Professional Documents
Culture Documents
Manual
Service Manual
Serial
Serial
Number
Number
Range
Range
TML-4000
TML-4000N
from TML01-226
from TML01-226
July 2007
Introduction
Important
Title
Part No.
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
ii
TML-4000 TML-4000N
July 2007
Model: GS-1930
GS3005A-12345
Serial number:
Model year: 2005 Manufacture date: 04/12/05
Electrical schematic number: ES0141
Machine unladen weight: 2,714 lb / 1,231 kg
N/A
GS30 05
Gradeability: N/A
Maximum allowable side force :
100 lb / 445 kg
Model
A - 12345
Sequence
number
Model year
Country of manufacture: USA
This machine complies with:
Facility code
(used only for models manufactured
in multiple facilities)
ANSI A92.6-1999
B354.2-01
Serial number
stamped on chassis
Genie Industries
18340 NE 76th Street
Redmond, WA 98052
USA
PN - 77055
Serial label
TML-4000 TML-4000N
iii
July 2007
iv
TML-4000 TML-4000N
July 2007
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
operators manual are also safety hazards
when maintenance and repair procedures
are performed.
TML-4000 TML-4000N
July 2007
SAFETY RULES
Personal Safety
Workplace Safety
vi
TML-4000 TML-4000N
July 2007
Table of Contents
Introduction
Important Information ......................................................................................... ii
How to Read Your Serial Number ...................................................................... iii
Parts Stocking List .......................................................................................... xiii
How to Order Parts .......................................................................................... xiv
Service Parts Fax Order Form ......................................................................... xv
Section 1
Safety Rules
General Safety Rules ........................................................................................ v
Section 2
Rev
B
Specifications
Machine Specifications ................................................................................ 2 - 1
Performance Specifications ......................................................................... 2 - 1
Deutz F3M 1008 Engine ............................................................................... 2 - 2
Lombardini LDW 1003/L and Deutz F3M 1008F Engine ................................ 2 - 3
Perkins 103-10 Engine ................................................................................. 2 - 4
Perkins 403C-11 Engine ............................................................................... 2 - 5
Generator Specifications .............................................................................. 2 - 6
SAE and Metric Fasteners Torque Charts .................................................... 2 - 7
Section 3
Rev
Checklist A Procedures
A-1
A-2
A-3
A-4
A-5
A-6
A-7
A-8
vii
July 2007
TABLE OF CONTENTS
Section 3
Rev
viii
Checklist B Procedures
B-1
B-2
B-3
Inspect the Tires and Wheels (including lug nut torque) .................... 3 - 12
B-4
B-5
B-6
B-7
B-8
Checklist C Procedures
C-1
C-2
C-3
C-4
C-5
Checklist D Procedures
D-1
D-2
D-3
D-4
D-5
Checklist E Procedure
E-1
E-2
E-3
E-4
E-5
TML-4000 TML-4000N
July 2007
TABLE OF CONTENTS
Section 4
Rev
Repair Procedures
Introduction .................................................................................................. 4 - 1
Lighting
1-1
Mast
2-1
Rev
Generator
4-1
Section 5
Mast ................................................................................................... 4 - 4
Chassis
3-1
Lighting ............................................................................................... 4 - 2
Generator ......................................................................................... 4 - 11
Troubleshooting
Introduction .................................................................................................. 5 - 1
Section 6
Rev
Schematics
Introduction .................................................................................................. 6 - 1
TML-4000 TML-4000N
ix
July 2007
TABLE OF CONTENTS
Section 7
Rev
B
Section 8
Rev
Decals
Figure 7-A
Decals ................................................................................. 7 - 2
Base Components
Figure 8-A
Figure 8-B
Figure 8-C
Figure 8-D
Figure 8-E
Figure 8-F.1
Figure 8-F.2
Control Box
(from serial number TML02-522 to TML06-00699) ............ 8 - 14
Figure 8-F.3
Control Box
(after serial number TML06-00700) ................................... 8 - 16
Figure 8-G
Covers ............................................................................... 8 - 18
Figure 8-H
Figure 8-I
Figure 8-J
Figure 8-K
Figure 8-L
TML-4000 TML-4000N
July 2007
TABLE OF CONTENTS
Section 9
Rev
Engine Components
Figure 9-A
Figure 9-B
Figure 9-C
Figure 9-D
Figure 9-E
Figure 9-F
Figure 9-G
Figure 9-H
Figure 9-I
Figure 9-J
Figure 9-K
Figure 9-L
TML-4000 TML-4000N
xi
July 2007
TABLE OF CONTENTS
Section 10
xii
Rev
Mast Components
Figure 10-A
Figure 10-B
Figure 10-C
Figure 10-D
Figure 10-E
Figure 10-F.3
Figure 10-G
Figure 10-H
Lightbar Installation
(before serial number TML02-219) .................................. 10 - 16
TML-4000 TML-4000N
July 2007
Manuals
Description
Part No.
Title
Part No.
Recommended Parts
Description
Part No.
TML-4000 TML-4000N
xiii
July 2007
Machine Information
Model
Serial Number
Date of Purchase
Authorized Genie Distributor
Phone Number
xiv
TML-4000 TML-4000N
_________________________________
_________________________________
_________________________________
Ship To
___________________________________
_________________________________
___________________________________
_________________________________
___________________________________
_________________________________
___________________________________
Ship Via
___________________________________
Description
Quantity
Price
Bill To
All back-ordered parts will be shipped when available via the same ship method as the original order
unless Noted below:
Ship complete order only - No back orders
Ship all available parts and contact customer on disposition of back-ordered parts
Other (please specify)
FOR GENIE INDUSTRIES USE ONLY
Order Number ______________
Comments _________________________
__________________________________
__________________________________
July 2007
xvi
TML-4000 TML-4000N
July 2007
Section 2 Specifications
Specifications
REV B
Machine Specifications
Total lighting wattage
Performance Specifications
4000 watts
Fuel capacities
TML-4000
TML-4000N
TML-4000
50 gallons
189 liters
145 lbs
66 kg
TML-4000N
30 gallons
114 liters
110 lbs
50 kg
Run time
Battery - Standard
Type
Group
100 hours
60 hours
70
Quantity
450
105 minutes
12V DC
Group
31
Quantity
950
190 minutes
ST185/80D13
Load range
Lug nut torque, dry
Tire pressure, maximum (cold)
B
80 ft-lbs
108 Nm
50 psi
3.4 bar
TML-4000 TML-4000N
2-1
Section 2 Specifications
July 2007
SPECIFICATIONS
REV B
Engine coolant
55.9 cu in
0.916 liters
3
Horsepower
Firing order
1-3-2
Compression ratio
Engine speed
Governor
22.8:1
Exhaust
mechanical
Oil capacity
(including filter)
Oil pressure switch
(engine shut-off pressure)
230 5F
110 3C
Injection system
Injection pump make
Injection pump pressure
Injector opening pressure
Bosch
6500 700 psi
450 50 bar
1958 72 psi
135 5 bar
Fuel requirement
For fuel requirements, refer to the engine Operator's
Manual on your machine.
0.0079 in
0.2 mm
0.0079 in
0.2 mm
Lubrication system
Oil pressure (hot @ 1800 rpm)
5.2 quarts
4.9 liters
1800 rpm
Capacity
40 to 60 psi
2.75 to 4.1 bar
2.65 quarts
2.5 liters
Alternator
Output
45A, 12V DC
90 4 ft-lbs
400 20 N
56 4 ft-lbs
250 20 N
Temperature sensor
Engine block temperature, maximum
4.35 2 psi
0.3 0.15 bar
302F
150C
2-2
TML-4000 TML-4000N
July 2007
Section 2 Specifications
REV B
SPECIFICATIONS
Engine coolant
62.85 cu in
1.03 liters
Capacity
5.2 quarts
4.9 liters
230 5F
110 3C
3
Injection system
Horsepower
Firing order
1-3-2
Compression ratio
Engine speed
Governor
22.8:1
1800 rpm
mechanical
0.0079 in
0.2 mm
0.0079 in
0.2 mm
Lubrication system
Oil pressure (hot @ 1800 rpm)
Oil capacity
(including filter)
Oil pressure switch
(engine shut-off pressure)
40 to 60 psi
2.75 to 4.1 bar
2.65 quarts
2.5 liters
Bosch
6500 700 psi
450 50 bar
1958 72 psi
135 5 bar
Fuel requirement
For fuel requirements, refer to the engine Operator's
Manual on your machine.
Alternator
Output
45A, 12V DC
90 4 ft-lbs
400 20 N
56 4 ft-lbs
250 20 N
Temperature sensor
Engine block temperature, maximum
302F
150C
4.35 2 psi
0.3 0.15 bar
TML-4000 TML-4000N
2-3
Section 2 Specifications
July 2007
SPECIFICATIONS
REV B
Engine coolant
58.21 cu in
0.954 liters
Number of cylinders
Bore and stroke
3
3.3 x 3.15 inches
84 x 80 mm
Horsepower
Firing order
1-2-3
Compression ratio
23:1
Compression pressure
425 psi
29.3 bar
Capacity
5.5 quarts
5.21 liters
221 7F
105 4C
Injection system
Injection pump make
Kikicexel
1764 psi
121 bar
Fuel requirement
For fuel requirements, refer to the engine Operator's
Manual on your machine.
Alternator
Output
1500 rpm
1800 rpm
all-speed mechanical
15A, 12V DC
0.19 in
5 mm
0.0078 in
0.2 mm
Exhaust
0.0078 in
0.2 mm
Lubrication system
Oil pressure (hot @ 1800 rpm)
Oil capacity
(including filter)
Oil pressure switch
(engine shut-off pressure)
40 to 60 psi
2.75 to 4.1 bar
3.7 quarts
3.5 liters
5 psi
0.34 bar
2-4
TML-4000 TML-4000N
July 2007
Section 2 Specifications
REV B
SPECIFICATIONS
Engine coolant
69 cu in
1.131 liters
Number of cylinders
Bore and stroke
3
3.03 x 3.19 inches
77 x 81 mm
Horsepower
Firing order
1-2-3
Compression ratio
23:1
Compression pressure
425 psi
29.3 bar
Capacity
5.5 quarts
5.21 liters
221 7F
105 4C
Injection system
Injection pump make
Kikicexel
1764 psi
121 bar
Fuel requirement
For fuel requirements, refer to the engine Operator's
Manual on your machine.
Alternator
Output
1500 rpm
1800 rpm
mechanical
15A, 12V DC
0.19 in
5 mm
0.0078 in
0.2 mm
Exhaust
0.0078 in
0.2 mm
Lubrication system
Oil pressure (hot @ 1800 rpm)
Oil capacity
(including filter)
Oil pressure switch
(engine shut-off pressure)
40 to 60 psi
2.75 to 4.1 bar
5.18 quarts
4.9 liters
7 psi
0.48 bar
TML-4000 TML-4000N
2-5
Section 2 Specifications
July 2007
SPECIFICATIONS
REV B
60 Hz
104F
40C
Power
Capacitor (disconnected)
Capacitor (disconnected)
1800 rpm
6 kw
70 F @ 10%
22.5 F @ 5%
50 Hz
60 Hz
104F
40C
Power
Capacitor (disconnected)
220V / 50Hz
240V / 60Hz
1500 rpm
1800 rpm
6 kw
50 F @ 3.4V 10%
70 F @ 6.3V 10%
Marathon Generator
Generator speed @ full load
Temperature, ambient maximum
Power
Capacitor (disconnected)
2-6
60 Hz
1800 rpm
104F
40C
6 kw
45 F
TML-4000 TML-4000N
July 2007
Section 2 Specifications
REV B
SPECIFICATIONS
SIZE
Grade 5
THREAD
LUBED
20
28
1/4
5/16
3/8
7/16
1/2
9/16
5/8
3/4
7/8
1
1.125
1.25
1.5
LUBED
DRY
DRY
in- lbs
Nm
in- lbs
Nm
in- lbs
Nm
in- lbs
Nm
in- lbs
Nm
100
90
11.3
10.1
80
120
9
13.5
140
120
15.8
13.5
110
160
12.4
18
130
140
14.7
15.8
LUBED
18
24
16
24
14
20
13
20
12
18
11
18
10
16
9
14
8
12
7
12
7
12
6
12
Grade 8
DRY
LUBED
DRY
LUBED
f t - lbs
Nm
f t - lbs
Nm
f t - lbs
Nm
f t - lbs
Nm
f t - lbs
Nm
13
14
23
26
37
41
57
64
80
90
110
130
200
220
320
350
480
530
590
670
840
930
1460
1640
17.6
19
31.2
35.2
50.1
55.5
77.3
86.7
108.4
122
149
176
271
298
433
474
650
718
800
908
1138
1260
1979
2223
17
19
31
35
49
55
75
85
110
120
150
170
270
300
430
470
640
710
790
890
1120
1240
1950
2190
23
25.7
42
47.4
66.4
74.5
101.6
115
149
162
203
230
366
406
583
637
867
962
1071
1206
1518
1681
2643
2969
18
20
33
37
50
60
80
90
120
130
160
180
280
310
450
500
680
750
970
1080
1360
1510
2370
2670
24
27.1
44.7
50.1
67.8
81.3
108.4
122
162
176
217
244
379
420
610
678
922
1016
1315
1464
1844
2047
3213
3620
25
27
44
49
70
80
110
120
150
170
210
240
380
420
610
670
910
990
1290
1440
1820
2010
3160
3560
33.9
36.6
59.6
66.4
94.7
108.4
149
162
203
230
284
325
515
569
827
908
1233
1342
1749
1952
2467
2725
4284
4826
21
24
38
43
61
68
93
105
130
140
180
200
320
350
510
560
770
840
1090
1220
1530
1700
2670
3000
28.4
32.5
51.5
58.3
82.7
92.1
126
142
176
189
244
271
433
474
691
759
1044
1139
1477
1654
2074
2304
3620
4067
Class 4.6
Size
(m m )
5
6
7
LUBED
DRY
LUBED
Class 10.9
8.8
DRY
LUBED
Class 12.9
10.9
DRY
LUBED
12.9
DRY
in- lbs
Nm
in- lbs
Nm
in- lbs
Nm
in- lbs
Nm
in- lbs
Nm
in- lbs
Nm
in- lbs
Nm
in- lbs
Nm
16
19
45
1.8
3.05
5.12
21
36
60
2.4
4.07
6.83
41
69
116
4.63
7.87
13.2
54
93
155
6.18
10.5
17.6
58
100
167
6.63
11.3
18.9
78
132
223
8.84
15
25.2
68
116
1.95
7.75
13.2
22.1
91
155
260
10.3
17.6
29.4
LUBED
8
10
12
14
16
18
20
22
24
Class 8.8
4.6
DRY
LUBED
DRY
LUBED
DRY
LUBED
DRY
f t - lbs
Nm
f t - lbs
Nm
f t - lbs
Nm
f t - lbs
Nm
f t - lbs
Nm
f t - lbs
Nm
f t - lbs
Nm
f t - lbs
Nm
5.4
10.8
18.9
30.1
46.9
64.5
91
124
157
7.41
14.7
25.6
40.8
63.6
87.5
124
169
214
7.2
14.4
25.1
40
62.5
86.2
121
166
210
9.88
19.6
34.1
54.3
84.8
117
165
225
285
14
27.9
48.6
77.4
125
171
243
331
420
19.1
37.8
66
105
170
233
330
450
570
18.8
37.2
64.9
103
166
229
325
442
562
25.5
50.5
88
140
226
311
441
600
762
20.1
39.9
69.7
110
173
238
337
458
583
27.3
54.1
94.5
150
235
323
458
622
791
26.9
53.2
92.2
147
230
317
450
612
778
36.5
72.2
125
200
313
430
610
830
1055
23.6
46.7
81
129
202
278
394
536
682
32
63.3
110
175
274
377
535
727
925
31.4
62.3
108
172
269
371
525
715
909
42.6
84.4
147
234
365
503
713
970
1233
TML-4000 TML-4000N
2-7
Section 2 Specifications
July 2007
2-8
TML-4000 TML-4000N
July 2007
Symbols Legend
Safety alert symbolused to alert
personnel to potential personal
injury hazards. Obey all safety
messages that follow this symbol
to avoid possible injury or death.
TML-4000 TML-4000N
3-1
July 2007
Checklist
A
A+B
A+B+C
A+B+C+D
A+B+C+D+E
3-2
TML-4000 TML-4000N
Pre-Deliver
Pre-Deliveryy Preparation
Fundamentals
Instructions
Pre-Delivery Preparation
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
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
July 2007
3-4
TML-4000 TML-4000N
July 2007
Checklist A - Rev C
Serial number
Y N R
Date
Machine owner
Inspected by (print)
Inspector signature
Inspector title
Inspector company
Checklist D - Rev B
Daily or 8 hours
Inspection:
Two year or
2000 hours
Inspection:
A
A+B
A+B+C
Checklist E - Rev B
B-1 Battery
A+B+C+D
A+B+C+D+E
Y N R
Y N R
Annually or
1000 hours
Inspection:
Y N R
Checklist C - Rev B
Legend
Y = yes, acceptable
N = no, remove from service
R = repaired
TML-4000 TML-4000N
3-5
July 2007
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 operators 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
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.
REV C
3-6
TML-4000 TML-4000N
July 2007
REV C
CHECKLIST A PROCEDURES
A-2
Perform Pre-operation
Inspection
A-4
Perform Engine Maintenance Perkins Models
150137
97360
A-3
Perform Function Tests
Genie specifications require that this procedure be
performed every 8 hours or daily, whichever comes
first.
A-5
Perform Winch Maintenance
TML-4000 TML-4000N
150143
3-7
July 2007
CHECKLIST A PROCEDURES
REV C
A-6
Perform Engine Maintenance Lombardini and Deutz Models
150108
116031
3-8
A-7
Perform Hitch Maintenance
TML-4000 TML-4000N
150139
July 2007
REV C
CHECKLIST A PROCEDURES
A-8
Perform 30 Day Service
A-9
Perform Engine Maintenance Perkins 103-10 Models
TML-4000 TML-4000N
150137
3-9
July 2007
CHECKLIST A PROCEDURES
REV C
A-10
Perform Engine Maintenance Lombardini and Deutz Models
A-11
Perform Engine Maintenance Perkins 103-10 Models
150108
116031
150137
A-12
Perform Generator Maintenance
Marathon Models
3 - 10
TML-4000 TML-4000N
150109
July 2007
Checklist B Procedures
REV C
B-1
Inspect the Battery
TML-4000 TML-4000N
3 - 11
July 2007
CHECKLIST B PROCEDURES
REV C
B-2
Inspect the Electrical Wiring
B-3
Inspect the Tires and Wheels
(including lug nut torque)
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.
3 - 12
TML-4000 TML-4000N
July 2007
REV C
CHECKLIST B PROCEDURES
B-4
Perform Engine Maintenance Lombardini and Deutz Models
B-5
Perform Engine Maintenance Perkins 403C-11 Models
150108
116031
TML-4000 TML-4000N
97360
3 - 13
July 2007
CHECKLIST B PROCEDURES
REV C
B-6
Perform Hitch Maintenance
B-7
Perform Engine Maintenance Perkins 103-10 Models
150139
150137
B-8
Perform Axle Maintenance
3 - 14
TML-4000 TML-4000N
July 2007
Checklist C Procedures
REV B
C-1
Inspect the Cable and
Cable Pulleys
C-2
Perform Engine Maintenance Perkins 403C-11 Models
97360
TML-4000 TML-4000N
3 - 15
July 2007
CHECKLIST C PROCEDURES
REV B
C-3
Perform Engine Maintenance Lombardini and Deutz Models
C-4
Perform Engine Maintenance Perkins 103-10 Models
150108
116031
150137
C-5
Perform Axle Maintenance
3 - 16
TML-4000 TML-4000N
July 2007
REV B
Checklist D Procedures
D-1
Perform Engine Maintenance Lombardini and Deutz Models
D-2
Perform Engine Maintenance Perkins 403C-11 Models
150108
116031
TML-4000 TML-4000N
97360
3 - 17
July 2007
CHECKLIST D PROCEDURES
REV B
D-3
Perform Generator Maintenance
Leroy Somer Models
D-4
Perform Tongue Jack and
Outrigger Jack Maintenance
150140
D-5
Perform Axle Maintenance
3 - 18
TML-4000 TML-4000N
July 2007
REV B
Checklist E Procedures
E-1
Perform Engine Maintenance Lombardini and Deutz Models
E-2
Perform Engine Maintenance Perkins 403C-11 Models
150108
116031
TML-4000 TML-4000N
97360
3 - 19
July 2007
CHECKLIST E PROCEDURES
REV B
E-3
Perform Engine Maintenance Perkins 403C-11 Models
E-4
Perform Generator Maintenance
Marathon Models
97360
150109
E-5
Perform Generator Maintenance Leroy Somer Models
3 - 20
TML-4000 TML-4000N
July 2007
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 after troubleshooting
the problem.
Wheels chocked
TML-4000 TML-4000N
4-1
July 2007
Lighting
REV A
1-1
Lighting
4-2
TML-4000 TML-4000N
July 2007
LIGHTING
REV A
Time
Line Voltage
Initial ignition
427V AC
30 seconds
436V AC
1 minute
435V AC
2 minutes
431V AC
5 minutes
241V AC
10 minutes
No significant change
400V AC to 445V AC
TML-4000 TML-4000N
4-3
July 2007
Mast
REV A
2-1
Mast
a
b
a
b
c
guide pad
wire harness pulley
number 2 mast tube
4-4
TML-4000 TML-4000N
July 2007
REV A
MAST
TML-4000 TML-4000N
4-5
July 2007
MAST
REV A
4-6
TML-4000 TML-4000N
July 2007
REV A
MAST
s
r
l
p
m
n
o
TML-4000 TML-4000N
a
b
c
d
e
f
g
h
i
j
k
l
m
n
o
p
q
r
s
4-7
July 2007
Chassis
REV A
3-1
Ground Controls
How to Check a
Lighting Capacitor
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.
4-8
TML-4000 TML-4000N
July 2007
REV A
CHASSIS
LAMP
COM
COM
or
120V
240V
a
b
c
d
e
SHARP CORNER
CAP
capacitor
ballast
primary coil
transformer harness connector
(see legend below)
secondary coil
1
2
120V or 240V
common
3
4
common
lamp
TML-4000 TML-4000N
4-9
July 2007
CHASSIS
REV A
4 - 10
TML-4000 TML-4000N
July 2007
Generator
REV B
4-1
Generator
How to Check a
Generator Capacitor
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.
TML-4000 TML-4000N
4 - 11
July 2007
GENERATOR
REV B
4 - 12
TML-4000 TML-4000N
July 2007
REV B
GENERATOR
TML-4000 TML-4000N
4 - 13
July 2007
GENERATOR
REV B
4 - 14
TML-4000 TML-4000N
July 2007
GENERATOR
REV B
TML-4000 TML-4000N
4 - 15
July 2007
4 - 16
TML-4000 TML-4000N
July 2007
Section 5 Troubleshooting
Troubleshooting
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.
TML-4000 TML-4000N
5-1
Section 5 Troubleshooting
July 2007
TROUBLESHOOTING
Identify
symptoms
Malfunction
discovered
Troubleshoot
problem
still exists
Return to
service
5-2
problem
solved
Inspect
and test
Perform
repair
TML-4000 TML-4000N
July 2007
Section 5 Troubleshooting
Theory of Operation
REV A
500
Voltage
400
300
200
100
0.5
1.5
2.5
3.5
4.5
Unit Time
TML-4000 TML-4000N
5-3
Section 5 Troubleshooting
July 2007
Lamp Troubleshooting
Problem
Lamp will not start
Slow or erratic starting
Blinking or flickering
Cycling (lamps turn on and off)
Light output reduced
Short lamp life
Tripped circuit breaker
Chart
1
2
3
4
5-4
Solution
Refer to Charts 1 through 8
Refer to Charts 1 through 10
Refer to Charts 3, 9, 11 and 12
Refer to Charts 1, 3, 5 and 9
Refer to Charts 3, 4, 6 and 8
Refer to Charts 1, 4, 13 and 14
Refer to Charts 15, 16 and 17
Cause
Incorrect lamp or
ballast
Lamp is improperly
seated in socket
Solution
Check fixture label against lamp type
Incorrect or loose
wiring
Lamp is at or near end
of life
REV A
TML-4000 TML-4000N
July 2007
Section 5 Troubleshooting
LAMP TROUBLESHOOTING
REV A
Chart
6
Cause
Ballast burned out
Dirty or burned-out
lamp
Improper ambient
temperature
10
11
Hard-starting lamp
New lamp needs to be
seasoned
Significant air
movement across
lamps
Lamp operates less
than 10 hours per start
12
13
14
15
16
17
Faulty Lamp
Improper circuit
breakers installed for
fixture
Overloaded circuit
Shorted or grounded
fixtures
Solution
Check circuit continuity. Replace capacitor at
the same time.
Visually inspect lamp for dirt or foreign
materials. Visually inspect lamp for
discoloration.
Metal halide lamps will start above -20F.
Other lamps experience starting problems
when the ambient temperature is below 50F.
Check incoming voltage with voltmeter. If this
is the issue, check other equipment on the
same circuit.
Replace with new lamp if delay is lengthy.
Turn lamp on and off several times at 30minute intervals
Check for fans or air conditioning blowing
across lamps.
Rated lamp life is based on 10 hours of
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.
Replace with new lamp
Confirm that the circuit breakers match
manufacturers specification.
Verify that the total circuit load is less than
circuit rating.
Test for a short in the circuit. Replace faulty
fixture.
TML-4000 TML-4000N
5-5
Section 5 Troubleshooting
July 2007
5-6
TML-4000 TML-4000N
July 2007
Section 6 Schematics
Schematics
About This Section
There are two groups of schematics in this section.
An illustration legend precedes each group of
drawings.
Electrical Schematics
Hydraulic Schematics
Bodily injury hazard. Spraying
hydraulic 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.
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.
Malfunction
discovered
Identify
symptoms
Troubleshoot
problem
still exists
Return to
service
TML-4000 TML-4000N
problem
solved
Inspect
and test
Perform
repair
6-1
Section 6 Schematics
July 2007
L35A
L35B
BK
WH
BK
WH
BN/GN
GN
WH
WH
BN/GN
BN
GN
GN
QD19A
L33
HARNESS CONNECTOR
WH
BN/GN
BN/YL
YL
L58
QD12
TRAILER
PLUG
L34
QD19B
HARNESS CONNECTOR
YL
4
3
3
2
1
WH
BN/GN
BN/YL
YL
GN
BN/YL
YL
GN
BN/YL
BN
WH
WH
WH
WH
BK
WH
L36A
BK
L36B
ES0119A
6-2
TML-4000 TML-4000N
July 2007
Section 6 Schematics
RESET
Circuit breaker
Lamp
AC Outlet
Capacitor
Switch
Swtich
Transformer
Ground
TML-4000 TML-4000N
6-3
Section 6 Schematics
July 2007
Electrical Schematic
TML-4000N
(before serial number TML02-522)
REV A
LEFT
UPPER
BK
LEFT
LOWER
BK
L1
BK
GN
WH
L2
RIGHT
UPPER
GN
WH
L3
BK
GN
WH
L4
RIGHT
LOWER
GN
WH
BK
BK
WH
GN
BK
BL
WH
GN
BK
WH
BK
RD
OR
LAMP
WIRE COLORS
WH/BK
JUNCTION
BOX
MAST CABLE
WIRE COLORS
BALLAST #1
CONTROL
PANEL
S1 15A
RD
TRANSFORMER
24 F
CAPACITOR
1000W
M47
MAST
CABLE
RD
GENERATOR
WH
WH
WH
1
S2 15A
GN
RD
RD
RD
WH
WH/BK
OR
BK
T3
T2
T1
T4
S3 15A
BK
BK
BK
24 F
CAPACITOR
1000W
M47
RD
RD
RD
BK
BK
OR
OR
BL
BL
WH/BK
WH/BK
WH
WH
GN
GN
TRANSFORMER
S4 15A
BALLAST #3
BK
BALLAST #2
WH
TRANSFORMER
GN
24 F
CAPACITOR
GN
GN
BK
WH
2
BK
WH
RD
1000W
M47
15A
RD
BK
WH
WH
BK
BL
RESET
1000W
M47
120V
24 F
CAPACITOR
TRANSFORMER
BALLAST #4
6-4
ES0065C
TML-4000 TML-4000N
July 2007
Section 6 Schematics
Electrical Schematic
TML-4000
(before serial number TML02-522)
REV A
LEFT
UPPER
BK
LEFT
LOWER
BK
L1
BK
GN
WH
L2
RIGHT
UPPER
GN
WH
L3
BK
GN
WH
L4
GN
WH
RIGHT
LOWER
BK
BK
WH
GN
BK
BL
WH
GN
BK
WH
BK
RD
OR
LAMP
WIRE COLORS
WH/BK
JUNCTION
BOX
MAST CABLE
WIRE COLORS
BALLAST #1
CONTROL
PANEL
S1 15A
RD
BREAKER
BOX
GENERATOR
WH
WH
1
S2 15A
24 F
CAPACITOR
1000W
M47
RD
RD
RD
WH
WH/BK
OR
BK
T3
T2
T1
T4
MAST
CABLE
RD
WH
GN
GN
TRANSFORMER
S3 15A
BK
BK
BK
BK
25A
RD
24 F
CAPACITOR
1000W
M47
RD
RD
RD
BK
BK
OR
OR
BL
BL
WH/BK
WH/BK
WH
WH
GN
GN
TRANSFORMER
S4 15A
RD
BALLAST #3
BK
15A
BK
BALLAST #2
WH
BK
GN
RD
GN
BK
24 F
CAPACITOR
1000W
M47
4
GN
WH
RD
BK
RD
TRANSFORMER
GN
BK
RD
BK
WH
WH
BK
BL
WH
RESET
GN
240V
BK
WH
120V
BK
WH
1000W
M47
120V
24 F
CAPACITOR
TRANSFORMER
BALLAST #4
ES0076B
TML-4000 TML-4000N
6-5
Section 6 Schematics
July 2007
Electrical Schematic
TML-4000 and TML-4000N
(after serial number TML02-521)
LEROY SOMER
60 Hz
GENERATOR
MECC ALTE
60 Hz
GENERATOR
GN
RD
RD
LAMP
WIRE COLORS
MECC ALTE
50 Hz
GENERATOR
JUNCTION
BOX
WH
GN
WH
T4
MAST CABLE
WIRE COLORS
GN
BALLAST #1
BK
BK
RD
RD
CONTROL
PANEL
33
S1 10A
BK
TRANSFORMER
24 F
CAPACITOR
1000W
M47
RD
RD
RD
GENERATOR
SEE ABOVE
FOR
SPECIFIC MODEL
S2 10A
GN
GN
BK
RD
BK
BK
BK
RD
RD
WH/BK
BK
OR
RD
MODELS
WITH
120V/240V
OUTLET
(OPTION)
S3 10A
BK
BK
BK
RD
RD
RD
25A
RD
MAST
CABLE
BK
WH
WH
GN
BK
GN
WH
WH
24 F
CAPACITOR
1000W
M47
RD
RD
BK
BK
OR
OR
BL
BL
WH/BK
WH/BK
WH
WH
GN
GN
TRANSFORMER
MODELS WITH
120V OUTLET
(STANDARD)
15A
S4 10A
BK
BK
RD
RD
BALLAST #3
BALLAST #2
GN
BK
WH
TRANSFORMER
GN
RESET
24 F
CAPACITOR
1000W
M47
120V
RD
WH
BK
GN
RD
GN
BK
BK
WH
8
BK
BK
RD
RIGHT
LOWER
GN
WH
5
BK
WH
L4
BK
BK
GN
BL
L3
BK
WH
T2,T3
RIGHT
UPPER
GN
BK
WH
WH
GN
MARATHON
60 Hz
GENERATOR
T1
L2
WH
WH/BK
T4
BK
BK
GN
WH
BK
T1
LEFT
LOWER
L1
WH
OR
T2
BK
BK
T3
LEFT
UPPER
RD
WH
WH
REV A
BL
RESET
GN
240V
WH
BK
120V
WH
1000W
M47
120V
BK
24 F
CAPACITOR
TRANSFORMER
BALLAST #4
6-6
ES0118C
TML-4000 TML-4000N
July 2007
Section 6 Schematics
TML-4000 TML-4000N
6-7
Section 6 Schematics
July 2007
Electrical Schematic
Deutz Engine
(before serial number TML05-213)
REV A
DIODE
1A 400V
RD
BK
87
50
30
2
1
CR15
86
85
GLOW
PLUG
KS1
BK
START
BL
RUN
RD
OIL
TEMP
F9
50A
AIR
GLOW
BK
WH
RD
GN
RD/BK
BK/WH
ENGINE CONTROL
CIRCUIT BOARD
D1
M3
WH
GN
PK
GN/YL
U32
WH/BK
RD
GY
Q8
D+
GN
PP
S1
B+
WH
BK
SW1
WH/BK
U23
OR
PK/BK
OR
SW2
1
2
3
4
5
6
7
8
9
OR/BK
RD/BK
1
2
3
4
5
6
7
8
9
10
11
12
13
14
SW33
B1
1
2
3
4
5
6
7
8
220 OHM
0.6W
G6
ALTERNATOR
GLOW PLUG
HOUR METER
ALTERNATOR
START MOTOR
6-8
ES0066D
TML-4000 TML-4000N
July 2007
Section 6 Schematics
Electrical Schematic
Lombardini and Deutz Engines
(after serial number TML05-212)
REV B
DIODE
1A 400V
RD
BK
CR15
GLOW
PLUG
30
87A
2
1
86
87
85
KS1
BK
START
BL
RUN
RD
OIL
TEMP
F9
50A
AIR
GLOW
BK
WH
RD
GN
RD/BK
BK/WH
D1
M3
ENGINE CONTROL
CIRCUIT BOARD
WH
GN
PK
GN/YL
U32
WH/BK
RD
GY
Q8
D+
GN
PP
S1
B+
WH
BK
SW1
WH/BK
U23
OR
PK/BK
OR
SW2
1
2
3
4
5
6
7
8
9
OR/BK
RD/BK
1
2
3
4
5
6
7
8
9
10
11
12
13
14
SW33
B1
1
2
3
4
5
6
7
8
220 OHM
0.6W
G6
ALTERNATOR
GLOW PLUG
HOUR METER
ALTERNATOR
START MOTOR
ES7178A
TML-4000 TML-4000N
6-9
Section 6 Schematics
July 2007
Electrical Schematic
Perkins Engine
(before serial number TML05-362)
REV A
KS1
START
YL
RUN
PP
RD
F9A
7.5A
LG
TIMER
RD
RD
POWER TO
ENGINE
STARTER
30
87A
87
85
OIL
TEMP
CR15
GLOW
PLUG
30
86
AIR
87A
87
85
RD
GLOW
RD
#30 OR
1
2
3
4
5
6
7
8
#2 BN
#3 BL
#28 PP
#5 BK
BK/WH
#27 YL
#8 WH
OR
#30 OR
BN
#2 BN
BL
#3 BL
PP
#28 PP
#5 BK
G6
#27 YL
#8 WH
Q8
RD
SW1
RD
SW2
SW33
B1
1
2
3
4
5
6
7
8
BK
U23
ENGINE CONTROL
CIRCUIT BOARD
86
BK/WH
CR1A
RD
40A
GN
F9B
U32
D1
M3
15 AMP
2
1
BL
BL
U33
VOLTAGE REGULATOR
GRN
YEL
RED
BLU
BLK
BLU
ALTERNATOR
GLOW PLUG
START MOTOR
1 2 3 4 5 6
6 - 10
ES0117A
TML-4000 TML-4000N
July 2007
Section 6 Schematics
Electrical Schematic
Perkins Engine
(after serial number TML05-361)
REV A
KS1
START
YL
RUN
PP
RD
F9A
7.5A
RD
RD
F9B
40A
CR1A
POWER TO
ENGINE
STARTER
30
87A
87
U23
ENGINE CONTROL
CIRCUIT BOARD
86
85
OIL
TEMP
CR15
GLOW
PLUG
30
86
AIR
87A
87
85
RD
GLOW
RD
#30 OR
1
2
3
4
5
6
7
8
#2 BN
#3 BL
#28 PP
#5 BK
LG
#27 YL
#8 WH
OR
#30 OR
BN
#2 BN
BL
#3 BL
PP
#28 PP
#5 BK
G6
#27 YL
#8 WH
Q8
RD
SW1
RD
SW2
SW33
B1
1
2
3
4
5
6
7
8
U32
D1
M3
15 AMP
2
1
BL
BL
U33
VOLTAGE REGULATOR
GRN
YEL
RED
BLU
BLK
BLU
ALTERNATOR
GLOW PLUG
START MOTOR
1 2 3 4 5 6
ES7179A
TML-4000 TML-4000N
6 - 11
Section 6 Schematics
July 2007
6 - 12
TML-4000 TML-4000N
July 2007
Section 7 Decals
Section Seven
Decals
TML-4000 TML-4000N
7-1
Section 7 Decals
July 2007
Figure 7-A
REV B
Decals
72889
28161
72009 or
72010
72871 or
82219 or
82957
72891
72890
72077
28161
97637
72008
82224
72018
114007
72019
82237
72874
82223
65408
65411
or 82304
72008
28164
65414
82303
72870
65421
97602
65423
or 82302
or 97767
97661
72828
97518
97635
82224
97635
28161
52475
97635
82224
97635
82222
97518
72826
65409
72009
or 72010
28161
65412
82224
104533
82223
80321
97602
82223
28164
65414
28161
52475
28161
7-2
82237 and
62707 82221
72870
31072
65421
28159
72828
28171
TML-4000 TML-4000N
Shading indicates
that the decal is
hidden from view.
July 2007
Section 7 Decals
REV B
Item
FIGURE 7-A
Part No.
80280
82004
85307
85308
97306
97307
116028
116029
97308
Description
Qty.
Item
Part No.
Description
Qty.
97309
28159
28161
28164
28171
31072
52475
62707
65408
65409
10
65411
11
65412
Warning - Transport
Instructions ................................... 1
12
65414
13
65421
Warning - Electrocution,
Generator ..................................... 2
14
65423
116030
15
72008
16
72009
17
72010
18
72018
19
72019
20
72077
21
72826
22
72828
23
72865
24
72870
25
72871
TML-4000 TML-4000N
7-3
Section 7 Decals
July 2007
FIGURE 7-A
REV B
72889
28161
72009 or
72010
72871 or
82219 or
82957
72891
72890
72077
28161
97637
72008
82224
72018
114007
72019
82237
72874
82223
65408
65411
82304 or
72008
28164
65414
82303
72870
65421
97602
65423
or 82302
or 97767
97661
72828
97518
97635
82224
97635
28161
52475
97635
82224
97635
82222
97518
72826
65409
72009
or 72010
28161
65412
82224
104533
82223
80321
97602
82223
28164
65414
28161
52475
28161
7-4
82237 and
62707 82221
72870
31072
65421
28159
72828
28171
TML-4000 TML-4000N
Shading indicates
that the decal is
hidden from view.
July 2007
Section 7 Decals
REV B
Item
FIGURE 7-A
Part No.
Description
Qty.
26
72874
27
72889
28
72890
29
72891
30
80321
31
82219
32
82221
33
82222
34
82223
35
82224
36
82237
37
82302
97767
38
82303
39
82304
40
82957
41
97518
42
97602
43
97635
44
97637
Item
Part No.
Description
Qty.
45
97638
46
97661
47
104533
48
114007
TML-4000 TML-4000N
7-5
Section 7 Decals
July 2007
7-6
TML-4000 TML-4000N
July 2007
Section Eight
Base
Components
TML-4000 TML-4000N
8-1
July 2007
Figure 8-A
REV A
4
5
36 37 38
10 9
8
11
35
2
13 12
34
32 33
31
14
17 16 16 15
29
30
18
26 27 27 28
19
29
7
26 27 27 27 27 28
20
21
20
8-2
25
24
TML-4000 TML-4000N
23
22
November 2007
REV B
Item
FIGURE 8-A
Part No.
25969
Ref.
Description
Qty.
Item
Part No.
Description
Qty.
22
57572
57551
23
57571
57550
24
57568
57546
25
57567
69211
46716
Ref.
39560
80417
80418
4266
Screw - HHC,
1/4 -20 x 2 inches, GR 5
26
12461
Screw - HHC,
1/2 -13 x 5 inches, GR 8
80340
80334
27
13066
10
6091
28
6198
11
57710
Fender .......................................... 2
29
46715
12
6888
Screw - HHC,
1/4 -20 x 1 inch, GR 5
30
57332
57625
13
6638
14
Ref.
30
69937
15
10006
Screw - HHC,
3/4 -10 x 5 inches, GR 5
59720
67535
16
10256
Flat Washer,
31
57331
17
10258
32
6034
18
57570
57549
33
80231
19
57393
34
85262
20
116021
97333
116025
116023
35
57470
20
116022
21
13/16
inch
36
6019
116026
116024
Screw - HHC,
3/8 -16 x 1.25 inches, GR 5
37
5397
46717
38
4828
TML-4000 TML-4000N
8-3
July 2007
Figure 8-B
REV A
Outrigger Components
1
10
11
34
32 33
13 12
30 31
15 14
29
19 18 17 16
28
25 26 27
22 23 24
21
20
18
19
8-4
TML-4000 TML-4000N
July 2007
REV A
Item
FIGURE 8-B
Part No.
Description
Qty.
Item
Part No.
Description
Qty.
57331
28
80130
69818
69809
29
80232
69815
Sleeve Spacer,
0.63 x 0.75 x 0.5 inch ................... 2
30
6034
31
80231
32
69879
33
8915
Screw - HHC,
1/4 -20 x 1.25 inches, GR 5
34
80127
80128
80129
13066
2161
69814
69813
69800
32499
80003
80000
10
69649
Compression Spring,
0.953 x 4.38 inches ...................... 2
11
69990
12
69667
13
22547
14
6091
15
8914
Screw - HHC,
1/4 -20 x 0.625 inch, GR 5
16
6198
17
80323
18
6095
19
13854
Screw - HHC,
1/2 -13 x 4.5 inches, GR 8 ............. 4
20
33373
Flat Washer,
0.89 x 1.5 x 0.09 inch
21
80203
22
38028
23
42191
24
51131
Screw - HHC,
5/8 -11 x 2.5 inches, GR 5
25
5224
Screw - HHC,
3/8 -16 x 2 inches, GR 5
26
6097
27
46017
TML-4000 TML-4000N
8-5
July 2007
Figure 8-C
REV A
8-6
TML-4000 TML-4000N
July 2007
REV A
Item
FIGURE 8-C
Part No.
Description
Qty.
6888
Screw - HHC,
1/4 -20 x 1 inch, GR 5
6356
6638
25969
6019
Screw - HHC,
3/8 -16 x 1.25 inches, GR 5
4828
Nylock Nut,
3/8
66717
6873
Item
Part No.
Description
Qty.
24
69719
25
69798
80350
26
69770
80694
Screw - FHSM,
10-32 x 1 inch, GR 2
27
69773
14392
69773
10
36372
11
6002
12
Ref.
Control Box
(refer to Figure 8-F.1 or 8-F.2)
28
69773
Weather-stripping,
3/8 inch ............................. 15 inches
13
69983
87797
29
69773
14
6090
Screw - HHC,
1/4 -20 x 0.75 inch, GR 5
15
6091
16
8914
Screw - HHC,
1/4 -20 x 0.625 inch, GR 5
17
46716
18
10107
Screw - HHC,
5/16 -18 x 0.75 inch, GR 5
19
33277
Flat Washer, M8
20
6271
21
21619
80544
22
69884
85201
23
4512
Nylon Spacer,
0.25 x 0.69 x 0.25 inch
-16
TML-4000 TML-4000N
8-7
July 2007
Figure 8-D
REV A
Winch installation
1
21
20
10
9 19 19
11
18
16 3
16 3
14 13 12
17 14
16 3
15
8-8
TML-4000 TML-4000N
July 2007
REV A
FIGURE 8-D
Item
Part No.
Description
104189
Winch Bracket
6019
Screw - HHC,
3/8 -16 x 1.25 inches, GR 5
5397
4828
6888
Screw - HHC,
1/4 -20 x 1 inch, GR 5
6638
6091
69736
69981
57408
6086
10
Ref.
Winch Handle
(refer to Figure 8-H)
11
69673
12
69654
13
69638
Compression Spring,
0.75 x 8 inches ............................. 1
14
6094
15
Ref.
16
8516
Screw - HHC,
3/8 -16 x 1.5 inches, GR 5
17
69680
18
15657
19
6034
20
80107
21
Ref.
Qty.
TML-4000 TML-4000N
8-9
July 2007
Figure 8-E
REV B
8 - 10
TML-4000 TML-4000N
July 2007
REV B
Item
FIGURE 8-E
Part No.
Description
Qty.
85275
57750
80005
57730
80530
891520
Elbow, Fitting,
1/4 MNPT x 1/4 inch, 90 ................ 1
116034
44909
30490
C90200200
Item
Part No.
17
57367
69216
80507
104015
104776
17
69216
80507
104776
18
6175
Screw - HHC,
3/8 -16 x 1 inch, GR 5
Flat Washer, 5/16 inch
35418
Hose,
69734
19
5397
101726
20
15086
10
6888
Screw - HHC,
1/4 -20 x 1 inch, GR 5
6091
12
85271
85272
14
57587
6638
1/4
inch
1/4
inch
15
6356
Lock Washer,
16
25969
Qty.
Fender Washer,
x 1.5 x 0.125 inch
3/8
11
13
Description
21
80333
80035
22
6019
Screw - HHC,
3/8 -16 x 1.25 inches, GR 5
23
4828
24
6097
25
57600
26
56050
67325
27
57414
28
8170
29
28853
Battery Blanket,
110V AC, 60HZ ............................ 1
TML-4000 TML-4000N
8 - 11
July 2007
Figure 8-F.1
REV B
3
4
6
7
18 19
17
6
9
15 3 16
14
10
13
11
12
8 - 12
TML-4000 TML-4000N
July 2007
REV B
Item
FIGURE 8-F.1
Part No.
Description
Qty.
69882
80399
18542
Nut, 8-32, GR 2
42421
Lock Washer, #8
38987
Rubber Grommet,
0.13 x 0.38 inch ............................ 1
18605
69776
116062
66816
66818
104851
104854
10
69831
11
80040
69784
69785
69786
12
116062
21982
37947
13
80304
14
19506
15
65230
16
40766
17
69777
18
69765
19
30255
Flat Washer,
1.27 x 2.13 x 0.062 inch
TML-4000 TML-4000N
8 - 13
July 2007
Figure 8-F.2
REV C
2
12
3
4
11
5
10
7
6
8
8 - 14
TML-4000 TML-4000N
July 2007
REV C
FIGURE 8-F.2
Item
Part No.
Description
104851
61225
61226
81767
81766
104852
104854
104853
104852
85305
116062
66816
66818
18605
80562
104851
104854
69831
18542
Nut, 8-32, GR 2
42421
Lock Washer, #8
80040
69784
69785
69786
116062
21982
37947
Qty.
Item
Part No.
Description
Qty.
10
80304
11
19506
12
80533
TML-4000 TML-4000N
8 - 15
July 2007
Figure 8-F.3
REV A
8 - 16
TML-4000 TML-4000N
July 2007
REV A
FIGURE 8-F.2
Item
Part No.
Description
104851
61225
61226
81767
81766
104852
104854
104853
104852
85305
80303
66816
66818
18605
80562
104851
104854
69831
18542
Nut, 8-32, GR 2
42421
Lock Washer, #8
80040
69784
69785
69786
80302
21982
37947
Qty.
Item
Part No.
Description
Qty.
10
684380
11
19506
12
80533
TML-4000 TML-4000N
8 - 17
July 2007
Figure 8-G
REV B
Covers
8 - 18
TML-4000 TML-4000N
July 2007
REV B
Item
FIGURE 8-G
Part No.
85269
85268
Description
Qty.
Item
Part No.
Description
Qty.
23
4828
24
69667
25
69650
26
80274
27
69649
Compression Spring,
0.953 x 4.38 inches ...................... 1
28
69693
85266
80108
69738
7265
29
8516
Screw - HHC,
3/8 -16 x 1.5 inches, GR 5
80111
30
80368
69735
31
80371
85267
32
57398
33
6606
80109
Screw - RHSM,
10-32 x 0.75 inch
34
6607
57416
35
80366
Nylon Clip, 15 x 13 mm
69754
36
69648
10
6638
37
5365
11
69824
Compression Spring,
0.38 x 0.5 inch .............................. 5
38
6146
12
6002
39
29752
13
40267
40
116002
2223
14
6888
Screw - HHC,
1/4 -20 x 1 inch, GR 5
41
116001
15
6356
42
116000
16
6638
17
6091
18
80369
43
6888
19
80370
20
10107
Screw - HHC,
5/16 -18 x 0.75 inch, GR 5
Screw - HHC,
1/4 -20 x 1 inch, GR 5
(after serial number
TML 06-000708)
44
6638
45
6091
21
6019
Screw - HHC,
3/8 -16 x 1.25 inches, GR 5
22
5397
TML-4000 TML-4000N
8 - 19
July 2007
Figure 8-H
REV A
Winch Components
1
9
10
11
20
19
18
12
17
16
15
8 - 20
14
TML-4000 TML-4000N
13
July 2007
REV A
Item
FIGURE 8-H
Part No.
Description
Qty.
14085
6204
Bushing ......................................... 1
14190
14191
5157
14193
14194
6200
6199
Bushing ......................................... 1
5156
10
Ref.
11
6190
12
5320
13
Ref.
14
5376
15
12981
Screw - HHC,
3/8 -16 x 4.5 inches, GR 5
16
12012
17
16342
18
6086
19
6034
20
14189
TML-4000 TML-4000N
8 - 21
July 2007
Figure 8-I
REV C
To Mast
2
Circuit
Breaker
Box
Multiple
Outlet
Box
Engine
Single
Outlet
Box
Generator
Ballasts
8 - 22
TML-4000 TML-4000N
Battery
July 2007
REV C
Item
FIGURE 8-I
Part No.
Description
Qty.
57525
104807
80559
80560
80561
80191
69797
104963
104964
57430
43956
80547
116037
116038
85258
TML-4000 TML-4000N
8 - 23
July 2007
Figure 8-J
REV C
Circuit
Breaker
Box
Multiple
Outlet
Box
To Mast
Engine
Generator
Single
Outlet
Box
Starter
Control
Panel
Ballasts
+
Battery
8 - 24
TML-4000 TML-4000N
July 2007
REV C
FIGURE 8-J
Description
80559
80560
80561
80191
69797
80547
80007
57430
85156
97459
85203
69797
116038
85258
116037
Qty.
TML-4000 TML-4000N
8 - 25
July 2007
Figure 8-K
REV A
11 14 14
2
6
10
7
8
15
8 - 26
TML-4000 TML-4000N
July 2007
REV A
Item
FIGURE 8-K
Part No.
Description
Qty.
24018
21858
69996
6091
42492
10775
T-box ............................................. 1
45437
49820
Screw - PHPM,
6-32 x 0.5 inch, GR 2
69626
10
13585
11
6935
12
38709
Flat Washer,
0.938 x 1.375 x 0.05 inch
13
12456
14
33576
Squeeze Connecter,
inch NPT .................................. 1
1/2
15
87795
16
80693
TML-4000 TML-4000N
8 - 27
July 2007
Figure 8-L
REV A
3
TML-4000
TML-4000N
19 20 22
21
4
19 20
6
7
18
8
9
Configurable Outlet
Enhanced Outlet
10
11
12
17
13
14
12
16
12
8 - 28
15
TML-4000 TML-4000N
July 2007
REV A
Item
FIGURE 8-L
Part No.
Description
Qty.
80693
6091
6090
Screw - HHC,
1/4 -20 x 0.75 inch, GR 5
21858
69996
80397
80396
57451
Squeeze Connector,
NPT .................................. 2
1/2 inch
85351
10
80543
11
45437
12
49820
Screw - PHPM,
6-32 x 0.5 inch, GR 2
13
80555
14
80357
15
80556
16
57581
17
10777
18
57535
19
12456
20
38709
Flat Washer,
0.938 x 1.375 x 0.05 inch
21
10775
T-box ............................................. 1
22
6935
TML-4000 TML-4000N
8 - 29
July 2007
8 - 30
TML-4000 TML-4000N
July 2007
Section Nine
Engine
Components
TML-4000 TML-4000N
9-1
July 2007
Figure 9-A
REV B
10
11
12
13
14
38
15
16
37
17
39
18
36
19
20
21
33 34 35
32
22
23
24
29
31
9-2
30
28
27
TML-4000 TML-4000N
26
25
July 2007
FIGURE 9-A
REV B
Item
Part No.
85008
85199
104788
116020
97496
Ref.
Ref.
Ref.
80584
Description
Qty.
Glow Plug
Deutz F3M-1008
Engine Complete
Deutz F3M-1008F
Engine Complete
Lombardini LDW-1003/L
Engine Complete
Cold Start - Accessory Kit
(includes item 27)
Battery - Blanket
(refer to Figure 8-E)
Fuel/Water Separator
(refer to Figure 9-C)
Heavy Duty Battery
(refer to Figure 8-E)
Wire Harness Assembly,
Jumper
Item
Part No.
Description
Qty.
18
80121
19
85046
20
85058
Nut, M8
21
85050
22
85200
80282
97480
85215
23
85051
Screw - SHC,
M8 - 1.25 x 30 mm
24
80279
58311
85216
80054
80124
25
69775
85047
Screw - SHC,
M8 -1.25 x 65 mm, GR 12.9 ......... 6
26
69774
Fitting ............................................ 1
80285
Fuel Pump
27
80010
85057
Hex Nut, M8
28
58052
Screw - HHC,
M6 -1 x 12 mm, GR 8.8
75417
Flat Washer, M8
29
49407
Lock Washer, M6
85007
30
85009
85000
31
85010
85049
Screw - SHC,
M6 -1 x 20 mm, GR 12.9 ............ 12
32
85011
58295
10
85001
33
85053
97478
Screw - HHC,
M10 -1.5 x 70 mm, GR 8.8
34
85054
11
85002
Rubber Cover,
Oil Pressure Switch ...................... 1
35
85055
Nut, M10
36
80283
12
80278
37
85012
13
85003
38
85056
14
85004
39
97481
15
85005
16
85067
17
80053
TML-4000 TML-4000N
9-3
July 2007
Figure 9-B
REV C
10
11 12
14
15
10 16
13
17
18
19
20
21
22
23
9
17
9
13
23 9 17
50
49
48
47
46
45
44
43
42
41
24
40
25
10
26
2
27
36
37
37
39
9-4
38
36
35
34
33
32
16
31
30
29
28
13
13
17
16
TML-4000 TML-4000N
July 2007
FIGURE 9-B
REV C
Item
Part No.
Description
Qty.
Ref.
44909
69734
85066
Item
Part No.
Description
Qty.
29
85062
30
85026
31
85100
Screw - SHC,
M12 x 1.75 x 16 mm, GR 12.9 ...... 2
32
49409
55098
Screw - HHC,
M8 x 1.25 x 80 mm, GR 8.8
33
85027
34
69829
Radiator ........................................ 1
49408
Lock Washer, M8
35
116040
85096
Screw - SHC,
M6 x 1 x 35 mm, GR 12.9 ............. 3
36
25368
Nylock Nut, M8
85049
Screw - SHC,
M6 -1 x 20 mm, GR 12.9 ............ 11
37
75417
Flat Washer, M8
38
85030
39
49378
Screw - HHC,
M8 x 1.25 x 16 mm, GR 8.8
40
85031
41
85032
42
85034
43
85101
44
85045
45
80284
V-belt ............................................ 1
46
85035
47
85036
97477
85037
85063
85064
75382
Flat Washer, M6
10
35434
11
85019
12
49375
Screw - HHC,
M6 -1 x 16 mm, GR 8.8
13
55017
Nut, M6
14
85102
15
85020
16
85097
Screw - SHC,
M6 x 1 x 10 mm, GR 12.9 ............. 3
17
85029
18
85028
19
85098
20
80571
21
80391
22
18503
48
85038
23
56123
Screw - HHC,
M6 x 1 x 10 mm, GR 8.8
49
85039
50
85040
24
85099
Screw - SHC,
M8 x 1.25 x 20 mm, GR 12.9 ........ 1
25
85021
26
85022
27
85023
28
85025
TML-4000 TML-4000N
9-5
July 2007
Figure 9-C
REV B
6
44
43
45
40 41 42
39
10 9
38
13 12 11
37
36
14
35
15
FUEL
34
16
33
17
32
19 18
20
22 12 21
23
29 12 30
24
26
28
27
26
25 12
9-6
TML-4000 TML-4000N
July 2007
FIGURE 9-C
REV B
Item
Part No.
97497
80584
27089
85091
85094
69825
Description
Qty.
Fuel/Water Separator,
Accessory Kit (includes
items 3, 5, 7,8, 37 and 45)
Wire Harness Assembly,
Jumper
Fuel Hose, 5/16, ................ 16 inches
Item
Part No.
Description
Qty.
18
27585
Screw - HHC,
M12 -1.75 x 20 mm, GR 8.8 ......... 2
19
49409
20
80131
21
23057
Screw - HHC,
M8 x 1.25 x 20 mm, GR 8.8
22
22571
Nut, M8
23
32064
24
69828
58306
Muffler ........................................... 1
Guard Plate (Heat Shield)
25
49379
Screw - HHC,
M8 x 1.25 x 25 mm, GR 8.8
26
69830
27
80358
Screw - FHS,
M8 x 1.25 x 16 mm ....................... 2
28
80454
29
49378
Screw - HHC,
M8 x 1.25 x 16mm
Ref.
6091
1/4
104736
104737
4266
Screw, HHC,
1/4 -20 x 2 inches, GR 5
Ref.
30
44605
30490
32
80571
80391
33
85013
Flywheel ....................................... 1
10
18503
34
85059
Screw - HHC,
M10 x 1.5 x 35 mm
11
22586
Screw - HHC,
M8 -1.25 x 20 mm, GR 8.8
35
61110
Screw - SHC,
M10 -1.5 x 30 mm, GR 8.8
12
49408
Lock Washer, M8
36
85014
13
6638
37
29560
14
80567
38
69826
15
80464
39
Ref.
80578
110002
80570
Nylock Nut,
-20 ........................ 1
16
80093
17
80360
TML-4000 TML-4000N
9-7
July 2007
FIGURE 9-C
REV B
6
44
43
45
40 41 42
39
10 9
38
13 12 11
37
36
14
35
15
FUEL
34
16
33
17
32
19 18
20
22 12 21
23
29 12 30
24
26
28
27
26
25 12
9-8
TML-4000 TML-4000N
July 2007
FIGURE 9-C
REV B
Item
Part No.
Description
Qty.
40
6019
Screw - HHC,
3/8 -16 x 1.25 inches, GR 5
41
5397
42
4828
43
85016
44
110003
Ref.
45
104675
TML-4000 TML-4000N
9-9
July 2007
Figure 9-D
Lombardini and Deutz
Engine with Leroy Somer Generator
9 - 10
TML-4000 TML-4000N
REV C
July 2007
FIGURE 9-D
REV C
Item
Part No.
Description
Qty.
14
67722
630905
15
80330
16
116027
17
740925
18
996290
19
22736
20
990415
116032
85017
836707
85092
Flange Screw,
M5 x 0.8 x 12 mm
85018
Capacitor, 70 MF
(before serial number
TML07-000600) ............................ 1
836711
Capacitor, 22.5 MF
(after serial number
TML07-000600) ............................ 2
97335
Terminal Strip
28443
6198
6095
8177
Screw - HHC,
1/2 -13 x 1.5 inches, GR 5
59746
Screw - HHC,
5/8 -11 x 4 inches, GR 5
6035
10
6024
11
80379
12
57418
13
85093
Screw - SHC,
M12 x 1.75 x 25 mm, GR 12.9
TML-4000 TML-4000N
9 - 11
July 2007
Figure 9-E
REV C
1
4
5
6
18 19 20
10
11
12
13
14
10
17
15 16
14
9 - 12
TML-4000 TML-4000N
July 2007
FIGURE 9-E
REV C
Item
Part No.
Description
Qty.
85206
Marathon Generator
Complete (includes items 1-6)
78196
Screw - PHPH,
8-32 x 0.625 inch
85209
18605
21618
85207
Capacitor, 45MF,
450V AC, 60 HZ ........................... 1
85208
14033
Screw - HHC,
3/8 -16 x 2.75 inches, GR 5
5397
4828
10
80601
11
80572
12
80573
13
27585
Screw - HHC,
M12 x 1.75 x 20 mm
14
740925
15
85093
Screw - SHC,
M12 x 1.75 x 25 mm, GR 12.9 ...... 2
16
67722
17
Ref.
18
6024
19
6035
20
59746
Screw - HHC,
-11 x 4 inches, GR 5
5/8
TML-4000 TML-4000N
9 - 13
July 2007
Figure 9-F
REV B
5
6
11
5
6
10
29
28
12
7
13
27
26
14
15
18 17 16
21 20 19
4
10
24
25 15
9 - 14
23
22
TML-4000 TML-4000N
July 2007
FIGURE 9-F
REV B
Item
Part No.
Description
104784
85145
85071
85078
22571
Hex Nut, M8
49408
Lock Washer, M8
44605
Flat Washer, M8
85135
85088
85147
10
85129
11
85075
85079
85118
85119
12
85134
13
85146
14
85132
85133
15
85131
16
49375
Screw - HHC,
M6 x 1 x 16 mm, GR 8.8
17
25926
Flat Washer, M6
18
49364
Nylock Nut, M6
19
49417
Screw - PHM,
M5 x 0.8 x 16 mm, GR 4.8
20
6607
21
6146
22
80515
23
85128
24
49407
Lock Washer, M6
25
80516
26
85086
Radiator ........................................ 1
Qty.
Item
Part No.
Description
Qty.
27
85130
28
85068
Fan ............................................... 1
29
58236
30
97462
TML-4000 TML-4000N
9 - 15
July 2007
Figure 9-G
REV A
18
16 17
5
7
8
9
11
10
23
15
19
14
22 21
20
24
9 - 16
13
12
TML-4000 TML-4000N
July 2007
REV A
Item
FIGURE 9-G
Part No.
Description
Qty.
97495
44723
Ref.
Ref.
97498
44723
27089
Ref.
85106
85105
85104
85149
85123
72350
85124
72337
85155
72348
10
85107
85148
65639
Dipstick ......................................... 1
Dipstick Tube
O-ring, Dipstick Tube
11
85069
12
65541
65542
13
80581
14
85151
15
72351
16
65636
17
65638
18
85152
19
104736
104737
Item
Part No.
Description
20
104675
21
6091
22
4266
Screw - HHC,
1/4 -20 x 2 inches GR 5
23
80010
24
80583
TML-4000 TML-4000N
Qty.
9 - 17
July 2007
Figure 9-H
REV A
4
5
7
23
8
7
10
9
10
11
12
22
11
13
14
21
20
9 - 18
19
18
17
16
TML-4000 TML-4000N
15
July 2007
REV A
Item
FIGURE 9-H
Part No.
Description
Qty.
85137
85081
85070
58307
85138
85139
85127
85136
85115
85110
10
85112
11
85113
12
85111
13
72343
14
Ref.
15
85116
Muffler
(includes item number 15) ............ 1
16
85087
17
85143
18
85103
85122
10
72339
20
85117
21
85141
22
85140
23
85089
85082
TML-4000 TML-4000N
9 - 19
July 2007
Figure 9-I
REV A
13
12
6 10 11
11
10
9
8
6
5
4
9 - 20
TML-4000 TML-4000N
December 2007
REV B
Item
FIGURE 9-I
Part No.
Description
Qty.
85153
97345
85154
85202
116156
85108
97334
Ref
80552
67349
Screw - HHC,
M8 x 1.25 x 50 mm, GR 8.8
67306
Fender Washer, M8
6024
80379
80550
80551
10
6035
11
59746
Screw - HHC,
5/8 -11 x 4 inches, GR 5
12
Ref.
13
Ref.
Capacitor,
35MF, 450V AC, 50/60 Hz
(models with one capacitor)
Capacitor,
35MF, 450V AC, 50/60 Hz
(models with two capacitors)
Cover - Capacitor,
MeccAlte Generator
Clamp
Generator, 6000 Watt,
115/230V AC, 50 Hz ..................... 1
Generator, 6000 Watt,
115/230V AC, 60 Hz
Terminal Strip .................................
Wire Harness, 240V, AC
Generator (refer to Figure 8-J)
TML-4000 TML-4000N
9 - 21
July 2007
Figure 9-J
REV D
9 - 22
TML-4000 TML-4000N
July 2007
FIGURE 9-J
REV D
Item
Part No.
30490
35418
44909
116034
891520
Ref.
630905
116041
Ref.
116035
104750
Description
-11 x 4 inches
11
6035
12
6024
13
58239
14
51131
Screw - HHC,
5/8 -11 x 2.5 inches
15
104777
16
67349
Screw - HHC,
M8 -1.25 x 50 mm, GR 8.8
17
67306
Fender Washer, M8
18
49408
Lock Washer, M8
19
80601
Engine Mount
Vibration Isolator .......................... 2
20
996290
20
8177
21
990415
22
22736
23
116039
8177
Screw, HHC,
1/2 -13 x 1.5 inches, GR 5
6095
6198
740925
80399
104655
104654
10
59746
Screw - HHC,
5/8
Qty.
TML-4000 TML-4000N
9 - 23
July 2007
Figure 9-K
REV B
2
17
3
16
4
15
14
2 13
12
11
10
9
8
9 - 24
TML-4000 TML-4000N
July 2007
FIGURE 9-K
REV B
Item
Part No.
Description
112288
112288
Ref.
85155
84860
58291
Radiator ........................................ 1
97476
Fan ............................................... 1
97407
97474
97426
97425
97472
85103
85122
97430
101326
101327
85143
10
97473
11
85071
V - Belt .......................................... 1
12
101322
97483
13
101319
14
72343
15
58292
16
Ref.
17
97428
Qty.
TML-4000 TML-4000N
9 - 25
July 2007
Figure 9-L
REV A
4
5
17
16
14 15
13
12
11
10
9 - 26
TML-4000 TML-4000N
July 2007
REV A
Item
FIGURE 9-L
Part No.
Description
Qty.
84812
84813
84814
97405
97429
97427
84811
84815
97460
10
97404
11
72348
12
101321
13
94762
14
101320
Dipstick ......................................... 1
15
97461
16
62421
17
94889
TML-4000 TML-4000N
9 - 27
July 2007
9 - 28
TML-4000 TML-4000N
July 2007
Section Ten
Mast
Components
TML-4000 TML-4000N
10 - 1
July 2007
Figure 10-A
REV B
2
3
4
20
19 4
15 16 17 18
8
9
10
14
13
10 - 2
12
TML-4000 TML-4000N
11
July 2007
REV B
Item
FIGURE 10-A
Part No.
Description
Qty.
69682
6637
Screw - HHC,
1/4 -20 x 1.75 inches, GR 5
6638
6091
51428
Screw - HHC,
3/4 -10 x 2.75 inches, GR 5
6564
Shim Washer,
0.75 x 1.125 x 0.093 inch
10258
69684
69687
Wear Pad,
Number 1, Mast Tube ................... 1
10
69885
Pivot Assembly,
Number 1, Mast Tube
(includes item 15) ......................... 1
11
57316
12
80107
13
69680
14
6094
15
57589
Screw - HHC,
-10 x 10 inches, GR 8 .............. 1
3/4
16
74323
17
42641
Flange Bearing,
0.75 x 1 x 1.25 inches ................... 2
18
10258
19
6090
Screw - HHC,
1/4 -20 x 0.75 inch, GR 5
20
Ref.
TML-4000 TML-4000N
10 - 3
July 2007
Figure 10-B.1
REV A
10
11
13 12
13 12
9
37
15 14
36 13
16
17
18
35
19
34
30
21 20
32 33 13
1 22
31
26 25 24 23
2
30
27
28
13
29
10 - 4
TML-4000 TML-4000N
July 2007
REV A
Item
FIGURE 10-B.1
Part No.
Description
Qty.
Item
Part No.
Description
Qty.
6091
18
80118
6833
19
80094
85274
20
5094
Screw - RHM,
10-32 x 0.5 inch, GR 2
21
6178
22
6090
Screw - HHC,
1/4 -20 x 0.75 inch, GR 5
57646
85273
80117
7339
Screw - HHC,
1/4 -20 x 0.5 inch, GR 5
23
6145
Screw - HHC,
1/4 -20 x 1.5 inches, GR 5
6356
24
6638
80640
25
40735
Aluminum Spacer,
1/4 x 0.375 x 0.875 inch ............... 1
26
6889
85304
27
23394
28
80324
29
69843
Screw - FHSC,
3/8 -16 x 1.25 inches
80641
69680
6094
30
48075
10
85260
31
69708
32
6019
11
57316
Screw - HHC,
3/8 -16 x 1.25 inches, GR 5
12
13918
Screw - HHC,
3/8 -16 x 1.75 inches, GR 8 ........... 2
33
11978
34
69658
13
4828
35
69657
14
8255
Screw - HHC,
3/8 -16 x 0.75 inch, GR 5
36
5224
15
6021
Screw - HHC,
3/8 -16 x 2 inches, GR 5
16
Ref.
37
61295
17
Ref.
Winch Housing
(refer to Figure 8-H)
TML-4000 TML-4000N
10 - 5
July 2007
Figure 10-B.2
REV A
10 - 6
TML-4000 TML-4000N
July 2007
REV A
Item
FIGURE 10-B.2
Part No.
Ref.
7339
Description
Qty.
Item
Part No.
Description
Qty.
23
64154
Carriage Bolt,
3/8 -16 x 1 inch, GR 5
24
48075
25
Ref.
26
6019
Screw - HHC,
3/8 -16 x 1.25 inches, GR 5
Nylon Flat Washer, 1/2 inch
6356
Lock Washer,
inch
80641
80640
27
11978
Ref.
28
Ref.
Winch Housing
(refer to Figure 8-H)
Ref.
29
Ref.
69680
30
5224
6094
Screw - HHC,
3/8 -16 x 2 inches, GR 5
10
13918
Screw - HHC,
3/8 -16 x 1.75 inches, GR 8 ........... 2
31
Ref.
11
4828
32
Ref.
12
Ref.
33
61295
13
6833
34
8255
Screw - HHC,
3/8 -16 x 0.75 inch, GR 5
14
6090
Screw - HHC,
1/4 -20 x 0.75 inch, GR 5
35
6021
15
6091
16
6145
Screw - HHC,
1/4 -20 x 1.5 inches, GR 5
17
5397
18
40735
Aluminum Spacer,
1/4 x 0.375 x 0.875 inch ............... 1
19
6889
20
Ref.
21
80324
22
97321
TML-4000 TML-4000N
10 - 7
July 2007
Figure 10-C.1
REV A
12
10
10
14
11
11
15
13
12
10
11
16
17
18
19
20
22 21
22 21
23
26
5
24 2
25
3
2
5
10 - 8
24
TML-4000 TML-4000N
July 2007
REV A
Item
FIGURE 10-C.1
Part No.
Description
Qty.
Item
Part No.
8914
Screw - HHC,
1/4 -20 x 0.63 inch, GR 5
25
Ref.
6356
26
80126
Ref.
57302
80206
Ref.
69680
6094
43391
6888
Screw - HHC,
1/4 -20 x 1 inch, GR 5
10
6638
11
6091
12
6145
Screw - HHC,
1/4 -20 x 1.5 inches, GR 5
13
69699
14
25926
Flat Washer, M6
15
40735
Description
Qty.
Aluminum Spacer,
x 0.375 x 0.875 inch ................ 1
1/4
16
Ref.
17
69664
18
69638
19
80204
20
57316
21
6708
Screw - HHC,
3/8 -16 x 2.25 inches, GR 5
22
4828
23
80205
24
7339
Screw - HHC,
1/4 -20 x 0.5 inch, GR 5
TML-4000 TML-4000N
10 - 9
July 2007
Figure 10-C.2
REV B
5
6
8
9
10
11
6 13 12
14
24 25
22 23
15
20 21
2
16
19
18
17
10 - 10
TML-4000 TML-4000N
July 2007
REV B
Item
FIGURE 10-C.2
Part No.
Description
Qty.
85277
6094
43391
6888
Screw - HHC,
1/4 -20 x 1 inch, GR 5
6638
6091
69699
69664
25926
Flat Washer, M6
10
Ref.
11
40735
12
6145
Screw - HHC,
1/4 -20 x 1.5 inches, GR 5
13
5397
14
69638
15
Ref.
16
69680
17
Ref.
18
Ref.
19
80641
20
8255
Screw - HHC,
3/8 -16 x 0.75 inch, GR 5
21
6021
22
7339
Screw - HHC,
1/4 -20 x 0.5 inch, GR 5
23
6356
24
13918
Screw - HHC,
3/8 -16 x 1.75 inches, GR 8 ........... 2
25
4828
TML-4000 TML-4000N
10 - 11
July 2007
Figure 10-D.1
REV B
10
3
9 18 19
7
20
11
12
13
17
10 - 12
16
15
14
TML-4000 TML-4000N
July 2007
REV B
Item
FIGURE 10-D.1
Part No.
Description
Qty.
57317
6175
Screw - HHC,
3/8 -16 x 1 inch, GR 5
4828
80138
104685
80135
6090
Screw - HHC,
1/4 -20 x 0.75 inch, GR 5
6091
11335
Screw - SHS,
-16 x 0.5 inch
3/8
10
11978
11
Ref.
12
80134
13
57352
14
7265
15
33277
Flat Washer, M8
16
80641
17
80125
18
5397
19
7713
20
Ref.
TML-4000 TML-4000N
10 - 13
July 2007
Figure 10-D.2
REV B
3
4
17 18
16
10 9
15
10 - 14
14
13
12
11
TML-4000 TML-4000N
July 2007
REV B
Item
FIGURE 10-D.2
Part No.
Description
Qty.
80200
11335
Screw - SHS,
3/8 -16 x 0.5 inch
11978
7713
104685
Ref.
57352
6002
6638
10
30973
Rubber Bumper,
1 x 1.25 inches ............................. 2
11
Ref.
Steel Rivet,
(refer to Figure 10-D.1)
12
Ref.
Flat Washer, M8
(refer to Figure 10-D.1)
13
Ref.
Wear Pad
(refer to Figure 10-D.1)
14
85286
15
Ref.
16
Ref.
17
22832
Screw - HHC,
3/8 -16 x 6 inches, GR 5
18
4828
TML-4000 TML-4000N
10 - 15
July 2007
Figure 10-E.1
REV B
10 - 16
TML-4000 TML-4000N
July 2007
REV B
Item
FIGURE 10-E.1
Part No.
Description
Qty.
6086
40658
6034
11978
57673
69641
Screw - HHC,
3/8 -16 x 0.75 inch
6700
8177
Screw - HHC,
1/2 -13 x 1.5 inches, GR 5
Ref.
Light Assembly
(refer to Figure 10-F.1 or 10-F.2 )
10
6019
Screw - HHC,
3/8 -16 x 1.25 inches, GR 5
11
7713
12
57674
13
69766
14
57535
57581
T-box ............................................. 1
Cover, T-box
15
49819
Screw - PHM,
10-32 x 0.5 inch, GR 2
16
6607
17
15513
18
69701
19
48075
TML-4000 TML-4000N
10 - 17
July 2007
Figure 10-E.2
REV B
10 - 18
TML-4000 TML-4000N
July 2007
REV B
Item
FIGURE 10-E.2
Part No.
Description
Qty.
57451
Squeeze Connector,
1/2 inch NPT .................................. 1
57535
57581
T-box ............................................. 1
Cover, T-box
33576
Squeeze Connector,
1/2 inch NPT .................................. 4
57582
57582
80475
85278
80478
80445
10
33776
11
80441
12
Ref.
13
80409
Light Bracket,
Vertical Adjustment ...................... 4
14
8255
Screw - HHC,
3/8 -16 x 0.75 inch, GR 5
15
6021
16
80411
Light Bracket,
Horizontal Adjustment .................. 4
17
6002
18
11978
19
80466
20
69766
21
80448
Screw - HHC,
5/16 -18 x 6.5 inches, GR 5
22
13005
Screw - HHC,
1/2 -13 x 6 inches, GR 8 ................ 2
23
48075
Item
Part No.
Description
Qty.
24
69207
25
59972
26
80336
27
6086
28
6034
Light Assembly
(refer to Figure 10-F.1 or 10-F.2 )
TML-4000 TML-4000N
10 - 19
July 2007
Figure 10-E.3
REV B
10 - 20
TML-4000 TML-4000N
July 2007
REV B
Item
FIGURE 10-E.3
Part No.
Description
Qty.
57451
Squeeze Connector,
1/2 inch NPT .................................. 1
57535
57581
T-box ............................................. 1
Cover, T-box
33576
Squeeze Connector,
1/2 inch NPT .................................. 4
57582
57582
80475
85278
80478
80445
10
33776
11
80441
12
Ref.
13
80409
Light Bracket,
Vertical Adjustment ...................... 4
14
8255
Screw - HHC,
3/8 -16 x 0.75 inch, GR 5
15
6021
16
80411
Light Bracket,
Horizontal Adjustment .................. 4
17
6002
18
11978
19
80466
20
69766
21
80448
Screw - HHC,
5/16 -18 x 6.5 inches, GR 5
22
13005
Screw - HHC,
1/2 -13 x 6 inches, GR 8 ................ 2
23
48075
Item
Part No.
Description
Qty.
24
69207
25
59972
26
80336
27
6086
28
6034
29
6097
Light Assembly
(refer to Figure 10-F.1 or 10-F.2 )
TML-4000 TML-4000N
10 - 21
July 2007
Figure 10-F.1
REV B
16
15
9
14
5
6
13
4
7
12
11
10 - 22
10
TML-4000 TML-4000N
July 2007
REV B
Item
FIGURE 10-F.1
Part No.
Description
Qty.
57449
66844
80539
78196
Screw - PHPM,
8-32 x 0.625 inch
69886
58190
85042
71979
80566
Fiberglass Insulation,
6 x 6 x 1.5 inches .......................... 1
80599
80100
69889
69868
10
69888
11
80102
12
58191
13
80103
14
Ref.
15
69890
16
69887
TML-4000 TML-4000N
10 - 23
December 2007
Figure 10-F.2
REV C
10 - 24
TML-4000 TML-4000N
December 2007
REV C
FIGURE 10-F.2
Item
Part No.
Description
112290
Light Fixture
(from serial number
TML06-000708 to TML08-372)
112282
116019
116017
116018
116014
116013
116012
116009
116010
116008
10
116011
11
80101
Qty.
TML-4000 TML-4000N
10 - 25
December 2007
Figure 10-F.3
REV C
10 - 26
TML-4000 TML-4000N
December 2007
REV C
FIGURE 10-F.3
Item
Part No.
Description
161090
Light Fixture
(after serial number
TML08-373)
116054
116049
Gasket, Rectangular
Glass Lens .................................. 1
116048
116051
116052
80101
116047
116045
116046
116057
10
116056
11
116044
12
116059
13
116053
14
116042
15
116043
16
116113
17
116109
18
116058
19
116061
Qty.
TML-4000 TML-4000N
10 - 27
July 2007
Figure 10-G
REV A
4
3
10 - 28
TML-4000 TML-4000N
July 2007
REV A
Item
FIGURE 10-G
Part No.
Description
Qty.
47601
57430
57582
85382
6091
28443
6833
28443
TML-4000 TML-4000N
10 - 29
July 2007
Figure 10-H
REV A
Mast 3
Mast 2
10 - 30
TML-4000 TML-4000N
Mast 1
July 2007
REV A
Item
FIGURE 10-H
Part No.
Description
Qty.
Ref.
80281
28487
5397
4828
TML-4000 TML-4000N
10 - 31
July 2007
10 - 32
TML-4000 TML-4000N