Home

Lighting Tower Workshop Manual

1. 28 3 17 Draining Fuel Tank 28 3 18 Charging the Battery 29 Section 4 Fault Finding 31 4 1 Engine will not Crank 31 4 2 Engine Cranks but will not Start 31 4 3 Battery Charging Check 31 4 4 Mast Will not Stay Up 32 Section 5 Parts Replacement 33 5 1 Recommended Tools 33 5 2 Lamp replacement 33 5 3 Housing Removal 34 SA PI ENO aaa RR DOR DOR OR AR ve b deed 34 5 5 Exhaust System seen eres renie r nia 34 5 6 Fan Replacement 35 5 7 Alternator Replacement 35 5 8 Engine Removal 36 5 9 RYGrAUC UD anne 37 5 10 AMOSS Valve Replacement 37 5 11 Mast O ring Replacement 38 5 12 Mast Seal Replacement 39 5 13 Mast Flat Bar Replacement 40 Section 6 Drawings 41 6 1 Rolling Chassis Assy TCP 2995 Sh A 41 6 2 Rolling Chassis Assy TCP 2995 Sh B 42 6 3 Upper Body Assy TCP 2870 Sh 1A 43 6 4 Upper Body Assy TCP 2870 Sh 1B 44 6 5 Upper Body Assy TCP 2870 Sh 2 45 6 6 Four head Lamp Gimbal Assy TCP 2970 SA IA salaria 46 6 7 Four head Lamp Gimbal
2. Ecolite Workshop Manual TCP 3247 01 Iss B Appendix B Options 6
3. Lighting Tower Workshop Manual TCP 3247 01 Iss B Nov 09 Taylor Construction Plant Lid Ouayside Industrial Park Bates Road Maldon Essex CM9 5FA Tel 44 0 1621 850777 Fax 44 0 1621 843330 mail tcp eu com www icp eu com Contents 2 Ecolite Workshop Manual TCP 3247 01 Iss B Contents Preliminary 5 melts A N 5 VATA E 5 HABI ea 5 Audits and Surveys 5 Service and Warranty Training 5 Warranty Terms eere rennen 9 General Excluslons 5 Warranty Claim Submission Procedures 5 Certificate of Conformity 6 Hatz Engine Dealers 6 Service Bulletins cc ee 6 Machine Identification 6 Theft Deterrenee wow aaa D Recovery of a Stolen Machine 6 SEY en e he M 7 OR T ERROR EPEE Fire Precautions une er 7 Flammable Fluid Precautions 7 ere GEET 8 EEEa 19 asia 8 SEI EE 8 Lubrication and Servicing 8 Towing Safety eretas 9 Specifications ina 9 Section 1 Description 11 id INMOOUCUON ap EIDEM 11 A A 11 LAT IQQUION zeze ins ecin 11 1 2 2 ne ele E le 12 eo Ol Pressure LIG E 12 12 4 Hours COUN lOs 12 sn 12 1 4 Road Running Lights 12 A 52 5 aono n Evo frr i
4. Crows foot 32 mm spanner The AMOSS valve is responsible for ensuring that the mast cannot be raised unless the handbrake is off It is located under the tow bar E 3 Fig 5 23 AMOSS valve 3 Section 5 Parts Replacement When removing the nuts securing the valve to the cross strut and the hose connector take care to avoid turning the 41 mm nuts on the valve as they have a very low torgue setting 5 11 Mast O ring Replacement 1 Remove the bolt securing the Light Assembly to the mast and lift the assembly off the mast using a hoist or similar 2 Atthe cap containing the faulty O ring remove the screws securing the cap Fig 5 24 qt Screws removed Fig 5 24 Hoisting mast section 3 Attach a strop to the assembly just above the cap and use a hoist or fork lift to raise the upper section by about 20 cm Fig 5 26 Fig 5 25 Removing cap 38 4 Using a hammer and copper drift tap off the cap Fig 5 25 and raise it a few cm The O ring is located just under the rim of the cap Figs 5 26 and 5 30 iso GE e KA ZMR k Fig 5 26 O ring Extract the O ring from the cap rim Carefully clean the area Remove the strop from the assembly SS S Se o Remove the O ring by stretching it and lifting it over the assembly Fig 5 27 Fig 5 27 Removing O ring Fitting a new O ring is the reverse of this procedure However Ecolite Workshop Manual TCP 3247 01 Iss B Section 5 Part
5. The Interlock relay ensures that the mast can only be raised or lowered if the 230V supply from the alternator is present meaning that the engine is running to keep the battery charged for raising the mast The function of the AMOSS valve is to prevent the unit being moved while the tower is raised A rod links the handbrake to the AMOSS valve so that if the brake is off any pressure in the mast cylinders is relieved and the mast comes down A spring operates on the valve to allow the mast to rise When the handbrake is off the rod operates against the spring to prevent raising of the mast As long as the hand brake is on the mast can be raised and lowered normally Ecolite Workshop Manual TCP 3247 01 Iss B 13 Section 1 Description 1 5 Hydraulics 14 Ecolite Workshop Manual TUP 3247 01 Iss B Section 2 Operation Section 2 Operation 2 1 Daily Pre start Inspection These instructions must be carried out to assure continuance of engine warranty Full routine maintenance procedures are given in Section 3 Maintenance 1 Ensure that the machine is ready for operation before the starting it 2 The machine should be in a level position to permit accurate checking of fluid guantities in the engine and other components 3 Open the left hand side of the engine enclosure to access to the engine for routine maintenance Note Refer to the engine manufacture s handbook for engine maintenance details 4 Engine W
6. 6 23 Mud Flap Kit TCP 3104 8 BS 4464 M5 FormB 393 SPRING WASHER METRIC SERIES 4 7 DIN6921 M5x12 01 0205 HEXAGONFLANGEDBOLT 4 6 DIN6921 M5x16 010175 HEXAGONFLANGEDBOLT 4 WASHER As 3 TCP29007 MUDELAP tt j 2 TCP 2966 MUD FLAP WITH EXHAUST CUT OUT 1 1 TCP 2965 JMUDFLAPBRACKET 2 QTY Iss A 23 09 2008 pd 4 ISO7040 M5 01 0085 JHEXNUT WITH TORQUE PART 4 Mud Flap Kit TCP 3104 Ecolite Workshop Manual TCP 3247 01 Iss B 63 Section 6 Drawings 64 Ecolite Workshop Manual TCP 3247 01 Iss B Appendix A Nut 8 Bolt Torgue Specification Appendix A Nut amp Bolt Torgue Specification 1 Specific Torgue Settings Wheels 80 90 nm Fig A 1 Light fitting torgue settings 2 Generic Torgue Settings Bolts not defined above should be tightened to the torgue settings listed in Table A 1 Friction coefficient total 0 14 for screws and nuts without after treatment as well as for phosphate nuts Tighten by hand If nothing special is indicated select correct torque limits from the following tabulations 8 8 10 9 12 9 Standard Hex Bolt Some Engine Bolt Standard Cap head 49 664 69 609 es 0 8 8 2 295 E 1200 Table A 1 Torque settings for Metric ISO Thread DIN 13 Ecolite Workshop Manual TCP 3247 01 Iss B 65 Appendix A Nut 8 Bolt Torgue Specification 66 Ecolite Workshop Manual TCP 3247 01 Iss B Appendix B Options
7. E WE a 230V AC FS3 10A RELAY 1A FUSE IRAISE LOWER SWITCH ca PUMP SOLENOID died COURTESY LAMP HYDRAULIC PUMP E MOTOR Version with 110V CTE out les B Circuit Diagram 3110 04 Ecolite Workshop Manual TCP 3247 01 Iss B 57 Section 6 Drawings 6 18 Cable Identification and Termination Sh 1 i WET NIZ gt gt B AC X O EE Sr TTT pE 7 c RRE S oo S 01 34 BZ 2N E e H TEE CONTROL BOX BASE UNIT CHANGEOVER SWITCH CONTROL PANEL Cable Identification 8 Termination 3111 Sh 1 Iss B 58 Ecolite Workshop Manual TCP 3247 01 Iss B 6 19 Cable Identification and Termination Sh 2 a Taar s cone voe Wa Lei s cone 71005 am ra A R 8 1 5mm 2 CORE 15mm 1 CORE 73 3071 14 15 16 17 anta Bs CTDSTIGTEY EP dv FRE TW 2 z WO TES kO 25 s3 C C OOOOOODOOOO ALIHM MOVIE 0 a z m rm ama NMOYA CN lt COURTESY LIGHT ama TJA NNO NMOHA Section 6 Dravvings c aw p O and TO ENGINE SOUND BOX Fr MONTOS WHEN FITTED ISOLATOR O78 BATTERY 12V D C 0000909099999 o i DOO DO 2 w 3 2 w 2 w 2 w E 2 S RZ S ZERSH E m Z m Z m D Ar DGA o 5 a l a_i E Bee SE E gt AAA zme HESE E Lott E sarai AUX AUX 240v 240v INPUT DUTPU NMOYA ania NMOUA w E c
8. Engine oil level See Section 3 9 Engine Oil Check Fig 3 1 Engine side panel 24 Ecolite Workshop Manual TUP 3247 01 Iss B 3 10 Engine Oil Filter Clean the oil filter after every 1000 operating hours 1 To gain access to the oil filter it is necessary to remove the side panel from the engine Fig 3 1 shows the side panel and some of the fixing screws The oil filter is located near the bottom of the engine Fig 3 3 Fig 3 3 Engine oil filter 2 Use anAllen key to remove the filter Fig 3 4 and extract it Fig 3 5 3 Wash out oil filter with degreaser Replace filter if damaged 4 Check joint washers Fig 3 6 Replace if necessary Lubricate joint washers before fitting Insert filter to limit of travel Ensure that tension springs Fig 3 7 sit close to filter before tightening screw I Fig 3 4 Unscrewing oil filter Ecolite Workshop Manual TCP 3247 01 Iss B 7 Section 3 Maintenance Fig 3 7 Oil filter spring Unless doing an oil change check oil level and top Up as necessary 25 Section 3 Maintenance 3 11 Engine Oil Change Parts Oil filter TCP Change the oil every 250 operating hours Take care that no contamination enters the sump 1 Ensure that the unit is level 2 Run the engine until it is warm 3 Clean the area around the oil filler cap dipstick Remove the filler cap dipstick Fig 3 8 Attach a suitable tube to the oil evacuation pump and route it t
9. HT w resoa oso EXHAUSTHEATSHIELDASSY 1 Do fresco fiasco reme HR 8 rero 613063 s BSP TO mm ROSE BARB TO MALE 1 7 fresco ersoe sea BSP 90 ELBOW MALE FEMALE 1 6 rors rsos 38S TO smm HOSE BARSTO MALE 1 Dos repate 14005 rmmioruet ose 17 Da reze a ra MATZINLINEFUELFLTER prop zese rese zvracerruec pune 2 roe RT rue river cap UAT r romae ees retas AT Iss B 12 08 2008 Stock No 2867 SA Fuel Tank Assy TCP 2867 50 Ecolite Workshop Manual TCP 3247 01 Iss B 6 11 Hydraulic Schematic Section 6 Drawings H Il Ju 7 v2 MAST LOWERING CHECK i MAST PUMP 45LYMin VALVE EE Sg A i 12V DC H MOTOR 5 gt e K 4 ll 5 V d V1 AMOSS en VALVE V3 HANDBRAKE OFF SUCTION AR FILTER gt v HYDRAULIC TANK HYDRAULICS SCHEMATIC Ecolite Workshop Manual TCP 3247 01 Iss B TCP 3127 Sh 1 les A 51 Section 6 Drawings 6 12 Hydraulic Assy Layout TCP 3010 Solenoid 18 alve 15 m x 16 20 ER 11 21 Return SCH 9 to tank 5 1 8 14 AMOSS return 12 13 Main supply and return 9 2 AMOSS valve 2 AMOSS valve 2 620011 1 2INCH BONDED WASHER A 21 620135 3 4 SWEPTELBOWMALE FEMALE 1 TE L re E 19 TCP 2989 _ 62 289 1 2 TO 3 4 M F SWIVEL ADAPTOR mim 18 TCP 3
10. Iss B 33 Section 5 Parts Replacement 5 3 Housing Removal The housing is held in place by the lifting frame 1 Release the lifting frame by removing the two bolts at the rear Fig 5 4 and the single bolt at the front Fig 5 3 2 f necessary disconnect the licence plate wiring 3 Remove the lifting frame and lift off the housing Refitting is the reverse of this procedure Lifting frame Lifting frame Fixing bolts Fig 5 4 Lifting frame rear fixing 5 4 Air Filter Parts Air filter element Safety element TCP 10 0273 TCP 10 0274 Fig 5 5 Air filter cover removal 34 Fig 5 7 Safety element 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 Unscrew the air filter cover Fig 5 5 Extract the filter element Fig 5 6 Extract the inner safety element Fig 5 7 Replace filter if damaged or dirty o om A Mm Reassemble the filter assembly 5 5 Exhaust System A WARNING The ceramic wrapping on the exhaust pipe is toxic possible low risk carcinogenic Minimise dust release and use appropriate personal protection eguipment when handling it Parts 10 2924 Silencer 10 3003 Exhaust Flexible Pipe 10 2962 Exhaust Elbow 10 2878 Exhaust Outlet Pipe 10 3032 Si
11. a credit note corresponding to the invoice will be despatched to the customer lf 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 reguest 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 issue 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 eguipment that are not present on your particular machine It is important that you know your machine and its eguipment 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 guote the machine model and serial number in correspondence with your dealer or the factory Tol 44 0 1621 B507TT Fax dl 01621 843330 EC Approval No Vehicle Identification No Gross Vehicle Weight Axle Weight 1 Axle Weight 2 H Fig 1 Data plate Theft Deterrence The owner operator should take the following precautions to discourage theft to aid in recovery in the even
12. adhered to TCP Ltd will not pay for normal maintenance or servicing nor any materials used to carry out routine servicing Ecolite Workshop Manual TCP 3247 01 Iss B 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 breach 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 reguired Training can be carried out at a 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 equip
13. in a slot at the bottom of the assembly The new bar will be seen to be slightly bowed Orient the bar so that it bows out at the centre When in place it will thus be supported by the outer cylinder 6 Smear some thick grease on the outer surface of the top of the bars and press them against the cylinder The grease is intended to keep the bars in position until they can be engaged with the top slots Ouickly and carefully lower the assembly with the correct orientation into the cylinder and position it so that the bars fit into the designated slots If the bars come adrift repeat the procedure Reassemble the unit Ecolite Workshop Manual TCP 3247 01 Iss B Section 6 Drawings 20 21 22 16 16 17 TCP 2384 30 0050 ISO 7040 M5 01 0085 BS 4320 M5 Form A 02 0013 ISO 7045 M5 x 20 4 8 Z 01 0190 DIN 9021 13 NS AS SUPPLIED ISO 4032 M6 01 0081 BS 4320 M6 Eorm A ISO 10642 M6 x 30 01 0178 ISO 7040 M20 01 0046 24 BS 4320 M20 Form A 02 0047 ISO 4014 M20 x 130 01 0186 ISO 4017 M16 x 45 01 0185 BS 4464 M16 Form B 02 0046 20 Bs4320 M16 FormA 02 0025 ISO 4014 M12 x 100 01 0184 ISO 4017 M12 x 35 01 0183 ISO 7040 M12 01 0038 BS 4320 M12 Form A 02 0021 ISO 4762 M12 x 35 01 0024 6 1 Rolling Chassis Assy TCP 2995 Sh A FOAM STRIP 30 X 6 HEX NUT WITH TORQUE PART BRIGHT METAL WASHER METRIC SERIES PAN HEAD SCREW GRADE A WASHER HEXAGON FULL NUT BRI
14. the suspect seal Also check replace the O ring 5 Carefully clean the area and apply water resistant grease 6 Check replace the seals and O rings on the remaining caps that have been removed Ecolite Workshop Manual TCP 3247 01 Iss B 39 Section 5 Parts Replacement 7 Refit the caps as described in Section 5 11 Mast O ring Replacement However e Ensure that the orientation of each cap is correct as marked Fig Error Reference source not found e Use the guide jigs as shown in Fig 5 32 These compress the inner pressure seal so that the cap will fit over the tube Seal guide jig 5 Fig 5 32 Fitting a cap 40 5 13 Mast Flat Bar Replacement Within each cylinder of the mast two flat bars connect upper and lower sections to maintain their alignment The bars are not fixed in place but sit in slots at top and bottom To replace a bar proceed as follows 1 Remove the bolt securing the Light Assembly to the mast and lift the assembly off the mast using a hoist or similar Mark the caps with Tipex or similar to ensure that they can be refitted with the correct orientation Fig Error Reference source not found Attach two strops to the cap where the problem lies and hitch them to a hoist Fit the strops in such a way as to ensure horizontal stability Hoist the mast section clear of the remainder to reveal the two flat bars Remove the faulty bar and replace it with a new one he barsits
15. 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 Ecolite Workshop Manual TCP 3247 01 Iss B Replace all missing and hard to read labels Labels provide important operating instructions and warn of dangers and hazards Make sure slings chains hooks ramps jacks and other types of lifting devices are attached securely and have enough weight bearing ca pacity to lift or hold the equipment safely Always remain aware of the position of other people around you when lifting the eguipmeni Towing Safety Towing a trailer reguires care Both the trailer and vehicle must be in good condition and securely fastened to each other to reduce the possibility of an accident Check that the hiteh and coupling on the towing vehicle are rated egual to or greater than the trailer s gross vehicle weight rating GVWR Inspect the hitch and coupling for wear or damage DO NOT tow trailer using defective parts Make sure the coupling is securely fastened to the vehicle Check tyres on trailer for tread wear inflation and condition Connect breakaway safety line securely to towing vehicle Make sure directional reverse and trailer lights are connected and working properly Check that wheel nuts are tight and that none are missing Maximum recommended speed for high
16. 016 030204 JUBILEEHOSECLIP 18 25mm 2 17 TCP 3015 62 3015 Tad INCH ID RUBBER HOSE SAE100R6 64mm 16 TCP 3011 62 3011 34INCHSWEPTS0ELBOW 2 15 TCP 2981 60 2981 34 INCH 12 VOLT SOLANOID VALVE 1 14 TCP 2979 6229799 3MINCHMALETEE A 13 TCP 3013 62 3013 MAIN SUPPLY AND RETURN HOSE 1 12 TCP 3014 623014 1 AMOSSHOSE A 11 TCP 2251 62 0013 3 4 INCH BSP MALE MALE ADAPTOR 2 10 TCP 2180 62 0158 3MINCHBSPHOSETAL 2 9 16P 3057 623057 sa INCHM F COMPACTELBOW 1 8 TCP 2252 620144 8 4 INCH BULKHEAD ADAPTOR NUT 2 7 820134 3 4 INCH BULKHEAD ADAPTOR CW NUTS 1 6 TCP 2796 10 0082 JUBILEEHOSECLIP30 40mm_ 2 5 TCP 2389 620014 Tad INCHBONDEDWASHER 8 4 TCP 2467 620132 Taid INCH MALE FEMALE SWIVEL 2 3 62 013 St RUBBER HOSE SAE100R 136 lo 2 TCP 2151 60 0064 Taa BSP3WAYBALLVALVE CAST 1 1 TCP 1961 62 0133 3 4BSPP 90 ROTARY COUPLING 1 ITEM DRG No STOCKNo KIT DESCRIPTION ary Iss B 24 10 2008 Hydraulic Assy Layout TCP 3010 B2 Ecolite Workshop Manual TCP 3247 01 Iss B Section 6 Drawings 6 13 Hydraulic Tank TCP 2862 HEXAGON HEAD SCREW HEX NUT WITH TORQUE PART TY Iss B 11 07 2008 Stock No 2862 2 1 0 1 9 A 6 BS 4320 M8 Form A 02 0011 BRIGHT METAL WASHER METRIC SERIES Ka TCP 2862 Hy
17. 1 Maintenance Intervals 3 1 General Lubrication is an essential part of preventive maintenance It is important that the instructions regarding types of lubricants and the frequency of their application be followed to prolong the useful life of the machine Periodic lubrications of moving parts reduce mechanical failures While servicing thoroughly clean all fittings caps plugs etc to prevent dirt from entering the system Lubricants must be at operating temperatures before draining Do not operate any system unless oil level is within the operating range as indicated on the dipstick or level plug All change and service periods are recommendations based on average operating conditions Lubricants showing evidence of excessive heat oxidation or dirt should be changed more frequently to prevent these conditions Lubricants change and service periods must be established on the basis of individual job conditions 3 2 Engine Maintenance Since the workshop manual provided by the engine manufacturer contains comprehensive information on servicing the engine this Routine Maintenance section only provides information on the engine for daily servicing and where it differs from the standard application covered by the engine workshop manual Refer to the manufacturer s manual for all other information and instructions relating to the engine Ecolite Workshop Manual TCP 3247 01 Iss B 3 3 Safety Precautions Do not all
18. 3247 01 Iss B 45 Section 6 Drawings 6 6 Four head Lamp Gimbal Assy TCP 2970 SA ShA 20 IS04014 Miox80 01 0188 HEXAGON HEAD BOLT PRODUCT GRADES A and B 19 Sp 7040 Min 01 006 HEX NUT WITH TORQUE PART eki 18 BS 4320 M8 Forma 02 0011 BRIGHT METAL WASHER METRIC SERIES 2 17 TCP 1000 80 0040 DECAL WARNING HOT SURFACE 4 16 TCP 109 o o 80 0041 SC DECAL WARNING LAMP GLASS BROKEN 4 15 is07040 M20 o1 0046 HEXNUTWITHTORGUEPART _ 6 14 iso7040 M4 01 0019 JHEXNUTWITHTORQUEPART 1a 13 BS 4320 MA Forma _ 02 0028 BRIGHT METAL WASHER METRIC SERIES 4 12 150 7045 M4x16 4 8 2 01 0552 PANHEADSCREW GRADEA 4 11 iso7o40 M12 01 0028 JHEXNUTWITHTORQUEPART 8 10 D2812215 40 0022 M12DISKSPRINO 16 9 rcP 2181 __ 720088 JBOOSTERLAMP 150Wx9330mm 1 4 8 D4o20425 40 0000 M20DISKSPRINO 12 7 rcP 180 st 0307 JLAMPSUPPORTBRACKETEIXED 1a 6 rCcP 4053 514105 FRICTION WASHER GIMBAL TEEBAR 4 5 rcP 2137 _ 2 amp 019 M25 CABLE GLAND o RAN 4 rcpP 2113 iR3880 M15CABLEGLANDNUT 4 3 rcP 2112 IR3375 LMISINDEXCABLE GLAND 4 2 rcP2192 _ 71 0230 JJUNCTONBOX 1 1 rep4046 514105 GIMBALTEEBARASSY LI Iss A 29 09 2008 Stock No
19. 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 12 switch to position 0 before retrying 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 Ecolite Workshop Manual TCP 3247 01 Iss B 2 8 Redirecting the Lights 13 Raise the tower by turning the Tower switch clockwise and holding it there 14 Release the Tower switch when the lights reach either the reguired 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 Sections 5 11 Mast O ring Replacement and 5 12 Mast Seal Replacement 15 Set the Supply Selector switch if fitted to Generator 16 Set the Light switches to On clockwise The lamps take a minute or two to warm up 17 Close the cover to protect the Control Panel Closing down the unit is the reverse of this procedure Before lowering the tow
20. Assy TCP 2970 SA IE 47 6 8 Jack Leg Assy TCP1655 48 6 9 Jack Leg TCP 2064 49 6 10 SA Fuel Tank Assy TCP 2867 50 6 11 Hydraulic Schematic 51 6 12 Hydraulic Assy Layout TCP 3010 52 6 13 Hydraulic Tank TCP 2862 53 6 14 Basic Unit Circuit Diagram 3110 01 54 6 15 Circuit Diagram with 230V Output 55 6 16 Circuit Diagram 230V In and Out 56 6 17 Circuit Diagram 110V CTE Out 57 6 17 Cable Identification and Termination Sh 158 6 17 Cable Identification and Termination Sh 259 6 18 Control Box Assy Tank Mounted TCP 9200150 15 e A 60 6 19 Battery Kit TCP 3034 SA 61 6 20 Interior Light Assy TCP 3059 SA 62 6 21 Mud Flap Kit TCP 3104 63 Contents Appendix A Nut amp Bolt Torgue Specification 65 1 Specific Torque Settings 65 2 Generic Torque Settings 65 Appendix B Options Ecolite Workshop Manual TCP 3247 01 Iss B 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 Iong term service This manual is intended to serve as
21. DESCRIPTION i U SH peg pea Los Z IN kd E RN E TCP 2995 SA Rolling Chassis Assy A 50 mm Pressed Steel Head 41 Section 6 Drawings 6 2 Rolling Chassis Assy TCP 2995 Sh B 130 0050 FOAMSTRIP30X6 HEX NUT WITH TORQUE PART 29 DIN 9021 13 NS 2 ISO 4032 M6 27 BS 4320 M6 Form A ISO 7040 M20 24 BS 4320 M20 Form A ISO 4017 M16 x 45 20 BRIGHT METAL WASHER METRIC SERIES 19 1SO 4014 M12 x 100 HEXAGON HEAD BOLT PRODUCT GRADES A and 18 z HEXAGON HEAD SCREW 17 01 0038 HEX NUT WITH TORQUE PART 16 BRIGHT METAL WASHER METRIC SERIES 15 HEXAGON SOCKET HEAD CAP SCREW 14 TCP 1983 REFLECTOR WHITE 502982 BRAKE ROD KNOTTIECOLITE Omm COUPLING 1000 kg PRESSED STEEL HEAD ACK LEG ASSY ACK LEG STOP IFTING FRAME 50 2900 50 2982 HASSIS FRONT 60mm 2 0245 50 2982 OCKEY WHEEL HEEL BOLT 165R13 WHEEL 8 TYRE ASSY EGOLITE AXLE ASSY 5X 112 38mm SPHERICAL BLANKING PLUG 60mm SPHERICAL BLANKING PLUG CHASSIS WELDMENT DESCRIPTION DID 12 11 10 1 1 1 LU nai l O o I o s ne O l m N o KO mg kel bal al kl kal bal kal kaf kal kal bs OIOTO L OOOO L L 9 FNP TMT HTN IN ID IN eo lG e oo oo oi TO I lO PD jt Pole so joo jt ini co ciale IS S S JOJO I Jon LD gt o PI ru o e E T an n LO OD NG SILID LL ID lt O O N3 e o e N A Q Iss A 10 09 2008 Stock No SA 2995 TCP 2995 SA Rolling Chas
22. GHT METAL WASHER METRIC SERIES 50 2982 0 2982 HEX NUT WITH TORQUE PART BRIGHT METAL WASHER METRIC SERIES HEXAGON HEAD SCREW SPRING WASHER METRIC SERIES BRIGHT METAL WASHER METRIC SERIES HEXAGON HEAD SCREW HEX NUT WITH TORQUE PART BRIGHT METAL WASHER METRIC SERIES HEXAGON SOCKET HEAD CAP SCREW OPPO APO nino ion aoc PIPIPIPIPIPIPIPIPIPIP cio PO N3 PO LOS DSJ DSJ SJ LSB IN DSJ n2 NIN Ba ho PO Cox el Kiel Kieg NG O OJO O O CO Io o O O do Go Go Go Co O2 1001 co Oo co co o Oo o oo co ROP PR IB PRS IND IND DOS in PR n2 mim PI IN po HEXAGON SOCKET COUNTERSUNK HEAD SCREW HEXAGON HEAD BOLT PRODUCT GRADES A and HEXAGON HEAD BOLT PRODUCT GRADES A and ANT IST Section 6 Drawings Ing a o 1 59292 BRAKERODIKNOTNECOGTE Ct 11 repiess O 50 0056 50 202 JACKLEGASSY 1 4 10 TcP 2046 sooos0 so 2e22 JACKLEGSTOP Le 19 rCP 2899 50 2899 s0 2982 LIFTING FRAME 1 TCP 2900 50 2900 7 TCP 1998 5 TCP 1934 3 TCP 2907 2 TCP 1979 TCP 1997 1 TCP 2905 50 2905 50 2892 CHASSIS WELDMENT ITEM DRG No STOCK No Iss A 10 09 2008 Stock No SA 2995 Ecolite Workshop Manual TCP 3247 01 Iss B rcP 1998 _ 220245 TCP 2810 2 0152 2 0247 HASSIS FRONT 60mm OCKEY WHEEL HEEL BOLT 65R13 WHEEL 8 TYRE ASSY EGOLITE AXLE ASSY 5 x 112 38mm SPHERICAL BLANKING PLUG 60mm SPHERICAL BLANKING PLUG KIT
23. SA 2970 TCP 2970 SA Ecolite 330 Four lamp Gimbal Assy Sh A 46 Ecolite Workshop Manual TCP 3247 01 Iss B Section 6 Drawings 6 7 Four head Lamp Gimbal Assy TCP 2970 SA Sh B 20 01 0182 HEX NUT WITH TORQUE PART 1 DECAL WARNING HOT SURFACE 4 DECAL WARNING LAMP GLASS BROKEN 4 01 0046 HEX NUT WITH TORQUE PART 6 01 0019 HEX NUT WITH TORQUEPART 4 di EM EA p Lo i E E Z 02 0028 BRIGHT METAL WASHER METRICSERIES A EA E p mi BS 4320 M8 Form A 02 0011 TCP 1090 80 0040 2 ISO 7040 M10 01 0006 TCP 1091 80 0041 12 ISO 7045 M4 x 16 4 8 Z 01 0152 9 TCP BOOSTER LAMP 150Wx 330mm_ 4 8 D4020425 1 0307 LAMP SUPPORT BRACKETFIXED 4 6 TCP 453 _ _ 514105 FRICTION WASHER GIMBAL TEEBAR 4 N25CABLEGLAND 1 4 j rCP2113 _ Jirasso MISCABLEGLANDNUT 0 0 4 3 j TCP 2112 iR3375 M15 INDEX CABLE GLAND 4 2 j TcP 21922 _ 710250 X JJUNCTIONBOX LT reposo 614105 GIMBALTEEBARASSY LI Iss A 29 09 2008 Stock No SA 2970 D2812215 TCP 2181 TCP 2970 SA Ecolite 330 Four lamp Gimbal Assy Sh B Ecolite Workshop Manual TCP 3247 01 Iss B 4 Section 6 Drawings 6 8 Jack Leg Assy TCP1655 114 ISO 13337 6x12 020045 Spring tyn rep G GUIDE PIN E 2 repterr 500087 JACKLEGTUBE A Iss E 12 03 2008 Jack Leg Assy TCP 1655 48 Ecolite Workshop Manual TCP 3247 01 Iss B Sectio
24. a 13 Section 2 Operation 15 2 1 Daily Pre start Inspection 15 2 2 OSM Jane cde dsas AA 15 2 3 H aeeie ae t ronnie 16 2 4 Jacking up the Unit 17 2 5 Using the Lights 18 2 6 Auxiliary Supply Optional 19 2 7 Moving the Trailer 19 2 8 Redirecting the Lights 20 29 M Ta Tee PA AA 20 2 10 Emergency Stop 20 2 11 Starting the Engine with Jumper Cables 21 2 12 Battery Charging 21 Section 3 Maintenance 23 ON EE ee 23 3 2 Engine Maintenance 23 3 3 Safety Precautions 23 3 4 Maintenance Intervals 23 3 9 DEVICE ACCESS nu 23 3 60 EUDICANON He 24 3 7 General Inspection 24 Ecolite Workshop Manual TCP 3247 01 Iss B Contents 3 8 Daily Check 24 3 9 Engine Oil Check 24 3 10 Engine Oil Filter 25 3 11 Engine Oil Change 26 3 12 Hydraulic Fluid 27 3 13 Fuel Filters 27 3 14 Tresen 28 3 15 Engine Conditioning 28 3 16 Inertia Brake
25. a manual for workshop engineers It assumes an engineering knowledge commensurate with tasks that will be undertaken in a workshop For completeness the manual incorporates operating instructions necessary to familiarise the operator and service engineer with the controls recommended inspections start up operating and shutdown procedures for the eguipment 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 changes 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 eguipment 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 strengih 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 reguirements as set out and detailed by the manufacturer have not been
26. adjustments to the position of the unit and apply the parking brake by pulling the lever upward to the limit of its travel Coupling the unit to a towing vehicle is the reverse of this procedure Before moving off check the tyres and check that the lights on the trailer work 16 Trailer lighting connecto i Breakaway cable Towing cup Fig 2 2 Parking brake Ecolite Workshop Manual TCP 3247 01 Iss B Section 2 Operation Fig 2 3 Jack components 24 Jacking up the Unit 2 Pull out the Outrigger Locking Pin Fig 2 5 and pull the Jack Leg away from the body of Jack up the unit as follows Start with the jack the unit to its fullest extent Fig 2 6 that is on the highest ground 1 Hold the Jack Leg with one hand and pull the Rotation Locking pin to release the leg Allow the leg to fall to the vertical position Ensure that the pin locks the leg in the vertical position Fig 2 4 REI D J x gt Ce aa P B l e x NV ka re Fig 2 4 Jack vertical Fig 2 5 Extending the jack Ecolite Workshop Manual TCP 3247 01 Iss B 17 Section 2 Operation 3 Wind the foot of the jack down to the ground Fig 2 7 Fig 2 7 pam up Repeat the procedure for all four jacks so that the unit is stable and level Do not use the jacks to raise the tyres off the ground 2 5 Using the Lights 1 Check that the brake is on Note that the mast cannot be raised if the brake is off Check th
27. agments 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 e 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 e Check the engine for rubbish oily rags or other debris that could cause fires before starting the engine e Safely dispose of greasy oily rags or similar hazards Flammable Fluid Precautions e 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 e Don t use diesel fuel or other flammable fluids for cleaning purposes Use approved non flammable solvents e Make sure all fluid systems caps drain valves fittings lines etc are secure and leak free e Shut off engine and use extra caution if engine is hot when refuelling Preliminary 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 inhibito
28. at the brakes are operating correcily on both wheels by attempting to move the trailer 2 Check that the light lenses are clean and undamaged 3 Drive the earth spike Fig 2 14 into the ground earth follow any risk assessment Check that the earth spike cable is securely attached to the unit 4 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 18 Engine temperature high 4 TI a RCD Lights Aux Supply selector meter test MCB MCB switch Light on off mow ena TOWEL switch Si a raise lower Fig 2 13 Control panel Engine running OK Battery not charging Low oil pressure Not used i Not used Fig 2 14 Ignition panel Note Fig 2 13 shows a 230V machine with an 10 11 auxiliary output The mcb configuration on other versions will be different 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 The Battery and Oil Pressure lights adjacent to the switch should light Turn the key to position 2
29. awy Use appropriate lifting eguipment and or get the necessary help 1 Ensure that the engine is switched off Remove and pocket the key 2 lsolate the battery by disconnecting the negative terminal of the battery 3 Remove the enclosure as detailed in Section 5 3 Housing Removal 4 Remove the four bolts securing the engine pod to the Ecolite chassis 5 Disconnect the lead to the alternator from the terminal block attached to the underside of the plate on the top corner of the engine pod Fig 5 12 and extract the lead from the engine pod Air filter Alternator connector block Fig 5 12 Alternator connector block 6 Disconnect the exhaust at the elbow where the pipe leaves the engine pod 36 10 11 Fig 5 13 Engine exhaust outlet Disconnect the fuel lines Fig 5 14 Fuel lines Disconnect the concertina duct from the engine extractor fan Fig 5 15 Engine extractor duct Attach the hoist straps to the lifting eyes of the engine pod Lift the pod out and deposit it on a bench working area Remove the two screws securing the dip stick and pump assembly to the panel J Dipstick DR a securing screws UW Fig 5 16 Dipstick securing screws 6 Ecolite Workshop Manual TCP 3247 01 Iss B 12 Tip the engine pod on its side to reveal the sump cover 13 Disconnect the sump adaptor from the dip stick assembly Fig 5 18 x SH Sum 4 cover z Pi L j Su
30. bles only as recommended Improper use can result in battery explosion or unexpected machine motion 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 fluid could freeze in cold conditions resulting in damage to the eguipment 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 gualified 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
31. d all serial numbers Ecolite Workshop Manual TCP 3247 01 Iss B Report the model and serial numbers of the stolen machine to a dealer handling the respective line of eguipment Reguest that the dealer forward this same information to the equipment manufacturer Safety Report all malfunctions to those responsible for maintenance Do not operate the eguipment until corrected Normal service or maintenance performed as reguired can prevent unexpected and unnecessary down time This handbook describes general inspections servicing and operation with the normal safety precautions reguired 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 General e Read this operators 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 hardha
32. draulic Tank Ecolite Workshop Manual TCP 3247 01 Iss B 53 Section 6 Drawings 6 14 Basic Unit Circuit Diagram 3110 01 Ke X m 150 WATT TIT d PRISMALENCE SCH LAMPS XX TO HATZ 1B20 STARTER MOTOR amp ALTERNATOR 12V 230V AC 10A RELAY E LOWER euren SOLENOID Imst LOWER AYDRAULIC AVE PUMP a MOTOR 54 x COURTESY r e 1B20 1B20 BEZ SWITCH LAMP 384 WIRE 7 WIRE 1 BLUE BROWN SWITCH EMERGENCY LAMP 1 amp 2 STOP 230V RCD N 30mA 230V HOUR METER E FS2 E 1A FUSE mine b GENSET ALTERNATOR N Basic Unit Circuit Diagram 3110 01 E LAMP 8 Iss B Ecolite Workshop Manual TCP 3247 01 Iss B 6 15 Circuit Diagram with 230V Output WHITE maa BLACK SWITCH _ 150 WATT ska sma LAMP 3 amp 4 PRISMALENCE SCH e LAMPS ang BROWN SWITCH LAMP 182 TO HATZ 1B20 STARTER MOTOR 8 ALTERNATOR 12V 230V RCD i SOMA 230V AC Ca 10A RELAY 15A FUSE RATSE LOWER SWITCH SOLENOID x COURTESY MAST LAMP LOWER i HYDRAULIC MENE PUMP MOTOR Iss B Ecolite Workshop Manual TCP 3247 01 Iss B Section 6 Drawings HATZ HATZ 1B20 1B20 WIRE 7 WIRE 1 EMERGENCY STOP Auxiliary Outlet Socket 230V 230V HOUR METER FS2 1A FUSE 230V GENSET ALTERNATOR Version with 230V Output Circuit Diagram 3110 02 55 Section 6 Drawings 6 16 C
33. ed carbon deposits The 2 6 kW can comprise a 2 kW load connected to the Auxiliary Supply output plus 600W for the lights 28 3 16 Inertia Brake The inertia brake applies the trailer brakes when the towing vehicle brakes Apply medium multipurpose grease to the nipples Fig 3 14 Fig 3 14 Inertia brake grease nipples The frequency of greasing depends on the extent of towing If the trailer is towed frequently with frequent braking the brake will need more frequent greasing than if the brake is seldom used Inspect the brake every three months If adequate lubricant is showing grease annually 3 17 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 Fita polyethylene tube diameter 4 mm length 700mm approx to a commercial syringe 20 ml or larger 2 Remove the diesel filler cap and run the tube down to the bottom of the tank 3 Drain off the fuel water mixture with the syringe 4 Repeat the procedure until the transparent syringe is found to contain only diesel fuel Ecolite Workshop Manual TCP 3247 01 Iss B Section 3 Maintenance 3 18 Charging the Battery The battery can be charged by means of a standard 12V car battery charger Connect the charger between positi
34. er switch off the lights and allow time for them to cool To stop the engine turn the Key Switch to 0 2 6 Auxiliary Supply Optional Where an input plug is fitted Fig 2 15 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 2 15 Output socket Fig 2 15 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 Ecolite Workshop Manual TCP 3247 01 Iss B Section 2 Operation To use the auxiliary supply follow the instructions given in Section 2 5 Using the Lights but set the Supply Selector switch to Aux Input in Step 15 On completion turn off the generator leaving the lights powered from the Auxiliary mains input 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 2 7 Moving the Trailer The trailer cannot be moved with the tower raised Releasing the brake causes the tower to telescope down To move the trailer 1 Turn off the lights and allow time for them to cool Lower the tower Ensure that the jockey wheel is down and locked so that the unit will not tip over when the jacks are removed 4 Raise retract and stow the four jacks Ensure mast rotation clamp is secure to prevent movement in transit The uni
35. ess Fig 2 14 Rotation lock 20 Fig 2 16 Facade illumination 2 9 Parking A WARNING when parking the machine overnight or for an extended period the following procedure will help maintain it in good condition 1 To prevent condensation from contaminating the fuel fill the fuel tank completely before parking the machine overnight or for extended periods If a security kit is supplied keep it locked 2 Park on level ground where possible If it must be parked on a slope position machine at right angles to the slope and block tracks securely 3 Remove key to a place of safety 2 10 Emergency Stop The Emergency Stop button Fig 2 18 shuts off the engine in under 20 seconds m sda DANGER ser 5 ALL JACKS FIRMLY TO UND AND INSTALL GROUNDING F 1o o gt BEF ORE STARTING ENGINE Fig 2 18 Emergency Stop button Ecolite Workshop Manual TCP 3247 01 Iss B 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 There is also an emergency stop inside the cover Fig 2 20 Pull the knob to cut off the fuel to the engine which will stop after a short delay 2 11 Starting the Engine with Jumper Cables For jump starting jumper cables can be connect can be connected to stud terminals on the side of the engine compartment Fig 2 20 To access these terminals open the le
36. fluid has become diluted drain the tank as described for the fuel in Section 3 17 Draining Fuel Tank and refill with the prescribed TCP fluid Take care not to mix fuel and hydraulic fluid 3 13 Fuel Filters Parts In line fuel filter TCP 14 0131 Fixed fuel filter TCP 14 0128 A WARNING 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 Dirty or contaminated fuel will damage the engine For this reason three fuel filters are fitted as follows Two fuel filters are fitted one on top of the fuel tank in the line to the fuel pump Fig 3 12 and the other mounted on the side of the engine compartment Fig 3 13 Replace the in line filter after 250 hours of operation and the fixed filter after 500 hours Hydraulic pump tp D s ci Hydraulic tank cap Pan Fig 3 11 Hyaraulics Ecolite Workshop Manual TCP 3247 01 Iss B 2 Section 3 Maintenance In line fuel filter Fuel tank Fig 3 12 In line fuel filter Fig 3 13 Fixed fuel filter 3 14 Tyres Check the condition of the tyres They should meet local wear regulations if used on public roads Check the tyre pressures They should be 2 5 bar 35 psi 3 15 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 accumulat
37. ft hand side of the enclosure Do not jump start a vehicle by using arc welding eguipment Currents and voltages are dangerously high and cannot be sufficienily reduced to make the method safe Be sure machines are not touching each other Use cables that are the same size as those on the machine If jumper cables are used to start an engine be sure to follow this procedure 1 Connect one end of the jumper cable usually coloured red to the battery supply stud terminal Fig 2 20 gi ci Emergency stop pull WIER n Battery supply E stud terminals 2 Connect the other end of the same cable to the POSITIVE post on the booster or charged battery 3 Connect one end of the second cable usually coloured black to the NEGATIVE post of the booster battery 4 Connect one end of the jumper cable to the battery supply stud terminal or to a convenient point on the engine frame Ecolite Workshop Manual TCP 3247 01 Iss B Section 2 Operation 5 Keep grounding point clear of battery so that if a spark occurs it is away from battery fumes explosive hydrogen 6 Locate cause of battery failure 2 12 Battery Charging If the battery is not being charged properly refer to Section 4 3 Battery Charging Check The battery can be charged from the mains as detailed in Section 3 18 Charging the Battery Charging of Odyssey Batteries Check polarity of discharged battery connecti
38. ircuit Diagram 230V In and Out 5 Dr Es me SL Cd E Z I to LE f a r3 O LLI LLI gt E e r1 E Es L Jo gt ZR h Z x Zz 323 2G Zz u T O Zdj di lt a tz Y d Qc FS1 RLB 15A FUSE ee 230V AC 10A RELAY RAISE LOWER SWITCH w p ole gt SOLENOID m SO gt OI da DY AN sla O O PUMP MOTOR HYDRAULIC 56 LL WHITE m t N N ES KS Es BLACK SWITCH E OD P NG Tyan S EI SE LAMP 3 amp 4 aro soo I tt oz BLUE M O p PLA E KJO t Exo BROWN SWITCH a i5 PAGES LAMP 18 2 NO EMERGENCY amp MCB 10A i c EMERGENCY STOP e c 230V RCD 30mA L TEL lt uy3 JE So x26 z 399 z E LL 5 LO ZO O ee dE nw GENSET ALTERNATOR S a MASTER SLAVE CHANGEOVER SWITCH Version with 230V in and out iss B Circuit Diagram 3110 03 Ecolite Workshop Manual TCP 3247 01 Iss B Section 6 Drawings 6 17 Circuit Diagram 110V CTE Out HATZ HATZ WHITE see 1B20 1B20 Ka Ka Jo BLACK SWITCH WIRE 7 WIRE 1 5 LAMP 3 amp 4 StR FE 150 WATT PRISMALENCE LAMPS l SWITCH LAMP 182 EMERGENCY STOP e gt 1B20 STARTER FUEL gg MOTOR LIFT ALTERNATOR u 12V e Ts m ENGINE MCB 10A BOX COOLING 110V FAN TRANSFORMER AUXILIARY OUTLET SOCKET Battery 110V CTE 230V Eh rar ee 15A FUSE e
39. ith engine off check oil level The oil should be just over the top thread at filler Add oil if low See Table 3 2 for correct oil 5 Inspect the engine air cleaner for any damage If damaged replace it immediately Using an engine with a damaged air cleaner will seriously reduce engine life 6 Check that oil cooler outlet grill between body and chassis is clear of obstructions 7 Inspect for any leaks whether fuel engine oil or hydraulic oil 8 Check fuel level To prevent condensation from contaminating the fuel fill the fuel tank at end of each shift Lifting point for crane Fig 2 1 Lifting points Ecolite Workshop Manual TCP 3247 01 Iss B 2 2 Positioning When choosing a location of the Ecolite bear in mind the following e 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 e Assess site conditions carefully before positioning and operating the tower e Do not position the tower in the vicinity of overhead cables or power lines e Locate the light tower on the same or a higher level than the area being lit the higher the light the less shadow length e 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 dow
40. lencer Spark Arrestor MS Ecolite Workshop Manual TCP 3247 01 Iss B 1 Release the clamp securing the exhaust chamber to the down pipe on the underside of the unit 2 Remove the four screws securing the exhaust chamber Fig 5 8 and remove the chamber g s A fixing amp Lok RE Fig 5 8 Exhaust chamber fixing points Fitting the exhaust is the reverse of this procedure 5 6 Fan Replacement To replace the fan on the engine compartment 1 Ensure that the engine is switched off Remove and pocket the key 2 lsolate the battery by disconnecting the negative terminal of the battery 3 Remove the enclosure as detailed in Section 5 3 Housing Removal 4 Remove the side panels from the engine compartment Remove the concertina hose from the fan Remove the panel on which the fan is mounted Fig 5 9 Fan 7 Disconnect the fan supply leads The red lead unplugs from a free socket The black lead is attached to the alternator frame 8 Remove the fan from the panel four screws Fitting the new fan is the reverse of this procedure Ecolite Workshop Manual TCP 3247 01 Iss B Section 5 Parts Replacement 5 7 Alternator Replacement 1 Ensure that the engine is switched off Remove and pocket the key 2 Isolate the battery by disconnecting the negative terminal of the battery 3 Remove the enclosure as detailed in Section 5 3 Housing Removal 4 Remove the side top a
41. ltant compression ignites the fuel and the engine starts vd Engine running OK 19 Ae Engine temperature high N MC 714 L Battery not charging Low oil pressure Nor used s MM On Not used 00 Bos ai l Fig 1 2 Ignition Controller FS1 Generator 15A fuse O Y OOff Q Emergency Supply A Stop E selector 12V switch L battery I Sato Vos a Ignition 12V to switch Control motor A I I DEEG M I Relay gt RLA MR 16 1 1 0 se O M Fuel pump Fig 1 1 Ignition circuit Ecolite Workshop Manual TCP 3247 01 Iss B 11 Section 1 Description 1 3 Lighting Supply 1 2 2 Charging Circuit To Battery charging indicator elapsed time while the alternator is operating 1 3 Lighting Supply The engine drives an alternator to provide nominal 230V a c for the lights Fig 1 4 Optionally the lighting supply can be obtained from an external source connected via a socket on the case and selected by the Supply Selector switch Also optionally the generator supply can be fed to a optional transformer is fitted 1 4 Road Running Lights Some models have road running lights Fig 1 3 Charging circuit The alternator unit incorporates a rectifier that converts the a c from the alternator into d c The regulator regulates the charging current it supplies to the battery to maintain a full charge 1 2 3 Oil Pressure Light An oil pressure switch turns on
42. m EMERGENCY STOP Cable Identification amp Termination Ecolite Workshop Manual TCP 3247 01 Iss B 3111 Sh 2 Iss B 59 Section 6 Drawings 6 20 Control Box Assy Tank Mounted TCP 3001 01 SA ISO 4017 M6 x 16 01 0075 HEXAGON HEAD SCREW BS 4464 M6 Form B 02 0003 SPRING WASHER METRIC SERIES EE BRIGHT METAL WASHER METRIC SERIES HEXAGON FLANGED BOLT TCP 2946 51 2946 T MOUNTING BRACKET HATZ CONTROLLER CONTROL BOX ASSY BASIC OPTION CONTROL BOX MOUNTING BRACKET Iss A 25 09 2008 Stock No SA 3001 01 Control Box Assy Tank Mounted TCP 3001 01 SA 60 Ecolite Workshop Manual TCP 3247 01 Iss B Section 6 Drawings 6 21 Battery Kit TCP 3034 SA ISO 4017 M5x12 010041 HEXAGON HEAD SCREW 2 BS 4464 M5 Form B SPRING WASHER METRIC SERIES 2 3 TCP 2889 51 2869 BATTERYCLAMP ni FOAM INLAY 12 VOLT BATTERY SEM QTY Iss A 26 9 2008 Battery Kit TCP 3034 SA Ecolite Workshop Manual TCP 3247 01 Iss B 61 Section 6 Drawings 6 22 Interior Light Assy TCP 3059 SA KU ISO 7045 M4 x 20 4 8 Z 01 0181 PAN HEAD SCREW GRADE A BS 4320 M5 Form A 02 0013 BRIGHT METAL WASHER METRIC SERIES DIN 6921 M5 x 12 01 0205 HEXAGON FLANGED BOLT REES 2 TCP 3060 72 0075 COURTESY LIGHT 1 ITEM QTY ISO 7040 M4 01 0019 HEX NUT WITH TORQUE PART Iss A 30 08 2008 Interior Light Assy TCP 3059 SA 62 Ecolite Workshop Manual TCP 3247 01 Iss B Section 6 Drawings
43. ment stop solenoid relay charge regulator leaks oil and air IN ADDITION paintwork and parts that wear 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 OQ Preliminary ENGINE NUMBER Serial number of engine Hours USED Sate hours used on hour clock Please do not guess the hours used DETAILS OF FAILURE Give a full report on the failure ORDER NUMBER An order number will be reguired 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 ot warranty
44. mp adaptor m hose EC Dipstick a assy y e a W I gt be V d 4 u CN LJ x gt n t lt m Fig 5 19 Sump cover and adaptor hose 14 Remove the sump cover from the frame 15 Remove the hose from the sump adaptor and unscrew the sump adaptor from the sump Sump adaptor Fig 5 18 Sump adaptor 16 Remove the four bolts securing the engine to the pod and lift out the engine 17 Remove the alternator from the engine as described in Section 5 7 Alternator Replacement Fitting the new engine is the reverse of this procedure Fit the sump adaptor and hose from the old engine to the sump of the new engine 5 9 Hydraulic Pump 1 Ensure that the engine is switched off Remove and pocket the key 2 Isolate the battery by disconnecting the negative terminal of the battery 3 Remove the enclosure as detailed in Section 5 3 Housing Removal 4 Disconnect the supplies to the pump motor and the pump motor solenoid 5 Disconnect the hoses from the pump assembly Fig 5 21 Ecolite Workshop Manual TCP 3247 01 Iss B Section 5 Parts Replacement Fig 5 21 Disconnecting pump assembly 6 Remove the four screws securing the pump assembly to the tank Fig 5 22 Pump screws 7 Carefully lift out the pump taking care not to to observe the safety precautions appropriate to the hydraulic fluid Refitting is the reverse of this procedure 5 10 AMOSS Valve Replacement Recommended tools
45. n 6 Drawings 6 9 Jack Leg TCP 2064 12 04 2007 03 2008 31 03 2007 12 DATE 23 01 2007 20 03 2007 DESCRIPTION INITIAL ISSUE D LENGTH INCREASED E SEE DCA 00263 B UPDATED FROM MODEL C REVISED LOCK PIN dI LA pi 4901999723320 4 Spring type straight pins slotted light dut BRIGHT METAL WASHER METRIC SERIES M TCP 2120 SC LOCATING PIN 10 JTCP2124 SPRING 9 prepara IL JLOCATNGBRACKET JL 1 8 TCP21231 0 0 JLOCATNGRING LI 7 j TCP 23147 BLANKNGPLUG LL 2 L6 oo o o o 4 J kNOB 5 j TCcP288 HANDLE LL MJ Ok NN GEARBOX O ij ap J LEGBOX5 tt l2 op X j tEGBOX40 gt Pajo ft M9 _ o o TEA Iss E 12 03 2008 Jack Leg TCP 2064 Ecolite Workshop Manual TCP 3247 01 Iss B 49 Section 6 Drawings 6 10 SA Fuel Tank Assy TCP 2867 1 10 6 onon Tozooso o paro TO Me sorsom oro __ HexNUTWITHTORGUEPART Ja 7 Vas a320 we Forma 92 0011 BRIGHT METAL WASHER METRIC SERIES 3 o es 464 m Form 02 0022 SPRING WASHER METRIC SERIES 1 Mas 150 4017 M8x 16 sust orowe HEXAGONHEAD sera 14 Jes 4320 MG Form ay 02000 BRIGHT METAL WASHER METRIC SERIES 2 5 150 7045 M6x16 48 2 01 0201 PANHEADSCREW GRADEA 2 e eser RTE Hose Cup dia 5mm TO m rer 140038 Hose cup DIA tamm
46. n properly if the unit is not level e Put the handbrake on before attempting to raise the mast The mast cannot be raised unless the handbrake is on e Do not move the tower with the mast raised The mast will telescope down automatically if the brake is released e Never raise the mast or operate the tower without the jacklegs touching the ground The Ecolite would normally be towed into the required position and then uncoupled from the towing vehicle However the Ecolite has a lifting point for use with a crane and two pockets for use with a forklift Fig 2 7 that can be used 15 Section 2 Operation 2 3 Uncoupling A WARNING Do not release the Jockey Wheel Assy Clamp Lever while the Jockey Wheel is taking the weight of the unit The unit would tip forward and could cause damage or personal injury Uncouple the Ecolite trailer from the towing vehicle if necessary as follows 9 Apply the parking brake by pulling up the lever Fig 2 2 The mast cannot be raised unless the brake is on 10 Disconnect the trailer lighting from the towing vehicle 11 Detach the breakaway cable from the towing vehicle 12 Release the jockey wheel assembly clamp and lower the wheel approximately half way to the ground 13 Retighten the clamp 14 Wind the jockey wheel down to release the weight from the towing eye 15 Release and remove the pin from the towing eye on the towing vehicle 16 Make any final
47. nd fan panels from the engine compartment 5 Unbolt Hatz engine controller from control panel and lift away with engine pod 6 Disconnect cables from alternator white multi connector 7 Remove the two or four screws securing the alternator vibration mount s to the base 8 Remove the four screws securing the alternator to the engine A Tie bolt Fig5 10 Fan 9 Remove the alternator end cap two screws 10 Unscrew the tie bolt that passes through the centre of the alternator The next step is to disconnect the alternator from the motor which drives the alternator via a tapered shaft Fig 5 11 7 RW m Ki Ny A gt iz Ray Gi m A eh A dj E s uv NO n K 4 D Y Tapered 4 drive shaft i J i PF Z n mna sti ee Fig 5 11 Drive shaft on alternator 35 Section 5 Parts Replacement 11 Screw the tie bolt two turns back into the shaft While pulling the alternator away from the engine tap sharply on the end of tie bolt with a copper mallet to release the shaft from the taper If necessary use a pry bar in the gap between the alternator and the engine to prise them apart while tapping the bolt Fitting the new alternator is the reverse of this procedure 5 8 Engine Removal 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 The engine is he
48. ne Lights powered from the diesel engine or optionally from a local mains supply Mounted on a two wheel trailer that can either be lifted onto a vehicle for transport or towed AMOSS system prevents towing while the mast is raised The mast cannot be raised unless the handbrake is on The diesel engine is coupled directly to an alternator to provide 240V a c power for the lights The hydraulic power for raising the tower is provided by a 12V d c pump 1 2 Electrics The diagrams in this section are for explanatory purposes only Refer to circuit diagrams TCP 3220 Ox in Section 6 for full information Versions are available with an auxiliary 230V input and or output Another version incorporates a transformer to provide a 110V 50 Hz centre tapped output Only units with a 230V input option Section 1 Description 1 1 Introduction Description have a Supply Selector switch 1 2 1 Ignition Engine starting is controlled by the ignition controller Fig 1 2 The Hatz diesel engine has no glow plug but employs fuel rich starting When the controller key switch is set to 2 Start the controller applies 12V d c to the starter motor to turn the engine and to a solenoid to supply fuel to the engine Initially the engine valves are open so that no fuel compression occurs and the engine turns easily The valves remain open until the engine reaches a pre determined speed At this point the valves close and the resu
49. o a suitable container 6 Use the hand pump to evacuate all the oil from the sump Disconnect the tube Refill the sump with oil of the correct grade for Fig 3 9 Oil SAE grades the conditions Fig 3 9 to the correct level as indicated on the dipstick Oil should meet at least one of the following 9 Refit the filler cap dipstick SPELA ACEA B2 E2 or better API CD CE CF CF 4 1 CG 4 or better If engine oil of a poorer quality is used reduce oil Oil filler and change interval to 150 hours of operation dipstick Oil evacuation pump D A x 3 Fig 3 8 Oil filler dipstick and pump 26 Ecolite Workshop Manual TCP 3247 01 Iss B 3 12 Hydraulic Fluid Check the fluid in the hydraulic tank daily 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 3 10 If necessary top up with Ecolite Mast Fluid TCP Part No 80 0372 A WARNING Only use the specified TCP hydraulic fluid undiluted This fluid is specially formulated for the purpose If 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 Fig 3 10 Hydraulic fluid level check Pump motor solenoid p One way valve Section 3 Maintenance If it is suspected that the
50. of 14V If the battery voltage has not 31 Section 4 Fault Finding increased significanily from its off load value suspect an alternator regulator or wiring problem To check the alternator switch off the engine disconnect the connections to the alternator and connect an d c voltmeter to the alternator Start the engine and measure the off load output from the alternator this should be more than 14V d c If the alternator output is correct check the regulator and wiring as detailed in the engine workshop manual 32 4 4 Mast Will not Stay Up Check that the handbrake is fully on Check that the linkage to the handbrake is correcily operating the AMOSS valve under the tow bar Check for leakage around the mast segments If necessary replace the relevant seals on the mast See Section 5 12 Mast Seal Replacement Ecolite Workshop Manual TCP 3247 01 Iss B Section 5 Parts Replacement Section 5 Parts Replacement 5 1 Recommended Tools e Crows foot 32 mm spanner 5 2 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 5 1 and remove the lens Fig 5 2 Fig 5 2 Lamp lens Unclip the lamp from the holder Fig 3 3 Install the new lamp and refit the lens Fig 3 3 Lamp and holder Ecolite Workshop Manual TCP 3247 01
51. ommended lubricants 3 6 Lubrication Note Grease the tow bar coupling at least once per year more freguently if the unit is towed freguently e Service air cleaners more often when operating under extremely dusty conditions e Do not wash the air cleaner element out with 3 7 General Inspection e Engine air intake Check air intake system for wear or damage to piping loose clamps and detergent Replace with new 3 9 Engine Oil Check leaks Check the engine oil after each day s use e Check for loose bolts or fixings Tighten as per 1 Ensure that the unit is level bolt chart in Appendix A 2 Switch off the engine e Check for oil leaks Securely tighten any loose 3 Clean the area around the oil filler cap dipstick joints and replenish any losses EN l 4 Remove the dipstick Fig 3 8 and allow a few e Examine the body particularly the chassis for cracks or broken welds Repair where necessary moments for the oil level to settle 5 Check the oil level using the dipstick Fig 3 1 pia 6 If necessary top up the oil see Fig 3 9 Do Minimum not overfill level PA Fig 3 1 Dipstick levels 3 8 Daily Check After every 10 hours of operation do a walk around inspection Side panel Fixing SCrews e Visually check engine for damage listen for any unusual noises e Engine Air Cleaner Inspect and remove any obstructions from the air cleaner inlet with the engine stopped e Check
52. ons Do not allow charging voltage to exceed 15 volts Excessive booster voltage and or incorrect jumper cable connections will destroy plates inside battery Keep all sources of ignition away from batteries Do not lean over batteries Do not allow the battery to become fully discharged The battery may no be able to recover from this state rendering it unserviceable Voltmeter State of Reading charge 12 84 Volts 100 12 50 Volts 75 12 18 Volts 50 11 88 Volts 25 When Ecolite power is supplied from an outside source via the input socket engine not used and supply Selector switch set to Auxiliary the Emergency Stop button is inoperative and will not turn off the power The RCD provides protection against electric shock 21 Section 2 Operation 22 Ecolite Workshop Manual TCP 3247 01 Iss B Section 3 Maintenance Section 3 Maintenance Replace uel Filter fixed NENNEN EEE Hydraulic fluid Check Engine oil filter E EE Service interval Every Every Ever Every Operation Daily 250 hr Bu hr 000 tr hr R hr E rie Check replace AAA E Filter in line A o 27 Replace __ 27 EEE 27 Cem 24 Lubricate inertia Grease NES brake Drain fuel tank Oa Annually 28 Engine conditioning Decke 28 Check replace air filter daily if operating in dusty conditions Table 3
53. ow unauthorised personnel to service or maintain this machine Study the manual before starting operating or servicing this machine Always follow the procedures and safety precautions detailed in this manual Do not work under or near any unblocked or unsupported linkage or any part of machine Always shut down machine before cleaning lubricating or servicing the machine Always relieve pressure before servicing any pressurised system Always attach a DO NOT OPERATE or similar warning sign to ignition switch or a control before cleaning or servicing the machine The ceramic insulation wrapped around the exhaust pipe and the engine cover ceramic heat barrier are made of toxic material possible low risk carcinogenic Minimise dust release and use appropriate Personal Protection Equipment when handling them 3 4 Maintenance Intervals Table 3 1 lists the maintenance intervals 3 5 Service Access To access the engine for routine maintenance open both sides of the engine enclosure 23 Section 3 Maintenance Component Lubricant Specifications API SAE Code Grade Engine Crankcase Engine Oil 1 85 max sulphated ash limit CC CD 10W 30 and Filter Hydraulic System Hydraulic fluid on MOTT Diesel Fuel Oil with A S T M No 2 Diesel Fuel at 3 Fuel tank max Sulphur 0 5 NA na temp blend No 2 with l l Multipurpose Lithiium grease Towbar greasing Morris Lubricants K2 EP NLGI No 2 I Table 3 2 Rec
54. own in Fig 4 1 Emergency stop pull a i ja Fig 4 1 Battery test stud The battery voltage varies with charge as follows Voltmeter reading State of charge 12 84 V 100 12 50V 15 12 2V 50 11 9V 25 Ecolite Workshop Manual TCP 3247 01 Iss B If a charging problem is suspected check the charging circuit as detailed in Section 4 3 Battery Charging Check 6 Check starter motor 4 2 Engine Cranks but will not Start 1 Check fuel amount and quality 2 Check that the emergency Pull to Stop button on the engine compartment is fully in 3 Check that the electric fuel pump is running It should produce audible clicking 4 Check baitery voltage as detailed in Section 4 1 Engine will not Crank 5 To check for water in the base of the fuel filter unscrew the tap on the underside of the filter Use a container to catch any water or fuel that comes out 6 Check the fuel valve accessed by removing the side panel of the engine compartment The valve should produce an audible click when the ignition is turned on Check the continuity of the valve solenoid o Fig 4 2 Fuel valve 4 3 Battery Charging Check The battery is charged from an a c alternator driven by the engine A regulator converts the a c to a d c charging current which it regulates to ensure a full battery charge To check charging start the engine and measure the battery voltage The charging voltage should be of the order
55. r 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 disconnect 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 ca
56. s Replacement e Be sure to use the correct O ring There is a different size for each mast section 3 numbered 1 for the bottom one largest to 6 Tube for the top one 4 4 I e Ensure that the O ring and the surrounding area are clean Combi seal 2f ih Tube e 6 Z Fig 5 30 Mast detail e Apply water resistant grease to the area e After stretching the new O ring over the caps allow time for the ring to regain its proper size before attempting to fit it into the groove in the Cap e On refitting the cap tap it down with a soft mallet 5 12 Mast Seal Replacement Tools A machine seal guide kit 51 0381 A seal is fitted in each of the caps on the mast Each seal is a combination pressure and wiper seal Fig 5 28 Refitting cap e After refitting the cap check for rubber debris in the cap fixing holes Fig 5 29 The presence of debris could indicate that the O ring has been damaged by a burr around the hole If debris is present remove and check replace the O ring Fig 5 31 Mast seal 1 Remove the bolt securing the Light Assembly to the mast and lift the assembly off the mast using a hoist or similar 2 Mark the caps with Tipex or similar to ensure that they can be refitted with the correct orientation 3 Remove the caps down to and including the cap with the faulty seal as described in Section 5 11 Mast O ring Replacement Fig 5 29 Checking for debris 4 Check replace
57. sis Assy B 50 mm Pressed Steel Head 42 Ecolite Workshop Manual TUP 3247 01 Iss B Section 6 Drawings 6 3 Upper Body Assy TCP 2870 Sh 1A Iss C 10 10 2008 Stock No 30 2870 XX Ecolite Workshop Manual TCP 3247 01 Iss B UPPER BODY COLOUR 2 WHITE 30 2870 02 4 YELLOW RAL1007 130 2870 04 5 pik poo 30 287005 6 LIGHT GREEN 30 2870 06 __ Upper Body Assy TCP 2870 Sh 1A 43 Section 6 Drawings 6 4 Upper Body Assy TCP 2870 Sh 1B 15 16 17 18 VV SS KAO S NE Detail C from Sh 1A 10 ISO4017 M6 x25 01 0000 HEXAGONHEADSCREW 1 4 9 Bs4320 M amp FormA 02 0004 BRIGHT METAL WASHER METRIC SERIES 20 8 bN903 64 _ o2 00s8 wase a 7 TCP 2190 ao 0024 GASSRUT 2 6 ToP 3os3 _ JHNGESHM 4 Iss C 10 10 2008 Upper Body Assy TCP 2870 Sh 1B Stock No 30 2870 XX 44 Ecolite Workshop Manual TCP 3247 01 Iss B Section 6 Drawings 6 5 Upper Body Assy TCP 2870 Sh 2 HEXAGON FULL NUT HEX NUT WITH TORQUE PART 17 BS4320 M5 Form A 02 0013 BRIGHT METAL WASHER METRIC SERIES PAN HEAD SCREW GRADEA REFLECTOR YELLOW DOOR CATCH ASSY 10 s04017 M6x25 01 0000 HEXAGONHEADSCREW 4 8 _ DIN 9021 6 4 o2 0033 WASHER NA 6 rcp s053 IHINGESHIM O A Issue C 22 07 2008 Stock No 30 2870 XX Upper Body Assy TCP 2870 Sh 2 Ecolite Workshop Manual TCP
58. t 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 use or if high winds or electrical storms are expected in the area Ecolite Workshop Manual TCP 3247 01 Iss B Preliminary 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 failure or misapplication If an arc tube ruptures it can shatter the outer glass bulb resulting in the discharge of glass fr
59. t can be either manhandled or towed to the new location Before towing e Check that the hitch and coupling on the towing vehicle are rated egual to or greater than the trailer s gross vehicle weight rating GVWR e nspect the hitch and coupling for wear or damage DO NOT tow trailer using defective parts e Make sure the coupling is securely fastened to the vehicle e Check tyres on trailer for tread wear inflation and condition e Connect breakaway safety line securely to towing vehicle e Make sure directional reverse and trailer lights are connected and working properly e Check that wheel nuts are tight and that none are missing e Connect the road running lights if applicable and check that they work The maximum recommended speed for highway towing is 75 kph Recommended maximum off road towing speed is 15 kph less on uneven terrain 19 Section 2 Operation 2 8 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 2 14 and turn the Rotation Handle so as to direct the lights as reguired 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 2 17 Thus the lights can be directed either downwards or horizontally e g to illuminate a facade Fig 2 16 For any adjustments the mast must be lowered to allow acc
60. t that the machine is stolen or to reduce vandalism e Remove all keys any time the machine is left unattended e mmobilise 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 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 an
61. the oil pressure warning light if the oil pressure is low 1 2 4 Hours Counter The hours counter Fig 7 4 powered from the 230V a c supply from the alternator measures the Optional L Aux input 1 RCD MCB AE Of O e OU 0 em 1 2 Generatori MCB O Ji N 230V a c O ig OTO e Alternator gt Supply et Tower selector i Fiona i 110V lamps FS2 switch i transformer 3 4 1A fuse if fitted et i A i 4 E NL Optional 230V a c Aux output H ERBE 110V with RLB Mast transformer raise lower interlock relay Fig 1 4 Lights circuit socket on the case This supply can be 110V if the 12 Ecolite Workshop Manual TUP 3247 01 Iss B Section 1 Description 1 5 Hydraulics 12V FS1 15A fuse Lower 8 20 O A Gate SA PA 230VL O Raise i O 3 12V Interlock Pump Link to relay re MP Lowering hand Pump valve brake motor solenoid 12V Hydraulic tank Hydraulics Fig 1 5 Hydraulics 1 5 Hydraulics Refer to the Hydraulic Schematic drawing Fig 1 5 The mast contains concentric telescopic hydraulic cylinders and is raised by pumping hydraulic fluid into the cylinders A one way valve holds the pressure up when the pump is not operating so that the mast will stay up A solenoid valve lowers the mast by routing the pressurised fluid back to the tank The Raise Lower switch activates the pump motor solenoid to raise the mast or activates the Lowering valve to lower it
62. ve and negative battery stud terminals or between the positive stud and engine chassis negative Fig 3 15 i F y Battery supply Emergency _ Stud terminals stop pull n 47 p 2A p si um N d Fig 3 15 Battery test stud Ecolite Workshop Manual TCP 3247 01 Iss B 29 Section 3 Maintenance 30 Ecolite Workshop Manual TCP 3247 01 Iss B Section 4 Fault Finding Section 4 Fault Finding 4 1 Engine will not Crank The ignition controller Fig 1 2 controls engine starting The Hatz diesel engine has no glow plug but employs fuel rich starting At startup the engine valves initially open so that no fuel compression occurs and the starter motor turns the engine easily The resultant compression ignites the fuel and the engine starts If the battery voltage is low the controller releases a solenoid which cuts off the fuel supply to the engine so that the engine will not start Similarly if the engine is running and the battery voltage falls below the acceptable threshold the engine will stop This could occur if the mast were raised repeatedly within too short a time for the battery to recharge 1 Check that Emergency Stop button is released 2 Check that Supply Selector switch is set to Generator 3 Check that Supply Isolator switch if fitted is on Check the battery connections Check the battery voltage with the ignition switch off This can be measured between the battery test studs sh
63. way towing is 75 kph Recommended maximum off road towing speed is 15 kph less on uneven terrain Check that the road running lights are connected and operating if applicable Ecolite Workshop Manual TCP 3247 01 Iss B Specifications Overall length Overall height floodlighting position Overall mast height Overall height travel position Overall width travel position Overall width with jack legs deployed Tow hitch height Wheel size Axle weight GVM Total weight with fuel Stabilizing levelling positions Lamps Operating voltage Fuel consumption Fuel tank capacity Preliminary 2503 mm 9500 mm 8 40 mm 2200 mm 1455 mm 2106 mm 420 mm 155 R13 1000 kg 750 kg 4 4 or 6 110 cte 220V 0 5 l hour 95 Its Fuel specification Diesel meeting EN 590 BS 2869 A1 A2 or ASTM D 975 1D 2D Total run time Braking System Ground clearance Max wind speed for safe operation Additional Safety Systems 170 hours Fully fitted axle braking 240 mm Up to 100 kph Automatic Mast Operating Safety System AMOSS fitted as standard Preliminary 10 Ecolite Workshop Manual TCP 3247 01 Iss B Section 1 1 1 Introduction The Ecolite is a lighting tower designed for general use on building sites It 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 engi

Lighting Tower Workshop Manual

Contents

Download Pdf Manuals

Related Search

Related Contents