Genie Tml 4000 Users Manual 65176o11

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Towing Checklist
Hitching

·
·
·
·
·

Hitch is sufficient to tow trailer and load
Hitch is properly attached to tow vehicle
Safety chains (if required) are properly attached
All tires have correct pressure
All lights are connected and working

Towing

·
·
·
·

Genie North America
Phone 425.881.1800
Toll Free USA and Canada
800.536.1800
Fax 425.883.3475

California Proposition 65

Genie Australia Pty Ltd.
Phone +61 7 3375 1660
Fax +61 7 3375 1002

Genie China

WARNING

Phone +86 21 53852570
Fax +86 21 53852569

Genie Malaysia
Phone +65 98 480 775
Fax +65 67 533 544

The exhaust from this product contains chemicals

Genie Japan

known to the State of California to cause cancer,

Phone +81 3 3453 6082
Fax +81 3 3453 6083

birth defects or other reproductive harm.

Genie Korea
Phone +82 25 587 267
Fax +82 25 583 910

Genie Brasil
Phone +55 11 41 665 755
Fax +55 11 41 665 754

Genie Holland

Phone +46 31 3409612
Fax +46 31 3409613

Genie France
Phone +33 (0)2 37 26 09 99
Fax +33 (0)2 37 26 09 98

Genie Iberica
Phone +34 93 579 5042
Fax +34 93 579 5059

Genie Germany
Phone +49 (0)4202 88520
Fax +49 (0)4202 8852-20

Genie U.K.
Phone +44 (0)1476 584333
Fax +44 (0)1476 584334

Genie Mexico City
Phone +52 55 5666 5242
Fax +52 55 5666 3241

Distributed By:

Phone +31 10 220 7911
Fax +31 10 220 6642

Genie Scandinavia

Do not exceed 60 mph / 97 km/h
Check connections and tire pressure at each stop
Slow down for hazardous conditions
Allow extra distance for following and passing other vehicles

Operator’s Manual

Second
Third
Edition
Edition

with Maintenance Information

Part No. 97600
43645

SeventhPrinting
Second
Printing

Operator's Manual

Third Edition • Second Printing

Important
Read, understand and obey these safety rules and
operating instructions before operating this machine.
Only trained and authorized personnel shall be
permitted to operate this machine. This manual should
be considered a permanent part of your machine and
should remain with the machine at all times. If you have
any questions, call Genie Industries.

Contents
Page
Safety ........................................................................ 1
Legend ....................................................................... 6
Controls ..................................................................... 7
Pre-operation Inspection ............................................ 8
Maintenance ............................................................. 10
Function Tests .......................................................... 13
Workplace Inspection ................................................ 16
Operating Instructions ............................................... 17
Transport and Lifting Instructions .............................. 20
Decals ...................................................................... 22
Specifications ........................................................... 24
Reporting Safety Defects .......................................... 25

Second Printing, March 2001

Second Edition: Fourth Printing, April 2002
Third Edition:

Second Printing, October 2004

"Genie" is a Registered Trademark of Genie
Industries in the USA and many other countries.
"TML" is a trademark of Genie Industries.

Printed on recycled paper
Printed in U.S.A.

Genie TML-4000 and TML-4000N

Part No. 97600

Third Edition • Second Printing

Operator's Manual

Safety Rules

Warning
Failure to obey the instructions and
safety rules in this manual may
result in death or serious injury.
Do Not Operate Unless:
You learn and practice the principles of safe
machine operation contained in this operator's
manual.
1 Avoid hazardous situations.
Know and understand the safety rules
before going on to the next section.
2 Always perform a pre-operation
inspection.
3 Always perform the function tests prior to
use.
4 Inspect the workplace.
5 Only use the machine as it was intended.
You read, understand and obey the
manufacturer's instructions and safety rules—
safety and operator's manuals and machine
decals.
You read, understand and obey employer's
safety rules and worksite regulations.
You read, understand and obey all applicable
governmental regulations.
You are properly trained to safely operate the
machine.

Part No. 97600

Genie TML-4000 and TML-4000N

Operator's Manual

Third Edition • Second Printing

SAFETY RULES

Do not adjust or stow the outriggers when the mast
is raised.

Fall Hazards
Do not stand on the
machine.

Do not use the machine on a moving or mobile
surface or vehicle.

Do not climb on the mast.

Be sure the tires are in good condition and the lug
nuts are properly tightened.

Tip-over
Hazards

Electrocution Hazards

Do not raise the mast to the vertical position unless
all outriggers are properly deployed, the foot pads
are in firm contact with the ground and the machine
is level.

This machine is not electrically insulated and will
not provide protection from contact with or
proximity to electrical current.

Do not set the machine up on a surface where it
cannot be leveled using only the leveling jacks.

Maintain safe distances away from electrical power
lines and apparatus in accordance with applicable
governmental regulations and the following chart.

Do not hang any objects from the lights or mast.
Do not use the mast to raise material or personnel.

Voltage
Phase to Phase

Minimum Safe
Approach Distance
Feet
Meters

Do not move the machine unless the mast is
lowered to the horizontal position and securely
locked in place.

0 to 300V

Avoid Contact

300V to 50KV

3.05

Do not extend the mast when wind speeds may
exceed 60 mph / 27 m/sec.

50KV to 200KV

4.60

200KV to 350KV

6.10

350KV to 500KV

7.62

500KV to 750KV

10.67

750KV to 1000KV

13.72

Allow for mast movement and electrical line sway
or sag, and be aware of strong or gusty winds.
Do not place ladders or scaffolds against any part
of the machine.

Do not operate the machine during lightning or
storms.

Do not alter or disable machine components that in
any way affect safety and stability.

Do not use the machine as a ground for welding.

Genie TML-4000 and TML-4000N

Part No. 97600

Third Edition • Second Printing

Operator's Manual

SAFETY RULES

Keep away from the
machine if it contacts
energized power lines.
Personnel must not
touch or operate the
machine until power
lines are shut off.

Burn Hazard
Do not touch the lamp fixtures while they are turned
on. Turn the lamps off and allow them to cool
before touching.

Crushing Hazards

Do not connect wires
directly to the generator.
Connect auxiliary
equipment only to the
power outlets provided.

Do not lower the mast unless the area below is
clear of personnel and obstructions.

Inspect the power cord for damage prior to each
use. Replace any damaged cord before operating.
Do not allow the power cord to become caught or
crushed while raising, lowering or rotating the mast.
Avoid electrical shock from contact with battery
terminals. Remove all rings, watches and other
jewelry.
This machine should be grounded in accordance
with all local electrical codes. Consult the local
electrical codes or Authority Having Jurisdiction in
the area where the machine will be used for specific
requirements.

Collision Hazard
Check the work area for overhead obstructions or
other possible hazards.

Do not release the spring latch on the side of the
machine unless the mast sections are fully
retracted.
Keep hands and fingers away from any potential
pinch points.

Damaged Machine Hazards
Do not use a damaged or
malfunctioning machine.
Do not use a machine with
a worn, frayed, kinked or
damaged cable.
Be sure the operator's
manual is complete, legible
and in the storage container
located on the machine.
Be sure all decals are legible and in place.

Bodily Injury Hazard
Do not grasp the cable.
Use proper lifting techniques when lifting and
positioning the tongue of the machine.
Always replace the protective lamp cover after
replacing the lamp bulbs.

Part No. 97600

Genie TML-4000 and TML-4000N

Operator's Manual

Third Edition • Second Printing

SAFETY RULES

Explosion and Fire Hazards

Towing Hazards

Do not start the engine if you smell or detect diesel
fuel or other explosive substances.

Read, understand and obey all of your tow vehicle
manufacturer’s recommendations, warnings and
instructions before towing this machine.

Do not refuel the machine with the engine running.
Refuel the machine and charge the battery only in
an open, well-ventilated area away from sparks,
flames and lighted tobacco.
Do not operate the machine in hazardous locations
or locations where potentially flammable or
explosive gases or particles may be present.

Do not tow the machine unless the mast is lowered
to the horizontal position and is properly stowed in
the transport cradle.
Do not tow the machine unless the mast hold-down
latch is securely locked in place.

Do not spray ether into the engine.

Do not overload your tow vehicle. Check the
manufacturer's Gross Vehicle Weight Rating
(GVWR). To obtain the gross vehicle weight, add
the tongue weight of the trailer to the vehicle
weight (including vehicle, passengers and cargo).

Component Damage Hazards

Do not load cargo on the machine. The TML is not
designed to carry any extra cargo.

Keep sparks, flames and lighted tobacco away
from the battery. Batteries emit an explosive gas.

Do not turn the lights on unless the engine is
running. Always turn the lights off before shutting
down the engine.
Do not use any battery charger greater than 12V to
charge the battery.
Do not expose the battery or the charger to water
or rain.

Be sure the hitch is securely attached to the tow
vehicle.
Be sure the safety chains (if required) are securely
attached to the tow vehicle.
Be sure that all driving lights are operational.

Do not replace lamp bulbs with any bulbs other than
those specified on the machine and in this manual.

Be sure all hitch components, lights and mirrors
and methods of attaching the trailer to the tow
vehicle conform to local, state and federal
regulations.

Improper Use Hazard

Do not tow the machine on public roads unless it
meets all governmental regulations for towing.

When leaving the machine unattended, secure from
unauthorized use. Unauthorized personnel may
attempt to operate the machine without proper
instruction, creating an unsafe condition.

Do not exceed 60 mph / 97 km/h. Obey all local
and national towing speed laws.
Be sure to chock the wheels of the trailer when
parking on a hill.

Genie TML-4000 and TML-4000N

Part No. 97600

Third Edition • Second Printing

Operator's Manual

SAFETY RULES

Decal Legend
Genie product decals use symbols, color coding
and signal words to identify the following:
Safety alert symbol—used to alert
personnel to potential personal
injury hazards. Obey all safety
messages that follow this symbol
to avoid possible injury or death.
Red—used to indicate the
presence of an imminently
hazardous situation which, if not
avoided, will result in death or
serious injury.
Orange—used to indicate the
presence of a potentially
hazardous situation which, if not
avoided, could result in death or
serious injury.
Yellow with safety alert symbol—
used to indicate the presence of a
potentially hazardous situation
which, if not avoided, may cause
minor or moderate injury.
Yellow without safety alert
symbol—used to indicate the
presence of a potentially
hazardous situation which, if not
avoided, may result in property
damage.
Green—used to indicate operation
or maintenance information.

Part No. 97600

Genie TML-4000 and TML-4000N

Operator's Manual

Third Edition • Second Printing

Legend
7

9
6
10
5

9
11

13
2

14
2

15
1
21

1 Outrigger leveling jack with
footpad
2 Outrigger jack handle

Access under opposite cover:
Fuel tank
Power outlets (Narrow models)
Manual storage container

13 Front spring latch (behind
mast)
14 Tongue outrigger

3 Outrigger

6 Mast hold-down latch

15 Coupler

4 Transport tie-down (hidden
behind machine)

7 Lamp fixtures
8 Mast

16 Transport tie-down (one on
each side of tongue outrigger)

5 Cover

9 Forklift pocket

17 Control panel (under cover)

10 Lifting eye

18 Mast release latch

11 Mast rotation lever

19 Raise/Lower winch handle

12 Extend/Retract winch handle

20 Fender

Access under this cover:
Engine
Generator
Grounding rod attachment
Power outlets (Standard models)

21 Tire
6

Genie TML-4000 and TML-4000N

Part No. 97600

Third Edition • Second Printing

Operator's Manual

Controls

00009.9
5
6
OFF

RUN

AIR
FILTER

START

Control Panel
1 Key switch

4 Glow plug indicator light

2 Hour meter

5 Oil pressure indicator
light

3 Circuit breaker switches for
lights (4)

Part No. 97600

Genie TML-4000 and TML-4000N

6 Water temperature
indicator light
7 Air filter condition indicator
light

Operator's Manual

Third Edition • Second Printing

Pre-operation Inspection
Fundamentals
It is the responsibility of the operator to perform a
pre-operation inspection and routine maintenance.
The pre-operation Inspection is a visual inspection
performed by the operator prior to each work shift.
The inspection is designed to discover if anything
is apparently wrong with a machine before the
operator performs the function tests.

Do Not Operate Unless:
You learn and practice the principles of safe
machine operation contained in this operator’s
manual.
1 Avoid hazardous situations.
2 Always perform a pre-operation inspection.
Know and understand the pre-operation
inspection before going on to the next
section.
3 Always perform the function tests prior to use.
4 Inspect the workplace.
5 Only use the machine as it was intended.

The pre-operation inspection also serves to
determine if routine maintenance procedures are
required. Only routine maintenance items specified
in this manual may be performed by the operator.
Refer to the list on the next page and check each
of the items.
If damage or any unauthorized variation from
factory delivered condition is discovered, the
machine must be tagged and removed from
service.
Repairs to the machine may only be made by a
qualified service technician, according to the
manufacturer's specifications. After repairs are
completed, the operator must perform a
pre-operation inspection again before going on to
the function tests.
Scheduled maintenance inspections shall be
performed by qualified service technicians,
according to the manufacturer's specifications.

Genie TML-4000 and TML-4000N

Part No. 97600

Third Edition • Second Printing

Operator's Manual

PRE-OPERATION INSPECTION

Pre-operation Inspection
o Be sure that the operator’s manual is complete,
legible and in the storage container located on
the machine.

Check entire machine for:

o Be sure that all decals are legible and in place.
See Decals section.

o Dents or damage to machine

o Check for engine oil leaks and proper fluid level.
Add oil if needed. See Maintenance section.
o Check for engine coolant leaks and proper
coolant level. Add coolant if necessary. See
Maintenance section.

o Cracks in welds or structural components
o Be sure that all structural and other critical
components are present and all associated
fasteners and pins are in place and properly
tightened.
o Be sure that the battery is in place and properly
connected.

o Check for battery fluid leaks and proper fluid
level. Add distilled water if needed. See
Maintenance section.
o Check for proper tire pressure and lug nut
torque. Add air to tires if needed. See
Maintenance section.
Check the following components or areas for
damage, improperly installed or missing parts and
unauthorized modifications:
o Electrical components, wiring and electrical
cables
o Mast tubes
o Winches and related components
o Latches and pins
o Tires and wheels
o Trailer lights and reflectors
o Outriggers, leveling jacks and foot pads
o Nuts, bolts and other fasteners
o Lamp fixtures and bulbs
o Cable (kinks, frays and abrasions)
o Safety chains (if required)
o Engine and related components
o Fuel tank
o Generator

Part No. 97600

Genie TML-4000 and TML-4000N

Operator's Manual

Third Edition • Second Printing

Maintenance
Check the Engine Oil Level
Maintaining the proper engine oil level is essential
to good engine performance and service life.
Operating the machine with an improper oil level
can damage engine components.

Observe and Obey:
Only routine maintenance items specified in this
manual shall be performed by the operator.
Scheduled maintenance inspections shall be
completed by qualified service technicians,
according to the manufacturer's specifications
and the requirements specified in the
responsibilities manual.

Check the oil level with the
engine off.
1 Check the oil level dipstick. Add oil if needed.
Deutz F3M 1008 Engine
Deutz F3M 1008F Engine
oil type
oil type cold conditions

10W-40
5W-40

Perkins 103-10 Engine

Maintenance Symbols Legend

oil type

The following symbols have been
used in this manual to help
communicate the intent of the
instructions. When one or more of
the symbols appear at the
beginning of a maintenance
procedure, it conveys the meaning
below.

oil type cold conditions

15W-40
5W-20

Perkins 403C-11G
oil type
oil type cold conditions

15W-40
5W-20

Indicates that tools will be required to
perform this procedure.

Indicates that new parts will be
required to perform this procedure.

Genie TML-4000 and TML-4000N

Part No. 97600

Third Edition • Second Printing

Operator's Manual

MAINTENANCE

Check the Engine Coolant Level

Check the Battery

Maintaining the engine coolant at the proper level is
essential to engine service life. Improper coolant
level will affect the engine's cooling capability and
damage engine components. Daily checks will
allow the inspector to identify changes in coolant
level that might indicate cooling system problems.

Proper battery condition is essential to good engine
performance and operational safety. Improper fluid
levels or damaged cables and connections can
result in engine component damage and hazardous
conditions.
This procedure does not need to
be performed on machines with
sealed or maintenance-free
batteries.

1 Remove the radiator cap and check the coolant
level. Add fluid as needed.
Bodily injury hazard. Fluids in the
radiator are under pressure and
extremely hot. Use caution when
removing cap and adding fluids.

Electrocution hazard. Contact with
hot or live circuits could result in
death or serious injury. Remove all
rings, watches and other jewelry.
Bodily injury hazard. Batteries
contain acid. Avoid spilling or
contacting battery acid. Neutralize
battery acid spills with baking soda
and water.
1 Put on protective clothing and eye wear.
2 Be sure the battery cable connections are tight
and free of corrosion.
3 Remove the battery vent caps.
4 Check the battery acid level. If needed,
replenish with distilled water to the bottom of
the battery fill tube. Do not overfill.
5 Install the vent caps.

Part No. 97600

Genie TML-4000 and TML-4000N

Operator's Manual

Third Edition • Second Printing

MAINTENANCE

Check the Tires and Wheels

4 Check the torque of each lug nut.
Tires and wheels - Standard and Narrow models
Tire size

Bodily injury hazard. An overinflated tire can explode and may
cause death or serious injury.

Rim size

Collision hazard. An excessively
worn tire can cause poor handling
and continued use could result in
tire failure.

Tire pressure (cold)

Tip-over hazard. Do not use
temporary flat tire repair products.
Maintaining the tires and wheels in good condition
is essential to safe operation and good
performance. Tire and/or wheel failure could result
in a machine tip-over. Component damage may
also result if problems are not discovered and
repaired in a timely fashion.
1 Check the tire surface and sidewalls for cuts,
cracks, punctures and uneven or excessive
tread wear. Replace the tire if uneven or
excessive tread wear is found.

Lug nut torque

ST185/80D13
13 x 4.5 in

33 x 11.4 cm

80 ft-lbs

108 Nm

50 psi

3.4 bar

Scheduled Maintenance
Maintenance performed quarterly, annually and
every two years must be completed by a person
trained and qualified to perform maintenance on
this machine according to the procedures found in
the service manual for this machine.
Machines that have been out of service for more
than three months must receive the quarterly
inspection before they are put back into service.

2 Check each wheel for damage, bends and
cracks. Replace the wheel if any damage is
found.
Tires and wheels must be replaced
with tires and wheels of the
specifications listed.
3 Check each tire with an air pressure gauge and
add air as needed.

Genie TML-4000 and TML-4000N

Part No. 97600

Third Edition • Second Printing

Operator's Manual

Function Tests
Fundamentals
The function tests are designed to discover any
malfunctions before the machine is put into service.
The operator must follow the step-by-step
instructions to test all machine functions.

Do Not Operate Unless:
You learn and practice the principles of safe
machine operation contained in this operator's
manual.
1 Avoid hazardous situations.
2 Always perform a pre-operation inspection.
3 Always perform function tests prior to use.

A malfunctioning machine must never be used. If
malfunctions are discovered, the machine must be
tagged and removed from service. Repairs to the
machine may only be made by a qualified service
technician, according to the manufacturer's
specifications.
After repairs are completed, the operator must
perform a pre-operation inspection and function
tests again before putting the machine into service.

Know and understand the function tests
before going on to the next section.
4 Inspect the workplace.
5 Only use the machine as it was intended.

Part No. 97600

Genie TML-4000 and TML-4000N

Operator's Manual

Third Edition • Second Printing

FUNCTION TESTS

Setup

Test the Machine Functions

1 Position the machine at the desired work site.

By raising and extending, then retracting and
lowering the mast back to the horizontal position,
the following functions will be tested: winches,
latches, mast extension and mast rotation.

2 Disconnect the trailer lights and safety chains.
3 Open the latch on the coupler.
4 Pull the release pin on the tongue outrigger and
rotate the outrigger towards the ground until the
outrigger pin locks securely in place.
5 Turn the jack handle to lower the outrigger foot
pad and raise the tongue of the machine
enough to clear the tow vehicle.
6 Release the spring pin on the side outriggers
and lower them to the ground. Make sure the
locking arms are locked in place.
7 Turn the outrigger jack handles to level the
machine. Level the machine using only the
leveling jacks.

Install the Lamp Fixtures (if
applicable)
For each lamp fixture:
8 Remove the lamp fixture from the storage
location under the covers.
9 Slide the fixture into the holes on the mounting
bracket and close the latches.

12 Unlock the mast hold-down latch.
13 Turn the raise/lower winch handle clockwise until
the mast raises approximately 2 feet /
60 cm.
Result: A clicking sound should be heard as the
winch handle is turned.
14 Release the winch handle.
Result: The winch brake should hold when the
handle is released.
15 Continue to turn the winch handle clockwise
until the mast reaches full vertical position.
Result: The mast should raise smoothly, free of
hesitation or binding.
Result: The spring latch on the front of the
machine should lock the mast securely into
place.
16 Turn the extend/retract winch handle clockwise
until the mast extends approximately 2 feet /
60 cm.

10 Insert and close the safety pins.

Result: A clicking sound should be heard as the
winch handle is turned.

11 Remove the cap from the receptacle socket and
connect the electrical plug.

Result: The mast sections should telescope
smoothly, free of hesitation or binding.

Note: Make sure the safety pins are properly
installed before raising the mast.

17 Release the winch handle.
Result: The winch brake should hold when the
handle is released.

Genie TML-4000 and TML-4000N

Part No. 97600

Third Edition • Second Printing

Operator's Manual

FUNCTION TESTS

18 Press and hold the mast rotation lever.

Test the Lights

19 Rotate the mast clockwise and then
counterclockwise as far as it will go in either
direction.

27 Make sure the circuit breaker light switches are
in the off position.

Result: The mast should rotate smoothly and
easily in both directions.
20 Rotate the mast back to its original position.
Line up the black arrows on the front of the
mast.
21 Release the mast rotation lever.
22 Attempt to rotate the mast in both directions.
Result: The mast should not rotate.
23 Turn the extend/retract winch handle
counterclockwise until the mast sections are
fully retracted. Line up the blue arrows on the
side of the mast.

28 Start the engine. See Starting the Engine in the
Operating Instructions section.
29 Turn all four circuit breaker light switches to the
on position.
Result: The lights should come on.
Note: It can take up to 20 minutes for the lights to
reach full intensity. If the lights are turned off and
turned back on while they are still warm, they will
not light up again for 20-30 minutes.
Note: Make sure the circuit breaker light switches
are turned off before shutting down the engine.

Result: No clicking sound should be heard
when the winch handle is turned.
24 Pull and hold the mast release latch below the
control panel.
25 Begin lowering the mast to the horizontal
position by turning the raise/lower winch handle
counterclockwise and holding the release latch
open.
Result: No clicking sound should be heard
when the winch handle is turned.
26 Release the mast release latch and continue to
crank the winch handle counterclockwise until
the mast reaches horizontal position.
Note: Make sure the mast is lowered completely
into the transport cradle. Follow the mast stowing
instructions in the Operating Instructions section to
make sure the mast hold-down latch is securely
locked.

Part No. 97600

Genie TML-4000 and TML-4000N

Operator's Manual

Third Edition • Second Printing

Workplace Inspection
Be aware of and avoid the following hazardous
situations:

Do Not Operate Unless:
You learn and practice the principles of safe
machine operation contained in this operator's
manual.
1 Avoid hazardous situations.
2 Always perform a pre-operation inspection.

Drop-offs or holes

Bumps and obstructions

Debris

Slopes that exceed the machine’s leveling
capability

Unstable or slippery surfaces

Overhead obstructions and high voltage
conductors

Hazardous locations

Inadequate surface support to withstand all
load forces imposed by the machine

Wind and weather conditions

The presence of unauthorized personnel

All other possible unsafe conditions

3 Always perform function tests prior to use.
4 Inspect the workplace.
Know and understand the workplace
inspection before going on to the next
section.
5 Only use the machine as it was intended.

Fundamentals
The workplace inspection helps the operator
determine if the workplace is suitable for safe
machine operation. It should be performed by the
operator prior to moving the machine to the
workplace.
It is the operator's responsibility to read and
remember the workplace hazards, then watch for
and avoid them while moving, setting up and
operating the machine.

Genie TML-4000 and TML-4000N

Part No. 97600

Third Edition • Second Printing

Operator's Manual

Operating Instructions
Setup
Make sure the machine is set up according to the
Setup procedure in the Function Tests section.

Starting the Engine
Do Not Operate Unless:
You learn and practice the principles of safe
machine operation contained in this operator's
manual.

1 Make sure the circuit breaker light switches are
in the off position.
2 At the control panel, turn the key or turn the
switch to the run position. The glow plug light
will come on.

1 Avoid hazardous situations.

3 Wait for the glow plug light to go off.

2 Always perform a pre-operation inspection.

4 Turn the key or turn the switch to start.

3 Always perform function tests prior to use.

Note: If the key or switch is not turned to start
within 10 seconds of the glow plug light going off,
the engine may fail to start. If this happens, turn
the key or switch to the off position and repeat the
procedure.

4 Inspect the workplace.
5 Only use the machine as it was intended.

Note: If the glow plug light is flashing during the
preheat cycle, the battery is low.

Operation of Lights
Fundamentals
The Operating Instructions section provides
instructions for each aspect of machine operation.
It is the operator's responsibility to follow all the
safety rules and instructions in the operator's,
safety and responsibilities manuals.
If more than one operator is expected to use a
machine at different times in the same work shift,
each operator is expected to follow all safety rules
and instructions in the operator's manual. That
means every new operator should perform a preoperation inspection, function tests and a work
place inspection before using the machine.

Part No. 97600

1 Turn on the lights using the circuit breaker
switches located on the control panel. Each
switch corresponds to one of the lamps.
Note: The lights can take up to 20 minutes to reach
full intensity.
Note: If the lights are turned off and turned back on
while they are still warm, they will not light up again
for 20-30 minutes.
2 Turn the lights off by turning the circuit breaker
switches to the off position. Make sure the
lights are turned off before shutting down the
engine.

Genie TML-4000 and TML-4000N

Operator's Manual

Third Edition • Second Printing

OPERATING INSTRUCTIONS

Note: If the mast has not been fully retracted, it will
not rest completely in the cradle.

To Raise the Mast
1 Unlock the mast hold-down latch.
2 Turn the Raise/Lower winch handle clockwise
until the mast reaches the full vertical position
and the front spring latch locks the mast firmly
in place.

To Extend the Mast

5 Turn the mast hold-down latch handle
counterclockwise and push into the lock.
6 Turn the latch handle clockwise until the handle
points straight down. The latch should turn
freely without binding or hesitation.

Grounding Rod Attachment

1 Turn the Extend/Retract winch handle clockwise
to extend the mast sections.
2 Approximately 6 inches / 15 cm below full mast
extension, the lamp fixture will begin to tilt. The
more the winch handle is turned, the greater the
tilt, until the mast is fully extended and the lights
are positioned.
Note: To adjust the lights after the mast is fully
extended, slowly lower the mast by turning the
winch handle counterclockwise until the lights are
in the desired position.

A grounding rod attachment is located next to the
generator under the cover on the control panel side
of the machine.

After Each Use
1 Select a safe parking location—firm, level
surface, clear of obstructions and traffic.
2 Remove the key OR lock the control panel to
secure from unauthorized use.

To Store the Lamp Fixtures
(Standard models)

To Rotate the Mast
1 Press and hold the mast rotation lever and
rotate the mast to the desired position.
2 Release the lever.

Note: Do not touch hot lamp fixtures. Make sure
the lights are turned off and the lamp fixtures have
cooled down before touching.
For each lamp fixture:

To Stow the Mast
1 Press and hold the mast rotation lever and
rotate the mast to its original position. Line up
the black arrows on the front of the mast.
2 Turn the Extend/Retract winch handle
counterclockwise until the mast sections retract.
The mast is fully retracted when the blue arrows
on the side of the mast are lined up.
3 Pull and hold the mast release latch below the
control panel.

1 Disconnect the electrical plug and cap the
receptacle socket.
2 Remove the safety pins and release the
latches.
3 Pull the lamp fixture up and off the mounting
bracket.
4 Slide the lamp fixture onto the channels located
under the covers.
5 Close and secure the covers before transport.

4 Turn the Raise/Lower winch handle
counterclockwise and lower the mast
completely into the transport cradle.

Genie TML-4000 and TML-4000N

Part No. 97600

Third Edition • Second Printing

Operator's Manual

OPERATING INSTRUCTIONS

Towing
1 Make sure the mast hold-down latch is securely
locked in place.
2 Make sure the covers are closed and secured.
3 Push to release the lock handle on each of the
side outriggers and place in the stowed
position. Make sure the spring pins lock the
outriggers securely in place.
4 Raise the tongue of the machine by turning the
tongue outrigger jack handle.
5 Position the transport vehicle under the coupler
on the tongue of the machine.
6 Open the latch on the coupler.
7 Turn the tongue outrigger jack handle to lower
the tongue and raise the outrigger foot pad off
the ground.
8 Close the latch on the coupler.
9 Rotate the tongue outrigger to the stowed
position and secure with the lock pin.
10 Attach the safety chains (if required).
11 Connect and test the trailer lights.

Increase the distance between your vehicle and the
vehicle in front of you to twice the normal following
distance when towing a trailer. Allow more following
distance in adverse weather.
Slow down for downgrades and shift your
transmission into a lower gear.
Slow down for curves, hazardous road conditions,
freeway exits, and when driving in adverse
weather.
Heavy winds, excessive speed, load shifting or
passing vehicles can cause the trailer to sway
while driving. If this occurs, do not brake, speed up
or turn the steering wheel. Turning the steering
wheel or applying the brakes can cause the vehicle
and trailer to jackknife. Let up on the gas pedal and
keep the steering wheel straight.
If the vehicle and/or trailer travels off the paved
road, hold the steering wheel firmly and let up on
the gas pedal. Do not apply the brakes. Do not turn
sharply. Slow down to under 25 mph / 40 km/h.
Gradually turn the steering wheel to get back on
the road. Proceed with caution when entering
traffic.
When passing other vehicles, be sure to leave
enough room for the extra length of the trailer. You
will need to go much farther beyond the passed
vehicle before you can return to your lane.
Avoid jerky or sudden movements when turning.

Towing Information
Use the checklist provided on the back cover of
this manual before towing and while on the road.
Inspect all connections at each stop.
Driving a vehicle/trailer combination is different
from driving a vehicle alone.
All tires must be properly inflated. Find the
recommended cold tire pressures on the tire
sidewall or trailer decal. Do not overinflate the tires.
Tire pressures go up during driving. Checking the
tire pressure when the tires are warm will give you
an inaccurate pressure reading.

Part No. 97600

Genie TML-4000 and TML-4000N

Operator's Manual

Third Edition • Second Printing

Transport and Lifting Instructions
Securing the Chassis
Place a block on both sides of the axle behind the
wheels.
Place a block under the chassis at both ends of the
machine.

Observe and Obey:

Use the two tie-down points on the machine for
anchoring down to the transport surface.

Common sense and planning must be applied to
control the movement of the machine when
lifting it with a crane or forklift.

Use chains or straps of ample load capacity.

The transport vehicle must be parked on a level
surface.

Adjust the rigging to prevent damage to the chains.

Use a minimum of 2 chains to secure the chassis.

The transport vehicle must be secured to
prevent rolling while the machine is being
loaded.
Be sure the vehicle capacity, loading surfaces
and chains or straps are sufficient to withstand
the machine weight. See the serial plate for the
machine weight.

Securing to Truck or Trailer for
Transit
Fully lower and retract the mast. See To Stow the
Mast in the Operating Instructions section.
Make sure the mast hold-down latch is securely
locked in place.
Close and secure the covers.
Lower the tongue outrigger jack to support the
tongue during transport.
Raise and stow the outriggers.
Chock the machine wheels in preparation for
transport.
Turn the key switch to the off position and remove
the key OR lock the control panel to secure from
unauthorized use.
Inspect the entire machine for loose or unsecured
items.

Genie TML-4000 and TML-4000N

Part No. 97600

Third Edition • Second Printing

Operator's Manual

TRANSPORT AND LIFTING INSTRUCTIONS

Lifting the Machine With a Crane
Fully lower and retract the mast. See To Stow the
Mast in the Operating Instructions section.
Make sure the mast hold-down latch is securely
locked in place.

Observe and Obey:

Close and secure the covers.

Only qualified riggers should rig and lift the
machine.

Inspect the entire machine for loose or unsecured
items.

Be sure the crane capacity, loading surfaces
and straps or lines are sufficient to withstand
the machine weight. See the serial plate for the
machine weight.

Use the lifting eye mounted on the mast to lift the
machine.

Part No. 97600

Genie TML-4000 and TML-4000N

Operator's Manual

Third Edition • Second Printing

Decals
Decal Inspection

Part No. Description

Use the pictures on the next page to verify that all
decals are legible and in place.

72870

Caution - Component Contact

72871

Label - Power Outlet, 120V

72874

Label - Locked, Unlocked

72889

Warning - Transport Hazard

72890

Notice - Mast Retraction

72891

Label - Blue Arrow

82219

Label - Power Outlets Under Cover

82222

Caution - Light Storage,
Standard Models

82223

Label - Light Storage, Standard Models

82224

Label - HOT

82237

Danger - High Voltage

82302

Notice - Perkins Engine Specs

82303

Label - Mast Release Latch

82304

Control Panel

82957

Label - Power Outlets Under Cover

97518

Notice - Lamp Disposal

97602

Warning - Explosion Hazard, Ether

97635

Warning - Bodily Injury Hazard

97637

Label - Wet Locations

97638

Label - Lamp Replacement

97661

Label - Grounding Rod Attachment

97767

Notice - Perkins Engine Specs, Tier II

Below is a numerical list with quantities and
descriptions.

Part No. Description

Quantity

28159

Label - Diesel

28161

Warning - Crushing Hazard

28164

Notice - Hazardous Materials

28171

Label - No Smoking

31072

Manual Storage Container

52475

Label - Transport Tie-down

62707

Warning - Tow Speed

65408

Notice - Operating Instructions

65409

Notice - Mast Rotation Instructions

65411

Warning - General Safety

65412

Warning - Transport Instructions

65414

Danger - Electrocution Hazard

65421

Warning - Electrocution, Generator

65423

Notice - Deutz Engine Specs

72008

Caution - Turn Off Lights

72009

Cosmetic - Genie TML-4000

72010

Cosmetic - Genie TML-4000N

72018

Label - Raise/Lower Winch

72019

Danger - High Voltage

72077

Label - Black Arrow

72826

Label - Extend/Retract Winch

72828

Notice - Tire Specifications

Quantity

Shading indicates decal is hidden from view, i.e.
under covers

Genie TML-4000 and TML-4000N

Part No. 97600

Third Edition • Second Printing

Operator's Manual

DECALS

72889

28161

72009 or
72010

72871 or
82219 or
82957

72891

72890

72077

Control
Panel
Side
28161
97637
72008

82224

72018
72019

82237
72874
82223

65408
65411
82304

28164
65414

82303

72870

65421
97602
65423
or 82302
or 97767
97661
72828
97518
97635
82224
97635

28161
52475
97635
82224
97635
82222
97518
72826
65409

72009
or 72010

28161
65412

82224

Serial
Plate

82223

NHTSA

97602

82223

28164
65414
28161
52475
28161

Part No. 97600

62707

28159

65421

72870

31072
72828

28171

Genie TML-4000 and TML-4000N

Fuel Tank
Side
23

Operator's Manual

Third Edition • Second Printing

Specifications
Model - TML-4000 Standard

Model - TML-4000 Narrow

Height, stowed

71 in
1.8 m

Height, stowed

71 in
1.8 m

Length, stowed

14 ft 7 in
4.4 m

Length, stowed

14 ft 7 in
4.4 m

Width, stowed

70 in
1.8 m

Width, stowed

55 in
1.4 m

Extended tower height

28 ft
8.5 m

Extended tower height

28 ft
8.5 m

Weight
See Serial Plate
(Machine weights vary with option configurations)

Maximum tongue weight

145 lbs
66 kg

Tire size
Engine type

ST185/80D13
3 cylinder diesel, water cooled
Deutz F3M 1008 OR Perkins 103-10

Fuel capacity

50 gallons
189 liters

Generator

6 kw

Total lighting wattage
Replacement bulbs

4000 watts
1000 watts
Type BT-37 Metal Halide

Run time (full load with full fuel tank)
Tower rotation
Maximum towing speed
Maximum wind speed rating

100 hours
360 degrees,
non-continuous
60 mph
97 km/h
60 mph
27 m/sec

Airborne Noise Emissions
71 dB
Maximum sound level at normal operating workstations
(A-weighted)

110 lbs
50 kg

Tire size
Engine type

ST185/80D13
3 cylinder diesel, water cooled
Deutz F3M1008 OR Perkins 103-10

Fuel capacity

30 gallons
114 liters

Generator

6 kw

Total lighting wattage
Replacement bulbs

4000 watts
1000 watts
Type BT-37 Metal Halide

Run time (full load with full fuel tank)
Tower rotation
Maximum towing speed
Maximum wind speed rating

60 hours
360 degrees,
non-continuous
60 mph
97 km/h
60 mph
27 m/sec

Airborne Noise Emissions
71 dB
Maximum sound level at normal operating workstations
(A-weighted)

Continuous improvement of our products is a Genie
policy. Product specifications are subject to change
without notice or obligation.

Genie TML-4000 and TML-4000N

Part No. 97600

Third Edition • Second Printing

Operator's Manual

Reporting Safety Defects
Genie Industries
PO Box 97030
Redmond, WA 98073-9730

Reporting Safety Defects
If you believe that your vehicle has a defect which
could cause a crash or could cause injury or death,
you should immediately inform the National
Highway Traffic Safety Administration (NHTSA) in
addition to Genie Industries.
If NHTSA receives similar complaints, it may open
an investigation, and if it finds that a safety defect
exists in a group of vehicles, it may order a recall
and remedy campaign. However, NHTSA cannot
become involved in any individual problems
between you, your dealer or Genie Industries.
To contact NHTSA you may either call the Auto
Safety Hotline toll-free at 1-800-424-9393 (3660123 in Washington DC area) or write to:
NHTSA
U.S. Department of Transportation
400 7th Street SW, (NSA-11)
Washington DC 20590
You can also obtain information about motor
vehicle safety from the Hotline.

Part No. 97600

Genie TML-4000 and TML-4000N

Towing Checklist
Hitching

·
·
·
·
·

Towing

·
·
·
·

Genie North America
Phone 425.881.1800
Toll Free USA and Canada
800.536.1800
Fax 425.883.3475

California Proposition 65

Genie Australia Pty Ltd.
Phone +61 7 3375 1660
Fax +61 7 3375 1002

Genie China

WARNING

Phone +86 21 53852570
Fax +86 21 53852569

Genie Malaysia
Phone +65 98 480 775
Fax +65 67 533 544

The exhaust from this product contains chemicals

Genie Japan

known to the State of California to cause cancer,

Phone +81 3 3453 6082
Fax +81 3 3453 6083

birth defects or other reproductive harm.

Genie Korea
Phone +82 25 587 267
Fax +82 25 583 910

Genie Brasil
Phone +55 11 41 665 755
Fax +55 11 41 665 754

Genie Holland

Phone +46 31 3409612
Fax +46 31 3409613

Genie France
Phone +33 (0)2 37 26 09 99
Fax +33 (0)2 37 26 09 98

Genie Iberica
Phone +34 93 579 5042
Fax +34 93 579 5059

Genie Germany
Phone +49 (0)4202 88520
Fax +49 (0)4202 8852-20

Genie U.K.
Phone +44 (0)1476 584333
Fax +44 (0)1476 584334

Genie Mexico City
Phone +52 55 5666 5242
Fax +52 55 5666 3241

Distributed By:

Phone +31 10 220 7911
Fax +31 10 220 6642

Genie Scandinavia

Do not exceed 60 mph / 97 km/h
Check connections and tire pressure at each stop
Slow down for hazardous conditions
Allow extra distance for following and passing other vehicles

Operator’s Manual

Second
Third
Edition
Edition

with Maintenance Information

Part No. 97600
43645

SeventhPrinting
Second
Printing

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