Terex Genie AL6-6000 User manual

Operator's Manual
A
L
6
-6000 AUS
Australia
A
L
6
-9000
with
Maintenance
Information
First Edition
First Printing
Part No. 1254860

Operator's Manual First Edition • First Printing
AL6-6000 • AL6-9000 Part No. 1254860
FrontMatter
Contents
Introduction ........................................................... 1
Symbol and Hazard Pictorials Definitions............. 5
General Safety ...................................................... 7
Work Area Safety.................................................. 9
Legend ................................................................ 15
Controls............................................................... 16
Inspections.......................................................... 19
Operating Instructions......................................... 30
Transport and Lifting Instructions ....................... 36
Maintenance ....................................................... 39
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

First Edition • First Printing Operator's Manual
Introduction
Part No. 1254860 AL6-6000 • AL6-9000 1
Introducti on
About this manual
Genie appreciates your choice of our machine for
your application. Our number one priority is user
safety, which is best achieved by our joint efforts.
This book is an operation and daily maintenance
manual for the user or operator of a Genie
machine.
This manual should be considered a permanent
part of your machine and should remain with the
machine at all times. If you have any questions,
contact Genie.
Product Identification
The machine serial number is located on the serial
label.
Intended Use
This machine is intended to be used only to
provide lighting and electrical power to a work site.
Bulletin Distribution and
Compliance
Safety of product users is of paramount
importance to Genie. Various bulletins are used by
Genie to communicate important safety and
product information to dealers and machine
owners.
The information contained in the bulletins is tied to
specific machines using the machine model and
serial number.
Distribution of bulletins is based on the most
current owner on record along with their
associated dealer, so it is important to register your
machine and keep your contact information up to
date.
To ensure safety of personnel and the reliable
continued operation of your machine, be sure to
comply with the action indicated in a respective
bulletin.
serial label

Operator's Manual First Edition • First Printing
Introduction
2 AL6-6000 • AL6-9000 Part No. 1254860
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
safety
Standards and regulatory compliance information
Current owner updates, such as changes in
machine ownership or changes in your contact
information. See Transfer of Ownership, below.
Transfer of Machine Ownership
Taking a few minutes to update owner information
will ensure that you receive important safety,
maintenance and operating information that
applies to your machine.
Please register your machine by visiting us on the
web at www.genieindustries.com.au or by calling
us toll free at 1800 788 633.

First Edition • First Printing Operator's Manual
Introduction
Part No. 1254860 AL6-6000 • AL6-9000 3
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.
1 Avoid hazardous situations.
Know and understand the safety rules
before going on to the next section.
2 Always perform a pre-operation inspection.
3 Always perform function tests prior to use.
4 Inspect the workplace.
5 Only use the machine as it was intended.
You read, understand and obey the
manufacturer’s instructions and safety
rules—safety and operator’s manuals and
machine decals.
You read, understand and obey employer’s
safety rules and worksite regulations.
You read, understand and obey all applicable
governmental regulations.
You are properly trained to safely operate the
machine.

Operator's Manual First Edition • First Printing
Introduction
4 AL6-6000 • AL6-9000 Part No. 1254860
Hazard Classification
Decals on this machine use symbols, color coding
and signal words to identify the following:
Safety alert symbol—used to alert
you to potential personal injury
hazards. Obey all safety
messages that follow this symbol
to avoid possible injury or death.
Indicates a hazardous situation
which, if not avoided, will result in
death or serious injury.
Indicates a hazardous situation
which, if not avoided, could result
in death or serious injury.
Indicates a hazardous situation
which, if not avoided, could result
in minor or moderate injury.
Indicates a property damage
message.
Safety Sign Maintenance
Replace any missing or damaged safety signs.
Keep operator safety in mind at all times. Use mild
soap and water to clean safety signs. Do not use
solvent-based cleaners because they may damage
the safety sign material.
DANGER
WARNING
CAUTION
NOTICE

First Edition • First Printing Operator's Manual
Symbol and Hazard Pictorials Definitions
Part No. 1254860 AL6-6000 • AL6-9000 5
Symbol and Hazard P ictorials Definiti ons
Read the operator’s
manual
Electrocution hazard Stop engine Earth ground Electrocution hazard
Maintain required
clearance
Explosion / Burn
hazard
Disconnect battery
Read the service
manual
Keep away from
moving parts
Keep away from
moving parts
Burn hazard Stay clear of hot
exhaust
Burn hazard Explosion / Burn
hazard
Corrosive acid.
Crush hazard Keep clear of
outriggers and tires
No smoking No flame No flame
Tip-over hazard Towing instructions Tip-over hazard Raising tower
instructions
Tie-down point
P
P
P
P

Operator's Manual First Edition • First Printing
Symbol and Hazard Pictorials Definitions
6 AL6-6000 • AL6-9000 Part No. 1254860
Burn hazard, hot
components
Stay clear of hot
surfaces under cover
Carbon Monoxide
hazard
Wear protective
clothing
Shattering glass
hazard
Lifting point

First Edition • First Printing Operator's Manual
General Safety
Part No. 1254860 AL6-6000 • AL6-9000 7
General Safety
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T108022
T108021
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1251976
12519761251976
133148
114431
114258
133483
T108022
T108021
1251981
1251967
1251976

Operator's Manual First Edition • First Printing
General Safety
8 AL6-6000 • AL6-9000 Part No. 1254860
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133148
133012
31788
1251971
1251981
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1251970
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28236
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133148
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28236
1251970
1251981
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31788
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First Edition • First Printing Operator's Manual
Work Area Safety
Part No. 1254860 AL6-6000 • AL6-9000 9
WorkArea Safety
Electrocution Hazards
This machine is not electrically insulated and will
not provide protection from contact with or
proximity to electrical current.
Obey all local and governmental regulations
regarding required clearance from electrical power
lines. At a minimum, the required clearance
contained in the chart below must be followed.
Line Voltage Required Clearance
0 to 50KV 3.05 m
50 to 200KV 4.60 m
200 to 350KV 6.10 m
350 to 500KV 7.62 m
500 to 750KV 10.67 m
750 to 1000KV 13.72 m
Allow for mast movement, electrical line sway or
sag, and beware of strong or gusty winds.
Do not operate the machine during lightning or
storms.
Do not use the machine as a ground for welding.
Keep away from the
machine if it contacts
energized power lines.
Personnel must not touch
or operate the machine
until energized power
lines are shut off.
Do not connect wires directly to the generator.
Connect auxiliary equipment only to the power
outlets provided.
Do not perform service or replace the lamps with
the engine/generator running or the battery
connected.
This machine should be grounded in accordance
with all local electrical codes. Consult the local
electrical codes or authority having jurisdiction in
the area where the machine will be used for
specific requirements.
There is a permanent conductor between the
generator (static winding) and the frame.
Explosion and Fire Hazards
Do not start the engine if you smell or detect liquid
petroleum gas (LPG), gasoline, diesel fuel or other
explosive substances.
Do not refuel the machine with
the engine running.
Do not refuel the machine while
it is hot. Allow to cool for
several minutes before
refueling.
Do not spill fuel inside the
engine compartment.
Refuel the machine and charge the battery only in
an open, well-ventilated area away from sparks,
flames and lighted tobacco.
Do not operate the machine in hazardous locations
or locations where potentially flammable or
explosive gases or particles may be present.
Do not spray ether into
engines equipped with
glow plugs.

Operator's Manual First Edition • First Printing
Work Area Safety
10 AL6-6000 • AL6-9000 Part No. 1254860
Tip-over Hazards
Do not raise the mast unless all
outriggers are properly deployed,
the foot pads are in firm contact
with the ground and the machine
is level.
Do not set the machine up on a
surface where it cannot be leveled
using only the leveling jacks.
Do not hang objects from the lights or the mast.
Do not use the mast to raise material or personnel.
Do not move the machine unless the mast is
lowered to the horizontal position.
Do not raise the mast
when wind speeds
may exceed 62 mph /
100 km/h. Do not alter
or disable machine
components that in any
way affect safety and
stability.
Do not alter or disable machine components that in
any way affect safety and stability.
Do not adjust or stow the outriggers when the mast
is raised.
Be sure the tires are in good condition and the lug
nuts tightened.
Do not place ladders or
scaffolds against any part
of the machine.
Do not use the machine on
a moving or mobile surface
or vehicle.
Crushing Hazard
Do not lower the mast
unless the area below is
clear of personnel and
obstructions.
Keep hands and fingers
away from any potential
pinch points.
Keep clear of moving
outriggers.

First Edition • First Printing Operator's Manual
Work Area Safety
Part No. 1254860 AL6-6000 • AL6-9000 11
Collision Hazards
Check the work area for overhead obstructions or
other possible hazards.
The machine must be on a level surface before
releasing the parking brake.
Do not attempt to manually move a machine
unless it is on a firm, level surface. Use the parking
brake to control the speed of the machine while
pushing it.
Burn Hazards
Do not touch the lamp fixtures
while they are turned on. Turn
the lamps off and allow them
to cool before touching.
Do not touch hot parts of the
engine or tailpipe, Use
protective gloves when
handling hot parts.
Bodily Injury Hazard
Do not use the machine indoors unless properly
ventilated.
Do not breathe exhaust fumes.
Do not work on this equipment when mentally or
physically fatigued.
Do not work on this equipment when under the
influence of drugs or alcohol.
Stay clear of belts and fan when engine is running.
Do not use the machine if the protective barrier on
any of the lamps is broken or punctured. Metal
halide lamps produce shortwave ultra-violet
radiation and can cause serious skin burns or eye
inflammation if the protective barrier is not in place.
Do not use where people will remain close to the
lamps for more than a few minutes unless
adequate shielding or other safety precautions are
used.
Stay clear of moving mast.
Use proper lifting techniques when lifting and
positioning the tongue of the machine.
Always replace the protective lamp cover after
replacing the lamp bulbs.

Operator's Manual First Edition • First Printing
Work Area Safety
12 AL6-6000 • AL6-9000 Part No. 1254860
Fall Hazards
Do not climb or stand on any part of the light tower.
Traffic Hazards
Stand clear of traffic when starting or checking the
unit along the road.
Damaged Machine Hazards
Do not use a damaged or malfunctioning machine.
Do not use a machine with a worn, frayed, kinked
or damaged cable.
Conduct a thorough pre-operation inspection of the
machine and test all functions before each work
shift. Immediately tag and remove from service a
damaged or malfunctioning machine.
Be sure all maintenance has been performed as
specified in this manual and the appropriate Terex
service manual.
Be sure the operator's manual is complete, legible
and in the storage container located on the
machine.
Be sure all decals are in place and legible.
Do not modify or alter the light tower without the
prior written permission of the manufacturer.
Component Damage Hazards
Do not turn the lights on unless the engine is
running. Always turn the lights off before shutting
down the engine.
Do not tow the light tower while the lamps are hot.
Hot lamps will break if moved.
Do not replace lamp bulbs with any bulbs other
than those specified on the machine and in this
manual.
Note: Lamp bulbs contain mercury (Hg). Dispose
of lamp bulbs according to local, state and federal
laws.
Do not extend the mast when both red lines are
visible on mast.
Do not retract a raised mast while the mast
retaining pin is engaged.
Be sure lamp fixture connections are properly
tightened before turning lights on.
Align tower arrows before retracting mast.
Connect and secure travel lock turnbuckle before
towing or picking with a crane.

First Edition • First Printing Operator's Manual
Work Area Safety
Part No. 1254860 AL6-6000 • AL6-9000 13
Battery Safety
Burn Hazards
Batteries contain acid.
Always wear protective
clothing and eye wear
when working with
batteries.
Avoid spilling or
contacting battery acid.
Neutralize battery acid
spills with baking soda
and water.
Do not use any battery charger greater than 12V to
charge the battery.
Do not remove the vent caps from the battery
when charging.
Do not expose the batteries or the charger to water
or rain during charging.
Explosion Hazards
Keep sparks, flames and lighted
tobacco away from batteries.
Batteries emit explosive gas.
Do not contact the battery
terminals or the cable clamps with
tools that may cause sparks.
Electrocution/Burn Hazards
Avoid contact with electrical terminals.
Inspect the power cord for damage prior to each
use.
Replace any damaged cord before operating.
Do not allow the power cord to become caught or
crushed while raising, lowering or rotating the
mast.
Avoid electrical shock from contact with battery
terminals. Remove all rings, watches and other
jewelry.
Lifting Hazard
Use the appropriate number of people and proper
lifting techniques when lifting batteries.

Operator's Manual First Edition • First Printing
Work Area Safety
14 AL6-6000 • AL6-9000 Part No. 1254860
Towing Hazards
Read, understand and obey all of your tow vehicle
manufacturer's recommendations, warnings and
instructions before towing this machine.
Do not tow the machine unless all outriggers have
been retracted and stowed and the drawbar has
been extended and secured.
Do not overload your tow vehicle.
Do not load cargo on the machine. The light tower
is not designed to carry any extra cargo.
Be sure the tow coupling is securely attached to
the tow vehicle.
Be sure the safety chains are securely attached to
the tow vehicle.
Be sure that all driving lights are operational.
Be sure all hitch components, lights and mirrors
and methods of attaching the trailer to the tow
vehicle conform to local, state and federal
regulations.
Do not tow the machine on public roads unless it
meets all governmental regulations for towing.
Do not exceed 100 km/h. Obey all local and
national towing speed laws.
Be sure to set the parking brake when parking on a
hill.
Use extreme care and slow speeds while towing
across uneven terrain, debris, holes or drop-offs.
Note: Do not tow the machine when the engine is
running. This can cause severe engine/radiator
damage and will not be covered under warranty.
Lockout After Each Use
When leaving the machine unattended, secure
from unauthorized use. Unauthorized personnel
may attempt to operate the machine without proper
instruction, creating an unsafe condition.

First Edition • First Printing Operator's Manual
Legend
Part No. 1254860 AL6-6000 • AL6-9000 15
Legend
1Hydraulic outrigger
2Control panel (located inside cabinet)
3MEN point (located inside cabinet)
4Drawbar with tow coupling
5Jockey wheel
6Bubble level
7Jockey wheel handle
8Tower rotation handle
9Forklift pockets
10 Mast
11 Lights
12 Curbside door
13 Manual storage container
14 Battery isolator
15 Starter isolator
16 Lifting eye
17 Travel lock turnbuckle
18 Outrigger spring pin
19 Outrigger jack handle
20 Outrigger lock handle
21 Outrigger
22 Outrigger footpad
23 Transport tie-down
24 Drawbar lock pin
25 Parking brake
26 Grounding lug (if equipped)
27 Roadside door
10
7
8
11
9
4
1
2
5
3
12 1
11
10
21
16
19 23 4 5 23 7
22
1
21 27
13 14
17
6
18
19
26 25 24
9
16
15
20

Operator's Manual First Edition • First Printing
Controls
16 AL6-6000 • AL6-9000 Part No. 1254860
Controls
1Timer down button
Push the timer down button to set the timer
preset run time.
2Timer up button
Push the timer up button to set the timer preset
run time.
3Timer digital display
Displays the preset run time in hours.
4Timer on/off switch
Move the timer on/off switch to the right to turn
on the timer. Turn the switch to the left to turn
off the timer.
5Function enable button
Push and hold the function enable button to
enable the functions on the ground controls to
operate.
6Hydraulic tower raise/lower switch
Rotate the switch to the left and the tower will
raise. Rotate the switch to the right and the
tower will lower.
1251966 A
!
10
11
8
6
9
7
5
12 13 14 15 16
19
20
11
12
21
25
16
6 57 8
14
Models with
manual start
Models with
auto start
9
17
18
24
22
23
4
3
2
1

First Edition • First Printing Operator's Manual
Controls
Part No. 1254860 AL6-6000 • AL6-9000 17
7Hydraulic tower retract button
Push the button and the tower will retract.
8Hydraulic tower extend button
Push the button and the tower will extend.
9Light bar raise/lower switch
Rotate the switch to the right and the light bar
will lower. Rotate the switch to the left and the
light bar will raise.
10 Ignition key switch for engine
Turn the key switch to the glow plug position
and hold for 5 seconds to pre-heat the glow
plug.
Turn the key switch to the start position to start
the engine. Release the key switch once the
engine starts.
Turn the key switch to the off position to turn
the engine off.
11 Hour meter
The hour meter displays the number of hours
the machine has operated.
1234MAIN
26
28
27
26
27
AL6-6000
MAIN RCD 1 2 3 4 5 6
MAIN RCD 1 2 3 4
AL6-9000
27
26
28
29
Outriggers

Operator's Manual First Edition • First Printing
Controls
18 AL6-6000 • AL6-9000 Part No. 1254860
12 30A breaker for control electrical circuits
13 Alternator failure light
Light on indicates that the engine's DC
alternator isn't producing enough voltage.
14 15A breaker for engine control electrical
circuits
15 Engine shutdown indicator light
Light on indicates that engine has shutdown
due to low oil pressure, low coolant level, high
coolant temperature or low fuel level.
16 15A breaker for hydraulic control electrical
circuits
17 Glow plug indicator light
Light on indicates the glow plugs are on.
18 Engine shutdown indicator light
Flashing light (when oil pressure, coolant
temperature, alternator failure and engine
overspeed lights are off) indicates that engine
start sequence has failed or engine has shut
down due to low coolant level or low fuel level.
Light also flashes when oil pressure, coolant
temperature, alternator failure and engine
overspeed lights flash.
19 Oil pressure light
20 Ignition key switch for engine
Turn the key switch to the I (run) position
before setting timer to automatically start and
stop the engine at a preset time.
Turn the key switch to the II (start) position and
hold to manually start the engine. Glow plugs
will be activated for 8 seconds and then engine
will start. Release key switch once engine has
started and key switch will return to I (run)
position.
Turn the key switch to the O (off) position to
turn the engine off.
21 Timer
The timer is used to automatically start the
engine and turn on the lights at a preset time.
22 Coolant temperature indicator light
23 Alternator failure light
24 Engine overspeed indicator light
25 Timer switch
The timer is used to automatically stop the
engine and turn off the lights at a preset time.
Move the switch to the right to reset and turn
on the timer. Move the switch to the left to turn
off the timer.
26 Main circuit breaker
Move the main circuit breaker switch up on the
control panel before turning the individual light
switches on.
27 Light switches
Move each light switch up to turn on the
indicated light. Move each light switch down to
turn off the indicated light.
28 Residual current circuit breaker
Move the residual current circuit breaker
switch up before turning the individual light
switches on.
29 Outrigger control handles
Move the outrigger control handle up to raise
an individual outrigger. Move the control
handle down to lower an individual outrigger.