Terex Series AL4000 User manual

Operator's Manual First Edition • First Printing
AL4000 • AL5000 Part No.116416
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, call Terex.
Contents
Page
Introduction ...........................................................1
GeneralSafety-AL4000.......................................3
GeneralSafety-AL5000.......................................5
Work Area Safety .................................................7
Legend-AL4000.................................................10
Controls-AL4000 ...............................................11
Legend-AL5000.................................................13
Controls-AL5000 ...............................................14
External Power Access -
AL500020kWOption..........................................16
Inspections .........................................................17
OperatingInstructions.........................................24
TransportandLiftingInstructions ........................28
Maintenance .......................................................30
Specifications .....................................................32
ReportingSafetyDefects ....................................33
Contact us:
Internet:www.terex.com
Copyright © 2008 by Terex
Terex Light Construction Division
590 Huey Road
RockHill, SC 29730
First Edition: First Printing, November 2008
Printed on recycled paper
Printed in U.S.A.

Part No.116416 AL4000 • AL5000 1
Operator's Manual
First Edition • First Printing
Introduction
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.
Owners, Users and Operators:
Terex appreciates your choice of 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.
If there is anything in this manual that is not clear
or which you believe should be added, please
contact us.
Internet: www.terex.com

Operator's Manual First Edition • First Printing
2 AL4000 • AL5000 Part No.116416
Intended Use
This machine is intended to be used only to provide
lighting and electrical power to a work site.
Introduction
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.
Hazard Classification
Terex uses symbols, color coding and signal words
to identify the following:
Safety alert symbol—used to alert
personnel 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.
Red
Orange
Yellow
Blue

Part No.116416 AL4000 • AL5000 3
Operator's Manual
First Edition • First Printing
General Safety - AL4000
Safety signs and locations

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4 AL4000 • AL5000 Part No.116416
General Safety - AL4000
Safety signs and locations

Part No.116416 AL4000 • AL5000 5
Operator's Manual
First Edition • First Printing
General Safety - AL5000
Safety signs and locations

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6 AL4000 • AL5000 Part No.116416
Safety signs and locations
General Safety - AL5000

Part No.116416 AL4000 • AL5000 7
Operator's Manual
First Edition • First Printing
Work Area Safety
Electrocution Hazards
This machine is not electrically insulated and will
not provide protection from contact with or
proximity to electrical current.
Maintain required clearances from electrical
power lines and apparatus in accordance with
applicable governmental regulations and the
following chart.
Line Voltage Required Clearance
0 to 50KV 10 ft 3.0 m
50 to 200KV 15 ft 4.6 m
200 to 350KV 20 ft 6.1 m
350 to 500KV 25 ft 7.6 m
500 to 750KV 35 ft 10.6 m
750 to 1000KV 45 ft 13.7 m
Allow for tower movement and 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
power lines are shut off.
Do not connect wires directly to the generator.
Connect auxiliary equipment only to the power
outlets provided.
Do not service or replace the lamps with the
engine/generator running.
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.
Explosion and Fire Hazards
Do not start the engine if you smell or detect diesel
fuel or other explosive substances.
Do not refuel the machine with the engine running.
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.
Tip-over Hazards
Do not raise the tower 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 any objects from the lights or the
tower.
Do not use the tower to raise material or
personnel.
Do not move the machine unless the tower is
lowered to the horizontal position.
Do not raise the tower when
wind speeds may exceed 62
mph / 100 km/h.

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8 AL4000 • AL5000 Part No.116416
Work Area Safety
Do not alter or disable machine components that in
any way affect safety and stability.
Do not adjust or stow the outriggers when the tower
is raised.
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 Hazards
Do not lower the tower
unless the area below is
clear of personnel and
obstructions.
Keep hands and fingers
away from any potential
pinch points.
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 Hazards
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.
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.
Stay clear of the moving tower.
Fall Hazards
Do not climb or stand on any part of the light
tower.
Damaged Machine Hazards
Do not use a damaged or malfunctioning machine.
Be sure the operator's manual is complete, legible
and in the storage container located on the
machine.
Be sure all decals are legible and in place.
Component Damage Hazard
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.

Part No.116416 AL4000 • AL5000 9
Operator's Manual
First Edition • First Printing
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.
Explosion Hazard
Keep sparks, flames and lighted
tobacco away from batteries.
Batteries emit explosive gas.
Electrocution/Burn Hazards
Avoid contact with electrical terminals.
Avoid electrical shock from contact with battery
terminals. Remove all rings, watches and other
jewelry.
Lockout
When leaving the machine unattended, secure
from unauthorized use. Unauthorized personnel
may attempt to operate the machine without
proper instruction, creating an unsafe condition.
Work Area Safety
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 tower is lowered
to the horizontal position and the travel lock is
secured.
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.
DO NOT TOW MACHINE WHEN ENGINE IS
RUNNING! This can cause severe engine/
radiator damage and WILL NOT BE COVERED
UNDERWARRANTY!

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10 AL4000 • AL5000 Part No.116416
1 Tower, 2 inch section
2 Tower, 3 inch section
3 Tower, 4 inch section
4 Coil cord sleeve
5 Leveling jack
6 Fender
7 Tire
8 Ballasts (located inside cabinet)
9 Tower winch
10 Tongue
11 Curb side door
12 Forklift pockets
13 Lifting eye
14 Lamps
15 Travel lock pin
16 Muffler
17 Outrigger
18 Road side door
19 Light bar
20 Coil cord
Legend - AL4000

Part No.116416 AL4000 • AL5000 11
Operator's Manual
First Edition • First Printing
Controls - AL4000
Control Panel
1 Light switches
2 Main circuit breaker
3 Hour meter
4 Ignition switch for engine
5 Engine prime button
6 Alternator failure light
7 Mini breaker
8 Duplex receptacle with GFI
9 T-lock receptacle

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12 AL4000 • AL5000 Part No.116416
Controls - AL4000
Control Panel - AL4000
1 Light switches
Move each switch to turn on the indicated
light(s).
2 Main circuit breaker
Flip the main circuit breaker switch on before
turning the individual light switches on.
3 Hour meter
The hour meter displays the number of hours the
machine has operated.
4 Ignition switch for engine
Turn the ignition switch to the run 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.
5 Engine prime button
With the ignition switch in the run position, press
and hold the prime button for 15 seconds before
starting the engine.
6 Alternator failure light
Light on indicates that the alternator isn’t
producing enough voltage.
7 Mini breaker
8 Duplex receptacle with GFI
9 T-lock receptacle

Part No.116416 AL4000 • AL5000 13
Operator's Manual
First Edition • First Printing
Legend - AL5000
1 Tower, 2 inch section
2 Tower, 3 inch section
3 Tower, 4 inch section
4 Coil cord sleeve
5 Leveling jack
6 Fender
7 Tire
8 Ballasts (located inside cabinet)
9 Tower winch
10 Tongue
11 Curb side door
12 Forklift pockets
13 Lifting eye
14 Lamps
15 Travel lock pin
16 Muffler
17 Outrigger
18 Road side door
19 Light bar
20 Coil cord

Operator's Manual First Edition • First Printing
14 AL4000 • AL5000 Part No.116416
Controls - AL5000
Control Panel
1 Light switches
2 Main circuit breaker
3 Hour meter
4 Ignition switch for engine
5 Engine prime button
6 Alternator failure light
7 Mini breaker
8 Duplex receptacle with GFI
9 T-lock receptacle

Part No.116416 AL4000 • AL5000 15
Operator's Manual
First Edition • First Printing
Controls - AL5000
Control Panel - AL5000
1 Light switches
Move each switch to turn on the indicated
light(s).
2 Main circuit breaker
Flip the main circuit breaker switch on before
turning the individual light switches on.
3 Hour meter
The hour meter displays the number of hours the
machine has operated.
4 Ignition switch for engine
Turn the ignition switch to the run 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.
5 Engine prime button
With the ignition switch in the run position, press
and hold the prime button for 15 seconds before
starting the engine.
6 Alternator failure light
Light on indicates that the alternator isn’t
producing enough voltage.
7 Mini breaker
8 Duplex receptacle with GFI
9 T-lock receptacle

Operator's Manual First Edition • First Printing
16 AL4000 • AL5000 Part No.116416
External Power Access - AL5000 20kW Option
External Power Access
1 Breakers, 2P, 30A, 240V
2 Receptacle, GFI 20A, 120V
3 Breaker, Mini 1P, 20A
4 Receptacle, T-Lock, 30A, 120/240V

Part No.116416 AL4000 • AL5000 17
Operator's Manual
First Edition • First Printing
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.
manual.

Operator's Manual First Edition • First Printing
18 AL4000 • AL5000 Part No.116416
Inspections
Pre-operation Inspection
oBe sure that the operator’s manual is complete,
legible and in the storage container located on
the machine.
oBe sure that all decals are legible and in place.
See Inspections section.
oCheck for engine oil leaks and proper fluid level.
Add oil if needed. See Maintenance section.
oCheck for engine coolant leaks and proper
coolant level. Add coolant if necessary. See
Maintenance section.
oCheck for battery fluid leaks and proper fluid
level. Add distilled water if needed. See
Maintenance section.
oCheck for proper tire pressure and lug nut
torque. Add air to tires if needed. See
Maintenance section.
Check the following components or areas for
damage, improperly installed or missing parts and
unauthorized modifications:
oElectrical components, wiring and electrical
cables
oTower components
oLatches and pins
oTires and wheels
oTrailer lights and reflectors
oOutriggers, leveling jacks and foot pads
oNuts, bolts and other fasteners
oLamp fixtures and bulbs
oSafety chains (if required)
oEngine and related components
oFuel tank(s)
oGenerator
Check entire machine for:
oCracks in welds or structural components
oDents or damage to machine
oExcessive rust, corrosion or oxidation
oBe sure that all structural and other critical
components are present and all associated
fasteners and pins are in place and properly
tightened.
oBe sure that the battery is in place and properly
connected.