Terex AL5 User manual

Operator's Manual
A
L5
ANSI/CSA
North America
South America
Asia
Vertical Mas
t
with tier
4 o
p
tion
with
Maintenance
Information
First Edition
First Printing
Part No. 1255533

Operator's Manual First Edition • First Printing
AL5 Vertical Mast Part No. 1255533
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............. 4
General Safety ...................................................... 6
Work Area Safety................................................ 10
Legend ................................................................ 15
Controls............................................................... 16
Inspections.......................................................... 22
Operating Instructions......................................... 32
Transport and Lifting Instructions ....................... 37
Maintenance ....................................................... 39
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.

First Edition • First Printing Operator's Manual
Introduction
Part No. 1255533 AL5 Vertical Mast 1
Introducti on
About this manual
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.
This book is an operation and daily maintenance
manual for the user or operator of a Terex
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 Terex.
Product Identification
The machine serial number is located on the serial
label.
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.
Bulletin Distribution and
Compliance
Safety of product users is of paramount importance
to Terex. Various bulletins are used by Terex to
communicate important safety and product
information to dealers and machine owners.
The information contained in the bulletins is tied to
specific machines using the machine model and
serial number.
Distribution of bulletins is based on the most
current owner on record along with their associated
dealer, so it is important to register your machine
and keep your contact information up to date.
To ensure safety of personnel and the reliable
continued operation of your machine, be sure to
comply with the action indicated in a respective
bulletin.
Serial number stamp
Serial label

Operator's Manual First Edition • First Printing
Introduction
2 AL5 Vertical Mast Part No. 1255533
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
minimum, Terex should be contacted for:
Accident reporting
Questions regarding product applications and
safety
Standards and regulatory compliance information
Current owner updates, such as changes in
machine ownership or changes in your contact
information. See Transfer of Ownership, below.
Transfer of Machine Ownership
Taking a few minutes to update owner information
will ensure that you receive important safety,
maintenance and operating information that
applies to your machine.
Please register your machine by visiting us on the
web at www.genielift.com or by calling us toll free
at 1-800-536-1800.
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.

First Edition • First Printing Operator's Manual
Introduction
Part No. 1255533 AL5 Vertical Mast 3
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
that if not avoided, will result in
death or serious injury.
Indicates a hazardous situation
that if not avoided, could result in
death or serious injury.
Indicates a hazardous situation
that if not avoided, could result in
minor or moderate injury.
Indicates information considered
important, but not hazard related
(e.g. messages related to
property damage)
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

Operator's Manual First Edition • First Printing
Symbol and Hazard Pictorials Definitions
4 AL5 Vertical Mast Part No. 1255533
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
Keep away from
moving parts
Keep away from
moving parts
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.

First Edition • First Printing Operator's Manual
Symbol and Hazard Pictorials Definitions
Part No. 1255533 AL5 Vertical Mast 5
No smoking No flame No flame Burn hazard Burn hazard
Burn hazard Burn hazard Stay clear of hot
exhaust
Burn hazard, hot
components
Stay clear of hot
surfaces under cover
Carbon Monoxide
hazard
Do not use light tower
indoors
Wear protective
clothing
Shattering glass
hazard
Lifting point
Tie-down point Tip-over hazard Deploy outriggers
before raising mast
Tip-over hazard, tow
speed

Operator's Manual First Edition • First Printing
General Safety
6 AL5 Vertical Mast Part No. 1255533
General Safety
133484
114431
97602
97666
228711
228711
97675 133148
114258
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31788
133482
133484
133482
114431 228708 133483
114258
97602
97666
133148
97675
31788

First Edition • First Printing Operator's Manual
General Safety
Part No. 1255533 AL5 Vertical Mast 7
T108022
T108021
133483
133148
133012
1261258
114431
133483
133148
133012
T108022
T108021
1261258
114431
DANGER
Electrocution
hazard.
Contact with
voltage will
result in death
or serious
injury.
1261258 A
STOP
Shut down
engine/generator
and disconnect
battery supply
before servicing.
Read the service
manual.
1
2
3
4

Operator's Manual First Edition • First Printing
General Safety
8 AL5 Vertical Mast Part No. 1255533
133149
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116893
133149
82487
133042
114251
116894
133065116895
82481
114251
82481
229782
229782
133042

First Edition • First Printing Operator's Manual
General Safety
Part No. 1255533 AL5 Vertical Mast 9
T108023
116894
T108024
133055
133065
T108023
T108024
161700
133065
116894
133149
133055
82481
161700

Operator's Manual First Edition • First Printing
Work Area Safety
10 AL5 Vertical Mast Part No. 1255533
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
over 1000KV see below
For power lines over 1000kV, the minimum
clearance distance must be established by the
utility owner or operator or by a registered
professional engineer who is a qualified person
with respect to electrical power transmission and
distribution.
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.
Explosion and Fire Hazards
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.
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.

First Edition • First Printing Operator's Manual
Work Area Safety
Part No. 1255533 AL5 Vertical Mast 11
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 rotate mast while standing on the platform.
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.
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.
Collision Hazards
Check the work area for overhead obstructions or
other possible hazards.
Ensure that the collision area around the mast and
light fixtures is clear before rotating the mast.
Always use the light fixture bar rotation lock before
replacing light fixtures.
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.

Operator's Manual First Edition • First Printing
Work Area Safety
12 AL5 Vertical Mast Part No. 1255533
Bodily Injury Hazard
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.
Stay clear of belts and fan when engine is running.
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.
Do not use where people will remain close to the
lamps for more than a few minutes unless
adequate shielding or other safety precautions are
used.
Stay clear of moving mast.
Do not grasp the cable.
Use proper lifting techniques when lifting and
positioning the tongue of the machine.
Always replace the protective lamp cover after
replacing the lamp bulbs.
Fall Hazards
Always use the hand holds when climbing on or off
the platform.
Do not access the platform until the outriggers
have been properly deployed and the machine has
been leveled.
Keep the platform floor clear of debris.
Keep clear of platform edges during maintenance
and operation.
Do not stand on any other part of the machine
during maintenance and 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.

First Edition • First Printing Operator's Manual
Work Area Safety
Part No. 1255533 AL5 Vertical Mast 13
Component Damage Hazards
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.
Note: Lamp bulbs contain mercury (Hg). Dispose of
lamp bulbs according to local, state and federal
laws.
Do not extend the mast when both red lines are
visible on mast.
Do not retract a raised mast while the mast
retaining pin is engaged.
Be sure lamp fixture connections are properly
tightened before turning lights on.
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 use any battery charger greater than 12V to
charge the battery.
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.

Operator's Manual First Edition • First Printing
Work Area Safety
14 AL5 Vertical Mast Part No. 1255533
Electrocution/Burn Hazards
Avoid contact with electrical terminals.
Inspect the power cord for damage prior to each
use.
Replace any damaged cord before operating.
Do not allow the power cord to become caught or
crushed while raising, lowering or rotating the mast.
Avoid electrical shock from contact with battery
terminals. Remove all rings, watches and other
jewelry.
Lifting Hazard
Use the appropriate number of people and proper
lifting techniques when lifting batteries.
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 to the stowed position and 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 are securely attached to
the tow vehicle. Safety chains should be crossed
below hitch.
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 • First Printing Operator's Manual
Legend
Part No. 1255533 AL5 Vertical Mast 15
Legend
1Leveling jack
2Tongue with trailer hitch
3Air shutoff system Emergency Stop button (if
equipped with automatic air shutoff system)
4Air shutoff system pull handle (if equipped with
manual air shutoff system)
5T-handle for mast rotation lock
6Tie-downs
7Curbside door
8Forklift pockets
9Lifting eye
10 Mast retention pin
11 Mast
12 Red stripes
13 Ballast (located inside cabinet)
14 Lamps
15 Electric winch
16 Mast rotation handle
17 Flashing beacon (if equipped with auto-start
system)
18 Roadside door
19 Outrigger
20 Control panel (located inside cabinet)
21 Platform
22 Manual storage (located inside cabinet)
23 Grounding lug (located on chassis beneath
platform)
4
5
21
10
6
19
23
19
7
8
9
10
16
11
10
6
12
12
13
6
14
17
15
20
22
18

Operator's Manual First Edition • First Printing
Controls
16 AL5 Vertical Mast Part No. 1255533
Controls
Control Panel
1T-lock receptacle, 240V/30A
2Light switches
Move each light switch up to turn on the
indicated light. Move each light switch down to
turn off the indicated light. On models with
6 lights, the switches marked 1/5 and 2/6 turn
on 2 lights each. On models with 4 lights, each
switch turns on one light.
3Circuit breaker for GFI receptacle
4Main circuit breaker
Move the main circuit breaker switch up on the
control panel before turning the individual light
switches on or before attempting to use the
convenience receptacles.
5Duplex receptacle with GFI, 120V/20A
Convenience duplex receptacle with Ground
Fault Interrupter (GFI).
6Hour meter
The hour meter displays the number of hours
the machine has operated.
341
2
4
3
1
6
7
8
9
5
10
HOURS
5 6
2
AL5 8 kW

First Edition • First Printing Operator's Manual
Controls
Part No. 1255533 AL5 Vertical Mast 17
7Ignition 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.
8Engine 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.
9Alternator failure light
Light on indicates that the engine's DC
alternator isn't producing enough voltage.
10 Raise/lower switch
Move the switch up to extend the mast. Move
the switch down to retract the mast.

Operator's Manual First Edition • First Printing
Controls
18 AL5 Vertical Mast Part No. 1255533
6
34
1
7
8
5
9
11
12
13
10
HOURS
5 6
2
2
5
1
6
4
2
3
4
AL5 12kW &20kW
AL5 external panel