Genie Tml 4000 Users Manual 65176o11

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Operator’s Manual

with Maintenance Information

Genie North America

Phone 425.881.1800

Toll Free USA and Canada

800.536.1800

Fax 425.883.3475

Genie Australia Pty Ltd.

Phone +61 7 3375 1660

Fax +61 7 3375 1002

Genie China

Phone +86 21 53852570

Fax +86 21 53852569

Genie Malaysia

Phone +65 98 480 775

Fax +65 67 533 544

Genie Japan

Phone +81 3 3453 6082

Fax +81 3 3453 6083

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 +31 10 220 7911

Fax +31 10 220 6642

Genie Scandinavia

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

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

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

Second Edition

Seventh Printing

Part No. 43645

California Proposition 65

WARNINGWARNING

The exhaust from this product contains chemicals

known to the State of California to cause cancer,

birth defects or other reproductive harm.

Distributed By:

Towing Checklist

Third Edition

Second Printing

Part No. 97600

Hitching

Towing

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Genie TML-4000 and TML-4000N Part No. 97600

Operator's Manual Third Edition • Second Printing

Copyright © 2000 by Genie Industries

First Edition: 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.

Contact us:

Internet: http://www.genielift.com

e-mail: techpub@genieind.com

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

Operator's ManualThird Edition • Second Printing

Part No. 97600 Genie TML-4000 and TML-4000N 1

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.

2 Genie TML-4000 and TML-4000N Part No. 97600

Operator's Manual Third Edition • Second Printing

Fall Hazards

Do not stand on the

machine.

Do not climb on the mast.

Tip-over

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.

Do not set the machine up on a surface where it

cannot be leveled using only the leveling jacks.

Do not hang any objects from the lights or mast.

Do not use the mast to raise material or personnel.

Do not move the machine unless the mast is

lowered to the horizontal position and securely

locked in place.

Do not extend the mast when wind speeds may

exceed 60 mph / 27 m/sec.

Do not place ladders or scaffolds against any part

of the machine.

Do not alter or disable machine components that in

any way affect safety and stability.

SAFETY RULES

Do not adjust or stow the outriggers when the mast

is raised.

Do not use the machine on a moving or mobile

surface or vehicle.

Be sure the tires are in good condition and the lug

nuts are properly tightened.

Electrocution Hazards

This machine is not electrically insulated and will

not provide protection from contact with or

proximity to electrical current.

Maintain safe distances away from electrical power

lines and apparatus in accordance with applicable

governmental regulations and the following chart.

Voltage Minimum Safe

Phase to Phase Approach Distance

Feet Meters

0 to 300V Avoid Contact

300V to 50KV 10 3.05

50KV to 200KV 15 4.60

200KV to 350KV 20 6.10

350KV to 500KV 25 7.62

500KV to 750KV 35 10.67

750KV to 1000KV 45 13.72

Allow for mast movement and electrical line sway

or sag, and be aware of strong or gusty winds.

Do not operate the machine during lightning or

storms.

Do not use the machine as a ground for welding.

Operator's ManualThird Edition • Second Printing

Part No. 97600 Genie TML-4000 and TML-4000N 3

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.

Do not connect wires

directly to the generator.

Connect auxiliary

equipment only to the

power outlets provided.

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.

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.

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 lower the mast unless the area below is

clear of personnel and obstructions.

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.

4 Genie TML-4000 and TML-4000N Part No. 97600

Operator's Manual Third Edition • Second Printing

SAFETY RULES

Towing Hazards

Read, understand and obey all of your tow vehicle

manufacturer’s recommendations, warnings and

instructions before towing this machine.

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 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).

Do not load cargo on the machine. The TML is not

designed to carry any extra cargo.

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.

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.

Do not tow the machine on public roads unless it

meets all governmental regulations for towing.

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.

Explosion and Fire Hazards

Do not start the engine if you smell or detect diesel

fuel or other explosive substances.

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.

Keep sparks, flames and lighted tobacco away

from the battery. Batteries emit an explosive gas.

Do not spray ether into the engine.

Component Damage Hazards

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.

Do not replace lamp bulbs with any bulbs other than

those specified on the machine and in this manual.

Improper Use Hazard

When leaving the machine unattended, secure from

unauthorized use. Unauthorized personnel may

attempt to operate the machine without proper

instruction, creating an unsafe condition.

Operator's ManualThird Edition • Second Printing

Part No. 97600 Genie TML-4000 and TML-4000N 5

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.

SAFETY RULES

6 Genie TML-4000 and TML-4000N Part No. 97600

Operator's Manual Third Edition • Second Printing

1 Outrigger leveling jack with

footpad

2 Outrigger jack handle

3 Outrigger

4 Transport tie-down (hidden

behind machine)

5 Cover

Access under this cover:

Engine

Generator

Grounding rod attachment

Power outlets (Standard models)

Access under opposite cover:

Fuel tank

Power outlets (Narrow models)

Manual storage container

6 Mast hold-down latch

7 Lamp fixtures

8 Mast

9 Forklift pocket

10 Lifting eye

11 Mast rotation lever

12 Extend/Retract winch handle

13 Front spring latch (behind

mast)

14 Tongue outrigger

15 Coupler

16 Transport tie-down (one on

each side of tongue outrigger)

17 Control panel (under cover)

18 Mast release latch

19 Raise/Lower winch handle

20 Fender

21 Tire

Legend

3

2

5

4

1

1

18

19

20

21

12

17 16

2

15

14

13

11

10

9

9

8

6

7

7

Operator's ManualThird Edition • Second Printing

Part No. 97600 Genie TML-4000 and TML-4000N 7

1 Key switch

2 Hour meter

3 Circuit breaker switches for

lights (4)

Control Panel

4 Glow plug indicator light

5 Oil pressure indicator

light

Controls

6 Water temperature

indicator light

7 Air filter condition indicator

light

00009.9

AIR

FILTER

AIR

FILTER

RUN

START

OFF

2

4

7

6

5

3

1

8 Genie TML-4000 and TML-4000N Part No. 97600

Operator's Manual Third Edition • Second Printing

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.

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.

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.

Operator's ManualThird Edition • Second Printing

Part No. 97600 Genie TML-4000 and TML-4000N 9

Pre-operation Inspection

oBe sure that the operator’s manual is complete,

legible and in the storage container located on

the machine.

oBe sure that all decals are legible and in place.

See Decals section.

oCheck for engine oil leaks and proper fluid level.

Add oil if needed. See Maintenance section.

oCheck for engine coolant leaks and proper

coolant level. Add coolant if necessary. See

Maintenance section.

oCheck for battery fluid leaks and proper fluid

level. Add distilled water if needed. See

Maintenance section.

oCheck 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:

oElectrical components, wiring and electrical

cables

oMast tubes

oWinches and related components

oLatches and pins

oTires and wheels

oTrailer lights and reflectors

oOutriggers, leveling jacks and foot pads

oNuts, bolts and other fasteners

oLamp fixtures and bulbs

oCable (kinks, frays and abrasions)

oSafety chains (if required)

oEngine and related components

oFuel tank

oGenerator

Check entire machine for:

oCracks in welds or structural components

oDents or damage to machine

oBe sure that all structural and other critical

components are present and all associated

fasteners and pins are in place and properly

tightened.

oBe sure that the battery is in place and properly

connected.

PRE-OPERATION INSPECTION

10 Genie TML-4000 and TML-4000N Part No. 97600

Operator's Manual Third Edition • Second Printing

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.

Maintenance Symbols Legend

The following symbols have been

used in this manual to help

communicate the intent of the

instructions. When one or more of

the symbols appear at the

beginning of a maintenance

procedure, it conveys the meaning

below.

Indicates that tools will be required to

perform this procedure.

Indicates that new parts will be

required to perform this procedure.

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.

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 10W-40

oil type cold conditions 5W-40

Perkins 103-10 Engine

oil type 15W-40

oil type cold conditions 5W-20

Perkins 403C-11G

oil type 15W-40

oil type cold conditions 5W-20

Maintenance

Operator's ManualThird Edition • Second Printing

Part No. 97600 Genie TML-4000 and TML-4000N 11

MAINTENANCE

Check the Engine Coolant Level

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.

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.

Check the Battery

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.

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.

12 Genie TML-4000 and TML-4000N Part No. 97600

Operator's Manual Third Edition • Second Printing

MAINTENANCE

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.

Check the Tires and Wheels

Bodily injury hazard. An over-

inflated tire can explode and may

cause death or serious injury.

Collision hazard. An excessively

worn tire can cause poor handling

and continued use could result in

tire failure.

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.

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.

4 Check the torque of each lug nut.

Tires and wheels - Standard and Narrow models

Tire size ST185/80D13

Rim size 13 x 4.5 in 33 x 11.4 cm

Lug nut torque 80 ft-lbs 108 Nm

Tire pressure (cold) 50 psi 3.4 bar

Operator's ManualThird Edition • Second Printing

Part No. 97600 Genie TML-4000 and TML-4000N 13

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.

3 Always perform function tests prior to use.

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.

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.

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.

14 Genie TML-4000 and TML-4000N Part No. 97600

Operator's Manual Third Edition • Second Printing

FUNCTION TESTS

Setup

1 Position the machine at the desired work site.

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.

10 Insert and close the safety pins.

11 Remove the cap from the receptacle socket and

connect the electrical plug.

Note: Make sure the safety pins are properly

installed before raising the mast.

Test the Machine Functions

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.

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.

Result: A clicking sound should be heard as the

winch handle is turned.

Result: The mast sections should telescope

smoothly, free of hesitation or binding.

17 Release the winch handle.

Result: The winch brake should hold when the

handle is released.

Operator's ManualThird Edition • Second Printing

Part No. 97600 Genie TML-4000 and TML-4000N 15

18 Press and hold the mast rotation lever.

19 Rotate the mast clockwise and then

counterclockwise as far as it will go in either

direction.

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.

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.

FUNCTION TESTS

Test the Lights

27 Make sure the circuit breaker light switches are

in the off position.

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.

16 Genie TML-4000 and TML-4000N Part No. 97600

Operator's Manual Third Edition • Second Printing

Workplace Inspection

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.

Be aware of and avoid the following hazardous

situations:

· 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

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.

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.

Operator's ManualThird Edition • Second Printing

Part No. 97600 Genie TML-4000 and TML-4000N 17

Operating Instructions

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.

4 Inspect the workplace.

5 Only use the machine as it was intended.

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 pre-

operation inspection, function tests and a work

place inspection before using the machine.

Setup

Make sure the machine is set up according to the

Setup procedure in the Function Tests section.

Starting the Engine

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.

3 Wait for the glow plug light to go off.

4 Turn the key or turn the switch to start.

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.

Note: If the glow plug light is flashing during the

preheat cycle, the battery is low.

Operation of Lights

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.

18 Genie TML-4000 and TML-4000N Part No. 97600

Operator's Manual Third Edition • Second Printing

OPERATING INSTRUCTIONS

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

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.

To Rotate the Mast

1 Press and hold the mast rotation lever and

rotate the mast to the desired position.

2 Release the lever.

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.

4 Turn the Raise/Lower winch handle

counterclockwise and lower the mast

completely into the transport cradle.

Note: If the mast has not been fully retracted, it will

not rest completely in the cradle.

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

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)

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:

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.

Operator's ManualThird Edition • Second Printing

Part No. 97600 Genie TML-4000 and TML-4000N 19

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.

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.

OPERATING INSTRUCTIONS

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.

20 Genie TML-4000 and TML-4000N Part No. 97600

Operator's Manual Third Edition • Second Printing

Transport and Lifting Instructions

Observe and Obey:

Common sense and planning must be applied to

control the movement of the machine when

lifting it with a crane or forklift.

The transport vehicle must be parked on a level

surface.

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.

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.

Use the two tie-down points on the machine for

anchoring down to the transport surface.

Use chains or straps of ample load capacity.

Use a minimum of 2 chains to secure the chassis.

Adjust the rigging to prevent damage to the chains.

Operator's ManualThird Edition • Second Printing

Part No. 97600 Genie TML-4000 and TML-4000N 21

Observe and Obey:

Only qualified riggers should rig and lift the

machine.

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.

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.

Close and secure the covers.

Inspect the entire machine for loose or unsecured

items.

Use the lifting eye mounted on the mast to lift the

machine.

22 Genie TML-4000 and TML-4000N Part No. 97600

Operator's Manual Third Edition • Second Printing

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

under covers

Decal Inspection

Use the pictures on the next page to verify that all

decals are legible and in place.

Below is a numerical list with quantities and

descriptions.

Part No. Description Quantity

28159 Label - Diesel 1

28161 Warning - Crushing Hazard 6

28164 Notice - Hazardous Materials 2

28171 Label - No Smoking 1

31072 Manual Storage Container 1

52475 Label - Transport Tie-down 2

62707 Warning - Tow Speed 1

65408 Notice - Operating Instructions 1

65409 Notice - Mast Rotation Instructions 1

65411 Warning - General Safety 1

65412 Warning - Transport Instructions 1

65414 Danger - Electrocution Hazard 2

65421 Warning - Electrocution, Generator 2

65423 Notice - Deutz Engine Specs 1

72008 Caution - Turn Off Lights 1

72009 Cosmetic - Genie TML-4000 2

72010 Cosmetic - Genie TML-4000N 2

72018 Label - Raise/Lower Winch 1

72019 Danger - High Voltage 1

72077 Label - Black Arrow 2

72826 Label - Extend/Retract Winch 1

72828 Notice - Tire Specifications 2

Part No. Description Quantity

72870 Caution - Component Contact 2

72871 Label - Power Outlet, 120V 1

72874 Label - Locked, Unlocked 1

72889 Warning - Transport Hazard 1

72890 Notice - Mast Retraction 1

72891 Label - Blue Arrow 2

82219 Label - Power Outlets Under Cover 1

82222 Caution - Light Storage,

Standard Models 1

82223 Label - Light Storage, Standard Models 4

82224 Label - HOT 8

82237 Danger - High Voltage 1

82302 Notice - Perkins Engine Specs 1

82303 Label - Mast Release Latch 1

82304 Control Panel 1

82957 Label - Power Outlets Under Cover 1

97518 Notice - Lamp Disposal 2

97602 Warning - Explosion Hazard, Ether 2

97635 Warning - Bodily Injury Hazard 4

97637 Label - Wet Locations 1

97638 Label - Lamp Replacement 1

97661 Label - Grounding Rod Attachment 1

97767 Notice - Perkins Engine Specs, Tier II 1

Decals

Operator's ManualThird Edition • Second Printing

Part No. 97600 Genie TML-4000 and TML-4000N 23

52475

28164

97602

28171

72828

72828

97661

97602

28161

28161

72874

82224

82237

82224

82224

97518

97635

97635

97518

82224

97635

97635

82223

82223

82222

72889

65414

65414

72871 or

82219 or

82957

72870

72870

28164

28161

28161

65421

72018

72890

28159

72077

65412

Serial

Plate

NHTSA

82223

28161

65409

72826

52475

72009 or

72010

72009

or 72010

65411

72019

97637

28161

82304

82303

72008

65408

72891

65421

62707

65423

or 82302

or 97767

31072

DECALS

Control

Panel

Side

Fuel Tank

Side

24 Genie TML-4000 and TML-4000N Part No. 97600

Operator's Manual Third Edition • Second Printing

Specifications

Continuous improvement of our products is a Genie

policy. Product specifications are subject to change

without notice or obligation.

Model - TML-4000 Standard

Height, stowed 71 in

1.8 m

Length, stowed 14 ft 7 in

4.4 m

Width, stowed 70 in

1.8 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 ST185/80D13

Engine type 3 cylinder diesel, water cooled

Deutz F3M 1008 OR Perkins 103-10

Fuel capacity 50 gallons

189 liters

Generator 6 kw

Total lighting wattage 4000 watts

Replacement bulbs 1000 watts

Type BT-37 Metal Halide

Run time (full load with full fuel tank) 100 hours

Tower rotation 360 degrees,

non-continuous

Maximum towing speed 60 mph

97 km/h

Maximum wind speed rating 60 mph

27 m/sec

Airborne Noise Emissions 71 dB

Maximum sound level at normal operating workstations

(A-weighted)

Model - TML-4000 Narrow

Height, stowed 71 in

1.8 m

Length, stowed 14 ft 7 in

4.4 m

Width, stowed 55 in

1.4 m

Extended tower height 28 ft

8.5 m

Weight See Serial Plate

(Machine weights vary with option configurations)

Maximum tongue weight 110 lbs

50 kg

Tire size ST185/80D13

Engine type 3 cylinder diesel, water cooled

Deutz F3M1008 OR Perkins 103-10

Fuel capacity 30 gallons

114 liters

Generator 6 kw

Total lighting wattage 4000 watts

Replacement bulbs 1000 watts

Type BT-37 Metal Halide

Run time (full load with full fuel tank) 60 hours

Tower rotation 360 degrees,

non-continuous

Maximum towing speed 60 mph

97 km/h

Maximum wind speed rating 60 mph

27 m/sec

Airborne Noise Emissions 71 dB

Maximum sound level at normal operating workstations

(A-weighted)

Operator's ManualThird Edition • Second Printing

Part No. 97600 Genie TML-4000 and TML-4000N 25

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 (366-

0123 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.

Operator’s Manual

with Maintenance Information

Genie North America

Phone 425.881.1800

Toll Free USA and Canada

800.536.1800

Fax 425.883.3475

Genie Australia Pty Ltd.

Phone +61 7 3375 1660

Fax +61 7 3375 1002

Genie China

Phone +86 21 53852570

Fax +86 21 53852569

Genie Malaysia

Phone +65 98 480 775

Fax +65 67 533 544

Genie Japan

Phone +81 3 3453 6082

Fax +81 3 3453 6083

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 +31 10 220 7911

Fax +31 10 220 6642

Genie Scandinavia

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

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

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

Second Edition

Seventh Printing

Part No. 43645

California Proposition 65

WARNINGWARNING

The exhaust from this product contains chemicals

known to the State of California to cause cancer,

birth defects or other reproductive harm.

Distributed By:

Towing Checklist

Third Edition

Second Printing

Part No. 97600

Hitching

Towing

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