Terex AL4000, AL5000, RL4000 Operator's Manual

Operator's Manual First Edition • First Printing

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

General Safety - AL4000.......................................3

General Safety - AL5000.......................................5

Work Area Safety .................................................7

Legend - AL4000.................................................10

Controls - AL4000 ...............................................11

Legend - AL5000.................................................13

Controls - AL5000 ...............................................14

External Power Access -

AL5000 20kW Option..........................................16

Inspections .........................................................17

Operating Instructions......................................... 24

Transport and Lifting Instructions ........................28

Maintenance .......................................................30

Specifications ..................................................... 32

Reporting Safety Defects ....................................33

Contact us:

Copyright © 2008 by Terex

Internet: www.terex.com

Terex Light Construction Division
590 Huey Road
Rock Hill, SC 29730
First Edition: First Printing, November 2008

Printed on recycled paper

Printed in U.S.A.

AL4000 • AL5000 Part No. 116416

First Edition • First Printing

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:

Operator's Manual

Introduction

Danger

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

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.

Part No. 116416 AL4000 • AL5000 1

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 • First Printing

Introduction

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

Red

Orange

Yellow

Blue

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.

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.

2 AL4000 • AL5000 Part No. 116416

First Edition • First Printing

Safety signs and locations

Operator's Manual

General Safety - AL4000

Part No. 116416 AL4000 • AL5000 3

Operator's Manual First Edition • First Printing

General Safety - AL4000

Safety signs and locations

4 AL4000 • AL5000 Part No. 116416

First Edition • First Printing

Safety signs and locations

Operator's Manual

General Safety - AL5000

Part No. 116416 AL4000 • AL5000 5

Operator's Manual First Edition • First Printing

General Safety - AL5000

Safety signs and locations

6 AL4000 • AL5000 Part No. 116416

First Edition • First Printing

Operator's Manual

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.

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.

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.

Part No. 116416 AL4000 • AL5000 7

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.

Operator's Manual First Edition • First Printing

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.

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.

Bodily Injury Hazards

Do not use the machine indoors unless properly
ventilated.

Do not breathe exhaust fumes.

8 AL4000 • AL5000 Part No. 116416

Do not replace lamp bulbs with any bulbs other
than those specified on the machine and in this
manual.

First Edition • First Printing

Operator's Manual

Work Area Safety

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.

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.

Part No. 116416 AL4000 • AL5000 9

DO NOT TOW MACHINE WHEN ENGINE IS
RUNNING! This can cause severe engine/
radiator damage and WILL NOT BE COVERED
UNDER WARRANTY!