Read NL PRO OPS BOOK Cable Elec 1-22-02.p65 text version

MAY 2000

NIGHT-LITE NIGHT-LITE PRO SERIES OPERATOR'S 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

NIGHT-LITE SERIES

For Parts and Updates visit Allmand on the Web at www.allmand.com

1

INSPECTION CHECK LIST

FOR PREPARING THE NIGHT-LITE PRO FOR DELIVERY OR RENTAL The NIGHT-LITE PRO 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 machine 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 latch and knob assembly which locks the tower in the vertical position 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, undamaged, and functional. Inspect the tires to ensure good condition and proper inflation Check oil, fuel, coolant levels, and hydraulic fluid levels. Check 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 operation 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!

2

TABLE OF CONTENTS

INSPECTION CHECK LIST ..................................................................................................... 2 TABLE OF CONTENTS ........................................................................................................... 3 INTRODUCTION ...................................................................................................................... 4 SAFETY SYMBOL INFORMATION .......................................................................................... 4 SAFETY AND WARNING DECALS ...................................................................................... 5-7 MANUAL WINCH MAST OPERATION .................................................................................. 8-9 ELECTRIC WINCH MAST OPERATION ............................................................................10-11 SPECIFICATIONS ............................................................................................................. 12-14 STARTING INSTRUCTIONS ............................................................................................. 15-16 SERIAL NUMBER LOCATIONS ....................................................................................... 17-18 CONTROLS AND COMPONENTS ................................................................................... 19-25 ROUTINE MAINTENANCE SCHEDULE ............................................................................... 26 KUBOTA D905, D1105, PERKINS 103-10, and LOMBARDINI LDW 903 TROUBLESHOOTING ........................................................................................................... 27

ASSEMBLY PARTS AND ACCESSORIES ........................................................................... 28

3

INTRODUCTION

This manual provides the information necessary for the safe operation of the Allmand Bros., Inc., NIGHT-LITE PRO light tower. The NIGHT-LITE PRO standard tower configuration is operated with two manual crank winches or single electric winch used to erect, extend, and lower the tower. Specific operating instructions and specifications are contained in this publication to familiarize 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 SYMBOL shown below is to attract your special attention to safety related information contained in the text.

! !

DANGER 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.

4

SAFETY AND WARNING DECALS

! SAFETY WARNING

ALWAYS REPLACE ANY SAFETY AND INSTRUCTION DECALS THAT BECOME DAMAGED, PAINTED, OR OTHERWISE ILLEGIBLE. Refer to these representations of the safety warning decals used on the NIGHT-LITE to insure correct ordering if replacing becomes necessary.

PART NO. D-249 Location: Inside left hand door panel of Kubota engine units.

PART NO. D-264 Location: Inside left hand door panel.

5

SAFETY AND WARNING DECALS

6

SAFETY AND WARNING DECALS

7

MANUAL WINCH MAST OPERATION

DESCRIPTION OF OPERATION

The Allmand NIGHT-LITE tower assembly consists of a three section telescoping mast which can be raised and extended by operating two hand crank winches. One winch, mounted with the handle extending through the side of the trailer frame, raises and lowers the mast from the horizontal towing position, the vertical position, and back. The second winch mounted on the tower extends the telescopic sections. The three section mast assembly can be rotated from the ground by loosening a knob and rotating the entire assembly 360° to aim the lights as necessary.

TO ERECT MAST 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

WHEN EXTENDING REAR JACK, WATCH TO ENSURE YOU ARE CLEAR OF THE OVERHANGING ENDS OF THE MAST BEFORE YOU STAND UP. THE SUPPLEMENTAL GROUND ROD IS A SAFETY DEVICE THAT MAY REDUCE THE CHANCE OF PERSONAL INJURY FROM STRAY ELECTRICAL CURRENT.

!

SAFETY WARNING

ALWAYS CHECK FOR OVERHEAD OBSTRUCTIONS BEFORE RAISING AND LOWERING MAST. ALLOW 35' CLEARANCE. AVOID ALL OVERHEAD ELECTRICAL WIRES. TO PREVENT INSTABILITY AND HELP ENSURE SAFE OPERATION, ALWAYS PROVIDE PROPER GROUND SUPPORT BEFORE RAISING MAST. BEFORE RAISING MAST, VISUALLY INSPECT EQUIPMENT FOR DAMAGE OR WEAR. FAMILIARIZE YOURSELF WITH THE LOCATION AND FUNCTION OF ALL OPERATING PARTS BY STUDYING THIS MANUAL. OBSERVE ALL CAUTION DECALS LOCATED ON EQUIPMENT

Therefore, Allmand recommends using the ground rod. However, it is the user's responsibility to determine the requirements 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. 3. Release the pin that secures the mast to the rear mast support.

NOTE: The latch locks the mast in the vertical position and disengages the sections allowing the tower assembly to be rotated to position the lights. 8

4. Operate the hand crank on the side of the trailer to raise the mast from horizontal to vertical. 5. Turn black knob counterclockwise and engage latch in strike plate. Retighten black knob. 6. Operate the hand crank winch on the tower clockwise to raise the lights vertically. 7. To rotate the lights, release the black knob and turn the tower assembly with the handles provided. 8. To turn on lights, flip the breaker switches to the up position. (SEE FIG. 1)

MANUAL WINCH MAST OPERATION

!

SAFETY WARNING

6. Operate the hand crank on the side of the trailer counterclockwise to fold the mast down into the towing position.

IF THE TOWER CANNOT BE ROTATED AFTER LOOSENING THE BLACK KNOB, CHECK TO ASSURE THE LOWER LATCH IS ENGAGED IN THE STRIKE PLATE. THIS DOUBLE LATCH FEATURE PREVENTS THE TOWER FROM BEING ROTATED IF THE LATCH IS NOT ENGAGED.

NOTE: Sufficient load (75 lb. min ) must be applied to the cable to overcome internal resistance and operate the brake properly. Insufficient load will not turn the reel thus continual turning without sufficient load will remove the winch handle from the shaft.

7. Secure light cords into hook on the rear tower support for towing. 8. Secure pin locking mast to rear tower support. 9. Remove ground rod from earth. Disconnect wire from ground lug and secure in trailer 10. Raise jacks and rear stand, retract outriggers and secure for towing

!

SAFETY WARNING

VISUALLY INSPECT EQUIPMENT FOR DAMAGE BEFORE OPERATING. ALLOW ADEQUATE CLEARANCE AROUND TRAILER FOR TOWER AND INSURE THAT NO PERSONS ARE STANDING IN FRONT OF OR BEHIND UNIT WHEN LOWERING.

TO LOWER MAST AND LIGHTS

1. 2. Turn off lights. Release black knob and rotate tower until winch handle points to the front of the trailer and retighten knob. 3. Operate hand crank winch on tower counterclockwise to lower the lights to the lowest vertical position 4. Operate hand crank winch on side of trailer clockwise to take up any cable slack. 5. Turn the black knob counterclockwise and lift to release the latch from the strike plate. Retighten the knob with the latch disengaged from the strike plate.

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.

9

STRONG ARM ELECTRIC WINCH MAST OPERATION

DESCRIPTION OF OPERATION

The Allmand NIGHT-LITE tower assembly consists of a three section telescoping mast which can be raised and extended by operating a single electric winch mounted inside the enclosure. A single three position toggle switch mounted on the control panel is used to raise and lower the mast. 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 overload. The electric winch operates off the 120 volt circuit breaker along with 120 volt receptacle thus requiring that the 120 volt circuit breaker switch must be on to operate the winch. The three section mast assembly can be rotated from the ground by loosening a knob and rotating the entire assembly 360° to aim the lights as necessary.

BEFORE RAISING MAST, VISUALLY INSPECT EQUIPMENT FOR DAMAGE OR WEAR. FAMILIARIZE YOURSELF WITH THE LOCATION AND FUNCTION OF ALL OPERATING PARTS BY STUDYING THIS MANUAL. OBSERVE ALL CAUTION DECALS LOCATED ON EQUIPMENT

TO ERECT MAST 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!

WHEN EXTENDING REAR JACK, WATCH TO ENSURE YOU ARE CLEAR OF THE OVERHANGING ENDS OF THE MAST BEFORE YOU STAND UP. THE SUPPLEMENTAL GROUND ROD IS A SAFETY DEVICE THAT MAY REDUCE THE CHANCE OF PERSONAL INJURY FROM STRAY ELECTRICAL CURRENT. There-

! SAFETY WARNING!

ALWAYS CHECK FOR OVERHEAD OBSTRUCTIONS BEFORE RAISING AND LOWERING MAST. ALLOW 35' CLEARANCE. AVOID ALL OVERHEAD ELECTRICAL WIRES. TO PREVENT INSTABILITY AND HELP ENSURE SAFE OPERATION, ALWAYS PROVIDE PROPER GROUND SUPPORT BEFORE RAISING MAST.

fore, Allmand recommends using the ground rod. However, it is the user's responsibility to determine the requirements 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. 3. Start engine and switch the 120 volt circuit breaker switch to the ON position. 4. Release the pin that secures the mast to the rear mast support. 5. Push the toggle switch in the up position to raise the mast from horizontal to vertical.

NOTE: The latch locks the mast in the vertical position and disengages the sections allowing the tower assembly to be rotated to position the lights 10

STRONG ARM ELECTRIC WINCH MAST OPERATION

6. Turn black knob counterclockwise and engage latch in strike plate. Retighten knob. 7. Release the latch by squeezing the handle and push the toggle switch to the UP position to raise lights 8. To rotate the lights, release the black knob and turn the tower assembly with the handles provided 6. Operate the electric winch toggle switch DOWN to fold the mast down into the towing position. 7. Stop engine. 8. Secure light cords into hook on the rear tower support for towing. 9. Secure pin locking mast to rear tower 10. Remove ground rod from earth. Disconnect wire from ground lug and secure in trailer 11. Raise jacks and rear stand, retract outriggers and secure for towing

! SAFETY WARNING!

IF THE TOWER CANNOT BE ROTATED AFTER LOOSENING THE BLACK KNOB, CHECK TO ASSURE THE LOWER LATCH IS ENGAGED IN THE STRIKE PLATE. THIS DOUBLE LATCH FEATURE PREVENTS THE TOWER FROM BEING ROTATED IF THE LATCH IS NOT ENGAGED.

NOTE: Ensure the detent pins are properly engaged in the outriggers before towing.

AUXILIARY HANDLE

An emergency crank handle is provided for use in the event of a power failure. 1. Remove the electrical power from the winch 2. Insert the handle so that it completely engages with the driveshaft. The handle can be cranked in either direction with the clutch in the engaged position. 3. Always remove the handle from the winch after use.

! SAFETY WARNING!

VISUALLY INSPECT EQUIPMENT FOR DAMAGE BEFORE OPERATING. ALLOW ADEQUATE CLEARANCE AROUND TRAILER FOR TOWER AND INSURE THAT NO PERSONS ARE STANDING IN FRONT OF OR BEHIND UNIT WHEN LOWERING.

TO LOWER MAST AND LIGHTS

1. Turn off lights. 2. Release black knob and rotate tower until winch handle points to the front of the trailer and retighten knob. 3. Operate electric winch toggle switch in the down position to lower the lights to the lowest vertical position until the latch clicks. 4. Operate electric winch in the UP position to take up any cable slack. 5. Turn the black knob counterclockwise and lift to release the latch from the strike plate. Retighten the knob with the latch disengaged from the strike plate.

! SAFETY WARNING!

NEVER OPERATE THE WINCH ELECTRICALLY WITH THE EMERGENCY HANDLE IN POSITION.

11

SPECIFICATIONS

OVERALL DIMENSIONS

Weight Length Height lowered Height extended Width ( outriggers retracted ) Width ( outriggers extended ) Trailer Wheels and tires

72mm

1600 LBS 13' 6" (4.04 m) 6' 1" (1.85 m) 30' (9.14 m) 4' 1 1/2" (1.26 m) 7' 9 1/2" (2.37 m) steel frame, leaf spring axle 13"

ENGINE SPECIFICATIONS

ISUZU 3LB1 Water cooled 4-cycle diesel 77.4 mm 79.7 mm 69 cu. in (1124 cc) 16 HP (11.9 kw) 3% per 1000 ft. above 360 ft. 1% per 10 ° above 77°F. Indirect injected diesel 12 volt DC 22:1 249 lb (115 kg) 5.4 qt. (5.1 L) Forced lubrication by pump Cartridge type 2.3 qt. (2.2 L) Pressurized radiatior, forced circulation with water pump ISUZU LDW LOMBARDINI3LD1 903 Water cooled 4-cycle diesel 83.1mm 72 mm 92 mm 75 mm 91 56 cu. in (1496 cc) in. (916 cc) 21 HP (15.7 kw) 10.8 HP (8.1kw) 3% per 1000 ft. above 360 ft. 1% per 10 ° above 77°F. Indirect injected diesel 12 volt DC 22:1 22.8:1

188 lbs (85 kg) 291lb (132 kg)

MODEL TYPE BORE STROKE DISPLACEMENT POWER @ 1800 RPM POWER OUTPUT DERATING FUEL SYSTEM STARTING SYSTEM COMPRESSION RATIO WEIGHT OIL CAPACITY LUBRICATION OIL FILTRATION COOLANT CAPACITY COOLING SYSTEM

KUBOTA D905-EBG1 Water cooled 4-cycle diesel 2.83" (72 mm) 2.90" (73.6 mm) 54.9 cu. in. (898 cc) 10.5 HP (8.8kw) 3% per 1000 ft above 360 ft 1% per 10 ° above 77°F. Indirect injected diesel 12 volt DC 22:1 205 lbs (93 kg) 5.4 qt. (5.1 L) Forced lubrication by pump Cartridge type .82 gal. (3.1 L) Pressurized radiatior, forced circulation with water pump

PERKINS 103-10 Water cooled 4-cycle diesel 75 mm 72 mm 58.3 cu. in.(954 cc) 10.7 HP (8.0 kw) 3% per 1000 ft. above 360 ft. 1% per 10 ° above 77°F. Cassette type fuel injected diesel 12 volt DC 22:1 183 lb (83 kg) Fill to correct level Forced lubrication by pump Cartridge type 1.8 qt. (1.7 L) (Engine Only) Pressurized radiatior, forced circulation with water pump

7.2 2.5 qt. (6.8 L) (2.4 Forced lubrication by pump Cartridge type 2.6 5.1 qt. (2.5 L) (4.9 Pressurized radiatior, forced circulation with water pump

Low oil pressure and high engine temperature shut-downs are standard equipment. Both The Kubota, Perkins, Isuzu, and Lombardini diesel are equipped with glow plug cold start assist 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 Small Engine Test Code- J1349 GROSS. 12

SPECIFICATIONS

GENERATOR

Make Model Construction Speed: 60HZ Air cooled Max. ambient temp. Insulation Voltage response Marathon electric 332RSA1020 Capacitor excitation 1850 RPM at no load 1800 RPM at full load 104 deg. F (40 deg. C) Class "F" 0.1 sec.

NOTE: Operate the generator at 60 hertz, 1800 RPM only. Consult the factory if an operating speed of less than the rated speed is required.

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 is very low in cetane rating, adversely effects the engine. Refer to the Kubota, Perkins, or Isuzu Operators Manual for more detailed fuel requirements.

ENGINE OIL REQUIREMENTS

Use a high quality engine oil of API (American Petroleum Institute) service class CC/CD/CE Refer to the Kubota, Perkins, Lombardinior Isuzu Operator's Manual for more detailed engine oil requirements. KUBOTA LUBRICATION CHART ISUZU LUBRICATION CHART

LOMBARDINI LUBRICATION CHART PERKINS LUBRICATION CHART

13

SPECIFICATIONS

TRAILER

The complete generator is housed in a lockable enclosure with the frame fabricated from heavy gauge steel mounted on a two - wheel, leaf spring axle. The design enables the trailer to contain the outriggers in a simple, compact position. 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. This system was engineered to allow the light tower to remain operational in sustained winds of 65 MPH with the mast extended to full height and the outriggers in position.

MAST

The mast consists of a three section steel tube that extends to 30 feet. The mast is extended with two manual winches.The mast includes self lubricating nylon guide pads and a 360 degree rotatable light bar .

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 1000 watt lamp fixtures sealed for all weather use. SHO 1000 fixture - BT - 37 lamp, Metal Halide Laboratory rated life is 12,000 hours. Lumen rating: 110,000 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: 1. 2. 3. 4. 5. 6. 7. 8. Hitch is securely attached to the towing vehicle (safety chains securely attached All outriggers and jacks are retracted and secured. Rear tower support pin is in the locked position. 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.

14

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, Perkins, or Isuzu 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 D905, Perkins 103-10, Lombardini LDW 903 and the Isuzu 3LD 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 D905, LOMBARDINI LDW 903 (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: KUBOTA D905 Power Unit 1. Turn the key switch to the PREHEAT position, hold for 5 seconds, then release switch. 2. Depress the START ASSIST button and turn the key switch to the START position and the engine should start. Release the key immediately when the engine starts. Hold the START ASSIST button for five seconds after the engine starts then release. If engine fails to start it may be necessary to cycle the glow plugs again (see chart below). IF ENGINE HAS RUN OUT OF FUEL: 1. Hold the START ASSIST button for 10 seconds and then release. This will allow the fuel system to re-prime itself. 2. Follow normal starting procedures. PREHEATING TIME AMBIENT TEMPERATURE Ordinary heat type With glow plug timer

Above 50°F (10°C) 50°F (10°C) to 23°F (-5°C) Below 23°F (-5°C) Limit of continuous use NO NEED Approx. 5 seconds Approx. 10 seconds 20 seconds Automatic preheating is made for about 6 seconds when starter switch key is turned to preheating position

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 Engine Service Dealer for trouble analysis

15

STARTING INSTRUCTIONS

COLD WEATHER STARTING ISUZU 3LD and PERKINS 103-10 (for temperatures below 32° F/ 0° C)

1. If the 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 5 seconds or damage to the glow plugs may occur. 2. Turn the key switch to the "start" position and start the engine immediately once the indicator turns red. Release the key immediately when the engine starts. (If engine fails to start, repeat steps 1 and 2.) 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 ISUZU Engine Service Dealer for trouble analysis.

FOR A WARM ENGINE (Kubota, Perkins, Isuzu, and Lombardini engines)

Follow the same procedure as described for cold weather starting, skipping step 1. Use 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 fuel control to the shut-off position

16

SERIAL NUMBER LOCATIONS

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

17

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 serial number stamped on the engine block just below the exhaust manifold. (see illustration below ) The ISUZU and PERKINS 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 engine has the serial number tag located on the right side of the engine block. (see illustration below)

PERKINS engine serial number KUBOTA engine serial number

ISUZU engine serial number LOMBARDINI engine serial number

18

CONTROLS AND COMPONENTS

NOTE: COMPONENTS SHOWN ARE STANDARD. PICTURES MAY VARY WITH DIFFERENT OPTIONS.

FIG. 1. A.C./D.C.CONTROL PANEL (Kubota)

FIG. 1a. A.C./D.C.CONTROL PANEL (Isuzu and Perkins) 1. Breaker Switch Controls lights 1 and 2 2. Breaker Switch Controls lights 3 and 4 3. Hour Meter 33 2 2 Shows the total elapsed hours of engine operation. 4 4 4. Glow Plug Lamp 5. Key Switch 5 Turn key counter-clockwise to activate the glow plugs.

5

Fig. 1 (Kubota)

1

1

NOTE: Release key as soon as the engine fires.

FIG. 1a (Isuzu and Perkins)

19

CONTROLS AND COMPONENTS

NOTE: COMPONENTS SHOWN ARE STANDARD. PICTURES MAY VARY WITH DIFFERENT OPTIONS.

FIG. 1b. A.C./D.C.CONTROL PANEL (Lombardini) 1. Breaker Switch Controls lights 1 and 2 2. Breaker Switch Controls lights 3 and 4 3. Hour Meter Shows the total elapsed hours of engine operation. 4. Key Switch Turn key clockwise one click to activate the glow plugs. 5. Glow Plug Lamp NOTE: Release key as soon as the engine fires.

5

1 4

2 3

FIG. 2a. A.C./D.C.CONTROL PANEL (Electric Winch Model) 1a. Breaker Switches Controls lights 1 through 4 2a. Hour Meter Shows the total elapsed hours of engine operation. 3a. Glow Plug Lamp 4a. Key Switch Turn key counter-clockwise to activate the glow plugs. 5a. Electric Winch On/Off Switch 6a. Electric Winch Up/Down Switch NOTE: Release key as soon as the engine fires.

2a 3a 4a 6a 5a

1a

FIG. 2a (Electric Winch Model)

20

CONTROLS AND COMPONENTS

NOTE: COMPONENTS SHOWN ARE STANDARD. PICTURES MAY VARY WITH DIFFERENT OPTIONS.

7

6

FIG. 3. BALLAST PANEL 6. Transformer (lights 1 thru 4) 7. Capacitors (lights 1 thru 4)

FIG. 3

FIG. 4. CONVENIENCE PANEL 8. Grounding Lug (not shown) Attach ground rod lead here 9. 15 Amp Pop-up Circuit Breaker 9 10. 120 volt Outlet Receptacle

FIG. 4

10

FIG. 5. GROUND ROD 11. 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. 5

11

21

CONTROLS AND COMPONENTS

NOTE: COMPONENTS SHOWN ARE STANDARD. PICTURES MAY VARY WITH DIFFERENT OPTIONS. FIG. 6A ENGINE COMPONENT IDENTIFICATION (KUBOTA and PERKINS) 12. Water temp switch 13. Alternator 14. Starter 15. Air cleaner

12 13

15

14

FIG. 6A

FIG. 6B ENGINE COMPONENT IDENTIFICATION (ISUZU) 16. Water temp switch 17. Alternator 18. Starter 19. Air cleaner (not shown)

17 16 18

FIG. 6B

FIG. 6C ENGINE COMPONENT IDENTIFICATION (LOMBARDINI) 16c. Muffler 17c. Alternator 18c. Oil Filter 19c. Air cleaner (not shown)

19c 17c

16c

18c

FIG. 6C

22

20

FIG. 7A. ENGINE COMPONENT IDENTIFICATION (KUBOTA and PERKINS cont'd) 20. Oil fill 21. Glow plugs 22. Fuel solenoid 23. Fuel lift pump 24. Fuel filter 25. Oil filter

21

22 23 24 25

FIG. 7A

28

26 27

FIG. 7B. ENGINE COMPONENT IDENTIFICATION (ISUZU cont'd) 26. Oil fill 27. Glow plugs 28. Fuel solenoid 29. Fuel lift pump (not shown) 30. Fuel filter 31. Oil filter

30

31

FIG. 7B

FIG. 7C. ENGINE COMPONENT IDENTIFICATION (LOMBARDINI cont'd) 26c. Air Cleaner 27c. Starter 28c. Fuel solenoid 29c. Fuel pump 30c. Fuel filter 31c. Cooling Fan

31c 29c

26c 27c 30c

FIG. 7C

23

CONTROLS AND COMPONENTS

NOTE: COMPONENTS SHOWN ARE STANDARD. PICTURES MAY VARY WITH DIFFERENT OPTIONS.

35 32

FIG. 8 TOWING COMPONENT IDENTIFICATION 32. Tongue jack 33. Safety chains 34. Taillight wiring harness 35. Hitch (2" ball)

34

33

FIG. 8

FIG. 9. REAR OUTRIGGERS 36. Jack Handle Crank handle to raise or lower foot of jack to level trailer 37. Jack Pin Pull to allow jack to rotate 38. Outrigger Lock Stud

!

SAFETY WARNING

FIG. 9

Be sure outrigger jack is securely latched on the outrigger lock stud before towing.

40

FIG. 10. REAR TOWER SUPPORT 39. Pin Locks tower into the rear tower support 40. Tower Interlocking Pin Keeps tower from extending during towing 41. Cord Hanger Holds lamp cords up during towing

39 41

FIG. 10

24

CONTROLS AND COMPONENTS

NOTE: COMPONENTS SHOWN ARE STANDARD.

PICTURES MAY VARY WITH DIFFERENT OPTIONS.

FIG. 11 POSITIVE DOOR LATCH 42. Positive door latch Locks door in the open position

42

FIG. 11

43

FIG. 12. MANUAL WINCH HANDLE 43. Manual Winch Crank handle to raise or lower foot of jack to level trailer 44. Manual Winch Handle Used to raise and fold mast

44

FIG. 12 FIG. 13. MANUAL WINCH 45. Manual Winch Extends and lowers mast 46. Mast Handle Used to rotate tower and lights 47. Swivel Lock Knob Locks tower in position

45

47

46

FIG. 13 FIG. 13a ELECTRIC WINCH 45a. Strong Arm Winch--Used to raise and extend, lower and fold mast. 46a. Slack Limit Switch-(Located below winch on ballast panel) -Shuts off winch when cable slack is sensed by sensor arm. NOTE: See pages 10-11, Strong Arm Electric Winch Mast Operation, for correct operating procedures. 25 FIG. 13a

45a

46a

CONTROLS AND COMPONENTS

NOTE: COMPONENTS SHOWN ARE STANDARD. PICTURES MAY VARY WITH DIFFERENT OPTIONS.

FIG. 14 MAST LOCKING BAR LATCH 48. Mast Locking Bar Latch Locks mast in the vertical position and allows tower to rotate NOTE : Tower must be positioned with the manual winch forward before the mast locking bar can be released from the strike plate, allowing the tower to rotate toward the horizontal towing position.

FIG. 14

FIG. 15. KICK-OUT SPRING 49. Kick-out spring Tilts mast off center when folding mast down

FIG. 15

50

FIG. 16. LIFTING ATTACHMENT POINTS 50. Forklift Lifting Pockets Used to lift light tower using forklift to ease loading and unloading 51. Tower Lifting Eye Used for lifting light tower using a crane

51

FIG. 16

26

NOTE: COMPONENTS SHOWN ARE STANDARD. PICTURES MAY VARY WITH DIFFERENT OPTIONS.

FIG. 17 Electric Mast 52. Mast Handle--Use to rotate mast. 53. Lock Handle--Pull to unlock tower sections when raising tower. 54. Mast Locking Knob--Prevents accidental release of lock when rotating mast.

53

52

54

FIG. 17

56

FIG. 18 Rear Tower Lock Safety Switch 55. Safety Switch--Prevents winch operation while tower is in the down and locked position 56. Safety Switch Actuator cam--Closes switch and allows tower operation only when in the UNLOCKED position.

55

FIG. 18

27

ROUTINE MAINTENANCE SCHEDULE

KUBOTA D905, D1105, PERKINS 103-10, and LOMBARDINI LDW 903 INSPECTION AND LUBRICATION SCHEDULE

Check condition of the steel cable and make sure it is properly secured. Check hydraulic fluid level. LUBRICATION GREASE SPECIFICATIONS: N.G.L.I. consistency #2, high temperature anti-friction bearing lubricating grease. Service intervals shown below have been established for operation under normal conditions. Where equipment is operated under severe conditions (very dusty, extreme heat or cold, etc.) affected items should be serviced more frequently.

KUBOTA AND ISUZU

PERKINS ONLY

LOMBARDINI ONLY

28

TROUBLESHOOTING

!

SAFETY WARNING

DANGER!

HIGH VOLTAGE! DO NOT ATTEMPT TO TEST AND REPAIR GENERATOR AND

BALLAST ELECTRICAL SYSTEMS UNLESS YOU UNDERSTAND AND ARE QUALIFIED TO WORK ON SUCH SYSTEMS.

When one lamp does not light, TURN OFF THE GENERATOR and test the lamp by switching leads with a lamp that DOES light. DO NOT WEAR JEWELRY WHILE WORKING WITH ELECTRICITY! If the following 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

1. Circuit breakers in the outlet box are not turned on or have tripped. 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 lam 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 operations where the temperatures of the ballasts falls below ­20 degrees F. some means of warming the ballast must be used. 7. Low electrical system voltage. 8. A loose connection in the back of the lamp socket in the lamp holder. 9. A circuit breaker or breakers are defective. 10. A loose connection on the terminal board. 11. The engine and generator are not running up to speed (1800 RPM) 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.

ONE OR MORE LIGHTS DO NOT LIGHT UP.

For engine and generator troubleshooting, see engine and generator manuals or contact your dealer.

29

NIGHT-LITE NIGHT-LITE PRO SERIES PARTS 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

NIGHT-LITE SERIES

30

Information

NL PRO OPS BOOK Cable Elec 1-22-02.p65

30 pages

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