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Towing Checklist
Hitching
Hitch is sufficient to tow trailer and load
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Hitch is properly attached to tow vehicle
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Safety chains (if required) are properly attached
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All tires have correct pressure
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All lights are connected and working
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Towing
Do not exceed 60 mph / 97 km/h
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Check connections and tire pressure at each stop
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Genie North America Slow down for hazardous conditions
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Phone 425.881.1800
Allow extra distance for following and passing other vehicles
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Toll Free USA and Canada
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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 .....................................................................
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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. 4
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Operator's Manual Third Edition Second Printing SAFETY RULES Do not adjust or stow the outriggers when the mast Fall Hazards is raised. Do not stand on the Do not use the machine on a moving or mobile machine. surface or vehicle. Do not climb on the mast. Be sure the tires are in good condition and the lug nuts are properly tightened. Tip-over Hazards Electrocution Hazards Do not raise the mast to the vertical position unless This machine is not electrically insulated and will all outriggers a
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Third Edition Second Printing Operator's Manual SAFETY RULES Keep away from the Burn Hazard machine if it contacts Do not touch the lamp fixtures while they are turned energized power lines. on. Turn the lamps off and allow them to cool Personnel must not before touching. touch or operate the machine until power lines are shut off. Crushing Hazards Do not connect wires Do not lower the mast unless the area below is directly to the generator. clear of personnel and obstructions. Connect auxilia
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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 Read, understand and obey all of your tow vehicle fuel or other explosive substances. manufacturer’s recommendations, warnings and instructions before towing this machine. Do not refuel the machine with the engine running. Do not tow the machine unless the mast is lowered Refuel the machine and charge the battery only in to the horizontal
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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. Orange—used to indicate the prese
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Operator's Manual Third Edition Second Printing Legend 7 7 8 9 6 10 5 9 4 11 12 3 13 2 14 2 1 15 1 20 16 21 19 18 17 Access under opposite cover: 1 Outrigger leveling jack with 13 Front spring latch (behind Fuel tank footpad mast) Power outlets (Narrow models) 2 Outrigger jack handle Manual storage container 14 Tongue outrigger 3 Outrigger 6 Mast hold-down latch 15 Coupler 4 Transport tie-down (hidden 7 Lamp fixtures 16 Transport tie-down (one on behind machine) each side of tongue outrigger)
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Third Edition Second Printing Operator's Manual Controls 3 4 2 00009.9 5 6 OFF RUN AIR AIR FILTER FILTER 1 START 7 Control Panel 1 Key switch 4 Glow plug indicator light 6 Water temperature indicator light 2 Hour meter 5 Oil pressure indicator light 7 Air filter condition indicator 3 Circuit breaker switches for light lights (4) Part No. 97600 Genie TML-4000 and TML-4000N 7
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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 Do Not Operate Unless: operator performs the function tests. You learn and practice the principles of safe
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Third Edition Second Printing Operator's Manual PRE-OPERATION INSPECTION Pre-operation Inspection Check entire machine for: Be sure that the operator’s manual is complete, legible and in the storage container located on Cracks in welds or structural components the machine. Dents or damage to machine Be sure that all decals are legible and in place. See Decals section. Be sure that all structural and other critical Check for engine oil leaks and proper fluid level. components are pr
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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: Check the oil level with the engine off. Only routine maintenance items specified in this manual shall be performed by the operator. 1 Check the oil level dipstick. Add oil if needed. Scheduled maintenance inspection
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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 Proper battery condition is essential to good engine essential to engine service life. Improper coolant performance and operational safety. Improper fluid level will affect the engine's cooling capability and levels or damaged cables and connections can damage engine components. Daily checks will result in engine component damage
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Operator's Manual Third Edition Second Printing MAINTENANCE 4 Check the torque of each lug nut. Check the Tires and Wheels Tires and wheels - Standard and Narrow models Tire size ST185/80D13 Bodily injury hazard. An over- Rim size 13 x 4.5 in 33 x 11.4 cm inflated tire can explode and may Lug nut torque 80 ft-lbs 108 Nm cause death or serious injury. Tire pressure (cold) 50 psi 3.4 bar Collision hazard. An excessively worn tire can cause poor handling and continued use could result in tire fai
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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. A malfunctioning machine must never be used. If Do Not Operate Unless: malfunctions are discovered, the machine must be tagged and removed from service. Repairs to the You learn and practice the principles of safe machine may only be m
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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, 2 Disconnect the trailer lights and safety chains. the following functions will be tested: winches, latches, mast extension and mast rotation. 3 Open the latch on the coupler. 4 Pull the release pin on the tongue outrigger and 12 Unlock the mast hold-down
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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 27 Make sure the circuit breaker light switches are counterclockwise as far as it will go in either in the off position. direction. 28 Start the engine. See Starting the Engine in the Result: The mast should rotate smoothly and Operating Instructions section. easily in both directions. 29 Turn all four circuit breaker light switches to
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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 · Slopes that exceed the machine’s leveling Do Not Operate Unless: capability You learn and practice the principles of safe · Unstable or slippery surfaces machine operation contained in this operator's · Overhead obstructions and high voltage manual. conductors 1 Avoid hazardous situations. · Hazardous locations 2
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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 1 Make sure the circuit breaker light switches are Do Not Operate Unless: in the off position. 2 At the control panel, turn the key or turn the You learn and practice the principles of safe switch to the run position. The glow plug light machine operation contained in this operator's will come on. manual
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Operator's Manual Third Edition Second Printing OPERATING INSTRUCTIONS Note: If the mast has not been fully retracted, it will To Raise the Mast not rest completely in the cradle. 1 Unlock the mast hold-down latch. 5 Turn the mast hold-down latch handle 2 Turn the Raise/Lower winch handle clockwise counterclockwise and push into the lock. until the mast reaches the full vertical position 6 Turn the latch handle clockwise until the handle and the front spring latch locks the mast firmly points
