Related Manuals for Terex Genie AL6-6000
Summary of Contents for Terex Genie AL6-6000
- Page 1 Operator's Manual AL6-6000 Australia AL6-9000 with Maintenance Information First Edition First Printing Part No. 1254860...
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Page 2: Table Of Contents
Specifications ............42 Copyright © 2014 Terex Corporation First Edition: First Printing, January 2014 “Terex” is a registered trademark of Terex USA, LLC in the USA and many other countries. These machines comply with the Motor Vehicles Standard Act 1989 AL6-6000 •... -
Page 3: Introduction
First Edition • First Printing Operator's Manual Introduction Introduction About this manual Intended Use Genie appreciates your choice of our machine for This machine is intended to be used only to your application. Our number one priority is user provide lighting and electrical power to a work site. safety, which is best achieved by our joint efforts. - Page 4 Operator's Manual First Edition • First Printing Introduction Contacting the Manufacturer At times it may be necessary to contact Genie. When you do, be ready to supply the model number and serial number of your machine, along with your name and contact information. At minimum, Genie should be contacted for: Accident reporting Questions regarding product applications and...
- Page 5 First Edition • First Printing Operator's Manual Introduction Danger Failure to obey the instructions and safety rules in this manual will result in death or serious injury. Do Not Operate Unless: You learn and practice the principles of safe machine operation contained in this operator’s manual.
- Page 6 Operator's Manual First Edition • First Printing Introduction Hazard Classification Safety Sign Maintenance Replace any missing or damaged safety signs. Decals on this machine use symbols, color coding Keep operator safety in mind at all times. Use mild and signal words to identify the following: soap and water to clean safety signs.
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Page 7: Symbol And Hazard Pictorials Definitions
First Edition • First Printing Operator's Manual Symbol and Hazard Pictorials Definitions Symbol and Hazard Pictorials Definitions Read the operator’s Electrocution hazard Stop engine Earth ground Electrocution hazard manual Maintain required Explosion / Burn Disconnect battery Keep away from Keep away from clearance hazard Read the service... - Page 8 Operator's Manual First Edition • First Printing Symbol and Hazard Pictorials Definitions Burn hazard, hot Stay clear of hot Carbon Monoxide Wear protective Shattering glass components surfaces under cover hazard clothing hazard Lifting point AL6-6000 • AL6-9000 Part No. 1254860...
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Page 9: General Safety
First Edition • First Printing Operator's Manual General Safety General Safety T108022 T108022 133148 114258 114431 1251967 114431 1251981 133148 133483 133483 1251976 T108021 T108022 T108021 114258 1251967 1251981 1251976 1251976 1251976 Part No. 1254860 AL6-6000 • AL6-9000... - Page 10 Operator's Manual First Edition • First Printing General Safety 28161 133148 28161 28236 133148 1251970 114431 28236 97666 133483 1251981 114431 1251970 133483 31788 1251971 1251981 133012 133148 1251971 1251980 97666 1251980 133012 31788 AL6-6000 • AL6-9000 Part No. 1254860...
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Page 11: Work Area Safety
First Edition • First Printing Operator's Manual Work Area Safety Work Area Safety Do not perform service or replace the lamps with Electrocution Hazards the engine/generator running or the battery This machine is not electrically insulated and will connected. not provide protection from contact with or This machine should be grounded in accordance proximity to electrical current. - Page 12 Operator's Manual First Edition • First Printing Work Area Safety Be sure the tires are in good condition and the lug Tip-over Hazards nuts tightened. Do not raise the mast unless all Do not place ladders or outriggers are properly deployed, scaffolds against any part the foot pads are in firm contact of the machine.
- Page 13 First Edition • First Printing Operator's Manual Work Area Safety Collision Hazards Bodily Injury Hazard Check the work area for overhead obstructions or Do not use the machine indoors unless properly other possible hazards. ventilated. The machine must be on a level surface before Do not breathe exhaust fumes.
- Page 14 Be sure lamp fixture connections are properly Be sure all maintenance has been performed as tightened before turning lights on. specified in this manual and the appropriate Terex service manual. Align tower arrows before retracting mast. Be sure the operator's manual is complete, legible...
- Page 15 First Edition • First Printing Operator's Manual Work Area Safety Electrocution/Burn Hazards Battery Safety Avoid contact with electrical terminals. Burn Hazards Inspect the power cord for damage prior to each use. Batteries contain acid. Always wear protective Replace any damaged cord before operating. clothing and eye wear Do not allow the power cord to become caught or when working with...
- Page 16 Operator's Manual First Edition • First Printing Work Area Safety Towing Hazards Lockout After Each Use Read, understand and obey all of your tow vehicle When leaving the machine unattended, secure manufacturer's recommendations, warnings and from unauthorized use. Unauthorized personnel instructions before towing this machine.
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Page 17: Legend
First Edition • First Printing Operator's Manual Legend Legend 21 27 25 24 15 Starter isolator Hydraulic outrigger 16 Lifting eye Control panel (located inside cabinet) 17 Travel lock turnbuckle MEN point (located inside cabinet) 18 Outrigger spring pin Drawbar with tow coupling 19 Outrigger jack handle Jockey wheel 20 Outrigger lock handle... -
Page 18: Controls
Operator's Manual First Edition • First Printing Controls Controls Models with manual start Models with auto start 1251966 A Function enable button Timer down button Push and hold the function enable button to Push the timer down button to set the timer enable the functions on the ground controls to preset run time. - Page 19 First Edition • First Printing Operator's Manual Controls AL6-6000 MAIN MAIN AL6-9000 MAIN Outriggers 10 Ignition key switch for engine Hydraulic tower retract button Turn the key switch to the glow plug position Push the button and the tower will retract. and hold for 5 seconds to pre-heat the glow plug.
- Page 20 Operator's Manual First Edition • First Printing Controls 12 30A breaker for control electrical circuits 21 Timer 13 Alternator failure light The timer is used to automatically start the engine and turn on the lights at a preset time. Light on indicates that the engine's DC alternator isn't producing enough voltage.
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Page 21: Inspections
First Edition • First Printing Operator's Manual Inspections Inspections Pre-operation Inspection Fundamentals It is the responsibility of the operator to perform a pre-operation inspection and routine maintenance. The pre-operation inspection is a visual inspection performed by the operator prior to each work shift. Do Not Operate Unless: The inspection is designed to discover if anything is apparently wrong with a machine before the... - Page 22 Operator's Manual First Edition • First Printing Inspections Hydraulic outriggers, cylinders and foot Pre-operation Inspection pads Be sure that the operator’s manual is complete, Nuts, bolts and other fasteners legible and in the storage container located on ...
- Page 23 First Edition • First Printing Operator's Manual Inspections Function Test Fundamentals The function tests are designed to discover any malfunctions before the machine is put into service. The operator must follow the step-by-step instructions to test all machine functions. A malfunctioning machine must never be used. If malfunctions are discovered, the machine must be Do Not Operate Unless: tagged and removed from service.
- Page 24 Operator's Manual First Edition • First Printing Inspections Manual outrigger models Function Tests 11 Release the spring pin on the front and back Setup manual outriggers and slide each outrigger out until the spring pin locks. Pull the lock handle Position the light tower at the desired work on the outrigger jack to rotate the outrigger site.
- Page 25 First Edition • First Printing Operator's Manual Inspections 21 Turn the jockey wheel handle to lower the Hydraulic outrigger models jockey wheel to the ground. 13 Push and hold the function enable button. 22 Drive the grounding rod (if equipped) into the Push each hydraulic outrigger lever down to ground and connect it to the grounding lug on lower the hydraulic outriggers.
- Page 26 Operator's Manual First Edition • First Printing Inspections Test the Hydraulic Outrigger Functions (if Test the Tower Functions equipped) 36 Do not push the function enable button. Attempt to activate each switch or button on 29 Make sure the engine is running the tower control panel.
- Page 27 First Edition • First Printing Operator's Manual Inspections 44 Return the light bar to the horizontal travel Test the Lights position. Note: Make sure the engine is running. 45 Pull the tower rotation lock up until the spring 49 Raise and fully extend the tower pin unlocks and push the tower rotation handle in each direction.
- Page 28 Operator's Manual First Edition • First Printing Inspections Workplace Inspection Fundamentals The workplace inspection helps the operator determine if the workplace is suitable for safe machine operation. It should be performed by the operator prior to moving the machine to the workplace.
- Page 29 First Edition • First Printing Operator's Manual Inspections Workplace Inspection Checklist Be aware of and avoid the following hazardous situations: drop-offs or holes bumps, floor obstructions or debris sloped surfaces unstable or slippery surfaces overhead obstructions and high voltage conductors ...
- Page 30 Operator's Manual First Edition • First Printing Inspections Decal Inspection Part No. Decal Description 1251963 Label – Starter Isolator Use the pictures on the next page to verify that all 1251965 Control Panel – Key Switch Start decals are legible and in place. 1251966 Control Panel –...
- Page 31 First Edition • First Printing Operator's Manual Inspections 1251974 T108022 28161 1251965 1251972 28176 or 1251973 52475 72086 72086 1251966 28236 1251974 1251979 1251972 or 1251973 114258 133148 28159 1251970 97666 133483 114431 1251963 1251981 1251962 133148 1251981 133483 114431 1253433 Serial label 1251977...
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Page 32: Operating Instructions
Operator's Manual First Edition • First Printing Operating Instructions Operating Instructions Fundamentals The Operating Instructions section provides instructions for each aspect of machine operation. It is the operator’s responsibility to follow all the safety rules and instructions in the operator’s, safety and responsibilities manuals. - Page 33 First Edition • First Printing Operator's Manual Operating Instructions Setup Hydraulic outrigger models Make sure the machine is set up according to Note: Make sure the engine is running. the Setup procedure in the Function Tests To deploy hydraulic outriggers: section.
- Page 34 Operator's Manual First Edition • First Printing Operating Instructions Start the Engine - Manual Engine Start Operating Instructions (auto start option) Timer (machines with manual key switch Note: The main circuit breaker and the light start) switches must be off before starting the engine. The timer is used to automatically stop the engine Pull out the red Emergency Stop button on the and turn off the lights after a preset run time.
- Page 35 First Edition • First Printing Operator's Manual Operating Instructions To program the timer: To enable engine automatic start/stop cycle: Push the Program button and 1on will appear at the bottom left of the display; 1on refers to Turn the key switch to the I (run) position. the start time of the first start/stop cycle.
- Page 36 Operator's Manual First Edition • First Printing Operating Instructions Make sure that the drawbar is extended, the Manual Operation of Lights drawbar lock pin is inserted through the Note: The engine must be running before the lights chassis and the drawbar, and the retaining pin are turned on.
- Page 37 First Edition • First Printing Operator's Manual Operating Instructions Towing After Each Use Make sure the machine is shut down according to Select a safe parking location—firm level surface, the Shutdown of Tower procedure in the Operating clear of obstruction and traffic. Retract and lower Instructions section.
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Page 38: Transport And Lifting Instructions
Terex customers needing to containerize any Push the tow coupling handle to retract the Terex product should source a qualified freight drawbar. forwarder with expertise in preparing, loading and securing construction and lifting Insert the drawbar lock pin through the chassis equipment for international shipment. - Page 39 First Edition • First Printing Operator's Manual Transport and Lifting Instructions Manual outrigger models 14 Pull the lock handle on the outrigger jack to rotate the outrigger jack into the vertical position and then release the lock handle. 15 Turn the outrigger jack handles to lower the outrigger jacks to the transport surface.
- Page 40 Operator's Manual First Edition • First Printing Transport and Lifting Instructions Lifting the Machine with a Crane Fully retract and lower the mast to the stowed position. Secure the mast for transport with the travel lock turnbuckle. Observe and Obey: Fully retract, raise and lock all outriggers.
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Page 41: Maintenance
Oil type 10W-30 responsibilities manual. Use only Terex approved replacement parts. Maintenance Symbols Legend The following symbols have been used in this manual to help communicate the intent of the instructions. When one or more of the symbols appear at the beginning of a maintenance procedure, it conveys the meaning below. - Page 42 Operator's Manual First Edition • First Printing Maintenance Check the Engine Coolant Level Check the Batteries Maintaining the engine coolant at the proper level Proper battery condition is essential to good is essential to engine service life. Improper coolant machine performance and operational safety. level will affect the engine’s cooling capability and Improper fluid levels or damaged cables and damage engine components.
- Page 43 First Edition • First Printing Operator's Manual Maintenance Check the Tire Pressure Scheduled Maintenance Maintenance performed quarterly, annually and every two years must be completed by a person trained and qualified to perform maintenance on Bodily injury hazard. An over-inflated tire can this machine according to the procedures found in explode and may cause death or serious the service manual for this machine.
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Page 44: Specifications
Maximum wind speed 100 km/h Maximum wind speed 100 km/h Continuous improvement of our products is a Terex Continuous improvement of our products is a Terex policy. Product specifications are subject to change policy. Product specifications are subject to change without notice or obligation. - Page 45 www.genielift.com...