Genie RL4 Vertical Mast Service Manual
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Genie RL4 Vertical Mast Service Manual

Genie RL4 Vertical Mast Service Manual

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Service Manual
RL4 Vertical Mast
Part No. 1266665
Rev A
August 2015

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  • Page 1 Service Manual RL4 Vertical Mast Part No. 1266665 Rev A August 2015...

  • Page 2: Introduction

    Copyright © 2015 by Terex Corporation 1266665 Rev A, August 2015 First Edition, First Printing 'Terex' and 'AWP' are registered trademarks of Terex USA, LLC in the U.S.A. and many other countries. RL4 Vertical Mast Part No. 1266665...

  • Page 3: Serial Number Legend

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

  • Page 4: Safety Rules

    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. RL4 Vertical Mast Part No. 1266665...
  • Page 5 Be aware of potential crushing hazards such as moving parts, free swinging or unsecured components when lifting or placing loads. Always wear approved steel-toed shoes. Part No. 1266665 RL4 Vertical Mast...

  • Page 6: Table Of Contents

      SAE and Metric Fasteners Torque Charts ............. 5     Section 3 Scheduled Maintenance Procedures ..............7   Introduction ......................7   Pre-Delivery Preparation Report ................10   Maintenance Inspection Report ................11 RL4 Vertical Mast Part No. 1266665...
  • Page 7 B-2 Inspect the Electrical Wiring ................27   B-3 Torque the Wheel Lug Nuts ................28   B-4 Perform Engine Maintenance - Kubota ............28   B-5 Inspect and Lubricate the Winch ..............29 Part No. 1266665 RL4 Vertical Mast...
  • Page 8 E-5 Perform Engine Maintenance - Kohler ............44   E-6 Perform Engine Maintenance - Kohler ............45   E-7 Perform Generator Maintenance ..............45   E-8 Perform Generator Maintenance ..............46   E-9 Perform Generator Maintenance ..............46 viii RL4 Vertical Mast Part No. 1266665...
  • Page 9 5-3 How to Check a Generator Diode ..............60   Light Ballast ......................62   6-1 Ground Controls ..................... 62   6-2 Light Ballast ....................63   Fuel Tank ......................64   7-1 Fuel Tank ....................... 64 Part No. 1266665 RL4 Vertical Mast...
  • Page 10   RL4 Running Lights - Rear Fairing Section ............91   RL4 Running Lights - Rear Fairing Section ............92   RL4 Electrical Winch Option ................93   RL4 Electrical Winch Option ................94 RL4 Vertical Mast Part No. 1266665...

  • Page 11: Specifications

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

  • Page 12: Kohler Kdw1003Ge Engine Specifications

    Oil pressure 28.8 to 50.6 psi 3 to 4.5 bar Alternator output 45A, 12V DC Oil capacity (including filter) 5 quarts Fan belt deflection 1/4 to 3/8 inch 4.7 liters 7 to 9 mm RL4 Vertical Mast Part No. 1266665...
  • Page 13 Oil pressure 28 to 64 psi 1.93 to 4.41 bar Alternator output 30A, 12V DC Oil capacity (including filter) 5.4 quarts Fan belt deflection 1/4 to 3/8 inch 5.1 liters 7 to 9 mm Part No. 1266665 RL4 Vertical Mast...

  • Page 14: Machine Torque Specifications

    Engine vibration isolators Mounting bolts, dry 75 ft-lbs 102 Nm Mounting bolts, lubricated 57 ft-lbs 77 Nm Continuous improvement of our products is a Genie policy. Product specifications are subject to change without notice or obligation. RL4 Vertical Mast Part No. 1266665...

  • Page 15: Sae And Metric Fasteners Torque Charts

    August 2015 Service Manual Specifications Part No. 1266665 RL4 Vertical Mast...
  • Page 16 Service Manual August 2015 This page intentionally left blank. RL4 Vertical Mast Part No. 1266665...

  • Page 17: Scheduled Maintenance Procedures

    Repair any machine damage or malfunction before operating the machine.  Use only Terex approved replacement parts.  Machines that have been out of service for a period longer than 3 months must complete the quarterly inspection. Part No. 1266665 RL4 Vertical Mast...

  • Page 18: About This Section

    Indicates that a specific result is expected after performing a series of steps. Indicates that an incorrect result has occurred after performing a series of steps. RL4 Vertical Mast Part No. 1266665...
  • Page 19 Make copies of the Maintenance Inspection Report to use for each inspection. Maintain completed forms for a minimum of 4 years or in compliance with your employer, jobsite and governmental regulations and requirements. Part No. 1266665 RL4 Vertical Mast...

  • Page 20: Pre-Delivery Preparation Report

    Date Machine owner Inspected by (print) Inspector signature Inspector title Inspector company Terex South Dakota, Inc USA Genie UK 500 Oak Wood Road The Maltings, Wharf Road PO Box 1150 Grantham, Lincolnshire Watertown, SD 57201-6150 NG31- 6BH England (605) 882-4000...

  • Page 21: Maintenance Inspection Report

     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 Part No. 1266665 RL4 Vertical Mast...

  • Page 22: August

     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 RL4 Vertical Mast Part No. 1266665...

  • Page 23: Checklist A Procedures

    Note: Contact your authorized Terex distributor or Check to make sure that the operator's and Terex if replacement manuals or decals are safety manuals are present and complete in needed. the storage container inside the cabinet. Part No. 1266665 RL4 Vertical Mast...

  • Page 24: Perform Pre-Operation Inspection

    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. RL4 Vertical Mast Part No. 1266665...

  • Page 25: Perform Engine Maintenance - Kubota

    Kubota D-1105 and V-1505 Operator's Manual pocket and the pin is inserted behind the collar Genie part number 893020 or latch. Check mounting bracket hardware for wear and proper tightness. Result: Replace bent, broken or worn hardware. Part No. 1266665 RL4 Vertical Mast...

  • Page 26: Test The Brakes (If Equipped)

    Check each lug nut for proper torque. Refer to may also result if problems are not discovered and Specifications, Machine Specifications. repaired in a timely fashion. Test the brakes for proper function. Repair or replace any faulty components as needed. RL4 Vertical Mast Part No. 1266665...

  • Page 27: Perform Engine Maintenance - Kohler

    Check tire surface and sidewalls for cuts, Genie part number 1268769 cracks, punctures and unusual wear. Check each wheel for damage, bends and cracks. Check the pressure in each air-filled tire. Refer to Specifications, Machine Specifications. Part No. 1266665 RL4 Vertical Mast...

  • Page 28: Inspect The Engine Air Filter

    Open the engine side cover. Empty the dust discharge valve by pressing together the sides of the discharge slot. Clean the discharge slot as needed. 1 clamp 2 cannister end cap 3 dust discharge valve RL4 Vertical Mast Part No. 1266665...

  • Page 29: Perform Generator Maintenance

    (if equipped) engine information is available in the Kubota D1105-E and V1505-E Operator's Manual (Kubota 16683-89169 part number ) Coliseum Manual Genie part number 1268770 Kubota D-1105 and V-1505 Operator's Manual Genie part number 893020 Part No. 1266665 RL4 Vertical Mast...

  • Page 30: Perform Engine Maintenance - Kohler

     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. RL4 Vertical Mast Part No. 1266665...

  • Page 31: Perform Engine Maintenance - Kubota

    The cable must immediately be 16683-89169 part number ) replaced. Kubota D-1105 and V-1505 Operator's Manual Wind cable onto the winch, ensuring that the Genie part number 893020 cable is correctly installed onto each of the pulleys. Part No. 1266665 RL4 Vertical Mast...

  • Page 32: Perform Engine Maintenance - Kubota

    Kubota watches and other jewelry. D1105-E and V1505-E Operator's Manual (Kubota 16683-89169 part number ) Coliseum Manual Genie part number 1268770 Kubota D-1105 and V-1505 Operator's Manual Genie part number 893020 a generator RL4 Vertical Mast Part No. 1266665...

  • Page 33: Drain The Fuel Filter/Water Separator

    Note: If the fuel bowl is completely drained, you must prime, or bleed, the fuel filter/water separator before starting the engine. See step Start the engine from the electrical control panel and check the fuel filter/water separator for leaks. Part No. 1266665 RL4 Vertical Mast...
  • Page 34 Kubota D-1105 and V-1505 Operator's Manual tighten the brakes. Genie part number 893020 Note: It may be helpful to use a flashlight when locating the brake adjuster wheel. RL4 Vertical Mast Part No. 1266665...

  • Page 35: Adjust The Brakes (If Equipped)

    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. Part No. 1266665 RL4 Vertical Mast...

  • Page 36: Checklist B Procedures

    Note the results. Note: Adding terminal protectors and a corrosion preventative sealant will help eliminate corrosion on the battery terminals and cables. RL4 Vertical Mast Part No. 1266665...

  • Page 37: Inspect The Electrical Wiring

    Inspect for a liberal coating of dielectric grease 13 Close the side covers. in the following locations:  Lighting junction box  Ground controls  All wire harness connectors Part No. 1266665 RL4 Vertical Mast...

  • Page 38: Torque The Wheel Lug Nuts

    Check each lug nut for proper torque. Refer to engine information is available in the Kubota Specifications, Machine Specifications. D1105-E and V1505-E Operator's Manual (Kubota 16683-89169 part number ) Kubota D-1105 and V-1505 Operator's Manual Genie part number 893020 RL4 Vertical Mast Part No. 1266665...

  • Page 39: Inspect And Lubricate The Winch

    Remove all dust, dirt and copper anti-seize from the threaded surfaces of the T-bolt, and apply a few drops of light oil or copper anti-seize lubricant onto the threaded surfaces. Fully install the T-bolt into the mast. a T-bolt Part No. 1266665 RL4 Vertical Mast...

  • Page 40: Inspect And Adjust The Brakes (If Equipped)

    Remove the castle nut and washer. seat the bearings. Pull the hub off of the spindle. The washer and 12 Fully loosen the castle nut. Do not rotate the outer bearing should fall loose from the hub. hub. RL4 Vertical Mast Part No. 1266665...
  • Page 41 18 Repeatedly move the tip of the adjuster tool in an upwards direction to tighten the brakes until the wheel locks up and will no longer turn. Note: This centers the brake shoes on the brake drum, ensuring the shoes are positioned correctly. Part No. 1266665 RL4 Vertical Mast...

  • Page 42: Inspect The Suspension

    KDW1003 Engine Owner's Manual (Kohler part Working with a flashlight or in a well lit shop, number ED0053028440). carefully inspect all suspension components and fasteners. Replace as necessary. Kohler KDW1003 Engine Owner's Manual Genie part number 1268769 RL4 Vertical Mast Part No. 1266665...

  • Page 43: Perform Engine Maintenance - Kubota

     Replace fuel filter Required maintenance procedures and additional engine information is available in the Kubota D1105-E and V1505-E Operator's Manual (Kubota 16683-89169 part number ) Kubota D-1105 and V-1505 Operator's Manual Genie part number 893020 Part No. 1266665 RL4 Vertical Mast...

  • Page 44: Checklist C Procedures

    Do not Kubota D-1105 and V-1505 Operator's Manual allow harsh cleaning agents to Genie part number 893020 make contact with the light surface.. Thoroughly rinse, then dry with a soft cloth. RL4 Vertical Mast Part No. 1266665...

  • Page 45: Grease The Wheel Bearings

    Remove the rear bearing. 23 Install the dust cap, then the tire and wheel Pack both bearings with clean, fresh grease. assembly. Torque the wheel lug nuts to specification. Refer to Section 2, Specifications. Part No. 1266665 RL4 Vertical Mast...

  • Page 46: Inspect The Electric Brake Magnets

    The brake circuit is faulty. Inspect the wire harness and harness connections and repair as required, and repeat this procedure beginning with step 2. RL4 Vertical Mast Part No. 1266665...

  • Page 47: Perform Engine Maintenance - Kohler

    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. Part No. 1266665 RL4 Vertical Mast...

  • Page 48: Perform Engine Maintenance - Kubota

    Kubota D-1105 and V-1505 Operator's Manual Required maintenance procedures and additional Genie part number 893020 engine information is available in the Kohler KDW1003 Engine Owner's Manual (Kohler part number ED0053028440). Kohler KDW1003 Engine Owner's Manual Genie part number 1268769 RL4 Vertical Mast Part No. 1266665...

  • Page 49: Perform Generator Maintenance

     Inspect all wire and electrical connections for proper clearance..  Inspect and clean inside of outlet box, air screens and air baffles with compressed air.  Inspect for machine vibration and bearing wear. Coliseum Manual Genie part number 1268770 Part No. 1266665 RL4 Vertical Mast...

  • Page 50: Checklist D Procedures

    16683-89169 part number )  Check resistance to ground on generator Kubota D-1105 and V-1505 Operator's Manual windings, main rotating assembly, stator, Genie part number 893020 exciter field and armature. Coliseum Manual Genie part number 1268770 RL4 Vertical Mast Part No. 1266665...

  • Page 51: Perform Coupler Maintenance

    Result: 1.5 full threads of the locking bolt must be exposed beyond the lock nut after the adjustment. Apply automotive grease to the coupler ball pocket. Oil coupler pivot points using SAE 30 motor oil. Part No. 1266665 RL4 Vertical Mast...

  • Page 52: Checklist E Procedures

    Wind cable onto the winch, ensuring that the cable is correctly installed onto each of the pulleys. If the mast cables need replacing, refer to Repair Procedure 1-1, How to Replace the Mast Lift Cables. RL4 Vertical Mast Part No. 1266665...

  • Page 53: Perform Engine Maintenance - Kubota

    Kubota D-1105 and V-1505 Operator's Manual engine information is available in the Kubota D1105-E and V1505-E Operator's Manual (Kubota Genie part number 893020 16683-89169 part number ) Kubota D-1105 and V-1505 Operator's Manual Genie part number 893020 Part No. 1266665 RL4 Vertical Mast...

  • Page 54: Perform Engine Maintenance - Kohler

    Kohler number ED0053028440). KDW1003 Engine Owner's Manual (Kohler part number ED0053028440). Kohler KDW1003 Engine Owner's Manual Genie part number 1268769 Kohler KDW1003 Engine Owner's Manual Genie part number 1268769 RL4 Vertical Mast Part No. 1266665...

  • Page 55: Perform Engine Maintenance - Kohler

     Replace the generator shaft bearing. KDW1003 Engine Owner's Manual (Kohler part Consult a trained Coliseum service number ED0053028440). professional. Kohler KDW1003 Engine Owner's Manual Genie part number 1268769 Coliseum Manual Genie part number 1268770 Part No. 1266665 RL4 Vertical Mast...

  • Page 56: Perform Generator Maintenance

     Inspect and clean generator components Coliseum Manual including generator windings. Genie part number 1268770  Replace the generator shaft bearings. Consult a trained Coliseum service professional. Coliseum Manual Genie part number 1268770 RL4 Vertical Mast Part No. 1266665...

  • Page 57: Repair Procedures

    Be sure that all necessary tools and parts are available and ready for use.  Use only Terex approved replacement parts.  Read each procedure completely and adhere to the instructions. Attempting shortcuts may produce hazardous conditions. Part No. 1266665 RL4 Vertical Mast...
  • Page 58 Indicates that a specific result is expected after performing a series of steps. Indicates that an incorrect result has occurred after performing a series of steps. RL4 Vertical Mast Part No. 1266665...

  • Page 59: Lighting

    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. Part No. 1266665 RL4 Vertical Mast...

  • Page 60: Mast

    Remove the 2 inch / 5 cm mast section from the 3 inch / 7.5 cm mast section. Disconnect the cable from the 3 inch / 7.5 cm mast section by removing the cable retention pin. RL4 Vertical Mast Part No. 1266665...
  • Page 61 Note: During assembly, carefully install the mast cable. Refer to the illustration on the following page for cable routing. Part No. 1266665 RL4 Vertical Mast...

  • Page 62: 2-3 How To Replace The Mast Lift Cables

    Cable #3 Mast Lift Cable #1 Mast Lift Mast Lift Mast Lift Cable #2 Cable #3 Cable #1 Winch 3 inch 2 inch 1.5 inch Mast Mast Mast Section Section Section 4 inch Mast Section RL4 Vertical Mast Part No. 1266665...

  • Page 63: 2-4 How To Remove The Manual Winch

    Unwind the cable from the winch drum. CAUTION Bodily injury hazard. Cables can fray. Always wear adequate hand protection when handling the cable. Remove the winch from the machine. Part No. 1266665 RL4 Vertical Mast...

  • Page 64: 2-5 How To Remove The Electric Winch

    CAUTION Bodily injury hazard. Cables can fray. Always wear adequate hand protection when handling the cable. a winch covers b electric winch c engaged/free spool lock d 4 inch / 10 cm mast assembly RL4 Vertical Mast Part No. 1266665...

  • Page 65: 2-6 How To Disengage The Tower Lock

    Feed the draw bar wiring up through the hole service is strongly recommended. then remove the front fairing and set aside. CAUTION Bodily injury hazard. Cables can fray. Always wear adequate hand protection when handling the cable. Part No. 1266665 RL4 Vertical Mast...
  • Page 66 (2) until the tower lock lever (3) tower disassembly and rebuild. disengages. 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. RL4 Vertical Mast Part No. 1266665...

  • Page 67: Kohler Kdw1003Ge Engine

    Result: The resistance should be approximately 1 ohm. Result: The resistance is 0 ohm or greater than 1 ohm. The glow plug is faulty. Part No. 1266665 RL4 Vertical Mast...

  • Page 68: Kubota D1105-E4Bg Engine

    Result: The resistance should be shut off to prevent damage. approximately 1 ohm. Result: The resistance is 0 ohm or greater than 1 ohm. The glow plug is faulty. RL4 Vertical Mast Part No. 1266665...

  • Page 69: Generator

    Remove the left side cabinet weldment and Remove the fasteners. fender. 14 Remove the generator from the machine. CAUTION Crushing hazard. The generator may become unbalanced and fall if not properly supported when removed from the machine. Part No. 1266665 RL4 Vertical Mast...

  • Page 70: 5-2 How To Check A Generator Capacitor

    Tag and disconnect the wires attached to the Remove the fasteners securing the end capacitor. cover/bearing housing to the generator. Remove the cover. RL4 Vertical Mast Part No. 1266665...
  • Page 71 (the threads of the diode should not be coated). Torque to 20 to 30 in-lbs / 2.2 to 3.4 Nm. Part No. 1266665 RL4 Vertical Mast...

  • Page 72: Light Ballast

    Press the hour button (h) repeatedly until the actual hour of the day is displayed. Press the minute button (m) repeatedly until the minute of the present hour is displayed. RL4 Vertical Mast Part No. 1266665...

  • Page 73: Light Ballast

    Using an insulated conductor or a screwdriver with an insulated handle, discharge the capacitor by shorting across the capacitor terminals. Note: Refer to the instructions which are provided for your multimeter to ensure the diode is accurately tested. Part No. 1266665 RL4 Vertical Mast...

  • Page 74: Fuel Tank

    Disconnect the gas struts on the rear fairing assembly from the lift bar. Remove the screws from the hinges attaching the rear fairing assembly to the lift bar. Carefully lift the rear fairing assembly off the unit and set aside. RL4 Vertical Mast Part No. 1266665...

  • Page 75: Diagnostics

     Light switches in the off position may cause severe burns. Use caution when working around  All external AC power supply disconnected lamps or a hot engine. from the machine Part No. 1266665 RL4 Vertical Mast...
  • Page 76 Low compression Inspect for broken/seized piston rings or inspect valve clearance. Injector nozzle faulty Replace injector. Combustion incomplete due to faulty timing, Inspect and repair as needed. poor valve adjustment or poor compression RL4 Vertical Mast Part No. 1266665...
  • Page 77 Inspect and repair as needed. Faulty relay or wiring connection in control Inspect and repair as needed. Battery is discharged or low Charge or replace battery. Air cleaner is dirty Clean or replace more frequently. Part No. 1266665 RL4 Vertical Mast...
  • Page 78 Inspect and repair as needed. Power supply cable connector faulty or poor Inspect and repair as needed. connection Unusual noise from the Generator has a faulty bearing or faulty fan Inspect and repair as needed. generator blade RL4 Vertical Mast Part No. 1266665...
  • Page 79 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...
  • Page 80 August 2015 Diagnostics Problem Possible Cause Solution 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. RL4 Vertical Mast Part No. 1266665...

  • Page 81: Schematics

    Read, understand and obey the safety rules squirt or spray. and operating instructions in the appropriate operator's manual on your machine.  Be sure that all necessary tools and test equipment are available and ready for use. Part No. 1266665 RL4 Vertical Mast...

  • Page 82: Wire Color Legend

    Service Manual August 2015 Wire Color Legend Wire Color Legend Blue Black Brown Green Orange Violet White 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 Vertical Mast Part No. 1266665...

  • Page 83: Rl4 Control Box Ac Voltage Wiring - Standard

    August 2015 Service Manual RL4 Control Box AC Voltage Wiring - Standard...

  • Page 84: Rl4 Control Box Ac Voltage Wiring - Standard

    Service Manual August 2015 RL4 DC CONTROL BOX, AC VOLTAGE WIRING, STANDARD 240 VAC FROM GENERATOR (U1) (U1) (V2) (V2) (C1) (C1) MAIN BREAKER (C2) (C2) (V1) (U2) KOHLER GENSET LIGHT CAPACITOR BREAKERS NEUTRAL BONDED 25 AMP TO GROUND 12 AWG GREEN 12 AWG WHITE BLACK 120V TRANSFORMER...

  • Page 85: Rl4 Control Box Ac Voltage Wiring - Autostart

    August 2015 Service Manual RL4 Control Box AC Voltage Wiring - Autostart RL4 Control Box AC Voltage Wiring - Autostart...

  • Page 86: Rl4 Control Box Ac Voltage Wiring - Autostart

    Service Manual August 2015 RL4 DC CONTROL BOX, AC VOLTAGE WIRING, AUTOSTART (U1) 240 VAC FROM GENERATOR (U1) (V2) RELAY A (V2) (C1) 12VDC (C1) MAIN (C2) DYNAGEN BREAKER CONTROLLED (C2) (V1) (U2) RELAY B LIGHT BREAKERS 25 AMP GENSET CAPACITOR NEUTRAL BONDED 12 AWG GREEN...

  • Page 87: Rl4 Dc Control Box - Standard

    August 2015 Service Manual RL4 DC Control Box - Standard...

  • Page 88: Rl4 Dc Control Box - Standard

    Service Manual August 2015 RL4 DC CONTROL BOX, STANDARD ALTERNATOR FAILURE LIGHT YEL 10 AWG YEL 10 AWG PREHEAT PUSH BUTTON RELAY 12V SPST (NC) YEL 10 AWG WHT 12 AWG RED 10 AWG HOUR METER 12V DC OPERATION...

  • Page 89: Rl4 Dc Engine Components - Dynagen Autostart

    August 2015 Service Manual RL4 DC Control Box Wiring - DynaGen...

  • Page 90: Rl4 Dc Engine Components - Dynagen Autostart

    Service Manual August 2015 RL4 WITH DYNAGEN TG350 AUTOSTART 12V DC OPERATION 5 AMP FUSE CLOCK TIMER SENSOR INPUT B - LOW IMPEDANCE - TEMP AND OIL ON - OFF MODULE POWER +12V 12V + BATTERY TIMER TEMP/OIL PRESSURE SWITCH ALT D+ PHOTOCELL J5 FROM GENERATOR...

  • Page 91: Rl4 Dc Engine Components - Kohler

    August 2015 Service Manual RL4 DC Engine Components - Kohler...

  • Page 92: Rl4 Dc Engine Components - Kohler

    Service Manual August 2015 RL4 DC ENGINE COMPONENTS (KOHLER) 12VDC OPERATION BATTERY 12 VOLT FUSE STARTER E-STOP OPTION FUEL ALTERNATOR SOLENOID N.C. IN4004 RESISTORS LOW OIL 110 OHM 110 OHM PRESSURE LT BLU (NC) HIGH COOLANT FUEL PUMP TEMPERATURE TELEMATICS (NO) GLOW PLUGS...

  • Page 93: Rl4 Dc Engine Components - Kubota

    August 2015 Service Manual RL4 DC Engine Components - Kubota...

  • Page 94: Rl4 Dc Engine Components - Kubota

    Service Manual August 2015 RL4 DC ENGINE COMPONENTS (KUBOTA) 12VDC OPERATION BATTERY 12 VOLT FUSE STARTER E-STOP OPTION FUEL ALTERNATOR SOLENOID N.C. LOW OIL PRESSURE LT BLU (NC) HIGH COOLANT FUEL PUMP TEMPERATURE TELEMATICS (NO) GLOW PLUGS HARNESS PART NUMBER = 116820 TELEMATICS PIN# CKT#...

  • Page 95: Rl4 Dc Control Box - Timed Oil Switch

    August 2015 Service Manual RL4 DC Control Box - Timed Oil Switch...

  • Page 96: Rl4 Dc Control Box - Timed Oil Switch

    Service Manual August 2015 RL4 DC CONTROL BOX, TIMED OIL SWITCH ALTERNATOR FAILURE LIGHT YEL 10 AWG YEL 10 AWG PREHEAT PUSH BUTTON RELAY 12V SPST (NC) (NC) 100K /16VDC CAPACITOR YEL 10 AWG WHT 12 AWG RED 10 AWG HOUR METER 12VDC OPERATION...

  • Page 97: Rl4 Dc Control Box - Low Fuel Shut Down

    August 2015 Service Manual RL4 DC Control Box - Low Fuel Shut Down...

  • Page 98: Rl4 Dc Control Box - Low Fuel Shut Down

    Service Manual August 2015 RL4 DC CONTROL BOX, LOW FUEL SHUT DOWN ALTERNATOR FAILURE LIGHT YEL 10 AWG YEL 10 AWG PREHEAT PUSH BUTTON RELAY 12V SPST (NC) (NC) LOW FUEL WARNING 100K /16VDC CAPACITOR YEL 10 AWG TO LOW FUEL CUT-OFF FUEL LEVEL SWITCH WHT 12 AWG (REED SWITCH)

  • Page 99: Rl4 Running Lights - Front Fairing Section

    August 2015 Service Manual RL4 Running Lights - Front Fairing Section...

  • Page 100: Rl4 Running Lights - Front Fairing Section

    Service Manual August 2015 ITEM PART NUMBER DESCRIPTION DT06-3S DEUTSCH CONNECTOR, PLUG, 3-PIN DEUTSCH CONNECTOR, WEDGE 0462-201-16 DEUTSCH CONNECTOR, SOCKET NEW RL4 RUNNING LIGHTS 7/16" BLACK PLASTIC WIRE LOOM W SLIT, .413 ID 85" ELECTRICAL TAPE 24" FRONT SECTION DT04-3P DEUTSCH CONNECTOR, RECEPTACLE 3-PIN DEUTSCH CONNECTOR, WEDGE 0460-202-16...

  • Page 101: Rl4 Running Lights - Rear Fairing Section

    August 2015 Service Manual RL4 Running Lights - Rear Fairing Section...

  • Page 102: Rl4 Running Lights - Rear Fairing Section

    Service Manual August 2015 ITEM PART NUMBER DESCRIPTION DT06-3S DEUTSCH CONNECTOR, PLUG, 3-PIN DEUTSCH CONNECTOR, WEDGE 0462-201-16 DEUTSCH CONNECTOR, SOCKET NEW RL4 RUNNING LIGHTS 7/16" BLACK PLASTIC WIRE LOOM W SLIT, .413 ID ELECTRICAL TAPE REAR SECTION DT04-3P DEUTSCH CONNECTOR, RECEPTACLE 3-PIN DEUTSCH CONNECTOR, WEDGE 0460-202-16 DEUTSCH CONNECTOR, PIN...

  • Page 103: Rl4 Electrical Winch Option

    August 2015 Service Manual RL4 Electrical Winch Option...

  • Page 104: Rl4 Electrical Winch Option

    Service Manual August 2015 RL4 ELECTRICAL WINCH OPTION WIRING SUPERWINCH COMPONENTS RL4 CONTROL BOX 12VDC FWD/RVS WINCH CONTROL SWITCH 12VDC WINCH MOTOR WINCH CONTACTOR SPDT MOMENTARY, CENTER RETURN HARNESS 1267114 BLUE DOWN YELLOW RED HEAT SHRINK +12V SUPPLY CURRENT LIMIT KEY SWITCH BAT 12V BATTERY...
  • Page 105 August 2015 Service Manual This page intentionally left blank. RL4 Vertical Mast Part No. 1266665 Service Manual August 2015 Part No. 1266665 RL4 Vertical Mast...
  • Page 106 Genie North America Phone 425.881.1800 Toll Free USA and Canada 800.536.1800 Fax 425.883.3475 Genie Australia Pty Ltd. Phone +61 7 3375 1660 Fax +61 7 3375 1002 Genie Sweden Genie China Phone 0046 3157 5101 Fax 00...

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