Genie TML-4000N User manual
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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GenieTML-4000andTML-4000N PartNo.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:[email protected]
Important
Read,understandandobeythesesafetyrulesand
operatinginstructionsbeforeoperatingthismachine.
Onlytrainedandauthorizedpersonnelshallbe
permitted to operate this machine. This manual should
beconsidered apermanentpart of yourmachineand
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-operationInspection ............................................ 8
Maintenance ............................................................. 10
Function Tests.......................................................... 13
WorkplaceInspection................................................ 16
OperatingInstructions ............................................... 17
Transportand LiftingInstructions .............................. 20
Decals ...................................................................... 22
Specifications ........................................................... 24
ReportingSafety Defects .......................................... 25
Operator's ManualThird Edition • Second Printing
PartNo.97600 GenieTML-4000andTML-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.
Youread,understandandobeythe
manufacturer'sinstructions and safety rules—
safetyandoperator'smanualsandmachine
decals.
Youread,understandandobeyemployer's
safety rules and worksite regulations.
Youread,understandandobeyallapplicable
governmentalregulations.
Youareproperlytrainedtosafelyoperate the
machine.
2 GenieTML-4000andTML-4000N PartNo.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
alloutriggers areproperlydeployed, the footpads
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
loweredtothe horizontal position andsecurely
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.
Donotoperatethemachine duringlightning or
storms.
Do not use the machine as a ground for welding.
Operator's ManualThird Edition • Second Printing
PartNo.97600 GenieTML-4000andTML-4000N 3
SAFETY RULES
Keep away from the
machine if it contacts
energizedpowerlines.
Personnelmustnot
touchoroperatethe
machineuntilpower
lines are shut off.
Do not connect wires
directlytothegenerator.
Connectauxiliary
equipment only to the
poweroutletsprovided.
Inspect the power cord for damage prior to each
use.Replaceanydamagedcordbeforeoperating.
Do not allow the power cord to become caught or
crushedwhileraising,loweringor rotating the mast.
Avoid electrical shock from contact with battery
terminals. Remove all rings, watches and other
jewelry.
Thismachineshouldbegroundedinaccordance
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
Checkthework area for overheadobstructionsor
otherpossiblehazards.
Bodily Injury Hazard
Do not grasp the cable.
Useproper lifting techniques whenliftingand
positioning the tongue of the machine.
Always replace the protective lamp cover after
replacingthe lamp bulbs.
Burn Hazard
Do not touch the lamp fixtures while they are turned
on. Turn the lamps off and allow them to cool
beforetouching.
Crushing Hazards
Do not lower the mast unless the area below is
clearof personnel andobstructions.
Do not release the spring latch on the side of the
machine unless the mast sections are fully
retracted.
Keephands and fingers away from anypotential
pinch points.
Damaged Machine Hazards
Donot use a damaged or
malfunctioningmachine.
Do not use a machine with
a worn, frayed, kinked or
damagedcable.
Besuretheoperator's
manualis complete, legible
andin thestoragecontainer
located on the machine.
Be sure all decals are legible and in place.
4 GenieTML-4000andTML-4000N PartNo.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
thetransportcradle.
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.
Donotrefuel the machine with the engine running.
Refuel the machine and charge the battery only in
anopen, well-ventilated areaawayfrom sparks,
flames and lighted tobacco.
Donotoperatethe machine in hazardous locations
orlocationswherepotentially flammableor
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
orrain.
Do not replace lamp bulbs with any bulbs other than
those specified on the machine and in this manual.
Improper Use Hazard
Whenleavingthemachineunattended,securefrom
unauthorizeduse.Unauthorizedpersonnelmay
attempttooperatethemachinewithoutproper
instruction, creating an unsafe condition.
Operator's ManualThird Edition • Second Printing
PartNo.97600 GenieTML-4000andTML-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 GenieTML-4000andTML-4000N PartNo.97600
Operator's Manual Third Edition • Second Printing
1 Outriggerleveling jackwith
footpad
2 Outriggerjackhandle
3 Outrigger
4 Transporttie-down(hidden
behindmachine)
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 Masthold-downlatch
7 Lampfixtures
8 Mast
9 Forklift pocket
10 Lifting eye
11 Mast rotation lever
12Extend/Retractwinchhandle
13 Frontspringlatch(behind
mast)
14Tongueoutrigger
15 Coupler
16 Transporttie-down(oneon
eachsideoftongueoutrigger)
17Controlpanel(undercover)
18 Mast release latch
19 Raise/Lowerwinchhandle
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
PartNo.97600 GenieTML-4000andTML-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 Watertemperature
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 GenieTML-4000andTML-4000N PartNo.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-operationinspectionandroutinemaintenance.
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.
Thepre-operationinspectionalso servesto
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.
Ifdamage oranyunauthorizedvariation from
factory delivered condition is discovered, the
machinemustbe 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.
This manual suits for next models
1
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