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

Internet: http://www.genielift.com e-mail: techpub@genieind.com

"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

1 Outrigger leveling jack with

footpad 2 Outrigger jack handle 3 Outrigger 4 Transport tie-down (hidden

behind machine) 5 Cover

Access under this cover:

Engine Generator

Grounding rod attachment

Power outlets (Standard models)

Access under opposite cover:

Fuel tank Power outlets (Narrow models) Manual storage container

6 Mast hold-down latch 7 Lamp fixtures 8 Mast 9 Forklift pocket 1 0 Lifting eye 1 1 Mast rotation lever 12 Extend/Retract winch handle

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

21 Tire

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

Operator's ManualThird Edition • Second Printing

AIR FILTER

Controls

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

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

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