Related Manuals for Terex AL4L
Summary of Contents for Terex AL4L
- Page 1 Operator's Manual AL4L ANSI/CSA North America AL5L South America Asia with Maintenance Information First Edition Fifth Printing Part No. 229101...
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Page 2: Table Of Contents
Specifications ............43 Reporting Safety Defects ........44 Copyright © 2011 Terex Corporation First Edition: Fifth Printing, May 2015 "Terex" is a registered trademark of Terex USA, LLC in the USA and many other countries. AL4L • AL5L Part No. 229101... -
Page 3: Introduction
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. Part No. 229101 AL4L • AL5L... - Page 4 Indicates a hazardous situation which, if not avoided, could result in death or serious injury. CAUTION Indicates a hazardous situation which, if not avoided, could result in minor or moderate injury. NOTICE Indicates a property damage message. AL4L • AL5L Part No. 229101...
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Page 5: Symbol And Hazard Pictorials Definitions
Explosion / Burn Crushing hazard Burn hazard Corrosive acid. hazard Explosion hazard Do not use ether or No smoking No flame No flame other high energy starting aids on machines equipped with glow plugs. Part No. 229101 AL4L • AL5L... - Page 6 Lifting point Tie-down point Carbon Monoxide Wear protective Retract mast, then hazard clothing pull pin Crushing hazard Stay clear of Tip-over hazard Deploy outriggers descending mast before raising mast AL4L • AL5L Part No. 229101...
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Page 7: General Safety
First Edition • Fifth Printing Operator's Manual General Safety General Safety Part No. 229101 AL4L • AL5L... - Page 8 Operator's Manual First Edition • Fifth Printing General Safety AL4L • AL5L Part No. 229101...
- Page 9 First Edition • Fifth Printing Operator's Manual General Safety Part No. 229101 AL4L • AL5L...
- Page 10 Operator's Manual First Edition • Fifth Printing General Safety AL4L • AL5L Part No. 229101...
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Page 11: Work Area Safety
Explosion and Fire Hazards Allow for mast movement, electrical line sway or sag, and beware of strong or gusty winds. AL4L with engine and AL5L: Do not operate the machine during lightning or storms. Do not start the engine if you smell or detect liquid petroleum gas (LPG), gasoline, diesel fuel or other Do not use the machine as a ground for welding. - Page 12 All AL4L and AL5L: Do not alter or disable machine components that in Do not operate the machine in hazardous locations any way affect safety and stability. or locations where potentially flammable or Do not adjust or stow the outriggers when the mast explosive gases or particles may be present.
- Page 13 Crushing Hazard Bodily Injury Hazard Do not lower the mast unless the area below is AL4L with engine and AL5L: clear of personnel and Do not use the machine indoors unless properly obstructions. ventilated. Keep hands and fingers Do not breathe exhaust fumes.
- Page 14 Do not expose the batteries or the charger to water damaged or malfunctioning machine. or rain during charging. Be sure all maintenance has been performed as specified in this manual and the appropriate Terex Explosion Hazards service manual. Keep sparks, flames and lighted Be sure the operator's manual is complete, legible tobacco away from batteries.
- Page 15 Avoid electrical shock from contact with battery terminals. Remove all rings, watches and other jewelry. Component Damage Hazards AL4L with batteries and AL5L: Do not use any battery charger greater than 48V to charge the batteries. Do not use an external charger or booster battery.
- Page 16 Use extreme care and slow speeds while towing across uneven terrain, debris, holes or drop-offs. Note: Do not tow machine when engine is running! This can cause severe engine/radiator damage and WILL NOT BE COVERED UNDER WARRANTY! AL4L • AL5L Part No. 229101...
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Page 17: Legend
16 Upper retaining bar Forklift pockets 17 Control panel (located inside cabinet) Curbside door 18 Charger plug (AL4L with batteries and AL5L) AL4L with batteries: Battery access (located inside cabinet, below control panel) AL4L with engine: Engine access 19 Raise/lower winch (for models with manual... -
Page 18: Controls
Duplex receptacle with GFI, 120V/20A Light hour meter Hour meter, engine Light switches Ignition switch for engine Main circuit breaker Engine prime button T-lock receptacle 10 Alternator failure light Circuit breaker for DC power supply (AL4L with engine) AL4L • AL5L Part No. 229101... - Page 19 Light on indicates that the engine's DC either position. alternator isn't producing enough voltage. AL4L with engine: Move the main circuit breaker up on the control panel before turning on the lights. Move the main circuit breaker switch down to turn off the lights.
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Page 20: Inspections
Scheduled maintenance inspections shall be performed by qualified service technicians, according to the manufacturer’s specifications and the requirements listed in the responsibilities manual. AL4L • AL5L Part No. 229101... - Page 21 Be sure that all decals are legible and in place. Safety chains See Inspections section. AL4L with engine and AL5L: Engine and Check for proper tire pressure and lug nut related components torque. Add air to tires if needed. See ...
- Page 22 After repairs are completed, the operator must perform a pre-operation inspection and function tests again before putting the machine into service. AL4L • AL5L Part No. 229101...
- Page 23 14 Insert the retaining pin through the lower 24 When the mast sections are fully retracted, pull retaining bar. the lower retaining bar. Part No. 229101 AL4L • AL5L...
- Page 24 31 Turn the light switches to the on position. Result: The lights should come on. Test the Lights - AL4L with batteries and AL5L 32 Make sure the circuit breakers and the light switches are in the off position.
- Page 25 overhead obstructions and high voltage conductors hazardous locations inadequate surface support to withstand all load forces imposed by the machine wind and weather conditions the presence of unauthorized personnel other possible unsafe conditions Part No. 229101 AL4L • AL5L...
- Page 26 28159 Label — Diesel 227519 Cosmetic — Terex Logo, AL5 28161 Warning — Crushing Hazard 227709 Label — Control Panel, AL4L with Engine 28162 Warning — Bodily Injury Hazard 227710 Label — Control Panel, AL5L 31788 Danger — Explosion/Burn Hazard,...
- Page 27 First Edition • Fifth Printing Operator's Manual Inspections Part No. 229101 AL4L • AL5L...
- Page 28 227348 Instructions — Tire Specifications place. 227518 Cosmetic — Terex Logo Below is a numerical list with quantities and 227708 Label — Ground Control Panel, AL4L descriptions. with Batteries Part No. Decal Description 227823 Cosmetic — AL4L 28161 Warning — Crushing Hazard 228711 Warning —...
- Page 29 First Edition • Fifth Printing Operator's Manual Inspections Part No. 229101 AL4L • AL5L...
- Page 30 Operator's Manual First Edition • Fifth Printing Inspections Inspection for Decals with Part No. Decal Description Symbols - AL5L and AL4L with 116895 Label — Tip-over Hazard, Outriggers 133031 Label — Burn Hazard Engine 133055 Label — Burn/Carbon Monoxide Determine whether the decals on your machine Hazard have words or symbols.
- Page 31 First Edition • Fifth Printing Operator's Manual Inspections Part No. 229101 AL4L • AL5L...
- Page 32 133149 Label — Electrocution Hazard place. 227518 Cosmetic — Terex Logo Below is a numerical list with quantities and 227708 Label — Ground Control Panel, AL4L with Batteries descriptions. 227823 Cosmetic — AL4L Part No. Decal Description 228714 Label — Manual Winch 52475 Label —...
- Page 33 First Edition • Fifth Printing Operator's Manual Inspections Part No. 229101 AL4L • AL5L...
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Page 34: Operating Instructions
2 Always perform a pre-operation inspection. inspection, function tests, and a workplace 3 Always perform function tests prior to use. inspection before using the machine. 4 Inspect the workplace. 5 Only use the machine as it was intended. AL4L • AL5L Part No. 229101... - Page 35 Turn the extend/retract winch handle clockwise to extend mast sections. Attention: Stop extending the mast when red is visible on mast. Continuing to extend the mast when red is visible can result in machine damage. Part No. 229101 AL4L • AL5L...
- Page 36 Operating Instructions Operation of Lights - AL4L with Starting the Engine engine Starting the Engine – AL4L with engine Using engine power and AL5L Note: On machines equipped with a shore plug, the Note: The main circuit breaker and the light shore plug should be plugged into the T-lock switches must be off before starting the engine.
- Page 37 AL5L machine for use or charging. Be sure the AL5L machine is running and main circuit breaker Operation of Lights - AL5L is on before plugging in AL4L machines. Plug AL4L machines in one at a time. The lights will turn on with engine power, battery power or with the charger plugged in.
- Page 38 AL5L charger cord is plugged in to the convenience receptacles. When the engine is running, up to 4 AL4L machines can be plugged in to an AL5L machine, but the AL5L batteries will not charge. Be sure the AL5L machine is running and the main circuit breaker is on before plugging in the AL4L machines.
- Page 39 When passing other vehicles, be sure to leave enough room for the extra length of the trailer. You will need to go much farther beyond the passed vehicle before you can return to your lane. Avoid sudden movements when turning. Part No. 229101 AL4L • AL5L...
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Page 40: Transport And Lifting Instructions
US Department of Transportation regulations, other localized regulations, and their company policy. Terex customers needing to containerize any Terex product should source a qualified freight forwarder with expertise in preparing, loading and securing construction and lifting equipment for international shipment. ... - Page 41 Be sure the crane capacity, loading surfaces and straps or lines are sufficient to withstand the machine weight. See the serial label for the machine weight. Part No. 229101 AL4L • AL5L...
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Page 42: Maintenance
First Edition • Fifth Printing Maintenance Maintenance Check the Engine Oil Level - AL4L with Engine and AL5L Maintaining the proper engine oil level is essential to good engine performance and service life. Observe and Obey: Operating the machine with an improper oil level ... - Page 43 Check each tire with an air pressure gauge. Add air as needed. Check the torque of each lug nut. Tire Specifications, U.S. Tire Size ST205/75R15 Load C Lug nut torque 90 ft/lbs 122 Nm Tire pressure (cold) 50 psi 3.4 bar Part No. 229101 AL4L • AL5L...
- Page 44 "Wet Stacking". type of wet stack burns off. Terex suggests a minimum load of 30 percent of nameplate to prevent wet stacking, inversely related to temperature (the lower the ambient temperature the higher the minimum load).
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Page 45: Specifications
2.06 m Extended mast height 30 ft 9.14 m Extended mast height 30 ft 9.14 m AL4L with engine 1986 lbs 901 kg Total weight, no fuel 2828 lbs 1283 kg Total weight, no fuel (Machine weights vary with option configurations. See... -
Page 46: 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... - Page 47 · Do not exceed 60 mph / 97 km/h. Obey all local and national towing speed laws · Check connections and tire pressure at each stop · Slow down for hazardous conditions · Allow extra distance for following and passing other vehicles www.terex.com...