Operatr s Manual with Maintenance Infrmatin Secnd First Editin Editin Seventh Secnd Printing Part N. 43645 65176
Imprtant Read, understand and bey these safety rules and perating instructins befre perating this machine. Only trained and authrized persnnel shall be permitted t perate this machine. This manual shuld be cnsidered a permanent part f yur machine and shuld remain with the machine at all times. If yu have any questins, call Genie Industries. Cntents Page Safety... 1 Legend... 6 Cntrls... 7 Pre-peratin Inspectin... 8 Maintenance... 10 Functin Tests... 13 Wrk Place Inspectin... 16 Operating Instructins... 17 Decals... 20 Specificatins... 22 Reprting Safety Defects... 23 Cntact us: Internet: http://www.genielift.cm e-mail: techpub@genieind.cm Cpyright 2000 by Genie Industries First Editin: First Printing, February 2001 Secnd Printing, March 2001 "Genie" is a Registered Trademark f Genie Industries in the USA and many ther cuntries. "TML" is a trademark f Genie Industries. Printed n recycled paper Printed in U.S.A. Genie TML-4000N
Safety Rules W arning Failure t bey the instructins and safety rules in this manual may result in death r serius injury. D Nt Operate Unless: Yu learn and practice the principles f safe machine peratin cntained in this peratr's manual. 1 Avid hazardus situatins. Knw and understand the abve principle befre ging n t the next sectin. 2 Always perfrm a pre-peratin inspectin. 3 Always perfrm the functin tests prir t use. 4 Inspect the wrkplace. 5 Only use the machine as it was intended. Yu read, understand and bey: manufacturer's instructins and safety rules peratr's manual and machine decals emplyer's safety rules and wrksite regulatins applicable gvernmental regulatins Part N. 65176 Genie TML-4000N 1
SAFETY RULES Fall Hazards D nt stand n the machine. D nt climb n the mast. Tip-ver Hazards D nt raise the mast t the vertical psitin unless all utriggers are prperly deplyed, the ft pads are in firm cntact with the grund and the machine is level. D nt set the machine up n a surface where it cannt be leveled using nly the leveling jacks. D nt use chcks, blcks r shims f any kind t level the machine. D nt hang any bjects frm the lights r mast. D nt use the mast t raise material r persnnel. D nt mve the machine unless the mast is lwered t the hrizntal psitin and securely lcked in place. D nt extend the mast when wind speed may exceed 60 mph (27 m/sec). D nt adjust r stw the utriggers when the mast is raised. D nt use the machine n a mving r mbile surface r vehicle. Be sure the tires are in gd cnditin and the lug nuts are prperly tightened. Electrcutin Hazards This machine is nt electrically insulated and will nt prvide prtectin frm cntact with r prximity t electrical current. Maintain safe distances away frm electrical pwer lines and apparatus in accrdance with applicable gvernmental regulatins and the fllwing chart. Vltage Phase t Phase Minimum Safe Apprach Distance Feet Meters 0 t 300V Avid Cntact 300V t 50KV 10 3.05 50KV t 200KV 15 4.60 200KV t 350KV 20 6.10 350KV t 500KV 25 7.62 500KV t 750KV 35 10.67 750KV t 1000KV 45 13.72 Allw fr mast mvement and electrical line sway r sag, and be aware f strng r gusty winds. D nt place ladders r scafflds against any part f the machine. D nt alter r disable machine cmpnents that in any way affect safety and stability. 2 Genie TML-4000N Part N. 65176
SAFETY RULES Keep away frm the machine if it cntacts energized pwer lines. Persnnel must nt tuch r perate the machine until pwer lines are shut ff. D nt perate the machine during lightning r strms. D nt use the machine as a grund fr welding. D nt cnnect wires directly t the generatr. Cnnect auxiliary equipment nly t the pwer utlets prvided. Inspect the pwer crd fr damage prir t each use. Replace any damaged crd befre perating. D nt allw the pwer crd t becme caught r crushed while raising, lwering r rtating the mast. Avid electrical shck frm cntact with battery terminals. Remve all rings, watches and ther jewelry. Cllisin Hazard Check the wrk area fr verhead bstructins r ther pssible hazards. Bdily Injury Hazard D nt grasp the cable. Use prper lifting techniques when lifting and psitining the tngue f the machine. Burn Hazard D nt tuch the lamp fixtures while they are turned n. Turn ff the lamps and allw t cl befre tuching. Crushing Hazards D nt lwer the mast unless the area belw is clear f persnnel and bstructins. D nt release the spring latch n the side f the machine unless the mast sectins are fully retracted. Keep hands and fingers away frm any ptential pinch pints. Damaged Machine Hazards D nt use a damaged r malfunctining machine. D nt use a machine with a wrn, frayed, kinked r damaged cable. Be sure the peratr's manual is cmplete, legible and in the manual strage cntainer lcated n the machine. Be sure all decals are in place and legible. Explsin and Fire Hazards D nt start the engine if yu smell r detect diesel fuel r ther explsive substances. D nt refuel the machine with the engine running. Refuel the machine and charge the battery nly in an pen, well-ventilated area away frm sparks, flames and lighted tbacc. D nt perate the machine in hazardus lcatins r lcatins where ptentially flammable r explsive gases r particles may be present. Keep sparks, flames and lighted tbacc away frm the battery. Batteries emit an explsive gas. Part N. 65176 Genie TML-4000N 3
SAFETY RULES Cmpnent Damage Hazards D nt turn the lights n unless the engine is running. Always turn the lights ff befre shutting dwn the engine. D nt use any battery charger greater than 12V t charge the batteries. D nt expse the batteries r the charger t water r rain. Imprper Use Hazard When leaving the machine unattended, secure frm unauthrized use. Unauthrized persnnel may attempt t perate the machine withut prper instructin, creating an unsafe cnditin. Twing Hazards Read, understand and bey all f yur tw vehicle manufacturer s recmmendatins, warnings and instructins befre twing this trailer. D nt tw the machine unless the mast is lwered t the hrizntal psitin and the mast hld-dwn latch is securely lcked in place. D nt tw the machine n public rads unless it meets all gvernmental regulatins fr twing. D nt exceed 60 mph / 97 km/h. Obey all lcal and natinal twing speed laws. D nt verlad yur tw vehicle. Check the Grss Vehicle Weight Rating (GVWR) n the label, inside the driver dr. T btain the GVWR, add the tngue weight f the trailer t the vehicle weight (including vehicle, passengers and carg). D nt lad carg n the machine. The TML is nt designed t carry any extra carg. Be sure the hitch is securely attached t the tw vehicle. Be sure the safety chains (if required) are securely attached t the tw vehicle. Be sure that all driving lights are peratinal. Be sure all hitch cmpnents, lights and mirrrs and methds f attaching the trailer t the tw vehicle cnfrm t lcal, state and Federal regulatins. Be sure t chck the wheels f the trailer when parking n a hill. 4 Genie TML-4000N Part N. 65176
SAFETY RULES Decal Legend Genie prduct decals use symbls, clr cding and signal wrds t identify the fllwing: Safety alert symbl used t alert persnnel t ptential persnal injury hazards. Obey all safety messages that fllw this symbl t avid pssible injury r death. Red used t indicate the presence f an imminently hazardus situatin which, if nt avided, will result in death r serius injury. Orange used t indicate the presence f a ptentially hazardus situatin which, if nt avided, culd result in death r serius injury. Yellw with safety alert symbl used t indicate the presence f a ptentially hazardus situatin which, if nt avided, may cause minr r mderate injury. Yellw withut safety alert symbl used t indicate the presence f a ptentially hazardus situatin which, if nt avided, may result in prperty damage. Green used t indicate peratin r maintenance infrmatin. Part N. 65176 Genie TML-4000N 5
Legend 1 Outrigger leveling jack with ftpad 2 Outrigger jack handle 3 Outrigger 4 Cver Access under this cver: Engine Generatr Manual strage cntainer Pwer utlets Access under ppsite cver: Fuel tank 5 Exhaust pipe 6 Mast hld-dwn latch 7 Lamp fixtures 8 Mast 9 Frklift pcket 10 Lifting eye 11 Mast rtatin lever 12 EXTEND/RETRACT winch handle 13 Frnt spring latch (behind mast) 14 Tngue utrigger 15 Cupler 16 Cntrl panel (under cver) 17 Mast release latch 18 RAISE/LOWER winch handle 19 Fender 20 Tire 6 Genie TML-4000N Part N. 65176
Cntrls Cntrl Panel 1 Key switch 2 Hur meter 3 Circuit breaker switches fr lights (4) 4 Glw plug indicatr light 5 Oil pressure indicatr light 6 Water temperature indicatr light 7 Air filter cnditin indicatr light Part N. 65176 Genie TML-4000N 7
Pre-peratin Inspectin Fundamentals It is the respnsibility f the peratr t perfrm a Pre-peratin Inspectin and rutine maintenance. D Nt Operate Unless: Yu learn and practice the principles f safe machine peratin cntained in this peratr s manual. 1 Avid hazardus situatins. 2 Always perfrm a pre-peratin inspectin. Knw and understand the pre-peratin inspectin befre ging n t the next sectin. 3 Always perfrm the functin tests prir t use. 4 Inspect the wrk place. 5 Only use the machine as it was intended. The Pre-peratin Inspectin is a visual inspectin perfrmed by the peratr prir t each wrk shift. The inspectin is designed t discver if anything is apparently wrng with a machine befre the peratr perfrms the functin tests. The Pre-peratin inspectin als serves t determine if rutine maintenance prcedures are required. Only rutine maintenance items specified in this manual may be perfrmed by the peratr. Refer t the list n the next page and check each f the items and lcatins fr mdificatins, damage r lse r missing parts. A damaged r mdified machine must never be used. If damage r any variatin frm factry delivered cnditin is discvered, the machine must be tagged and remved frm service. Repairs t the machine may nly be made by a qualified service technician, accrding t the manufacturer's specificatins. After repairs are cmpleted, the peratr must perfrm a pre-peratin inspectin again befre ging n t the functin tests. Scheduled maintenance inspectins shall be perfrmed by qualified service technicians, accrding t the manufacturer's specificatins. 8 Genie TML-4000N Part N. 65176
PRE-OPERATION INSPECTION Pre-peratin Inspectin Be sure that the peratr s manual is cmplete, legible and in the strage cntainer lcated n the machine. Be sure that all decals are legible and in place. See Decals sectin. Check fr engine il leaks and prper fluid level. Add il if needed. See Maintenance sectin. Check fr engine clant leaks and prper clant level. Add clant if necessary. See Maintenance sectin. Check fr battery fluid leaks and prper fluid level. Add distilled water if needed. See Maintenance sectin. Check fr prper tire pressure and lug nut trque. Add air t tires if needed. See Maintenance sectin. Check the fllwing cmpnents r areas fr damage, mdificatins and lse r missing parts: Check entire machine fr: Cracks in welds r structural cmpnents Dents r damage t machine Be sure that all structural and ther critical cmpnents are present and all assciated fasteners and pins are in place and prperly tightened. Be sure that the battery is in place and prperly cnnected. Electrical cmpnents, wiring and electrical cables Mast clumns Winches and related cmpnents Latches and pins Tires and wheels Trailer lights and reflectrs Outriggers, leveling jacks and ft pads Nuts, blts and ther fasteners Lamp fixtures and bulbs Cable (kinks, frays and abrasins) Safety chains (if required) Engine and related cmpnents Fuel tank Generatr Part N. 65176 Genie TML-4000N 9
Maintenance Check the Engine Oil Level Observe and Obey: Only rutine maintenance items specified in this manual shall be perfrmed by the peratr. Scheduled maintenance inspectins shall be cmpleted by qualified service technicians, accrding t the manufacturer's specificatins and the requirements specified in the respnsibilities manual. Maintaining the prper engine il level is essential t gd engine perfrmance and service life. Operating the machine with an imprper il level can damage engine cmpnents. Check the il level with the engine ff. 1 Check the il level dipstick. Result: The il level shuld be at the FULL mark n the dipstick. Add il as needed. Oil capacity 2.64 quarts 2.50 liters Oil viscsity requirements Maintenance Symbls Legend The fllwing symbls have been used in this manual t help cmmunicate the intent f the instructins. When ne r mre f the symbls appear at the beginning f a maintenance prcedure, it cnveys the meaning belw. -40 t 77 F / -40 t 25 C 5W-30 (synthetic) -25 t 86 F / -13 t 30 C 10W-40-20 t 77 F / -4 t 25 C 15W-30 Use ils meeting API classificatin CC, CF r CE, as they ffer imprved wear prtectin. Indicates that tls will be required t perfrm this prcedure. Indicates that new parts will be required t perfrm this prcedure. 10 Genie TML-4000N Part N. 65176
MAINTENANCE Check the Tires and Wheels Bdily injury hazard. An verinflated tire can explde and may cause death r serius injury. Cllisin Hazard. An excessively wrn tire can cause pr handling and cntinued use culd result in tire failure. Tip-ver hazard. D nt use temprary flat tire repair prducts. Maintaining the tires and wheels in gd cnditin is essential t safe peratin and gd perfrmance. Tire and/r wheel failure culd result in a machine tip-ver. Cmpnent damage may als result if prblems are nt discvered and repaired in a timely fasin. 1 Check the tire surface and sidewalls fr cuts, cracks, punctures and uneven r excessive tread wear. Result: Replace the tire if uneven r excessive tread wear is fund. Always replace the tire with specificatins equal t riginal equipment manufacturer. 2 Check each wheel fr damage, bends and cracks. Result: Replace the wheel if any damage is fund. 3 Check each tire with an air pressure gauge and add air as needed. 4 Check the trque f each lug nut. Tires and wheels - Narrw mdels Tire size ST185/80D13 Lug nut trque 80 ft-lbs 108 Nm Tire pressure (cld) 50 psi 3.45 bar Check the Engine Clant Level Maintaining the engine clant at the prper level is essential t engine service life. Imprper clant level will affect the engine's cling capability and damage engine cmpnents. Daily checks will allw the inspectr t identify changes in clant level that might indicate cling system prblems. 1 Remve the radiatr cap and check the clant level. Add fluid as needed. Result: The fluid level shuld be full. Bdily injury hazard. Fluids in the radiatr are under pressure and extremely ht. Use cautin when remving cap and adding fluids. Part N. 65176 Genie TML-4000N 11
MAINTENANCE Check the Battery Prper battery cnditin is essential t gd engine perfrmance and peratinal safety. Imprper fluid levels r damaged cables and cnnectins can result in engine cmpnent damage and hazardus cnditins. Electrcutin hazard. Cntact with ht r live circuits may result in death r serius injury. Remve all rings, watches and ther jewelry. Bdily injury hazard. Batteries cntain acid. Avid spilling r cntacting battery acid. Neutralize battery acid spills with baking sda and water. 1 Put n prtective clthing and eye wear. 2 Be sure that the battery cable cnnectins are free f crrsin. 3 Be sure that the battery hld dwns and cable cnnectins are tight. 4 Remve the battery vent caps. 5 Check the battery acid level. If needed, replenish with distilled water t the bttm f the battery fill tube. D nt verfill. 6 Install the vent caps. Scheduled Maintenance The scheduled maintenance items must be cmpleted by a persn trained and qualified t perfrm maintenance n this machine accrding t the prcedures fund in the service manual fr this machine. Inspectins and maintenance described belw require the qualified entity t recrd and retain recrds f all inspectins and maintenance items fr fur years. Machines that have been ut f service fr mre than three mnths must receive the quarterly inspectin befre placing the machine back int service. The Schedule There are fur types f maintenance inspectins that must be perfrmed accrding t a schedule daily, quarterly, annual and tw year. T accunt fr repeated prcedures, the Maintenance Tables and Maintenance Inspectin Reprt have been divided int fur subsectins A, B, C and D. Use the fllwing chart t determine which grup(s) f prcedures are required t perfrm a scheduled inspectin. Inspectin Daily r every 8 hurs Quarterly Table r Checklist A A + B Annual Tw year A + B + C A + B + C + D Maintenance Inspectin Reprt The maintenance inspectin reprt cntains checklists fr each type f scheduled inspectin. Make cpies f the Maintenance Inspectin Reprt t use fr each inspectin. Stre cmpleted frms fr fur years. 12 Genie TML-4000N Part N. 65176
Functin Tests Fundamentals D Nt Operate Unless: Yu learn and practice the principles f safe machine peratin cntained in this peratr's manual. 1 Avid hazardus situatins. 2 Always perfrm a pre-peratin inspectin. 3 Always perfrm functin tests prir t use. Knw and understand the abve principle befre ging n t the next sectin. 4 Inspect the wrk place. 5 Only use the machine as it was intended. The Functin Tests are designed t discver any malfunctins befre the machine is put int service. The peratr must fllw the step-by-step instructins t test all machine functins. A malfunctining machine must never be used. If malfunctins are discvered, the machine must be tagged and remved frm service. Repairs t the machine may nly be made by a qualified service technician, accrding t the manufacturer's specificatins. After repairs are cmpleted, the peratr must perfrm a pre-peratin inspectin and functin tests again befre putting the machine int service. Symbls Legend Indicates that a specific result is expected after perfrming a series f steps. Part N. 65176 Genie TML-4000N 13
FUNCTION TESTS Setup 1 Psitin the machine at the desired wrk site. 2 Discnnect the trailer lights and safety chains. 3 Open the latch n the cupler. 4 Pull the release pin n the tngue utrigger and rtate the utrigger twards the grund until the utrigger pin lcks securely in place. 5 Turn the jack handle t lwer the utrigger ft pad and raise the tngue f the machine enugh t clear the tw vehicle. 6 Release the spring pin n the side utriggers and lwer them t the grund. Make sure the lcking arm is lcked in place. 7 Turn the utrigger jack handles t level the machine. Level the machine using nly the leveling jacks. D nt use chcks, blcks r shims t level the machine. 8 Unlck the mast hld-dwn latch. Test the Machine Functins By raising and extending, then retracting and lwering the mast back t the hrizntal psitin, the fllwing functins will be tested: winches, latches, mast extensin and mast rtatin. 9 Turn the RAISE/LOWER winch handle clckwise until the mast raises apprximately 2 feet (61 cm). Result: A clicking sund shuld be heard as the winch handle is turned. 10 Release the winch handle. Result: The winch brake shuld hld when the handle is released. 11 Cntinue t turn the winch handle clckwise until the mast reaches full vertical psitin. Result: The mast shuld raise smthly, free f hesitatin r binding. Result: The spring latch n the frnt f the machine shuld lck the mast securely int place. 13 Turn the EXTEND/RETRACT winch handle clckwise until the mast extends apprximately 2 feet (61 cm). Result: A clicking sund shuld be heard as the winch handle is turned. Result: The mast sectins shuld telescpe smthly, free f hesitatin r binding. 14 Release the winch handle. Result: The winch brake shuld hld when the handle is released. 14 Genie TML-4000N Part N. 65176
FUNCTION TESTS 15 Press and hld the mast rtatin lever. 16 Rtate the mast clckwise and then cunterclckwise as far as it will g in either directin. Result: The mast shuld rtate smthly and easily in bth directins. 17 Rtate the mast back t its riginal psitin. Line up the black arrws n the frnt f the mast. 18 Release the mast rtatin lever 19 Attempt t rtate the mast in bth directins. Result: The mast shuld nt rtate. 20 Turn the EXTEND/RETRACT winch handle cunterclckwise until the mast sectins are fully retracted. Line up the blue arrws n the side f the mast. Result: N clicking sund shuld be heard when the winch handle is turned. 21 Pull and hld the mast release latch belw the cntrl panel. 22 Begin lwering the mast t the hrizntal psitin by turning the RAISE/LOWER winch handle cunterclckwise and hlding the release latch pen. Result: N clicking sund shuld be heard when the winch handle is turned. 23 Release the mast release latch and cntinue t crank the winch handle cunterclckwise until the mast reaches hrizntal psitin. Nte: Make sure the mast is lwered cmpletely int the transprt cradle. Fllw the mast stwing instructins t make sure the mast hld-dwn latch is securely lcked. Test the Lights 24 Make sure the circuit breaker light switches are in the OFF psitin. 25 Start the engine. See Starting the Engine in the Operating Instructins sectin. 26 Turn all fur circuit breaker light switches t the ON psitin. Result: The lights shuld cme n. Nte: It can take up t 20 minutes fr the lights t reach full intensity. Nte: Make sure the circuit breaker light switches are turned ff befre shutting dwn the engine. Part N. 65176 Genie TML-4000N 15
Wrkplace Inspectin Be aware f and avid the fllwing hazardus situatins: Drp-ffs r hles Bumps and bstructins D Nt Operate Unless: Yu learn and practice the principles f safe machine peratin cntained in this peratr's manual. 1 Avid hazardus situatins. 2 Always perfrm a pre-peratin inspectin. 3 Always perfrm functin tests prir t use. 4 Inspect the wrk place. Knw and understand the abve principle befre ging n t the next sectin. 5 Only use the machine as it was intended. Debris Overhead bstructins and high vltage cnductrs Hazardus lcatins Inadequate surface supprt t withstand all lad frces impsed by the machine Wind and weather cnditins The presence f unauthrized persnnel All ther pssible unsafe cnditins Fundamentals The Wrk Place Inspectin helps the peratr determine if the wrk place is suitable fr safe machine peratin. It shuld be perfrmed by the peratr prir t mving the machine t the wrk place. It is the peratr's respnsibility t read and remember the wrk place hazards, then watch fr and avid them while mving, setting up and perating the machine. 16 Genie TML-4000N Part N. 65176
Operating Instructins Setup 1 Psitin the machine at the desired wrk site. 2 Discnnect the trailer lights and safety chains. 3 Open the latch n the cupler. D Nt Operate Unless: Yu learn and practice the principles f safe machine peratin cntained in this peratr's manual. 1 Avid hazardus situatins. 2 Always perfrm a pre-peratin inspectin. 3 Always perfrm functin tests prir t use. 4 Inspect the wrk place. 5 Only use the machine as it was intended. 4 Pull the release pin n the tngue utrigger and rtate the utrigger twards the grund until the utrigger pin lcks securely in place. 5 Turn the jack handle t lwer the utrigger ft pad and raise the tngue f the machine enugh t clear the tw vehicle. 6 Release the spring pin n the side utriggers and lwer them t the grund. Make sure the lcking arm is lcked in place. 7 Turn the jack handle n each utrigger t level the machine. Level the machine using nly the leveling jacks. D nt use chcks, blcks r shims t level the machine. Starting the Engine Fundamentals The Operating Instructins sectin prvides instructins fr each aspect f machine peratin. It is the peratr's respnsibility t fllw all the safety rules and instructins in the peratr's, safety and respnsibilities manuals. 1 Make sure the circuit breaker light switches are in the OFF psitin. 2 Turn the key t the RUN psitin. The glw plug light will cme n. 3 Wait fr the glw plug light t g ff. 4 T start the engine, turn the key t START. If mre than ne peratr is expected t use a machine at different times in the same wrk shift, each peratr is expected t fllw all safety rules and instructins in the peratr's manual. That means every new peratr shuld perfrm a preperatin inspectin, functin tests and a wrk place inspectin befre using the machine. Part N. 65176 Genie TML-4000N 17
OPERATING INSTRUCTIONS Operatin f Lights 1 Turn n the lights using the circuit breaker switches lcated n the cntrl panel. Each switch crrespnds t ne f the lamps. Nte: The lights can take up t 20 minutes t reach full intensity. Nte: If the lights are turned ff and turned back n while they are still warm, they will nt light up again fr 20-30 minutes. 2 Turn the lights ff by turning the circuit breaker switches t the OFF psitin. Make sure the lights are turned ff befre shutting dwn the engine. T Raise the Mast 1 Unlck the mast hld-dwn latch. 2 Turn the RAISE/LOWER winch handle clckwise until the mast reaches the full vertical psitin and the frnt spring latch lcks the mast firmly in place. T Extend the Mast 1 Turn the EXTEND/RETRACT winch handle clckwise t extend the mast sectins. 2 Apprximately 6 inches belw full mast extensin, the lamp fixture will begin t tilt. The mre the winch handle is turned, the greater the tilt, until the mast is fully extended and the lights are psitined. Nte: T adjust the lights after the mast is fully extended, slwly lwer the mast by turning the winch handle cunterclckwise until the lights are in the desired psitin. Mast Rtatin 1 Press and hld the mast rtatin lever and rtate the mast t the desired psitin. 2 Release the lever. T Retract the Mast 1 Press and hld the mast rtatin lever and rtate the mast t its riginal psitin. Line up the black arrws n the frnt f the mast. 2 Turn the EXTEND/RETRACT winch handle cunterclckwise until the mast sectins retract. Make sure the blue arrws n the side f the mast are lined up. T Lwer the Mast 1 Turn the RAISE/LOWER winch handle cunterclckwise until the mast reaches the hrizntal psitin. 2 Lck the mast hld-dwn latch. After Each Use 1 Select a safe parking lcatin firm, level surface, clear f bstructin and traffic. 2 Remve the key t secure frm unauthrized use. 18 Genie TML-4000N Part N. 65176
OPERATING INSTRUCTIONS Transprt 1 Make sure the mast hld-dwn latch is securely lcked in place. 3 Push t release the lck handle n each f the side utriggers and place in the stwed psitin. Make sure the spring pin lcks each utrigger securely in place. 4 Raise the tngue f the machine by turning the tngue utrigger jack handle. 5 Psitin the transprt vehicle under the cupler n the tngue f the machine. 6 Open the latch n the cupler. 7 Turn the tngue utrigger jack handle t lwer the tngue and raise the utrigger ft pad ff the grund. 8 Clse the latch n the cupler. 9 Rtate the tngue utrigger t the stwed psitin and secure. 10 Attach the safety chains (if required). 11 Cnnect and test the trailer lights. Twing Infrmatin Use the checklist prvided n the back cver f this manual befre twing and while n the rad. Driving a vehicle/trailer cmbinatin is different frm driving a vehicle alne. Anticipate stps. Brake early. Increase the distance between yur vehicle and the vehicle in frnt f yu t twice the nrmal fllwing distance when twing a trailer. Allw mre fllwing distance in adverse weather. Slw dwn fr dwngrades and shift yur transmissin int a lwer gear. Slw dwn fr curves, adverse weather, hazardus rad cnditins and expressway exits. Yur vehicle/trailer cmbinatin may experience mmentary disturbances. If a disturbance happens, d nt brake, speed up r turn the steering wheel. Let ff the gas pedal and keep the steering wheel in a straight ahead psitin, sufficient t maintain the lane f travel. If the cmbinatin travels ff the paved radway, hld the steering wheel firmly. Let ff the gas pedal. D nt apply yur brakes. D nt turn sharply. Slw dwn belw 25 mph (40 km/h). Then gradually turn the steering wheel t get back n the radway. Prceed with cautin when entering traffic. Set all tires t the prper pressure. Find the recmmended cld pressures n the tire sidewall, in the wner s manual r n the trailer decal. D nt put mre pressure in the tire than is n the tire sidewall. Tire pressures g up during driving. D nt let ff this extra pressure. When passing ther vehicles, be sure t leave enugh rm fr the extra length f the trailer. Yu will need t g much farther beynd the passed vehicle befre yu can return t yur lane. When turning with a trailer, avid jerky r sudden mvements. Inspect all cnnectins at each stp. Use the checklist prvided n the back cver f this manual. Transprt (nt attached t a tw vehicle) Make sure the mast is fully lwered t the hrizntal psitin and the mast hld-dwn latch is securely lcked in place befre lifting the TML with a frklift r crane. Part N. 65176 Genie TML-4000N 19
Decals Decal Inspectin Use the pictures n the next page t verify that all decals are legible and in place. Belw is a numerical list with quantities and descriptins. Part N. Descriptin Quantity 28159 Label - Diesel 1 28161 Warning - Crush Hand 5 28164 Ntice - Hazardus Materials 2 28171 Label - N Smking 1 31072 Manual Strage Cntainer 1 52475 Label - Transprt Tie-dwn 2 62707 Warning - Tw Speed 1 65408 Ntice - Operating Instructins 1 65409 Ntice - Mast Rtatin Instructins 1 65411 Warning - General Safety 1 Part N. Descriptin Quantity 72077 Label - Black Arrw 2 72826 Label - Extend/Retract Winch 1 72828 Ntice - Tire Specs 2 72865 Cntrl Panel 1 72870 Cautin - Cmpnent Cntact 1 72871 Label - Pwer Outlet, 120V 1 72874 Label - Lcked, Unlcked 1 72889 Warning - Transprt Hazard 1 72890 Ntice - Mast Retractin 1 72891 Label - Blue Arrw 2 65412 Warning - Transprt Instructins 1 65414 Danger - Electrcutin Hazard 2 65421 Warning - Electrcutin, Generatr 2 65423 Ntice - Engine specs 1 72008 Cautin - Turn Off Lights 1 72010 Csmetic - Genie TML-4000N 2 72018 Label - Raise/Lwer Winch 1 72019 Warning - High Vltage 1 20 Genie TML-4000N Part N. 65176
DECALS Cntrl Panel Side Shading indicates decal is hidden frm view, i.e. under cvers Fuel Tank Side Part N. 65176 Genie TML-4000N 21
Specificatins Mdel - TML-4000 Narrw Height, stwed Length, stwed Width, stwed Extended twer height Weight (dry) Weight (fuel tank full) Maximum tngue weight Tire size 74 in 1.9 m 14 ft 10 in 4.5 m 53 in 1.3 m 28 ft 8.5 m 1695 lbs 769 kg 1890 lbs 857 kg 110 lbs 50 kg ST185/80D13 Engine type Fuel capacity Generatr Ttal lighting wattage Replacment bulbs Deutz F3M1008 3 cylinder diesel, water cled 30 gallns 114 liters 6 kw 4000 watts 1000 W Metalarc M47 R M1000/U/BT37 r equivalent Run time (full lad with full fuel tank) Twer rtatin Maximum twing speed Maximum wind speed rating 60 hurs 360 degrees, nn-cntinuus 60 mph 97 km/h 60 mph 27 m/sec Airbrne Nise Emissins 71 db Maximum sund level at nrmal perating wrkstatins (A-weighted) Cntinuus imprvement f ur prducts is a Genie plicy. Prduct specificatins are subject t change withut ntice r bligatin. 22 Genie TML-4000N Part N. 65176
Reprting Safety Defects Genie Industries PO Bx 97030 Redmnd, WA 98073-9730 Reprting Safety Defects If yu believe that yur vehicle has a defect which culd cause a crash r culd cause injury r death, yu shuld immediately infrm the Natinal Highway Traffic Safety Administratin (NHTSA) in additin t Genie Industries. If NHTSA receives smilar cmplaints, it may pen an investigatin, and if it finds that a safety defect exists in a grup f vehicles, it may rder a recall and remedy campaign. Hwever, NHTSA cannt becme invlved in any individual prblems between yu, yur dealer r Genie Industries. T cntact NHTSA yu may either call the Aut Safety Htline tll-free at 1-800-424-9393 (366-0123 in Washingtn DC area) r write t: NHTSA U.S. Department f Transprtatin 400 7th Street SW, (NSA-11) Washingtn DC 20590 Yu can als btain infrmatin abut mtr vehicle safety frm the Htline. Part N. 65176 Genie TML-4000N 23
Twing Checklist (Use at each stp) Befre Twing Befre Driving Twing hitch and hitch ball are secure Safety chains (if required) are prperly attached and secure (chains are crssed belw hitch) All lights are cnnected and wrking Check all tires fr crrect pressure Fasten safety restraints Prperly adjust mirrrs Genie Nrth America Phne 425.881.1800 Tll Free USA and Canada 800.536.1800 Fax 425.883.3475 Genie Australia Pty Ltd. Phne 1 61 7 3375 1660 Fax 1 61 7 3375 1002 Genie China Phne 86 21 53852570 Fax 86 21 53852569 Genie Malaysia Phne 604 228 1235 Fax 604 226 6872 Genie Japan Phne 81 3 3453 6082 Fax 81 3 3453 6083 Genie Krea Phne 82 2 558 7267 Fax 82 2 558 3910 On The Rad D nt exceed 60 mph / 97 km/h. Obey all lcal and natinal twing speed laws. Stp ften fr rest. Inspect vehicles and cnnectins at each stp. Anticipate stps; brake early. Califrnia Prpsitin 65 WARNING The exhaust frm this prduct cntains chemicals knwn t the State f Califrnia t cause cancer, birth defects r ther reprductive harm. Genie Africa Phne 27 11 455 0373 Fax 27 11 455 0355 Genie Latin America Phne 55 11 4055 2499 Fax 55 11 4043 1661 Genie Hlland Phne 31 70 51 78836 Fax 31 70 51 13993 Genie France Phne 33237260999 Fax 332372609985 Genie Spain Phne 34 93 579 5042 Fax 34 93 579 5059 Genie Germany Phne 49 4202 8852-0 Fax 49 4202 8852-20 Genie U.K. Phne 44 1476 584333 Fax 44 1476 584334 Genie Mexic City Phne 52 5 653 03 84 Fax 52 5 664 40 16 Distributed By: