Terex AL4L Setup guide

Operator's Manual
A
L4L
ANSI/CSA
North America
South America
Asia
A
L5L
with
Maintenance
Information
First Edition
Fifth Printing
Part No. 229101

Operator's Manual First Edition • Fifth Printing
AL4L • AL5L Part No. 229101
FrontMatter
Important
Read, understand and obey these safety rules and
operating instructions before operating this
machine. Only trained and authorized personnel
shall be permitted to operate this 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 us.
Contact Us:
Internet: www.terex.com
E-mail: [email protected]
Contents
Introduction ........................................................... 1
Symbol and Hazard Pictorials Definitions............. 3
General Safety ...................................................... 5
Work Area Safety.................................................. 9
Legend ................................................................ 15
Controls............................................................... 16
Inspections.......................................................... 18
Operating Instructions......................................... 32
Transport and Lifting Instructions ....................... 38
Maintenance ....................................................... 40
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.

First Edition • Fifth Printing Operator's Manual
Introduction
Part No. 229101 AL4L • AL5L 1
Introducti on
Owners, Users and Operators:
Thank you for choosing our machine for your
application. Our number one priority is user safety,
which is best achieved by our joint efforts. We feel
that you make a major contribution to safety if you,
as the equipment users and operators:
1 Comply with employer, job site and
governmental rules.
2 Read, understand and follow the instructions
in this and other manuals supplied with this
machine.
3 Use good safe work practices in a
commonsense way.
4 Only have trained/certified operators,
directed by informed and knowledgeable
supervision, running the machine.
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 • Fifth Printing
Introduction
2 AL4L • AL5L Part No. 229101
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.
Intended Use
This machine is intended to be used only to provide
lighting and electrical power to a work site. Use of
this product in any other way is prohibited and
contrary to its intended use.
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 • Fifth Printing Operator's Manual
Symbol and Hazard Pictorials Definitions
Part No. 229101 AL4L • AL5L 3
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
Bodily injury hazard Keep away from
moving parts
Crushing hazard Stay clear of belts and
fan
Burn hazard Explosion / Burn
hazard
Corrosive acid.
Explosion hazard Do not use ether or
other high energy
starting aids on
machines equipped
with glow plugs.
No smoking No flame No flame

Operator's Manual First Edition • Fifth Printing
Symbol and Hazard Pictorials Definitions
4 AL4L • AL5L Part No. 229101
Burn hazard Burn hazard Stay clear of hot
exhaust
Stay clear of hot
surfaces under
cover
Tip-over hazard, tow
speed
Lifting point Tie-down point Carbon Monoxide
hazard
Wear protective
clothing
Retract mast, then
pull pin
Crushing hazard Stay clear of
descending mast
Tip-over hazard Deploy outriggers
before raising mast

First Edition • Fifth Printing Operator's Manual
General Safety
Part No. 229101 AL4L • AL5L 5
General Safety

Operator's Manual First Edition • Fifth Printing
General Safety
6 AL4L • AL5L Part No. 229101

First Edition • Fifth Printing Operator's Manual
General Safety
Part No. 229101 AL4L • AL5L 7

Operator's Manual First Edition • Fifth Printing
General Safety
8 AL4L • AL5L Part No. 229101

First Edition • Fifth Printing Operator's Manual
Work Area Safety
Part No. 229101 AL4L • AL5L 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 10 ft 3.05 m
50 to 200KV 15 ft 4.60 m
200 to 350KV 20 ft 6.10 m
350 to 500KV 25 ft 7.62 m
500 to 750KV 35 ft 10.67 m
750 to 1000KV 45 ft 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 batteries
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.
Do not disconnect the shore plug while the engine
is running.
Do not perform service with the engine\generator
running or the batteries connected. Turn off the
engine/generator and disconnect the battery quick
disconnect plug.
Explosion and Fire Hazards
AL4L with engine and AL5L:
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.

Operator's Manual First Edition • Fifth Printing
Work Area Safety
10 AL4L • AL5L Part No. 229101
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.
All AL4L and AL5L:
Do not operate the machine in hazardous locations
or locations where potentially flammable or
explosive gases or particles may be present.
Refuel the machine and charge the batteries only
in an open, well-ventilated area away from sparks,
flames and lighted tobacco.
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.

First Edition • Fifth Printing Operator's Manual
Work Area Safety
Part No. 229101 AL4L • AL5L 11
AL4L with batteries:
Do not use batteries that weigh less than the
original equipment. Batteries are used as
counterweight and are critical to machine stability.
Each battery must weigh 88 pounds / 40 kg.
Do not remove batteries
from the battery
compartment unless all
outriggers are lowered
and in firm contact with
the ground.
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.
Do not lower the mast
until the mast is retracted
and the upper retaining
bar is locked into the
mast. No red should be
visible on the mast.
Collision Hazards
Check the work area for overhead obstructions or
other possible hazards.
Burn Hazards
Do not touch hot parts
of the engine or tailpipe,
Use protective gloves
when handling hot
parts.
Allow surfaces to cool
before servicing.
Bodily Injury Hazard
AL4L with engine and AL5L:
Do not use the machine indoors unless properly
ventilated.
Do not breathe exhaust fumes.
Stay clear of belts and fan when engine is running.
All AL4L and AL5L:
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.
Do not look directly into the lights when close to the
lights.
Stay clear of moving mast.
Do not grasp the cable.
Use proper lifting techniques when lifting and
positioning the tongue of the machine.

Operator's Manual First Edition • Fifth Printing
Work Area Safety
12 AL4L • AL5L Part No. 229101
Fall Hazards
Do not climb or stand on any part of the light tower
during maintenance or operation.
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
AL4L with engine:
Do not turn the lights on unless the engine is
running. Always turn the lights off before shutting
down the engine.
All AL4L and AL5L:
Do not replace lamp assemblies with any
assemblies other than those approved by Terex.
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 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.

First Edition • Fifth Printing Operator's Manual
Work Area Safety
Part No. 229101 AL4L • AL5L 13
Electrocution/Burn Hazards
Connect the battery charger to
a grounded, AC 3-wire
electrical outlet only.
Inspect daily for damaged
cords, cables and wires.
Replace damaged items before
operating.
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.
Disconnect the battery pack plug before removing
the batteries.
AL5L and AL4L with engine:
Do not use any battery or charger greater than 12V
to jump-start the engine.
Tip-over Hazard
AL4L with batteries
Do not use batteries that weigh less than the
original equipment. Batteries are used as
counterweight and are critical to machine stability.
Each battery must weigh 88 lbs / 40 kg.
Lifting Hazard
Use the appropriate number of people and proper
lifting techniques when lifting batteries.
AL4L with batteries:
Do not use batteries that weigh less than the
original equipment. Batteries are used as
counterweight and are critical to machine stability.
Each battery must weigh 88 pounds / 40 kg.

Operator's Manual First Edition • Fifth Printing
Work Area Safety
14 AL4L • AL5L Part No. 229101
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 the mast is
retracted and lowered to the horizontal position and
the travel lock pin is secured.
Do not tow the machine unless all outriggers have
been retracted and stowed.
Do not overload your tow vehicle. Check the
manufacturer's Gross Vehicle Weight Rating
(GVWR). To obtain the gross vehicle weight, add
the tongue weight of the trailer to the vehicle weight
(including vehicle, passengers and cargo).
Do not load cargo on the machine. The light tower
is not designed to carry any extra cargo.
Be sure the hitch is securely attached to the tow
vehicle.
Be sure the safety chains (if required) 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 60 mph / 97 km/h. Obey all local
and national towing speed laws.
Be sure to chock the wheels 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 machine when 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 • Fifth Printing Operator's Manual
Legend
Part No. 229101 AL4L • AL5L 15
Legend
1Outrigger with leveling jack
2Tongue with trailer hitch
3Shore plug (if equipped)
4Upper retaining bar
5T-handle for mast rotation lock
6Tie-downs
7Mast
8Forklift pockets
9Curbside door
AL4L with batteries: Battery access
AL4L with engine: Engine access
AL5L: Engine and battery access
10 Lifting eye
11 Green stripe
12 Red stripe
13 Lights
14 Travel lock pin
15 Roadside door
AL4L with batteries: Battery access
AL4L with engine: Engine access
AL5L: Engine and battery access
16 Upper retaining bar
17 Control panel (located inside cabinet)
18 Charger plug (AL4L with batteries and AL5L)
(located inside cabinet, below control panel)
19 Raise/lower winch (for models with manual
winch)
20 Lower retaining bar

Operator's Manual First Edition • Fifth Printing
Controls
16 AL4L • AL5L Part No. 229101
Controls
1Light hour meter
2Light switches
3Main circuit breaker
4T-lock receptacle
5Circuit breaker for DC power supply (AL4L with
engine)
6Duplex receptacle with GFI, 120V/20A
7Hour meter, engine
8Ignition switch for engine
9Engine prime button
10 Alternator failure light

First Edition • Fifth Printing Operator's Manual
Controls
Part No. 229101 AL4L • AL5L 17
Control Panel
1Light hour meter
The light hour meter displays the number of
hours the lights have operated.
2Light switches
Move each light switch up to turn on the
indicated light. Move each light switch down to
turn off the indicated light.
3Main circuit breaker
AL5L: Move the main circuit breaker switch up
on the control panel before attempting to use
the convenience receptacles. Move the main
circuit breaker switch down to turn off power to
the convenience receptacles. The lights can be
used with the main circuit breaker switch in
either position.
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.
4T-lock receptacle
5Circuit breakers for DC power supply (AL4L
with engine)
6Duplex receptacle with GFI, 120V/20A
Convenience duplex receptacle with Ground
Fault Interrupter (GFI).
7Hour meter, engine
The engine hour meter displays the number of
hours the engine has operated.
8Ignition switch for engine
Turn the ignition switch to the prime position
and hold the engine prime button down to
prime the engine.
Hold the prime button down and turn the
ignition switch to the start position to start the
engine.
Turn the ignition switch to the off position to
turn the engine off.
9Engine prime button
With the ignition switch in the run position,
press and hold the prime button for 15 seconds
before starting the engine. Release the prime
button when the engine starts.
10 Alternator failure light
Light on indicates that the engine's DC
alternator isn't producing enough voltage.

Operator's Manual First Edition • Fifth Printing
Inspections
18 AL4L • AL5L Part No. 229101
Inspections
Do Not Operate Unless:
You learn and practice the principles of safe
machine operation contained in this operator’s
manual.
1 Avoid hazardous situations.
2 Always perform a pre-operation
inspection.
Know and understand the pre-operation
inspection before going on to the next
section.
3 Always perform function tests prior to use.
4 Inspect the workplace.
5 Only use the machine as it was intended.
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
apparently wrong with a machine before the
operator performs the function tests.
The pre-operation inspection also serves to
determine if routine maintenance procedures are
required. Only routine maintenance items specified
in this manual may be performed by the operator.
Refer to the list on the next page and check each of
the items.
If damage or any unauthorized variation from
factory delivered condition is discovered, the
machine must be tagged and removed from
service.
Repairs to the machine may only be made by a
qualified service technician, according to the
manufacturer’s specifications. After repairs are
completed, the operator must perform a
pre-operation inspection again before going on to
the function tests.
Scheduled maintenance inspections shall be
performed by qualified service technicians,
according to the manufacturer’s specifications and
the requirements listed in the responsibilities
manual.