Terex AL5 Operator's Manual
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Terex AL5 Operator's Manual

Vertical mast with tier 4 option
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Operator's Manual
AL5
Vertical Mast
with tier 4 option
ANSI/CSA
North America
South America
Asia
with
Maintenance
Information
First Edition
First Printing
Part No. 1255533

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Summary of Contents for Terex AL5

  • Page 1 Operator's Manual ANSI/CSA North America Vertical Mast South America Asia with tier 4 option with Maintenance Information First Edition First Printing Part No. 1255533...

  • Page 2: Table Of Contents

    Specifications ............42   Reporting Safety Defects ........43 Copyright © 2014 Terex Corporation First Edition: First Printing, February 2015 "Terex" is a registered trademark of Terex USA, LLC in the USA and many other countries. AL5 Vertical Mast Part No. 1255533...

  • 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 First Edition • First 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 CAUTION Indicates a hazardous situation that if not avoided, could result in minor or moderate injury. NOTICE Indicates information considered important, but not hazard related (e.g. messages related to property damage) Part No. 1255533 AL5 Vertical Mast...

  • Page 6: Symbol And Hazard Pictorials Definitions

    Read the service moving parts moving parts manual Burn hazard Explosion / Burn Corrosive acid. Explosion hazard Do not use ether or hazard other high energy starting aids on machines equipped with glow plugs. AL5 Vertical Mast Part No. 1255533...
  • Page 7 Carbon Monoxide Do not use light tower Wear protective Shattering glass Lifting point hazard indoors clothing hazard Tie-down point Tip-over hazard Deploy outriggers Tip-over hazard, tow before raising mast speed Part No. 1255533 AL5 Vertical Mast...

  • Page 8: General Safety

    Operator's Manual First Edition • First Printing General Safety 97675 97666 General Safety 133148 133482 97675 97602 133148 97602 133482 31788 31788 133484 97666 114258 228711 114431 228708 133483 133484 228708 228711 114258 133483 114431 AL5 Vertical Mast Part No. 1255533...
  • Page 9 Shut down engine/generator STOP and disconnect battery supply before servicing. Read the service manual. 1261258 A 1261258 T108021 T108021 T108022 114431 133148 133483 133148 133012 133012 114431 Part No. 1255533 AL5 Vertical Mast...
  • Page 10 Operator's Manual First Edition • First Printing General Safety 133042 229782 133149 82481 82487 116893 229782 114251 116894 116895 133065 82487 114251 116893 133149 133065 133042 116895 82481 116894 AL5 Vertical Mast Part No. 1255533...
  • Page 11 First Edition • First Printing Operator's Manual General Safety 161700 T108024 T108023 133065 133055 116894 82481 133149 133055 T108024 T108023 133065 161700 116894 Part No. 1255533 AL5 Vertical Mast...

  • Page 12: Work Area Safety

    Personnel must not touch or operate the machine Do not spray ether into until energized power engines equipped with glow lines are shut off. plugs. AL5 Vertical Mast Part No. 1255533...
  • Page 13 Use protective gloves when Do not place ladders or handling hot parts. scaffolds against any part of the machine. Do not use the machine on a moving or mobile surface or vehicle. Part No. 1255533 AL5 Vertical Mast...
  • Page 14 Stay clear of moving mast. Be sure all maintenance has been performed as Do not grasp the cable. specified in this manual and the appropriate Terex service manual. Use proper lifting techniques when lifting and positioning the tongue of the machine.
  • Page 15 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. Part No. 1255533 AL5 Vertical Mast...
  • Page 16 (GVWR). To obtain the gross vehicle weight, add from unauthorized use. Unauthorized personnel the tongue weight of the trailer to the vehicle weight may attempt to operate the machine without proper (including vehicle, passengers and cargo). instruction, creating an unsafe condition. AL5 Vertical Mast Part No. 1255533...

  • Page 17: Legend

    19 Outrigger Forklift pockets 20 Control panel (located inside cabinet) Lifting eye 21 Platform 10 Mast retention pin 22 Manual storage (located inside cabinet) 11 Mast 23 Grounding lug (located on chassis beneath platform) Part No. 1255533 AL5 Vertical Mast...

  • Page 18: Controls

    Operator's Manual First Edition • First Printing Controls Controls AL5 8 kW HOURS Main circuit breaker Control Panel Move the main circuit breaker switch up on the control panel before turning the individual light T-lock receptacle, 240V/30A switches on or before attempting to use the Light switches convenience receptacles.
  • Page 19 Turn the ignition switch to the off position to alternator isn't producing enough voltage. turn the engine off. 10 Raise/lower switch Move the switch up to extend the mast. Move the switch down to retract the mast. Part No. 1255533 AL5 Vertical Mast...
  • Page 20 Operator's Manual First Edition • First Printing Controls AL5 12 kW & 20kW HOURS AL5 external panel AL5 Vertical Mast Part No. 1255533...
  • Page 21 Release the prime switches on or before attempting to use the button when the engine starts. convenience receptacles. 13 Alternator failure light Light on indicates that the engine's DC alternator isn't producing enough voltage. Part No. 1255533 AL5 Vertical Mast...
  • Page 22 Operator's Manual First Edition • First Printing Controls AL5 20kW tier 4 option 1261973 AL5 external panel AL5 Vertical Mast Part No. 1255533...
  • Page 23 Move the switch up to raise and extend the Hour meter mast. Move the switch down to retract and The hour meter displays the number of hours lower the mast. the machine has operated. Part No. 1255533 AL5 Vertical Mast...

  • Page 24: 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. AL5 Vertical Mast Part No. 1255533...
  • Page 25  Mast components latched.  Mast locking pins  Latches and pins  Tires and wheels  Trailer lights and reflectors  Outriggers, leveling jacks and foot pads  Winch Part No. 1255533 AL5 Vertical Mast...
  • Page 26 3 Always perform function tests prior to use. Know and understand the function tests before going on to the next section. 4 Inspect the workplace. 5 Only use the machine as it was intended. AL5 Vertical Mast Part No. 1255533...
  • Page 27 Result: The mast retention pin should "snap" into the retention position freely without hesitation or binding. 11 Release the extend/retract switch. Result: The winch brake should hold the mast. Part No. 1255533 AL5 Vertical Mast...
  • Page 28 20-30 minutes. the retracted position. Note: Make sure the circuit breaker and the light switches are turned off before shutting down the engine. AL5 Vertical Mast Part No. 1255533...
  • Page 29 It is the operator’s responsibility to read and remember the workplace hazards, then watch for and avoid them while moving, setting up and operating the machine. Part No. 1255533 AL5 Vertical Mast...
  • Page 30 31788 Danger — Explosion/Burn Hazard 235731 Cosmetic — AL5 52475 Label — Transport Tie-down 237271 Label — AL5 Control Panel, 8 kW 72086 Label — Lifting Point 237272 Label — AL Control Panel, 12 & 97518 Instruction — Lamp Disposal...
  • Page 31 237273 133148 or 237274 1255755 228709 133462 or 133463 or 227349 or 227350 T108022 T108021 31788 1260638 227519 or 237301 114431 52475 Ballast Box-Control Side 851691 851692 851693 851694 235731 133148 133483 52475 Part No. 1255533 AL5 Vertical Mast...
  • Page 32 28159 Label — Diesel 235731 Cosmetic — AL5 52475 Label — Transport Tie-down 237271 Label — AL5 Control Panel, 8 kW 72086 Label — Lifting Point 237272 Label — AL Control Panel, 12 & 82472 Label — Crushing Hazard 20 kW 82481 Label —...
  • Page 33 133031 116893 133065 116895 52475 237271 or 237272 133149 or 237273 or 237274 1255755 133055 161700 T108024 T108023 227519 82481 133065 52475 133062 Ballast Box-Control Side 851691 851692 851693 851694 52475 235731 133149 133031 Part No. 1255533 AL5 Vertical Mast...

  • 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. AL5 Vertical Mast Part No. 1255533...
  • Page 35 Wait ten seconds then turn the ignition switch to the start position. Rotate the mast to the desired position. Tighten the T-handle to secure the mast in the desired position. Before retracting the mast, rotate mast to align arrows on mast. Part No. 1255533 AL5 Vertical Mast...
  • Page 36 Drive the rod into the ground and Pull out the Emergency Stop button on the connect it to the grounding lug located front of the machine to reset the system. on the curbside of the chassis near the platform. AL5 Vertical Mast Part No. 1255533...
  • Page 37 14 Attach safety chains. Chains should be Remove the lights and secure them inside the crossed below hitch. cabinet. 15 Connect and test the trailer lights. Make sure the covers are closed and secured. Part No. 1255533 AL5 Vertical Mast...
  • Page 38 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. AL5 Vertical Mast Part No. 1255533...

  • Page 39: Transport And Lifting Instructions

    Inspect the entire machine for loose or unsecured items.  Terex customers needing to containerize any Terex product should source a qualified freight Use the three tie-down points for anchoring down forwarder with expertise in preparing, loading to the transport surface.
  • Page 40 Be sure the crane capacity, loading surfaces items. and straps or lines are sufficient to withstand Use the lifting bar to lift the machine. the machine weight. See the serial label for the machine weight. AL5 Vertical Mast Part No. 1255533...

  • Page 41: Maintenance

    10W-30 and the requirements specified in the Oil type - cold conditions 5W-20 responsibilities manual. Kubota V-1505 Engine  Use only Terex approved replacement parts. Oil type 10W-30 Oil type - cold conditions 5W-20 Maintenance Symbols Legend Isuzu 4LE2 The following symbols have been used in this...
  • Page 42 Refer to Kubota Operator's Manual 97897-01090. Be sure that the battery hold-down brackets are in place and secure. Note: Adding terminal protectors and a corrosion preventative sealant will help eliminate the corrosion on the battery terminals and cables. AL5 Vertical Mast Part No. 1255533...
  • 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. 1255533 AL5 Vertical Mast...

  • Page 44: Specifications

    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. AL5 Vertical Mast Part No. 1255533...

  • Page 45: 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 46 · 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...

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