1287632GT

Service Manual
RL™4 LED
Part No. 1287632GT

Rev A
March 2018
Service Manual March 2018
Introduction
Intr oducti on Intr oducti on
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. However, Contact Us:
several procedures require specialized skills, tools,
lifting equipment and a suitable workshop. In these Internet: www.genielift.com
instances, we strongly recommend that E-mail: awp.techpub@terex.com
maintenance and repair be performed at an
authorized Terex dealer service center.
Copyright © 2018 by Terex Corporation

1287632GT Rev A, March 2018
First Edition, First Printing
'Terex' and 'AWP' are registered trademarks of Terex USA, LLC

in the U.S.A. and many other countries.
"RL" is a trademark of Terex South Dakota, Inc.
ii RL™4 LED Part No. 1287632GT

March 2018 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. 1287632GT RL™4 LED 3

Safety Rules
Section 1 Safety R ules
Danger
Failure to obey the instructions and safety rules in
this manual and the appropriate Operator's Manual
on your machine will result in death or serious
injury.
Many of the hazards identified in the operator's
manual are also safety hazards when maintenance
and repair procedures are performed.
Do Not Perform Maintenance

Unless:
 You are trained and qualified to perform
maintenance on this machine.
 You read, understand and obey:
• manufacturer's instructions and safety rules
• employer's safety rules and worksite
regulations
• applicable governmental regulations
 You have the appropriate tools, lifting
equipment and a suitable workshop.
iv RL™4 LED Part No. 1287632GT

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 alert approved fire extinguisher within easy
personnel to potential personal reach.
injury hazards. Obey all safety
messages that follow this symbol Be sure that all tools and working areas
to avoid possible injury or death. are properly maintained and ready for
use. Keep work surfaces clean and free of
Indicates a imminently hazardous debris that could get into machine
situation which, if not avoided, will components and cause damage.
result in death or serious injury.
Be sure any forklift, overhead crane or
Indicates a potentially hazardous other lifting or supporting device is fully
situation which, if not avoided, capable of supporting and stabilizing the
could result in death or serious weight to be lifted. Use only chains or
injury. straps that are in good condition and of
ample capacity.
Indicates a potentially hazardous
situation which, if not avoided, Be sure that fasteners intended for one
may cause minor or moderate time use (i.e., cotter pins and self-locking
injury. nuts) are not reused. These components
may fail if they are used a second time.
situation which, if not avoided, Be sure to properly dispose of old oil or
may result in property damage. other fluids. Use an approved container.
Please be environmentally safe.
Be sure to wear protective eye wear and
other protective clothing if the situation Be sure that your workshop or work area
warrants it. is properly ventilated and well lit.
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. 1287632GT RL™4 LED v

March 2018
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
Inverter Options...................................................................................................... 1
Machine Torque Specifications .............................................................................. 1
SAE and Metric Fasteners Torque Charts ............................................................. 2
Section 3 Scheduled Maintenance Procedures ................................................................. 3

Introduction ............................................................................................................ 3
Pre-Delivery Preparation Report ............................................................................ 6
Maintenance Inspection Report ............................................................................. 7
Checklist A Procedures ....................................................................................... 8

A-1 Inspect the Manuals and Decals ..................................................................... 8
A-2 Perform Pre-operation Inspection ................................................................... 9
A-3 Perform Function Tests ................................................................................... 9
A-4 Perform Inverter Maintenance ....................................................................... 10
A-5 Perform Coupler Maintenance ...................................................................... 10
A-6 Test the Brakes (if equipped) ........................................................................ 11
A-7 Torque the Wheel Lug Nuts .......................................................................... 11
A-8 Perform Inverter Maintenance ....................................................................... 12
A-9 Check the Tires and Wheels ......................................................................... 12
A-10 Inspect the Cable and Cable Pulleys .......................................................... 13
A-11 Adjust the Brakes (if equipped) ................................................................... 14
A-12 Perform Inverter Maintenance ..................................................................... 15
vi RL™4 LED Part No. 1287632GT

March 2018
Table of Contents
Checklist B Procedures ..................................................................................... 17

B-1 Inspect the Electrical Wiring .......................................................................... 17
B-2 Torque the Wheel Lug Nuts ........................................................................... 17
B-3 Inspect and Lubricate the Winch ................................................................... 18
B-4 Lubricate the T-bolt ........................................................................................ 18
B-5 Inspect and Adjust the Brakes (if equipped) .................................................. 19
B-6 Inspect the Suspension ................................................................................. 21
Checklist C Procedures ..................................................................................... 22

C-1 Clean the LED Modules................................................................................. 22
C-2 Grease the Wheel Bearings .......................................................................... 22
C-3 Inspect the Electric Brake Magnets (if equipped) .......................................... 24
Checklist D Procedures ..................................................................................... 26

D-1 Perform Coupler Maintenance....................................................................... 26
Checklist E Procedures ..................................................................................... 27

E-1 Inspect the Cable and Cable Pulleys ............................................................. 27
E-2 Perform Inverter Maintenance ....................................................................... 28
Part No. 1287632GT RL™4 LED vii

March 2018
Table of Contents
Section 4 Repair Procedures ............................................................................................. 29

Introduction .......................................................................................................... 29
LED Module ........................................................................................................ 31

1-1 How to Remove a LED Module ..................................................................... 31
Mast ..................................................................................................................... 32
2-1 How to Remove the Mast Assembly .............................................................. 32
2-2 How to Disassemble the Mast Assembly ...................................................... 32
2-3 How to Replace the Mast Lift Cables ............................................................ 34
2-4 How to Remove the Manual Winch ............................................................... 35
2-5 How to Disengage the Tower Lock ................................................................ 35
Inverter ................................................................................................................ 37
3-1 Champion 3.5 KW Inverter ............................................................................ 37
Section 5 Diagnostics ......................................................................................................... 38

Introduction .......................................................................................................... 38
Diagnostic Charts .............................................................................................. 39
Section 6 Schematics ......................................................................................................... 41

Introduction .......................................................................................................... 41
Wire Color Legend ............................................................................................... 42
Engine Inverter Electrical Schematic ................................................................... 44
AC Control Schematic .......................................................................................... 48
Running Lights ..................................................................................................... 49
viii RL™4 LED Part No. 1287632GT

Specifications
Section 2 Specific ati ons
Machine Specifications Inverter Options

Total lighting wattage 4 X 230 Watt LED Modules Champion 3.5 KW Inverter
Fuel capacities Temperature, ambient maximum 104° F
40° C
Single tank 17.5 gallons
66.25 liters Model 100467
Tires and wheels Watts (Starting/Running) 4000/3500
Tire size ST175/80D13 AC Volts 120
Load range C AC Amps @ 120 V 29.2
Lug nut torque, dry 90 ft-lbs DC Volts 12-24 VDC
122 Nm DC Amps 4-8 amps DC
Lug nut torque, lubricated 67.5 ft-lbs Frequency 60 Hz
91.5 Nm
Phase Single
Performance Specifications
Machine Torque Specifications
Tongue weight, maximum
Wheel lugs
With fuel (17.5 gallon tank) 203 lbs
92 kg Lug nut torque, lubricated 67.5 ft-lbs
91.5 Nm
Run time
Lug nut torque, dry 90 ft-lbs
17.5 gallon tank 80 hours
122 Nm
For operational specifications, refer to the
Operator's Manual.
Continuous improvement of our products is a
Genie policy. Product specifications are
subject to change without notice or obligation.

Specifications
2 RL™4 LED Part No. 1287632GT

Scheduled Maintenance Procedures
Machine Configuration:
Section 3 Schedul ed Mai ntenance Pr ocedures
 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: • Engine Power switch in the off position
 Maintenance inspections shall be completed • The red Emergency Stop button in the off
by a person trained and qualified on the
position on the electrical control box
maintenance of this machine.
• Wheels chocked
 Scheduled maintenance inspections shall be
completed daily, quarterly, semi-annually, • Light switches in the off position
annually and every 2 years as specified of the
Maintenance inspection Report. The frequency • All external AC power supply disconnected
and extent of periodic examinations and tests from the machine
may also depend on national regulations. • Fuel Valve in the OFF Position
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
messages that follow this symbol
to avoid possible injury or death.
Indicates a imminently hazardous

situation which, if not avoided, will

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

may cause minor or moderate
injury.

may result in property damage.
Indicates that a specific result is expected

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

Maintenance Symbols Legend Pre-delivery Preparation Report

Note: The following symbols have been used in this The pre-delivery preparation report contains
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
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 completed.
A damaged or modified machine must never be Follow the instructions in the operator’s manual.
used. If damage or any variation from factory
delivered condition is discovered, the machine If any inspection receives an N, remove the
must be tagged and removed from service. machine from service, repair and re-inspect it. After
repair, place a check in the R box.
Repairs to the machine may only be made by a
qualified service technician, according to the Legend
manufacturer's specifications. Y = yes, acceptable
N = no, remove from service
Scheduled maintenance inspections shall be R = repaired
performed by qualified service technicians, Comments
according to the manufacturer's specifications and
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

Model Checklist A Y N R Checklist B Y N R
Serial number A-1 Inspect the manuals B-1 Electrical wiring
Date and decals
B-2 Lug nuts
Hour meter A-2 Pre-operation
inspection B-3 Winch
Machine owner
A-3 Function tests B-4 T-bolt
Inspected by (print)
Perform after 8 hours: Perform every 3000 miles:
Inspector signature
Inspector title A-4 Perform Inverter B-5 Brakes (if equipped)
Maintenance
Inspector company B-6 Suspension
Perform before towing:
Checklist C Y N R
Instructions A-5 Coupler
C-1 Clean the LED
• Make copies of this report to use for A-6 Brakes (if equipped) Modules
each inspection. Perform after 10 miles: Perform every 6000 miles:
• Select the appropriate checklist(s) for
the type of inspection(s) to perform. A-7 Lug nuts C-2 Wheel bearings
Daily or every 8 hours A Perform after 20 hours: C-3 Brakes (if equipped)
Quarterly or every A+B A-8 Perform Inverter Checklist D Y N R
250 hours Maintenance
D-1 Coupler
Semi-annually or A+B+C Perform weekly:
every 500 hours Checklist E Y N R
A-9 Tires and wheels
Annually or A+B+C+D E-1 Cable
every A-10 Inspect the Cables
1000 hours E-2 Perform Inverter
and Cable Pulleys
Maintenance
Two-year or A+B+C+D+E A-11 Adjust the Brakes
every (if equipped)
2000 hours
Perform after 50 hours:
• Place a check in the appropriate box
A-12 Perform Inverter
after each inspection procedure is
Maintenance
completed.
• Use the step-by-step procedures in Perform every 100 hours:
this section to learn how to perform A-13 Perform Inverter
these inspections. Maintenance
• If any inspection receives an "N," tag
and remove the machine from service, Perform every 200 hours:
repair and re-inspect it. After repair, A-14 Perform Inverter
place a check in the "R" box. Maintenance
Legend
Y = yes, acceptable
N = no, remove from service
R = repaired

Checklist A Procedures
A-1 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 comes in good condition.
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
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 comes performed every 8 hours or daily, whichever comes
first. 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 performs machine must be tagged and removed from
the function tests. The Pre-operation Inspection service.
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
Perform Inverter Maintenance Perform Coupler Maintenance
Inverter specifications require that this procedure Coupler specifications require that this procedure
be performed every 8 hours or daily, whichever be performed before towing.
comes first.
Maintaining the coupler in good condition is
• Inspect for debris and clean essential to safe operation and good performance.
Coupler failure could result in a machine tip-over
• Inspect the Engine Air Filter during transport, and component damage may also
• Loose or missing fasteners result if problems are not discovered and repaired
in a timely fashion.
• Engine oil level – check
1 Check vehicle, mounting bracket, hitch ball
Required maintenance procedures and additional and coupler for signs of wear or damage and
engine/generator information is available in the that the coupler handle opens and closes
Operation Manual. freely.
Digital Inverter Operator's Manual Result: if coupler and/or mounting bracket is
Genie part number 1287633 deformed or damaged, replace complete
coupler and mounting bracket. Replace bent,
broken or worn parts before use.
2 Close coupler securely by ensuring that the
hitch ball is fully seated in the coupler ball
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
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
Perform Inverter Maintenance Check the Tires and Wheels
Inverter specifications require that this procedure

be performed the first month or 20 hours of use, Axle specifications require that this procedure be
whichever comes first. performed weekly.
• Engine oil - replace Maintaining the tires and wheels in good condition
and the tires at the correct pressure is essential to
Required maintenance procedures and additional safe operation and good performance. Tire and/or
engine/generator information is available in the wheel failure could result in a machine tip-over.
Operation Manual. Component damage may also result if problems
are not discovered and repaired in a timely fashion.
Digital Inverter Operator's Manual
Genie part number 1287633 Bodily injury hazard. An
over-inflated tire can explode
and could cause death or serious
injury.
Tip-over hazard. Do not use

temporary flat tire repair
products.
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 5 Visually inspect the winch cable for the

Inspect the Cables and Cable following:
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 monthly. splatter are. The cable must immediately be
Detection of damage to the cables or pulleys is replaced.
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 may Result: A crushed spot on the cable
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
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-11 4 Insert a brake adjuster tool into the opening of

Adjust the Brakes (if equipped) the brake backing plate, engaging it with the
teeth of the brake adjuster wheel. Move the tip
of the adjuster tool in an upwards direction to
tighten the brakes.
Axle specifications require that this procedure be Note: It may be helpful to use a flashlight when
performed initially at 250 miles of use. locating the brake adjuster wheel.
Maintaining the axle brakes in good condition is 5 Repeatedly move the tip of the adjuster tool in
essential to safe operation and good performance. an upwards direction to tighten the brakes until
Brakes which are out of adjustment can result in the wheel locks up and will no longer turn.
longer stopping distances and excessive brake
Note: This centers the brake shoes on the brake
wear on the towing vehicle. Component damage
drum, ensuring the shoes are positioned correctly.
may also result if problems are not discovered and
repaired in a timely fashion. 6 Move the tip of the adjuster tool in a
Note: Perform this procedure with the machine on downwards direction 3 to 5 clicks to loosen the
a firm, level surface with the machine in the stowed brakes only until the wheel spins freely with
position. little drag.
7 Securely install the small rubber plaug into the
1 Select a wheel. Chock the front and rear of the brake backing plate.
tire at the opposite side of the machine.
8 Check the wheel bearing wear by attempting
2 Place a lifting jack under the axle near the to move wheel hub side to side, then up and
brake to be adjusted. Lift the axle until the down.
wheel is off the ground and place a jack stand
under the axle. Lower the axle onto the jack There is no side to side or up and down
stand. movement. The bearing is good.
3 Working from the back side of the wheel at the There is side to side or up and down
brake backing plate, locate and remove the movement. The bearing must be adjusted or
small rubber plug from the lower side of the replaced. See B-8, Inspect and Adjust the
backing plate to access the star-shaped brake Brakes (if equipped).
adjuster wheel. Set the plug to the side.
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.

A-12 A-13
Perform Inverter Maintenance Perform Inverter Maintenance
Inverter specifications require that this procedure Engine specifications require that this procedure be
be performed every 50 hours or quarterly, performed every 100 hours or 6 months, whichever
whichever comes first. comes first.
• Air filter - clean • Engine oil - replace

Clean more often when using generator in • Spark plugs - clean/adjust/replace
dusty areas.
• Spark arrestor - clean
• Run engine
Required maintenance procedures and additional
It is recommended that the generator is run for engine/generator information is available in the
15-30 minutes every three months to ensure Operation Manual.
the battery remains charged.
engine/generator information is available in the Genie part number 1287633
Operation Manual.

Genie part number 1287633

A-14
Perform Inverter Maintenance
Engine specifications require that this procedure be

performed every 200 hours or yearly, whichever
comes first.
• Inverter cooling fins - clean

• Engine valve lash – inspect/adjust
engine/generator information is available in the
Operation Manual.


Checklist B Procedures
B-1 B-2
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.
Electrocution/burn hazard.
Contact with electrically charged
circuits could result in death or
serious injury. Remove all rings,
watches and other jewelry.
1 Inspect the following areas for burnt, chafed,

corroded pinched and loose wires:
• Ground controls
• Battery
• Generator
• 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.

B-3 B-4
Inspect and Lubricate the Winch Lubricate the T-bolt
Terex specifications require that this procedure be Terex specifications require that this procedure be
performed every 250 hours or quarterly, whichever performed every 250 hours or quarterly, whichever
comes first. comes first.
Maintaining the winch is essential to good machine Maintaining the T-bolt is essential to good machine
performance and safe operation. An unsafe performance and safe operation. An unsafe
working condition exists if the winch has excessive working condition exists if the T-bolt has excessive
wear and/or does not operate smoothly, free of wear and/or does not operate smoothly, free of
hesitation and binding. hesitation and binding.
1 Carefully lubricate the winch. 1 Using the illustration as a guide, locate the
T-bolt at the bottom of the mast assembly.
Remove the T-bolt from the mast.
2 Remove all dust, dirt and 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.
3 Fully install the T-bolt into the mast.
a T-bolt

B-5 7 Inspect the brake lining for wear (if equipped).

Inspect and Adjust the Brakes Result: the thickness of the brake lining is
(if equipped) greater than 1/16 inch / 1.6 mm. The brake
shoes are good.
Result: the thickness of the brake lining is
1/16 inch / 1.6 mm or less. The brake shoes
Axle specifications require that this procedure be must be replaced and the brake drums must
performed every 3000 miles or quarterly, be inspected for wear, scoring and other
whichever comes first. damage.
Maintaining the axle brakes in good condition is Note: The maximum bore of a good brake drum
essential to safe operation and good performance. shall not be greater than 0.090 inch / 2.29 mm in
Brakes which are out of adjustment can result in excess of the drum diameter.
longer stopping distances and excessive brake
wear on the towing vehicle. Component damage Note: If drum resurfacing is required, the brake
may also result if problems are not discovered and drum should be resurfaced to a 120 micron finish.
repaired in a timely fashion. Note: If replacing the brake shoes, apply a light
Note: Perform this procedure with the machine on coat of grease or anti-seize compound to the
a firm, level surface with the machine in the stowed anchor pin, arm bushing and pin, and areas of the
position. backing plate which contact the magnet arm and
brake shoes frame. Apply a small amount of lube to
1 Select a wheel. Chock the front and rear of the the actuating cam at the top of the magnet arm. Do
tire at the opposite side of the machine. not allow grease or oil to contact the brakes shoes
or the inside of the drum.
2 Loosen the wheel lug nuts. Do not remove
them. 8 Slide the hub onto the yoke spindle.
3 Place a lifting jack under the axle near the Component damage hazard. Do
wheel to be removed. Lift the axle until the not apply excessive force or
wheel is off the ground and place a jack stand damage to the lip of the seal may
under the axle. Lower the axle onto the jack occur.
stand and remove the wheel.
4 Remove the dust cap from the hub. Remove 9 Place the outer bearing into the hub.
the cotter pin from the castle nut. 10 Install the washer and the castle nut.
5 Remove the castle nut and washer. 11 Tighten the castle nut to 50 ft-lbs / 68 Nm to
6 Pull the hub off of the spindle. The washer and seat the bearings.
outer bearing should fall loose from the hub. 12 Fully loosen the castle nut. Do not rotate the
hub.
13 Finger tighten the castle nut until snug.

14 Install a new cotter pin. Bend the cotter pin to 20 Securely install the small rubber plug into the
lock it in place. brake backing plate.
Note: Always replace the cotter pin with a new one 21 Check the wheel bearing wear by attempting
when removing the castle nut. to move wheel hub side to side, then up and
down.
15 Install the dust cap, then the tire and wheel
assembly. Torque the wheel lug nuts to There is no side to side or up and down
specification. Refer to Section 2, movement. The bearing is good.
Specifications. There is side to side or up and down
16 Working from the back side of the wheel at the movement. The bearing must be adjusted or
brake backing plate, locate and remove the replaced. See B-8, Inspect and Adjust the
small rubber plug from the lower side of the Brakes (if equipped).
backing plate to access the star-shaped brake 22 Lift the axle slightly. Remove the jack stand
adjuster wheel. Set the plug to the side. and lower the machine to the ground. Chock
17 Insert a brake adjuster tool into the opening of the front and rear of the tire.
the brake backing plate, engaging it with the 23 Repeat this procedure, beginning with step 2,
teeth of the brake adjuster wheel. Move the tip for the other wheel.
of the adjuster tool in an upwards direction to
tighten the brakes.
Note: It may be helpful to use a flashlight when
locating the brake adjuster wheel.
18 Repeatedly move the tip of the adjuster tool in

an upwards direction to tighten the brakes until
the wheel locks up and will no longer turn.
Note: This centers the brake shoes on the brake
drum, ensuring the shoes are positioned correctly.
19 Move the tip of the adjuster tool in a

downwards direction 3 to 5 clicks to loosen the
brakes only until the wheel spins freely with
little drag.

B-6
Inspect the Suspension
Axle specifications require that this procedure be

performed every 3000 miles or quarterly,
whichever comes first.
Maintaining the axle suspension in good condition
is essential to safe operation and good
performance. Towing the machine with worn or
damaged suspension components could result in a
tip-over. Component damage may also result if
problems are not discovered and repaired in a
timely fashion.
1 Working with a flashlight or in a well lit shop,

carefully inspect all suspension components
and fasteners. Replace as necessary.

Checklist C Procedures
C-1 C-2
Clean the LED Modules Grease the Wheel Bearings
Terex specifications require that this procedure be Axle specifications require that this procedure be
performed every 500 hours or semi-annually, performed every 6,000 hours or semi-annually,
whichever comes first. whichever comes first.
Maintaining the LED Modules is essential to good Maintaining the axle wheel bearings is essential to
machine performance. Failure to regularly clean safe machine operation and service life. Operating
the light assemblies may result in less light than a machine with loose or worn wheel bearings may
expected and, over time, could result in damage to cause an unsafe operating condition and continued
the machine. use may result in component damage. Extremely
wet or dry conditions or regular steam cleaning and
Note: Perform this procedure with the light pressure washing of the machine may require that
assemblies out of direct sunlight and cool to the this procedure be performed more often.
touch.
Note: Perform this procedure with the machine on
1 Use clean, cool water to rinse the surface of a firm, level surface with the machine in the stowed
each light assembly. position.
2 Clean each light assembly using a soft cloth, 1 Select a wheel. Chock the front and rear of the
water and a mild dishwashing detergent. tire at the opposite side of the machine.
Component damage hazard. 2 Loosen the wheel lug nuts. Do not remove
Harsh checmcals and cleaning them.
agents will damage the surface
of the light assembly. Do not 3 Place a lifting jack under the axle near the
allow harsh cleaning agents to wheel to be removed. Lift the axle until the
make contact with the light wheel is off the ground and place a jack stand
surface.. under the axle. Lower the axle onto the jack
stand and remove the wheel.
3 Thoroughly rinse, then dry with a soft cloth. 4 Remove the dust cap from the hub. Remove
the cotter pin from the castle nut.

5 Remove the castle nut and washer. 16 Slide the hub onto the yoke spindle.
6 Pull the hub off of the spindle. The washer and Component damage hazard. Do
outer bearing should fall loose from the hub. not apply excessive force or
damage to the lip of the seal may
7 Place the hub on a flat surface and gently pry
occur.
the bearing seal out of the hub. Remove the
rear bearing.
17 Place the outer bearing into the hub.
8 Pack both bearings with clean, fresh grease.
18 Install the washer and the castle nut.
9 Inspect the hub for wear. Replace if
19 Tighten the castle nut to 50 ft-lbs / 68 Nm to
necessary.
seat the bearings.
10 Place the large inner bearing into the rear of
20 Fully loosen the castle nut. Do not rotate the
the hub.
hub.
11 Install a new bearing grease seal into the hub
by pressing it evenly into the hub until it is
flush. 22 Install a new cotter pin. Bend the cotter pin to
Note: Always replace the bearing grease seal when lock it in place.
removing the hub. Note: Always replace the cotter pin with a new one
when removing the castle nut.
12 Inspect the brake lining for wear (if equipped).
Install the dust cap, then the tire and wheel
13 Inspect the brake cylinder for leaks (if
assembly. Torque the wheel lug nuts to
equipped).
specification. Refer to Section 2, Specifications.
14 Inspect the brake springs for wear or loss of
arch (if equipped).
15 Inspect the brake wiring/hoses for wear (if
equipped).

C-3 3 With the engine running, press down on the

Inspect the Electric Brake brake pedal and use a multimeter to measure
the total amp draw of the brake circuit by
Magnets (if equipped) positioning an amp clamp around the brake
wire lead near the trailer connector. Note the
reading.
Axle specifications require that this procedure be Result: The total amp draw measures 5.5 to
6.0 amps. The brake circuit is functioning
performed every 6,000 hours or semi-annually,
whichever comes first. correctly.
Result: The total amp draw measures less
Maintaining the axle brakes in good condition is than 5.5 amps. Replace the magnets and
essential to safe operation and good performance. magnet springs on both sides of the axle, and
A faulty brake magnet can severely impact the resurface the brake drums. Repeat this
stopping power of a trailer. While some magnet procedure beginning with step 4.
problems will be apparent upon visual inspection,
there may also be electrical problems that can 4 Stop the engine of the tow vehicle.
impact performance. A failing or faulty brake
5 Select a wheel. Chock the front and rear of the
magnet can lead to weak or surging brakes, or
tire at the opposite side of the machine.
cause the brakes to pull to one side. It is important
to inspect and test the magnets at regular intervals 6 Loosen the wheel lug nuts. Do not remove
to ensure maximum effectiveness. them.
1 Connect the electric brake wire harness to a 7 Place a lifting jack under the axle near the
tow vehicle capable of towing the machine. wheel to be removed. Lift the axle until the
wheel is off the ground and place a jack stand
2 Start the engine of the tow vehicle, and press under the axle. Lower the axle onto the jack
down on the brake pedal. stand and remove the wheel.
Result: An audible 'click' is noted at each 8 Remove the dust cap from the hub. Remove
brake when the brake magnet is activated and the cotter pin from the castle nut.
pulls itself into contact with the brake drum.
The brake circuit is functioning correctly. 9 Remove the castle nut and washer.
Result: An audible 'click' is not noted at each 10 Pull the hub off of the spindle. The washer and
brake because the brake magnet is not outer bearing should fall loose from the hub.
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.

11 Locate the brake magnet. Inspect the surface

of the magnet for pitting and any irregular
surface wear.
Result: Replace the magnets and magnet
springs on both sides of the axle if pitting or
any irregular surface wear is detected, and
resurface the brake drums.
12 Inspect the copper coil at the center of the
magnet.
Result: Replace the magnets and magnet
springs on both sides of the axle if the
exposed copper coil is visible in any way, and
resurface the brake drums.
13 Slide the hub onto the yoke spindle.
Component damage hazard. Do
not apply excessive force or
damage to the lip of the seal may
occur.
14 Place the outer bearing into the hub.

15 Install the washer and the castle nut.
16 Tighten the castle nut to 50 ft-lbs / 68 Nm to
seat the bearings.
17 Fully loosen the castle nut. Do not rotate the
hub.
19 Install a new cotter pin. Bend the cotter pin to
lock it in place.
Note: Always replace the cotter pin with a new one
when removing the castle nut.
20 Install the dust cap, then the tire and wheel

assembly. Torque the wheel lug nuts to
specification. Refer to Section 2,
Specifications.
21 Repeat this procedure, beginning with step 6,
for the other side of the machine.

Checklist D Procedures
D-1
Perform Coupler Maintenance
Coupler specifications require that this procedure

be performed annually.
Maintaining the coupler in good condition is
essential to safe operation and good performance.
Coupler failure could result in a machine tip-over
during transport, and component damage may also
result if problems are not discovered and repaired
in a timely fashion.
1 Check 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
E-1 5 Visually inspect the winch cable for the

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 may Result: A crushed spot on the cable
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.

Checklist E Procedures
E-2
Perform Inverter Maintenance
Inverter specifications require that this procedure

be performed every 2 years.
• Check fuel line - replace if needed

engine/generator information is available in the
Operation Manual.


Repair Procedures
Machine Configuration:
Section 4 Repair Pr oc edures
 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
• The red Emergency Stop button in the off
this machine.
 Immediately tag and remove from service a • Wheels chocked
damaged or malfunctioning machine.
• Light switches in the off position
 Repair any machine damage or malfunction
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
messages that follow this symbol
to avoid possible injury or death.
Indicates a imminently hazardous

situation which, if not avoided, will

could result in death or serious
injury.

may cause minor or moderate
injury.

may result in property damage.
Indicates that a specific result is expected

Indicates that an incorrect result has occurred

LED Module
1-1
How to Remove a LED Module
circuits could result in death or
watches and other jewelry.
1 Turn off all machine power.

2 Unplug the LED Module from the Current
Driver.
1 LED current driver

2 LED module
3 LED connector
4 mounting fasteners
3 Remove the LED Modules mounting

fasteners.
4 Wrap a clean cloth around the LED module
and remove it from the socket.

Mast
2-1 2-2
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
service is required. Bodily injury hazard. Cables
can fray. Always wear adequate
hand protection when handling
Bodily injury hazard. Cables
the cable.
can fray. Always wear adequate
hand protection when handling
the cable. Component damage hazard.
Cables can be damaged if they
1 Tag and remove the LED modules 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 set
Remove and retain the coil cord clamp and 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 heads Disconnect the cable from the 2 inch / 5 cm
to the side. mast section by removing the cable retention
3 Remove the fasteners securing the mast base pin.
to the chassis. 5 Working at the top of the 3 inch / 7.5 cm mast
4 Attach a lifting strap from an overhead crane section, use a drill to remove the rivets
to the mast base beneath the rotating section securing the wear pads in position.
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
2-3 Note: Refer to the illustration below for cable

routing detail.
How to Replace the Mast Lift
Cables
See 2-2, How to Disassemble the Mast Assembly.

Mast
2-4 2-5
How to Remove the Manual Winch How to Disengage the Tower Lock
1 Turn the handle of the mast pivot winch and To disengage the light tower lock so the tower can
fully loosen the mast pivot cable. Remove the be lowered to the stowed position and towed to a
handle from the winch. suitable workshop for repairs follow the steps
below.
2 Open the cabinet doors and locate the winch.
Remove the fasteners securing the handle to Bodily injury hazard. This
the winch, and remove the handle. procedure requires specific repair
3 Remove the cable retaining fastener securing skills, lifting equipment and a
the cable to the winch drum. Unwind the cable suitable workshop. Attempting
from the winch drum. this procedure without these skills
and tools could result in death or
Bodily injury hazard. Cables serious injury and significant
can fray. Always wear adequate component damage. Dealer
hand protection when handling service is strongly recommended.
the cable.
Bodily injury hazard. Cables
4 Remove the winch from the machine. can fray. Always wear
adequate hand protection
when 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
Unlock the tower: 8 Using a Telehandler or construction forklift

slowly begin lifting up the first movable tower
6 Loosen the T-bolt and rotate the tower so that
section (2) until the tower lock lever (3)
the lock holes are facing forward. Re-tighten
disengages.
T-bolt to secure the tower.
7 Using the figure below, attach a lifting strap
around the first movable tower section (1) as
shown.
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.

Inverter
3-1
Champion 3.5 KW Inverter
1 Air Cleaner 6 Hour meter - Logs run time of generator.

2 Connectors A, B, C - Interface between 7 120VAC, 30 Amp Receptacle (L5-30R)
generator and Light Tower. 8 Oil Fill Port
3 12VDC 9AH Battery - Used to power 9 Oil Drain
starter during remote starting.
4 Wireless Rest Button - Used to reset or pair
remote fob.
5 Wireless Reset Indicator

Diagnostics
Before Troubleshooting:
Section 5 Diagnostics
 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 qualified conditions.
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: High voltage. Exposure to
electrical wires or electrical
• Machine parked on a firm, level surface current will result in death or
• Mast in the stowed position serious injury. Turn off all power
when not needed for testing. Use
• Key switch in the off position with the key extreme caution when working
removed with high voltage electrical
• The red Emergency Stop button in the off components.
Burn hazard. Beware of hot
• Wheels chocked engine components. Contact
with hot engine components
• Light switches in the off position may cause severe burns. Use
• All external AC power supply disconnected caution when working around
from the machine lamps or a hot engine.

Diagnostic Charts
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 Thermostat faulty Inspect and repair as needed.
Head gasket faulty Inspect and repair as needed.
Unsuitable fuel used Drain fuel system and replace with

specified fuel.
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.
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.
Fuel valve off turn on valve.
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.
Faulty wiring connection in control box Inspect and repair as needed.
Battery is discharged or low Charge or replace battery.
Air cleaner is dirty Clean or replace more frequently.

Diagnostic Charts
Problem Possible Cause Solution

Engine battery quickly Wiring loose or disconnected Inspect and repair as needed.
discharged
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.
Power supply cable connector faulty or poor Inspect and repair as needed.
connection
Unusual noise from the Inspect and repair as needed.
generator
Generator produces full voltage Loose or broken lead wires Inspect lead wires and connections for
at no load or voltage drops at broken wires and loose connections.
full load

Schematics
About This Section

Section 6 Schem atics
There are two groups of schematics in this section.
Electrical Schematics
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
Hydraulic Schematics
 Immediately tag and remove from service a
damaged or malfunctioning machine. Bodily injury hazard. Spraying
hydraulic oil can penetrate and
 Repair any machine damage or malfunction burn skin. Loosen hydraulic
before operating the machine.
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

BL Blue
BK Black
BR Brown
GR Green
OR Orange
VI Violet
RD Red
WH White
YL Yellow
CN Carnation
WH/GR White/Green
OR/BK Orange/Black
BK/WH Black/White
WH/RD White/Red
GR/YL Green/Yellow
RD/BK Red/Black
YL/RD Yellow/Red
BL/WH Blue/White

Engine Inverter Electrical Schematic
43


46
AC Control Schematic
47
AC Control Schematic

Running Lights

Running Lights
RL™ 4 LED Part No. 1287632GT Servic e M anual March 2018
50

1287632GT

Uploaded by

Copyright:

Available Formats

1287632GT

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

1287632GT

Uploaded by

Copyright:

Available Formats

Service Manual

Part No. 1287632GT

Important Technical Publications

Basic mechanical, hydraulic and electrical skills are

Copyright © 2018 by Terex Corporation

'Terex' and 'AWP' are registered trademarks of Terex USA, LLC

ii RL™4 LED Part No. 1287632GT

Serial Number Legend

1 Model 4 Sequence number

1 Model 3 Sequence number

Part No. 1287632GT RL™4 LED 3

Do Not Perform Maintenance

iv RL™4 LED Part No. 1287632GT

Personal Safety Workplace Safety

Part No. 1287632GT RL™4 LED v

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

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

Section 2 Specifications ....................................................................................................... 1

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

Checklist A Procedures ....................................................................................... 8

vi RL™4 LED Part No. 1287632GT

Checklist B Procedures ..................................................................................... 17

Checklist C Procedures ..................................................................................... 22

Checklist D Procedures ..................................................................................... 26

Checklist E Procedures ..................................................................................... 27

Part No. 1287632GT RL™4 LED vii

Section 4 Repair Procedures ............................................................................................. 29

LED Module ........................................................................................................ 31

Section 5 Diagnostics ......................................................................................................... 38

Diagnostic Charts .............................................................................................. 39

Section 6 Schematics ......................................................................................................... 41

viii RL™4 LED Part No. 1287632GT

Machine Specifications Inverter Options

Part No. 1287632GT RL™4 LED 1

2 RL™4 LED Part No. 1287632GT

Scheduled Maintenance Procedures

 Unless otherwise specified, perform each

 Immediately tag and remove from service a

Part No. 1287632GT RL™4 LED 3

Scheduled Maintenance Procedures

About This Section

Indicates a imminently hazardous

Indicates a potentially hazardous

Indicates a potentially hazardous

Indicates a potentially hazardous

Indicates that a specific result is expected

4 RL™4 LED Part No. 1287632GT

Scheduled Maintenance Procedures

Maintenance Symbols Legend Pre-delivery Preparation Report

Indicates that tools will be required to Maintenance Schedule

Indicates that dealer service will be Inspection Checklist

Indicates that a warm engine will be

Part No. 1287632GT RL™4 LED 5

Pre-Delivery Preparation Report

Maintenance Inspection Report

Part No. 1287632GT RL™4 LED 7

A-1 3 Open the operator's manual to the decals

1 Check to make sure that the operator's and

8 RL™4 LED Part No. 1287632GT