4000N Parts Manual
Contents
1. Section 100 Decals September2008 FIGURE101 1 REV 72889 72009 or 72871 or 72890 28161 72010 82957 72891 CR51A107 28161 82224 97637 nh om Cw x 72008 T END a RE Ne Cmm M ad WN cB KT 114007 82237 NL His mm aii ei VK 65408 02223 i SE x ay or 82304 28164 2A 2 EN gt 72008 65414 NG 82303 72870 ii 65421 97602 28161 65423 52475 or 82302 97635 or 97767 82224 97661 97635 ee 89999 97518 97635 82224 97518 97635 72826 72009 65409 A or 72010 i asa 65412 C 82224 104533 82223 97602 82223 E 28164 U U ee 6541 4 28161 52415 Shading indicates 28161 82237 and 65421 31072 72870 Me aa qd 62707 82221 28159 72828 28171 100 4 TML 4000 e TML 4000N Part No 116471 September2008 Section 100 Decals REV A ltem Part No 42 43 44 45 46 47 48 97602 97635 97637 97638 97661 104533 114007 Description Warning Explosion Hazard l iii ei Warning Bodilv Injury Hazard Label Wet Locations Label Lamp Replacement Label Grounding Rod Attachment Se2. TML 4000 TML 4000N Part No 116471 400 2 September2008 Section 400 Mast Components SSS REVA FIGURE 401 1 ltem Part No Description Qty 1 69682 Mast Rotate Wear Pad 4 2 6637 Screw HHC 1 4 20 x 1 75 inches GR 5 3 6638 Flat Washer 4 inch 4 6091 Nylock Nut 1 4 20 5 51428 Screw HHC 3 4 10 x 2 75 inches GR 5 6 6564 Shim Washer 0 75 x 1 125 x 0 093 inch 7 10258 Nylock Nut 3 4 10 8 69684 End Cap Plate Number 1 Mast Tube 1 9 69687 Wear Pad Number 1 Mast Tube 1 10 69885 Pivot Assembly Number 1 Mast Tube includes item 15 1 11 57316 Mast Cable Pulley 1 12 80107 Winch Cable Assembly Mast PIVOt cernes 1 13 69680 Clevis Pin 0 63 x 1 5 inches 1 14 6094 Cotter Pin 0 125 x 1 inch 15 57589 Screw HHC 3 4 10 x 10 inches GR 8 1 16 74323 Flat Washer 3 4 inch 17 42641 Flange Bearing 0 75 x 1 x 1 25 inches 2 18 10258 Nylock Nut 3 4 10 19 6090 Screw HHC 1 4 20 x 0 75 inch GR 5 20 14085 Winch Frame Assembly A TEREX COMPANY PartNo 116471 TML 4000 TML 4000N 400 3 Section 400 e Mast Components September 2008 Figure 402 1 Mast Components View 2 REV A OOO
3. Section 100 Decals September2008 Figure 101 1 Decals 72889 72009 or 72871 or 72890 28161 72010 82957 72891 CR51A107 28161 82224 97637 UN E CN 43 72008 T END Er 4 Cmm M ad WN cB KT 114007 82237 NL ala f mm aii ei ME 65408 02223 i SE x ay or 82304 28164 2A 2 EN gt 72008 65414 Ke 82303 72870 ed 65421 97602 28161 65423 52475 or 82302 97635 or 97767 82224 97661 See 72828 89999 97518 97635 82224 97518 97635 72826 72009 65409 A or 72010 i asa 65412 el 82224 104533 82223 97602 82223 bt T 28164 0 Em 28161 52415 Shading indicates 28161 82237 and 65421 31072 72870 Me aa qd 62707 82221 28159 72828 28171 100 2 TML 4000 TML 4000N PartNo 116471 September2008 Section 100 Decals REV A Item Part No ON Oo wm DR gt 12 13 14 97306 97307 116028 116029 97308 97309 28159 28161 28164 28171 31072 52475 62707 65408 65409 65411 65412 65414 65421 65423 Description Qty Decal Kit Safety Instructional TML 4000N Deutz F3M 1008 includes items 1 15 18 22 24 29 32 35 36 38 46 and 48 Decal Kit Safety Instructional TML 4000 Deutz F3M 1008 Includes items 1 15 18 22 24 29 32 36 38 46 and 48 Decal Kit Safety Instructional TML 4000N Lombardini LDW 1003 L include
4. 400 4 TML 4000 TML 4000N Part No 116471 September2008 Section 400 Mast Components SSS A REVA FIGURE 402 1 Item PartNo Description Qty Item Part No Description Qty 1 85273 TML4000 Number 1 Mast Tube 23 64154 Carriage Bolt Assembly with 60818 1 3 8 16 x 1 inch GR 5 80117 TML4000N Number 1 Mast Tube Assembly with Decals 24 48075 Mast Rotate Handle Spring 2 2 7339 Screw HHC 25 69708 Mast Rotate Handle 1 1 4 20 x 0 5 inch GR 5 26 6019 Screw HHC 3 6356 Lock Washer 1 4 inch ROT inches GRS LE 4 80641 WearPad 1 88x1x0 34inch 5 27 11978 Nvlon Flat Washer 2 inch 5 80640 Weld Nut 1 4 20 1 inch Winen mousing refer to Figure 8 H 2 SIG Mast Cable Pulley 29 Ref Winch Reinforcement Plate 7 85260 Sequencing Cable Assembly refer to Figure 8 H 1 8 69680 Clevis Pin 0 63 x 1 5 inches 1 30 5224 Screw HHC 3 8 16 x 2 inch R 9 6094 Cotter Pin 0 125 x 1 inch 2 EE 10 13918 Screw HHC 31 69658 Extension Stop Plate 1 3 8 16 x 1 75 inches GR 8 2 32 69657 Extension Stop Wear Pad 1 11 4828 Nylock Nut 3 8 16 33 61295 Clevis Pin 0 625 x 2 inches 1 12 80118 Tilt Linkage Assembly with 34 8255 Screw HHC Decal 3 8 16 x 0 75 inch GR 5 13 6833 Rubber Cushioned Clamp 35 6021 Lock Washer 3 8 inch 0 5 1 14 60
5. 40 inches 5 80547 Generator Wire Harness 240V AC 6 116037 Battery Cable Assembly Red 1 7 116038 Battery Cable Assembly Black 1 8 85258 Battery Cable Assembly Black 1 A TEREX COMPANY Part No 116471 TML 4000 TML 4000N 200 19 Section 200 Base Components September2008 Figure 210 1 Power Cables Perkins Models Multiple Outlet Option Circuit Multiple Break 2 Outlet TO PO So To Mast Single Outlet Option Engine Starter O 0 Battery TIS 4 Single Generator Outlet 3 9 Control gt 5 Panel e Ballasts b 6 200 20 A TEREX COMPANY TML 4000 TML 4000N Part No 116471 September2008 Section 200 Base Components El REV A FIGURE210 1 ltem Part No Description Qty 80559 Wire Harness Running Lights D Bar 80560 Wire Harness Assembly Running Lights Right 80561 Wire Harness Assembly Running Lights Left 80191 Wire Harness Assembly Jumper Fuel Cut Off Switch 69797 Wire Harness Ballast 1 80547 Generator Wire Harness 240V 2 80007 Electrical Cord 12 Gauge 4 Conductor sirigis niea andaga 1 3 57430 Wire Harness Assembly 120 AC Mast pp 1 4 97459 Wire Harness Assembly 1 5 85203 Wire Harness Assembly 1 6 69797 Wir
6. A TEREX COMPANY 300 10 TML 4000 TML 4000N PartNo 116471 September2008 Section 300 Engine Components El REV A FIGURE 305 1 Item Part No Description Qty 116508 Perkins 403D 11G Engine Complete 60 HZ Ref PCB Glow Plug shutdown refer to Figure 8 F 85155 Hand Primer 84860 Valve Cover Breather 1 58291 Radiator tie 1 2 97476 Fangsten 1 3 97407 Air Filter Assembly en 1 97474 Element 4 97426 Flywheel Housing 1 5 97425 Flywheel Assembly 1 97472 Gear Ring 6 85103 Starter Motor 1 7 85122 Starter Motor Solenoid 1 8 97430 Exhaust Manifold 1 101326 Exhaust Studs 101327 Exhaust Nuts 9 85143 Exhaust Manifold Gasket 1 10 97473 Water Temperature Switch d 11 85071 Voe Belt PAs 1 12 101322 Water Pump 1 97483 Water Pump Gasket 13 101319 Fan Pulley ce 1 14 72343 Exhaust Flange Gasket 1 15 58292 Lower Radiator Hose 1 16 85089 Alternator 12V DC 15 Amp 17 97428 Upper Radiator Hose 1 A TEREX COMPANY PartNo 116471 TML 4000 TML 4000N 300 11 September2008 Section 300 Engine Components Figure 306 1 REV A Perkins 403D 11G Engine View 2 a QNIC TML 4000 TML 4000N G PartNo 116471 300 12 Septembe
7. PartNo 116471 TML 4000 TML 4000N 400 18 September2008 Section 400 Mast Components IE REV A FIGURE 408 1 ltem Part No Description Qty 1 85260 Sequencing Cable Assembly 2 80281 Winch Cable Assembly Mast Extension pe 1 3 28487 Screw BHHS 3 8 16 x 1 inch 4 5397 Flat Washer 5 16 inch 5 4828 Nylock Nut 3 8 16 Genie A TEREX COMPANY PartNo 116471 TML 4000 TML 4000N 400 19 Section 400 Mast Components September2008 EEN This page intentionally left blank 400 20 TML 4000 TML 4000N Part No 116471 Genie North America Phone 425 881 1800 Toll Free USAand Canada 800 536 1800 Fax 425 883 3475 Genie Australia Pty Ltd Phone 61 7 3375 1660 Fax 61 7 3375 1002 California Proposition 65 Warning The exhaust from this product contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm Towing Checklist Use at each stop Before Towing Boom hold down latch is securely locked in place Towing hitch is properly secured to tow vehicle Safety chains if required are properly attached and secure chains are crossed below hitch All lights are connected and working Tires are properly inflated Before Driving Fasten safety restraints Properly adjust mirrors On The Road Do not exceed 60 mph 97 km h Obey all local and national towing speed laws Check connections and tire pressure
8. 1 6 116012 Cable Assembly 1 7 116009 Lamp Support pp 1 8 116010 Glass beris tees 1 9 116008 Light Fixture Lens Gasket 1 10 116011 Lamp Socket nane 1 11 80101 Lamp 1000MH BH37 1 12 58493 Lamp Support Hardware Kit LL 1 Genie A TEREX COMPANY PartNo 116471 TML 4000 TML 4000N 400 13 Section 400 e Mast Components September 2008 Figure 406 2 Light Housing Assembly Eagle Lighting REV A 5 e 2 ODE OG TEREX COMPANY 400 14 TML 4000 TML 4000N PartNo 116471 September2008 Section 400 Mast Components SSS SSS REV A FIGURE 406 2 Item Part No Description Qty 161090 Light Fixture 1 116054 Top Frame Housing Base 1 2 116049 Gasket Rectangular Glass Lens ees 1 3 116048 Glass Lens Rectangular 1 4 116051 Retainer Clip Glass Lens 8 116052 Retainer Clip Glass Lens Go PEN NAK A iia 8 5 80101 Lamp 1000 Wati Metal Halide 1 6 116047 Reflector Lamp Side 1 7 116045 Reflector Base 1 8 116046 Reflector Side 1 9 116057 Light Socket 1 10 116056 Gasket Light Socket 1 11 116044 Bracket Socket Mount 1 12 116059 Fiberglass Pad Rectangular Lamp Fixture cce 1
9. 1 5 35 mm 8 30490 Fuel Hose 1 4 inch 35 61110 Screw SHC 17 inch option M10 1 5 x 30 mm GR 8 8 9 80391 U Bolt 5 16 18 x 2 inches 2 36 85014 Starter 12V DC 45A Les 1 10 18503 Flange Nut 5 16 18 37 29560 Fuel Water Separator 1 11 22586 Screw HHC 38 69826 Fuel Filter 1 M8 1 25 x 20 mm GR 8 8 39 35418 Hose 3 16 inch 1 12 49408 Lock Washer M8 110002 Plug M14 x 1 5 13 6688 Flat Washer 1 4 inch TML 4000 40 6019 Screw HHC 14 80567 Exh t t Bracket 1 9 Xhaus Support Bracke 9 8 16 1 25 inches GR 5 1 7 Fuel Filter Mount Bracket 1 8097 9 SS PERESA RERS 41 5397 Flat Washer 5 16 inch 16 80093 Exhaust rt Plate 1 Mag Support Plate 42 4828 Nylock Nut 3 8 16 17 80360 Exhaust Pipe 1 PURUS DUE 43 85016 Fuel Solenoid Valve 1 18 27585 Screw HHC M12 1 75 x 20 mm GR 8 8 2 44 110003 Plug M6 x 1 0 TML 4000 19 49409 Lock Washer M12 30490 Hose Fuel 1 4 inch 20 80131 Exhaust Support Bracket 1 45 104675 Fuel Strainer Mounting Plate 1 21 23057 Screw HHC M8 x 1 25 x 20 mm GR 8 8 A TEREX COMPANY PartNo 116471 TML 4000 TML 4000N 300 7 REV A September2008 Lombardini Engine with Marathon Generator Section 300 Engine Components Figure 304 1 mm 0 6 A Q 3
10. Genie A TEREX COMPANY Parts Manual Serial Number Range TML 4000 from TMLO1 226 TML 4000N from TMLO1 226 First Edition First Printing Part No 116471 September 2008 September 2008 Introduction Important Read understand and obey the safety rules and operating instructions in the appropriate Operator s Manual on your machine before attempting any maintenance procedure Basic mechanical hydraulic and electrical skills are required to perform most procedures However several procedures require specialized skills tools lifting equipment and a suitable workshop In these instances we strongly recommend that maintenance and repair be performed at an authorized Genie dealer service center Technical Publications Genie Industries has endeavored to deliver the highest degree of accuracy possible However continuous improvement of our products is a Genie policy Therefore product specifications are subject to change without notice Readers are encouraged to notify Genie of errors and send in suggestions for improvement All communications will be carefully considered for future printings of this and all other manuals Contact Us www genieindustries com e mail techsup genieind com A TEREX CON li TML 4000 e TML 4000N MPANY Serial Number Information Genie Industries offers the following manuals for these models Title Part No Genie TML 4000N Operator s Manua
11. 13 116053 Gasket Housing Base Top Frame 1 14 116042 Fixture Housing Base 1KW Rectangular ene 1 15 116043 Clevis Pin 4 6 X 60 mm 2 16 116113 Cord 16 3 STW 60 1 17 116109 Grommet Assembly 2 18 116058 Lamp Clip PSI Rectangular le n WE 2 19 116061 Spring Lamp Retainer 2 Genie A TEREX COMPANY PartNo 116471 TML 4000 TML 4000N 400 15 September2008 Section 400 Mast Components REV A 407 1 Figure Power Cable Routing CoA 0 PartNo 116471 TML 4000 TML 4000N 400 16 September2008 Section 400 Mast Components REV A ltem Part No 1 47601 2 57430 57582 85382 3 28443 4 28443 Description Qty Wire Loom 3 8 inch 6 inches Mast Harness 120V AC Electrical Cord 16 Gauge eee 378 inches Connector Kit Cable Tie 11 5 inches Cable Tie 11 5 inches Part No 116471 FIGURE 407 1 A TEREX COMPANY TML 4000 TML 4000N 400 17 September2008 Mast Components Section 400 F REV A 1 igure 408 Mast Extension Cable Routing Mast 1 Mast 2
12. 9 9 2 d je F 4 PartNo 116471 enie dr G TML 4000 TML 4000N 300 8 September2008 Section 300 Engine Components El REV A FIGURE 304 1 ltem Part No Description Qty 85206 Marathon Generator Complete includes items 1 6 1 78196 Screw PHPH 8 32 x 0 625 inch 2 85209 Connection Box Cover 1 3 18605 Nylock Nut 8 32 4 21618 Capacitor Clamp 2 5 85207 Capacitor 45MF 450V AC 60 HZ pe 1 116183 Capacitor 25MF 500V AC used on all Marathon models 201CSA 85208 Connection Box 1 Y 14033 Screw HHC 3 8 16 x 2 75 inches GR 5 8 5397 Flat Washer 5 16 inch 9 4828 Nylock Nut 3 8 16 10 80601 Vibration Isolator 2 11 80572 Rear Engine Mount Bracket Right Side 1 12 80573 Rear Engine Mount Bracket Left Side tet 1 13 27585 Screw HHC M12 x 1 75 x 20 mm 14 740925 Vibration Isolator Large 2 15 85093 Screw SHC M12 x 1 75 x 25 mm GR 12 9 2 16 67722 Flat Washer M12 17 80330 Front Engine Mount Bracket 18 6024 Nylock Nut 5 8 11 19 6035 Flat Washer 5 8 inch 20 59746 Screw HHC 5 8 11 x 4 inches GR 5 A TEREX COMPANY PartNo 116471 TML 4000 TML 4000N 300 9 Section 300 Engine Components September 2008 Figure 305 1 Perkins 403D 11G Engine View 1 REV A
13. authorized Genie Distributor in your area 8 8 ER Use the Service Parts Fax Order Form on the next page and fax your order to our Parts Department If you don t know the name of your authorized distributor or if your area is not currently serviced by an authorized distributor please call Genie Industries Machine Information Model Serial Number Date of Purchase Authorized Genie Distributor Phone Number A TEREX CON Xii TML 4000 e TML 4000N Genie North America Telephone 425 556 6551 Toll Free 877 367 5606 in U S A and Canada Fax 425 556 8659 Genie UK Parts Telephone 44 0 1476 584352 Parts Fax 44 0 1476 584340 Genie Australia Parts Telephone 617 03375 1660 Parts Fax 617 03375 1002 Genie France Parts Telephone 33 0 237 26 09 99 Parts Fax 33 0 237 31 50 10 Genie Germany Parts Telephone 49 0 4202 885223 Parts Fax 49 0 4202 885225 Genie Scandinavia Parts Telephone 46 31 3409612 Parts Fax 46 31 3409613 Genie Iberica Parts Telephone 34 93 5795042 Genie Brazil Parts Telephone 55 114 1665755 Parts Fax 55 114 1665754 Genie Japan Parts Telephone 81 33 4536082 Parts Fax 81 33 4536083 Genie China Parts Telephone 86 215 3852570 Parts Fax 86 215 3852569 Part No 116471 remove this page and make copies remove this page and make copies Service Parts Fax Order Form A 6 Fax to 425 556 8659 or T
14. 0 625 inch GR 5 16 6198 Nylock Nut 1 2 13 17 80323 Strut Guide Spacer 2 18 6095 Flat Washer 1 2 inch 19 13854 Screw HHC 1 2 13 x 4 5 inches GR 8 4 20 33373 Flat Washer 0 89 x 1 5 x 0 09 inch 21 80203 Outrigger Pivot Bushing 2 22 38028 Low Profile Nylock Nut 5 8 11 23 42191 Hardened Flat Washer 0 64 x 1 16 x 0 09 inch 2 24 51131 Screw HHC 5 8 11 x 2 5 inches GR 5 25 5224 Screw HHC 3 8 16 x 2 inches GR 5 26 6097 Flat Washer 3 8 inch 27 46017 Jam Nut 3 8 16 Genie FIGURE 202 1 Description Qty Outrigger Screw Jack Knob 2 Outrigger Screw Jack Handle Kit includes items 5 30 32 and 201 2 Jam Nut 1 2 13 GR 2 Outrigger Screw Jack Handle Spacek iude ens 2 Jam Nut 14 20 2 Screw HHC 1 4 20 x 1 25 inches GR 5 Pull Pin Kit ee innnan 1 Pull Pin Pull Pin Compression Spring 0 66 x 1 38 inches Flat Washer 1 2 inch Cotter Pin 1 16 x 1 inch ATEREX COMPANY Part No 116471 TML 4000 TML 4000N 200 5 Section 200 Base Components September2008 Figure 203 1 Control Box and Electrical Components REV A 200 6 TML 4000 TML 4000N Part No 116471 September2008 Section 200 Base Components Eee REV A FIGURE 203 1 Item Part No Description Qty Item Part No
15. 19 x 0 375 inch 16 11 80441 Light Mount Standoff TML 4000 pp 12 12 112290 Light Assembly refer to Figure 10 F 2 13 80409 Light Bracket Vertical Adjustment 4 14 8255 Screw HHC 3 g 16 x 0 75 inch GR 5 15 6021 Lock Washer 3 8 inch 16 80411 Light Bracket Horizontal Adjustment 4 17 6002 Low Profile Nylock Nut 5 16 18 18 11978 Nylon Flat Washer 1 2 inch 19 80466 Light Mount Bracket Spacer 0 5 x 0 75 x 5 06 inches 4 20 69766 Plastic Spacer 0 56 x 3 inches 4 21 80448 Screw HHC 5 16 18 x 6 5 inches GR 5 22 13005 Screw HHC 1 2 13 x 6 inches GR 8 2 23 48075 Compression Spring 8 Genie A TEREX COMPANY PartNo 116471 TML 4000 TML 4000N 400 11 Section 400 e Mast Components September 2008 Figure 406 1 Light Housing Assembly Spero Electric REV A A TEREX COMPANY 400 12 TML 4000 TML 4000N Part No 116471 September2008 Section 400 Mast Components IE REV A FIGURE 406 1 ltem Part No Description Qty 112290 Light Fixture 1 112282 Yoke Light Fixture 1 2 116019 Junction BOX 1 3 116017 Gasket Junction Box 1 4 116018 Cover Junction Box 1 5 116014 Cordset TML 4000 1 116013 Cordset TML 4000N
16. 4000N 37 5397 Flat Washer 5 16 inch 116024 Tire ST 205 75D15 TML 4000N 38 4828 Nylock Nut 3 s 16 21 46717 Acorn Nut 1 2 20 et 10 Genie ATEREX COMPANY Part No 116471 TML 4000 TML 4000N 200 3 Section 200 Base Components September2008 Figure 202 1 Outrigger Components o 60605 OO A pa 200 4 REVA 69 D A TEREX COMPANY TML 4000 TML 4000N Part No 116471 September2008 Section 200 Base Components REV A Item Part No Description Qty ltem Part No 1 57331 Outrigger Screw Jack 2 28 80130 2 69818 Outrigger Tank Side 1 29 80232 69809 Outrigger Engine Side 3 69815 Sleeve Spacer 0 63 x 0 75 x 0 5 inch 2 30 6034 4 69814 Torsion Spring 0 88 x 0 5 inch 2 31 80231 5 69813 Outrigger Strut Guide Bushing 2 6 69800 Outrigger Handle occ p 92 698 9 7 32499 Retainer Clip 0 88 inch 2 SS SST E 80003 Outrigger Strut 2 34 80127 9 80000 Outrigger Strut Guide 2 80128 10 69649 Compression Spring 7 BIES 0 953 x 4 38 inches 2 13066 11 69990 Outrigger Pin Bracket 2 2161 12 69667 Lock Pin 2 13 22547 Roll Pin 3 16 x 1 25 inches 14 6091 Nylock Nut 1 4 20 15 8914 Screw HHC 1 4 20 x
17. Description Qty 1 6888 Screw HHC 24 69719 Capacitor Mount Bracket 4 RE PEOR OR 25 69798 Ballast and Capacitor 2 6356 Lock Washer 1 4 inch Assembly 120 240V AC 60 Hz ija includes item 22 4 a Ko mat Waster Jen 80350 Ballast and Capacitor 4 25969 Spring Clip 1 4 20 Assembly 120 240V AC 50 Hz 5 6019 Screw HHC includes item 22 3 8 16 x 1 25 inches GR 5 26 80694 Ballast Mount Panel 1 6 4828 Nylock Nut 3 8 16 27 69773 Weather stripping Alai A 7 66717 Fuse Holder 1 10 inches 8 pere Screw FHSM EE m 15 inches 10 32 x 1 inch GR 2 il 29 69773 Weather stripping 3 14992 Low Profile Nylock Nut 10 32 3 8 INCR A 28 inches 10 36372 Fuse 50A Very Fast Acting 1 11 6002 Low Profile Nylock Nut 5 16 18 12 Ref Control Box refer to Figure 8 F 1 8 F 2 or 8 F 3 13 69983 Front Cover TML 4000 2 87797 Front Cover TML 4000N 14 6090 Screw HHC 1 4 20 x 0 75 inch GR 5 15 6091 Nylock Nut 4 20 16 8914 Screw HHC 1 4 20 x 0 625 inch GR 5 17 46716 Rubber Bumper 2 18 10107 Screw HHC 5 16 18 0 75 inch GR 5 19 33277 Flat Washer M8 20 6271 Steel Rivet 4 x 0 25 inch 21 80544 Rubber Cushioned Clamp 1 75 x 0 25 inch LL 4 22 69884 Capacitor 480V AC 60 Hz 4 85201 Capacitor 540V AC 50 Hz 23 4512 Nylon Spacer 0 25 x 0 69 x 0 25 inch A
18. Genie Industries offers the following support documents for these models Title Part No Genie TML 4000 and TML 4000N Description Part No Operator s Manual Third Edition Perkins 403D 11G Models after serial number TMLO4 559 97600 Dielectric Grease 66399 Oil GE cicdcidae 94762 Manual of Responsibilities ANSI A92 3 31587 97474 Fuel Filtet siii aaa i 62421 BE o1 e h AE E EE EEE E 85071 Valve Cover Breather pp 84860 Lombardini Models Dielectric Grease 66399 All aaa ee sena canina 80053 Recommended Parts Description Part No Genie Gray Paint 12 Ounce 355 ml Aerosol 1268 Genie Blue Paint 12 Ounce 355 ml Aerosol 1484 Genie Blue Paint 1 Gallon 3 78 liters 32150 Genie Gray Paint 1 Gallon 3 78 liters 32151 Genie A TEREX COMI X TML 4000 TML 4000N Part No 116471 September 2008 p Ma aaa maan This page intentionally left blank ATEREX COMPANY Part No 116471 TML 4000 TML 4000N Ki September 2008 How To Order Parts Please be prepared with the following information when ordering replacement parts for your Genie product Machine model number Machine serial number Genie part number Part description and quantity Purchase order number Ship to address Desired method of shipment Name and telephone number of the
19. Mast Tube Assembly includes items 11 13 1 15 Ref Number 1 Mast Tube Assembly refer to Figure 10 B 1 16 85277 Number 2 Mast Tube Assembly 17 22832 Screw HHC 3 8 16 x 6 inches GR 5 18 4828 Nylock Nut 3 8 16 A TEREX COMPANY PartNo 116471 TML 4000 TML 4000N 400 9 Section 400 e Mast Components September 2008 Figure 405 1 Lightbar Installation 0 099 REVA 400 10 TML 4000 TML 4000N Part No 116471 September2008 Section 400 Mast Components Na aaa REVA FIGURE 405 1 Item Part No Description Qty ltem Part No Description Qty 1 57451 Squeeze Connector 24 69207 Light Rotation Lock Plate 8 1 2 inch 1 25 59972 Clevis Pin 0 313 x 0 75 inch 8 2 57535 TEDON iii p 1 57581 Cover T box 26 80336 Cotter Pin 0 313 x 0 047 inch i 1 2 3 33576 Squeeze Connector 27 6086 Low Profile Nylock Nut 1 2 13 1 2 inch NPT asarana ndanani gana 4 28 6034 Jam Nut 1 2 13 GR 2 4 57582 Electrical Cord 16 Gauge 29 6097 Flat Washer 3 8 inch 7 conductor 44 inches after TML 06 000708 5 57582 Electrical Cord 16 Gauge 7 conductor 684 inches 6 80475 Male Connector eee 4 7 85278 Light Cable Assembly 4 8 80478 Receptacle Cap Assembly 4 9 80445 Draw Latch Spring Loaded TML 4000 pp 8 10 33776 Steel Rivet 0
20. at each stop Slow down for hazardous conditions Allow extra distance for following and passing other vehicles Genie China Phone 86 21 53852570 Fax 86 21 53852569 Genie Scandinavia Phone 46 31 575100 Fax 46 31 579020 Genie Malaysia Phone 65 98 480 775 Fax 65 67 533 544 Genie France Phone 33 0 2 37 26 09 99 Fax 33 0 2 37 26 09 98 Genie Japan Phone 81 3 3453 6082 Fax 81 3 3453 6083 Genie Korea Phone 82 25 587 267 Fax 82 25 583 910 Genie Iberica Phone 34 93 579 5042 Fax 34 93 579 5059 Genie Gerfnany Phone 49 0 4202 88520 Fax 49 0 4202 8852 20 Genie Brasil Phone 55 11 41 665 755 Fax 55 11 41 665 754 Genie U K Phone 44 0 1476 584333 Fax 44 0 1476 584334 Genie Holland Phone 31 183 581 102 Fax 31 183 581 566 Genie Mexico City Phone 52 55 5666 5242 Fax 52 55 5666 3241
21. 0 Rev gt gt gt gt gt gt Rev gt gt lt gt lt gt gt lt gt gt gt gt Engine Components Figure 301 1 Figure 302 1 Figure 303 1 Figure 304 1 Figure 305 1 Figure 306 1 Lombardini Engine View 1 300 2 Lombardini Engine View 2 300 4 Lombardini Engine View 3 900 6 Lombardini Engine with Marathon Generator 300 8 Perkins 403D 11G Engine View 1 300 10 Perkins 403D 11G Engine View 2 300 12 Mast Components Figure 401 1 Figure 402 1 Figure 403 1 Figure 404 1 Figure 405 1 Figure 406 1 Figure 406 2 Figure 407 1 Figure 408 1 Mast Components View 400 2 Mast Components View 2 400 4 Mast Components View 3 400 6 Mast Components View 4 400 8 Lightbar Installation nn 400 10 Light Housing Assembly Spero Electrical 400 12 Light Housing Assembly Eagle Lighting 400 14 Power Cable Routing pp 400 16 Mast Extension Cable Routing pp 400 18 Genie vili TEREX COMPANY TML 4000 e TML 4000N Part No 116471 September 2008 EEN TABLE OF CONTENTS This page intentionally left blank A TEREX COMPANY Part No 116471 TML 4000 e TML 4000N September 2008 Parts Stocking List Required Parts The following parts are required to perform maintenance procedures as outlined in the Genie TML 4000 and TML 4000N Parts and Service Manual Manuals
22. 0 1 5 x 70 mm GR 8 8 Flat Washer M10 Nut M10 Timing Belt rt 1 Intake Manifold Gasket 1 Intake Manifold 1 Timing Belt Cover 1 TML 4000 TML 4000N 300 3 Section 300 Engine Components September 2008 Figure 302 1 Lombardini Engine View 2 REV A o OG OG E OG 8 BEE EEN AA butt x TX o Si N 7 d g 2 b 4 j 7 i 3 Y s 3 D Lei i N D bi i 2 IN i LE l 4 N po i i I 77 Bi g fi LA 25 29 ES 4 7 LA x 1 i i 1 i i i i i d Y y E y i B 2 N C7 VE E kal PA 300 4 TML 4000 TML 4000N Part No 116471 September2008 Section 300 Engine Components REV A FIGURE 302 1 Item Part No Description Qty Item Part No Description Qty 30490 Fuel Hose 1 4 inch 29 85062 Radiator Mount Spacer 1 2 44909 Hose Clamp 0 25 inch 4 30 85026 Radiator Mount Bracket Side 2 3 69734 Fuel Shutoff Valve 1 31 85100 Screw SHC 4 85066 Lifting Lug 1 MIEL Sod GR TE ue 5 55098 Screw HHC 32 49409 Lock Washer M12 M8 x 1 25 x 80 mm GR 8 8 33 85027 Radiator Shroud 1 6 49408 Lock Washer M8 34 69829 Radiator mee 1 7 85096 Screw SHC 35 85029 Radiator Isola
23. 5 16 12012 Nylock Nut 3 8 16 L 1 17 16342 Winch Handle 11 inches 1 18 6086 Low Profile Nylock Nut 1 2 13 19 6034 Jam Nut 1 2 13 GR 2 20 14189 Pinion Plate aeng arakan 1 A TEREX COMPANY Part No 116471 TML 4000 TML 4000N 200 17 Section 200 Base Components September2008 Figure 209 1 Power Cables Lombardini and Deutz Models Kg A To Mast 2 Multiple Outlet Option ONE po CLE Circuit Multiple Break 4 Outlet en 0 Single Outlet Option Single Outlet Box Engine Generator Ballasts Battery 7 O 8 200 18 TEREX COMPANY TML 4000 TML 4000N Part No 116471 September2008 Section 200 Base Components SSS SS Se REV A FIGURE 209 1 Item Part No Description Qty 104807 Wire Harness Assembly Ignition 80559 Wire Harness Running Lights D Bar 80560 Wire Harness Assembly Running Lights Right 80561 Wire Harness Assembly Running Lights Left 80191 Wire Harness Assembly Jumper Fuel Cut Off Switch 69797 Wire Harness Ballast 1 104963 Wire Harness Assembly Lombardini or Deutz Starter 0806 1 2 104964 Wire Harness Assembly Lombardini 1 3 57430 Wire Harness Assembly 120 AC Mast pe 1 4 43956 Electrical Cord 14 Gauge 3 Conductor
24. 90 Screw HHC 1 4 20 x 0 75 inch GR 5 15 6091 Nylock Nut 1 4 20 16 6145 Screw HHC 1 4 20 x 1 5 inches GR 5 17 5397 Flat Washer 5 16 inch 18 40735 Aluminum Spacer 1 4 x 0 375 x 0 875 inch 1 19 6889 Low Profile Nylock Nut 1 4 20 20 23394 Control Cable Pulley 1 21 80324 Pulley Guard Control Cable 1 22 97321 Tilt Linkage Guide Bracket Assembly with Decal Genie A TEREX COMPANY PartNo 116471 TML 4000 TML 4000N 400 5 Section 400 e Mast Components September 2008 Figure 403 1 Mast Components View 3 OO e 97 0 REV A e OO 400 6 TML 4000 TML 4000N Part No 116471 September2008 Section 400 Mast Components a Na aaa aaa aaa aa aaa REVA FIGURE 403 1 ltem Part No Description Qty 1 85277 Number 2 Mast Tube Assembly 2 6094 Cotter Pin 0 125 x 1 inch 3 43391 Clevis Pin 0 5 x 9 75 inches 1 4 6888 Screw HHC 1 4 20 x 1 inch GR 5 5 6638 Flat Washer 4 inch 6 6091 Nylock Nut 4 20 7 69699 Actuator Stop Guide Pad 2 8 69664 Pulley Mount Bracket 1 9 25926 Flat Washer M6 10 23394 Control Cable Pulley 11 40735 Aluminum Spacer 1 4 x 0 375 x 0 875 inch 1 12 6145 Screw HHC 1 4 20 x 1 5 inches GR 5 13 5397 Flat Washer 5 16 inch 14 69638 Control Cable Pulley Sp
25. L 4000N 0 953 x 4 38 inches 1 3 69738 Hinge Tank Side WE NE ME o oii S 29 8516 Screw HHC 4 72 IR 1 37 i 65 Steel Rivet 1 4 x 0 375 inch 3 8 16 x 1 5 inches GR 5 5 80111 Controls Box Cover Assembly with Decals 1 30 80368 Side Marker Light Red 2 6 69735 Controls Cover Hinge 4 91 80371 Taillight Kit includes retaining ring and wire connector 2 7 85267 Main Cover Assembly with Decals Controls Side 32 57398 License Plate Light 1 TML 4000 nete 1 33 6606 Screw RHSM 80109 Main Cover with Decals 10 32 x 0 75 inch Controls Side TML 4000N 34 6607 Lock Washer 10 8 57416 Hinge Controls Side 1 35 80366 Nylon Clip 15 x 13 mm 9 69754 Eye Bolt 5 16 18 x 1 inch 5 36 69648 Mast Hold down Lock 1 10 6638 Flat Washer 4 inch 37 5365 Nylock Nut 10 24 11 69824 Compression Spring 38 6146 Flat Washer 10 0 38 Xx 0 5 Inch oes 5 12 6002 Low Profile Nylock Nut 5 16 18 39 29752 Screw HHC 10 24 x 0 75 inch 13 40267 Manual Storage Container with 40 116002 Light Storage Tray 1 0 2223 gt cue i um i 41 116001 Light Storage Bracket 1 14 6888 Screw HHC 42 116000 Light Storage Bracket 1 1 4 20 x 1 inch GR 5 43 6888 Screw HHC 15 6356 Lock Wash
26. TEREX COMPANY Part No 116471 TML 4000 TML 4000N 200 7 Section 200 Base Components September2008 Figure 204 1 Winch installation REV A A TEREX COMPANY 200 8 TML 4000 TML 4000N Part No 116471 September2008 Section 200 Base Components Eee REV A FIGURE204 1 ltem Part No Description Qty 104189 Winch Bracket 1 6019 Screw HHC 3 8 16 x 1 25 inches GR 5 2 5397 Flat Washer 5 16 inch 3 4828 Nylock Nut 3 8 16 4 6888 Screw HHC 1 4 20 x 1 inch GR 5 5 6638 Flat Washer 1 4 inch 6 6091 Nylock Nut 1 4 20 7 69736 Crank Handle Guide 1 8 69981 Crank Handle Extension TML 4000 socio dada 1 57408 Crank Handle Extension TML 4000N 9 6086 Low Profile Nylock Nut 1 2 13 10 16342 Winch Handle 11 69673 Mast Lock Bar 1 12 69654 Mast Lock Handle 1 13 69638 Compression Spring 0 75 x 8 0068 saanane aaa 1 14 6094 Cotter Pin s x 1 inch 15 57316 Mast Cable Pulley 1 16 8516 Screw HHC 3 g 16 x 1 5 inches GR 5 17 69680 Clevis Pin 5 s x 1 5 inches 18 15657 Winch Reinforcement Plate 1 19 6034 Jam Nut 1 2 13 GR 2 20 80107 Mast Pivot Cable Assembly 1 21 14085 Winch A TEREX COMPANY Part No 116471 TML 4000 TML 4000N 200 9 Section 200 Base Components September2008 Figure 205 1 Fuel Tank Battery and E
27. ae OTENE 1 22 6935 Locknut 2 inch A TEREX COMPANY Part No 116471 TML 4000 TML 4000N 200 25 Section 200 Base Components September2008 EEN This page intentionally left blank 200 26 TML 4000 TML 4000N PartNo 116471 September2008 Section 300 Engine Components Section 300 Engine Components A TEREX COMPANY PartNo 116471 TML 4000 TML 4000N 300 1 Section 300 Engine Components September 2008 Figure 301 1 Lombardini Engine View 1 O Dos GG REV A 300 2 TML 4000 TML 4000N Part No 116471 September2008 Section 300 Engine Components REV A Item Part No w 0 N O 0 E 10 11 12 13 14 15 16 17 18 19 20 21 85008 116020 97496 28853 29560 67325 80584 80054 80124 85047 80285 85057 75417 85007 85000 58496 58497 85049 97478 85002 80278 85003 85004 85005 85067 80053 80121 85046 85058 85050 Description Qty Glow Plug Lombardini LDW 1003 L Engine Complete Cold Start Accessory Kit includes item 27 Battery Blanket Fuel Water Separator Heavy Duty Battery Wire Harness Assembly Jumper Air Cleaner Housing 1 Air Cleaner Element 1 Screw SHC M8 1 25 x 65 mm GR 12 9 6 Fuel Pump Hex Nut M8 Flat Washer M8 O ring Fuel Pump 1 Oil Filler C
28. ap screw in 1 Oil Filler Cap thread in 1 O Ring for 58496 1 Screw SHC M6 1 20 mm GR 12 9 12 Engine Oil Dipstick Rubber Cover Oil Pressure Switch 1 Oil Pressure Switch 1 Rubber Seal Oil Pressure SWITCH Lisa etat Seded AC 1 Valve Cover includes item 8 1 Valve Cover Gasket 1 Oil Filter Threaded Nipple 1 Oil Filter ees 1 Exhaust Manifold Stud M8 x 1 25 x 45 mm 6 Exhaust Manifold Gasket 6 Nut M8 Exhaust Manifold 1 G Part No 116471 A TEREX CO Item Part No 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 MPANY 85200 97480 85215 85051 80279 58311 85216 69775 69774 80010 58052 49407 85009 85010 85011 58295 85053 85054 85055 80283 85012 85056 97481 FIGURE 301 1 Description Qty Thermostat Housing 1 Thermostat O ring Screw SHC M8 1 25 x 30 mm Temperature Sensor 1 Temperature Switch Sealing Ring A orisrpotiessireetiss 1 iii 1 Oil Pan Heater 1 Screw HHC M6 1 x 12 mm GR 8 8 Lock Washer M6 O ring Dip Stick Tube 1 Oil Pan Gasket pp 1 Alternator 12V DC 454A 1 Harness Wire Alternator Screw HHC M1
29. astic Plug enr 1 14 6638 Flat Washer 4 inch 15 6356 Lock Washer 1 4 inch 16 25969 Spring Clip 4 20 17 104776 Engine Tray us 1 18 6175 Screw HHC 3 8 16 x 1 inch GR 5 19 5397 Flat Washer 5 16 inch 20 15086 Fender Washer 3 8 x 1 5 x 0 125 inch 21 80333 Battery Tray shown 1 80035 Battery Tray Heavy Duty Battery 22 6019 Screw HHC 3 8 16 x 1 25 inches GR 5 Genie A TEREX COMPANY Part No 116471 TML 4000 TML 4000N 200 11 Section 200 Base Components September2008 Figure 206 1 Control Box REV A TEREX COMPANY 200 12 TML 4000 TML 4000N Part No 116471 September2008 Section 200 Base Components Eee REV A FIGURE 206 1 ltem Part No Description Qty 104851 Upgrade Kit Shutdown Controller Lombardini includes item 4 61225 Relay 12V DC 61226 Relay 12V DC 81767 Terminal AMP 14 18 GA 81766 Terminal AMP 10 12 GA 104852 Instructions Controller Update 104854 Update Kit Shutdown Controller Perkins includes item 4 104853 Controller Wire Assembly 104852 Instructions Controller Update 1 85305 Ground Control Box Assembly with Decal eies 1 2 80303 Switch Base with Contacts 1 66816 N O Contact 66818 N C Contact 3 18605 Nylock Nut 8 32 4 80562 Glowplug Shutdown Printed Circuit Board Lombardini models Perkins model
30. e 303 1 REV A Lombardini Engine View 3 3 a nie COM TML 4000 TML 4000N PartNo 116471 300 6 September2008 Section 300 Engine Components Eee REV A FIGURE 303 1 Item Part No Description Qty Item Part No Description Qty 97497 Fuel Water Separator 22 22571 Nut M8 Accessory Kit includes items 3 5 7 8 37 and 45 23 32064 Muffler Clamp 1 75 inches 1 80584 Wire Harness Assembly 24 69828 ME 1 Jumper 58306 Guard Plate Heat Shield 27 Fuel H 5 16 aana 16 inch 089 uel Hose 5 16 6 inches 25 49379 Screw HHC 1 85091 Hollow Screw HHC M8 x 1 25 x 25 mm GR 8 8 M10 x 1 5 x 30 mm IA 85094 O ring Hollow Screw 26 69830 Muffler Gasket 2 2 69825 Fuel Filter Assembly 27 80358 includes item 38 1 BORSE NS RIBUS aa ani 2 3 C90200200 Hose End Barbed 1 4 inch 28 80454 Muffler Adapter Plate 1 29 49378 Screw HHC 4 6091 Nylock Nut 11420 1 S VIGOR TUE Ion M8 x 1 25 x 16mm 5 104736 Fuel Strainer 4 NPT 250 micron nen 1 30 44605 Flat Washer M8 0 00eeeeee 1 104737 Fuel Strainer Element 32 80571 Rear Exhaust Pipe Support 1 6 4266 Screw HHC 33 85013 Flywheel 1 14 20 x 2 inches GR 5 34 85059 Screw HHC 7 44909 Hose Clamp 1 4 inch M10
31. e Harness Assembly control panel to ballast 7 116038 Battery Cable Assembly Black 1 8 85258 Battery Cable Assembly Black 1 9 116037 Battery Cable Assembly Red 1 A TEREX COMPANY Part No 116471 TML 4000 TML 4000N 200 21 Section 200 Base Components September2008 Figure 211 1 Single Outlet Packages REV A EG B TEREX COMPANY 200 22 TML 4000 TML 4000N Part No 116471 September2008 Section 200 Base Components Eee REV A FIGURE211 1 ltem Part No Description Qty 1 24018 Circuit Breaker 15A includes mounting fasteners 1 2 21858 Plastic Plug 0 38 inch 1 3 69996 T box Mount Bracket 1 4 6091 Nylock Nut 1 4 20 5 42492 Plastic Plug 1 032 inches 1 6 10775 A RE RUE 1 7 45437 GFCI Weatherproof Cover includes gasket and item 8 1 8 49820 Screw PHPM 6 32 0 5 inch GR 2 9 69626 Screw RHSM 6 32 x 0 625 inch 10 13585 GFCI Receptacle 110V AC 1 11 6935 Locknut 2 inch 12 38709 Flat Washer 0 938 x 1 375 x 0 05 inch 13 12456 Nipple 1 2 inch 14 33576 Squeeze Connecter 1 2 inch NP T iuste ica 1 15 87795 Single Gange Outlet Cover models with no receptacle option includes gasket and item 8 ees 1 16 80693 T box Mount Bracket 1 Genie A TEREX COMPANY Part No 116471 TML 4000 TML 4000N 200 23 Sectio
32. er 1 4 inch 1 4 20 x 1 inch GR 5 16 6638 Flat Washer 1 4 inch 44 6638 Flat Washer 1 4 inch 17 6091 Nylock Nut 1 4 20 45 6091 Nylock Nut 1 4 20 18 80369 Side Marker Light Amber 2 19 80370 Side Marker Grommet Kit 4 20 10107 Screw HHC 5 16 18 x 0 75 inch GR 5 21 6019 Screw HHC 3 8 16 x 1 25 inches GR 5 22 5397 Flat Washer 5 16 inch Genie A TEREX COMPANY Part No 116471 TML 4000 TML 4000N 200 15 Section 200 Base Components September2008 Figure 208 1 Winch Components D REVA TEREX COMPANY 200 16 TML 4000 TML 4000N Part No 116471 September2008 Section 200 Base Components Na Se REVA FIGURE 208 1 ltem Part No Description Qty 14085 Winch Frame Assembly does not include item 17 1 6204 BUSNINQ ss etie rin ecce 1 2 14190 Thrust Washer en 1 3 14191 Ratchet Gear L 1 4 5157 Friction DISC eee tte 1 5 14193 Pinion Gear 1 6 14194 Pinion Shaft sarsaran aaa aana 1 7 6200 Retaining Ring 1 8 6199 BUSHING kiri iain 1 9 5156 Ratchet Pawl Kit 2 10 Ref Winch Frame not available separately 11 6190 Cable Keeper Kit 1 12 5320 Frame Spacer 1 13 Ref Cable Drum not available separately 14 5376 Cable Drum Cover 1 15 12981 Screw HHC 3 8 16 x 4 5 inches GR
33. ing if the situation warrants it Be aware of potential crushing hazards sl such as moving parts free swinging or unsecured components when lifting or placing loads Always wear approved steel toed shoes Genie vi TML 4000 TML 4000N Part No 116471 September 2008 Table of Contents Introduction Important Information EE ii How to Read Your Serial Number iii Parts Stocking ES x Flow to Order Xii Service Parts Fax Order Form us Xiii Section 1 Safety Rules General Safety Rules sise V Section 7 Rev Decals B Figure 101 1 Decals ninder sikia 100 2 Section 8 Rev Base Components A Figure 201 1 Axle and Tongue 0 200 2 A Figure 202 1 Outrigger Component pp 200 4 A Figure 203 1 Control Box and Electrical Components 200 6 A Figure 204 1 Winch installation seen nn 200 8 A Figure 205 1 Fuel Tank Battery and Engine Tray Components 200 10 A Figure 206 1 Control Box 200 12 A Figure 207 1 e UC 200 14 A Figure 208 1 Winch Components Na ga a ami 200 16 A Figure 209 1 Power Cables Lombardini Models 200 18 A Figure 210 1 Power Cables Perkins Models pp 200 20 A Figure 211 1 Single Outlet Packages nn 200 22 A Figure 212 1 Duplex Outlet Packages pp 200 24 Genie A TEREX COMPANY Part No 116471 TML 4000 e TML 4000N vii September 2008 TABLE OF CONTENTS Section 9 Section 1
34. l Third Edition 0000 dci 97600 Genie TML 4000N Parts Manual First Edition 24 22 116471 Genie TML 4000N Service Manual First EAHON iia ida 116472 Copyright 2008 by Genie Industries 116471 Rev A September 2008 First Edition First Printing 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 Part No 116471 September 2008 How to Read Your Serial Number Serial Number Legend MANUFACTURED BY FABRIQUE PAR Genie Industries QAI 18340 NE 76th Street Redmond WA 98052 USA MODEL SERIAL XXXXXXXXXX 999999 NUMBER MODEL YEAR 9999 MANUFACTURE 99 99 99 DATE VIN NUMBER MACHINE UNLADEN 99 89911657 99 999 kg WEIGHT RATED GENERATOR OUTPUT Position 41 VOLTS Position 35 AC FREQUENCY Position 42 PHASES Position 43 GS30 05 A 12345 RATED Position 44 CURRENT ELECTRICAL SCHEMATIC Position 3 ETL CERTIFICATION 1 Position 45 Model Sequence ETL CERTIFICATION 2 Position 46 number ec Year of 7 manufacture seg P N 77172 3057837 Serial number stamped on chassis Serial label A TEREX COMPANY Part No 116471 TML 4000 e TML 4000N lii September 2008 EE AAA This page intentionally left blank iv TML 4000 e TML 4000N Part No 116471 Septembe
35. n 200 Base Components September2008 Figure 212 1 Duplex Outlet Packages REV A EE VOODOO 200 24 TML 4000 TML 4000N PartNo 116471 September2008 Section 200 Base Components IE REV A FIGURE 212 1 Item Part No Description Qty 1 80693 T box Mount Bracket 1 2 6091 Nylock Nut 1 4 20 3 6090 Screw HHC 1 4 20 x 0 75 inch GR 5 4 21858 Plastic Plug 0 38 inch 3 5 69996 T box Mount Bracket 1 6 80397 Circuit Breaker Box includes cover and screw pp 1 7 80396 Circuit Breaker 25A 1 8 57451 Squeeze Connector VSINCHINPT isa 2 9 85351 Wire Harness Assembly Outlet to Control Panel 1 10 80543 GFCI Receptacle 120V AC 1 0 dL nM Dt 1 11 45437 GFCI Weatherproof Cover includes gasket and item 12 1 12 49820 Screw PHPM 6 32 x 0 5 inch GR 2 13 80555 Receptacle 120V AC 20A 1 14 80357 GFCI Weatherproof Cover includes gasket and item 12 1 15 80556 Receptacle 240V AC 20A 1 16 57581 J box Cover 2 Gang includes gasket and item 12 1 17 10777 Blank Cover includes gasket and item 12 1 18 57535 Outlet Box 2 Gang 2 19 12456 Nipple 1 2 inch 3 20 38709 Flat Washer 0 938 x 1 375 x 0 05 inch 21 10775 Eoo d
36. ngine Tray Components REV A A TEREX COMPANY 200 10 TML 4000 TML 4000N Part No 116471 September2008 Section 200 Base Components Na Se REVA FIGURE 205 1 Item Part No Description Qty Item Part No Description Qty 85275 Cold Start Accessory 23 4828 Nylock Nut 3 8 16 includes heavy duty battery 31e battery tray and oil pan heater PA SES d 1 4 i 1 57750 Fuel Tank 50 gallons 25 57600 J bolt 1 4 20 x 9 inches 1 4000 sawarsa naen aana aan dan gawea 1 26 56050 Battery 12V DC 450 CCA 1 1 80530 Fuel Tank 30 gallons Bem a jissa Battery 12V DC TML 4000N 22 1 2 891520 Elbow Fitting 27 57414 Battery Hold down 1 1 4 MNPT x 1 4 inch 90 1 28 8170 Wing Nut 4 20 3 116034 Hose End Barbed 3 16 inch 1 29 28853 Battery Blanket 4 44909 Hose Clamp 1 4 inch 6 MOV AC GOMZ aU 1 5 30490 Fuel Hose 1 4 inch 2 13 inches 6 C90200200 Hose End Barbed 1 4 MNPT x 1 4 inch 90 1 7 35418 Hose 3 16 inch 26 25 inches 8 69734 Fuel Shutoff Valve 1 9 101726 Gas Cap Green 1 10 6888 Screw HHC 1 4 20 x 1 inch GR 5 11 6091 Nylock Nut 1 4 20 12 85271 Rear Cover with Decal TML 4000 pp 1 85272 Rear Cover with Decal TML 4000N 13 57587 Pl
37. oll Free 888 274 6192 A TEREX COMPANY International 1 425 556 8659 Please fill out completely Date Account Number Your Name Your Fax Number Your Phone Number Bill To Ship To Purchase Order Number Ship Via Model s Serial No s Optional Equipment All back ordered parts will be shipped when available via the same ship method as the original order unless Noted below O Ship complete order only No back orders H Ship all available parts and contact customer on disposition of back ordered parts O Other please specify Fon GENIE INDUSTRIES USE ONLY Order Number Origin Code Comments Date Scheduled Ship Condition Order Total Terms Code September 2008 A eaaa aaa aaa aaa aaa This page intentionally left blank xvi TML 4000 e TML 4000N Part No 116471 September2008 Section 100 Decals Section 100 Decals A TEREX COMPANY PartNo 116471 TML 4000 TML 4000N 100 1
38. r 2008 Section 1 Safety Rules Safety Rules Danger Failure to obey the instructions and safety rules in this manual and the appropriate Operators Manual on your machine will result in death or serious injury Many of the hazards identified in the operators manual are also safety hazards when maintenance and repair procedures are performed Do Not Perform Maintenance Unless You are trained and qualified to perform maintenance on this machine M You read understand and obey manufacturer s instructions and safety rules employer s safety rules and worksite regulations applicable governmental regulations M You have the appropriate tools lifting equipment and a suitable workshop A TEREX COMPANY Part No 116471 TML 4000 e TML 4000N V Section 1 Safety Rules September 2008 SAFETY RULES Personal Safety Any person working on or around a machine must be aware of all known safety hazards Personal safety and the continued safe operation of the machine should be your top priority Read each procedure thoroughly This manual and the decals on the machine use 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 A DANGER Indicates an imminently hazardous situation which if not avoided will result in death or serious inj
39. r2008 Section 300 Engine Components El REV A FIGURE 306 1 ltem Part No Description Qty 1 84812 Injector 1 Pipe 1 2 84813 Injector 2 Pipe 1 3 84814 Injector 3 Pipe 1 4 97405 Intake Manifold il 5 97429 Gasket Intake Manifold 1 6 97427 Crank Pulley oros 1 7 84811 Fuel Injector 3 8 84815 GOW citer centes 3 9 97460 Fuel Injection Pump 1 10 97404 Shutdown Solenoid 1 11 72348 Fuel Lift Pump 1 12 101321 Oil Pressure Switch 1 13 94762 Oil Eiter 1 14 101320 DIPSUGK qe 1 15 97461 Dipstick Tube 1 16 62421 Fuel Filter one 1 17 94889 Fuel Filter Assembly includes item 16 1 Genie A TEREX COMPANY PartNo 116471 TML 4000 TML 4000N 300 13 Section 300 Engine Components September 2008 i This page intentionally left blank 300 14 TML 4000 TML 4000N Part No 116471 September2008 Section 400 Mast Components Section 400 Miast Components A TEREX COMPANY Part No 116471 TML 4000 TML 4000N 400 1 September2008 Section 400 Mast Components REV A Figure 401 1 Mast Components View 1 D
40. rial Number Label Caution Latch Release FIGURE 101 1 Part No 116471 A TEREX COMPANY TML 4000 TML 4000N 100 5 Section 100 Decals September2008 a aaa aaa aaa This page intentionally left blank 100 6 TML 4000 TML 4000N Part No 116471 September2008 Section 200 Base Components Section 200 Base Components A TEREX COMPANY Part No 116471 TML 4000 TML 4000N 200 1 Section 200 Base Components September2008 Figure 201 1 Axle and Tongue Components REV A 8 K TEREX COMPANY 200 2 TML 4000 TML 4000N Part No 116471 September2008 Section 200 Base Components Na aaa aaa aaa aan REVA FIGURE 201 1 Item Part No Description Qty ltem Part No Description Qty 1 25969 Spring Clip 1 4 20 22 57572 Axle Mount Plate TML 4000 2 2 80370 Side Marker Gromm t 57551 Axle Mount Plate TML 4000N 23 57571 Flange Nut 1 2 20 TML 4000 8 3 46716 Rubber Bumper 10 57550 Flange Nut 3 8 24 TML 4000N 4 80368 side Marker Light 24 57568 Axle 3500 Ibs Capacity 5 39560 Cable Tie Mount 01 5 TML 4000 Lee 1 6 80417 Suspension Mount Bolt 7 GN e Capacity 7 16 20 x 2 5 INCHES srrrvrrnvennnnn 6 25 57567 Double Eye Leaf Spring 7 16 1 80418 Flange Nul 2006 20 2000 lbs Capacit
41. ring 1 15 57316 Mast Cable Pulley 16 69680 Clevis Pin 0 625 x 1 5 inches 1 17 Ref Number 1 Mast Tube Assembly refer to Figure 10 B 1 18 80640 Weld Nut 4 20 1 inch 19 80641 Wear Pad 1 88 x 1 x 0 34 inch after serial number TML02 564 nn 1 20 8255 Screw HHC 3 8 16 x 0 75 inch GR 5 21 6021 Lock Washer 3 8 inch 22 7339 Screw HHC 1 4 20 x 0 5 inch GR 5 23 6356 Lock Washer 1 4 inch 24 13918 Screw HHC 3 8 16 1 75 inches GR 8 2 25 4828 Nylock Nut 3 8 16 A TEREX COMPANY PartNo 116471 TML 4000 TML 4000N 400 7 Section 400 e Mast Components September 2008 Figure 404 1 Mast Components View 4 REV A TEREX COMPANY 400 8 TML 4000 TML 4000N Part No 116471 September2008 Section 400 Mast Components El REV A FIGURE 404 1 ltem Part No Description Qty 1 0000 Light Moura 1 2 11335 Screw SHS 3 8 16 x 0 5 inch 3 11978 Nylon Flat Washer 0 515 x 0 88 x 0 093 inch 4 7713 Low Profile Nylock Nut 3 8 16 inch 5 104685 Rubber Cushioned Clamp 0 56 x 1 2 inch 1 6 80118 Tilt Linkage Assembly 7 57352 Light Mount Spring 2 8 6002 Low Profile Nylock Nut 5 16 18 9 6638 Flat Washer 4 inch 10 30973 Rubber Bumper E 1 25 Inches uio en 2 11 7265 Steel Rivet 12 33277 Flat Washer M8 13 80641 Wear Pad 14 85286 Number 3
42. s 1 5 69831 Glow Plug Timer Relay Lombardini models 1 6 18542 Nut 8 32 GR2 7 42421 Lock Washer 8 8 80040 Glow Plug Relay Connector Kit Lombardini models 1 69784 Female Terminal Small 69785 Female Terminal Medium 69786 Female Terminal Large 9 80302 Key Switch 3 Position Momentati seves 1 21982 Single Key 37947 Key Package of 10 10 684380 Selector Switch 3 Position Momentary keyless 1 11 19506 Hour Meter 10 80V DC 1 12 80533 Circuit Breaker 10A 4 Genie ATEREX COMPANY Part No 116471 TML 4000 TML 4000N 200 13 Section 200 Base Components September2008 Figure 207 1 Covers REV A 200 14 TML 4000 TML 4000N PartNo 116471 September2008 Section 200 Base Components Na aaa aaa aaa aan REVA FIGURE 207 1 Item Part No Description Qty Item Part No Description Qty 1 85269 Top Cover Assembly with 23 4828 Nylock Nut 3 8 16 Decals TML 4000 1 A _ 85268 Top Cover Assembly with 24 69667 Lock Pin 1 Decals TML 4000N 25 69650 Roll Pin 3 16 x 2 inches 2 85266 Main Cover Assembly with 26 80274 Mast Cradle Assembly 1 Decals Tank Side TML 4000 1 80108 Main Cover Assembly with 27 69649 Compression Spring Decals Tank Side TM
43. s items 1 15 18 22 24 29 32 35 36 38 46 and 48 Decal Kit Safety Instructional TML 4000 Lombardini LDW 1003 L Includes items 1 15 18 22 24 29 32 36 38 46 and 48 Decal Kit Safety Instructional TML 4000N Perkins 103 10 includes items 1 13 15 18 22 24 29 32 36 38 46 and 48 Decal Kit Safety Instructional TML 4000 Perkins 103 10 includes items 1 13 15 18 22 24 29 32 46 and 48 Label Diesel 1 Warning Crushing Hazard 6 Notice Hazardous Materials 2 Label No Smoking 1 Manual Storage Container 1 Label Transport Tie down 2 Warning Tow Speed 1 Notice Operating Instructions 1 Notice Mast Rotation iio 1 Warning General Safety 1 Warning Transport Instructions eese 1 Danger Electrocution Hazard 2 Warning Electrocution cn 2 Notice Deutz Engine Specs 1 PartNo 116471 A TEREX CO 15 16 17 18 19 20 21 22 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 72008 72009 72010 72018 72019 CR51A107 72826 72828 72870 72871 72874 72889 72890 72891 80321 82219 82221 82222 82223 82224 82237 97767 82303 82304 82957 97518 FIGURE 101 1 Caution Turn Off Lights 1 Cosmetic Genie TML 4000 2 Co
44. smetic Genie TML 4000N 2 Label Raise Lower Winch 1 Danger High Voltage 1 Label Black Arrow 1 Label Extend Retract Winch 1 Notice Tire Specifications 2 Caution Component Contact 2 Label Power Outlet 120V AC 1 Label Locked Unlocked 1 Warning Transport Hazard 1 Notice Mast Retraction 1 Label Blue Arrow 2 Serial Plate and NHTSA Label before serial number TMLOL 591 22 1 Label Power Outlets Under Cover before serial number TMLO2 522 RES 1 Danger Electrocution Hazard located under ballast cover 1 Caution Light Storage Standard Models 1 Label Light Storage Standard Models 2 ns 4 Label HOT iens 8 Danger High Voltage located under ballast cover 1 Notice Engine Specifications Label Mast Release Latch 1 Control Panel en 1 Label Power Outlets Under COVER je teet diede 1 Notice Lamp Disposal 2 This list continues on the next page MPANY TML 4000 TML 4000N 100 3
45. tor 2 M6 x 1x 35 mm GR 12 9 3 36 25368 Nylock Nut M8 4 oe Se A A 129 qi E FOME Pla een Ade 9 75382 Flat Washer M6 38 85030 Radiator Mount Bracket Front 1 10 35434 Hose Clamp 2 inches 4 39 aeons Set 7 mm GR 8 8 11 85019 Radiator Guard Bracket scenes 1 40 85031 Radiator Cap Less 1 der uM SC Dm BRE 41 85032 Fan Guard Assembly 1 13 55017 Nut M6 42 85034 Crankshaft Pulley 1 1485102 Upper Radiator Hose Clamp TT TT sd EE E 44 85045 Radiator Fan 1 eee SE m Pa ee Ven 1 17 85024 RadiaierGuaidilsolator cscs 4 46 85035 Fan Pulley iii did neues 1 18 85028 Fan Guard Bracket ocn aM e Mia deis c CHEM 19 85098 Flange Nut M 1 85063 Screw HHC M8 x 1 25 x 35 mm 20 80571 Exhaust Pipe Bracket PT 1 994 SE Me 21 80391 U bolt 5 16 18 x 2 inches 22 18503 Flange Nut 5 16 18 coco 2 49 85039 Water Inlet Housing 1 23 56123 Screw HHC 50 85040 Fan Shroud Bracket 1 M6 x 1 x 10 mm GR 8 8 24 85099 Screw SHC M8 x 1 25 x 20 mm GR 12 9 1 25 85021 Radiator Shroud Bracket 1 26 85022 Lower Radiator Hose 1 27 85023 Temperature Sensor Hose 1 28 85025 Fan Guard Bracket 1 PartNo 116471 TML 4000 TML 4000N 300 5 September2008 Section 300 Engine Components Figur
46. ury AWARNING Indicates a potentially hazardous situation which if not avoided could result in death or serious injury Indicates a potentially hazardous ACAUTION situation which if not avoided may cause minor or moderate injury Workplace Safety Be sure to keep sparks flames and lighted tobacco away from flammable and Ae combustible materials like battery gases and engine fuels Always have an approved fire extinguisher within easy reach SN are properly maintained and ready for use Keep work surfaces clean and free of debris that could get into machine components and cause damage Be sure that all tools and working areas Be sure any forklift overhead crane or l other lifting or supporting device is fully capable of supporting and stabilizing the weight to be lifted Use only chains or straps that are in good condition and of ample capacity Be sure that fasteners intended for one N time use i e cotter pins and self locking nuts are not reused These components may fail if they are used a second time Be sure to properly dispose of old oil or eS other fluids Use an approved container Please be environmentally safe Be sure that your workshop or work area p Indicates a potentially hazardous iW is properly ventilated and well lit eegen EE N S situation which if not avoided PIN may result in property damage Be sure to wear protective eye wear and ES other protective cloth
47. y TML 4000 2 8 4266 Screw HHC 69211 Double Eye Leaf Spring 1 4 20 x 2 inches GR 5 1400 lbs Capacity TML 4000N 9 80340 Suspension Stop TML 4000 2 26 12461 Screw HHC 80334 Suspension Stop TML 4000N 1 2 13 5 inches GR 8 10 6091 Nylock Nut 1 4 20 27 13066 Flat Washer 1 2 inch 11 57710 Fender L 2 28 6198 Nylock Nut 1 2 13 12 6888 Screw HHC 29 46715 Safety Chain L 2 PANE ANKER 30 57332 Hitch Coupler Assembly 13 6638 Flat Washer 1 4 inch 2 inch ball shown 1 A 57625 Standard Hitch Assemblv 14 80369 Side Marker Light includes items 30 31 and 34 16 0008 een SE 30 69937 Hitch Coupler Combo PERSONER Assembly with Pintle Ring 16 10256 Flat Washer 13 16 inch 59720 Pintle Ring 67535 Coupler 2 inch Ball Lever Lock 31 57331 Tongue Screw Jack includes 17 10258 Nylock Nut 3 4 10 18 57570 U Bolt Axle Mount TML 4000 4 mounting hardware 1 57549 U Bolt Axle Mount TML 4000N 32 6034 Jam Nut 1 2 13 GR 2 19 57393 Axle Spring Hanger Plate 2 33 80231 S Jack Spacer 1 20 116021 Tire and Wheel Assembly vos Gas OMA TML 4000N Ne 2 34 97333 Tongue Assembly with Decals 1 116025 Wheel 13 inches TML 4000N 35 747 Mast Spring Le 116023 Tire ST 175 80D13 TML 4000N Mis 1 HH 20 116022 Tire and Wheel Assembly dil s S ER D TML 4000N pp 2 116026 Wheel 15 inches TML
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