Operator`s Manual - Genie Industries
Contents
1. DECALS 72889 72009 or 728710r 72890 Control 72010 82219 28161 82219 72891 72077 Panel models Side 82224 E m 1 72019 T SS Titi 82 02 a I k KANG ACE gt TB018 82237 c m peel 9 85408 _ Cee lt 1 __ ___ MM 6 5 411 72874 aa _ E 82223 ee 72865 anaa D ee a or 82304 MEI _ 28164 c 6 65414 Se 82303 65421 52475 or 82302 Shading indicates decal 72828 is hidden from view i e under covers 72009 72826 or 72010 65409 82224 O a 65412 a ee F DC SS He go WEE Cn es a A models S Standard Serial SS ils UO Plate d 62223 models 72871 28164 Sera Exi ai 65414 28161 L 52475 Fuel Tank Side 28161 65421 31072 72870 62707 28159 72828 28171 Part No 82199 Genie TML 4000 and TML 4000N 21 Operator s Manual Second Edition Fourth Printing Specifications Model TML 4000 Standard Model TML 4000 Narrow Height stowed 71 in Height stowed 71 in 1 8m 1 8m Le2. a 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 ADANGER presence of an imminently hazardous situation which if not avoided will result in death or serious injury Orange used to indicate the AWARNING presence of a potentially hazardous situation which if not avoided could result in death or serious injury Yellow with safety alert symbol ACAUTION used to indicate the presence of a potentially hazardous situation which if not avoided may cause minor or moderate injury Yellow without safety alert CAUTION 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 82199 Genie TML 4000 and TML 4000N 5 Operator s Manual Second Edition Fourth Printing Legend 1 Outrigger leveling jack with footpad 2 Outrigger jack handle 3 Outrigger 4 Cover Access under this cover Engine Generator Power outlets Standard models Access under opposite cover Fuel tank Power outlets Narrow models Manual storage container
3. Mast hold down latch Lamp fixtures Mast Forklift pocket o N Oo OC Lifting eye 10 Mast rotation lever 11 ExrEND RETRACT Winch handle 12 Front spring latch behind mast 13 Tongue outrigger 14 Coupler 15 Control panel under cover 16 Mast release latch 17 RAaise LowER winch handle 18 Fender 19 Tire Genie TML 4000 and TML 4000N Part No 82199 Second Edition Fourth Printing Operator s Manual Controls 2 RUN AIR o i START ss 7 OFF Control Panel 1 Key switch 4 Glow plug indicator light 6 Watertemperature 2 Hourmeter 5 Oil pressure indicator indicator light 3 Circuit breaker switches for light 7 Airfilter condition indicator lights 4 light Part No 82199 Genie TML 4000 and TML 4000N 7 Operator s Manual Second Edition Fourth Printing Pre operation Inspection 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 Fundamentals It is the responsibility of
4. Be sure that all decals are legible and in place See Decals section Add oil if needed See Maintenance section Check for engine coolant leaks and proper coolant level Add coolant if necessary See Maintenance section 2 Check for battery fluid leaks and proper fluid level Add distilled water if needed See Maintenance section 4 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 modifications and improperly installed or missing parts Electrical components wiring and electrical cables Mast tubes Winches and related components Latches and pins Tires and wheels Trailer lights and reflectors Outriggers leveling jacks and foot pads Nuts bolts and other fasteners Lamp fixtures and bulbs Cable kinks frays and abrasions Safety chains if required Engine and related components Fuel tank UoovovovooooOoeoe oO oso Generator Check for engine oil leaks and proper fluid level PRE OPERATION INSPECTION Check entire machine for Cracks in welds or structural components Dents or damage to machine Be sure that all structural and other critical components are present and all associated fasteners and pins are in place and properly tightened L1 Be sure that the battery is in place and properly connected Part No 82199 Genie TML 4000 and TML 4000N 9 Operator
5. Genie Australia Pty Ltd Phone 1 61 7 3375 1660 Fax 1 61 7 3375 1002 Genie China Phone 86 21 53852570 Fax 86 21 53852569 Genie Malaysia Phone 604 228 1235 Fax 604 226 6872 Genie Japan Phone 81 3 3453 6082 Fax 81 3 3453 6083 Genie Korea Phone 82 2 558 7267 Fax 82 2 558 3910 Genie Africa Phone 27 11 455 0373 Fax 27 11 455 O355 Genie Latin America Phone 55 11 4055 2499 Fax 55 11 4043 1661 Genie Holland Phone 31 70 51 78836 Fax 31 70 51 13993 Genie Denmark Phone 45 6612 5544 Fax 45 6612 5530 Genie France Phone 33 2 37 26 09 99 Fax 33 2 37 26 09 985 Genie Spain Phone 34 93 579 5042 Fax 34 93 579 5059 Genie Germany Phone 49 4202 8852 0 Fax 49 4202 8852 20 Genie U K Phone 44 1476 584333 Fax 44 1476 584334 Genie Mexico City Phone 52 5 653 84 Fax 52 5 664 40 16 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 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 California Proposition 65 WARNING The exhaust from this product contains chemicals known to the State of California to cause cancer birth defects or other reproduc
6. Genie d Second Edition Operator s Manual ae with Maintenance Information Part No 82199 TML 4000 TML 4000N Operator s Manual Second Edition Fourth Printing M il 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 nennen enn nnn nnne 1 Legerid zu ede pute n ei ee 6 E 7 Pre operation Inspection 8 Maintenance saith cecinere 10 Function Tests ssssssseeeennn 13 Workplace Inspection 16 Operating Instructions eseeseseeeseeees 17 Decals ni eere HL tote Ens 20 Specifications eite eene etus estara Porra 22 Reporting Safety Defects 23 Co ntact us Copyright 2000 by Genie Industries First Edition Second Printing March 2001 Internet http www genielift com e mail techpub genieind com Second Edition Fourth Printin
7. 4 Inspect the workplace 5 Only use the machine as it was intended 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 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 Symbols Legend Indicates that a specific result is expected after performing a series of steps Part No 82199 Genie TML 4000 and TML 4000N Operator s Manual Second Edition Fourth 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 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 pla
8. Materials 2 72828 Notice Tire Specifications 2 28171 Label No Smoking 1 72865 Control Panel 1 31072 Manual Storage Container 1 72870 Caution Component Contact 2 52475 Label Transport Tie down 2 72871 Label Power Outlet 120V 1 62707 Warning Tow Speed 1 72874 Label Locked Unlocked 1 65408 Notice Operating Instructions 1 72889 Warning Transport Hazard 1 65409 Notice Mast Rotation Instructions 1 72890 Notice Mast Retraction 1 65411 Warning General Safety 1 72891 Label Blue Arrow 2 65412 Warning Transport Instructions 1 82219 Label Power Outlets 1 65414 Danger Electrocution Hazard 2 82222 Caution Light Storage Standard Models 2 65421 Warning Electrocution Generator 2 82223 Label Light Storage Standard Models 4 65423 Notice Engine specs Deutz 1 82224 Label HOT 8 72008 Caution Turn Off Lights 1 82237 Danger High Voltage 1 72009 Cosmetic Genie TML 4000 2 d g d 82302 Notice Engine Spec Perkins 1 72010 Cosmetic Genie TML 4000N 2 82303 Label Mast Release Latch 1 72018 Label Raise Lower Winch 1 82304 Control Panel 1 72019 Danger High Voltage 1 20 Genie TML 4000 and TML 4000N Part No 82199 Second Edition Fourth Printing Operator s Manual
9. 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 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 Part No 82199 Genie TML 4000 and TML 4000N 3 Operator s Manual Second Edition Fourth Printing SAFETY RULES 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 Improper Use Hazard When leaving the machine unattended secure from unauthorized use Unauthorized personnel may attempt to operate the machine withou
10. mast extends approximately 2 feet 61 cm O Result A clicking sound should be heard as the winch handle is turned O 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 14 Genie TML 4000 and TML 4000N Part No 82199 Second Edition Fourth Printing Operator s Manual 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 O 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 nAisE 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
11. s Manual Second Edition Fourth Printing Maintenance Observe and Obey Only routine maintenance items specified in this manual shall be performed by the operator M 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 Deutz models Result The oil level should be at the FULL mark on the dipstick Add oil as needed Perkins models Result The oil level should be between the two notches on the dipstick Add oil as needed Deutz F3M 1008 Engine Cil viscosity requirements 40 to 77 F 40 to 25 5W 30 synthetic 25 to 86 F 13 to 30 C 10W 40 20 to 77 F 4 to 2
12. 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 orr position 2 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 To start the engine turn the key OR turn the switch to START 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 orr position Make sure the lights are turned off before shutting down the engine Part No 82199 Genie TML 4000 and TML 4000N 17 Operator s Manual Second Edition Fourth Printing OPERATING INSTRUCTIONS To Raise the Mast 1 Unlock the
13. 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 orr 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 Part No 82199 Genie TML 4000 and TML 4000N 15 Operator s Manual Second Edition Fourth Printing Workplace Inspection Do Not Operate Unless You learn and practice the principles of safe machine operation contained in this operator s manual 1 Avoid hazardous situations Always perform a pre operation inspection Always perform function tests prior to use A N 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 Fu
14. this machine Improper fluid levels or damaged cables and connections can result in engine component Machines that have been out of service for more damage and hazardous conditions than three months must receive the quarterly inspection before they are put back into service This procedure does not need to be performed on machines with sealed or maintenance free batteries Electrocution hazard Contact with AWARNING hot or live circuits could result in death or serious injury Remove all rings watches and other jewelry Bodily injury hazard Batteries AWARNING contain acid Avoid spilling or contacting battery acid Neutralize battery acid spills with baking soda and water 1 Puton protective clothing and eye wear 2 Besure the battery cable connections are tight and free of corrosion 3 Remove the battery vent caps 4 Checkthe 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 82199 Second Edition Fourth Printing Operator s Manual 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
15. 5 C 15W 30 Use oils meeting API classification CC CF or CE as they offer improved wear protection Perkins 103 10 Engine Oil viscosity requirements Below 32 F 0 C ow 13 to 68 F 25 to 20 C 5W 20 10 to 104 F 15 to 40 C 10W 30 14 to 122 F 10 to 50 C 15W 40 Above 23 F Above 5 C 20W 50 Use oils meeting API classification CC CD CE CF CF 4 or CF G as they offer improved wear protection 10 Genie TML 4000 and TML 4000N Part No 82199 Second Edition Fourth Printing Operator s Manual Check the Tires and Wheels Bodily injury hazard An over AWARNING inflated tire can explode and may cause death or serious injury Collision hazard An excessively AWARNING worn tire can cause poor handling and continued use could result in tire failure Tip over hazard Do not use AWARNING 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 mu
16. cal line sway or sag and be aware of strong or gusty winds 2 Genie TML 4000 and TML 4000N Part No 82199 Second Edition Fourth Printing Operator s Manual Keep away from the f machine if it contacts energized power lines Personnel must not touch or operate the machine until power lines are shut off Do not operate the machine during lightning Tr or storms Do not use the machine as a ground for welding 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 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 Burn Hazard Do not touch the lamp fixtures while they are turned on Turn off the lamps and allow them to cool before touching SAFETY RULES 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
17. ce 7 Turn the outrigger jack handles to level the machine Level the machine using only the leveling jacks Do not use chocks blocks or shims to level the machine 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 61 cm O 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 ExrEND RETRACT winch handle clockwise until the
18. g April 2002 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 amp Genie TML 4000N Part No 82199 Second Edition Fourth 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 manufacturer s instructions and safety rules operator s manual and machine decals employer s safety rules and worksite regulations applicable governmental regulations Part No 82199 Genie TML 4000 and TML 4000N 1 Operator s Manual Second Edition Fourth Printing SAFETY RULES Fall Hazards Do not stand on the machine fu Do not climb on the mast Tip over Hazards 1 11 Do not raise the mast to the vertical position unless all outriggers are properly deployed the foot pads are in firm contact with the
19. 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 use chocks blocks or shims of any kind to level the machine 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 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 electri
20. ise and push into the lock 3 Turn the latch handle clockwise until the handle points straight down The latch should turn freely without binding or hesitation After Each Use 1 Select a safe parking location firm level surface clear of obstructions and traffic 2 Remove the key OR lock the conrol 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 Pullthe lamp fixture up and off the mounting bracket 3 Slide the lamp fixture onto the channels located under the covers 4 Close and secure the covers before transport 18 Genie TML 4000 and TML 4000N Part No 82199 Second Edition Fourth Printing Operator s Manual Transport 1 Make sure the mast hold down latch is securely locked in place 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 T
21. 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 ExrEND RETRACT Winch handle clockwise to extend the mast sections 2 Approximately 6 inches 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 ExrEND 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 2 Turnthe mast hold down latch handle counterclockw
22. ndamentals 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 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 16 Genie TML 4000 and TML 4000N Part No 82199 Second Edition Fourth Printing Operator s Manual Operating Instructions Do Not Operate Unless You learn and practice the principles of safe machine operation contained in this operator s manual Avoid hazardous situations Always perform a pre operation inspection Always perform function tests prior to use Inspect the workplace a A Cc I 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
23. ngth stowed 14 ft 7 in Length stowed 14 ft 7 in 4 4m 4 4m Width stowed 70 in Width stowed 55 in 1 8m 1 4m Extended tower height 28 ft Extended tower height 28 ft 8 5m 8 5m Weight See Serial Plate Weight See Serial Plate Machine weights vary with option configurations Machine weights vary with option configurations Maximum tongue weight 145 Ibs Maximum tongue weight 110 Ibs 66 kg 50 kg Tire size ST185 80D13 Tire size T185 80D13 Engine type 3 cylinder diesel water cooled Engine type 3 cylinder diesel water cooled Deutz F3M1008 OR Perkins 103 10 Deutz F3M1008 OR Perkins 103 10 Fuel capacity 50 gallons Fuel capacity 30 gallons 189 liters 114 liters Generator 6 kw Generator 6 kw Total lighting wattage 4000 watts Total lighting wattage 4000 watts 1000 W Metalarc M47 R M1000 U BT37 or equivalent Replacment bulbs 1000 W Metalarc M47 R M1000 U BT37 or equivalent Replacment bulbs Run time full load with full fuel tank 100 hours Run time full load with full fuel tank 60 hours Tower rotation 360 degrees non continuous Tower rotation 360 degrees non continuous Maximum towing speed 60 mph Maximum towing speed 60 mph 97 km h 97 km h Maximum wind speed rating 60 mph Maximum wind speed rating 60 mph 27 m sec 27 m sec Airborne Noise Emissions 71 dB Airborne Noise Emissions 71 Maximum sound level at normal operating workstatio
24. ns A weighted 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 22 Genie TML 4000 and TML 4000N Part No 82199 Second Edition Fourth 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 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 Part No 82199 Genie TML 4000 and TML 4000N 23 Genie North America Phone 425 881 1800 Toll Free USA and Canada 800 536 1800 Fax 425 883 3475 Towing Checklist
25. se 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 Transport not attached to a tow vehicle Make sure the mast is fully lowered to the horizontal position and the mast hold down latch is securely locked in place before lifting the TML with a forklift or crane Part No 82199 Genie TML 4000 and TML 4000N 19 Operator s Manual Second Edition Fourth Printing Decals 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 PartNo Description Quantity 28159 Label Diesel 1 72077 Label Black Arrow 2 28161 Warning Crush Hand 4 72826 Label Extend Retract Winch 1 28164 Notice Hazardous
26. st 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 MAINTENANCE Tires and wheels Standard and Narrow models Tire size ST185 80D13 Rim size 13x4 5 33 x 11 4 cm Lug nut torque 80 ft lbs 108 Nm Tire pressure cold 50 psi 3 4 bar 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 O Result The fluid level should be full Bodily injury hazard Fluids in the AWARNING radiator are under pressure and extremely hot Use caution when removing cap and adding fluids Part No 82199 Genie TML 4000 and TML 4000N 11 Operator s Manual Second Edition Fourth Printing MAINTENANCE Check the Battery Scheduled Maintenance Maintenance performed quarterly annually and every two years must be completed by a person 22 trained and qualified to perform maintenance on Proper battery condition is essential to good this machine according to the procedures found in engine performance and operational safety the service manual for
27. t proper instruction creating an unsafe condition 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 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 4 Genie TML 4000 and TML 4000N Part No 82199 Second Edition Fourth Printing Operator s Manual X
28. 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 and locations for modifications damage or loose or missing parts A damaged or modified machine must never be used If damage or any 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 8 Genie TML 4000 and TML 4000N Part No 82199 Second Edition Fourth Printing Operator s Manual Pre operation Inspection 11 Be sure that the operators manual is complete legible and in the storage container located on the machine
29. tive harm
30. urn 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 cau
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