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TML Service Manual-116472-08-05-08

1. LEROY SOMER MECC ALTE LEFT D ci GN RIGHT 60 Hz 60 Hz GENERATOR GENERATOR UPPER a UPPER WH _ LEFT EI 9 RIGHT e re LOWER 8 Zo gt LOWER T3 T2 1 T 4 T1 T4 5 e BK LAMP WIRE COLORS Aas d MECC ALTE JUNCTION 60 Hz 50 Hz BOX GENERATOR Le EE WH WH es E GN WH GN MAST CABLE WIRE COLORS e e e WI e 1 T2 T3 TA 1 4 3 5 2 4 e e CONTROL TRANSFORMER Has ju al e T ee MAST L m CABLE de See e Litt RD GN GN S2 SES p Kl GENERATOR M EC WTH e 120V 240V SEE ABOVE OUTLET FOR OPTION S3 1 SPECIFIC MODEL BK sid BK C e BK E fece ba nA eg HH t 1 ag p 1 RD RD 1 2 a 1000w 1 4 BB RO 7 CAPACITOR ak T eam LEE
2. Swtich Transformer Ground Genie A TEREX PartNo 116472 TML 4000 TML 4000N 6 3 Section 6 Schematics September 2008 Electrical Schematic TML 4000N REV before serial number 02 522 Le LEFT 5 C _ RIGHT N UPPER s UPPER LEFT 13 ei La 9 RIGHT A x 74 NS LOWER E CS LOWER LAMP WIRE COLORS 2 m z m m 0 JUNCTION amp x 2 c Ed m MAST CABLE WIRE COLORS BALLAST 1 CONTROL TRANSFORMER 2 EFIE SC RD MIT E bar MAST SSS E 7 CABLE GENERATOR WH WH 1 2 3 4 WH GN l S2 Lo RD 1 Ne RD WH psd WH BK OR 0 T3 T2 12 314 T T4 S3 15 BK Qo Vr LR mm eee emit cum rz qlr if RD 1 RD SS 4 Vor ME 1 M47 SATAS TOR BK BK dC TRANSFORMER 2 S4w
3. 7 BALLasT 3 oa eet BL 4 BL BALLAST 2 WH 4 1 1 WH BK WH BK TRANSFORMER 5 i 2482 WH WH CAPACITOR 6 8 856 GN 7 GN 1 2 3 4 1 2 3 4 8 RD BK WH 4 WH 9 15A BK BL U i 1 2 3 4 mim 0 e EE 01 gt air ji H 24 120V 3 Gg CAPACITOR 1 TRANSFORMER NOTE L BALLAST 4 MACHINE SHOWN THE STOWED POSITION WITH THE POWER OFF Genie TEREX COMPANY 6 4 TML 4000 TML 4000N Part No 116472 September 2008 Section 6 Schematics Electrical Schematic REVA TML 4000 before serial number TMLO2 522 NA e LEFT a e LS 9 RIGHT UPPER E ST UPPER 4 LEFT 4 Si en RIGHT LOWER AA LOWER LAMP WIRE COLORS zd X m m z ao o JUNCTION l Lol HI 48056 8 MAST CABLE WIRE COLORS BALLAST 1 CONTROL TRAN
4. CR15 GLOW 30 Te PLUG 1 po er 1 KS1 2 START BK 3 PK BK 9 o 4 an O BL Te BK 02704 RD g PP o 1 BK 5 1 RD BK e 2 _ORIBK ai OR g GY rw 3 WH wH fg wH vi je 4 RD 4 10 8 F9 50a an 5 PN sl SN fi Oe e FI WHK 45 PK Glow 7 Dn 13 si g WHBK 14 1 e 9 D Wa 023 9 2 200 o I ENGINE CONTROL N N Be De w CIRCUIT BOARD ge Gei D A A D1 G6 d ALTERNATOR A e gt Si 2 G gt e os HH cr 2 m 2 m m gt gt v gt T z gt z289 tuc m z o c m m m o o 2 2 D m m 2 Qs m Ug n I zm C 2 lt gt o m I8 2 o NOTE MACHINE SHOWN IN THE STOWED POSITION WITH THE POWER OFF REX COMPAN TML 4000 TML 4000N Part No 116472 September 2008 Section 6 Schematics EE Electrical Schematic REVA Lombardini and Deutz Engines after serial number 05 212 DIODE 220 OHM 1A 400V 0 6W
5. 3 20 E 5 Perform Generator Maintenance Leroy Somer Models 3 20 Genie TEREX COMPANY viii TML 4000 TML 4000N Part No 116472 September 2008 Section 4 Section 5 Section 6 Rev Rev Rev gt gt gt gt PartNo 116472 TABLE OF CONTENTS Repair Procedures tte ie Uer 4 1 Lighting T1 usu creat 4 2 Mast 21 Mast secs 4 4 Chassis 31 GroundControls nennen nnne 4 8 Generator 4 4 EE 4 11 Troubleshooting MALOU 5 1 Theory of Operation cecinit cnra ded e cd 5 3 Lamp 5 4 Schematics aiite ETE 6 1 Trailer Lighting Wiring m 6 2 Electrical Symbols Legend do pee pate etes terre 6 3 Electrical Schematic TML4000N before serial number TMLO2 522 6 4 Electrical Schematic TML 4000 before serial number 02 522 6 5 Electrical Schematic TML 4000 and TML 4000N after serial number TMLO2 521 sese 6 6 Electrical Schematic Deutz Engine before serial number 05 213 6 8 Electrical Schematic Lombardini and Deutz Engines after serial number TMLO05 212 siisii naa 6 9 Electrical Schematic Perkins Engine before serial number 05 362 6 10 Electrical Schema
6. 1 30 OR 4 3008 OR STARTER e 2 2BN p 2BN BN 912286 38 BL 15 ER 4 PP PP GLOW AIR SL BK 58 P PLUG e 618 4 GLOW 7 LIAC 7 gx i EU g mun B1 n ih RD Ss NEL St Ne U32 H SS D1 Y i a M3 S 15 AMP ar Fc e i e e e e ee RE gt Q d E E eg 98 d 4 2 2 2 2 m E 2 121314516 E 5 z gt gt Dome FH Q c c d 2 o CA lc gt m o e D D U33 5 VOLTAGE REGULATOR sa lt i 5 lt 2 s 2 MACHINE SHOWN IN THE STOWED POSITION WITH THE POWER OFF Genie A TEREX COMPAT PartNo 116472 TML 4000 TML 4000N 6 11 Section 6 Schematics September 2008 This page intentionally left blank 6 12 TML 4000 TML 4000N Part No 116472 Genie North America Phone 425 881 1800 Toll Free USA and 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
7. Class4 6 44 Class 8 8 Class 10 9 03 Class 12 9 DRY DRY DR ile Bl ilz af d ile af ile af 1 gt o Co ze Po Po A D Po a N P e M OF Al On D n age al CO Go rp N ox zil sech iol ojo n N Do A On e oi oO Oo A 54 NI m a AJ 91 gy D 5 5 lt r c D S lt E D DRY DR 9 365 23 6 2 722 0 612 830 1055 682 925 909 1233 4 CO 8 1 zi D A A e N o Ke 4 E OY za ex 9 gt poy ON ES D 5 co ol NX ol Gs i ge ol ol SIS oF D N D e A A 2 5 o DN OI oo mo Alo D SJs MA NI f gt AY C NI co ml 2 N GO A OF Ayo
8. Displacement Number of cylinders Bore and stroke 62 85 cu in 1 03 liters 3 2 95 x 3 06 inches 75 x 77 6 mm Horsepower see engine rating plate Firing order 1 3 2 Compression ratio 22 8 1 Engine speed 1800 rpm Governor mechanical Valve clearance cold Intake 0 0079 in 0 2 mm Exhaust 0 0079 in 0 2 mm Lubrication system Oil pressure hot 1800 rpm 40 to 60 psi 2 75 to 4 1 bar Oil capacity 2 65 quarts including filter 2 5 liters Oil pressure switch 4 35 2 psi engine shut off pressure 0 3 0 15 bar Oil viscosity requirements Units ship with 15W 40 Extreme operating temperatures may require the use of alternative engine oils For oil requirements refer to the Engine Operator Handbook on your machine PartNo 116472 ATER Section 2 Specifications ES SPECIFICATIONS Engine coolant Capacity 5 2 quarts 4 9 liters Coolant temperature switch 230 5 F engine shut off temperature 110 3 C Injection system Injection pump make Bosch Injection pump pressure 6500 700 psi 450 50 bar Injector opening pressure Fuel requirement 1958 72 psi 135 5 bar For fuel requirements refer to the engine Operator s Manual on your machine Alternator Output 45A 12V DC Fan belt tension 90 4 ft lbs new belt installation 400 20 N Fan belt tension 56 4 ft lbs retension after 15 min of use 250 20 N Temperature sen
9. Genie A TEREX COMPANY Serial Number Range TML 4000 from TMLO1 226 TML 4000N from TMLO1 226 First Edition First Printing Part No 116472 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 li TML 4000 TML 4000N MPANY Serial Number Information Genie Industries offers the following manuals for these models Title Part No Genie TML 4000N Operator s Manual First
10. 5 21 liters Coolant temperature switch 221 7 F engine shut off temperature 105 4 C Injection system Injection pump make Kikicexel Injection pump pressure 1764 psi 121 bar Fuel requirement For fuel requirements refer to the engine Operator s Manual on your machine Alternator Output 15A 12V DC Fan belt deflection 0 19 in along longest free length with finger force 5mm of approximately 11 ft lbs 49 TML 4000 TML 4000N 2 5 Section 2 Specifications September 2008 e H SPECIFICATIONS REVA Leroy Somer Generator Generator speed Q full load 60 Hz 1800 rpm Temperature ambient maximum 104 F 40 Power 6 kw Capacitor disconnected Capacitor disconnected Mecc Alte Generator 70 uF 10 22 5 uF Q 5 Generator rpm Q full load 50 2 1500 rpm 60 Hz 1800 rpm Temperature ambient maximum 104 F 40 C Power 6 kw Capacitor disconnected 220V 50Hz 240V 6 2 50 3 4V 10 70 6 3V 10 Marathon Generator Generator speed full load 60 Hz 1800 rpm Temperature ambient maximum 104 F 40 C Power 6 kw Capacitor disconnected 45 uF Genie TML 4000 TML 4000N Part No 116472 September 2008 Section 2 Specifications REVA SPECIFICATIONS SAE FASTENER TORQUE CHART This chart is to be used as a guide only unless noted elsewhere in this manual A574 High Strength Grade 5 lt gt
11. B 8 Axle maintenance PartNo 116472 A TEREX COMPANY C 2 Engine maintenance Perkins 403C11 model C 3 Engine maintenance Deutz models Perform every 600 hours C 4 Engine maintenance Perkins 103 10 models Perform every 6000 miles C 5 Axle maintenance Checklist D Rev B Y NR D 1 Engine maintenance Deutz models D 2 Engine maintenance Perkins 403C11 model D 3 Generator maintenance Leroy Somer models D 4 Jack maintenance D 5 Axle maintenance ChecklistE RevB YNR E 1 Engine maintenance Deutz models E 2 Engine maintenance Perkins 403C11 model E 3 Engine maintenance Perkins 403C11 model E 4 Generator maintenance Marathon models 5 Generator maintenance Leroy Somer models Comments TML 4000 TML 4000N Section 3 Scheduled Maintenance Procedures September 2008 Checklist A Procedures A 1 Inspect the Manuals and Decals Genie specifications require that this procedure be performed every 8 hours or daily whichever comes first Maintaining the operator s and safety manuals in good condition is essential to safe machine operation Manuals are included with each machine and should be stored in the container provided in the platform An illegible or missing manual will not provide safety and operational information necessary for a safe operating condition In addition maintaining all of the safety and
12. terminals JW 3 0143 High voltage Exposure to electrical wires or electrical current will result in death or serious injury Remove all rings watches and other jewelry Use extreme caution when working with high voltage electrical components 4 If equipped tag and disconnect the external resistor from the capacitor 5 With an ohmmeter set to its highest resistance scale connect the ohmmeter leads to the capacitor terminals and observe the reading on the meter Then reverse the connections and observe the reading on the meter Result Models with external resistor The meter indicates a very low resistance which then gradually increases AND a very high resistance which then gradually decreases The capacitor is working Result Models with internal resistor The meter indicates a resistance which then gradually decreases The capacitor is working W Result The meter indicates a very high resistance which does not decrease The capacitor is faulty and should be replaced Result The meter indicates a very low resistance which does not increase The capacitor is faulty and should be replaced Probable causes of capacitor failure Normal end of life failure Overheated due to fixture heat or high ambient temperature Capacitor heat barrier removed Incorrect capacitor voltage rating Part No 116472 September 2008 Section 4 Repair Procedures REVA How to Check a Ballast VT
13. 0297 9689 E 2 Perform Engine Maintenance Perkins 403C 11 Models Engine specifications require that this procedure be performed every 2000 hours Required maintenance procedures and additional engine information is available in the Perkins 400 Series User s Handbook Perkins part number 100816460 Perkins 400 Series User s Handbook Deutz 1008 Operation Manual Genie part number 97360 Genie part number 150108 Lombardini LDW 1003 L Operation Manual Genie part number 116031 Part No 116472 TML 4000 TML 4000N 3 19 Section 3 Scheduled Maintenance Procedures September 2008 CHECKLIST E PROCEDURES E 3 Perform Engine Maintenance Perkins 403C 11 Models Engine specifications require that this procedure be performed every 3000 hours Required maintenance procedures and additional engine information is available in the Perkins 400 Series User s Handbook Perkins part number 100816460 Perkins 400 Series User s Handbook REVA E 4 Perform Generator Maintenance Marathon Models Generator specifications require that this procedure be performed every 10 000 hours Required maintenance procedures and additional generator information is available in the Marathon Generator Service Manual Marathon part number SM301 Marathon Generator Service Manual Genie part number 97360 Genie part number 150109 E 5 Perform Generator Maintenance Leroy Somer Models Generator specificatio
14. 1 1 TRANSFORMER 2 MODELS WITH S4w BALLAST 3 120 OUTLET STANDARD BK ceu BK L EE l 3 1 B er Log BL 4 BL pe ow eee BALLAST 2 0 een WH BK 5 WH BK g pu i TRANSFORMER mem an 1ooow 24E TT wH wH 7 CAPACITOR 6 1207 7777777 1 2 s3 4 P RD di BK 8 LI BK tr wH 9 m ten GN LRRD BL 22 BK BK TNT WH 11213 4 GN 0 0 a 240V WH WH Gin d 1 eT 120V 120V ECH CAPACITOR TRANSFORMER L BALLAST 4 MACHINE SHOWN IN THE STOWED POSITION WITH THE POWER OFF A TEREX COMPANY 6 6 TML 4000 TML 4000N Part No 116472 September 2008 Section 6 Schematics m M M E i This page intentionally left blank Genie TEREX PartNo 116472 TML 4000 TML 4000N 6 7 Section 6 Schematics September 2008 Electrical Schematic Deutz Engine REVA before serial number TMLO5 213 bee 0 6W gt BK 1 el 87 50
15. 4000 TML 4000N iii September 2008 EE LLL LL LLL LL LLLI This page intentionally left blank iv TML 4000 TML 4000N Part No 116472 September 2008 Section 1 Safety Rules Safety Rules Danger Failure to obey the instructions and safety rules in this manual and the appropriate Operator s Manual on your machine will result in death or serious injury Many of the hazards identified in the operator s 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 You read understand and obey manufacturer s instructions and safety rules employer s safety rules and worksite regulations applicable governmental regulations You have the appropriate tools lifting equipment and a suitable workshop A TEREX COMPANY PartNo 116472 TML 4000 TML 4000N 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
16. bottom of the battery fill tube Do not overfill 11 Install the vent caps and neutralize any electrolyte that may have spilled Section 3 Scheduled Maintenance Procedures September 2008 CHECKLIST B PROCEDURES B 2 Inspect the Electrical Wiring Genie requires that this procedure be performed every 250 hours or quarterly whichever comes first Maintaining electrical wiring in good condition is essential to safe operation and good machine performance Failure to find and replace burnt chafed corroded or pinched wires could result in unsafe operating conditions and may cause component damage Electrocution hazard Contact with AWARNING hot or live circuits could result in death or serious injury Remove all rings watches and other jewelry 1 Inspect the following areas for burnt chafed corroded and loose wires and for a liberal coating of dielectric grease in the harness connections Mast Chassis Trailer lighting 2 Open the chassis side covers and inspect for a liberal coating of dielectric grease in the harness connections between the generator and the mast light assemblies 3 Inspect the engine and generator area for burnt chafed corroded pinched and loose wires and and for a liberal coating of dielectric grease in the harness connections TEREX TML 4000 TML 4000N REVA B 3 Inspect the Tires and Wheels including lug nut torque Genie requires that this procedu
17. engine information is available in the Perkins 400 Series User s Handbook Perkins part number 100816460 Perkins 400 Series User s Handbook Genie part number 97360 Section 3 Scheduled Maintenance Procedures September 2008 CHECKLIST C PROCEDURES C 3 Perform Engine Maintenance Lombardini and Deutz Models Engine specifications require that this procedure be performed every 500 hours or semi annually whichever comes first Required maintenance procedures and additional engine information is available in the Lombardini LDW 1003 L or Deutz 1008 Operation Manual Deutz part number 0297 9689 Deutz 1008 Operation Manual REV A 4 Perform Engine Maintenance Perkins 103 10 Models Engine specifications require that this procedure be performed every 600 hours or annually whichever comes first Required maintenance procedures and additional engine information is available in the Perkins 100 Series Operating Instructions Perkins part number 100816243 0695 Perkins 100 Series Operating Instructions Genie part number 150108 Genie part number 150137 Lombardini LDW 1003 L Operation Manual Genie part number 116031 C 5 Perform Axle Maintenance Axle specifications require that this procedure be performed every 6 months or 6000 miles whichever comes first Required maintenance procedures and additional axle information is available in the Dexter Axle Operation Maintenance Service Manual
18. fuel which may have spilled 6 Plug the supply hoses and remove the fuel tank from the machine Part No 116472 September 2008 Section 4 Repair Procedures Generator 4 1 How to Check a Generator Generator Capacitor How to Remove the Generator Capacitor Cover High voltage Exposure to electrical wires or electrical current will result in death or serious injury Remove all rings watches and other jewelry Turn off all power when not needed for testing Use extreme caution when working with high voltage electrical components Note Be sure the engine has been turned off for at least 15 minutes before servicing the machine Use a voltmeter to confirm there is no residual voltage in the capacitors 1 Loosen but do not remove the fasteners securing the capacitor cover to the top of the generator Burn hazard Contact with hot ACAUTION engine components may cause severe burns Use caution when working around a hot engine 2 Pullthe cover off the top of the generator just enough to access the wire harness where it connects to the generator 3 Tag and disconnect the wires at the top of the generator Remove the cover PartNo 116472 A TEREX TML 4000 TML 4000N MANY ADANGER High voltage Exposure to electrical wires or electrical current will result in death or serious injury Remove all rings watches and other jewelry Turn off all power when not needed for testing Use ext
19. generator housing over the armature until the rear armature race makes contact with the rear armature bearing 4 Install four longer bolts through the generator housing and into the bellhousing equally spaced around the housing Note These bolts will serve as a temporary guide while installing the generator housing onto the engine bellhousing 5 Install four ofthe generator to flywheel fasteners to finger tight equally spacing the fasteners around the generator In a star pattern tighten each bolt one half turn at a time just until the generator housing evenly contacts the bellhousing 6 Remove the long guide bolts 7 Remove the generator housing fasteners 8 Using a liquid threadlocker on the fastener threads install the generator housing fasteners into the engine bellhousing Install the fasteners to finger tight 9 Ina star pattern torque the generator housing fasteners to 24 ft lbs 38 Nm 10 Install the fasteners securing the generator to the chassis Securely tighten the fasteners 11 Install the wire harness onto the generator Securely tighten the fasteners 12 Install the capacitor cover onto the generator Install and securely tighten the fasteners Section 4 Repair Procedures September 2008 EEN This page intentionally left blank 4 16 TML 4000 TML 4000N Part No 116472 September 2008 Section 5 Troubleshooting Troubleshooting Before Troubleshooting Read understand and
20. 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 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 Phone 34 93 579 5042 Fax 34 93 579 5059 Genie Germany 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. leads to terminal 1 and 2 of the transformer harness connector and observe the reading on the meter Result Before serial number 02 522 with 120V AC ballast The meter shows 0 4Q to 0 6Q resistance Result After serial number TML02 521 with 240V AC ballast The meter shows 0 8Q to 0 90 resistance W Result There is no resistance or infinite resistance The ballast is faulty and must be replaced Secondary output coil resistance 4 With a multimeter set to read ohms connect the multimeter lead to terminal 3 of the transformer harness connector 5 Tag and disconnect the transformer wire lead from the capacitor and connect it to the other multimeter lead and observe the reading on the meter Result The meter shows 1 8Q to 1 90 resistance W Result There is no resistance or infinite resistance The ballast is faulty and must be replaced Section 4 Repair Procedures September 2008 CHASSIS How to Remove the Glow Plug Timer Circuit Board 1 Turn off all machine power 2 Remove the fasteners securing the inspection panel to the chassis High voltage Exposure to electrical wires or electrical current will result in death or serious injury Remove all rings watches and other jewelry Turn off all power when not needed for testing Use extreme caution when working with high voltage electrical components Note Be sure the engine has been turned off for at least 1
22. machine power 2 Remove the lamp See 1 1 How to Remove a Lamp Install an adapter into the lamp socket 4 With a voltmeter set to read 0 750V AC connect the voltmeter leads to the lamp socket adapter 5 Start the engine 6 Turn the appropriate circuit breaker light switch to the on position and observe the reading on the voltmeter Refer to the following chart Voltage Specification Lamp socket 400V AC to 445V AC Note If there is no reading on the meter Repair or replace the lamp socket capacitor ballast or wiring Section 4 Repair Procedures September 2008 Mast REV A 2 1 How to Disassemble the Mast Mast 1 Remove the mast assembly See 2 1 How to Remove the Mast Assembly How to Remove the Mast 2 Remove the guide pad from the top of the Assembly number 2 mast tube AWARNING lly injury hazard The procedures in this section require specific repair skills lifting equipment and a suitable workshop Attempting this procedure without these skills and tools could result in death or serious injury and significant component damage Dealer service is required 1 Turn the handle of the mast pivot winch and loosen the mast pivot cable 2 Remove the fasteners securing the cable pulley to the bottom of the mast and remove the pulley Lay the cable to the side Note Always replace the cotter pin with a new one when removing the pulley 3 Tagand disconnect th
23. number 150109 Part No 116472 September 2008 Section 3 Scheduled Maintenance Procedures Checklist B Procedures REVA B 1 Inspect the Battery Genie requires that this procedure be performed every 250 hours or quarterly whichever comes first Proper battery condition is essential to good machine performance and operational safety Improper fluid levels or damaged cables and connections can result in component damage and hazardous conditions AWARNING Electrocution hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry AWARNING Bodily injury hazard Batteries contain acid Avoid spilling or contacting battery acid Neutralize battery acid spills with baking soda and water 1 Puton protective clothing and eye wear 2 sure that the battery cable connections free of corrosion Note Adding terminal protectors and a corrosion preventative sealant will help eliminate corrosion on the battery terminals and cables 3 sure that the battery retainers and cable connections are tight 4 Fully charge the battery Allow the battery to rest 24 hours before performing this procedure to allow the battery cells to equalize 5 Remove the battery vent caps and check the specific gravity of each battery cell with a hydrometer Note the results PartNo 116472 A TEREX TML 4000 TML 4000N MANY 6
24. requirements refer to the engine Operator s Manual on your machine Alternator Output 15A 12V DC Fan belt deflection 0 19 in between crankshaft pulley and alternator with 5mm finger force of approximately 11 ft lbs 49 TML 4000 TML 4000N Part No 116472 September 2008 Section 2 Specifications REVA Perkins 403C 11 Engine Displacement Number of cylinders Bore and stroke 69 cu in 1 131 liters 3 3 03 x 3 19 inches 77 x 81 mm Horsepower see engine rating plate Firing order 1 2 3 Compression ratio 23 1 Compression pressure 425 psi 29 3 bar Pressure of the lowest cylinder must be within 50 psi 3 45 bar of the highest cylinder though at no time less than 360 psi 24 8 bar Engine speed models with 50 Hz generator 1500 rpm models with 60 Hz generator 1800 rpm Governor mechanical Valve clearance cold Intake 0 0078 in 0 2 mm Exhaust 0 0078 in 0 2 mm Lubrication system Oil pressure hot 1800 rpm 40 to 60 psi 2 75 to 4 1 bar Oil capacity 5 18 quarts including filter 4 9 liters Oil pressure switch 7 psi engine shut off pressure 0 48 bar Oil viscosity requirements Units ship with 15W 40 Extreme operating temperatures may require the use of alternative engine oils For oil requirements refer to the Engine User s Handbook on your machine PartNo 116472 A TEREX COMPANY SPECIFICATIONS Engine coolant Capacity 5 5 quarts
25. symbol to avoid possible injury or death A ADANGER Indicates an imminently hazardous situation which if not avoided will result in death or serious injury 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 Indicates a potentially hazardous Workplace Safety Be sure to keep sparks flames and Ae lighted tobacco away from flammable combustible materials like battery gases and engine fuels Always have an approved fire extinguisher within easy reach 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 d 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 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 cS other fluids Use an approved container Please environmentally safe Sure that your workshop or work area is Boni properly ventilated
26. 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 Indicates that a cold motor or pump will be required to perform this procedure Indicates that dealer service will be required to perform this procedure EE A TEREX 3 2 TML 4000 TML 4000N MPANY Pre delivery Preparation Report The pre delivery preparation report contains checklists for each type of scheduled inspection Make copies of the Pre delivery Preparation report to use for each inspection Store completed forms as required Maintenance Schedule There are five types of maintenance inspections that must be performed according to a schedule daily quarterly semi annually annually and two year The Scheduled Maintenance Procedures Section and the Maintenance Inspection Report have been divided into five subsections A B C D and E Use the following chart to determine which group s of procedures are required to perform a scheduled inspection Inspection Checklist Daily or every 8 hours A Quarterly or every 250 hours A B Semi annually or every 500 hours A B C Annually or every 1000 hours A B C D Two year or every 2000 hours A B C D E Maintenance Inspection Report The maintenance inspection report contains checklists for each type of scheduled inspection Make copies of t
27. to record the results Place a check in the appropriate box after each part is completed Follow the instructions in the operator s manual If any inspection receives an N remove the machine from service repair and re inspect it After repair place a check in the R box Legend Y yes completed no unable to complete R repaired Comments Pre Delivery Preparation Y N R Pre operation inspection completed Maintenance items completed Function tests completed Model Serial number Date Machine owner Inspected by print Inspector signature Inspector title Inspector company Section 3 Scheduled Maintenance Procedures September 2008 EE M 3 This page intentionally left blank 3 4 TML 4000 TML 4000N Part No 116472 September 2008 Section 3 Scheduled Maintenance Procedures Maintenance Inspection Report Model Serial number Date Hour meter Machine owner Inspected by print Inspector signature Inspector title Inspector company Instructions Make copies of this report to use for each inspection Select the appropriate checklist s for the type of inspection to be performed Daily or 8 hours Inspection A Quarterly or 250 hours Inspection A B Semi annually or 500 hours Inspection A B C Annually or 1000 hours Inspection A B C D Two year or 2000 hours Inspection A B C D E Place a che
28. use Note Contact your authorized Genie distributor or Genie Industries if replacement manuals or decals are needed Part No 116472 September 2008 Section 3 Scheduled Maintenance Procedures REVA A 2 Perform Pre operation Inspection Genie specifications require that this procedure be performed every 8 hours or daily whichever comes first Completing a Pre operation Inspection is essential to safe machine operation 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 The Pre operation Inspection also serves to determine if routine maintenance procedures are required Complete information to perform this procedure is available in the appropriate operator s manual Refer to the Operator s Manual on your machine A 3 Perform Function Tests Genie specifications require that this procedure be performed every 8 hours or daily whichever comes first Completing the function tests is essential to safe machine operation Function tests are designed to discover any malfunctions before the machine is put into service A malfunctioning machine must never be used If malfunctions are discovered the machine must be tagged and removed from service Complete information to perform this procedure is available in the appropriate operat
29. very low resistance which then gradually increases AND a very high resistance which then gradually decreases The capacitor is working Result The meter indicates a very high resistance which does not decrease The capacitor is faulty and should be replaced Result The meter indicates a very low resistance which does not increase The capacitor is faulty and should be replaced TEREX COMPANY REV A Probable causes of capacitor failure Normal end of life failure Overheated due to fixture heat or high ambient temperature Capacitor heat barrier removed Incorrect capacitor voltage rating Note After shorting out the capacitor it will be necessary to recharge it before starting the machine To recharge the capacitor connect the leads from a 6V DC battery to the leads of the capacitor for 1 second 4 12 TML 4000 TML 4000N Part No 116472 September 2008 Section 4 Repair Procedures REVA How to Remove the Generator High voltage Exposure to electrical wires or electrical current will result in death or serious injury Remove all rings watches and other jewelry Turn off all power when not needed for testing Use extreme caution when working with high voltage electrical components Note Be sure the engine has been turned off for at least 15 minutes before servicing the machine Use a voltmeter to confirm there is no residual voltage in the capacitors Model
30. 00 TML 4000N Part No 116472 September 2008 Section 2 Specifications REVA Machine Specifications Specifications Performance Specifications Total lighting wattage 4000 watis Tongue weight maximum Fuel capacities TML 4000 145 Ibs 66 kg TML 4000 50 gallons 189 liters TML 4000N 110 Ibs 50 kg TML 4000N 30 gallons 114 liters Run time Battery Standard TML 4000 full load with full fuel tank 100 hours Type 12V DC TML 4000N full load with full fuel tank 60 hours Group 70 Quantity 1 Continuous improvement of our products is Genie policy Product specifications are Cold cranking ampere 450 subject to change without notice Reserve capacity 25A rate 105 minutes Battery Heavy Duty Type 12V DC Group 31 Quantity 1 Cold cranking ampere 950 Reserve capacity 25A rate 190 minutes Tires and wheels Axle Tire size ST185 80D13 Load range B Lug nut torque dry 80 ft lbs 108 Nm Tire pressure maximum cold 50 psi 3 4 bar Airborne Noise Emissions 71 Maximum sound level at normal operating workstations A weighted For operational specifications refer to the Operator s Manual PartNo 116472 A TEREX COMPANY TML 4000 TML 4000N 2 1 Section 2 Specifications September 2008 SPECIFICATIONS Deutz F3M 1008 Engine Displacement Number of cylinders Bore and stroke 55 9 cu in 0 916 liters 3 2 83 x 2 95 inc
31. 018333 High voltage Exposure to electrical wires or electrical current will result in death or serious injury Remove all rings watches and other jewelry Turn off all power when not needed for testing Use extreme caution when working with high voltage electrical components ADANGER Electrocution hazard Attempting to service the machine before the capacitors are fully discharged will result in death or serious injury Note Be sure the engine has been turned off for at least 15 minutes before servicing the machine Use a voltmeter to confirm there is no residual voltage in the capacitors 1 Tag and disconnect the four transformer harness connectors from the machine wire harness capacitor ballast primary coil transformer harness connector see legend below secondary coil SHARP Harness connector terminal legend 120V or 240V common common 4 lamp PartNo 116472 TML 4000 TML 4000N CHASSIS 2 Usingan insulated conductor or a screwdriver with an insulated handle discharge each of the four capacitors by shorting across the capacitor terminals JW 3 0143 High voltage Exposure to electrical wires or electrical current will result in death or serious injury Remove all rings watches and other jewelry Use extreme caution when working with high voltage electrical components Primary input coil resistance 3 With a multimeter set to read ohms connect the multimeter
32. 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 116472 remove this page and make copies remove this page and make copies Service Parts Fax Order Form IQ Fax to 425 556 8659 or Toll 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 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 INpusrRIEs Use ONLY Order Number Origin Code Comments Date Scheduled Ship Condition Order Total Terms Code September 2008 EE LLL LL LLL LL LLLI This page intentionally left blank Xvi TML 40
33. 5 minutes before servicing the machine Use a voltmeter to confirm there is no residual voltage in the capacitors Note The inspection panel is located next to the ground control panel 3 Locate the glow plug circuit board behind the ground control panel 4 Tag and disconnect the wire harness connector from the circuit board 5 Carefully remove the retaining fastener and remove the circuit board from the machine TEREX TML 4000 TML 4000N REV A How to Remove the Fuel Tank ADANGER Explosion and fire hazard Engine fuels are combustible Remove the fuel tank in an open well ventilated area away from heaters sparks flames and lighted tobacco Always have an approved fire extinguisher within easy reach ADANGER Explosion and fire hazard Never drain or store fuel in an open container due to the possibility of fire ADANGER Explosion and fire hazard When transferring fuel connect a grounding strip between the machine and container 1 Raise the mast to the fully vertical position 2 Loosen the wire harness retainer at the chassis top cover 3 Remove the fasteners securing the top cover to the chassis and remove the cover from the machine 4 Remove the fasteners securing the fuel tank to the chassis 5 Remove the supply hoses from the fuel tank and allow all of the fuel from the tank to drain into a suitable container Refer to Section 2 Specifications Note Be sure to clean up any
34. 72 TML 4000 TML 4000N 3 9 Section 3 Scheduled Maintenance Procedures September 2008 CHECKLIST A PROCEDURES A 10 Perform Engine Maintenance Lombardini and Deutz Models Engine specifications require that this procedure be performed every 125 hours or quarterly whichever comes first Required maintenance procedures and additional engine information is available in the Lombardini LDW 1003 L or Deutz 1008 Operation Manual Deutz part number 0297 9689 Deuiz 1008 Operation Manual Genie part number 150108 REV A A 11 Perform Engine Maintenance Perkins 103 10 Models Engine specifications require that this procedure be performed every 200 hours or quarterly whichever comes first Required maintenance procedures and additional engine information is available in the Perkins 100 Series Operating Instructions Perkins part number 100816243 0695 Perkins 100 Series Operating Instructions Genie part number 150137 Lombardini LDW 1003 L Operation Manual Genie part number 116031 TEREX TML 4000 TML 4000N A 12 Perform Generator Maintenance Marathon Models Generator specifications require that this procedure be performed every 200 hours or quarterly whichever comes first Required maintenance procedures and additional generator information is available in the Marathon Generator Service Manual Marathon part number SM301 Marathon Generator Service Manual Genie part
35. Checkthe ambient air temperature and adjust the specific gravity reading for each cell as follows Add 0 004 to the reading of each cell for every 10 5 5 C above 80 F 26 7 C e Subtract 0 004 from the reading of each cell for every 10 5 5 C below 80 F 26 7 C Result All battery cells display an adjusted specific gravity of 1 277 or higher The battery is fully charged Proceed to step 10 Result One or more battery cells display a specific gravity of 1 217 or below Proceed to step 7 7 Perform an equalizing charge OR fully charge the batteries and allow the battery to rest at least 6 hours 8 Remove the battery vent caps and check the specific gravity of each battery cell with a hydrometer Note the results 9 Checkthe ambient air temperature and adjust the specific gravity reading for each cell as follows Add 0 004 to the reading of each cell for every 10 5 5 C above 80 F 26 7 C Subtract 0 004 from the reading of each cell for every 10 5 5 C below 80 F 26 7 O Result All battery cells display a specific gravity of 1 277 or greater The battery is fully charged Proceed to step 10 Result The difference in specific gravity readings between cells is greater than 0 1 OR the specific gravity of one or more cells is less than 1 217 Replace the battery 10 Check the battery acid level If needed replenish with distilled water to 1 inch 3 mm below the
36. Dexter part number LIT 001 00 Dexter Axle Operation Maintenance Service Manual Genie part number 84376 Genie TEREX TML 4000 TML 4000N Part No 116472 September 2008 Section 3 Scheduled Maintenance Procedures Checklist D Procedures REVA D 1 Perform Engine Maintenance Lombardini and Deutz Models Engine specifications require that this procedure be performed every 1000 hours or annually whichever comes first Required maintenance procedures and additional engine information is available in the Lombardini LDW 1003 L or Deutz 1008 Operation Manual Deutz part number 0297 9689 D 2 Perform Engine Maintenance Perkins 403C 11 Models Engine specifications require that this procedure be performed every 1000 hours Required maintenance procedures and additional engine information is available in the Perkins 400 Series User s Handbook Perkins part number 100816460 Perkins 400 Series User s Handbook Deutz 1008 Operation Manual Genie part number 97360 Genie part number 150108 Lombardini LDW 1003 L Operation Manual Genie part number 116031 Part No 116472 TML 4000 TML 4000N 3 17 Section 3 Scheduled Maintenance Procedures September 2008 CHECKLIST D PROCEDURES D 3 Perform Generator Maintenance Leroy Somer Models Generator specifications require that this procedure be performed annually Required maintenance procedures and additional generator in
37. E CONTROL m CIRCUIT BOARD ENGINE Bes tn OIL 1 300R 1 30 STARTER ei e 2 128 BN CH 3 3 BL 3 3 BL BL CRIS ei je ER A A 4 A GLOW AIR 5 5 BK e 5 5 BK PLUG si je g Boun e GLow 7 7 7 2L RD ei je 8 8 WH 8 8 WH 1 p e Re mol o FD 3 5 e 9 Mi e H U32 NENNEN d D1 2 8 y M3 15 AMP Qn SR e e e e e e o gt gt m ru rn gt 004 m e D 1 2 3 4 5 6 ZC v T 2 gt 9 S ror gt lt gt 4 c c c mom 2 2 d 2 gri m 9 m 9 2 m U33 o 5 H r VOLTAGE REGULATOR d lt S 91 ap z a m a o 2 o NOTE MACHINE SHOWN IN THE STOWED POSITION WITH THE POWER OFF Genie A TERI COMPA TML 4000 TML 4000N Part No 116472 September 2008 Section 6 Schematics Electrical Schematic REVA Perkins Engine after serial number TMLO5 361 KS1 eG I RN 20 F9A 7 5A RD gt RD F9B 023 2 CIRCUIT BOARD PO ENGINE Pe 85
38. Editlon ne certare tede cus 97600 Genie TML 4000N Parts Manual First Edition after serial number TMLO1 226 116471 Genie TML 4000N Service Manual First Edition 116472 Copyright 2008 by Genie Industries 116472 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 6 Printed recycled paper Printed in U S A Part No 116472 September 2008 How to Read Your Serial Number Serial Number Legend Genie Model GS 1930 Serial number GS3005A 12345 Model year 2005 Manufacture date 04 12 05 Electrical schematic number 50141 Machine unladen weight 2 714 Ib 1 231 kg Rated work load including occupants 500 Ib 227 kg Maximum allowable inclination of the chassis N A Gradeability N A e Model Maximum allowable side force 100 Ib 445 kg Sequence Maximum number of platform occupants 2 i number Model year Country of manufacture USA This machine complies with Facility code used only for models manufactured ANSI A92 6 1999 in multiple facilities B354 2 01 Serial number stamped on chassis Genie Industries 18340 NE 76th Street Redmond WA 98052 USA PN 77055 Serial label A TEREX COMPANY PartNo 116472 TML
39. Grade 8 Black Oxide Bolts LUBED DRY LUBED DRY LUBED Nm 00 140 158 130 120 120 135 140 LUBED LUBED DRY LUBED 24 339 271 447 50 1 678 813 80 1084 68 921 108 4 122 162 176 217 244 10 200 271 270 366 280 379 16 220 298 300 406 310 420 19 3520 483 430 583 450 610 610 827 510 69i 114 350 474 470 637 500 678 670 908 560 759 14 7 15 8 20 gt 13 5 S lt 13 14 23 17 6 19 31 2 26 35 2 37 50 1 41 55 5 57 77 3 64 86 108 4 122 110 149 130 176 170 230 17 19 31 35 49 55 75 85 110 120 150 23 25 42 47 4 66 4 74 5 101 6 115 149 162 203 18 20 33 3 50 120 130 160 180 EN co N 7 e 20 50 840 867 680 922 910 1233 1044 i12 530 718 710 962 750 1016 990 1342 1139 1071 1315 1290 1749 1090 1477 12 670 908 890 1206 1080 1464 1440 1952 1220 1654 1138 1120 1518 1360 1844 1820 2467 1530 2074 42 930 1260 1240 1681 1510 2047 2010 2725 1700 2304 6 1460 1979 1950 2643 2370 3213 3160 4284 2670 3620 12 1640 2223 2190 2969 2670 3620 3560 4826 3000 4067 METRIC FASTENER TORQUE CHART This chart is to be used as a guide only unless noted elsewhere in this manual
40. Lombardini and Deutz Models 3 13 B 5 Perform Engine Maintenance Perkins 403C 11 Models 3 13 B 6 Perform Hitch Maintenance 3 14 B 7 Perform Engine Maintenance Perkins 103 10 Models 3 14 B 8 Perform Axle Maintenance 3 14 B Checklist C Procedures C 1 Inspect the Cable and Cable Pulleys 3 15 C 2 Perform Engine Maintenance Perkins 403C 11 Models 3 15 C 3 Perform Engine Maintenance Lombardini and Deutz Models 3 16 C 4 Perform Engine Maintenance Perkins 103 10 Models 3 16 C 5 Perform Axle Maintenance 2 3 16 Checklist D Procedures D 1 Perform Engine Maintenance Lombardini and Deutz Models 3 17 D 2 Perform Engine Maintenance Perkins 403 11 Models 3 17 D 3 Perform Generator Maintenance Leroy Somer Models 3 18 0 4 Perform Tongue Jack and Outrigger Jack Maintenance 3 18 D 5 Perform Axle Maintenance 2 3 18 B Checklist E Procedure E 1 Perform Engine Maintenance Lombardini and Deutz Models 3 19 E 2 Perform Engine Maintenance Perkins 403 11 Models 3 19 E 3 Perform Engine Maintenance Perkins 403 11 Models 3 20 E 4 Perform Generator Maintenance Marathon Models
41. Manual Deutz part number 0297 9689 Deuiz 1008 Operation Manual REV A A 7 Perform Hitch Maintenance Hitch specifications require that this procedure be performed every 50 miles Required maintenance procedures and additional hitch information is available in the Fulton Coupler Use Manual Fulton part number F1937 Fulton Coupler Use Manual Genie part number 150139 Genie part number 150108 Lombardini LDW 1003 L Operation Manual Genie part number 116031 Genie TEREX TML 4000 TML 4000N Part No 116472 September 2008 Section 3 Scheduled Maintenance Procedures REVA A 8 Perform 30 Day Service The 30 day maintenance procedure is a one time procedure to be performed after the first 30 days or 40 hours of usage After this interval refer to the maintenance tables for continued scheduled maintenance 1 Perform the following maintenance procedures 3 Inspect the Tires Wheels including castle nut torque CHECKLIST A PROCEDURES A 9 Perform Engine Maintenance Perkins 103 10 Models Engine specifications require that this procedure be performed every 100 hours or quarterly whichever comes first Required maintenance procedures and additional engine information is available in the Perkins 100 Series Operating Instructions Perkins part number 100816243 0695 Perkins 100 Series Operating Instructions Genie part number 150137 PartNo 1164
42. N 4 1 MPANY Repair Procedures About This Section Most of the procedures in this section should only be performed by a trained service professional in a suitably equipped workshop Select the appropriate repair procedure aftertroubleshooting the problem Perform disassembly procedures to the point where repairs can be completed Then to re assemble perform the disassembly steps in reverse order Symbols Legend ADANGER Indicates an imminently hazardous lt situation which if not avoided will result in death or serious injury Safety alert symbol used to alert personnelto potential personal injury hazards Obey all safety messages that follow this symbol to avoid possible injury or death Indicates a potentially hazardous AWARNING 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 Indicates a potentially hazardous situation which if not avoided may result in property damage Indicates that a specific result is expected after performing a series of steps W Indicates that an incorrect result has occurred after performing a series of steps Section 4 Repair Procedures September 2008 Lighting 1 1 Lighting How to Remove a Lamp ADANGER High voltage Exposure to electrical wires or electrical current will result in death or serious
43. Remove the fasteners securing the generator to the engine flywheel 10 Remove the fasteners securing the generator to the chassis 11 Attach a lifting strap from an overhead crane to the generator Support the generator Do not apply any lifting pressure 12 Remove the fasteners securing the generator to the engine bellhousing 13 Remove the generator from the machine Crushing hazard The generator ACAUTION will fall if not properly supported when removed from the machine Section 4 Repair Procedures September 2008 GENERATOR Models with Perkins engine 1 Remove the fuel tank See 3 1 How to Remove the Fuel Tank 2 Loosen but do not remove the fasteners securing the capacitor cover to the top of the generator Burn hazard Contact with hot ACAUTION engine components may cause severe burns Use caution when working around a hot engine 3 Pull the cover off the top of the generator just enough to access the wire harness where it connects to the generator 4 Using an insulated conductor or a screwdriver with an insulated handle discharge the capacitor by shorting across the capacitor terminals Repeat for the second capacitor if equipped ADANGER High voltage Exposure to electrical wires or electrical current will result in death or serious injury Remove all rings watches and other jewelry Use extreme caution when working with high voltage electrical components 5 Tag and disconnect the
44. SFORMER PANEL 1000w sei pec a GENERATOR BREAKER BOX WH 1 2 3 4 WH SR GN S2 LL m 180 WH tl WH BK ee T3 T2 11213 4 T1 TA e e 53 18 BK a RD 1 1 RD 7 180 LCAPACITOR BK BK 7 pi TRANSFORMER 2 Sien dE Ba y SC BALLasT 3 Bang 15 CL BL BL BK Se A BALLAST 2 WH 4 1 WH BK WH BK TRANSFORMER p 5 a x tooow 24ur WH WH SE wa LCAPACITOR 6 1 2 s3 4 t GN 7 i 11234 8 RD BK WH 4 t WH 9 m ton GN BK BL y ccm WH 1 2 3 4 mim GN 240V 9 WH UN a 0 120V 120V mea 24 uF ma7 HUSS 1 TRANSFORMER L awe MACHINE SHOWN m E EE IN THE STOWED POSITION WITH THE POWER OFF Genie A TEREX COMPANY PartNo 116472 TML 4000 TML 4000N 6 5 Section 6 Schematics September 2008 Electrical Schematic TML 4000 and TML 4000N REV A after serial number TMLO2 521
45. and well lit situation which if not avoided rig may result in property damage Be sure to wear protective eye wear and other protective clothing if the situation warrants it Be aware of potential crushing hazards EI 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 116472 September 2008 Table of Contents Introduction Important INfonmation sicui eat aA Ba eal How to Read Your Serial Number iii Parts Stocking List nennen nnne nnne X Howto Order Parts ente bereits bx crc Xii Service Parts Fax Order Form sse eene xiii Section 1 Safety Rules General Safety AA Section 2 Rev Specifications B Machine SpecifICatiOris oe creer edet Eet 2 1 Performance Specifications 1 00 2 1 Deutz FIM 1008 Engine e reet 2 2 Lombardini LDW 1003 L and Deutz F3M 1008F Engine 2 3 Perkins 103 10 Engine ENEE 2 4 Perkins403C 11 Engifie zi out er 2 5 Generator Specifications sisina pa 2 6 SAE and Metric Fasteners Torque Charte 2 7 Section 3 Rev Scheduled Maintenance Procedures 3 1 Pre delivery Pr
46. ar A A C f Go O Coy AYO Co PO 0 OCH A O 41 Part No 116472 TML 4000 TML 4000N 2 7 Section 2 Specifications September 2008 This page intentionally left blank 2 8 TML 4000 TML 4000N Part No 116472 September 2008 Section 3 Scheduled Maintenance Procedures Scheduled Maintenance Procedures Observe and Obey Maintenance inspections shall be completed by a person trained and qualified on the maintenance of this machine Scheduled maintenance inspections shall be completed daily quarterly semi annually annually and every 2 years as specified on the Maintenance Inspection Report AWARNING Failure to perform each procedure as presented and scheduled could result in death serious injury or substantial damage Immediately tag and remove from service a damaged or malfunctioning machine Repair any machine damage or malfunction before operating the machine Use only Genie approved replacement parts Machines that have been out of service for a period longer than 3 months must complete the quarterly inspection Unless otherwise specified perform each maintenance procedure with the machine in the following configuration Machine parked on a firm level surface Mastin the stowed position Li
47. arting will become impossible at end of life Check for blackening of the ends of the arc tube 5 Line or ballast output Check line voltage at the fixture Check open voltage low circuit voltage 5 4 TML 4000 TML 4000N Part No 116472 September 2008 EEN Section 5 Troubleshooting LAMP TROUBLESHOOTING Chart Cause Solution 6 Ballast burned out Check circuit continuity Replace capacitor at the same time 7 Dirty or burned out Visually inspect lamp for dirt or foreign lamp materials Visually inspect lamp for discoloration 8 Improper ambient Metal halide lamps will start above 20 F temperature Other lamps experience starting problems when the ambient temperature is below 50 F 9 Line voltage varies Check incoming voltage with voltmeter If this is the issue check other equipment on the same circuit 10 Hard starting lamp Replace with new lamp if delay is lengthy 11 New lamp needs to be Turn lamp on and off several times at 30 seasoned minute intervals 12 Significant air Check for fans or air conditioning blowing movement across across lamps lamps 13 Lamp operates less Rated lamp life is based on 10 hours of than 10 hours per start operation per start General rule for expected lamp life is that a 50 reduction in burn time per start results in a 25 reduction in lamp life 14 Faulty Lamp Replace with new lamp 15 Improper circuit Confirm that the circuit breaker
48. ck in the appropriate box after each inspection procedure is completed Use the step by step procedures in this section to learn how to perform these inspections If any inspection receives an tag and remove the machine from service repair and re inspect it After repair place a check in the box Legend Y yes acceptable no remove from service repaired Checklist A Rev C Checklist C Rev B Y NR A 1 Manuals and decals C 1 Cable and pulleys A 2 Pre operation inspect A 3 Function tests Perform every 8 hours 4 Engine maintenance Perkins models A 5 Winch maintenance Perform every 10 hours A 6 Engine maintenance Duetz models Perform every 50 miles A 7 Hitch maintenance Perform after 40 hours A 8 30 day service Perform every 100 hours A 9 Engine maintenance Perkins 103 10 models Perform every 125 hours A 10 Engine maintenance Deutz models Perform every 200 hours A 11 Engine maintenance Perkins 103 10 models A 12 Generator maintenanc Marathon models Checklist B Rev C Y NR B 1 Battery B 2 Electrical wiring B 3 Tires and wheels B 4 Engine maintenance Duetz models B 5 Engine maintenance Perkins 403C11 model B 6 Hitch maintenance Perform every 400 hours B 7 Engine maintenance Perkins 103 10 models Perform every 3000 miles IT
49. e PartNo 116472 TML 4000 TML 4000N 5 3 Section 5 Troubleshooting September 2008 Lamp Troubleshooting REVA Problem Solution Lamp will not start Refer to Charts 1 through 8 Slow or erratic starting Refer to Charts 1 through 10 Blinking or flickering Refer to Charts 9 11 and 12 Cycling lamps turn on and off Refer to Charts 1 3 5 and 9 Light output reduced Refer to Charts 3 4 6 and 8 Short lamp life Refer to Charts 1 4 13 and 14 Tripped circuit breaker Refer to Charts 15 16 and 17 Chart Cause Solution 1 Incorrect lamp or Check fixture label against lamp type ballast 2 Lamp is improperly Remove and securely reinstall lamp Confirm seated in socket the pin connection in the lamp socket Check the center contact of the socket for compression if so disconnect the fixture from power supply and carefully bend the contact into position with a screwdriver 3 Incorrect or loose Disconnect from power supply and check all wiring wiring and connections 4 Lamp is at ornearend Replace with new lamp Metal Halide lamps of life will produce low light output may exhibit intermittent starting and suffer severe color changes High Pressure Sodium lamps will exhibit normal starting but will turn off and on during operation cycling and may develop a brownish discoloration and a general blackening at the ends of the tube Low Pressure Sodium lamps at nearly full light output but st
50. e mast wire harness connector from the machine at the firewall adjacent to the generator Release the wire harness from the engine cover a guide pad 4 Attach a lifting strap from an overhead crane to b wire harness pulley the mast Support the mast Do not apply any c number 2 mast tube lifting pressure 3 Remove the lighting wire harness from the 5 Unlock the mast hold down pin at the mast number 1 mast tube cradle 6 Remove the mast pivot fasteners securing the lower end of the mast to the machine and remove the mast from the machine TEREX COMPANY 4 4 TML 4000 TML 4000N Part No 116472 September 2008 Section 4 Repair Procedures REVA 4 Remove the light bar mounting fasteners Remove the light bar and number 4 mast tube from the mast assembly and set them to the side Component damage hazard Cables can be damaged if they are kinked or pinched 5 Remove the fasteners securing the number 3 lift cable to the top of the number 1 mast tube 6 Remove the fasteners securing the cable pulley to the top of the number 2 mast tube Remove the pulley from the mast and set it to the side Note Always replace the cotter pin with a new one when removing the pulley 7 Pullthe number 2 mast tube approximately 12 inches 30 cm out of number 1 mast tube 8 Remove the inner wear pads from the top of the number 2 mast tube 9 Remove the number 3 mast tube and cable from the mast assembly and set i
51. ect wire for the lamp to be tested 4 Startthe engine 5 Connecta voltmeter to the lamp wires 6 Turn the appropriate circuit breaker light switch to the on position Part No 116472 September 2008 Section 4 Repair Procedures REVA 7 Observe the voltage as the lamps warm up Refer to the following chart Note It can take up to 5 minutes for the lights to reach full intensity If the lights are turned off and then turned back on while they are still warm they will not light up again for 10 to 20 minutes Time Line Voltage Initial ignition 427V 30 seconds 436V AC 1 minute 435V AC 2 minutes 431V AC 5 minutes 241V AC 10 minutes No significant change Note If the voltage reading remains high during warm up check for loose or broken wire connections OR the lamp may be faulty Note The voltage readings provided in the chart are averages voltage on your machine may vary PartNo 116472 A TEREX TML 4000 TML 4000N MANY LIGHTING How to Check the Open Circuit Voltage Correct line voltage at the lamp socket is essential for proper operation of the lighting system High voltage Exposure to electrical wires or electrical current will result in death or serious injury Remove all rings watches and other jewelry Turn off all power when not needed for testing Use extreme caution when working with high voltage electrical components ADANGER 1 Turn off all
52. eparation 2 3 3 Maintenance Inspection Report AANEREN 3 5 C Checklist A Procedures A 1 Inspect the Manuals and Decals 3 6 2 Perform Pre operation Inspection 2 3 7 A 3 Perform Function Tests cci ettet dare 3 7 4 Perform Engine Maintenance Perkins Models 3 7 5 Perform Hitch Maintenance 3 7 6 Perform Engine Maintenance Lombardini and Deutz Models 3 8 A 7 Perform Huch Maintenance AANEREN 3 8 8 Perform 30 Day Service 3 9 Genie A TEREX COMPANY PartNo 116472 TML 4000 TML 4000N vil September 2008 SEF AEE TABLE OF CONTENTS Section 3 Rev Scheduled Maintenance Procedures continued A 9 Perform Engine Maintenance Perkins 103 10 Models 3 9 A 10 Perform Engine Maintenance Lombardini and Deutz Models 3 10 A 11 Perform Engine Maintenance Perkins 103 10 Models 3 10 A 12 Perform Generator Maintenance 3 10 Checklist Procedures B 1 Inspect the Battery eem e cot td e canted 3 11 B 2 Inspect the Electrical Wiring ssssesssssrsensssrrnneesinrnnnnnrennnnnessnnnnnnennna 3 12 B 3 Inspect the Tires and Wheels including lug nut torque 3 12 B 4 Perform Engine Maintenance
53. formation is available in the Leroy Somer Installation and Maintenance Manual Leroy Somer part number 1903 4 33 Leroy Somer Installation and Maintenance Manual REVA D 4 Perform Tongue Jack and Outrigger Jack Maintenance Tongue jack specifications require that this procedure be performed annually Required maintenance procedures and additional hitch information is available in the Cequent Tongue Jack Use Manual Cequent part number F3282ML Cequent Tongue Jack Use Manual Genie part number 150138 Genie part number 150140 D 5 Perform Axle Maintenance Axle specifications require that this procedure be performed annually or every 12 000 miles which ever comes first Required maintenance procedures and additional axle information is available in the Dexter Axle Operation Maintenance Service Manual Dexter part number LIT 001 00 Dexter Axle Operation Maintenance Service Manual Genie part number 84376 Genie TEREX TML 4000 TML 4000N Part No 116472 September 2008 Section Scheduled Maintenance Procedures Checklist E Procedures REVA E 1 Perform Engine Maintenance Lombardini and Deutz Models Engine specifications require that this procedure be performed every 2000 hours or two years whichever comes first Required maintenance procedures and additional engine information is available in the Lombardini LDW 1003 L or Deutz 1008 Operation Manual Deutz part number
54. g voltage sufficient to strike and maintain the arc within the lamp and 2 To supply the proper current to the lamp once the arc is established When using this type of ballast a line voltage variation of 10 will result change in lamp wattage of similar proportions Additionally the ballast input current during lamp warm up does not exceed the current when the lamp is stabilized Theory of Operation At lamp start up the ballast produces a higher voltage of approximately twice the lamps voltage to initiate and maintain the arc As the lamp temperature increases during warm up the voltage drops to the steady operating level Metal halide lamps take from 2 to 5 minutes to warm up and reach full lumen output The following illustration shows how the voltage varies from lamp start up to full umen output An interruption in the power supply at any time or a sudden drop in voltage may cause the arc to extinguish A lamp that is still hot will not restart until it has cooled enough to reduce vapor pressure within the arc tube to a point where the arc can restart typically 10 to 20 minutes The incidences of accidental lamp outages tied to voltage dips is relatively low when using CWA type ballasts because the lamps can tolerate drops in line voltage of 30 40 before the lamp extinguishes Lamp Voltage vs Ignition Time 600 500 400 D oO 300 gt 200 100 0 0 0 5 1 1 5 2 2 5 3 3 5 4 4 5 5 Unit Tim
55. ght switches in the off position Key switch in the off position Wheels chocked PartNo 116472 A TEREX TML 4000 TML 4000N 3 1 MPANY About This Section This section contains detailed procedures for each scheduled maintenance inspection Each procedure includes a description safety warnings and step by step instructions Symbols Legend Safety alert symbol used to alert personnelto potential personal injury hazards Obey all safety messages that follow this symbol to avoid possible injury or death Indicates an imminently hazardous situation which if not avoided will result in death or serious injury ADANGER Indicates a potentially hazardous AWARNING 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 Indicates a potentially hazardous situation which if not avoided may result in property damage Indicates that a specific result is expected after performing a series of steps W Indicates that an incorrect result has occurred after performing a series of steps Section 3 Scheduled Maintenance Procedures September 2008 SCHEDULED MAINTENANCE PROCEDURES Maintenance Symbols Legend Note The following symbols have been used in this manual to help communicate the intent of the instructions When one or more of the symbols appears at
56. ght switches in the off position ACAUTION yat hazard Contact with hot amp or engine components may cause severe burns Use caution when working around lamps or a hot engine Genie TEREX PartNo 116472 TML 4000 TML 4000N 5 1 Section 5 Troubleshooting September 2008 TROUBLESHOOTING About This Section When a malfunction is discovered the fault code chart in this section will help a service professional pinpoint the cause of the problem To use this section basic hand tools and certain pieces of test equipment are required voltmeter ohmmeter pressure gauges General Repair Process Malfunction Identify Troubleshoot discovered symptoms problem Still exists Perform repair Return to service problem solved TEREX COMPANY 5 2 TML 4000 TML 4000N Part No 116472 September 2008 Section 5 Troubleshooting REVA The light system consists of four 1000W metal halide lamps mounted in reflective fixtures Metal halide lamps are a specific type of lamp within the high intensity discharge HID lamp family These HID lamps are powered by four core and coil or constant wattage autotransformer CWA type ballasts which are mounted inside a secure compartment next to the ground control panel Generally the ballast in a metal halide lighting system has two purposes 1 To supply the proper startin
57. he Maintenance Inspection Report to use for each inspection Store completed forms for three years Part No 116472 Pre Delivery Preparation Fundamentals It is the responsibility of the dealer to perform the Pre delivery Preparation The Pre delivery Preparation is performed prior to each delivery The inspection is designed to discover if anything is apparently wrong with a machine before it is put into service A damaged or modified machine must never be used If damage or any 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 Scheduled maintenance inspections shall be performed by qualified service technicians according to the manufacturer s specifications and the requirements listed in the responsibilities manual Genie A TEREX COMPANY Genie Industries USA 18340 NE 76th Street PO Box 97030 Redmond WA 98073 9730 425 881 1800 Genie UK The Maltings Wharf Road Grantham Lincolnshire NG31 6BH England 44 1476 584333 Copyright 2002 by Genie Industries Genie is a registered trademark of Genie Industries Rev B Instructions Use the operator s manual on your machine The Pre delivery Preparation consists of completing the Pre operation Inspection the Maintenance items and the Function Tests Use this form
58. hes 72 x 75 mm Horsepower see engine rating plate Firing order 1 3 2 Compression ratio 22 8 1 Engine speed 1800 rpm Governor mechanical Valve clearance cold Intake 0 0079 in 0 2 mm Exhaust 0 0079 in 0 2 mm Lubrication system Oil pressure hot 1800 rpm 40 to 60 psi 2 75 to 4 1 bar Oil capacity 2 65 quarts including filter 2 5 liters Oil pressure switch 4 35 2 psi engine shut off pressure 0 3 0 15 bar Oil viscosity requirements Units ship with 15W 40 Extreme operating temperatures may require the use of alternative engine oils For oil requirements refer to the Engine Operator Handbook on your machine Genie REVA Engine coolant Capacity 5 2 quarts 4 9 liters Coolant temperature switch 230 5 engine shut off temperature 110 3 C Injection system Injection pump make Bosch Injection pump pressure 6500 700 psi 450 50 bar Injector opening pressure Fuel requirement 1958 72 psi 135 5 bar For fuel requirements refer to the engine Operator s Manual on your machine Alternator Output 45A 12V DC Fan belt tension 90 4 ft lbs new belt installation 400 20 N Fan belt tension 56 4 ft lbs retension after 15 min of use 250 20 N Temperature sensor Engine block temperature maximum 302 F 150 C TML 4000 TML 4000N Part No 116472 September 2008 REVA Lombardini LDW 1003 L Deutz F3M 1008F Engine
59. hreads install the fasteners securing the generator to the engine bellhousing Tighten to finger tight 3 Ina star pattern torque the bellhousing fasteners to 30 ft Ibs 20 Nm 4 Using a liquid threadlocker on the fastener threads install the fasteners securing the generator rotor to the engine flywheel Tighten to finger tight 5 Ina star pattern torque the flywheel fasteners to 15 ft lbs 41 Nm 6 Install the fasteners securing the generator to the chassis Securely tighten the fasteners 7 Install the generator fan screen onto the generator Install and securely tighten the retaining fasteners 8 Install the wires onto the terminal block at the top of the generator Securely tighten the fasteners 9 Install the capacitor cover onto the generator Install and securely tighten the fasteners 10 Models with over engine exhaust Install the exhaust pipe into the muffler Install and securely tighten all fasteners securing the exhaust pipe to the engine 11 Install the fuel tank PartNo 116472 A TEREX TML 4000 TML 4000N MANY GENERATOR Models with Perkins engine 1 Usinga liquid threadlocker on the fastener threads install the armature drive plate and plate fasteners onto the engine flywheel Install the fasteners to finger tight 2 Ina star pattern torque the armature drive plate fasteners to 18 ft lbs 24 Nm 3 Being careful to not damage the armature field windings gently slide the
60. injury Remove all rings watches and other jewelry Turn off all power when not needed for testing Use extreme caution when working with high voltage electrical components Burn hazard Contact with hot lam ACAUTION azard Contac ot lamp components may cause severe burns Use caution when working aroundlamps 1 Turn off all machine power 2 Remove the light lens mounting fasteners and remove the lens 3 Remove the mounting fasteners securing the lamp retainer to the reflector Component damage hazard Contacting the lamp with bare skin can cause damage to the lamp Do not allow bare skin contact with the lamps 4 Wrap aclean cloth around the lamp and remove the lamp from the socket Note Be sure to wrap a clean cloth around a lamp when installing a lamp into a lamp socket TEREX TML 4000 TML 4000N REV A How to Check Line Voltage Correct line voltage at the lamp socket is essential for proper operation of the lighting system ADANGER High voltage Exposure to electrical wires or electrical current will result in death or serious injury Remove all rings watches and other jewelry Turn off all power when not needed for testing Use extreme caution when working with high voltage electrical components 1 Turn off all machine power 2 Remove the cover from the lamp junction box Note The junction box is located between the light housings at the top of the mast 3 Locate the corr
61. instructional decals in good condition is mandatory for safe machine operation Decals alert operators and personnel to the many possible hazards associated with using this machine They also provide users with operation and maintenance information An illegible decal will fail to alert personnel of a procedure or hazard and could result in unsafe operating conditions 1 Check to make sure that the operator s and safety manuals are present and complete in the storage container on the platform 2 Examine the pages of each manual to be sure that they are legible and in good condition Result The operator s manual is appropriate for the machine and all manuals are legible and in good condition W Result The operator s manual is not appropriate for the machine or all manuals are not in good condition or is illegible Remove the machine from service until the manual is replaced A TEREX 3 6 TML 4000 TML 4000N REVA 3 Open the operator s manual to the decals inspection section Carefully and thoroughly inspect all decals on the machine for legibility and damage Result The machine is equipped with all required decals and all decals are legible and in good condition Result The machine is not equipped with all required decals or one or more decals are illegible or in poor condition Remove the machine from service until the decals are replaced 4 Always return the manuals to the storage container after
62. iters 32150 Genie Gray Paint 1 Gallon 3 78 liters 32151 Genie X TML 4000 TML 4000N A TEREX CON Part No 116472 September 2008 E This page intentionally left blank A TEREX COMPANY PartNo 116472 TML 4000 TML 4000N xi 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 authorized Genie Distributor in your area 414 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 TEREX Xii TML 4000 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
63. le drum cable drum cover drum bolt winch handle handle nut jam nut pinion plate PartNo 116472 TML 4000 TML 4000N 4 7 Section 4 Repair Procedures September 2008 Chassis 3 1 Ground Controls How to Check a Lighting Capacitor JW 1813 High voltage Exposure to electrical wires or electrical current will result in death or serious injury Remove all rings watches and other jewelry Turn off all power when not needed for testing Use extreme caution when working with high voltage electrical components Electrocution hazard Attempting to service the machine before the capacitors are fully discharged will result in death or serious injury Note Be sure the engine has been turned off for at least 15 minutes before servicing the machine Use a voltmeter to confirm there is no residual voltage in the capacitors Note This procedure is only for the capacitors which are attached to the lighting ballasts To test a generator capacitor see 4 1 How to Check a Generator Capacitor 1 Remove the front access cover next to the machine control panel 2 Tag and disconnect the four transformer harness connectors from the machine wire harness TEREX TML 4000 TML 4000N REV A 3 Usingan insulated conductor or a screwdriver with an insulated handle discharge each of the four capacitors by shorting across the capacitor
64. lithium grease to the the winch frame large threaded section of the pinion shaft L S j 9 Install the thrust washer and pinion plate onto 4 Insert the pinion shaft through the small bushing the pinion shaft in the winch frame the pinion gear friction disc ratchet gear and finally through the large bushing at the other side of the frame Refer to the illustration below Component damage hazard Be sure the pinion shaft is threaded all the way into the winch drum before tightening the two jam nuts 10 Install the two jam nuts onto the pinion shaft and tighten Component damage hazard Grease or oil on the friction disc will result in poor winch performance Do notallow grease 11 Install the handle onto the winch Install the or oil onto the friction disk handle nut onto the winch and securely tighten 5 Install the retaining ring into the small groove at 12 Route the cable onto the winch drum and install the non threaded end of the pinion shaft the cable retaining fasteners Wind the cable onto the drum Bodily injury hazard Cables can ACAUTION fray Always wear adequate hand protection when handling the cable Note Be sure the end of the cable does not extend past the edge of the winch drum pinion shaft bushing large thrust washer ratchet gear friction disc pinion gear pinion shaft retaining ring pinion shaft bushing small ratchet pawl assembly winch frame cable keeper kit frame spacer cab
65. ns require that this procedure be performed every three years Required maintenance procedures and additional engine information is available in the Leroy Somer Installation and Maintenance Manual Leroy Somer part number 1903 4 33 Leroy Somer Installation and Maintenance Manual Genie part number 150138 Genie TEREX TML 4000 TML 4000N Part No 116472 September 2008 Section 4 Repair Procedures Observe and Obey Repair procedures shall be completed by a person trained and qualified on the repair of this machine Immediately tag and remove from service damaged or malfunctioning machine Repair any machine damage or malfunction before operating the machine Before Repairs Start Read understand and obey the safety rules and operating instructions in the appropriate operator s manual on your machine Be sure that all necessary tools and parts are available and ready for use Use only Genie approved replacement parts Readeach procedure completely and adhere to the instructions Attempting shortcuts may produce hazardous conditions Unless otherwise specified perform each repair procedure with the machine in the following configuration Machine parked on a firm level surface Mastin the stowed position Key switch in the off position Light switches in the off position Wheels chocked PartNo 116472 A TEREX TML 4000 TML 4000
66. obey the safety rules and operating instructions in the appropriate operator s manual on your machine Be sure that all necessary tools and test equipment are available and ready for use Observe and Obey Be aware of the following hazards and follow Troubleshooting and repair procedures shall be generally accepted safe workshop practices completed by a person trained and qualified on DANGER Electrocution hazard Exposure to the repair of this machine ADA ad electrically charged circuits could Immediately tag and remove from service result in death or serious injury damaged or malfunctioning machine Remove all rings watches and e other jewelry Repair any machine damage or malfunction before operating the machine ADANGER Electrocution hazard Attempting to sevice the machine before the Unless otherwise specified perform each 4 capacitors are fully discharged will repair procedure with the machine in the in death 2 ees following configuration Machine parked on firm level surface 74711434 1 High voltage Exposure to u electrical wires or electrical current Mastin the stowed position will result in death or serious Key switch in the off position injury Remove all rings watches and other jewelry Turn off all power when not needed for Wheels chocked testing Use extreme caution when working with high voltage electrical components Li
67. ocedures and additional axle information is available in the Dexter Axle Operation Maintenance Service Manual Dexter partnumber LIT 001 00 Dexter Axle Operation Maintenance Service Manual Genie part number 84376 Genie TEREX TML 4000 TML 4000N Part No 116472 September 2008 Section 3 Scheduled Maintenance Procedures Checklist C Procedures REVA C 1 Inspect the Cable and Cable Pulleys Genie specifications require that this procedure be performed every 500 hours or semi annually whichever comes first Detection of damage to the cable or pulleys is essential for safe machine operation An unsafe working condition exists if these components are damaged and do not operate smoothly Regular inspection of this system allows the inspector to identify changes in the operating condition that may indicate damage 1 Visually inspect the cable and components for the following frayed or broken wire strands kinks in the cable corrosion paint or foreign materials cable is properly secured to the winch cable is on the pulleys broken or damaged pulleys unusual or excessive pulley wear Part No 116472 A TEREX TML 4000 TML 4000N 3 15 C 2 Perform Engine Maintenance Perkins 403C 11 Models Engine specifications require that this procedure be performed every 500 hours or semi annually whichever comes first Required maintenance procedures and additional
68. oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray General Repair Process Malfunction _ Identify discovered gt Troubleshoot symptoms Return to _ Perform service problem repair solved PartNo 116472 TML 4000 TML 4000N 6 1 Section 6 Schematics September 2008 Trailer Lighting Wiring Diagram REVA L35A m L35B RIGHTSIDEMARKER 7 RIGHT SIDE MARKER WH BK WH BK D19A L33 4 WH RIGHT REAR TAIL LIGHT 3 ve vc BN YL 1H YL L58 QD12 LICENSE PLATE LIGHT 1 PLUG GN L34 1 2 3 4 QD19B LEFT REAR TAIL LIGHT HARNESS CONNECTOR 4 WH BN YL BN BN GN WH 3 BN YL 2 YL WH BK WH BK 1 GN L36A x LEFT SIDE MARKER Genie TEREX COMPA L36B LEFT SIDE MARKER TML 4000 TML 4000N Part No 116472 September 2008 Section 6 Schematics Electrical Symbols Legend REVA o N Circuit breaker Lamp AC Outlet Switch Capacitor E
69. or s manual Refer to the Operator s Manual on your machine PartNo 116472 A TEREX TML 4000 TML 4000N MANY CHECKLIST A PROCEDURES 4 Perform Engine Maintenance Perkins Models Engine specifications require that this procedure be performed every 8 hours or daily whichever comes first Required maintenance procedures and additional engine information is available in the Perkins 100 Series Operating Instructions Perkins part number 100816243 0695 OR the Perkins 400 Series User s Handbook Perkins part number 100816460 Perkins 100 Series Operating Instructions Genie part number 150137 Perkins 400 Series User s Handbook Genie part number 97360 A 5 Perform Winch Maintenance Winch specifications require that this procedure be performed every 8 hours or daily whichever comes first Required maintenance procedures and additional winch information is available in the Fulton Winch Operator s Manual Fulton part number F1928 Fulton Winch Operator s Manual Genie part number 150143 Section 3 Scheduled Maintenance Procedures September 2008 CHECKLIST A PROCEDURES A 6 Perform Engine Maintenance Lombardini and Deutz Models Engine specifications require that this procedure be performed every 10 hours or daily whichever comes first Required maintenance procedures and additional engine information is available in the Lombardini LDW 1003 L or Deutz 1008 Operation
70. protection when handling the cable 3 Remove the winch from the machine 4 Ona workbench remove the handle handle nut and two jam nuts from the pinion shaft 5 Remove the retaining ring from the small groove at the non threaded end of the pinion shaft Rotate the pinion shaft until the shaft is removed Hold the winch components in place while removing the pinion shaft 6 Remove the cable drum 7 Remove the ratchet pawl assemblies 8 Remove the pinion shaft bushings Use a soft metal drift equal to the outside diameter of the bushing and tap with a rubber mallet Note Note the quantity and location of the shims between the winch drum and the bushing before disassembling TEREX COMPANY 4 6 TML 4000 TML 4000N Part No 116472 September 2008 Section 4 Repair Procedures SSS SS Se REVA MAST How to Assemble the Winch 6 Install the ratchet pawl kit as shown in the illustration Securely tighten the fasteners 1 Clean and inspect the winch components before installing Insert the drum bolt through the frame spacer and the winch drum Install and securely tighten 2 Install the pinion shaft bushings Use a soft the locknut metal drift equal to the outside diameter of the bushing and tap with a rubber mallet until fully seated Working from the threaded end of the pinion shaft turn the shaft in a clockwise direction until the retaining ring installed in step 5 is against 3 Apply a small amount of
71. re be performed every 250 hours or quarterly whichever comes first 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 also result if problems are not discovered and repaired in a timely fashion Check the tire tread and sidewalls for cuts cracks punctures and unusual wear 2 Check each wheel for damage bends and cracked welds 3 Check each lug nut or lug bolt for proper torque Refer to Section 2 Specifications 4 Check the air pressure of each tire Refer to Section 2 Specifications Part No 116472 September 2008 Section 3 Scheduled Maintenance Procedures REVA CHECKLIST B PROCEDURES B 4 B 5 Perform Engine Maintenance Lombardini and Deutz Models Engine specifications require that this procedure be performed every 250 hours or quarterly whichever comes first Required maintenance procedures and additional engine information is available in the Lombardini LDW 1003 L or Deutz 1008 Operation Manual Deutz part number 0297 9689 Deutz 1008 Operation Manual Perform Engine Maintenance Perkins 403C 11 Models Engine specifications require that this procedure be performed every 250 hours or quarterly whichever comes first Required maintenance procedures and additional engine information is available in the Perkins 400 Series User s Handbook Perkins par
72. reme caution when working with high voltage electrical components ADANGER Electrocution hazard Attempting to service the machine before the capacitors are fully discharged will result in death or serious injury Note Be sure the engine has been turned off for at least 15 minutes before servicing the machine Use a voltmeter to confirm there is no residual voltage in the capacitors Note This procedure is only for the capacitors which are attached to the generator To testa lighting capacitor see 3 1 How to Check a Lighting Capacitor 1 Remove the generator capacitor cover See 4 1 How to Remove the Generator Capacitor Cover 2 Tag and disconnect the wires attached to the capacitor s Section 4 Repair Procedures September 2008 GENERATOR 3 Usingan insulated conductor or a screwdriver with an insulated handle discharge the capacitor by shorting across the capacitor terminals Repeat for the second capacitor if equipped JW T4313 High voltage Exposure to electrical wires or electrical current will result in death or serious injury Remove all rings watches and other jewelry Use extreme caution when working with high voltage electrical components 4 With an ohmmeter set to its highest resistance scale connect the ohmmeter leads to the capacitor terminals and observe the reading on the meter Then reverse the connections and observe the reading on the meter Result The meter indicates a
73. s match breakers installed for manufacturers specification fixture 16 Overloaded circuit Verify that the total circuit load is less than circuit rating 17 Shorted or grounded Test for a short in the circuit Replace faulty fixtures fixture Genie Part No 116472 TML 4000 TML 4000N 5 5 Section 5 Troubleshooting September 2008 EEN This page intentionally left blank 5 6 TML 4000 TML 4000N Part No 116472 September 2008 Section 6 Schematics Observe and Obey Troubleshooting and repair procedures shall be completed by a person trained and qualified on the repair of this machine Immediately tag and remove from service a damaged or malfunctioning machine Repair any machine damage or malfunction before operating the machine Before Troubleshooting Read understand and obey the safety rules and operating instructions in the appropriate operator s manual on your machine Be sure that all necessary tools and test equipment are available and ready for use Schematics About This Section There are two groups of schematics in this section An illustration legend precedes each group of drawings Electrical Schematics AWARNING Electrocution hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry Hydraulic Schematics Bodily injury hazard Spraying AWARNING hydraulic
74. s with Lombardini or Deutz engine 1 Remove the fuel tank See 3 1 How to Remove the Fuel Tank 2 Models with over engine exhaust Remove the fasteners securing the exhaust pipe to the engine Remove the exhaust pipe from the machine 3 Loosen but do not remove the fasteners securing the capacitor cover to the top of the generator Burn hazard Contact with hot ACAUTION engine components may cause severe burns Use caution when working around a hot engine 4 Pullthe cover off the top of the generator just enough to access the wire harness where it connects to the generator PartNo 116472 A TEREX TML 4000 TML 4000N MANY GENERATOR 5 Usingan insulated conductor or a screwdriver with an insulated handle discharge the capacitor by shorting across the capacitor terminals Repeat for the second capacitor if equipped JW 3143 High voltage Exposure to electrical wires or electrical current will result in death or serious injury Remove all rings watches and other jewelry Use extreme caution when working with high voltage electrical components 6 Tagand disconnect the wires at the top of the generator Remove the cover 7 Usea lifting jack to support the rear of the engine Do not apply any lifting pressure 8 Remove the generator fan screen from the generator Note The generator fan screen covers the generator fan blades and is located between the generator andthe engine bellhousing 9
75. sor Engine block temperature maximum 302 F 150 C enie 2 3 TML 4000 TML 4000N Section 2 Specifications September 2008 SPECIFICATIONS Perkins 103 10 Engine Displacement 58 21 cu in 0 954 liters Number of cylinders 3 Bore and stroke 3 3 x 3 15 inches 84 x 80 mm Horsepower see engine rating plate Firing order 1 2 3 Compression ratio 23 1 Compression pressure 425 psi 29 3 bar Pressure of the lowest cylinder must be within 50 psi 3 45 bar of the highest cylinder though at no time less than 360 psi 24 8 bar Engine speed models with 50 Hz generator 1500 rpm models with 60 Hz generator 1800 rpm Governor all speed mechanical Valve clearance cold Intake 0 0078 in 0 2 mm Exhaust 0 0078 in 0 2 mm Lubrication system Oil pressure hot 1800 rpm 40 to 60 psi 2 75 to 4 1 bar Oil capacity 3 7 quarts including filter 3 5 liters Oil pressure switch 5 psi engine shut off pressure 0 34 bar Oil viscosity requirements Units ship with 15W 40 Extreme operating temperatures may require the use of alternative engine oils For oil requirements refer to the Engine Operating Instructions on your machine Genie REVA Engine coolant Capacity 5 5 quarts 5 21 liters Coolant temperature switch 221 7 F engine shut off temperature 105 4 C Injection system Injection pump make Kikicexel Injection pump pressure 1764 psi 121 bar Fuel requirement For fuel
76. t number 100816460 Perkins 400 Series User s Handbook Genie part number 150108 Genie part number 97360 Lombardini LDW 1003 L Operation Manual Genie part number 116031 Part No 116472 TML 4000 TML 4000N 3 13 Section 3 Scheduled Maintenance Procedures September 2008 CHECKLIST B PROCEDURES B 6 Perform Hitch Maintenance Hitch specifications require that this procedure be performed quarterly Required maintenance procedures and additional hitch information is available in the Fulton Coupler Use Manual Fulton part number F1937 Fulton Coupler Use Manual REVA B 7 Perform Engine Maintenance Perkins 103 10 Models Engine specifications require that this procedure be performed every 400 hours or semi annually whichever comes first Required maintenance procedures and additional engine information is available in the Perkins 100 Series Operating Instructions Genie part number 150139 Perkins partnumber 100816243 0695 Perkins 100 Series Operating Instructions Genie part number 150137 B 8 Perform Axle Maintenance Axle specifications require that this procedure be performed quarterly or every 3000 miles whichever comes first Proper axle maintenance following the axle manufacturer s maintenance schedule is essential to good axle performance and service life Failure to perform the maintenance procedures can lead to poor axle performance and component damage Required maintenance pr
77. t to the side Note If replacing the number 3 lift cable remove the cable from the mast Note To ensure that the mast extends properly after reassembly carefully measure the cable to be sure the new cable is the same length as the old one PartNo 116472 A TEREX COM TML 4000 TML 4000N MAST 10 Remove the cable retaining fastener securing the cable to the winch drum Unwind the cable from the winch drum Bodily injury hazard Cables can ACAUTION fray Always wear adequate hand protection when handling the cable 11 Remove the inner wear pads from the top of the number 1 mast tube 12 Remove the number 2 mast tube from the mast assembly and set it to the side Note If replacing the number 2 lift cable remove the cable from the mast Note To ensure that the mast extends properly after reassembly carefully measure the cable to be sure the new cable is the same length as the old one Section 4 Repair Procedures September 2008 mmm M MAST REV A How to Replace the Mast Lift How to Disassemble the Winch Cable Note For ease of disassembly refer to the See 2 1 How to Disassemble the Mast Illustration on the next page 1 Lowerthe mastto the stowed position 2 Remove the cable retaining fastener securing the cable to the winch drum Unwind the cable from the winch drum Bodily injury hazard Cables can ACAUTION fray Always wear adequate hand
78. tic Perkins Engine after serial number 05 361 6 11 TML 4000 TML 4000N ix 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 Genie Industries offers the following support documents for these models Title Part No Genie TML 4000 and TML 4000N Description PartNo Operator s Manual Second Edition B from serial number TML 01 225 to Models Sy I o n 82199 Dielectric Grease 2 Grease 2 Genie TML 4000 TML 4000N Vsus ME M Mp 2 Operator s Manual Third Edition Fuel Filter e refer to Figure 9 G _ after serial number TML04 559 20508 IT 85071 Perkins 403C 11 Models Manual of Responsibilities ANSI A92 3 31587 Dielectric Grease 66399 mc ies E 94762 Undc 97474 62421 VIe 85071 Valve Cover Breather 84860 Lombardini and Deutz Models Dielectric 66399 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 l
79. wires at the top of the generator Remove the cover 6 Use a lifting jack to support the rear of the engine Do not apply any lifting pressure 7 Remove the fasteners securing the generator to the engine bellhousing TEREX TML 4000 TML 4000N REVA 8 Remove the fasteners securing the generator to the chassis 9 Insert two pinch bars equally spaced from each other between the bellhousing and the generator Gently tap them in between the bellhousing and generator 10 Using equal pressure on both pinch bars pull the bars towards the rear of the machine until the generator housing is to 1 2 inch 9 to 13 mm away from the engine bellhousing Note It may be easier to open the gap by using larger bars after achieving some initial clearance 11 Remove the fasteners securing the generator to the engine flywheel 12 Attach a lifting strap from an overhead crane to the generator Support the generator Do not apply any lifting pressure 13 Remove the generator from the machine Crushing hazard The generator ACAUTION Will fall if not properly supported when removed from the machine Part No 116472 September 2008 Section 4 Repair Procedures REVA How to Install the Generator Models with Lombardini or Deutz engine 1 Remove the generator fan screen from the generator 2 With the engine supported install the generator onto the engine Using a liquid threadlocker on the fastener t
80. z RD BK CR15 30 86 GLOW S PLUG 87A 87 85 PE MP 1 n 1 K 2 START BK 3 PK BK 9 e 4 BL 5 BK E sss 4 RD LPP o nu 5 31 7 RD si je p OR BK 2 OR Lay tw WB 3 WH g WH f 4 D I e 4 10 9 9 50 am 5 SS 5 a e e 6 PDK 6 WHIBK 45 PK Glow 7 BKWH e 7 13 si g WH BK 8 14 GN YL G 23 9 o2 o G eren de 2 5 B D W O D1 H GS EE e ALTERNATOR LYVLS YOLVNYSLIV Had YNOH HOLIMS YANV319 HIV HOLIMS 55 HOSN3S dWAL LNV1IOOO ASOLNHS 13N4 MO19 E gt Pad 4 m U o e Ke z o NOTE MACHINE SHOWN IN THE STOWED POSITION WITH THE POWER OFF Genie A TEREX COMPAT PartNo 116472 TML 4000 TML 4000N 6 9 Section 6 Schematics September 2008 Electrical Schematic Perkins Engine REVA before serial number 05 362 7x 4 KS1 y D di RUN ___ PP RI el F9A AD TIMER V J U23 266 5 1 E ENGIN

TML Service Manual-116472-08-05-08

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