User Manual
Contents
1. Ecolite P User Manual Youngman Group Limited The Causeway Maldon Essex CM9 4LJ United Kingdom t 44 0 1621 745900 f 44 0 1621 859845 e sales youngmangroup com YOUNGMAN Ss a oe ea INNOVATIVE LIGHTING SOLUTIONS youngmangroup com Contents Contents Preliminary OLCW Ol Cit A e E e az gg at n T ates Liability meme 3 AvditsandSurveys Service and Warranty Training Warranty Terms sil ayak lk General Exclusions 3 Warranty Claim Submission Procedures CertificateofConformiy HatzEngineDealers ServiceBulletins Machineldentification Eleciricai AZA eski a kl ki al 6 PIC he M M asama ni im eek oat SUU EN eee Ren LubricatonandServicing e e e ee Section 1 Operating Instructions e ge tin aiaremate 152 POSITIONING sna eni aaa eli all amli 1 3 StabilisingtiheUnit 10 1 4 singthelighits 10 1 4 1 Lowering Mast if Battery is Flat 12 1 5 Auxiliary Supply Optional 1 6 MovingtheUnit W 1 7 Redirectingthelights 1 8 EmergencyStop Se2. Fig 2 10 Air filter cover removal Replace filter if damaged or dirty 6 Reassemble the filter assembly SY W m gt gt g e rot pes _ a m ee v VA zi esime Fig 2 11 Air filter element Fig 2 12 Safety element 20 TCP EcoLite P User s Manual Issue B July 2010 Section 2 Routine Maintenance 2 7 Hydraulic Fluid Check the fluid in the hydraulic tank daily a ee solenoid valve t ar 4 1 a Al La T E d bei DAY hi a V0 PN TH 0 Nn wii Hydraulic nian Mn A gt gt Se ai 24 Hydraulic fluid filler cap Fig 2 13 Hydraulics Remove the cap from the hydraulic tank and check the level The fluid should just reach the bottom of the filter that is under the cap Fig 2 14 If necessary top up with Ecolite Mast Fluid TCP Part No 80 0372 Warning Only use the specified TCP hydraulic fluid undiluted This fluid is specially formulated for the purpose f the wrong fluid is used or the fluid becomes diluted it could freeze under cold conditions with resultant structural damage to the equipment This could result in injuries to personnel and or damage to property f it is suspected that the fluid has become diluted drain the tank as described for the fuel in Section 2 8 Draining Fuel Tank and refill with the prescribed TCP fluid Fig 2 14 Hydraulic fluid level check Take care not to
3. Press to set the month default setting is 1 gt wW NN Press La to switch to year setting default setting is 01 and then press to set the year 01 2001 5 To save the settings WITH automatic summer winter time adjustment press a 1h appears in the display 6 To save the settings WITHOUT automatic summer winter time adjustment press e A4 4 Deactivating Automatic DST Adjustment Press D for 5 seconds then press Automatic DST adjustment is deactivated and the symbol 1h is removed from the display A4 5 Manual DST Adjustment Press the D button until the correct time is displayed If the symbol 1h appears in the display the DST setting cannot be changed manually 30 TCP EcoLite P User s Manual Issue B July 2010 Appendix A Timer and Dusk Dawn Functions A5 Main Functions A5 1 Setting a Switching Point 1 Press SET The display shows the first ON switching point 2 Press Ld repeatedly to obtain the required day or block of days for which this switching point will apply Press to set hours for the switch on point Press to set minutes for the switch on point Press again The display shows the OFF time for the switched period ot a Use the La h buttons again to set the day s hours and minutes for the switch off point 7 Press the button again to confirm your setting The next switching point will be displayed 8 Repeat the procedure as necessary to set more switching points
4. Check voltage with start switch in each of its three positions The voltage should be around 12V off load switch position 0 and should not fall below 10V while cranking Fuel pump operation should be audible in switch position 1 4 5 3 Engine cranks as normal but engine does not fire e Check fuel level in tank e Check that the fuel pump operates when the start switch is set to I Pump operation should be audible e Check fuel and filters TCP EcoLite P User s Manual Issue B July 2010 25 Section 4 Fault finding 26 TCP EcoLite P User s Manual Issue B July 2010 Section 5 Options TCP EcoLite P User s Manual Issue B July 2010 Section 5 Options 27 Appendix A Timer and Dusk Dawn Functions Appendix A Timer and Dusk Dawn Functions A1 Introduction This appendix describes two automatic operation options A timer can be fitted to turn the lights on and off at pre determined times for every day of the week Asensor can be fitted on top of the mast to turn the lights on at dusk and off at dawn Only one option can be fitted to a given unit Ignition imer panel 7 ha Phone 44 0 1621 850777 Fax 44 0 1621 843330 o e www tcp eu com sales tcp eu com Fig A1 Timer and ignition panel si 5 1 A2 Ignition Panel The key switch on the Capricorn ignition panel has three positions Manual on engine starts and lights come on if selected If lights fail to come on
5. The Battery and Oil Pressure lights adjacent to the switch should light 9 Turn the key to position 2 10 As soon as the engine starts release the Key to position 1 Check that the Battery and Oil Pressure lights go out and the green Running light remains on Note If the engine does not start return the key switch to position 0 before retrying TCP EcoLite P User s Manual Issue B July 2010 11 Section 1 Operating Instructions 11 Check that the lights on the tower are oriented so as to provide optimum illumination of the site The lights can be tipped up down and rotated as required It is also possible rotate the tower through 300 degrees See Section 1 7 Redirecting the Lights 12 Raise the tower by turning the Tower switch clockwise and holding it there Note Ifthe mast does not rise check that the mast lowering valve is closed see Section 1 4 1 Lowering Mast if Battery is Flat 13 Release the Tower switch when the lights reach either the required height or maximum You will hear a change in the pitch of the hydraulic motor when the mast is fully extended Note It is normal for the mast to appear wet as it is raised the hydraulic fluid acts as a lubricant for the seals between the telescopic sections Subsequent leakage from a raised mast could indicate a problem with a seal Seals and O rings can be replaced as detailed in the workshop manual 14 Set the Supply Selector switch if fitted to Generator 15 Set
6. Where an output socket is fitted it provides either 110V centre tap earth cte or 220V output depending on version region from the internal alternator 1 6 Moving the Unit To move the unit 1 Turn off the lights and allow time for them to cool 2 Lower the tower 3 Raise retract and stow the four jacks 1 7 Redirecting the Lights The tower can be rotated through up to 300 degrees so as to direct the light as required Slacken the Rotation Lock Fig 1 8 and turn the Rotation Handle so as to direct the lights as required Tighten the lock afterwards In addition to rotation of the mast each of the lights can be rotated on two axes and tipped back and forth Fig 1 7 Thus the lights can be directed either downwards or horizontally e g to illuminate a facade Fig 1 9 For any adjustments the mast must be lowered to allow access TCP EcoLite P User s Manual Issue B July 2010 13 Section 1 Operating Instructions Rotation lock Fig 1 9 Fa ade illumination Fig 1 10 Earth Spike 14 TCP EcoLite P User s Manual Issue B July 2010 1 8 Emergency Stop The Emergency Stop button shuts off the engine in under 20 seconds The engine and the power it generates will remain off until the Emergency Stop button is released To release the button twist it in the direction of the arrows on the button Note When Ecolite power is supplied from an outside source via the input socket engine not used and supply Selector sw
7. check that dip switch A4 is On See Section A11 Ignition Unit Settings Off engine turns off and lights go off Auto on engine and lights are controlled by the Dusk dawn sensor or the Timer according to which is fitted Engine running OK alae Battery not charging on git Emergency stop Engine temperature high yi Under over speed Glow plugs a Auxiliary shutdown Engine failed to start Low oil pressure Manual remote start Fig A2 Ignition panel 28 TCP EcoLite P User s Manual Issue B July 2010 Appendix A Timer and Dusk Dawn Functions A3 Timer A3 1 Introduction The timer allows the engine and lights to be turned on and off at predetermined times on a weekly basis The mast is not affected and remains in the set position The front panel buttons can be used to set numerous On and Off switching points at particular times on particular days or groups of days of the week e g Monday to Friday or Saturday and Sunday There are also various options for dusk and dawn switching Press the button repeatedly to see the switching points that are currently set Examples On 19 00 Off 2100 Monday to Thursday On 21 00 Monday Off 05 00 Tuesday On at Dusk Off after 1 hr Every day Either manual or automatic daylight saving time e g British Summer Time can be implemented To access the timer raise the control panel window and flip up the window covering the timer The timer window can be used to prop up the
8. 9 Press to exit the routine The current time is displayed again after 60 seconds or when is pressed A5 2 Changing a Switching Point 1 Press repeatedly until the desired switching point appears in the display 2 Set the new times as described in Section A5 1 Setting a Switching Point The current time is displayed again after 60 seconds or when 5 is pressed A5 3 Deleting a Switching Point 1 Press ISEN repeatedly until the desired switching point appears in the display 2 Press repeatedly until appears in the display 3 Press SET The switching point is deleted and the next switching point is displayed The current time is displayed again after 60 seconds or when 9 is pressed A5 4 Manual and permanent switching Repeated pressing of KI displays the following operating modes Automatic off OFF Automatic on ON Permanent off OFF FIX Permanent on ON FIX With the Permanently On ON FIX or Off OFF FIX settings the stored program will be bypassed without the loss of program values The current time is displayed again after 60 seconds or when 5 is pressed TCP EcoLite P User s Manual ssue B July 2010 31 Appendix A Timer and Dusk Dawn Functions A6 Special Functions A6 1 Deactivating Individual Switching Points Recall the switching point by pressing and deactivate it by pressing the KI button 1 is displayed above the colon This switching point remains inactive until it
9. P User s Manual Issue B July 2010 e Discourage the thief Inspect the gates and fences of the machinery storage yard or construction site Keep machines in well lit areas and ask the local law enforcement authorities to make frequent checks around the storage yard or work site e Liaise with neighbours Ask them to watch equipment left at job sites and to report any Suspicious activities to local allow enforcement authorities e Make frequent inventories of machines to promptly detect losses or vandalism Recovery of a Stolen Machine In the event of theft immediately notify the law enforcement authorities having jurisdiction Provide the investigating officer with name type of equipment chassis and serial numbers of major attachments and components It would be helpful to show the investigating officer an Operator s Handbook photographs and advertising to familiarise him with the appearance of the machine Report the theft to the insurance company Provide the model and all serial numbers Report the model and serial numbers of the stolen machine to a dealer handling the respective line of equipment Request that the dealer forward this same information to the equipment manufacturer Safety Report all malfunctions to those responsible for maintenance Do not operate the equipment until corrected Normal service or maintenance performed as required can prevent unexpected and unnecessary down time This handbook desc
10. fluid could freeze in cold conditions resulting in damage to the equipment and or danger to personnel DO NOT touch or lean against hot exhaust pipes or engine cylinder HIGH VOLTAGE This unit uses high voltage circuits capable of causing serious injury or death Only a qualified electrician should troubleshoot or repair electrical problems occurring in this equipment Replace all guards and safety devices immediately after servicing Before servicing light tower make sure engine Start switch is turned to OFF circuit breakers are open off and the battery isolation key is removed NEVER perform even routine service oi Ifilter changes cleaning etc un less all electrical components are shut down Never allow water to accumulate around the base of the light tower set If water is present DO NOT service Never service electrical components if clothing or skin is wet If the unit is stored outside check the engine and generator for any moisture and dry the unit before use Never wash the unit with a power washer or high pressure hose Open main circuit breaker before disconnect ing battery cables Keep hands feet and loose clothing away from moving parts on generator and engine Replace all missing and hard to read labels Labels provide important operating instruc tions and warn of dangers and hazards Make sure slings chains hooks ramps jacks and other types of lifting devices are attached securely
11. mix fuel and hydraulic fluid TCP EcoLite P User s Manual Issue B July 2010 21 Section 2 Routine Maintenance 2 8 Draining Fuel Tank When working on the fuel system do not expose it to a naked flame do not smoke Over time condensation results in a layer of water forming at the bottom of the fuel tank water being heavier than diesel fuel Once per year remove the water as follows 1 Fit a polyethylene tube diameter 4 mm length 700mm approx to a commercial syringe 20 ml or larger Remove the diesel filler cap and run the tube down to the bottom of the tank Drain off the fuel water mixture with the syringe Repeat the procedure until the transparent syringe is found to contain only diesel fuel 2 9 Engine Conditioning After every 1500 hours of operation the engine should be run under a 2 6 kW load for two hours in order to clear it of accumulated carbon deposits The 2 6 kW can comprise a 2 kW load connected to the Auxiliary Supply output plus 600W for the lights 22 TCP EcoLite P User s Manual Issue B July 2010 Section 3 Lamp Replacement Section 3 Lamp Replacement Note Do not touch the lamp bulb with bare fingers The grease deposited from skin will cause the lamp to fail when it is turned on Ensure that the new lamp is clean 1 Release the clips securing the lens Fig 3 1 and remove the lens Fig 3 2 Fig 3 1 Lens clips Fig 3 2 Lamp lens 2 Unclip the lamp from the holder Fig 3 3 3 Install the ne
12. use or if high winds or electrical storms are expected in the area e The tower extends up to 9 m 30 ft Make sure area above the tower is open and clear of overhead wires and obstructions e Bulbs become extremely hot is use Allow bulb and fixture to cool 10 15 minutes before han dling e Keep area around tower clear of people while raising and lowering mast e Tower must be levelled and outriggers ex tended before raising tower Outriggers must remain extended while tower is up e DO NOT use a lamp without the glass lens of the lamp unit in place and undamaged Ceramic discharge metal halide lamps are constructed of an outer glass bulb with an internal arc tube made of ceramic The arc tubes operate at high pressure up to 50 p s i and at very high temperatures They can rupture unexpectedly due to ballast Prelliminary failure or misapplication If an arc tube ruptures it can shatter the outer glass bulb resulting in the discharge of glass fragments and extremely hot ceramic particles as high as 18320F 1000C In the event of such rupture there is risk of personal injury property damage burns and fire if the protective lens is not fitted Fire Precautions Clean all dirt oil grease and other fluids from systems and components to minimise fire hazards and aid in spotting loose or leaking lines fittings etc Check the engine for rubbish oily rags or other debris that could cause fires before start
13. Lite P User s Manual Issue B July 2010 The light tower should not be placed where those working under the light are o Forced to look into the light regularly or o Forced to work with their backs to the light shadows will block the light from the work area Assess site conditions carefully before positioning and operating the tower Do not position the tower in the vicinity of overhead cables or power lines Locate the light tower on the same or a higher level than the area being lit the higher the light the less shadow length The area where the tower is positioned should be relatively level This will ensure smooth trouble free telescoping of the mast The mast may not telescope down properly if the unit is not level Do not move the tower with the mast raised Never raise the mast or operate the tower without the jacklegs touching the ground Section 1 Operating Instructions 1 3 Stabilising the Unit Jack leg Winding handle ii Locking Fig 1 1 Jack components Fig 1 2 Jack extended Stabilise the unit as follows Start with the jack that is on the highest ground 1 Pull up the Locking Pin Fig 7 7 and pull the Jack Leg away from the body of the unit to its fullest extent until the pin locks in the hole Fig 7 2 2 Wind the foot of the jack down to the ground Repeat the procedure for all four jacks so that the unit is stable and level Do not use the jacks to raise the unit off the ground 1 4 Using the Lig
14. PAN a Maximum i Minimum Fig 2 2 2 Dipstick levels TCP EcoLite P User s Manual Issue B July 2010 17 Section 2 Routine Maintenance 2 3 Engine Oil Change e fe Change the oil every 250 operating hours Take care that no contamination enters the sump 1 Ensure that the unit is level 2 Runthe engine until it is warm 3 Clean the area around the oil filler cap dipstick Remove the filler cap dipstick Fig 2 1 Attach a suitable tube to the oil evacuation pump and route it toa suitable container 6 Use the hand pump to evacuate all the oil ORIG GUMP Fig 2 3 Oil SAE grades Disconnect the tube Oil should meet at least one of the following Refill the sump with oil of the correct specifications grade for the conditions Fig 2 3 to the ACEA B2 E or better correct level as indicated on the dipstick Ap _ cp CE CE CF 4 CG or better 9 Refit the filler cap dipstick 2 4 Fuel Filters Parts In line fuel filter TCP 14 0131 Fixed fuel filter TCP 14 0128 Two fuel filters are fitted one behind the battery in the line to the fuel pump Fig 2 4 and the other mounted on the side of the engine Fig 2 5 Replace the in line filter after 250 hours of If engine oil of a poorer quality is used reduce oil change interval to 150 hours of operation Fuel filter pump Fuel tank AW Fig 2 4 In line fuel filter Fig 2 5 Fixed fuel filter 18 TCP EcoLite P User s Manual Issue B July 2010
15. Section 2 Routine Maintenance 2 5 Oil Filter Clean the oil filter after every 1000 operating hours 1 To gain access to the oil filter remove the side panel from the engine Fig 2 6 shows the side panel and some of the fixing screws The oil filter is located near the bottom of the engine Fig 2 7 Remove the filter as shown in Fig 2 8 k d Side panel Fixing Screws Fig 2 6 Engine side panel 2 Wash out oil filter with degreaser Replace filter if damaged 2 e a ee Cp a y a ew D gt gt gt th 4 m En er Fig 2 9 Oil filter refitting 3 Check joint washers Fig 2 9 Replace if necessary TCP EcoLite P User s Manual Issue B July 2010 19 Section 2 Routine Maintenance Lubricate joint washer before fitting Insert filter to limit of travel Ensure that tension springs Fig 2 9 sit close to filter before tightening screw 6 Check oil level and top up as necessary 2 6 Air Filter Parts Air filter element TCP 10 0273 Safety element TCP 10 0274 Check the air filter every 250 operating hours daily under dusty conditions The filter comprises an outer filter element and an inner safety element intended to stop the filter element being sucked in 1 Open the cover to access the air filter assembly 2 3 4 5 Unscrew the air filter cover Fig 2 10 Extract the filter element Fig 2 11 Extract the inner safety element Fig 2 12
16. and have enough weight bearing ca pacity to lift or hold the equipment safely TCP EcoLite P User s Manual ssue B July 2010 Preliminary Always remain aware of the position of other people around you when lifting the equipment Specifications Length 1200 mm Height 2050 mm Overall height floodlit position 9100 mm Width 1200 mm Overall width with jack legs 2700 mm deployed Lifting eye safe working load 1000 kg Engine Hatz IB20 Engine power 3 1 kW Noise Level 85 dBA LWA Engine oil capacity 2 6 Fuel capacity 95 Fuel consumption 0 5 I nour Fuel specification Diesel meeting EN 590 BS 2869 A1 A2 or ASTM D 975 1D 2D Total run time 170 hours Stabilising levelling positions 4 Operating voltages 12V d c 220V a c Max wind speed for safe 100 kph operation Lamps 4 x 150W Auxiliary power option 220V or 110V Prelliminary 8 TCP EcoLite P User s Manual Issue B July 2010 Section 1 Operating Instructions section 1 Operating Instructions 1 1 Features Four or six adjustable ceramic discharge metal halide lamps mounted on a telescopic tower 9m tower raised and lowered using hydraulics powered by a Hatz diesel engine Lights powered from the diesel engine or optionally from a local mains supply Mounted on a pallet style frame that occupies the same floor area as a pallet for ease of storage and transport 1 2 Positioning When choosing a location of the Ecolite bear in mind the following TCP Eco
17. bient temperatures however can cause an additional cycle error If the ambient conditions are constant to the greatest possible extent the error can be minimised by resetting the cycle correction value To do this the cycle error is determined by comparing it with a time signal e g radio or television over a period of exactly one week The value in seconds of cycle deviation per week obtained in this manner is then taken into account when resetting the cycle correction value lf the time switch is fast the cycle correction value is reduced by the number of seconds If the time switch is slow the value is increased by the number of seconds The factory default setting for cycle error correction is for conditions of approx 20 C The newly ascertained cycle deviation must be added to or subtracted from the default value Example Default value for cycle correction 2 sec per week Newly ascertained cycle deviation 3 sec per week 3 seconds must be deducted from the default setting i e 1 must appear in the display for setting see Table 1 36 TCP EcoLite P User s Manual Issue B July 2010 Appendix A Timer and Dusk Dawn Functions A10 Technical details A10 9 Updating the Switching Outputs If new switching points are entered or the current time is changed the current switching status is re calculated and the entered switching points are updated accordingly within 1 minute A10 10 Behaviour in the Case of Electrical Suppl
18. ch by TCP Ltd of this contract Audits and Surveys TCP Ltd reserves the right to carry out audits and inspections from time to time in relation to any reimbursed or outstanding warranty claims in order to determine that all relevant details and information is correct Service and Warranty Training Service and warranty training for service fitters can be provided at competitive rates if required Training can be carried out ata TCP depot or at a venue of your choice please contact TCP with your requirements Warranty Terms One year or 1000 hours whichever occurs first from date of installation All engine warranty issues must be directed to the engine manufacturer or the manufacturer s approved appointed engine dealer General Exclusions THE FOLLOWING ARE WARRANTY EXCLUSIONS AS DETERMINED BY HATZ Service items including lubricants filters glow plugs fuel injection equipment stop solenoid relay charge regulator leaks oil and air IN ADDITION paintwork and parts that wear Prelliminary Warranty Claim Submission Procedures Claims must be reported accurately and all relevant details given as follows OWNERS NAME AND ADDRESS full name and address of customer and site location if different MACHINE TYPE State machine type i e Ecolite Date of Failure SERIAL NUMBER Serial number of unit ENGINE NUMBER Serial number of engine Hours USED Sate hours used on hour clock Please do not guess the ho
19. control panel window The timer normally shows the current time Use an implement such as a ball point pen to press the buttons Do not use a sharp pointed implement that could damage the meter A3 2 Display and Control Buttons Current switch state Day of week 1 Monday Set day amp time Programme DST manual set Recall Reset Hour Date Minutes Month Day Manual Set Change View switching point override Fig A3 Timer front panel TCP EcoLite P User s Manual Issue B July 2010 29 Appendix A Timer and Dusk Dawn Functions A4 Preliminary Settings A4 1 Initial Start up On a new unit or after the unit has been disconnected from the supply for some time the display will be off and the unit must be initialised as follows 4 Press and hold for 5s The display will appear after approximately 2 minutes 5 Set the time date etc as detailed below A4 2 Time Setting Check the displayed time If necessary set the time as follows 1 Press Gi The colon stops flashing 2 Use the La and buttons to set the day hours and minutes 3 Press to save your settings Daylight saving time DST adjustments will be made automatically A4 3 Setting Date and Automatic Daylight Saving Time The date must be set if you wish to use automatic daylight saving time DST or dusk dawn switching functions 1 Press D for 5 seconds 1 1 appears in the display Press to enter day default setting is 1
20. ction 2 Routine Maintenance ZA SCNCO UG ion resad aaa am el sl 2 2 EngineOilCheck 2 3 EngineOilChange 24 e K e a a cance Z9 B ga e A 2 0 AFFINE e e ay e 2 7 FAVYOFAUNC FlUld nap k 2 8 DraininggFuellank 2 9 EngineConditioning Section 3 Lamp Replacement Section 4 Fault finding yi e e ig E NA 4 2 BatterylightOn 4 3 OilPressurelightOn 4 4 High TemperaturelightOn 4S Stain ER ARE ROM AA AN EY 4 5 1 CorntrollightsOf 4 5 2 Enginedoesnotcrank 4 5 3 Engine cranks as normal but engine does not fif e ler a ie Salk Section 5 Options Appendix A Timer and Dusk Dawn TCP EcoLite P User s Manual Issue B July 2010 Preliminary Preliminary Foreword Thank you very much for purchasing this product We believe that it will serve you without fail Ensure that you read the operating instructions carefully before use With proper handling and maintenance this product will provide reliable long term service This manual is intended for users of the equipment All information illustrations and specifications contained in this publication are based on the latest product information available at the time of publication The right is reserved to make chan
21. ges at any time without notice Continuing improvement and advancement of the design may cause changes to your machine that may not be included in this publication Please read the operating instructions carefully and understand them before operating the equipment Warranty Liability The warranty period begins when the product is delivered to and installed at the first purchaser Only genuine parts may be used to carry out repairs Failure to use only genuine parts may invalidate the manufacturers warranty TCP Ltd will not be held responsible if e the machine has been used to perform tasks that demand more than it s design and strength limitations or e the machine has undergone modifications not approved by TCP Ltd or e conditions of use have been abnormal or e normal maintenance with regard to requirements as set out and detailed by the manufacturer have not been adhered to TCP EcoLite P User s Manual ssue B July 2010 TCP Ltd will not pay for normal maintenance or servicing nor any materials used to carry out routine servicing The warranty liability of TCP Ltd is limited to diagnosis repair or replacement of the defective part and actuating the repair depending on the product terms and conditions this will be free of charge TCP Ltd shall be under no liability whatever to the customer for any indirect loss and or expense including loss of profit suffered by the customer arising out of a brea
22. hts 1 Check that the light lenses are clean and undamaged 2 Drive the earth spike Fig 1 8 into the ground earth follow any risk assessment Check that the earth spike cable is securely attached to the unit 3 Check that the Emergency Stop button is not pressed If necessary rotate the button clockwise to release it Open the cover to access the Control Panel Check the fuel level and top up if necessary The fuel level can be seen through the translucent fuel tank 10 TCP EcoLite P User s Manual Issue B July 2010 Section 1 Operating Instructions Supply selector switch GENERATOR 232402 ot 1 Ce A Main i ROD On If fitted switch a 1 2 2 ala 2 3 4 6 6 N d i y j F Light shes switches Phone 44 0 1621 ren Te ver Fax 44 0 1621 84333 www ICp eu com Taise lower salesiitep eu com Engine running OK a Battery not charging Low oil pressure Engine temperature high Fig 1 4 Ignition panel Note Fig 1 3 shows a 230V machine with an auxiliary output The mcb configuration on other versions will be different 6 Check that the main switch and miniature circuit breakers MCBs are on up and the Light switches are off The main switch is a residual current device RCD that can be tripped by an earth leakage Set the Supply Selector Switch if fitted to Off Insert the key in the Key Switch and turn it to position 1
23. ing the engine Safely dispose of greasy oily rags or similar hazards Flammable Fluid Precautions Take due care when working with fuel Diesel fuel is a health hazard for contact with eyes or sin inhalation and ingestion There is also danger of fire and pollution Don t use diesel fuel or other flammable fluids for cleaning purposes Use approved non flammable solvents Make sure all fluid systems caps drain valves fittings lines etc are secure and leak free Shut off engine and use extra caution if engine is hot when refuelling Never smoke while checking or adding fuel or other fluid or handling fluid containers and lines Use care and do not stand downwind when adding fuel or other flammable fluids to tanks and reservoirs to avoid fluids being blown or splashed onto clothing When preparing machines or components for storage seal and tape all openings and close containers tightly to seal in all volatile inhibitor fluids and compounds used DO NOT fill fuel tank near an open flame while smoking or while engine is running DO NOT fill tank in an enclosed area with poor ventilation DO NOT run engine with the fuel tank cap loose or missing Electrical Hazard Never smoke or allow open flames or sparks near batteries Always disconnect batteries before repairing electrical system to avoid danger of fire Causing sparks Disconnect battery ground cable first and reconnect last Always disconnec
24. is reactivated To reactivate a switching point recall the switching point by pressing SET then press appears in the display above the colon The current time is displayed again after 60 seconds or when is pressed A6 2 Holiday switching This function enables the switching channels to be set permanently ON or OFF for a maximum period of up to 99 days without affecting the switching points programme Holiday switching is not possible in ON FIX and OFF FIX permanent switching modes This is indicated by the symbol FIX flashing on the display 1 Press the a button for five seconds until 0 d appears on the display Press a repeatedly until the desired number of holiday days appears in the display 2 Press KI to set the desired switching mode OFF or ON Do not press any other button after this or the holiday switching mode will be deactivated When the set holiday period has expired the time switch resets automatically to the normal display A6 3 Random Switching Points The actual switching time can be varied in a random fashion about the set time within a time frame of 1 59 minutes To set random timing for a switching point select the switching point using the button and then press The symbol E appears showing that the precise time of switching will be selected at random To set the range of fluctuation press e and then press eight times is displayed Use the button to select the required range betwee
25. itch set to Auxiliary the Emergency Stop button is inoperative and will not turn off the power The RCD provides protection against electric shock TCP EcoLite P User s Manual Issue B July 2010 Section 1 Operating Instructions 7 E mergency stop gt a g Fig 1 10 Emergency Stop button 15 Section 1 Operating Instructions 16 TCP EcoLite P User s Manual Issue B July 2010 Section 2 Routine Maintenance Section 2 Routine Maintenance 2 1 Schedule Service interval Every Every Every Every Ref Operation Dail 250 hr 500 hr 1000 hr 1500 hr Page Engine Oil Check Change HB Air fiter Checkreplce 19 Fuel Filter inline Replace 18 Fuel Filter fiked Replace 18 Hydraulic fluid ekoo yoo po Engine oil filter oo ean 19 Drain water from fuel Engine conditioning Decoke Check clean air filter daily in dusty conditions 2 2 Engine Oil Check Check the engine oil after each day s use 1 Ensure that the unit is level 2 Check the oil level with the engine cold OU e dipstick 3 Clean the area around the oil filler Big cap dipstick a 7 Oil 3 Le evacuation 4 Remove the dipstick Fig 2 1 and allow a pump few moments for the oil level to settle 5 Check the oil level using the dipstick Fig 2 2 6 If necessary top up the oil see Fig 2 3 Do not overfill Fig 2 1 Oil filer dipstiok and pump
26. itching parameters Latitude and Longitude The twilight times depend on the geographical position of the place of operation The default setting is 50 north latitude and 10 east longitude corresponding roughly to the geographical position of Frankfurt Main Germany Clock zone The standard clock zone is set for Central Europe The value must be changed corresponding to the place of operation UK 0 Sun below horizon the time switch calculates the current twilight times based on the angles entered The default setting is an angle of 6 corresponding to civil twilight nautical twilight 12 astronomic twilight 18 Morning and evening time differential the time differentials enable the twilight switching points to be shifted and determine the morning and evening switch on duration see Table A1 The setting 0 00 makes the time differentials ineffective The time differential settings are only effective for functions A1 and A2 A8 3 Twilight Times Display The twilight times are stored as special switching points and can be displayed by pressing the button The time is displayed the colon flashes The dawn switching point is displayed Pressing again displays the dusk switching point The date must be entered when using the automatic Daylight Saving Time switchover and Dusk Dawn Switching functions If the Dusk Dawn Switching function is deactivated AO no twilight switching points are displayed A8 4 Dus
27. k Dawn Switching Function A1 In Dusk Dawn Switching function A1 the dusk switching point acts as a switch on point and the dawn switching point as a switch off point Function A1 also allows for shifting the calculated twilight switching points One time differential each can be set for both the dawn and the dusk switching points enabling execution of the twilight switching points to be advanced or retarded A negative differential value gives an earlier the switching point and a positive value gives a later switching point See Fig A4 Activating Dusk Dawn Switching function A1 renders other set switching points ineffective 34 TCP EcoLite P User s Manual Issue B July 2010 Appendix A Timer and Dusk Dawn Functions Evening Morning differential differential F l Dusk Dawn Evening Morning differential differential aa pa i a Function A2 OF Te M Dusk Dawn Fig A4 Functions A1 and A2 A8 5 Dusk Dawn Switching Function A2 Function A2 enables the switching on of an item for a desired period of time after dusk or before dawn The period during which the light is switched on after dusk is determined by the evening time differential The morning time differential determines the duration of switch on time before dawn see Fig A4 If one of the evening or morning switching sequences is not required set the corresponding time differential to 0 00 Activating Dusk Dawn Switching function A2 renders other set switching point
28. n 1 and 59 minutes See Table A1 9 A6 4 Reset button Pressing the button deletes the currently set clock time day and date Pressing and together deletes the currently set time day date and all set switching points Settings revert to the defaults 32 TCP EcoLite P User s Manual Issue B July 2010 Appendix A Timer and Dusk Dawn Functions A6 5 Program button P The program modes are as follows em Function Display settings Default setting 1 Pulse function not used Pulse function not used function not used P1 P2 P3 C NE stem smon a AO 2 n rem m sem fe net m sa t f EET 8 ET Evening me DuskiDann Swiching 2s90250Z ooon e a 1wos9l8 90min Table A1 Program functions To select a program function press e and then press repeatedly to cycle through the available functions Having selected a function use the and buttons to set or select the parameters Press to confirm your setting The display will show the next function in the list Press 9 to exit program mode without saving the displayed function A7 Pulse Function A7 1 Pulse function P1 The Pulse function provides an option of generating a pulse at a switching point This function controlled by the D button is not used in this application A8 Dusk Dawn Switching Function This function provides for switching on at dusk and off at dawn It operates by calculating the morning and e
29. ribes general inspections servicing and operation with the normal safety precautions required for normal servicing and operating conditions It is not a guide however for other than normal conditions or situations Operators and service engineers must be safety conscious and alert to recognise potential operating or servicing safety hazards at all times and take necessary precautions to ensure safe operation and servicing of the machine TCP EcoLite P User s Manual ssue B July 2010 Preliminary General e Read this operator s Handbook and learn the operating characteristics and limitations of the machine Know what operating clearances the machine requires e Know clearances of all side and overhead obstructions such as wires etc for operating safety e Be aware of operating hazards that weather changes can create on the job Know proper procedures to follow when a severe rain or electrical storm strikes e Know what safety equipment is required and use it Such equipment may be hardhat safety glasses reflector type vests respirators and earplugs e Handle fuels and lubricants carefully and clean up spills to avoid fire and slipping hazards e Never rush Walk do not run e Ensure that the area immediately surrounding the light tower is clean neat and free of debris e Position and operate light tower on a firm level surface e NEVER start a unit that is in need of repair e Lower tower when not in
30. s ineffective A8 6 Dusk Dawn Switching Function A3 AND linked Function A3 combines set switching points with the twilight times in an AND fashion The switch is On only when both sources call for power See Fig A5 A8 7 Dusk Dawn Switching Function A4 OR linked Function A4 combines set switching points with the twilight times in an OR fashion The switch is On when either source calls for power See Fig A5 Set switching points Dusk dawn switching U m eg Mm a O Q 3 AND Function A result FunctionA4 OR result 5 Fig A5 Functions A3 and A4 TCP EcoLite P User s Manual Issue B July 2010 35 Appendix A Timer and Dusk Dawn Functions A8 8 Dusk Dawn Switching Function A5 With Function A5 the switch comes On at the dusk switching point and off with the next switching oO on the following day not by the dawn CCO AE ne points Switching points programmed programmed 22 00 22 00 18 00 18 00 Dusk dawn summer 6 00 6 00 Dusk dawn winter 8 00 8 00 a ee 22 00 22 00 re ai 18 00 18 00 Executed switching time Executed switching time Table A6 Further additionally entered switching points are not executed A9 Setting Cycle Error Correction Cycle error correction can only be set when mains voltage is connected Cycle correction value the cycle precision of the time switches at room temperature 20 C is generally better than 1 second per day Higher am
31. ssue service bulletins to keep you up to date as to any improvements or changes that may take place on the complete assembly or component parts Machine Identification This manual may refer to controls and equipment that are not present on your particular machine It is important that you Know your machine and its equipment and how to operate it properly Information regarding the machine model code and chassis serial number is on the unit serial number plate Fig 1 This plate is on the front Always quote the machine model and serial number in correspondence with your dealer or the factory e PEP Te I 44 0 1621 850777 Fax 44 0 1621 843330 Taylor Construction Plant Ltd iii EC Approval No Vehicle Identification No Gross Vehicle Weight Axle Weight 1 Axle Weight 2 Fig 1 Data plate Theft Deterrence The owner operator should take the following precautions to discourage theft to aid in recovery in the event that the machine is stolen or to reduce vandalism e Remove all keys any time the machine is left unattended e Immobilise the machine by removing a critical electrical or starting system device e Upon receipt of a machine record the machine serial number and the serial numbers of all major components and attachments Keep this list up to date and filed in a safe location for fast retrieval e Place a decal or notice on the machine Stating that all serial numbers are recorded TCP EcoLite
32. t batteries and alternator leads before carrying out any welding on the machine Never check battery charge by placing metal objects across battery posts to avoid sparks at battery posts Use jumper cables only as recommended Improper use can result in battery explosion Make certain light tower is well grounded and securely fastened to a good earth ground NEVER use tower if insulation on electrical cord is cut or worn through NEVER operate lights without protective lens cover in place or with a lens cover that is cracked or damaged Pre Starting If engine is to be started and run indoors ensure proper ventilation to remove deadly exhaust gases Always perform Pre Starting Inspection instructions described in this manual to ensure the machine is ready for operation Starting Do not start the engine or operate any control if there is a DO NOT OPERATE or similar warning sign attached to any control Use jumper cables only as recommended Improper use can result in battery explosion or unexpected machine motion TCP EcoLite P User s Manual Issue B July 2010 Lubrication and Servicing Do not allow unauthorised personnel to service or maintain the machine Study the Operator s handbook and Service Manual before starting operating or servicing the machine Always relieve pressure before servicing any pressurised system Use only the special hydraulic fluid supplied by TCP Unapproved or diluted
33. the Light switches to On clockwise The lamps take a minute or two to warm up 16 Close the cover to protect the Control Panel Closing down the unit is the reverse of this procedure Before lowering the tower switch off the lights and allow time for them to cool To stop the engine turn the Key Switch to 0 1 4 1 Lowering Mast if Battery is Flat Battery power is used to lower the mast as well as to raise it If the battery is flat the mast can be lowered by manually opening the valve shown in Fig 1 5 Turn the knob counter clockwise to open the valve and lower the mast Close the valve again after the mast has come down The mast cannot be raised while the valve is open Fig 1 5 Mast Lowering solenoid valve 12 TCP EcoLite P User s Manual Issue B July 2010 Section 1 Operating Instructions 1 5 Auxiliary Supply Optional Where an input plug is fitted Fig 1 6 the lamps can be powered from a local mains supply instead of from the generator Connect the mains supply to the Aux input plug Fig 1 6 fe Output socket Fig 1 6 Auxiliary supply connectors Note To avoid depleting the battery the unit is configured so that the mast can only be raised with the engine running To use the auxiliary supply follow the instructions given in Section 1 4 Using the Lights but set the Supply Selector switch to Aux Input in Step 14 On completion turn off the generator leaving the lights powered from the Auxiliary mains input
34. urs used DETAILS OF FAILURE Give a full report on the failure ORDER NUMBER An order number will be required Note that the order number is to cover the diagnostic and call out time as well as to determine the following e That the failure is to be covered under the terms and conditions of warranty If this is the case then the costs will be covered by TCP Ltd and the order number will not be used e lf the failure is determined to be of a non warrantable nature further authorisation to continue will be sought before any rectification work takes place The information above must be provided even if your warranty claim is a parts only claim An invoice will be raised for the exchange parts The reported faulty defective part must immediately be returned to TCP Ltd and full inspection of the parts carried out if the failure is covered under the terms and conditions of warranty a credit note corresponding to the invoice will be despatched to the customer If the failure is deemed to be of a non warrantable nature the invoice should be settled immediately Certificate of Conformity Each machine is issued with a certificate of conformity that is sent to the head office of the purchaser Further copies are available on request Hatz Engine Dealers To locate your nearest Hatz dealer access the HATZ Worldwide page from the http www hatz diesel de web site Service Bulletins TCP Ltd may from time to time i
35. vening twilight times from the lat long location and time of year The twilight times can like the entered switching points be used to execute switching functions The clock varies the switching times with the time of year A8 1 Setting a Dusk Dawn Switching Function The time switch provides five Dusk Dawn Switching function A1 A5 as shown in Table A1 2 Select AO if Dusk Dawn Switching is not required 1 Press e followed by to select Dusk Dawn Switching The display will snow A0 2 Press repeatedly to select the desired function A1 A5 see Sections A8 4 Dusk Dawn Switching Function A1 to A8 8 Dusk Dawn Switching Function A5 3 Press to confirm your selection The next function Latitude will be selected and the display will show n xx North or S xx South where xx is the currently set latitude TCP EcoLite P User s Manual Issue B July 2010 33 Appendix A Timer and Dusk Dawn Functions 4 Use the button to set the parameter value Press and hold the button to advance the setting in increments of 10 Press to confirm your setting The next parameter will be displayed Repeat steps 4 and 5 for each Dusk Dawn Switching parameter Longitude Time zone Sun below horizon and Morning and Evening differentials using the and buttons as required When a Dusk Dawn Switching function has been selected the clock calculates the current twilight times These are recalculated at 0 00 h on each subsequent day A8 2 Dusk Dawn Sw
36. w lamp and refit the lens Fig 3 3 Lamp and holder TCP EcoLite P User s Manual Issue B July 2010 23 Section 3 Lamp Replacement 24 TCP EcoLite P User s Manual Issue B July 2010 Section 4 Fault finding Section 4 Fault finding 4 1 Introduction The Hatz engine is a very reliable unit dirty fuel being the most likely problem This section covers the remaining most likely problem areas Any other faults should be handled by a competent engineer referring to the Ecolite Workshop Manual 4 2 Battery Light On If the engine is running this lamp indicates that the battery is not charging Check the alternator and regulator 4 3 Oil Pressure Light On Check the oil level Section 2 2 Engine Oil Check 4 4 High Temperature Light On If the engine has been running for a while and the High Temperature light is on check the cooling fan If the Fan indicator lamp Fig 1 4 is lit check the supply to the fan 4 5 Starting ante 4 5 1 Control Lights Off On turning the key switch to I On no indicator lamps light e Check that Emergency Stop button is released Turn button in direction of arrows e Check the battery voltage as detailed below 4 5 2 Engine does not crank es Fig 4 1 Battery voltage check e Check that Supply Selector switch is set to g y 9 Off Engine will not start with this switch set to Auxiliary e Check battery as follows Measure 12V battery voltage at terminals on side of motor Fig 4 1
37. y Failure In the supply voltage is lost the switching relay s will be deactivated OFF position and the digital display switched off The relays commence working again aS programmed approximately one minute after the supply voltage has been restored Should the reserve power supply be exhausted following a prolonged supply failure the switching points will be retained indefinitely but the time day and date will have to be re entered see A10 11 Technical data A10 11 Technical data Electrical connection Internal power consumption Switching output Switching contact Number of switching points Shortest switching interval Cycle accuracy lt 1 s day 20 C Reserve power supply gt 38 hours at 20 C Supercap charging time gt 1h 5 years lithium battery Temperature limits 10 to 50 C Protection categor Il acc to EN 60335 installed Protection type IP 20 acc to EN 60529 installed TCP EcoLite P User s Manual Issue B July 2010 37 Appendix A Timer and Dusk Dawn Functions A11 Ignition Unit Settings Fig A6 shows the Ignition Unit rear panel All the dip switches except A4 should be Off Switch A4 should be On to ensure that the selected lights are powered when the ignition switch is set to Manual O O Kk WwW u Zz Ww Zz I O nm LO lt W se lt O O L W o M Fig A6 Capricorn Ignition Unit rear panel 38 TCP EcoLite P User s Manual Issue B July 2010
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