Terex AL5HT Operator's Manual
A
A
Operator's Manual
L™5HT
L™5HT with tier 4 option
ANSI/CSA
North America
South America
Asia
with
Maintenance
Information
Second Edition
Third Printing
Part No. 235735GT
Operator's Manual Second Edition • Third Printing
Front Matter
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: awp.techpub@terex.com
Contents
Introduction ........................................................... 1
Symbol and Hazard Pictorials Definitions ............. 4
General Safety ...................................................... 6
Work Area Safety ................................................ 12
Legend ................................................................ 17
Controls ............................................................... 18
Inspections .......................................................... 27
Operating Instructions ......................................... 36
Transport and Lifting Instructions ....................... 41
Maintenance ....................................................... 43
Specifications ...................................................... 46
Reporting Safety Defects .................................... 47
AL™5HT Part No. 235735
Copyright © 2007 Terex Corporation
Second Edition: Third Printing, Ocotber 2018
"Terex" is a registered trademark of Terex USA, LLC in the
USA and many other countries.
Second Edition • Third Printing Operator's Manual
s
Introduction
Introduction
About this manual
Intended Use
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.
Serial label
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.
Part No. 235735 AL™5HT 1
Serial number
Operator's Manual Second Edition • Third 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
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.
2 AL™5HT Part No. 235735
Second Edition • Third Printing Operator's Manual
NOTICE
Introduction
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
DANGER
WARNING
CAUTION
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.
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.
Part No. 235735 AL™5HT 3
Operator's Manual Second Edition • Third Printing
Symbol and Hazard Pictorials Definitions
Symbol and Hazard Pictorials Definitions
Read the operator’s
manual
Maintain required
clearance
Keep away from
moving parts
Electrocution hazard Stop engine Earth ground Electrocution hazard
Electrocution
hazard/burn hazard
Disconnect battery
Read the service
manual
Crush hazard
Keep away from
moving parts
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.
4 AL™5HT Part No. 235735
No smoking
Keep open flames
away.
Keep open flames
away.
Second Edition • Third Printing Operator's Manual
Symbol and Hazard Pictorials Definitions
Burn hazard Burn hazard
Burn hazard, hot
components
Stay clear of hot
surfaces under cover
Crushing hazard
Stay clear of
descending mast
Stay clear of hot
surfaces under
cover
Carbon Monoxide
hazard
Tip-over hazard
Stay clear of hot
exhaust
Stay clear of hot
surfaces
Wear protective
clothing
Shattering glass
hazard
Deploy outriggers
before raising mast
Tip-over hazard, tow
speed
Lifting point Tie-down point
Part No. 235735 AL™5HT 5
Only trained
maintenance
personnel should
access
compartments
Operator's Manual Second Edition • Third Printing
General Safety
General Safety
97666
133483
31788
133484
97602133190
114431 228708
133148
133482
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114431
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133484
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31788
228708
6 AL™5HT Part No. 235735
Second Edition • Third Printing Operator's Manual
General Safety
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1280819
114258
1280819
WARNING
www.P65Warnings.ca.gov
133148
133017
28161 133012
Cancer and Reproductive Harm -
1280819 C
97675
114431 133483
1280820
Breathing diesel engine exhaust exposes you to chemicals known to
the State of California to cause cancer and birth defects or other
reproductive harm.
• Always start and operate the engine in a well-ventilated area.
• If in an enclosed area, vent the exhaust to the outside.
• Do not modify or tamper with the exhaust system.
• Do not idle the engine except as necessary.
For more information go to www.P65warnings.ca.gov/diesel.
1280819
133148 133190
1280820 C
133017
133012
133483
114431
133190
Part No. 235735 AL™5HT 7
Operator's Manual Second Edition • Third Printing
General Safety
T108021
T108022
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28161
1
STOP
2
DANGER
Electrocution
hazard.
Contact with
voltage will
result in death
or serious
injury.
Shut down
engine/generator
and disconnect
battery supply
before servicing.
Read the service
manual.
3
161699A
4
1292109
5
STOP
6
DANGER
Electrocution
hazard.
Contact with
voltage will
result in death
or serious
injury.
Shut down
engine/generator
and disconnect
battery supply
before servicing.
Read the service
manual.
7
1292109A
8
8 AL™5HT Part No. 235735
Second Edition • Third Printing Operator's Manual
General Safety
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133191
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Part No. 235735 AL™5HT 9
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133191133065
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82487
116894
Operator's Manual Second Edition • Third Printing
General Safety
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133042
82472
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133149
133065
133055
133191
133149
116894
133042
133191
116894
114251
133066
133065
133055
10 AL™5HT Part No. 235735
Second Edition • Third Printing Operator's Manual
General Safety
T108023
T108024
133149
161700
1
82472
2
1292200
5
6
3
STOP
161700 A
4
7
STOP
1292200A
8
Part No. 235735 AL™5HT 11
Operator's Manual Second Edition • Third Printing
Work Area Safety
Work Area 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
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.
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 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.
12 AL™5HT Part No. 235735
Second Edition • Third Printing Operator's Manual
Work Area Safety
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
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 alter or disable machine components that in
any way affect safety and stability.
surface where it cannot be leveled
using only the leveling jacks.
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.
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.
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.
Do not adjust or stow the outriggers when the mast
is raised.
Part No. 235735 AL™5HT 13
Collision Hazards
Check the work area for overhead obstructions or
other possible hazards.
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