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 · · · · Genie North America Phone 425.881.1800 Toll Free USA and Canada 800.536.1800 Fax 425.883.3475 California Proposition 65 Genie Australia Pty Ltd.
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 ........................................................................
Third Edition • Second Printing Operator's Manual Safety Rules Warning Failure to obey the instructions and safety rules in this manual may result in death or serious injury. Do Not Operate Unless: You learn and practice the principles of safe machine operation contained in this operator's manual. 1 Avoid hazardous situations. Know and understand the safety rules before going on to the next section. 2 Always perform a pre-operation inspection. 3 Always perform the function tests prior to use.
Operator's Manual Third Edition • Second Printing SAFETY RULES Do not adjust or stow the outriggers when the mast is raised. Fall Hazards Do not stand on the machine. Do not use the machine on a moving or mobile surface or vehicle. Do not climb on the mast. Be sure the tires are in good condition and the lug nuts are properly tightened.
Third Edition • Second Printing Operator's Manual 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. 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 connect wires directly to the generator. Connect auxiliary equipment only to the power outlets provided.
Operator's Manual Third Edition • Second Printing SAFETY RULES Explosion and Fire Hazards Towing Hazards Do not start the engine if you smell or detect diesel fuel or other explosive substances. Read, understand and obey all of your tow vehicle manufacturer’s recommendations, warnings and instructions before towing this machine. Do not refuel the machine with the engine running.
Third Edition • Second Printing Operator's Manual SAFETY RULES Decal Legend Genie product decals use symbols, color coding and signal words to identify the following: Safety alert symbol—used to alert personnel to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death. Red—used to indicate the presence of an imminently hazardous situation which, if not avoided, will result in death or serious injury.
Operator's Manual Third Edition • Second Printing Legend 7 7 8 9 6 10 5 9 11 4 12 3 13 2 14 2 1 15 1 21 1 Outrigger leveling jack with footpad 2 Outrigger jack handle 20 19 18 17 16 Access under opposite cover: Fuel tank Power outlets (Narrow models) Manual storage container 13 Front spring latch (behind mast) 14 Tongue outrigger 3 Outrigger 6 Mast hold-down latch 15 Coupler 4 Transport tie-down (hidden behind machine) 7 Lamp fixtures 8 Mast 16 Transport tie-down (one on each side
Third Edition • Second Printing Operator's Manual Controls 3 2 4 00009.9 5 6 OFF RUN 1 AIR FILTER START 7 Control Panel 1 Key switch 4 Glow plug indicator light 2 Hour meter 5 Oil pressure indicator light 3 Circuit breaker switches for lights (4) Part No.
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 is apparently wrong with a machine before the operator performs the function tests.
Third Edition • Second Printing Operator's Manual PRE-OPERATION INSPECTION Pre-operation Inspection o Be sure that the operator’s manual is complete, legible and in the storage container located on the machine. Check entire machine for: o Be sure that all decals are legible and in place. See Decals section. o Dents or damage to machine 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.
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.
Third Edition • Second Printing Operator's Manual MAINTENANCE Check the Engine Coolant Level Check the Battery 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. Proper battery condition is essential to good engine performance and operational safety.
Operator's Manual Third Edition • Second Printing MAINTENANCE Check the Tires and Wheels 4 Check the torque of each lug nut. Tires and wheels - Standard and Narrow models Tire size Bodily injury hazard. An overinflated tire can explode and may cause death or serious injury. Rim size Collision hazard. An excessively worn tire can cause poor handling and continued use could result in tire failure. Tire pressure (cold) Tip-over hazard. Do not use temporary flat tire repair products.
Third Edition • Second Printing Operator's Manual Function Tests Fundamentals The function tests are designed to discover any malfunctions before the machine is put into service. The operator must follow the step-by-step instructions to test all machine functions. 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.
Operator's Manual Third Edition • Second Printing FUNCTION TESTS Setup Test the Machine Functions 1 Position the machine at the desired work site. 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. 2 Disconnect the trailer lights and safety chains. 3 Open the latch on the coupler.
Third Edition • Second Printing Operator's Manual FUNCTION TESTS 18 Press and hold the mast rotation lever. Test the Lights 19 Rotate the mast clockwise and then counterclockwise as far as it will go in either direction. 27 Make sure the circuit breaker light switches are in the off position. Result: The mast should rotate smoothly and easily in both directions. 20 Rotate the mast back to its original position. Line up the black arrows on the front of the mast. 21 Release the mast rotation lever.
Operator's Manual Third Edition • Second Printing Workplace Inspection Be aware of and avoid the following hazardous situations: 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.
Third Edition • Second Printing Operator's Manual 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 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.
Operator's Manual Third Edition • Second Printing OPERATING INSTRUCTIONS Note: If the mast has not been fully retracted, it will not rest completely in the cradle. 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 5 Turn the mast hold-down latch handle counterclockwise and push into the lock.
Third Edition • Second Printing Operator's Manual 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.
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: Use the two tie-down points on the machine for anchoring down to the transport surface. Common sense and planning must be applied to control the movement of the machine when lifting it with a crane or forklift. Use chains or straps of ample load capacity.
Third Edition • Second Printing Operator's Manual 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. Observe and Obey: Close and secure the covers. Only qualified riggers should rig and lift the machine. Inspect the entire machine for loose or unsecured items.
Operator's Manual Third Edition • Second Printing Decals Decal Inspection Part No. Description Use the pictures on the next page to verify that all decals are legible and in place.
Third Edition • Second Printing Operator's Manual DECALS 72889 28161 72009 or 72010 72871 or 82219 or 82957 72891 72890 72077 Control Panel Side 28161 97637 72008 82224 72018 72019 82237 72874 82223 65408 65411 82304 28164 65414 82303 72870 65421 97602 65423 or 82302 or 97767 97661 72828 97518 97635 82224 97635 28161 52475 97635 82224 97635 82222 97518 72826 65409 72009 or 72010 28161 65412 82224 Serial Plate 82223 NHTSA 97602 82223 28164 65414 28161 52475 28161 Part No.
Operator's Manual Third Edition • Second Printing Specifications Model - TML-4000 Standard Model - TML-4000 Narrow Height, stowed 71 in 1.8 m Height, stowed 71 in 1.8 m Length, stowed 14 ft 7 in 4.4 m Length, stowed 14 ft 7 in 4.4 m Width, stowed 70 in 1.8 m Width, stowed 55 in 1.4 m Extended tower height 28 ft 8.5 m Extended tower height 28 ft 8.
Third Edition • Second Printing Operator's Manual Reporting Safety Defects Genie Industries PO Box 97030 Redmond, WA 98073-9730 Reporting Safety Defects If you believe that your vehicle has a defect which could cause a crash or could cause injury or death, you should immediately inform the National Highway Traffic Safety Administration (NHTSA) in addition to Genie Industries.
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 · · · · Genie North America Phone 425.881.1800 Toll Free USA and Canada 800.536.1800 Fax 425.883.3475 California Proposition 65 Genie Australia Pty Ltd.