Allmand Vertical Tower V Series User's Manual
Contents
1. 14 d zegie q el 15 17 STARTING INSIRUGTIONS 18 19 SERIAL NUMBER LOCATION OUS NM LUE 19 20 CONTROLS AND COMPONENTS szexcaoucsskussatus costainstaneucensosteacsnnsneusnsintsienerasas 22 31 ROUTINE MAINTENANCE SCHEDULE cie ras EUR 32 19812 c 33 EE EE E 34 INTRODUCTION This manual provides the information necessary for the safe operation of the Allmand Bros Inc NIGHT LITE PRO V Series light tower The NIGHT LITE PRO vertical tower configuration is operated with a single electric winch a manual winch or a hydraulic cylinder to raise and lower the tower Specific operating instructions and specifications are contained in this publication to fa miliarize the operator and maintenance personnel with the correct and safe procedures necessary to maintain and operate the equipment Take time to read this book thoroughly If you are uncertain about any of the information presented in the manual contact the factory or your dealer for clarification before operation SAFETY SYMBOLS The purpose of the SAFETY INFORMATION SYMBOL2. NIGHI LITE NIGHT LITE PRO V SERIES VERTICAL TOWER 5 MANUAL ALLMAND BROS INC P O BOX 888 HOLDREGE NE 68949 PHONE 308 995 4495 1 800 562 1373 ALLMAND FAX 308 995 5887 ALLMAND PARTS FAX 308 995 4883 SERIES INSPECTION CHECK LIST FOR PREPARING THE NIGHT LITE PROV SERIES FOR DELIVERY OR RENTAL The NIGHT LITE PRO V SERIES requires service as well as proper operation in order to provide the performance and safety it has been designed for Never deliver or put a ma chine into service with known defects or missing instructions or decals Always instruct the customer in the proper operation and safety procedures as described in the operator s manual Always provide the manual with the equipment for proper and safe operation CHECK LIST Visually inspect the equipment to ensure that all instructions and decals are in place and legible Inspect the tower pulleys and cables for proper operation Check the hitch assembly and safety tow chains Check the outriggers and jacks to make sure they operate properly Inspect the light assemblies for damage and test for proper operation Inspect the electrical wiring for signs of damage Check the ground rod cable and the ground lug Make sure they are clean undam aged and functional Inspect the tires to ensure good condition and proper inflation Check oil fuel coolant levels and hydraulic fluid levels Check
3. 1 Remove the electrical power from the winch Switch Electric Winch Switch to OFF 2 Insert the handle so that it completely engages with the driveshaft The handle can be cranked in either di rection with the clutch in the engaged position 3 Always remove the handle from the winch after use ELECTRIC WINCH ADJUSTMENT ELECTRIC WINCH CLUTCH SETTING PROCEDURE PURPOSE 1 Adjustment of the winch clutch nut is necessary to limit the power of the winch The clutch nut must be tight enough to prevent clutch slippage when raising the tower and loose enough so that the clutch does slip if the tower should come in contact with some overhead obstruction or be extended past the upper limit switch which would cause the tower to stop against the dead stop bolt 2 he clutch nut torque value is approximately 28 to 30 in Ibs DO NOT OVER TIGHTEN NOTE The nut may seem loose when it is properly set DO NOT ADJUST further tighten ing may cause cable failure INSTRUCTIONS FOR SETTING THE CLUTCH UNDER FIELD CONDITIONS WITHOUT A TORQUE WRENCH 1 Loosen clutch nut approximately 75 turn 2 Stand clear of the tower when raising or lowering tower 3 Start engine and operate the winch in the up direction The winch should run but the tower should not move At this time the clutch nut should be loose enough to let the clutch slip if not back off the clutch nut just enough so the clutch does slip 4 Start the clutch nut setting proce
4. CAL WIRES PREVENT INSTABILITY AND HELP ENSURE SAFE OPERATION ALWAYS PROVIDE PROPER GROUND SUPPORT BEFORE RAISING MAST BEFORE RAISING MAST VISU ALLY INSPECT EQUIPMENT FOR DAMAGE OR WEAR FAMILIARIZE YOURSELF WITH THE LOCATION AND FUNCTION OF ALL OPERAT ING PARTS BY STUDYING THIS MANUAL OBSERVE ALL CAU TION DECALS LOCATED ON EQUIPMENT TO SET UP TOWER AND RAISE LIGHTS 1 Extend both side outrigger jacks rear jack and tongue jack to stabilize and level the trailer NOTE Jacks should be placed only on firm footing SAFETY WARNING THE SUPPLEMENTAL GROUND ROD IS A SAFETY DEVICE THAT MAY REDUCE THE CHANCE OF PERSONAL INJURY FROM STRAY ELECTRICAL CURRENT Therefore Allmand recommends using the ground rod However it is the user s responsibility to determine the require ments and or applicability of local state or national electrical code which governs the use of the ground rod Attach the ground rod to the grounding lug and drive the ground rod fully for adequate electrical ground as required by local state or national code 3 Start engine and switch electric winch switch to ON While the tower is still in the down position position the light bar and lamps so they are aimed at the work zone and tilted at the ap proximate angle to get maximum coverage once the tower is raised Stand clear of the tower when raising and lowering the lights ELECTRIC WINCH VERTICAL MAST OPE
5. Location On left front and right side of tower section 1 ee ee WARNING Check for overhead obstructions before raising or lowering mast AWARNING EXCESSIVE TOWING SPEED Con Cause Sericus Personal or Daath f Exceed 50 mph 80 090160 Location On pintle hitch A eee hem RUE PART NO 090005 Location Inside left hand door panel N DANGER HIGH VOLTAGE PART NO 090002 Location Light bar cover A WARNING ees a MOVING PART HAZARD injury Com meving soris Chose ond secura querds 2nd baige sorting Kem hend feet and clolhing Gy from moving ports Disconmec before Gdisl ing ge PART NO 090161 Location Right hand side of electric winch cover Ta Prewent Seres Death Awnid unsale operation main limante oot operate or work on Is machine reads and un derstanding the cperaiar z imos i if is teat your necrest deger for new monud de PART NO 090158 Location Inside left hand door panel ELECTRICAL SHDCK HAZARD Ail Severe injury e Death not pealtion light tower under electric power mes PART NO 090165 Location Inside left hand door panel PA
6. click to activate the glow plugs T 5 Glow Plug Lamp NOTE Release key as soon as the engine FIG 1b Lombardini fires FIG 2 Winch Switch and Breaker Electric Winch Model 1 Breaker 5 Amp 2 Electric Winch Up Down Switch Controls raising and lowering of tower Hydraulic Lift Model 1 Breaker 5 Amp not used 2 Hydraulic Lift Up Down Switch FIG 3 BALLAST PANEL 1 Transformer lights 1 thru 4 2 Capacitors lights 1 thru 4 22 CONTROLS AND COMPONENTS NOTE PHOTOGRAPHS MAY SHOW NON STANDARD EQUIPMENT AND OPTIONS FIG 4 GROUND ROD LOCATION 1 Ground rod should be attached to grounding lug with wire provided and ground rod and then driven fully into the earth for adequate electrical ground as required by local state or national electrical code FIG ENGINE COMPONENT IDENTI FICATION KUBOTA Water temp switch Alternator Starter Air cleaner Oil Pressure Switch a FIG 5B ENGINE COMPONENT IDENTI FICATION KUBOTA Oil fill Glow plugs Fuel solenoid Fuel filter Oil filter oY FIG 5C ENGINE COMPONENT IDENTI FICATION KUBOTA 1 Fuel filter 2 Electric fuel pump FIG 6A ENGINE COMPONENT IDENTIFI CATION KUBOTA 1 FIG 6B ENGINE COMPONENT IDENTIFI CATION CAT 1 FIG CATION LOMBARDINI 2 3 4 2 Alternator 3 4 Air cleaner 2 Alternator 3 4 Air cleaner Alternator Air cleaner not shown CON
7. engine has the serial num CAT engine serial number men b FEL n 5 CN 1 E Ct 12 Tat damage KUBOTA engine EA serial number TH LOMBARDINI engine serial number 20 CONTROLS AND COMPONENTS NOTE PHOTOGRAPHS MAY SHOW NON STANDARD EQUIPMENT AND OPTIONS FIG 1 CONTROL PANEL Kubota 1 Breaker Switch Controls lights 1 and 2 2 Breaker Switch Controls lights 3 and 4 3 Electric Winch On Off Switch 4 Control Panel see close up below FIG 1a CONTROL PANEL Kubota CLOSE UP 1 Ignition On switch Must be in ON position to start engine 2 Engine Start Button NOTE Release button as soon as engine fires 3 Glow Plug Preheat Button 4 Engine Function Indicator Lights come on when there is a fault 5 Hour Meter shows the total elapsed hours of engine operation Fig 1a Control Panel Close Up FIG 1b CONTROL PANEL CAT 1 Breaker Switch Controls lights 1 and 2 2 Breaker Switch Controls lights 3 and 4 Hour Meter Key Switch Glow Plug Indicator d aa FIG 1a CAT 21 CONTROLS AND COMPONENTS NOTE PHOTOGRAPHS MAY SHOW NON STANDARD EQUIPMENT AND OPTIONS FIG 1c A C D C CONTROL PANEL Lom bardini 1 Breaker Switch Controls lights 1 and 2 2 Breaker Switch Controls lights 3 and 4 WAR 3 Hour Meter Shows the total elapsed hours of engine gps ONE operation M MAN 4 Key Switch Turn key clockwise one
8. shown below is to attract your spe cial attention to safety related information contained in the text A DANGER A WARNING CAUTION FAILURE TO UNDERSTAND AND COMPLY WITH SAFETY RELATED INFORMATIONAL INSTRUCTIONS MAY RESULT IN INJURY TO OPERATOR OR OTHERS IF YOU DO NOT UNDERSTAND ANY PART OF THIS INFORMATION CONTACT YOUR DEALER FOR CLARIFICATION PRIOR TO OPERATING EQUIPMENT NOTE The word NOTE is used to bring your attention to supplementary information in relation to various aspects of proper operation and maintenance NOTE Keep this manual accessible during operation to provide convenient reference NOTE Any reference in this manual to LEFT or RIGHT shall be determined by looking at the trailer from the rear SAFETY AND WARNING DECALS WARNING Refer to these representations of the safety ALWAYS REPLACE ANY SAFETY AND INSTRUC warning decals used on the NIGHT LITE to insure correct ordering if replacing be TION DECALS THAT BECOME DAMAGED PAINT comes necessary ED OR OTHERWISE ILLEGIBLE 100663 101208 ELECTRIC AND OR HYDRAULIC WINCH VERTICAL MANUAL WINCH VERTICAL TOWER OPERATING INSTRUCTIONS TOWER OPERATING INSTRUCTIONS CALIFORNIA eain 6S Warning exhaugt and aome ol Ita NWARNING Do not stand under lamp fixtures or near the mast when raising or lowering 101404 PART NO 090179 Oe 23 Location Inside left hand door panel PART NO 101404
9. the glow plugs may occur 2 Turn the key switch to the start position and start the engine immediately once the indicator turns red PREHEATING TIME AMBIENT TEMPERATURE ia B E made for about 6 50 F 10 C to 23 F 5 C Approx 5 seconds a Te eee Below 23 F 5 C Approx 10 seconds switch key is turned to Limit of continuous use 20 to 30 seconds preheating position preneat NOTE Do not operate starter for more than 10 seconds without allowing 30 seconds to pass between starting attempts Possible starter damage could result from excessive heat caused by cranking too long NOTE If the engine develops sufficient speed to disengage the starter but does not keep running a false start the engine rotation must be allowed to come to a complete stop before attempting to restart the engine If starter is engaged while the flywheel is rotating the starter pinion and flywheel ring gear may clash resulting in damage to the starter or flywheel ring gear NOTE If the starter does not turn the engine over stop cranking immediately Do not make further attempts to start the engine until the condition is corrected See your local Kubota CAT or Lombar dini Engine Service Dealer for trouble analysis 18 STARTING INSTRUCTIONS and SERIAL NUMBER LOCATIONS FOR A WARM ENGINE Kubota CAT and Lombardini engines Follow the same procedure as described for cold weather starting skipping step 1 step 2 for Kubota Us
10. to make sure the operator s manual is with the equipment Inspect the machine physically for damage and repair if necessary NOTE See appropriate section of manual for scheduled maintenance intervals After completing the inspection check list operate the tower through a complete op eration cycle following the operating instructions in the operator s manual WARNING NEVER ALLOW ANYONE TO OPERATE THE EQUIPMENT WITHOUT PROPER TRAINING ALWAYS READ THE INSTRUCTIONS FIRST TABLE OF CONTENTS INSPECTION CHECK LIST 2 TABLE OF CONTENTS M 3 INTRODUC TION 4 SAFETY 4 SAFETY AND WARNING DECALS isis 5 6 ELECTRIC WINCH MAST nennen nennen nnn nnn nnn 7 9 HYDRAULIC LIFT MAST OPERATION 2 4 10 12 VERTICAL TOWER ADJUSTMENTS 13 MANUAL WINCH MAST OPERATION
11. LIGHTING SYSTEMS LIMITED WARRANTY UNITED STATES and U S TERRITORIES THIS WARRANTY IS IN LIEU OF ALL OTHER WARRANTIES EXPRESSED OR IMPLIED INCLUDING WARRANTIES OF MERCHANTABILITY OR OF FITNESS FOR PURPOSE AND ANY EXCEPTIONS ARE DESCRIBED IN THE PUBLISHED LIMITED WARRANTY ADDENDUM AVAILABLE UPON REQUEST A COMPONENTS SUB ASSEMBLIES AND DEVICES MANUFACTURED BY OTHER MANUFAC TURERS ARE NOT COVERED BY THIS WARRANTY ALL WARRANTY INFORMATION FROM SUCH OTHER MANUFACTURERS IS PROVIDED WITHIN OR ACCOMPANIES THESE GOODS Subject to the foregoing the manufacturer Allmand Bros Inc hereby warrants all light towers manufactured by Allmand Bros Inc after April 1 2008 to be free from defects in material and workmanship for a period of 2 years after delivery to the original purchaser The first year warranty would include parts and labor The second year warranty would be limited to parts manufactured by Allmand Bros Inc and components warranted by the original equipment manufacturer for more than 12 months Additionally Allmand Bros Inc hereby warrants all replacement parts supplied by Allmand Bros Inc to be free from defects in material and workmanship for a period of 90 days after date of invoice Delivery shall be deemed for the purposes of this warranty to have occurred no later than five days following the date of sale agreement or invoice unless the purchase agreement or invoice specifically states a later delivery date in which case s
12. OSS 15 SPECIFICATIONS GENERATOR 7 5 kw and 8 kw models available 60 hz and 50 hz models available FUEL REQUIREMENTS Use a clean No 2 Diesel fuel oil SAE J313 JUN87 according to ASTM D975 Do not use alternative fuel because its quality is unknown or it may be inferior in quality and kerosene which 15 very low in cetane rating adversely effects the engine Refer to the Kubota CAT or Isuzu Operators Manual for more detailed fuel requirements LOMBARDINI LUBRICATION CHART CAT LUBRICATION CHART Ambient Temperature IE SAE30 10w 30 SAET0W 40 om E 32 oC to 26 SAE20 SAE 10W 4 SAE10W SAE10W 30 SAE10W 40 SPECIFICATIONS TRAILER The engine generator set is housed in a bunded two wheel trailer fabricated from heavy gauge steel The design enables the trailer to contain the outriggers in a simple com pact position MAST When the mast is in the operating position it is located in the middle of a three point outrigger system for optimum balance and stability The mast consists of seven fabricated steel sections that telescope to 25 ft and UHMW plastic guide pads to provide smooth operation and reduced friction The mast sections are extended with either a manual or electric winch or hydaulic pump The electric winch design includes limit switches that turn the winch off when the mast reaches full exten
13. RATION 6 Operate the electric winch switch to the position to raise tower to the de sired height 7 If lights need to be adjusted for better lighting of the work zone after raising the tower lower the tower using the down switch position and make desired adjust ments to the light bar and light fixtures Raise the tower into position Repeat this step if necessary SAFETY WARNING VISUALLY INSPECT EQUIPMENT FOR DAMAGE BEFORE OPERATING ALLOW ADEQUATE CLEARANCE AROUND TRAIL ER FOR TOWER AND INSURE THAT NO PERSONS ARE STANDING IN UNDER THE LIGHTS WHEN LOWERING iM LOWER TOWER AND LIGHTS Turn off lights 2 Operate the electric winch switch in the down position to lower the lights to the lowest vertical position 3 Stop engine 4 Rotate the light bar into the transport park position in line with trailer and engage the park pin by twisting on the park pin ring until the plunger is released and the pin engages the hole in the light bar 5 Reposition the lamp fixtures for transport by pulling them down into the lowest posi tion and face the fixtures toward the center of the trailer 6 Remove ground rod from earth Discon nect wire from ground lug and secure in trailer 7 Raise jacks and rear stand retract outrig gers and secure for towing NOTE Ensure the detent pins are prop erly engaged in the outriggers before towing AUXILIARY HANDLE An emergency crank handle is provided
14. RT NO 090474 Location Right side panel on manual winch models SAFETY AND WARNING DECALS OVERREAD HAZARD PREVENT SERIOUS INJURY DEATH DO NOT RAISE LOWER OR USE LMzHT TOWER UNLESS ALL GUTRIGGERS AMD JACKS ARE POSITIONED DRM GROUND LEVEL BEFORE USE v 090166 Location Side panel manual winch models MAY RESULT IN PART NO 090084 Location AC control panel GROUNDING 090133 Location Inside left hand panel below ground lug AW ARNING WARNING FAILURE TO TURN OFF LIGHTS BEFORE STOPPING ENGINE GENERATOR DAMAGE AND VOID WARRANTY A DANGER FLECTRIC SHOCK HAZARD Foilure to use graund rod could couse severe ar deoth Der grand red into earth and gt tack ground wire grounding lug zm ront af trailer 090163 Location Inside left hand door panel DANGER HAZARDOUS VOLTAGE To present serzas ine xc dadh fom sede not enter eompgperi ment while engine ix running cover before operating Keep componenis in reper PART NO 090162 Location On ballast access cover A WARNING COMBUSTIBLE GAS Couse Severe Beras or Blhnadsess sparka ond apen iome gway fram bolleries PART NO 090159 Location Above battery on tower support inside enclos
15. SHOW NON STANDARD EQUIPMENT AND OPTIONS FIG 8 REAR PANEL 1 Rear Panel 2 Serial Number Tag 3 Exhaust Outlet FIG 9 REAR OUTRIGGERS 1 Jack Handle Crank handle to raise or lower foot of jack to level trailer 2 Jack Pin Pull to allow jack to rotate 3 Outrigger Storage Latch Retains outriggers while in the stored or travel mode SAFETY WARNING Be sure outrigger jack and outriggers are FIG 9 securely latched before towing 2 CONTROLS AND COMPONENTS NOTE PHOTOGRAPHS MAY SHOW NON STAN DARD EQUIPMENT AND OPTIONS FIG 10 POSITIVE DOOR LATCH 1 Positive door latch Locks door in the open position FIG 11 MANUAL WINCH 1 Manual Winch Used to raise and lower vertical mast shown with safety cover 2 Manual Winch Handle FIG 11a MANUAL WINCH 1 Manual Winch Used fo raise and lower vertical mast shown with safety cover 2 Manual Winch Handle FIG 11b 11c HYDRAULIC TOWER 1 Hydraulic Pump Used to raise and lower hydraulic lift vertical mast 2 Hydraulic Cylinder Used to raise and lower hydraulic lift vertical mast RS E 1 FIG 28 CONTROLS AND COMPONENTS NOTE PHOTOGRAPHS MAY SHOW NON STANDARD EQUIPMENT AND OPTIONS FIG 12 ELECTRIC WINCH 1 Electric Winch Used to raise and lower vertical mast shown without safety cover for clarity 2 Breaker Switches for outlets FIG 12 FIG 12a ELECTRIC WINCH 1 Safety Cover Installed Left si
16. TROLS AND COMPONENTS NOTE PHOTOGRAPHS MAY SHOW NON STANDARD EQUIPMENT AND OPTIONS Water temp switch Starter Water temp switch Starter FIG 6B 6C ENGINE COMPONENT IDENTIFI Muffler Oil Filter 24 FIG 7A ENGINE COMPONENT IDENTI FICATION KUBOTA cont d FIG 7B ENGINE COMPONENT IDENTI FICATION CAT cont d FIG 7C ENGINE COMPONENT IDENTI FICATION LOMBARDINI cont d cad ED EU DO S nem CONTROLS AND COMPONENTS NOTE PHOTOGRAPHS MAY SHOW NON STANDARD EQUIPMENT AND OPTIONS Oil fill Glow plugs Fuel solenoid Electric Fuel Pump Fuel filter filter Oil fill Glow plugs Fuel solenoid Fuel pump Fuel filter Oil filter Air Cleaner Starter Fuel pump Fuel filter Cooling Fan CONTROLS AND COMPONENTS NOTE PHOTOGRAPHS MAY SHOW NON STANDARD EQUIPMENT AND OPTIONS FIG 8a REMOTE OIL DRAIN LOCATION 1 Remote oil drain valve Kubota Open illustrated valve 1 in engine oil pan tol drain oil from engine FIG 8b REMOTE OIL DRAIN LOCATION 1 Remote oil drain valve CAT Open illustrated valve 1 in engine oil pan to drain oil from engine FIG 8c REMOTE OIL DRAIN LOCATION 1 Remote oil drain valve Lombardini Open illustrated valve in engine oil pan to drain oil from engine FIG 8d REMOTE OIL DRAIN LOCATION 1 Remote oil drain all models Remove cap to drain engine oil 26 CONTROLS AND COMPONENTS NOTE PHOTOGRAPHS MAY
17. Y WARNING ALWAYS CHECK FOR OVERHEAD OB SIRUCTIONS BEFORE RAISING AND LOWERING MAST ALLOW 35 CLEAR ANCE AVOID ALL OVERHEAD ELEC TRICAL WIRES PREVENT INSTABILITY AND HELP ENSURE SAFE OPERATION ALWAYS PROVIDE PROPER GROUND SUP PORT BEFORE RAISING MAST BEFORE RAISING MAST VISUALLY IN SPECT EQUIPMENT FOR DAMAGE OR WEAR FAMILIARIZE YOURSELF WITH THE LOCATION AND FUNCTION OF ALL OPERATING PARTS BY STUDYING THIS MANUAL OBSERVE ALL CAU TION DECALS LOCATED ON EQUIP MENT TO ERECT MAST AND RAISE LIGHTS 1 Extend both side outrigger jacks and tongue jack to stabilize and level the trailer NOTE Jacks should be placed only on firm footing SAFETY WARNING SUPPLEMENTAL GROUND ROD IS A SAFETY DEVICE THAT MAY REDUCE THE CHANCE OF PERSONAL INJURY FROM STRAY ELECTRICAL CURRENT Therefore Allmand recommends us ing the ground rod However it is the user s responsibility to determine the quirements and or applicability of local state or national electrical code which governs the use of the ground rod 2 Attach the ground rod to the grounding lug and drive the ground rod fully for adequate electrical ground as required by local state or national code 14 3 While the tower is still in the down position position the light bar and lamps so they are aimed at the work zone and tilted at the approximate angle to get maximum cover age once the tower is raised 4 Stand clear of the t
18. de view FIG 12a FIG 12b ELECTRIC WINCH 1 Safety Cover Installed right sideview FIG 12b 29 CONTROLS AND COMPONENTS NOTE PHOTOGRAPHS MAY SHOW NON STANDARD EQUIPMENT AND OPTIONS 4 FIG 13 Electric Relay Assembly 1 Relays Kubota Only FIG 14 Tower Cord Reel Location 1 Cord Reel FIG 15 LIFTING ATTACHMENT POINTS 1 Forklift Lifting Pockets Used to lift light tower using forklift to ease loading and unloading 30 CONTROLS AND COMPONENTS NOTE PHOTOGRAPHS MAY SHOW NON STANDARD EQUIPMENT AND OPTIONS FIG 16 Vertical Tower 1 Seven Section Vertical Tower 2 Light Mounting Locations Mount lights here for use during operation 3 Light connector sockets optional attach light leads to light bar at these female receptacles when provided FIG 17 and 17a Light Bar and Mounting Locations 1 Light Bar 2 Light mounting locations Mount lights here for use during operation 3 Light connector sockets optional attach light leads to light bar at these female receptacles when provided FIG 18 Tower Limit Switch Assembly Electric Only 1 Tower Limit Switch 2 Tower Limit Switch Housing 31 ROUTINE MAINTENANCE KUBOTA D905 D1105 CAT C1 1 and LOMBARDINI LDW 1003 INSPECTION AND LUBRICATION SCHEDULE Check condition of the steel cable and make sure it is properly secured Check hydraulic fluid level Service intervals shown below have been established
19. dure making a slight tightening adjustment until the tower starts to rise 5 The tower may again stall even while the winch continues to run If so lower the tower and make another slight adjustment to the clutch nut by tightening in the clockwise direc tion approximately 10 to 20 degrees 6 Repeat the previous step until the tower reaches full elevation without stalling Do not make large adjustments to the clutch nut as it would be easy to over tighten the nut 7 Run the tower up and down at least 5 times to ensure consistent full elevation 9 he clutch is a serviceable part and may require slight adjustments periodically Remove this plastic plug to access clutch nut HYDRAULIC VERTICAL MAST OPERATION DESCRIPTION OF OPERATION The Allmand NIGHT LITE V Series hydraulic lift tower assembly consists of a seven sec tion telescoping mast which can be extended by operating a single hydraulic cylinder The light bar assembly can be rotated into position by releasing the light bar park pin To release the park pin pull the ring and turn it 90 degrees so that the pin remains in the retracted position The light bar is designed to rotate with enough resistance so that the bar will stay in the desired position once the operator has directed the lights on the work zone if the light bar rotates too easily or does not stay in position remove the cap plug from the center of the light bar cover and tighten the nut
20. e of the glow plugs is not recommended when engine is warm LOW OIL PRESSURE SHUT OFF SYSTEM Should a low oil pressure condition occur the oil pressure sending unit breaks the circuit between the battery and the fuel solenoid allowing the spring load to immediately move the fuel control to the shut off position HIGH COOLANT TEMPERATURE SHUT OFF SYSTEM Should a high coolant temperature condition occur the temperature sending unit breaks the circuit between the battery and the fuel solenoid allowing the spring load to immediately move the fuel control to the shut off position STOPPING THE ENGINE To stop the engine turn the ignition switch to the off position this breaks the circuit between the battery and the fuel solenoid allowing the spring load to immediately move the control to the shut off position SERIAL NUMBER LOCATION Trailer All NIGHT LITE PRO series trailers have a serial number plate attached to the rear tower support below the tower lock See illustration TRAILER SERIAL NUMBER LOCATION 19 SERIAL NUMBER LOCATIONS SERIAL NUMBER LOCATION Generator The generator has a plate attached to the side of the housing Engine The KUBOTA engine has the se rial number stamped on the engine block just below the exhaust manifold see illustration below The CAT engines have the serial number stamped on the right side of the engine block just ahead of the first cylinder see illustration below The LOMBARDINI
21. ed Hydraulic Fluids Ooo Dexron III or NER USE Hydraulic Fluid CONOCO PowerTran VG68 or equivelent 10 0 10 20 30 40 50 C 14 32 50 68 86 104 1227 Ambient Temperature Note For extreme cold conditions use MOBIL Aero HFA VG10 or equivelent hydraulic flud 12 VERTICAL TOWER ADJUSTMENTS VERTICAL TOWER CORNER GUIDE BLOCK ADJUSTMENT 1 Make sure the corner guide block cover plate is on top of the UHMW plastic corner friction block and a 3 8 internal star washer is between the block and the mounting flange of the tower This washer is necessary to insure a grip between the friction block and the metal flange of the tower 2 Use 1 8 spacers to center the inside tower in the middle of the outside tower SEE ILLUSTRATION 3 Using a 010 shim and 020 shim for spacers place a 010 shim between the friction block and the inner tower section sides SEE ILLUSTRATION 4 Make sure the inner tower is against the 3 8 thick UHMW blocks mounted inside the outer tower and use the 020 shim to set the friction block distance from the inner tower section SEE ILLUSTRATION 5 Tighten the 74 20 nuts And continue to set all corner friction blocks on all sec tions using this procedure 020 020 qu ENSURE THE INNER TUBE SECTION 18 AGAINST WEAR PADS 010 1 8 APROX 1 8 MANUAL WINCH VERTICAL MAST OPERATION DESCRIPTION OF OPERATION SAFET
22. for operation under normal conditions Where equip ment is operated under severe conditions very dusty extreme heat or cold etc affected items should be serviced more frequently KUBOTA INTERVAL ITEM PROCEDURE Check and fill as necessary Daily or 10 Hr Check level and condition Check for fuel and lubricating oil leaks Drain lubricating oil flush out system renew filter element and refill with correct grade and type oil Check level and condition Check tension and condition i Clean out fins with water or air AI 500 Hr items Engine valves Cable pulley at the bottom of the front mast support as abowe Adjust clearance Remove clean and grease 1000 Hr or yearly CAT ONLY Inspect for wear Clean and Cable pulleys on mast lubricate Axle Wheel bearings Fuel system Clean and repack Clean sediment from tank LOMBARDINI ONLY Every Day or every hours First Service 20 50 hours Every 100 hours or 3 months Every 200 hours months Every 400 hours 12 months Every 800 hours or 18 months Check level of captant Top up with coolant only Check concentration of coolant Check engine lubricating ail level Renew engine oil FILL SLOWLY ENSURE CORRECT QUANTITY J8 USED Renew engine ail filter Drain water from fuel filter and pre filter Renew fuel filter canister Air vent screws nn and fuel pump Check tension of alternator drive tel Check alternator dr
23. ion the light bar and lamps so they are aimed at the work zone and tilted at the ap proximate angle to get maximum coverage once the tower is raised Stand clear of the tower when raising and lowering the lights HYDRAULIC VERTICAL MAST OPERATION 6 Operate the hydraulic lift switch to the position to raise tower to the de sired height 7 If lights need to be adjusted for better lighting of the work zone after raising the tower lower the tower using the down switch position and make desired adjust ments to the light bar and light fixtures Raise the tower into position Repeat this step if necessary SAFETY WARNING VISUALLY INSPECT EQUIPMENT FOR DAMAGE BEFORE OPERATING ALLOW ADEQUATE CLEARANCE AROUND TRAIL ER FOR TOWER AND INSURE THAT NO PERSONS ARE STANDING IN UNDER THE LIGHTS WHEN LOWERING TO LOWER TOWER AND LIGHTS 1 Turn off lights 2 Operate the hydraulic lift switch in the down position to lower the lights to the lowest vertical position When tower reaches the bottom run switch for three additional seconds to ensure that the tower is at it s lowest possible position 3 Stop engine 4 Rotate the light bar into the transport park position in line with trailer and engage the park pin by twisting on the park pin ring until the plunger is released and the pin engages the hole in the light bar 5 Reposition the lamp fixtures for transport by pulling them d
24. ive belt for wear Renew alternator drive belt Check and adjust speed Tighten cylinder head Check and adjust valve clearances Cheek electrical systems Chack all nuts bolis for tightness Check injectors for performance Clean alr fitter earRer check may be necessary Renew air fitter element Check and correct any leaks or engine damage 32 Renew Coolant FILL SLOWLY ENSURE CORRECT QUANTITY 15 USED MAINTENANCE OPERATION OIL LEVEL CHECK D COOLANT LEVEL CHECK D MAINTENANCE INTERVAL ALTERNATOR BELT INSPECTION AIR FILTER ELEMENT CHECK DRY TYPE AIR FILTER CHECK OIL BATH TYPE RADIATOR CORE INSPECTION 9 FLUID LEAK INSPECTION GENERAL SAFETY GUARD INSPECTION OIL REPLACEMENT INITIAL ONLY see RECOMMENDED OIL TYPE OIL FILTER REPLACEMENT INITIAL ONLY OIL REPLACEMENT see RECOMMENDED OIL TYPE FUEL FILTER REPLACEMENT COOLANT HOSE INSPECTION FAN ALTERNATOR BELT TENSION ADJUSTMENT VALVE ADJUSTMENT FAN ALTERNATOR BELT REPLACEMENT FUEL INJECTION SYSTEM ADJUSTMENT CLEAN FUEL TANK 9 COOLANT REPLACEMENT REPLACE TIMING BELT TROUBLESHOOTING SAFETY WARNING DANGER HIGH VOLTAGE DO NOT ATTEMPT TO TEST AND REPAIR GENERATOR AND BAL LAST ELECTRICAL SYSTEMS UNLESS YOU UNDERSTAND AND ARE QUALIFIED TO WORK ON SUCH SYSTEMS DO NOT WEAR JEWELRY WHILE WORKING WITH ELECTRICITY If the fol
25. lowing procedures do not solve your problem have the circuit tested by a licensed electrician DO NOT attempt to test generator voltage or ballast electrical systems unless you are a qualified electrician Consult the factory for voltage specifications and test procedures PROBLEM POSSIBLE CAUSE 2 Lamps are not allowed time to cool after last being lit You must allow 15 minutes between the time the lights are shut off and the time they are restarted 3 The lamp or lamps are burned out or broken 4 One or more of the lamps are not screwed in securely 5 Plug and socket at light bar not securely pushed together and locked 6 The temperature of the ballast is below 20 degrees F the efficiency of the capacitors in the ballast is not enough to ignite the lamps For ONE OR MORE LIGHTS operations where the temperatures of the ballasts falls below 20 DO NOT LIGHT UP degrees F some means of warming the ballast must be used 12 A wrong style replacement lamp requiring a different ballast has been installed 13 Too much power is being drawn from the auxiliary outlets 14 Capacitor or transformer have failed 15 Corrosion has occurred on the lamp bases For engine and generator troubleshooting see engine and generator manuals or contact your dealer 29 LIMITED WARRANT Y TM Allmand Bros Inc man us 1502 West 4 Ave Holdrege NE 68949 800 562 1373 308 995 4495 Fax 308 995 5887 www allmand com ALLMAND
26. ower when raising and lowering the lights 5 turn on lights flip the breaker switches to the up position SEE FIG 1 6 Operate the hand crank to raise tower to the desired height 7 If lights need to be adjusted for better light ing of the work zone after raising the tower lower the tower and make desired adjust ments to the light bar and light fixtures Raise the tower into position Repeat this step if necessary TO LOWER TOWER AND LIGHTS 1 Turn off lights 2 Operate the hand crank to lower the lights to the lowest vertical position 3 Stop engine 4 Rotate the light bar into the transport park posi tion in line with trailer and engage the park pin by twisting on the park pin ring until the plunger is released and the pin engages the hole in the light bar 5 Reposition the lamp fixtures for transport by pulling them down into the lowest position and face the fixtures toward the center of the trailer 6 Remove ground rod from earth Disconnect wire from ground lug and secure in trailer 7 Raise jacks and rear stand retract outriggers and secure for towing NOTE Ensure the detent pins are properly engaged in the outriggers before towing NOTE Visually inspect the flood light mounting yokes for loose hardware This could prevent a broken fixture during towing OVERALL DIMENSIONS Weight 1800 LBS Length 9 5 2 90 m Height lowered 7 2 13 m Height extended 25 7 62 m Width outriggers
27. own into the lowest posi tion and face the fixtures toward the center of the trailer 6 Remove ground rod from earth Discon nect wire from ground lug and secure in trailer 7 Raise jacks and rear stand retract outrig gers and secure for towing NOTE Ensure the detent pins are prop erly engaged in the outriggers before towing 11 HYDRAULIC TOWER POWER UNIT POWER UNIT INSTALLATION amp START UP PROCEDURE Fill the reservoir with automatic transmission fluid or any clean hydraulic fluid having a viscosity index that is suitable for the climatic conditions in which the unit will be operated Recommended operating temperature range is 20 to 180 GENERAL START UP INSTRUCTIONS NOTE The ports are marked on the casting UP and DN When facing the power unit with the motor up plug the right hand or DN port Jog the motor until oil flows from the left hand or UP port If oil does not flow from the UP port reverse the wire leads on the motor and repeat The pump is now primed Connect the hose or tubing to the UP port and tighten Connect the other hose end to the blind end of a fully retracted hydraulic cylinder With the hose fitting loose operate the power unit until oil and no air bleeds from the fitting Tighten the fitting Refill the reservoir E Falel 1 174 Emi J E ty E HYDRAULIC FLUID SPEC CHART 108 SERIES HYDRAULIC POWER UNIT Recommend
28. preheat but ton on the control panel Glow plugs are not needed on a warm engine or if the ambient temperature is above 50 degrees F The CAT C1 1 and Lombardini LDW 1003 diesel engines include a glow plug cold start system controlled by the ignition switch on the control panel Glow plugs are not needed on a warm engine or if the ambient temperature is above 50 degrees F COLD WEATHER STARTING KUBOTA for temperatures below 32 F 0 C 1 Turn the on off switch to the ON position 2 Press the yellow PREHEAT button for 5 seconds 10 seconds below 23 F maximum 20 seconds continu OUS 3 Press the green START button to crank engine until the engine starts 4 If engine fails to start it may be necessary to recycle the PREHEAT and Start steps 2 and 3 above COLD WEATHER STARTING LOMBARDINI LDW 1003 for temperatures below 32 F 0 C 1 Turn the key switch to the PREHEAT position hold until the glow plug indicator lamp goes out then release switch 2 Turn the key switch to the START position and the engine should start Release the key immediately when the engine starts If engine fails to start it may be necessary to cycle the glow plugs again see chart below COLD WEATHER STARTING CAT C1 1 for temperatures below 32 F 0 C 1 engine is cold turn the key switch counterclockwise to the preheat position until the glow plug indicator turns red CAUTION Never heat glow plugs more than 30 seconds or damage to
29. retracted 4 6 1 372 m Width outriggers extended 7 9 2 36 m Wheels and tires 13 SPECIFICATIONS ENG INE SPECIFICATIONS LOMBARDINI LDW 1003 Water cooled 4 cycle diesel later cooled 4 cyce diesel Water cooled 4 cycle diesel 2 99 76 mm 2 05 75 mmy 3 03 7 mm STROKE 2 90 73 6 305 7T 3 197 81 mm DISPLACEMENT 61 1 cu In 1002 cc 62 6 In 1028 cc 69 cu In 110 cc POWER 1800RPM 13 6 HP 11 4kw 13 4 HP 11 2kw 14 3 HP 11 8kw non derate POWER OUTPUT 3 per 1000 above 360 t 3 per 1000 ft above 360 t 336 per 1000 t above 360 f DERATING 1 per 10 above 77 1 per 10 above 77 1 per 10 above FUEL SYSTEM Indirect injected diesel Indirect injected diesel ae p STARTING SYSTEM 12 volt DC 12 volt DC 12 volt DC RATIO WEIGHT 7 5 53 ko Forced lubrication by pump Forced lubrication by pump Forced lubrication by pump COOLING radiator forced circulation wath water pump Low oil pressure and high engine temperature shut downs are standard equipment Both The Kubota CAT and Lombardini diesel are equipped with glow plug cold start as sist as standard equipment NOTE See the appropriate section of this manual for cold weather starting instructions or consult the Operators Manual for your particular engine application Horsepower ratings are established in accordance with Society of Automotive Engineers omall Engine Test Code J1349 GR
30. sion or is fully retracted STABILIZERS The three point outrigger design consists of two retractable side outriggers and a tongue jack FLOOD LIGHT ASSEMBLY The flood light assembly consists of four 1250 watt lamp fixtures sealed for all weather use SHO 1250 fixture Metal Halide Lamp Lumen rating 150 000 initial lumens Warm up time 2 4 minutes Restart time 10 15 minutes TOWING INSTRUCTIONS Before towing the Night Lite Pro the trailer should be inspected visually to insure that the following operations have been completed Hitch is securely attached to the towing vehicle All outriggers and jacks are retracted and secured Light fixtures are positioned for transport Doors are closed and secure Check for adequate tire pressure Tail lights are connected and operational Ground rod is removed from ground and secured in trailer Se 17 STARTING INSTRUCTIONS BEFORE STARTING 1 Fill the engine with the right grade of lubricating oil refer to the proper page of this manual or the Kubota CAT or Lombardini diesel operators manual for oil specifications 2 Ensure there is an adequate supply of diesel fuel 3 Ensure that the air cleaner is firmly attached and air cleaner seals and hose clamps are properly sealed Air cleaner element should be checked and replaced if necessary STARTING ENGINE NOTE The Kubota diesel engine includes a glow plug cold start system controlled by the yellow
31. to achieve the desired resistance and replace the cap plug SAFETY WARNING ALWAYS CHECK FOR OVERHEAD OB STRUCTIONS BEFORE RAISING AND LOWERING MAST ALLOW 35 CLEAR ANCE AVOID ALL OVERHEAD ELECTRI 3 CAL WIRES PREVENT INSTABILITY AND HELP ENSURE SAFE OPERATION ALWAYS PROVIDE PROPER GROUND SUPPORT BEFORE RAISING MAST BEFORE RAISING MAST VISU ALLY INSPECT EQUIPMENT FOR DAMAGE OR WEAR FAMILIARIZE YOURSELF WITH THE LOCATION AND FUNCTION OF ALL OPERAT ING PARTS BY STUDYING THIS MANUAL OBSERVE ALL CAU TION DECALS LOCATED ON EQUIPMENT 10 TO SET UP TOWER AND RAISE LIGHTS 1 Extend both side outrigger jacks rear jack and tongue jack to stabilize and level the trailer NOTE Jacks should be placed only on firm footing SAFETY WARNING THE SUPPLEMENTAL GROUND ROD IS A SAFETY DEVICE THAT MAY REDUCE THE CHANCE OF PERSONAL INJURY FROM STRAY ELECTRICAL CURRENT Therefore Allmand recommends using the ground rod However it is the user s responsibility to determine the require ments and or applicability of local state or national electrical code which governs the use of the ground rod Attach the ground rod to the grounding lug and drive the ground rod fully for adequate electrical ground as required by local state or national code Start engine NOTE Tower may be raised and lowered as needed without engine run ning While the tower is still in the down position posit
32. ts that have been altered changed damaged or im properly installed repaired operated or maintained Provided this exclusion shall not apply to installations repairs or other work done the manufacturer s plant or under direct manufacturer s supervision The Operator s Manual to the extent cov ered therein is deemed to set forth the proper procedures for operation repair installation and maintenance ofthese goods No representative dealer or distributor of the company is authorized to make any changes or exceptions to this warranty unless expressly authorized in writing from the manufacturer All warranty claims must be filed within thirty 30 days of the failure 34
33. uch delivery date shall control The original purchaser shall be deemed to be a person who places the goods or products in actual use and any person holding such goods solely for wholesale or retail sale purposes shall not constitute an original purchaser PROVIDED any leasing of these goods or other use beyond normal demonstration of same shall be deemed to be in use by an original purchaser and all warranty periods shall commence at the time of such use During the warranty period any defective goods or parts hereof shall be repaired or replaced at manufacturer s discretion In the event it is necessary to return such goods or parts to the factory all transportation charges shall be prepaid The manufacturer shall in no event pay mileage expenses but will warrant outbound ground freight The manufacturer shall in no event be responsible for down time and or lost revenue The obligations of the manufacturer 15 solely to repair or replace defective goods or parts or to refund the cost of the same if it 15 determined by the manufacturer that repair or replacement will not return the goods to proper working order or utility THE REMEDIES SET FORTH HEREIN ARE EXCLUSIVE AND MANUFACTURER SHALL NOT BE LIABLE FOR SPECIAL INDIRECT OR CONSEQUENTIAL DAMAGES THE OBLIGATIONS OF THE MANUFACTURER HEREUNDER SHALL IN NO WAY EXCEED THE PRICE OF THE EQUIPMENT OR PART UPON WHICH SUCH LIABILITY IS BASED The warranty shall not extend to tires lamps batteries or par
34. ure ELECTRIC WINCH VERTICAL MAST OPERATION DESCRIPTION OF OPERATION The Allmand NIGHT LITE V Series tower as sembly consists of a seven section telescop ing mast which can be extended by operating a single electric winch mounted inside the enclosure The winch and cable are protected by an integral clutch and a circuit breaker The clutch is designed to slip when the mast reaches full extension The circuit breaker is a safeguard for the clutch If the clutch is misadjusted or inoperative the circuit breaker should trip to protect the system from over load The electric winch operates off the 120 volt circuit breaker along with 120 volt recep tacle thus requiring that the 120 volt circuit breaker switch must be on to operate the winch The light bar assembly can be rotated into position by releasing the light bar park pin To release the park pin pull the ring and turn it 90 degrees so that the pin remains in the retracted position The light bar is designed to rotate with enough resistance so that the bar will stay in the desired position once the operator has directed the lights on the work zone if the light bar rotates too easily or does not stay in position remove the cap plug from the center of the light bar cover and tighten the nut to achieve the desired resistance and SAFETY WARNING ALWAYS CHECK FOR OVERHEAD OB STRUCTIONS BEFORE RAISING AND LOWERING MAST ALLOW 35 CLEAR ANCE AVOID ALL OVERHEAD ELECTRI
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