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Terex AL5HT Operator's Manual

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See also: Service Manual
Operator's Manual
AL
5HT
™
AL
5HT
™
with tier 4 option
ANSI/CSA
North America
South America
Asia
with
Maintenance
Information
Second Edition
Third Printing
Part No. 235735GT

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Summary of Contents for Terex AL5HT

  • Page 1 Operator's Manual ™ ANSI/CSA North America ™ with tier 4 option South America Asia with Maintenance Information Second Edition Third Printing Part No. 235735GT...

  • Page 2: Table Of Contents

    E-mail: awp.techpub@terex.com Specifications ............46 Reporting Safety Defects ........47 Copyright © 2007 Terex Corporation Second Edition: Third Printing, Ocotber 2018 "Terex" is a registered trademark of Terex USA, LLC in the USA and many other countries. AL™5HT Part No. 235735...

  • Page 3: Introduction

    This book is an operation and daily maintenance contrary to its intended use. manual for the user or operator of a Terex machine. Bulletin Distribution and This manual should be considered a permanent...
  • Page 4 Second Edition • Third Printing Introduction Contacting the Manufacturer At times it may be necessary to contact Terex. When you do, be ready to supply the model number and serial number of your machine, along with your name and contact information. At...
  • Page 5 Second Edition • Third Printing Operator's Manual 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.

  • Page 6: Symbol And Hazard Pictorials Definitions

    Operator's Manual Second Edition • Third Printing 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 Electrocution Disconnect battery Crush hazard Keep away from clearance hazard/burn hazard Read the service moving parts...
  • Page 7 Second Edition • Third Printing Operator's Manual Symbol and Hazard Pictorials Definitions Burn hazard Burn hazard Stay clear of hot Stay clear of hot Stay clear of hot surfaces under exhaust surfaces cover Burn hazard, hot Stay clear of hot Carbon Monoxide Wear protective Shattering glass...

  • Page 8: General Safety

    Operator's Manual Second Edition • Third Printing General Safety 133190 97602 133148 General Safety 97666 133482 97666 31788 133483 133484 133483 114431 228708 133148 133484 133482 97602 133190 31788 114431 228708 AL™5HT Part No. 235735...
  • Page 9 Second Edition • Third Printing Operator's Manual General Safety 114258 133017 97675 1280819 1280819 114258 133148 133190 97675 28161 133012 114431 133483 1280820 1280819 Breathing diesel engine exhaust exposes you to chemicals known to the State of California to cause cancer and birth defects or other reproductive harm.
  • Page 10 Operator's Manual Second Edition • Third Printing General Safety T108021 T108022 133148 161699 DANGER Electrocution hazard. Contact with voltage will result in death or serious 28161 injury. Shut down engine/generator STOP and disconnect battery supply before servicing. Read the service manual.
  • Page 11 Second Edition • Third Printing Operator's Manual General Safety 82481 133065 116894 133191 82487 116893 133065 133191 133149 133149 116895 82487 82481 116894 116893 116895 Part No. 235735 AL™5HT...
  • Page 12 Operator's Manual Second Edition • Third Printing General Safety 82472 133042 82472 133055 133066 114251 133149 133191 133149 133065 116894 133042 114251 133066 133065 133191 116894 133055 AL™5HT Part No. 235735...
  • Page 13 Second Edition • Third Printing Operator's Manual General Safety T108023 T108024 133149 161700 82472 STOP 161700 A 1292200 STOP 1292200 A Part No. 235735 AL™5HT...

  • Page 14: Work Area Safety

    Operator's Manual Second Edition • Third Printing Work Area Safety Work Area Safety Do not connect wires directly to the generator. Electrocution Hazards Connect auxiliary equipment only to the power outlets provided. This machine is not electrically insulated and will not provide protection from contact with or Do not perform service or replace the lamps with proximity to electrical current.
  • Page 15 Second Edition • Third Printing Operator's Manual 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 16 Metal Be sure all maintenance has been performed as halide lamps produce shortwave ultra-violet specified in this manual and the appropriate Terex radiation and can cause serious skin burns or eye service manual.
  • Page 17 Second Edition • Third Printing Operator's Manual Work Area Safety Do not use any battery charger greater than 12V to Component Damage Hazards charge the battery. Do not turn the lights on unless the engine is Do not remove the vent caps from the battery when running.
  • Page 18 Operator's Manual Second Edition • Third Printing Work Area Safety Be sure all hitch components, lights and mirrors Towing Hazards and methods of attaching the trailer to the tow Read, understand and obey all of your tow vehicle vehicle conform to local, state and federal manufacturer's recommendations, warnings and regulations.

  • Page 19: Legend

    Second Edition • Third Printing Operator's Manual Legend Legend 12 Light bar Outrigger jack handle 13 Bubble level Outrigger 14 Mast Outrigger release pin 15 Forklift pockets Transport tie-down 16 Cable track Tire 17 Control panel (located inside cabinet) Fender 18 Red Emergency Stop button Electrical outlet panel (if equipped) 19 Roadside door...

  • Page 20: Controls

    Operator's Manual Second Edition • Third Printing Controls Controls Control Panel, Auto Start Auto start control module/status indicator Hydraulic mast rotate switch Engine start switch with timed start/off/manual Hydraulic mast raise/lower switch start Hydraulic mast extend/retract switch Timer Light switches 10 Photocell on/off switch Main circuit breaker 11 Light bar raise/lower switch...
  • Page 21 Second Edition • Third Printing Operator's Manual Controls Auto start control module/status indicator Control Panel, Auto Start Lights indicate failure or faults with the auto Hydraulic tower rotate switch start system. Refer to the appropriate service Move the switch to the right and the tower will manual.
  • Page 22 Operator's Manual Second Edition • Third Printing Controls Control Panel, Auto Start – Tier 4 option Auto start control module/status indicator Hydraulic mast rotate switch Engine start switch with timed start/off/manual Hydraulic mast raise/lower switch start Hydraulic mast extend/retract switch Timer Light switches 10 Photocell on/off switch...
  • Page 23 Second Edition • Third Printing Operator's Manual Controls Lights indicate failure or faults with the auto Control Panel, Auto Start – Tier 4 option start system. Refer to the appropriate service Hydraulic tower rotate switch manual. Move the switch to the right and the tower will Engine start switch with timed start/off/manual rotate to the right.
  • Page 24 Operator's Manual Second Edition • Third Printing Controls Control Panel, Manual Start Hour meter Hydraulic mast rotate switch Ignition key switch for engine Hydraulic mast raise/lower switch Engine prime button Hydraulic mast extend/retract switch Alternator failure light Light switches 10 Light bar raise/lower switch Main circuit breaker AL™5HT Part No.
  • Page 25 Second Edition • Third Printing Operator's Manual Controls Hour meter Control Panel, Manual Start The hour meter displays the number of hours Hydraulic tower rotate switch the machine has operated. Move the switch to the right and the tower will Ignition key switch for engine rotate to the right.
  • Page 26 Operator's Manual Second Edition • Third Printing Controls Control Panel, Manual Start – Tier 4 option Main circuit breaker Hydraulic mast rotate switch Hi/Lo engine speed switch Hydraulic mast raise/lower switch Ignition key switch for engine Hydraulic mast extend/retract switch Light bar raise/lower switch Light switches Digital read out...
  • Page 27 Second Edition • Third Printing Operator's Manual Controls Move the main circuit breaker switch up on the Control Panel, Manual Start – Tier 4 option control panel before turning the individual light Hydraulic tower rotate switch switches on or before attempting to use the convenience receptacles.
  • Page 28 Operator's Manual Second Edition • Third Printing Controls Control Panel, External Power Supply T-lock receptacle, 240V/30A Circuit breaker for twist-lock receptacle Circuit breaker for duplex receptacle Duplex receptacle with ground Fault Interrupter AL™5HT Part No. 235735...

  • Page 29: Inspections

    Second Edition • Third 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. The inspection is designed to discover if anything is Do Not Operate Unless: apparently wrong with a machine before the...
  • Page 30 Operator's Manual Second Edition • Third Printing Inspections Pre-operation Inspection  Nuts, bolts and other fasteners  Lamp fixtures, connections and bulbs  Be sure that the operator’s manual is complete, legible and in the storage container located on  Cable (kinks, frays and abrasions) the machine.
  • Page 31 Second Edition • Third 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 32 Operator's Manual Second Edition • Third Printing Inspections Note: This machine should be grounded in Function Tests accordance with all local electrical codes. Consult the local electrical codes or authority having Setup jurisdiction in the area where the machine will be used for specific requirements.
  • Page 33 Second Edition • Third 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 Do Not Operate Unless:  unstable or slippery surfaces ...
  • Page 34 227350 Instructions — Isuzu Engine 72086 Label — Lifting Point Specifications 97518 Instruction — Lamp Disposal 227519 Cosmetic — Terex Logo, AL5 97602 Warning — Explosion Hazard 228708 Danger — CO Hazard 97666 Warning — Improper Operation 228709 Label - Neutral Bond 97675 Warning —...
  • Page 35 Second Edition • Third Printing Operator's Manual Inspections 1261974*** 114458** 228708 133148 1264066 1261975*** 114457* 114431 133190 228709 114464 133463 114460 or 227349 or 227350 114456 227519 97666 Control panel - behind door 133483 1272242 235732 133484 133482 97602 227348 52475 or 133097 113062...
  • Page 36 Auto Start (Option) 52475 Label — Transport Tie-down 161700 Label — Electrocution Hazard 72086 Label — Lifting Point 227519 Cosmetic — Terex Logo, AL5 82472 Label — Crushing Hazard 235732 Cosmetic — AL5HT 82481 Label — Battery/Charger Safety 237301 Cosmetic — Terex Logo, Short 82487 Label —...
  • Page 37 Second Edition • Third Printing Operator's Manual Inspections 1261974*** 114458** 133065 133191 1261975*** 114457* 114464 114460 114456 227519 133149 82487 Control panel - behind door 116894 116893 235732 116895 52475 113062 133063 T108024 *Auto start option 133055 133149 **Manual start option 133066 72086 ***Tier 4 manual start option...

  • Page 38: Operating Instructions

    Operator's Manual Second Edition • Third 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 39 Second Edition • Third Printing Operator's Manual Operating Instructions Manual Engine Start (machines with tier Setup 4 option - manual key switch start) Make sure the machine is set up according to the Flip the Hi/Lo toggle to the Lo position. Setup procedure in the Function Test section.
  • Page 40 Operator's Manual Second Edition • Third Printing Operating Instructions Move the set switch to the left (clock icon) to To turn on the photocell: set the present day and time. Move the engine start switch to A default time of AM 12:00 will appear on the timed start.
  • Page 41 Second Edition • Third Printing Operator's Manual Operating Instructions Models with eight lights: Each switch turns on Towing two of the lights at one time. CAUTION: SHUT ENGINE OFF BEFORE Note: Lights can take up to 20 minutes to reach full MOVING THE LIGHT TOWER! Failure to do intensity.If the lights are turned off and turned back so can cause severe engine/radiator...
  • Page 42 Operator's Manual Second Edition • Third Printing Operating Instructions Towing Information Driving a vehicle/trailer combination is different from driving a vehicle alone. Inspect all connections at each stop. All tires must be properly inflated. Do not overinflate the tires. Tire pressures go up during driving.

  • Page 43: Transport And Lifting Instructions

     Terex customers needing to containerize any Use a minimum of four chains to secure the light Terex product should source a qualified freight tower. forwarder with expertise in preparing, loading and securing construction and lifting equipment Adjust the rigging to prevent damage to the chains.
  • Page 44 Operator's Manual Second Edition • Third 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 pin. Fully retract, raise and lock all tongue jacks Observe and Obey: and outriggers.

  • Page 45: Maintenance

    Oil type - cold conditions 5W-20 responsibilities manual. Isuzu 4LE2 & 4LE2-T  Use only Terex approved replacement parts. Oil type 10W-30 Oil type - cold conditions 5W-20 Maintenance Symbols Legend The following symbols have been used in this manual to help communicate the intent of the instructions.
  • Page 46 Operator's Manual Second Edition • Third 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 47 Second Edition • Third Printing Operator's Manual Maintenance Check each tire with an air pressure gauge. Check the Tire Pressure Add air as needed. Check the torque of each lug nut. Bodily injury hazard. An over-inflated tire can Tire Specifications, U.S. explode and may cause death or serious injury.

  • Page 48: Specifications

    Maximum wind speed 62 mph 100 km/h Sound level (dba rating) 71 dba @ 23 ft / 7 m Continuous improvement of our products is a Terex policy. Product specifications are subject to change without notice or obligation. AL™5HT Part No. 235735...

  • Page 49: Reporting Safety Defects

    However, NHTSA cannot become involved in any individual problems between you, your dealer or Terex Corporation. To contact NHTSA you may either call the Auto Safety Hotline toll-free at 1-800-424-9393...

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