FL1400TM LIGHTING TOWER OPERATOR & MAINTENANCE MANUAL

Table of Contents
1. INTRODUCTION ............................................................................................................................. .... 4 2. SAFE OPERATION ............................................................................................................................ 5 3. TECHNICAL SPSECIFICATION ...................................................................................................... 9 4BRIEF INTRODUCTION OF THE LIGHTINGTOWER .............................................................. 11 5. STRUCTURE OF THE LIGHTING TOWER ................................................................................. 12 5.1 EXTERNAL CONSTRUCTION............................................................................................................ 12 5.3 COMMAND PANEL ........................................................................................................................... 13 5.4 BATTERY ............................................................................................................................. ........... 14 5.5 FUEL TANK AND BATTERY SWITCH .................................................................................................. 15 6. OPERATION BEFORE LOADING AND UNLOADING .............................................................. 16 6.1 OPERATIONS BEFORE LOADING THE LIGHTING TOWER ................................................................. 16 6.2 OPERATIONS AFTER UNLOADING THE LIGHTING TOWER ............................................................... 17 7. PREPARATION FOR USE OF THE LIGHTING TOWER ........................................................... 18 7.1 LIGHTING TOWERS TRAVEL .......................................................................................................... 18 7.2 CONNECTING OF THE BATTERY...................................................................................................... 18 7.3 DRIVE GROUNDING ROD INTO EARTH ............................................................................................ 19 7.4 PRE-START CHECKLIST ................................................................................................................. 19 8. OPERATING INSTRUCTIONS ....................................................................................................... 21 8.1 STARTING THE ENGINE ................................................................................................................... 21 8.2 STOPING THE ENGINE .................................................................................................................... 22 8.3 ENGINE ALARMS ............................................................................................................................ 23 8.4 REMARKS ....................................................................................................................................... 23 8.5 USE OF THE LIGHTING TOWER ....................................................................................................... 24 9. LIGHTING TOWER STORAGE ...................................................................................................... 27 9.1 FUEL TANK SEALING ....................................................................................................................... 27 9.2 ENGINE SEALING ................................................................................................................... ......... 27 9.3 BATTERY SEALING .......................................................................................................................... 27 9.4 SPOTLIGHT SEALING ...................................................................................................................... 27 9.5 W HEEL SEALING ............................................................................................................................. 28 9.6 LIGHTING TOWER SEALING ............................................................................................................ 28 10. LIGHTING TOWER UNSEALING ................................................................................................ 29 11. MAINTENANCE OF THE LIGHTING TOWER........................................................................... 30 11.1 MAINTENANCE OF THE GENSET .................................................................................................. 30 11.2 MAST MAINTENANCE .................................................................................................................... 31 11.3 W IRE ROPES MAINTENANCE ........................................................................................................ 31

11.4 SPOTLIGHTS MAINTENANCE ......................................................................................................... 32 12. SPARE PARTS ............................................................................................................................... 34 12.1 FRAME ASSEMBLY ....................................................................................................................... 34 12.2 AXLE ASSEMBLY .......................................................................................................................... 36 12.3 INTERNAL COMPONENTS ............................................................................................................. 38 12.4 EXTERNAL COMPONENTS ............................................................................................................ 40 12.5 MAST BOOM ............................................................................................................................. ...42 12.6 LIGHT BAR ................................................................................................................................... 44 12.7 MAST BASE .................................................................................................................................. 46 12.8 ENGINE/ ALTERNATOR ................................................................................................................. 48 12.9 ELECTRICAL BOX ..................................................................................................................... .... 50 13. SCHEMATICS ................................................................................................................................. 52 13.1 ELECTRICAL SCHEMATIC ............................................................................................................. 52 14. CONCLUSION ................................................................................................................................53

1. INTRODUO ........................................................ .............................. 4 2. Operao Segura ............................ .................................................. .......................... 5 3. TCNICO SPSECIFICATION .............................. .................................................. .... 9 INTRODUO DO 4.BRIEF LIGHTINGTOWER ........................................... ................... 11 5. Estrutura da torre LIGHTING ............................................. .................................... 12 5,1 CONSTRUO EXTERNAS ............................... .................................................. ........... 12 5,3 painel de comando ............................ .................................................. .......................... 13 BATERIA 5,4 ................................. .................................................. ...................................... 14 TANQUE DE COMBUSTVEL E BATERIA 5,5 SWITCH ............................................... .... 15 6. ANTES DE CARGA E DESCARGA ............................................. ................. 16 6,1 OPERAES antes de carregar o TOWER LIGHTING .......... ...................... 16 6,2 OPERAES aps o desembarque do TOWER LIGHTING ............ .................... 17 7. PREPARAO PARA O USO DA TORRE DE ILUMINAO ............... ................ 18 TRAVEL 7,1 TOWER Lighting .................... .................................................. .......... 18 7,2 CONEXO DA BATERIA ................... .................................................. ....... 18 7,3 DRIVE haste de aterramento em terra .............................. ................................................ 19 7,4 LISTA DE PR-START ........................................................................... .................. 19 8. INSTRUES ................................................ .................................................. ..... 21 8,1 PARTIDA DO MOTOR ............................ .................................................. ................... 21 8,2 stoping DO MOTOR ......................... .................................................. .................... 22 8,3 ALARMES MOTOR ..................... .................................................. ........................... 23 OBSERVAES ....................................... 8,4 .................................................. ..................................... 23 8,5 USO DA TORRE DE ILUMINAO ..... .................................................. ......... 24 9. ILUMINAO DE CONSERVAO TOWER ..... .................................................. ..... 27 Tanque de combustvel 3 9,1 VEDAO ......... .................................................. ....................... 27

MOTOR DE VEDAO ................................... 9,2 .................................................. ........................... 27 BATERIA 9,3 VEDAO ............................................... .................................................. ......................... 27 9,4 SPOTLIGHT VEDAO ............................................... .................................................. ..................... 27 9,5 RODA DE VEDAO ................................................................. ............................ 28 9,6 TOWER LIGHTING VEDAO ................. .................................................. ............ 28 10. ILUMINAO TORRE unsealing ........................................................... 29 11. MANUTENO DA TORRE DE ILUMINAO ........................... .............................. 30 11,1 MANUTENO DO GENSET ............................. .................................................. ... 30 11.2 Manuteno MAST .............................. .................................................. ................... 31 11,3 MANUTENO DE CORDAS WIRE ................. .................................................. ........ 31 11,4 MANUTENO SPOTLIGHTS ............... .................................................. ........ 32 12. PEAS ........................................... .................................................. ............................. 34 12,1 ASSEMBLY FRAME ........................ .................................................. ...................... 34 12,2 conjunto do eixo .................... .................................................. ......................... 36 12,3 COMPONENTES INTERNOS ................................................................ ............ 38 12,4 componentes externos ............................ .................................................. ........... 40 12,5 mastro ................................. .................................................. ............................... 42 12,6 BAR LIGHT ....................... .................................................. .................................. 44 12,7 BASE MAST ...................... .................................................. ................................. 46 12,8 MOTOR ALTERNADOR / ..................... .................................................. ................. 48 12,9 caixa eltrica ...................... .................................................. ........................ 50 13. Esquemas ......................... .................................................. .............................. 52 13,1 ESQUEMA ELTRICO .................................................. ............ 52 14. CONCLUSO ................ .................................................. ............................. 53

1. Introduction
Thank you for purchasing our newly developed lighting tower. This operator s manual is supplied with the lighting tower and contains the information for the correct operation and maintenance of it. This manual especially the safety precautions must be read and understood prior to operating this machine and it must be kept with the lighting tower at all times for later preview. Not only the safety precautions presented in this manual have to be obeyed during operation but also some other related safety regulations have to be abided by. The user-friendly design of this lighting tower can guarantee your safety in loading, operation, and maintenance if all these steps are carried out in compliance with this manual. We reserve the right to improve this lighting tower. If there is any technical improvement without change in its nature function, this manual will not be modified. This lighting tower can only work within the range specified in the purchase contract. Any use out of this range is prohibited and any consequence result from this use is the user s responsibility. Operation is forbidden, if: The user has replaced its spare parts randomly. The safety device is incomplete or ineffective. The operator s manual is not fully understood. References are made in this manual that explains relevant information using a clock reference. In these instances the drawbar is considered to be at the 12 oclock position. Also the left is considered to be at the 9 oclock position and right is considered to be the 3 oclock position. When using the term front it refers to the 12 oclock position and back refers to the 6 oclock position.

1. Introduo

Obrigado por adquirir nossa torre de iluminao recm-desenvolvido.

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Este manual fornecido com a torre de iluminao e contm as informaes para a correta operao e manuteno do mesmo. Este manual especialmente as precaues de segurana devem ser lidas e compreendidas antes de operar esta mquina e deve ser mantido com a torre de iluminao em todos os momentos para visualizao posterior. No s as precaues de segurana apresentadas neste manual tm que ser obedecidas durante a operao, mas tambm alguns outros regulamentos relacionados com a segurana tm que ser respeitados. O projeto user-friendly da torre de iluminao pode garantir sua segurana no carregamento, operao e manuteno, se todas essas etapas so realizadas em conformidade com este manual. Reservamo-nos o direito de melhorar esta torre de iluminao. Se houver alguma melhoria tcnica, sem alteraes na sua funo de natureza, este manual no ser modificado. Esta torre de iluminao s pode trabalhar dentro do intervalo especificado no contrato de compra. Qualquer utilizao fora deste intervalo proibida e qualquer resultado conseqncia desse uso de responsabilidade do usurio. A operao proibida, desde que: O usurio tem suas peas substitudas aleatoriamente. O dispositivo de segurana incompleta ou ineficaz. manual do operador no totalmente compreendido. So feitas referncias a este manual que explica a informao relevante, utilizando uma referncia relgio. Nestes casos, a lana considerada a posio das 12 horas. Alm disso, a "esquerda" considerado em posio de 9 horas e "direita" considerada a 03:00 posio. Ao usar o termo 'frente' refere-se posio das 12 horas e 'voltar' refere-se posio 6:00.

2. Safe operation
Careful operation is your best assurance against an accident. Read and understand this section carefully before operating the lighting tower. All operators, no matter how much experience they may have, should read this and other related manuals before operating the lighting tower. It is the owner s obligation to provide all operators with this information and instruct them on safe operation.

Safety instructions
Be sure to observe the following for safe operation. 6

Read and understand carefully this OPERATORS MANUAL and LABELS ON THE ENGINE before attempting to start and operate the lighting tower. Learn how to operate and work safely. Know your machine and its limitations. Always keep the machine in good condition. DO NOT modify the machine. UNAUTHORIZED MODIFICATIONS to the machine may impair the function or safety and affect machine life. If the machine does not perform properly, consult your local Lighting Tower Distributor first.

Carefully read the safety symbols attached to the lighting tower and obey all messages that follow the symbols to avoid possible injury or death.

2. A operao segura

operao cuidadosa a melhor garantia contra acidentes. Ler e compreender esta seo cuidadosamente antes de operar a torre de iluminao. Todos os operadores, no importa o quanto eles podem ter experincia, deve ler este e outros manuais relacionados antes de operar a torre de iluminao. obrigao do proprietrio a fornecer a todos os operadores com esta informao e instru-los sobre o funcionamento seguro.

Instrues de segurana

Certifique-se observar o seguinte para uma operao segura.

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Leia atentamente e compreender este "Manual do Operador" e "rtulos de o motor" antes de iniciar e operar a torre de iluminao. Aprenda a operar e trabalhar com segurana. Conhea a sua mquina e suas limitaes. Sempre manter a mquina em boas condies. NO modifique o equipamento. UNAUTHORIZED modificaes na mquina pode prejudicar a funo ou a segurana e afetar a vida da mquina. Se a mquina no executar corretamente, consultar o seu local de iluminao Tower primeiro distribuidor.

Leia atentamente os smbolos de segurana ligado torre de iluminao e cumpra todas as mensagens que seguem os smbolos para evitar possveis ferimentos ou morte.

Indicates a hazardous situation which, if not avoided can result in serious injury or even death. Indica uma situao

perigosa que, se no for evitada pode resultar em ferimentos graves ou mesmo morte.

Indicates a hazardous situation which, if not avoided, could result in serious injury or even death. Indica uma

situao perigosa que, se no for evitada, pode resultar em ferimentos graves ou mesmo morte.

Indicates a hazardous situation which, if not avoided, could result in minor or major injury. Indica uma situao

perigosa que, se no for evitada, pode resultar

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em maior ou menor prejuzo.

CC.

Precautions against electrical shock

z This lighting tower also has provision for producing high voltage electricity (up to 220 volts) that can produce a fatal shock to a person who accidentally places itself in the electrical circuit. z z z Beware of a cut or damaged power cord and replace immediately. Shut down the machine when repair and maintance. When troubleshooting indicates a malfunction in the high voltage AC system, then pass the troubleshooting task on to a qualified and trained electrician. z Disconnect electrical power and turn off engine before removing protective electrician covers on high voltage enclosures. z Only use a multimeter (or voltage meter) with two well-insulated probes rated for 750 volts. z Keep one hand in your pocket when touching the multimeter probe to hot aonductor. This will prevent eletricity from passing into one hand and out the other, a path that takes the electricity across the heart. Always disconnect power from the circuit being measured before connecting test leads to hiagh voltage points. z Inspect the ground cable between the generator set and the frame. If damaged, replace immediately. z Use tools with insulated handles when working within the reach of live conductors, and remove any metal jewelry such as watchbands or bracelets that might make an inadvertent electrical contact. z Concentrate on the task until the danger from high voltage is removed.

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Wear personal protective equipment(PPE)

z DO NOT wear loose, torn or bulky clothing around the machine that may catch on canopy doors, stabiliser legs, and drawbar causing personal injury. z Use additional safety items-PPE, e.g. hardhat, safety protection, safety goggles, gloves, etc., as appropriate or required. z DO NOT operate the machine under the influence of alcohol, medication, or other drugs, or while fatigued. z DO NOT wear radio or music headphones while operating the machine.

Safe handling of fuel and lubricants-keep away from fire

z z z Fuel and lubricants are as flammable materials, keep away from fire. To ensure your safety , please stop the engine before refueling and/or lubricating. DO NOT smoke or allow flames or sparks in your work area. Fuel is extremely flammable and explosive under certain conditions. z z Refuel at a well-ventilated and open place after the engine cool down. DO NOT mix gasoline or alcohol with diesel fuel. The mixture can cause fire or severe engine damage. z z z Strictly prohibited in the lack of fuel, lubricants circumstances to start the machine. DO NOT use poor or unclean fuel and lubricants. Do not use unapproved container e.g. buckets, bottles, jars. Use approved storage containers.

Cautions against burns & battery explosion

z To avoid burns, be cautious of hot components, e.g. muffler, muffler cover, radiator, hoses, engine body, etc. during operation and after the engine has been shut off, when the engine has been turned off, do not touch them within one hour. z DO NOT remove the radiator cap while the engine is running or immediately after stopping. Otherwise hot water will spout out from the radiator. Wait until the radiator is
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completely cool to the touch before removing the cap. Wear safety goggles. z The battery presents an explosive hazard. When the battery is being charged, hydrogen and oxygen gases are extremely explosive. Keep sparks and open flames away from the battery, especially during charging.

Safety precautions against operation

z z z Please read the operate manual before operating the lighting tower. In accordance with the guidance of instructions to operate the lighting tower. Under no circumstances that the lighting tower be moved in any way before the mast is retracting, as it is extremely unsafe. z z z z z z Always ensure that only qualified people operate the lighting tower. Make sure earth spike is connected to the earth point at the front of the plant. Always dispose of any rags used to clean up fuel or oil in appropriate bins. Stay clear of any moving parts of the lighting tower. DO NOT remove or disconnect any of the safety devices. Only one operator at a time to operate the lighting tower and it is only to be operated from the main command panel. z Always make sure that the stabiliser legs are secured and the machine is level and stable before operation. z z z Ensure that all appropriate measures are taken with the legs to avoid a trip hazard. Never start the lighting tower when it is short of fuel or lubricants. All doors and caps that can be locked must be locked or fixed before starting the machine. z Running with overload is forbidden.

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3. Technical spsecification
Standrd equipment Length (mm) Widthmm Heightmm Mast height(fully extend,m) WeightKg Engine model FrequencyHZ Speedrpm Continued powerKVA Number of cylinders Diesel engine characters Combustion type Engine aspiration Emission level Alternator Alternator insulation Rating voltageV Fuel tank capacity Fuel tank operating hours Type of light Number & power of light Mast lifting & extension Mast rotation Stabilizing legs Leaf spring Axle Hitch
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FL1400TM 4600 (3100, Dismantling the tow bar) 1500 1850 9 890 380(Lester) 50 1500 7 3 4 Cycle, In line, Watercooled diesel Direct injection Nature N.A. Brush & Single phase H class 230 95 liters25US Gallons 60 hours Metal halide spotlight (Local brand) 4*1000 Manual operation 359 Manual operation Manual operation Leaf spring Axle Ball or O ring Tier4 60 1800 9

Tire rim size Acoustic pressure Max load quantity in a 20 container (sets)

14 75dB(A) at 7meters away 6

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4Brief introduction of the LightingTower

Lighting tower is a lighting device with the components of genset, light, mast, trailer and canopy. It is designed for working outside with strong wind stability and is rainproof. Its flexibility and reliability makes it ideal for the use of night construction, emergency handling, rescuing etc. With its mast galvanized and the canopy processed, it is rainproof and can work in all weather condition. FL1400TMseries is the latest design and manufacture lighting tower with the vertical telescopic mast. The operation is simpler than other series lighting tower. And the smaller size male the transportation become more convenient. 1. Mast lifting and extension are manually operated-simple, safe and reliable ; 2. The mast can be extended to 9 meters fully ; 3. Locating pin, locking pins, position limiting block ensure all operation to be safe and reliable ; 4. Tilt the lightbar and rotate the mast 359manually to adjust the illuminated area ; 5. Assembled with 4 high brightness and good shooting spotlights and floodlights are also optional ; 6. Using key switch or controller to manually start or syop the genset, control each light independently just by its oen independent switch ; 7. The excellent-quality and multi-fault protection generator with the low-emission diesel engine and brushless AVR alternator can power all of the lights stably and continuously ; 8. IP66 light plug and socket ; 9. The trailer with the leaf spring axle is simple in structuir, reliable in design and easy in maintenance.

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5. Structure of the lighting tower

5.1 External construction

Items 1 3 5 7

Description Telescopic mast Stabilizing legs Spot light Ventilation grille

Items 2 4 6 8

Description Drawbar Winch handle Cabinet roadside Hook

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5.3 Command panel

Items 9 11 13 15 17

Description Circuit breaker for lamps Main circuit breaker Hour meter Low oil pressure lamp Frequency meter

Items 10 12 14 16 18

Description Circuit breaker for outlet Outlet Water temperature lamp Engine starting key Fuse

The main input or other generators can power the lighting tower through the input socket, so that will get more benefit on the fuel consumption and noise pollution.

The minimal section of connection cables must be choose in relationship to the voltage, to the installed power and to the distance between source and uses.

WARNING:
Input currents are high-voltage, please pay attention to safety on the operation .

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5.4 Battery

Items 19

Description 36AH 12V battery

The machine is supplied with the battery not connected. Connect the battery with cables already predisposed making attention the correct polarity.

If the machine has to be stopped for a long period, we suggest to disconnect the battery.

WARNING:
The battery fluid contains sulphuric acid which is extremely corrosive and harmful to the skin . Always wear protective gloves snd be extremely careful .

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5.5 Fuel tank and battery switch

Items 20 22

Description Fuel tank cap battery switch

Items 21

Description Fuel contents gauge

The operation of refuelling must be done according to the instruction of fuel contents gauge.

Turn always off the engine before any operation of refuelling and take care of fire. DO NOT let fuel spill or leakage. Please protect the environment and proper dispose the waste oil.

CAUTION:
Contact with engine oil can damage your skin, put on golves when using engine oil. If you come in contact with engine oil, wash it off immediately.

A good command of the structure of the lighting tower will give you help in operation.

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6. Operation before loading and unloading

6.1 Operations before loading the lighting tower
In order to make each standard container can hold more lighting towers, so we need to remove some parts before loading. It is impossible to keep it steadily, stop running and its telescopic mast is in the prone position before remove the parts of the lighting tower. Specific steps are as follows:

(1) Take out the bolt and plug on the support of the floodlight (a), and then take the floodlights down. Floodlights are fragile goods, please carefully placed. (2) Remove the telescopic mast (b), the support of the telescopic mast(c)and the spool sheave (d). (3) Remove all of the stabilizer legs and the bolts with spanner which fixed the triangular metal bracket of the lighting tower(e). And then take down the triangular metal bracket.

Note :After take down the triangular metal bracket, Please keep the bolts in a safe
place. As mentioned above, we can put it into the standard container after removed the parts, the Max. load quantity in a 20standard container is 6 sets.

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6.2 Operations after unloading the lighting tower

When the standard cabinet geted to the destination, please follow the following steps to install the lighting tower. (1) Open the standard container, take out the lighting tower and its parts. (2) Install the telescopic mast(b) and the support of the telescopic mast(c)and the spool sheave(d). (3) Install the stabilizer legs and the triangular metal bracket(e). (4) Fix the floodlights on the support of the floodlight(a). As mentioned aboved, tow it with towing vehicle after the parts installed. (The towing operation like described at the chapter 7.1

Lighting Tower s Travel)

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7. Preparation for use of the lighting tower

7.1 Lighting Tower s Travel
Notes :
When the lighting tower is traveling, the genset must be off, all the stabilizing legs have to be retracted and the telescopic mast is in the supine position, all the parts that can move have to be fixed or locked. If the height of the towing vehicle is higher. In order to prevent the rear two stabilizing legs touch the ground and affect the traction tractor. Please lay the stabilizing legs horizontal, and then traction (Fig.1)

1Traveled to the work site which is a relatively flat place, and then lower the front stabilizing legs through the handle. 2Carbon monoxide can cause severe nausea, fainting or death. Avoid inhaling exhaust fumes, and never run the engine in a closed building or confined area.

(Fig.1)

7.2 Connecting of the battery

The machine is supplied with the battery not connected. Connect the battery with cables already predisposed making attention to the exactly polarity.

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7.3 Drive grounding rod into earth

WARNING:
Please check the grounding rod into earth, before operating.

7.4 Pre-Start Checklist

The tyres are to be inflated to the correct pressures. Make sure all the stabiliser legs are down and stability ,secure and that appropriate safety measures have been taken to avoid a trip hazard. Walk around the machine and look for any obvious damage to the body itself, the lights, the tyres and the tie down points. Check that all appropriate stickers are there and that they are legible. Check the grounding. Check that the oil drainage cap, the battery charging points and the battery isolator are all intact. Check that the engine of the lighting tower has fuel. Make sure none of the wiring is frayed and the connections are secure. Inspect the switches on the control panel to make sure they are intact.

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WARNING:
z Failure to follow the procedures listed may cause injury to personnel or damage to the lighting tower, the manufacturer is not responsible for these. z Be certain that all persons operating the lighting tower are certified or fully trained. z Always wear protective gloves, clothes and other protective equipment, as required.

Note : At the time of purchase, there is not fuel and lubrication in the engine of the
lighting tower.

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8. Operating instructions
WARNING:
Do not raise the lighting tower in the vicinity of overhead power lines.

Note : please perform the preparatory work carefully before start the engine.

8.1 Starting the engine

(1) Open the cabinet roadside (6) of the lighting tower, and then open the battery switch(22) (2) Pull the Main circuit breaker (11) to onposition. (3) By clockwise rotation the Engine starting key (16) to START position and the engine should start. Release the key immediately when the engine starts, and then the key should in the RUNposition.

NOTE :
z If the engine does not catch or start at 10 seconds after the switch is set at STARTING , wait for another 15 seconds and then begin the engine stating sequence again . z Do not allow the starter motor to run continuously for more than 20 seconds.

Technical specification : Full speed and full load operation is not allowed for the new or repaired engine , First wearing - in should be carried out for 45 hours in lowspeed and load. Then the engine could be put in normal load operation. This can

guarantee the normal use of the engine.

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WARNING:
z Engine exhaust fumes can be very harmful if allowed to accumulate . Be sure to run the engine in a well ventilated location and where there are no people or livestock near the engine . z Check moving parts and the surrounding components before the engine shut down. z Must be sure there id not any tools left in the body in the debris before starting diesel engine .

DANGER:
z Do not touch muffler or exhaust pipes while they are hot. Severs burns could result. Always stop the engine and allow it to cool before conducting inspections,maintenance,or for a cleaning procedure. z Air Filter breathe the air on the engine runing .So avoid the hands, body, clothing, etc.close to this site, This is to avoid injuries.

8.2 Stoping the engine

Before stopping the engine ,lower the speed to the idle condition and gradually discharge the load until the water temperature comes down below 70C, then the engine can be stopped by engine starting key (16). (1) Through the circuit breaker for lamps (9) to close all of the floodlights, and then let the engine run one minute no-load. NOTE: Do not shut down engine prior to turning lamps off. (2) With the engine starting key (16) placed at the OFFposition, stop the engine . (3) Pull the Main circuit breaker(11) to OFFposition. (4) Shut down the Battery Switch(22).

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WARNING :
If you turn off the engine emergent under load state, diesel will be a sharp increase in the temperature, this will shorten the life of diesel engines.

8.3 Engine Alarms

Battery charge and hours13 This meter will show the battery voltage, convenient to check the voltage. Also, it shows the hourage of the engine is running, convenient to maintenance and repair. High water temperature (14) This table will show the water temperature, convenient to check the water tank. Low oil pressure (15) If the module detects that the engine oil pressure has fallen below the low oil pressure switch after the safety on time has expired, the low oil pressure light will be light. So check oil pressure of the lighting tower. Frequency meter (17) The mete will show the voltage frequency meter ,convenient to check the frequency of the voltage.

8.4 Remarks
Always ensure that only qualified people operate the lighting tower.

UNAUTHORIZED MODIFICATIONS to the machine may impair the function or safety and affect machine life. When the personals operation, other personnel away from the lighting tower. When the lighting tower needs to work on the slope, please use anti-skid blocking the two wheels.In order to avoid the lighting tower moving . Always make sure that the stabiliser legs are secured and the machine is level and stable before operation,around the lighting tower may not have other moving parts, this can avoid accidents.
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NOTE :
Do not follow safety regulations for the operation and causing injury to persons or damage to the product, manufacturers are not responsible.

8.5 Use of the lighting tower

(1) Release the locking-pin from their hole (Fig.1) and then proceed manually to the extraction of stabilizing legs until the pins lock the exit of the tubular. check that the locking-pin go into the respective seats of blocking of the tubular.

(Fig.1)
(2) Level the traller, using the stabilizers as follows: (Fig.2) A. Extend the rear outriggers until the springs lock into place. Swing the stabilizing legs on each outrigger into vertical position. B. Start at hightest stabilizer position. Rotate the stabilizer handle until the stabilizer legs touches the ground. C. Raise the other stabilizers to level trailer.

WARNING:
insure that the stabilizing legs are down to prevent the tower from tipping over backwards when raise.

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(Fig.2)

(4) Clockwise rotation the handle that allows to raise and to lower the telescopic mast in easy way (Fig.4). Stop elevating when the red line comes out.

(Fig.3)

(Fig.4)

WARNING: z Insure all stabilizers are down and steady before raise the lighting tower. z Stop elevating when the red line comes out
(5) Starting the engine. Before starting the engine, make reference to the chapter 8.1

Starting the engine.

(6) Turn on the floodlights Pull the circuit breakers (9) to ON position, light the first lamp and allow 10 seconds for it to warm up, then light the next lamps.

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WARNING:
It is necessary to wait the cooling of the lamp (about 10 minutes) before a new lighting.

WARNING :
The lighting tower is prearranged to with stand 74km/h wind at the maximum height. In case of using in windy places, be careful and lower timely the telescopic mast .

DANGER:
It is strictly prohibited to retract the stabilizing legs when the lighting tower is in vertical position at maximum height.

NOTE: Relocating lighting tower to new location, please make reference to the chapter 7.1 lighting tower s travel.

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9. Lighting Tower Storage

If the lighting tower is not used for a long time, measures have to be taken for good storage to prevent corrosion or any damage to it.

9.1 Fuel tank sealing

(1) Drain the fuel completely and wash the inner tank with gasoline. (2) Dry-type sealing: Put 100g deoxidant or 20g antirust in the tank cock and then tighten the cock. (3) Wet-type sealing: Fill the tank with clean diesel to 95% of the specified capacity and then tighten the cock.

9.2 Engine sealing

(1) Keep the engine running at low speed for five minutes; (2) Before sealing it, run the genset for 30 minutes with the floodlight on until the coolant and the lubricant oil to reach appropriate temperature then drain them completely. (3) removed the fuel drain plug of the cylinder, add about 2ml lubricants. (4) Press the decompression handle, do not let go, pull the starter hander 2-3 times(do not start the engine). (5) Seal the air filter with rubber sleeve or plastic tape. (6) Seal the muffler outlet with rubber sleeve or plastic sleeve. (7) wipe off any oil or dust sticking to the machine completely, put the lighting tower in a safe and dry place.

9.3 Battery sealing

(1) Disconnect the battery. (2) Clean the battery connections, coat a thin layer of Vaseline on the joint, and pack them with plastic film. (3) Take out the battery and put it in a safe and dry place.

9.4 Spotlight sealing

Demount the spotlights and put them in cartons. The cartons should be placed at a dry

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and clean storage room free from rain and dust.

9.5 Wheel sealing

(1) Suspend the wheel Use steel or wooden support frame to support the wheel axle to suspend the wheels to let them above the ground 3-5cm. Put the chock under the wheels. (2) Seal the wheel Coat the wheel tread with paraffine or cover the wheel with craft paper, newspaper or canvas. Coat JXF rubber antioxidant is used to slow the oxidation of the wheel.

9.6 Lighting tower sealing

After the above components will be sealed, cover the lighting tower with canvas.

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10. Lighting Tower Unsealing

The operation of lighting tower unsealing: (1) Remove all the covers and seals. (2) Remove the support frame to let the wheel land. (3) Extend all the stabiliser legs to support the lighting tower and make sure it is level. (4) Connect the battery to the genset, make sure the battery voltage is enough to start the motor. (5) Add quality lubricants. (6) Add quality diesel. (8) Start the genset to see if it works well. Before starting the genset, please do the checks specified in chapter 7.4. (9) When the genset is running and all electric values are in limits no alarm is active, the lights maybe turned on.

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11. Maintenance of the Lighting Tower

11.1 Maintenance of the Genset
WARNING:
Whenever open the control panel, you must take the necessary protective measures to prevent possible electric shock accident. Only qualified person is permitted to do the repair works and can only use the spare parts approved by manufacture.

Regular Maintenance
The maintenance circle is determined by running time and mainly divides into daily, after 100 hours, after 500 hours maintenance. And for more detailed information please refer to engine maintenance manual.

Daily maintenance
(1) Check to see if there is any leak of fuel, lubricant oil. (2) Check water quantity in water tank. (3) Check the oil level in injection pump and adjustor, refill to specified position when insufficient. (3) Checkfor the tightness of engine braket.

Maintenance after 100 hours

(1) Replace oil in oil sump. (2) Clean or replace oil filter cartridge. (3) Clean or replace oil filter cartridge.(or after 200 hours) (4) Check whether the electrolyte level is 10 to 15mm higher than polar plates. Otherwise fill in vaporised water. (5) Replace cooling water when not clean.

Maintenance after 500 hours

(1) Check full injection pressure and automization quality. Clean and adjust when necessary.
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(2) Dismount cylinder head, remove carbon deposit. Check valve sealing and lap when necessary. (3) Check connecting rod bolts,main bolts and fly wheel bolts for tightness. (4) Replace oil in injection pump and speed adjustor. (5) Clean cooling system. Cleaning fluid is mixture of 150g NaOH and 1 liter water completeily. (6) Drain out cooling water before cleaning, then fill in cleaning fluid and run the engine after 8-12 hours. Stop the engine when working water temperature is achieved, drain out cooling fuid immediately to prevent the influid scale depositing, finally clean the cooling system with clean water. (7) Check each eletrical starting equipment to ensure all tigheness and wiring connections are tighten. Replace those burned out . (8) Check all engine parts, repair or adjust when necessary.

NOTE: For more information please refer to the engines manual and the
generator s manual.

11.2 Mast maintenance

(1) Always keep the mast clean and free from dust and rain. Wrap it with plastic paper when not being used. (2) The mast should not be hit. (3) When clean the mast, do not let the liquid flow inside the mast and acid or alkalic liquid should not be used.

11.3 Wire ropes maintenance

This wire ropes formed from metal wire, which is used to telescopic mast. Regularly check the conditions of wire rope, pulleys and the tightness of wire ropes. (1) The wire rope should be regularly maintained in order to get rid of the damage caused by rust or dirt. (2) The groove of the reel and pulley should ofen clean, if there is damaged, please repair or replacement promptly.
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(3) In the course of using wire ropes, please to avoid contact with dust,sand,coal sand,and Acid-base compounds. (4) In order to prevent the Wire ropes rust, please keep it clean and coated anti-rust oil. When the lighting tower is unused, the wire ropes shoud coating anti-rust oil every six months.

DANGER :
If the wire ropes is damaged or other conditions, please stop using it immediately, and check or replace it.

11.4 Spotlights maintenance

(1) The metal halide must be used with ballast and trigger which conform to national standards. The fluctuation range of the voltage source should not exceed 5%. (2) Please listen to the guidance of manufacturers, and choose the appropriate lighting. (3) Cut off the power source before maintance, and until the lamps is cooling. (4) when the light went out suddenly, you should first check all the lines and connections to see if they are tight and function well, otherwise the light may go end to its life and has to be replaced. In case of replacement of the lamps or the floodlights glass, open the spotlight through the 6 stainless steel hooks (Fig.1), inserting a screwdriver in the appropriate slots previewed on the hooks. The hooks are with hinge to support the frame when opened. Replace the lamp or the glass. Close the spotlights glass carefull to position correctly the hooks in their seat.

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(Fig.1)

Note: It is necessary to sustain manually the cover during the operations of lamp's
replacing.

The requirements of the floodlights are as follows: Type of lamp : metal halide Base: E40 Norminal power:1000W Nominal voltage: 220V

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12. Spare Parts

12.1 Frame Assembly

34

Frame Assembly Item 1 2 3 4 5 6 Quantity 1 1 1 2 3 4 Part Number D001 D002 D003 D004 D005 D006 Part Name BALL HITCH TONGUE FRAME KIT OUTRIGGER EXTENSION JACK UBULT Comment

35

12.2 Axle Assembly

36

Axle Assembly Item 1 2 3 4 5 6 7 8 Quantity 2 4 1 2 4 2 2 2 Part Number X001 X002 X003 X004 X005 X006 X007 X008 Part Name TIRE&WHEEL MOUNTED UBOLT AXLE AXLE REAR HANGER 1 AXLE SHCKLE LEAF SPRING FISH PLATE AXLE FRONT HANGER 2 Comment

37

12.3 Internal Components

38

Internal Components Item 1 2 3 4 5 6 7 Quantity 2 4 2 2 1 1 1 Part Number N001 N002 N003 N004 N005 N006 N007 Part Name BALLAST KIT ABSORBER ENGINE BRACKET RADIATOR BRACKET BATTERY BALLAST SWITCH FUEL TANK KIT Comment

39

12.4 External Components

40

External Components Item 1 2 3 4 5 6 7 8 9 10 11 12 13 Quantity 1 1 2 1 1 2 2 2 2 1 6 2 2 Part Number C001 C002 C004 C005 C006 C007 C008 C009 C010 C011 C012 C013 C014 Part Name CONNECTOR CABINET TOP PLASTIC PLUG MAST SUPPORT CABINET REAR TAIL BRAKE AND INDICATOR LIGHT CABINET ROADSIDE CABINET CURBSIDE FENDER CABINET FRONT HINGE LATCH UNIT HANDLE Comment

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12.5 Mast Boom

42

Mast Boom Item 1 2 3 4 5 6 7 8 9 Quantity 1 1 3 1 1 1 1 2 1 Part Number M001 M 002 M 003 M 004 M 005 M 006 M 007 M 008 M 009 Part Name ROUND TUBE MAST 1 ANCHOR EAR MAST 2 MAST 3 LINE PIPE SHEAVE 1 SHEAVE 2 SHEAVE 3 Comment

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12.6 Light Bar

44

LIGHT BAR Item 1 2 3 4 5 Quantity 4 4 1 1 4 Part Number L001 L002 L003 L004 L005 Part Name LIGHT LIGHT BRACKET 4 GANG MOUNTING BOX KIT LIGHT BAR FIXTURE MOUNTING WING NUT Comment

45

12.7 Mast Base

46

LIGHT BAR Item 1 2 3 4 5 Quantity 1 1 1 1 1 Part Number B001 B002 B003 B004 B005 Part Name MAST BASE KICKOUT SPRING PIN SLIDE LOCK MANUAL WINCH SPOOL SHAVE KIT Comment

47

12.8 Engine/ Alternator

48

Engine/ Alternator Item 1 2 3 Quantity 1 1 1 Part Number E001 E002 E003 Part Name ALTEMATOR ENGINE RADIATOR Comment REFER ALTEMATOR RARTS BOOK REFER ENGINE RARTS BOOK

49

12.9 Electrical Box

50

Electrical Box Item 1 2 3 4 5 6 7 8 9 10 11 12 13 Quantity 1 4 1 4 12 6 1 2 1 1 1 2 1 Part Number K001 K002 K003 K004 K005 K006 K007 K008 K009 K010 K011 K012 K013 Part Name CONTROL PANEL SWITCH 1 SWITCH 2 CONTROL BOX TERMINAL RECEPTACLE SWITCH 3 ENGINE RELAY FREQUENCR METER KEY SWITCH HOIR METER ALARM LIGHT FUSE BLOCK Comment

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2
A N

3
MCB A1 N1

Gense t

A N

50 52

1 2

51 52 26

MCB5 A11

MCB4 A12

MCB3

A13 MCB2 A14

MCB1

A15
T

53

54 52 26

Hz
T

55 57

4 5 6

56 57 26 59 57

B
58
T

St op Run Start

ACC

KA6 4C

4B

KA5

4C
7 26

26

13. Schematics

C
R2

5 4 KA4 KA6 KA5 KA1 KA2 30 31 KA3

C
KA2 KA3 3 FU 12 4A

HIGH WT

LOW OP

C
1 3

VH
4 2
3 FU:1 KA4 4A TB1:3

KA1 15A Fuse

5A

31

30

2 2
5A 3

D TB1 1
1 SB1

3
4A

5
31

6
30

13.1 Electrical Schematic

B M
5B

KA7 R ed

Green

E
2

YV
Blac k

12

E
2

NA ME KA 1 7 S ta r t rela y KA 3 O il rel ay KA 2-6 R el y In te rm e di at e te rm in al s TB 1 SB 1 B at te ry swi tc h V H Ho ur m et er

G M B YV M CB MC B1-7

NA ME Ch ar ge a lt ern at or St ar te r mo to r B atte ry St op S ol e no id Ma in M CB M CB

NA ME

Title

De sig ned by

Che c ked by D rawing No.

A pprov ed by da te

Da te

GENSET WIRING
3 4 5 6

F
Pa g e L AM P 010

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14. Conclusion
We absorbed advanced technology from home and abroad in developing this lighting tower, which is in the leading position in both markets. We are continuously sparing no efforts in developing various kinds of lighting tower to meet different needs of customers. Warmly welcome all the customers to give us suggestions and recommendations on the lighting tower. Thank you for purchasing our products again. As we are continuing commitment to the upgrading and development of lighting towers, so the chart, description, and parameters provided in this manual may be inconsistent with the product you purchased. If there is any doubt, please contact with our technical department.

Please safe handling the fluids and spare parts for the environment.

All the specifications and pictures of the present catalogue are subject to modifications without prior notice.

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