Genie TML-4000, TML-4000N User Manual

Operator’s Manual

with Maintenance Information

Second Edition

Third Edition

Seventh Printing

Second Printing

Part No. 43645

Part No. 97600

Operator's Manual Third Edition • Second Printing

Important

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

Contents

Page

Safety ........................................................................ 1

Legend ....................................................................... 6

Controls ..................................................................... 7

Pre-operation Inspection ............................................ 8

Maintenance ............................................................. 10

Function Tests.......................................................... 13

Workplace Inspection................................................ 16

Operating Instructions............................................... 17

Transport and Lifting Instructions .............................. 20

Decals ...................................................................... 22

Specifications ........................................................... 24

Reporting Safety Defects .......................................... 2 5

Contact us:

Internet: http://www.genielift.com
e-mail: [e-mail]

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.

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

Operator's ManualThird Edition • Second Printing

Safety Rules

Warning

Failure to obey the instructions and
safety rules in this manual may
result in death or serious injury.

Do Not Operate Unless:

You learn and practice the principles of safe

machine operation contained in this operator's
manual.

1 Avoid hazardous situations.
Know and understand the safety rules

before going on to the next section.

2 Always perform a pre-operation

inspection.

3 Always perform the function tests prior to

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

You read, understand and obey the

manufacturer's instructions and safety rules—
safety and operator's manuals and machine
decals.

You read, understand and obey employer's

safety rules and worksite regulations.

You read, understand and obey all applicable

governmental regulations.

You are properly trained to safely operate the

machine.

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

Operator's Manual Third Edition • Second Printing

SAFETY RULES

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 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 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.

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

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

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

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.

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

Be sure all decals are legible and in place.

Bodily Injury Hazard

Do not grasp the cable.
Use proper lifting techniques when lifting and

positioning the tongue of the machine.
Always replace the protective lamp cover after

replacing the lamp bulbs.

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

Operator's Manual Third Edition • Second Printing

SAFETY RULES

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.

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

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.

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

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.

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.

Operator's ManualThird Edition • Second Printing

SAFETY RULES

Yellow with safety alert symbol—
used to indicate the presence of a
potentially hazardous situation
which, if not avoided, may cause
minor or moderate injury.

Yellow without safety alert
symbol—used to indicate the
presence of a potentially
hazardous situation which, if not
avoided, may result in property
damage.

Green—used to indicate operation
or maintenance information.

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

Operator's Manual Third Edition • Second Printing

Legend

7

6

5

4

3

2

7

8

9

10

9

11

12

13

14

2

1

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)

20

21

19

17

18

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
1 0 Lifting eye
1 1 Mast rotation lever
12 Extend/Retract winch handle

16

1 3 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)
1 8 Mast release latch
19 Raise/Lower winch handle
20 Fender

15

1

21 Tire

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

Operator's ManualThird Edition • Second Printing

AIR
FILTER

Controls

3

2

1

Control Panel

1 Key switch
2 Hour meter
3 Circuit breaker switches for

lights (4)

00009.9

OFF

RUN

START

4 Glow plug indicator light
5 Oil pressure indicator

light

AIR
FILTER

6 Water temperature

indicator light

7 Air filter condition indicator

light

4

5

6

7

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

Operator's Manual Third Edition • Second Printing

Pre-operation Inspection

Fundamentals

It is the responsibility of the operator to perform a
pre-operation inspection and routine maintenance.

The pre-operation Inspection is a visual inspection
performed by the operator prior to each work shift.
The inspection is designed to discover if anything

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.

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.

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

Pre-operation Inspection

Operator's ManualThird Edition • Second Printing

PRE-OPERATION INSPECTION

o Be sure that the operator’s manual is complete,

legible and in the storage container located on
the machine.

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

See Decals section.

o Check for engine oil leaks and proper fluid level.

Add oil if needed. See Maintenance section.

o Check for engine coolant leaks and proper

coolant level. Add coolant if necessary. See
Maintenance section.

o Check for battery fluid leaks and proper fluid

level. Add distilled water if needed. See
Maintenance section.

o Check for proper tire pressure and lug nut

torque. Add air to tires if needed. See
Maintenance section.

Check the following components or areas for
damage, improperly installed or missing parts and
unauthorized modifications:

o Electrical components, wiring and electrical

cables

Check entire machine for:

o Cracks in welds or structural components
o Dents or damage to machine

o Be sure that all structural and other critical

components are present and all associated
fasteners and pins are in place and properly
tightened.

o Be sure that the battery is in place and properly

connected.

o Mast tubes
o Winches and related components
o Latches and pins
o Tires and wheels
o Trailer lights and reflectors
o Outriggers, leveling jacks and foot pads
o Nuts, bolts and other fasteners
o Lamp fixtures and bulbs
o Cable (kinks, frays and abrasions)
o Safety chains (if required)
o Engine and related components
o Fuel tank
o Generator

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

Operator's Manual Third Edition • Second Printing

Maintenance

Check the Engine Oil Level

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

Observe and Obey:

Only routine maintenance items specified in this

manual shall be performed by the operator.

Scheduled maintenance inspections shall be

completed by qualified service technicians,
according to the manufacturer's specifications
and the requirements specified in the
responsibilities manual.

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

Check the oil level with the
engine off.

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.

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

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

Operator's ManualThird Edition • Second Printing

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.

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

Operator's Manual Third Edition • Second Printing

MAINTENANCE

Check the Tires and Wheels

Bodily injury hazard. An over­inflated 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.

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

Scheduled Maintenance

Maintenance performed quarterly, annually and
every two years must be completed by a person
trained and qualified to perform maintenance on
this machine according to the procedures found in
the service manual for this machine.

Machines that have been out of service for more
than three months must receive the quarterly
inspection before they are put back into service.

2 Check each wheel for damage, bends and

cracks. Replace the wheel if any damage is
found.

Tires and wheels must be replaced
with tires and wheels of the
specifications listed.

3 Check each tire with an air pressure gauge and

add air as needed.

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

Operator's ManualThird Edition • Second Printing

Function T ests

Fundamentals

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

Do Not Operate Unless:

You learn and practice the principles of safe

machine operation contained in this operator's

manual.
1 Avoid hazardous situations.
2 Always perform a pre-operation inspection.

3 Always perform function tests prior to use.

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.

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.

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

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.

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.
1 3 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.

1 6 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.

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.

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

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

FUNCTION TESTS

1 8 Press and hold the mast rotation lever.
1 9 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.
2 1 Release the mast rotation lever.
2 2 Attempt to rotate the mast in both directions.

Result: The mast should not rotate.

2 3 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.

Test the Lights

2 7 Make sure the circuit breaker light switches are

in the off position.

2 8 Start the engine. See Starting the Engine in the

Operating Instructions section.

2 9 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.

25 Begin lowering the mast to the horizontal

position by turning the raise/lower winch handle

counterclockwise and holding the release latch

open.

Result: No clicking sound should be heard

when the winch handle is turned.
26 Release the mast release latch and continue to

crank the winch handle counterclockwise until

the mast reaches horizontal position.
Note: Make sure the mast is lowered completely

into the transport cradle. Follow the mast stowing
instructions in the Operating Instructions section to
make sure the mast hold-down latch is securely
locked.

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

Operator's Manual Third Edition • Second Printing

Workplace Inspection

Be aware of and avoid the following hazardous
situations:

· Drop-offs or holes

· Bumps and obstructions

· Debris

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.

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.

· 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

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.

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

Operator's ManualThird Edition • Second Printing

Operating Instructions

Setup

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

Starting the Engine

Do Not Operate Unless:

You learn and practice the principles of safe
machine operation contained in this operator's

manual.
1 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 pre­operation inspection, function tests and a work
place inspection before using the machine.

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.

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

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.

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.

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.

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

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

OPERATING INSTRUCTIONS

Towing

1 Make sure the mast hold-down latch is securely

locked in place.
2 Make sure the covers are closed and secured.
3 Push to release the lock handle on each of the

side outriggers and place in the stowed

position. Make sure the spring pins lock the

outriggers securely in place.
4 Raise the tongue of the machine by turning the

tongue outrigger jack handle.
5 Position the transport vehicle under the coupler

on the tongue of the machine.
6 Open the latch on the coupler.
7 Turn the tongue outrigger jack handle to lower

the tongue and raise the outrigger foot pad off

the ground.
8 Close the latch on the coupler.
9 Rotate the tongue outrigger to the stowed

position and secure with the lock pin.
10 Attach the safety chains (if required).
11 Connect and test the trailer lights.

Increase the distance between your vehicle and the
vehicle in front of you to twice the normal following
distance when towing a trailer. Allow more following
distance in adverse weather.

Slow down for downgrades and shift your
transmission into a lower gear.

Slow down for curves, hazardous road conditions,
freeway exits, and when driving in adverse
weather.

Heavy winds, excessive speed, load shifting or
passing vehicles can cause the trailer to sway
while driving. If this occurs, do not brake, speed up
or turn the steering wheel. Turning the steering
wheel or applying the brakes can cause the vehicle
and trailer to jackknife. Let up on the gas pedal and
keep the steering wheel straight.

If the vehicle and/or trailer travels off the paved
road, hold the steering wheel firmly and let up on
the gas pedal. Do not apply the brakes. Do not turn
sharply. Slow down to under 25 mph / 40 km/h.
Gradually turn the steering wheel to get back on
the road. Proceed with caution when entering
traffic.

When passing other vehicles, be sure to leave
enough room for the extra length of the trailer. You
will need to go much farther beyond the passed
vehicle before you can return to your lane.

Towing Information

Use the checklist provided on the back cover of
this manual before towing and while on the road.

Inspect all connections at each stop.

Driving a vehicle/trailer combination is different
from driving a vehicle alone.

All tires must be properly inflated. Find the
recommended cold tire pressures on the tire
sidewall or trailer decal. Do not overinflate the tires.
Tire pressures go up during driving. Checking the
tire pressure when the tires are warm will give you
an inaccurate pressure reading.

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

Avoid jerky or sudden movements when turning.

Operator's Manual Third Edition • Second Printing

Transport and Lifting Instructions

Securing the Chassis

Place a block on both sides of the axle behind the
wheels.

Place a block under the chassis at both ends of the
machine.

Observe and Obey:

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.

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.

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.

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

Observe and Obey:

Only qualified riggers should rig and lift the

machine.

Operator's ManualThird Edition • Second Printing

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.

Be sure the crane capacity, loading surfaces

and straps or lines are sufficient to withstand

the machine weight. See the serial plate for the

machine weight.

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

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

Operator's Manual Third Edition • Second 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

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

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

72019 Danger - High Voltage 1
72077 Label - Black Arrow 2
72826 Label - Extend/Retract Winch 1
72828 Notice - Tire Specifications 2

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

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

Operator's ManualThird Edition • Second Printing

DECALS

82224

82237
72874
82223

28164
65414

72870

28161

52475
97635
82224
97635
82222

97518

72826
65409

28161

65412

Serial

Plate

NHTSA

82223

72889

28161

72009 or
72010

72871 or
82219 or
82957

72891

72890

72077

Control

Panel

Side

28161
97637

72008

72018
72019

65408
65411
82304

82303

65421
97602
65423

or 82302
or 97767

97661
72828
97518

97635
82224
97635

72009

or 72010

82224

82223

97602

28164

65414
28161

52475

28161

62707

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

28159

65421

72828

31072

28171

72870

Side

Fuel T ank

Operator's Manual Third Edition • Second Printing

Specifications

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

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) 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)

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)

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

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

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.

Operator's ManualThird Edition • Second Printing

To contact NHTSA you may either call the Auto
Safety Hotline toll-free at 1-800-424-9393 (366­0123 in Washington DC area) or write to:

NHTSA
U.S. Department of Transportation
400 7th Street SW, (NSA-11)
Washington DC 20590

You can also obtain information about motor
vehicle safety from the Hotline.

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

Genie North America

Phone [phone]

Toll Free USA and Canada

800.536.1800

Fax [phone]

Towing Checklist

Hitching

Hitch is sufficient to tow trailer and load

·

Hitch is properly attached to tow vehicle

·

Safety chains (if required) are properly attached

·

All tires have correct pressure

·

All lights are connected and working

·

Towing

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

·

Genie Australia Pty Ltd.

Phone [phone]

Fax [phone]

Genie China

Phone [phone]

Fax [phone]

Genie Malaysia

Phone [phone]

Fax [phone]

Genie Japan

Phone [phone]

Fax [phone]

Genie Korea

Phone [phone]

Fax [phone]

Genie Brasil

Phone [phone]

Fax [phone]

Genie Holland

Phone [phone]

Fax [phone]

Genie Scandinavia

Phone [phone]

Fax [phone]

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.

Genie France

Phone [phone]

Fax [phone]

Genie Iberica

Phone [phone]

Fax [phone]

Genie Germany

Phone [phone]

Fax [phone]

Genie U.K.

Phone [phone]

Fax [phone]

Genie Mexico City

Phone [phone]

Fax [phone]

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