 1000 hours. semi-annually, whichever comes first.
Maintaining the generator in good condition is
• Injector cleaning and adjustment
essential to safe operation and long service life.
• Flush coolant system Storing the generator in a harsh environment may
require this procedure be performed more
• Clean fuel tank frequently. Loose or damaged connections or
• Replace coolant components may result in a generator to lose
efficiency, and reduce the life of the generator.
• Replace fuel hoses and clamps
• Inspect stator output leads and insulation
• Replace air intake hose and clamps for cracking and damage.
• Replace radiator hoses and clamps • Inspect exposed electrical for loose or
Required maintenance procedures and additional damaged connections.
• Inspect transformers, fuses, capacitors and
KDW1003 Engine Owner's Manual (Kohler part lighting arrestors for loose or damaged
number ED0053028440). component connections.
Kohler KDW1003 Engine Owner's Manual • Inspect all wire and electrical connections
Genie part number 1268769 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

Checklist D Procedures
D-2
Chec klis t D Pr oce d ur es D-2 Per for m Ge ner ato r M ainte nanc e
D-1
D-1 Per for m Engin e M ainte nanc e - Kubot a

Kubota

procedure be performed every 8000 hours or
Engine specifications require that this procedure
annually, whichever comes first.
be performed every 1500 hours or bi-annually,
whichever comes first. Maintaining the generator in good condition is
• Injectors
Storing the generator in a harsh environment may
Required maintenance procedures and additional require this procedure be performed more
engine information is available in the Kubota frequently. Poor resistance may result in a
D1105-E and V1505-E Operator's Manual (Kubota generator to lose efficiency, and reduce the life of
16683-89169 part number ) the generator.
Kubota D-1105 and V-1505 Operator's Manual • Check resistance to ground on generator
windings, main rotating assembly, stator,
exciter field and armature.
Coliseum Manual

Checklist D Procedures
D-3
D-3 Per for m Cou pler Mai nten ance
Perform Coupler Maintenance
Coupler specifications require that this procedure

be performed annually.
Maintaining the coupler in good condition is
Coupler failure could result in a machine tip-over
during transport, and component damage may
also result if problems are not discovered and
1 Check coupler welds and mounting bolt
torque. Torque the fasteners to 35 ft-lbs / 48
Nm.
Result: 1.5 full threads of the locking bolt must
be exposed beyond the lock nut after the
adjustment.
2 Apply automotive grease to the coupler ball
pocket.
3 Oil coupler pivot points using SAE 30 motor
oil.

Checklist E Procedures
Chec klis t E Pr oce dur e s
E-1
E-1 Ins pect t he C able and C able Pull eys

following:
Inspect the Cables and Cable
Pulleys • nicks (partial strand cut through)
• kinks in the cable (permanent bends)
• weld splatter
Terex specifications require that this procedure be Result: Nicks, kinks in the cable or weld
performed every two years. splatter are. The cable must immediately be
replaced.
Detection of damage to the cables or pulleys is
essential for safe machine operation. An unsafe 6 Visually inspect the winch cable for the
working condition exists if these components are following:
damaged and do not operate smoothly. Regular
inspection of this system allows the inspector to • crushed spot on the cable
identify changes in the operating condition that Result: A crushed spot on the cable
may indicate damage. measuring 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.
• broken or damaged pulleys 7 Wind cable onto the winch, ensuring that the
• unusual or excessive pulley wear cable is correctly installed onto each of the
pulleys.
Result: A pulley is broken or damaged, or
shows unusual or excessive pulley wear. The If the mast cables need replacing, refer to Repair
pulley must immediately be replaced. Procedure, How to Replace the Mast Lift Cables.
2 Put on protective leather gloves and eye
wear.
3 Fully unwind the cable from the winch.
4 Wearing leather gloves, run a hand up and
down a length of the cable, inspecting the
cable and components for the following:
• frayed or broken wire strands
Result: In any given one-foot of cable length
there are 4 or more broken wires on any 2 or
more strands. The cable must immediately be
replaced.

E-2 E-3
E-2 Perf orm Engin e M ainte nanc e - Ku bota E-3 Perf orm Engin e M ainte nanc e - Ku bota

Kubota Kubota
be performed every 2000 hours or bi-annually, be performed every 3000 hours.
• Inspect injection pump
• Replace coolant
• Inspect injection timing
• Replace radiator hoses and clamps
• Replace fuel hoses and clamps engine information is available in the Kubota
• Replace air intake hose and clamps 16683-89169 part number )
engine information is available in the Kubota Kubota D-1105 and V-1505 Operator's Manual
D1105-E and V1505-E Operator's Manual (Kubota Genie part number 893020


E-4 E-5
E-4 Perf orm Engin e M ainte nanc e - Ko hler E-5 Perf orm Engin e M ainte nanc e - Ko hler

Kohler Kohler
be performed every 4000 hours. be performed every 5000 hours.
• Replace timing belt • Partial engine overhaul
• Replace air filter Required maintenance procedures and additional
Required maintenance procedures and additional KDW1003 Engine Owner's Manual (Kohler part
number ED0053028440).
number ED0053028440). Kohler KDW1003 Engine Owner's Manual
Kohler KDW1003 Engine Owner's Manual Genie part number 1268769


E-6 E-7
E-6 Perf orm Engin e M ainte nanc e - Ko hler E-7 Perf orm Gen er ator Mai nten ance

Kohler

Engine specifications require that this procedure procedure be performed every 10,000 hours.
be performed every 10,000 hours. Maintaining the generator in good condition is
• Total engine overhaul
Regular replacement of the shaft bearing will
Required maintenance procedures and additional extend the life of the generator.
KDW1003 Engine Owner's Manual (Kohler part • Replace the generator shaft bearing.
number ED0053028440). Consult a trained Coliseum service
professional.
Coliseum Manual

E-8 E-9
E-8 Perf orm Gen er ator Mai nten ance E-9 Perf orm Gen er ator Mai nten ance
Perform Generator Maintenance Perform Generator Maintenance
Generator specifications require that this Generator specifications require that this
procedure be performed every 20,000 hours or procedure be performed every 30,000 hours or
3 years, whichever comes first. 5 years, whichever comes first.
Maintaining the generator in good condition is Maintaining the generator in good condition is
essential to safe operation and long service life. essential to safe operation and long service life.
Storing the generator in a harsh environment may Storing the generator in a harsh environment may
require this procedure be performed more require this procedure be performed more
frequently. Allowing dirt and grease to build up on frequently. Allowing dirt and grease to build up on
the generator may result in a generator which will the generator may result in a generator which will
run hotter, lose efficiency, and reduce the life of run hotter, lose efficiency, and reduce the life of
the generator. the generator. Regular replacement of the shaft
bearing will extend the service life of the
• Inspect and clean the generator and generator.
windings for oil or dirt contamination.
• Disassemble the generator, including rotor
removal.
Coliseum Manual
• Inspect and clean generator components
including generator windings.
• Replace the generator shaft bearings.
Consult a trained Coliseum service
professional.
Coliseum Manual

Repair Procedures
Machine Configuration:
Secti on 4 Repair P roce dur es
Intro ductio n
 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
Observe and Obey:
• Key switch in the off position with the key
 Repair procedures shall be completed by a removed
person trained and qualified on the repair of
this machine. • The red Emergency Stop button in the off
position on the electrical control box
 Immediately tag and remove from service a
damaged or malfunctioning machine. • Wheels chocked
 Repair any machine damage or malfunction • Light switches in the off position
before operating the machine.
• All external AC power supply disconnected
from 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.

Repair Procedures
About This Section

Most of the procedures in this section should only
be performed by trained service professional in a
suitably equipped workshop. Select the
appropriate repair procedure after troubleshooting
the problem.
Perform disassembly procedures to the point
where repairs can be completed. Then to re-
assemble, perform the disassembly steps in
reverse order.
Symbols Legend
Safety alert symbol—used to alert
personnel to potential personal
injury hazards. Obey all safety
messages that follow this symbol
to avoid possible injury or death.
Indicates a imminently hazardous

situation which, if not avoided, will
result in death or serious injury.

could result in death or serious
injury.

may cause minor or moderate
injury.

Indicates that a specific result is expected

Indicates that an incorrect result has occurred

Lighting
1-2
Lig hti ng 1-2 H ow to C heck Line Volt age
1-1
1-1 H ow to R emov e a La mp
How to Remove a Lamp How to Check Line Voltage

Electrocution/burn hazard. Correct line voltage at the lamp socket is essential
Contact with electrically charged for proper operation of the lighting system.
serious injury. Remove all rings, Electrocution/burn hazard.
watches and other jewelry. Contact with electrically charged
Burn hazard. Beware of hot
lamp components. Contact with 1 Turn off all machine power.
hot lamp components may result 2 Remove the cover from the lamp junction box.
in severe burns.
Note: The junction box is located between the light
1 Turn off all machine power. housings at the top of the mast.
2 Remove the light lens mounting fasteners and 1 Locate the correct wiring for the lamp to be
remove the lens. tested.
3 Remove the spring securing the lamp to the 2 Connect a voltmeter to the lamp wires.
lamp retainer.
3 Start the engine.
Component damage hazard. 4 Turn the appropriate circuit breaker light
Contacting the lamp with bare
switch to the "ON" position.
skin can cause damage to the
lamp. Do not allow bare skin 5 Observe the voltage as the lamps warm up.
contact with the lamps. Refer to the following chart.
Note: It can take up to 5 minutes for the lights to
4 Wrap a clean cloth around the lamp and
reach full intensity. If the lights are turned off and
remove it from the socket.
then turned back on while they are still warm, they
Note: Be sure to wrap a clean cloth around the may not light up again for 10 to 20 minutes.
lamp when installing it into the lamp socket.
Time Line Voltage
Initial ignition 415V AC
30 seconds 412V AC
1 minute 413V AC
2 minutes 416V AC
5 minutes 246V AC
10 minutes 251V AC
Note: If voltage reading remains high during warm
up, check for loose or broken wire connections or
the lamp may be faulty.
Note: The voltage readings provided in the chart
are averages, voltage on your machine may vary.

Mast
2-2
Mast 2-2 H ow to Dis asse mble t he Mast Ass embly
2-1
2-1 H ow to R emov e th e M ast Asse mbly
How to Remove the Mast How to Disassemble the Mast

Assembly Assembly
Bodily injury hazard. The 1 Remove the mast assembly. See 1-1, How to
procedures in this section Remove the Mast Assembly.
require specific repair skills, 2 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
Bodily injury hazard. Cables
service is required.
can fray. Always wear
adequate hand protection when
Bodily injury hazard. Cables handling the cable.
Component damage hazard.
handling the cable.
Cables can be damaged if they
1 Tag and remove the light heads from the are kinked or pinched.
mast.
4 Remove the light bar assembly and hardware
2 Remove the junction box from the light bar. from the 1.5 inch / 3.8 cm mast section and
Remove and retain the coil cord clamp and set aside. Remove the 1.5 inch / 3.8 cm mast
hardware from the base section of the mast. section from the 2 inch / 5 cm mast section.
Lay the coil cord, junction box and lamp Disconnect the cable from the 2 inch / 5 cm
heads to the side. mast section by removing the cable retention
pin.
3 Remove the fasteners securing the mast base
to the chassis. 5 Working at the top of the 3 inch / 7.5 cm mast
section, use a drill to remove the rivets
4 Attach a lifting strap from an overhead crane
securing the wear pads in position.
to the mast base beneath the rotating section
and T-bolt. Remove the mast from the 6 Remove the 2 inch / 5 cm mast section from
machine. 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.

Mast
7 Working at the top of the 4 inch / 10 cm mast

section, use a drill to remove the rivets
securing the wear pads in position.
8 Remove the 3 inch / 7.5 cm mast section from
the 4 inch / 10 cm mast section. Disconnect
the cable from the 4 inch / 10 mast section by
removing the cable retention pin.
9 Remove the clevis pin and sheave from the
2 inch / 5 cm mast section.
3 inch / 7.5 cm mast section.
4 inch / 10 cm mast section.
Note: For ease of assembly, note the location
where each wear pad is removed.
Note: To ensure that the mast extends properly
after assembly, carefully measure the cable to
confirm that the new cable is the same length as
the old one.
Note: During assembly, carefully install the mast
cable. Refer to the illustration on the following
page for cable routing.

Mast
Note: Refer to the illustration below for cable
2-3
2-3 H ow to R eplac e th e Ma st Lift Cable s
routing detail.
How to Replace the Mast Lift
Cables
See 2-2, How to Disassemble the Mast Assembly.

Mast
2-4
2-4 H ow to R emov e th e M anu al Winch
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.
handling the cable.
4 Remove the winch from the machine.

Mast
2-5
2-5 H ow to R emov e th e Elect ric Winch
3 On the electric winch, turn the yellow cap to

the free spool position.
How to Remove the Electric
Winch Bodily injury hazard. Cables
1 Lower the mast assembly to the stowed adequate hand protection when
position. handling the cable.
2 Remove the fasteners and winch covers from 4 Pull the cable to unwind it from the winch
the 4 inch / 10 cm mast assembly and set drum.
aside. Refer to the illustration below.
5 Loosen the set screw securing the cable.
Note: Before removing the cable from the winch
drum, make note of the cable routing. The cable
must be routed the same way when installing the
electric winch.
6 Remove the fasteners securing the electric
winch to the 4 inch / 10 cm mast assembly.
a winch covers
b electric winch
c engaged/free spool lock
d 4 inch / 10 cm mast assembly

Mast
2-6
2-6 H ow to Dis eng age the Tow er L ock
Unlock the tower:

How to Disengage the Tower
6 Loosen the T-bolt and rotate the tower so that
Lock the lock holes are facing forward. Re-tighten
To disengage the light tower lock so the tower can T-bolt to secure the tower.
be lowered to the stowed position and towed to a 7 Using the figure below, attach a lifting strap
suitable workshop for repairs follow the steps around the first movable tower section (1) as
below. shown.
Bodily injury hazard. This
procedure requires specific repair
skills, lifting equipment and a
suitable workshop. Attempting
this procedure without these
skills and tools could result in
death or serious injury and
significant component damage.
Dealer service is strongly
recommended.

handling the cable.
Remove the front fairing:

1 Raise the rear hatch fairing. Disconnect the
gas struts and close the rear hatch fairing.
2 Remove the hinge bolts that go through the
front fairing.
3 Next remove the remaining front fairing
fasteners and loosen the front fairing enough
to access the trailer wiring harness
connectors.
4 Disconnect the two connectors at the roll bar
located on the upper road side of the light
tower.
5 Feed the draw bar wiring up through the hole
then remove the front fairing and set aside.

Mast
8 Using a Telehandler or construction forklift
slowly begin lifting up the first movable tower
section (2) until the tower lock lever (3)
disengages.
9 Slowly begin lowering the tower while using a

pry bar to push in on the tower lock lever to
prevent it from engaging the lock hole.
10 Repeat step 9 until the tower is completely
down in the stowed position.
Transport the light tower to be repaired:

11 Once the light tower mast has been lowered
to the stowed position reinstall the front fairing
using the fasteners removed in the "Remove
the front fairing" section above.
12 The light tower can now be towed to the
nearest dealer service center for complete
tower disassembly and rebuild.

Kohler KDW1003GE Engine
3-3
Kohl er KDW100 3GE En gin e 3-3 C oolan t T emp era tur e an d Oil Pr essur e Switche s-Kohl er En gines
3-1
3-1 Timin g Adjust me nt-Kohl er En gines
Timing Adjustment-Kohler Coolant Temperature and Oil

Engines Pressure Switches-Kohler
Engines
Complete information to perform this procedure is
available in the Kohler KDW 702 - 1003 - 1404 The engine coolant temperature switch is a
Workshop Manual (Kohler part number: normally open switch. The switch contacts close at
ED0053029340). approximately 235°F / 113°C. If the coolant
temperature rises above the switch point, the
Kohler KDW 702 - 1003 - 1404 Workshop Manual
switch contacts close and the engine will shut off
Genie part number 1268828 to prevent damage. The engine will not start until
the temperature drops below the switch point.
Additionally a low coolant level can cause the
3-2
3-2 Gl ow Plugs -Kohle r Engin es
coolant temperature switch to not work properly.

Glow Plugs-Kohler Engines Make sure that the coolant system is at proper
level.
1 Disconnect the wiring and buss bar from the
glow plugs. The engine oil pressure switch is a normally
closed switch. The switch contacts open at
2 Connect the leads from an ohmmeter approximately 6.5 psi / 0.45 bar. If the oil pressure
between each glow plug terminal and ground. drops below the switch point, the contacts open
Result: The resistance should be and the engine will shut off to prevent damage.
approximately 1 ohm.
Result: The resistance is 0 ohm or greater
than 1 ohm. The glow plug is faulty.

Kubota D1105-E4BG Engine
4-3
Kub ota D110 5-E4B G En gin e 4-3 C oolan t T emp era tur e an d Oil Pr essur e Switche s-Kub ota En gines
4-1
4-1 Timin g Adjust me nt-Kub ota E ngines
Timing Adjustment-Kubota Coolant Temperature and Oil

Engines Pressure Switches-Kubota
Engines
Complete information to perform this procedure is
available in the Kubota 05 Series Workshop The engine coolant temperature switch is a
Manual (Kubota part number: 97897-02432). normally open switch. The switch contacts close at
approximately 225°F / 107°C. If the coolant
Kubota 05 Series Workshop Manual
temperature rises above the switch point, the
Genie part number 31742 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.
4-2
4-2 Gl ow Plugs -Kubo ta Engi nes
Additionally a low coolant level can cause the

Glow Plugs-Kubota Engines coolant temperature switch to not work properly.
Make sure that the coolant system is at proper
1 Disconnect the wiring and buss bar from the level.
glow plugs.
The engine oil pressure switch is a normally
2 Connect the leads from an ohmmeter closed switch. The switch contacts open at
between each glow plug terminal and ground. approximately 7 psi / 0.48 bar. If the oil pressure
Result: The resistance should be drops below the switch point, the contacts open
approximately 1 ohm. and the engine will shut off to prevent damage.
Result: The resistance is 0 ohm or greater

than 1 ohm. The glow plug is faulty.

Generator
Gener a tor
5-1
5-1 G ene rat or
7 Remove the screws and washers securing the

generator pedestal to the chassis.
Generator
engine components. Contact
How to Remove the Generator with hot engine components
High voltage. Exposure to may result in severe burns.
electrical wires or electrical
8 Open the control box by removing the two
current will result in death or
upper screws of the control panel. Tilt the
serious injury. Turn off all power
control panel forward in order to access the
when not needed for testing.
generator wiring located on the inside of the
Use extreme caution when
control box.
working with high voltage
electrical components. 9 Using an insulated conductor or a screwdriver
with an insulated handle, discharge the
capacitor by shorting across the capacitor
terminals.
Attempting to service the High voltage. Exposure to
machine before the capacitor is electrical wires or electrical
fully discharged will result in current will result in death or
death or serious injury. serious injury. Use extreme
caution when working with high
Note: Be sure the engine has been turned off for at voltage electrical components.
least 15 minutes before servicing the machine.
Use a voltmeter to confirm there is no residual 10 Tag and disconnect all external wires from the
voltage in the capacitor. generator.
1 Deploy the outriggers and level the machine. 11 Support the generator using the lifting eye.
2 Disconnect the rear fairing wiring harnesses 12 Remove the fasteners securing the generator
located along side the roadside lift bar. to the engine bellhousing.
3 Disconnect the gas struts on the rear fairing 13 Pull the generator away from the engine just
assembly from the lift bar. enough to reach the fasteners securing the
generator rotor to the engine flywheel.
4 Remove the screws from the hinges attaching Remove the fasteners.
the rear fairing assembly to the lift bar.
14 Remove the generator from the machine.
5 Carefully lift the rear fairing assembly off the
unit and set aside. Crushing hazard. The generator
may become unbalanced and fall
6 Remove the left side cabinet weldment and
if not properly supported when
fender.
removed from the machine.

Generator
5-2
5-2 H ow to C heck a Ge ner ator Cap acitor
4 With an ohmmeter set to its highest

resistance scale, connect the ohmmeter leads
How to Check a Generator to the capacitor terminals and observe the
Capacitor reading on the meter. Then, reverse the
connections and observe the reading on the
High voltage. Exposure to meter.
current will result in death or Result: The meter indicates a very low
serious injury. Turn off all power resistance which then gradually increases
when not needed for testing. AND a very high resistance which then
Use extreme caution when gradually decreases. The capacitor is
working with high voltage working.
electrical components. Result: The meter indicates a very high
resistance which does not decrease. The
capacitor is faulty and should be replaced.
Electrocution/burn hazard. Result: The meter indicates a very low
Attempting to service the resistance which does not increase. The
machine before the capacitor is capacitor is faulty and should be replaced.
fully discharged will result in
death or serious injury.
Note: Be sure the engine has been turned off for at

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
capacitor by shorting across the capacitor
terminals.
High voltage. Exposure to
serious injury. Use extreme
caution when working with high
voltage electrical components.
3 Tag and disconnect the wires attached to the

capacitor.

Generator
5-3
5-3 H ow to C heck a Ge ner ator Diod e
5 Reverse the multimeter lead connections.

Note the results.
How to Check a Generator Diode
Result: The two readings are at a ratio of
High voltage. Exposure to 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
serious injury. Turn off all power
be replaced.
when not needed for testing.
Use extreme caution when Note: Before installing a new diode, clean the
working with high voltage surface of the exciter rotor core, and run a bead of
electrical components. a thermal-electrical compound around the base of
the diode (the threads of the diode should not be
coated). Torque to 20 to 30 in-lbs / 2.2 to 3.4 Nm.
Attempting to service the
machine before the capacitor is
fully discharged will result in
Note: Be sure the engine has been turned off for at

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.
2 Locate the diode at the end of the generator.
3 Tag and disconnect the positive wire lead
from the diode.
4 With a multimeter set to test diodes, connect
one multimeter lead to the diode terminal and
the other multimeter lead to the 'Q' lead
terminal of the generator. Note the results.
Note: Refer to the instructions which are provided
for your multimeter to ensure the diode is
accurately tested.

Light Ballast
Lig ht B alla st
6-1
6-1 G rou nd C ontr ols
10 Use the day, hour and minute buttons to set

the timer to the desired start day and time.
Ground Controls
11 Press the program button (P) to set the timer
for the desired shut-off time. AM 12:00 will
How to Program the Engine Start appear in the display with a small 2 to the
Timer right.
The timer is used to automatically start the engine Note: The lamp symbol will not appear above the
and turn on the lights at a preset time. 2.
1 Move the engine start switch to timed start. 12 Use the day, hour and minute buttons to set
the timer to the desired shut-off day and time.
2 On the timer, move the mode switch (upper
left switch) to AUTO and the set switch (upper 13 Move the set switch to RUN.
right switch) to RUN.
3 Using the tip of a pencil or pen, press the
Reset button (R). A blinking display will show
0:00 for the time and an arrow under the day
7 (for Sunday).
4 Move the set switch to the left (clock icon) to
set the present day and time.
5 A default time of AM 12:00 will appear on the
display screen.
6 Press the day button (1..7) repeatedly until
the arrow points to the actual day of the week.
7 Press the hour button (h) repeatedly until the
actual hour of the day is displayed.
8 Press the minute button (m) repeatedly until
the minute of the present hour is displayed.
9 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.

Light Ballast
6-2
6-2 Li ght Ball ast
3 Using an insulated conductor or a screwdriver

Light Ballast capacitor by shorting across the capacitor
terminals.
How to Check a Ballast Capacitor Note: Refer to the instructions which are provided
for your multimeter to ensure the diode is
High voltage. Exposure to
accurately tested.
current will result in death or High voltage. Exposure to
serious injury. Turn off all power electrical wires or electrical
when not needed for testing. current will result in death or
Use extreme caution when serious injury. Turn off all power
working with high voltage when not needed for testing.
electrical components. Use extreme caution when
working with high voltage
electrical components.
4 With an ohmmeter set to its highest
Attempting to service the
machine before the capacitor is resistance scale, connect the ohmmeter leads
fully discharged will result in to the capacitor terminals and observe the
reading on the meter. Then, reverse the
connections and observe the reading on the
Note: Be sure the engine has been turned off for at meter.
least 15 minutes before servicing the machine. Result: The meter indicates a resistance
Use a voltmeter to confirm there is no residual which then gradually decreases. The
voltage in the capacitor. capacitor is working.
Note: This procedure is only for the capacitors Result: The meter indicates a very high
which are attached to the lighting ballasts. To test resistance which does not decrease. The
a generator capacitor, see 5-2, How to Check a capacitor is faulty and should be replaced.
Generator Capacitor.
Result: The meter indicates a very low
1 Open the control box by removing the two resistance which does not increase. The
upper screws of the control panel. Tilt the capacitor is faulty and should be replaced.
control panel forward to access the ballast 5 Repeat the above procedure for each ballast
capacitors located on the inside of the control capacitor.
box.
2 Choose a capacitor. Remove the plastic Probable causes of capacitor failure:
terminal cover and disconnect the wire
harness connector from the capacitor. • Normal end-of-life failure.
• Overheated due to light fixture heat or high
ambient temperature.
• Incorrect capacitor voltage rating.
• Capacitor becomes loose in ballast box.

Fuel Tank
Fue l T ank
7-1
7-1 Fuel Ta nk
Remove the front fairing assembly:

Fuel Tank
7 Remove the fasteners securing the front
fairing assembly to the chassis.
How to Remove the Fuel Tank 8 Carefully lift the front fairing assembly off the
1 Remove the fuel filler cap from the tank. chassis and set aside.
Using an approved hand-operated pump,
drain the fuel tank into a container of suitable Remove the lift bar assembly:
capacity. Refer to Section 2, Specifications.
9 Remove the fasteners securing the lift bar
Explosion and fire hazard. assembly to the chassis.
Engine fuels are combustible. 10 Remove the fasteners securing the lift
Perform this procedure in an structure cross brace to the light tower mast.
open, well-ventilated area
away from heaters, sparks, 11 Carefully remove the lift bar assembly off the
flames and lighted tobacco. chassis and set aside.
Always have an approved fire
extinguisher within easy reach. Remove the fuel tank assembly:
Explosion and fire hazard. 12 Tag, disconnect and plug the fuel hoses from
When transferring fuel, connect the fuel tank.
a grounding wire between the 13 Carefully remove the fuel tank assembly from
machine and pump or container. the chassis and set aside.
Be sure to only use a hand Component damage hazard. The
operated pump suitable for use fuel tank is plastic and may
with diesel fuel. become damaged if allowed to
fall.
Remove the rear fairing assembly: 14 Clean up any fuel that may have spilled.
2 Deploy the outriggers and level the machine. Note: Clean the fuel tank and inspect for cracks
3 Disconnect the rear fairing wiring harnesses and other damage before installing it onto the
located along side the roadside lift bar. machine.
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.

Diagnostics
Before Troubleshooting:
Secti on 5 Diagnostic s
Intro ductio n
 Read, understand and obey the safety rules

 Be sure that all necessary tools and test
equipment are available and ready for use.
Observe and Obey:  Read each appropriate fault code thoroughly.
 Troubleshooting and repair procedures shall Attempting short cuts may produce hazardous
be completed by a person trained and conditions.
qualified on the repair of this machine  Be aware of the following hazards and follow
 Immediately tag and remove from service a generally accepted safe workshop practices.
damaged or malfunctioning machine. Electrocution/burn hazard.
 Repair any machine damage or malfunction Contact with electrically charged
before operating the machine. circuits could result in death or
 Unless otherwise specified, perform each watches and other jewelry.
procedure with the machine in the following
configuration:
• Machine parked on a firm, level surface High voltage. Exposure to
• Mast in the stowed position electrical wires or electrical
• Key switch in the off position with the key serious injury. Turn off all power
removed when not needed for testing.
• The red Emergency Stop button in the off Use extreme caution when
position on the electrical control box working with high voltage
electrical components.
• Wheels chocked
• Light switches in the off position engine components. Contact
• All external AC power supply disconnected with hot engine components
from the machine may cause severe burns. Use
caution when working around
lamps or a hot engine.

Diagnostic Charts
Diag nos tic C har t s
Problem Possible Cause Solution

Mast will not rise to the Faulty cable or pulley Inspect and repair as needed.
operating position
Faulty winch Inspect and repair as needed.
Engine will not turn over 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 Inspect and repair switch and/or

switch wiring as needed
Engine overheats Low coolant level Top off radiator and coolant overflow
tank with correct coolant mixture per
engine operator's manual.
Radiator blocked Clear the radiator fins.
Radiator or cooling system clogged or Inspect and repair as needed.

corroded
Fan or radiator cap faulty Inspect and repair as needed.
Thermostat faulty Inspect and repair as needed.
Head gasket faulty Inspect and repair as needed.
Fan belt is loose Tighten or replace fan belt.
Unsuitable fuel used Drain fuel system and replace with

specified fuel.
Engine runs but produces a Crankcase oil level is too high Drain oil to the proper level.
dense smoke
Low compression Inspect for broken/seized piston rings
or inspect valve clearance.
Injector nozzle faulty Replace injector.
Combustion incomplete due to faulty Inspect and repair as needed.

timing, poor valve adjustment or poor
compression

Diagnostic Charts

Engine runs rough Air or contaminated fuel in fuel system Inspect and repair as needed.
Clogged or leaking fuel system Replace fuel lines, tighten all
connections, inspect the fuel pickup
tube and inspect the fuel filter.
Clogged exhaust system Inspect and repair as needed.
Clogged air filter Inspect and repair or replace as

needed.
Clogged or stuck fuel injectors Inspect and repair as needed.
Faulty governor or fuel pump Inspect and repair as needed.
Engine turns over but will not Empty fuel tank Add fuel to tank.
start or is difficult to start
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 Inspect and repair as needed.
Fuel solenoid valve faulty Inspect and repair as needed.
Faulty glow plug Inspect and repair as needed.
Faulty relay or wiring connection in control Inspect and repair as needed.

box
Battery is discharged or low Charge or replace battery.
Air cleaner is dirty Clean or replace more frequently.

Diagnostic Charts

Engine battery quickly Battery electrolyte low Add distilled water and charge.
discharged
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 Replace battery.
Engine runs but battery voltage Faulty alternator Inspect and repair as needed.
is low
Engine runs but lights will not Circuit breaker has tripped Reset circuit breaker.
operate
Loose wiring connections Inspect and repair as needed.
Faulty generator Inspect and repair as needed.
Lamp light output low Dirty light fixture Clean light fixture.
Light head will not illuminate End of life Replace lamp or light head.
Short in power supply cable Inspect and repair as needed.
Power supply cable connector faulty or Inspect and repair as needed.

poor connection
Unusual noise from the Generator has a faulty bearing or faulty fan Inspect and repair as needed.
generator blade

Diagnostic Charts

Generator produces full voltage Loose or broken lead wires Inspect lead wires and connections
at no load or voltage drops at for broken wires and loose
full load connections.
Rotor open or shorted Measure resistance between leads..
Stator grounded or shorted Contact the Genie Service

Department.
Generator voltage too high High engine speed Adjust the rpm
Refer to Section 2, Specifications
Generator produces no voltage Faulty capacitor Replace capacitor.
at no load or at full load
Loss of residual magnetism Flash the rotor.
Open winding Replace the generator.
Generator will not hold voltage Machine has been unused for a significant Flash the rotor.
(loss of residual magnetism) length of time
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 Replace the diode.

Diagnostic Charts

Generator voltage spikes Incorrect engine adjustment, fuel line or Change fuel filter and check engine
faulty fuel speed.
Loose connection Inspect all connections and repair as
needed.
Faulty ground connection Inspect all ground connections and
repair as needed.
Load induced Filter load.
Generator voltage low Loss of residual magnetism Flash the rotor.

Low engine speed Adjust idle. See Repair Section.
Faulty capacitor Replace the capacitor.
Faulty diode Replace the diode.

Schematics
About This Section

Secti on 6 Schematic s
Intro ductio n
There are two groups of schematics in this section.
Electrical Schematics
Contact with electrically charged
Observe and Obey: circuits could result in death or
 Troubleshooting and repair procedures shall watches and other jewelry.
be completed by a person trained and
qualified on the repair of this machine
 Immediately tag and remove from service a Hydraulic Schematics
damaged or malfunctioning machine. Bodily injury hazard. Spraying
 Repair any machine damage or malfunction hydraulic oil can penetrate and
before operating the machine. burn skin. Loosen hydraulic
connections very slowly to allow
Before Troubleshooting: the oil pressure to dissipate
gradually. Do not allow oil to
 Read, understand and obey the safety rules squirt or spray.
 Be sure that all necessary tools and test
equipment are available and ready for use.

Wire Color Legend
Wire Color Legend

Wire Colo r Le gen d
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

RL4 Control Box AC Voltage Wiring - Standard
73
RL4 Con trol Bo x AC Voltag e Wirin g - St and ard

RL4 Con trol Bo x AC Voltag e Wirin g - A utost art

RL4 Control Box AC Voltage Wiring - Autostart
76
RL4 DC Control Box - Standard
77
RL4 DC Co ntrol Box - St and ard

RL4 DC Engi ne Co mp onen ts - D ynaG en Aut osta rt
RL4 WITH DYNAGEN TG350 AUTOSTART

12V DC OPERATION
5 AMP
FUSE
CLOCK TIMER
SENSOR INPUT B - LOW IMPEDANCE - TEMP AND OIL
P1
2
3 1
J7 6 4
9 7
10 9 8 7 6 1 12 10
J6 11
5 4 3 2 1
2
J4
4 ON - OFF P1
MODULE POWER +12V RED 1
8 1 12V + BATTERY
9 2
TIMER ORG 2
TEMP/OIL PRESSURE SWITCH
10 3
11 4 OFF
GRN 3
ALT D+
12 5
BLU
PHOTOCELL J5 FROM GENERATOR WHT 4
STARTER
13 6 A PHASE
14 7 1 BLK 5
BATTERY -
B PHASE YEL 6
2 GLOW PLUGS
J1 BRN
3 7
FUEL PUMP
1 2 3 4 NEUTRAL 8
J3 4 TELEMATICS REMOTE ENABLE
5 6 7 8
9
10
DYNAGEN TG350 MODULE
11
12
PHOTO CELL
BLU BLK BATTERY -
RED 12V + BATTERY
WHT/BLK BLU TO J4 P6
6 5 4
J1
3 2 1 AUTOSTART WARNING
B
GLOW PLUGS
4
YLLW/BRN
1
A
FUEL PUMP
RED/BLK RELY PAK (RP100) RED/BLK
2 5
MAINS CONTACTORS
ORG/BLK
TELEMATICS 3 6
(NC) D A PHASE B PHASE

MAINS
C
CRANK
TELEMATICS (NO)
ACTIVE LOW
12VDC
TELEMATICS
ACTIVE HIGH
LT BLU

RL4 DC Control Box Wiring - DynaGen
80
RL4 DC Engine Components - Kohler
81
RL4 DC Engi ne Co mp onen ts - K ohler

RL4 DC Engi ne Co mp onen ts - K ubot a

RL4 DC Engine Components - Kubota
84
RL4 DC Control Box - Timed Oil Switch
85
RL4 DC Co ntrol Box - Tim ed Oil Switc h

RL4 DC Co ntrol Box - Low Fuel S hut D own

RL4 DC Control Box - Low Fuel Shut Down
88
RL4 Running Lights - Front Fairing Section
89
RL4 Run ning Light s - Fr ont Fairi ng Secti on

RL4 Run ning Light s - R ear Fai ring Se ction

RL4 Running Lights - Rear Fairing Section
92
RL4 Electrical Winch Option
93
RL4 Electric al Winch Opti on

Service Manual: RL4 Vertical Mast

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Service Manual

RL4 Vertical Mast

Part No. 1266665GT

Important Technical Publications

Basic mechanical, hydraulic and electrical skills

1266665GT Rev B, August 2022

'Terex' is a registered trademarks of Terex USA, LLC in the

ii RL4 Vertical Mast Part No. 1266665GT

Serial Number Legend

1 Model 4 Sequence number

1 Model 3 Sequence number

Part No. 1266665GT RL4 Vertical Mast 3

Do Not Perform Maintenance

iv RL4 Vertical Mast Part No. 1266665GT

Personal Safety Workplace Safety

Be aware of potential crushing hazards

Part No. 1266665GT RL4 Vertical Mast v

Introduction Introduction ...................................................................................................... ii

Section 1 Safety Rules .................................................................................................... iv

vi RL4 Vertical Mast Part No. 1266665GT

Section 3 Scheduled Maintenance Procedures ............................................................... 7

Checklist A Procedures ................................................................................. 13

Part No. 1266665GT RL4 Vertical Mast vii

Checklist B Procedures ................................................................................. 26

Checklist C Procedures ................................................................................. 34

Checklist D Procedures ................................................................................. 40

Checklist E Procedures ................................................................................. 42

viii RL4 Vertical Mast Part No. 1266665GT

Section 4 Repair Procedures.......................................................................................... 47

Kohler KDW1003GE Engine ........................................................................... 57

Kubota D1105-E4BG Engine .......................................................................... 58

Fuel Tank ........................................................................................................ 64

Part No. 1266665GT RL4 Vertical Mast ix

Section 5 Diagnostics .................................................................................................... 65

Diagnostic Charts .......................................................................................... 66

Section 6 Schematics ..................................................................................................... 71

x RL4 Vertical Mast Part No. 1266665GT

Machine Specifications Generator Options

Total lighting wattage 4 x 1000 watts Coliseum 6 kW 1CBC06-TX

Generator rpm @ full load 60 Hz, 1800 rpm

Run time For operational specifications, refer to the

Part No. 1266665GT RL4 Vertical Mast 1

Kohler KDW 1003GE Engine

2 RL4 Vertical Mast Part No. 1266665GT

Kubota D1105-E4BG Engine

Part No. 1266665GT RL4 Vertical Mast 3

Machine Torque Specifications

Continuous improvement of our products is a

4 RL4 Vertical Mast Part No. 1266665GT

Part No. 1266665GT RL4 Vertical Mast 5

This page intentionally left blank.

6 RL4 Vertical Mast Part No. 1266665GT

Scheduled Maintenance Procedures

 Unless otherwise specified, perform each

 Immediately tag and remove from service a

Part No. 1266665GT RL4 Vertical Mast 7

Scheduled Maintenance Procedures

About This Section

Indicates a imminently hazardous