Atlas Copco QLT H50 Kd ESF Bedienungsanleitung

User and maintenance manual

for light towers

English

QLT H50 Kd ESF D1105-EBG2

ATLAS COPCO - PORTABLE ENERGY DIVISION

www.atlascopco.com

Printed matter N°

2954 7550 02

06/2014

QLT H50 Kd ESF

User and maintenance manual

for light towers

User and maintenance manual ..............................................................5

Circuit diagrams ....................................................................................81

Original instructions

- 4 -

Warranty and Liability Limitation

Use only authorized parts.

Any damage or malfunction caused by the use of unauthorized parts is not covered by

Warranty or Product Liability.

The manufacturer does not accept any liability for any damage arising from modifications,

additions or conversions made without the manufacturer's approval in writing.

Neglecting maintenance or making changes to the setup of the machine can result in major

hazards, including fire risk.

While every effort has been made to ensure that the information in this manual is correct,

Atlas Copco does not assume responsibility for possible errors.

Any unauthorized use or copying of the contents or any part thereof is prohibited.This applies

in particular to trademarks, model denominations, part numbers and drawings.

- 5 -

Contents

1 Safety precautions.........................8

1.1 Introduction........................................8

1.2 General safety precautions ...............9

1.3 Safety during transport and

installation........................................10

1.4 Safety during use and

operation ..........................................11

1.5 Safety during maintenance

and repair..........................................13

1.6 Tool applications safety ..................14

1.7 Battery safety precautions..............14

2 Main parts ......................................15

2.1 General description .........................15

2.2 Markings ...........................................16

2.3 Mechanical features.........................17

2.3.1 Engine and alternator ......................17

2.3.2 Cooling system.................................17

2.3.3 Safety devices ..................................17

2.3.4 Bodywork..........................................17

2.3.5 Control panel ....................................17

2.3.6 Data plate and serial number..........17

2.3.7 Filler caps..........................................18

2.3.8 Spillage free frame...........................18

2.3.9 Mast and floodlights ........................18

2.3.10 Undercarriage, road lights

and reflectors....................................18

2.4 Electrical features.............................19

2.4.1 Control and indicator panel.............19

2.4.2 Outlet socket (10 Amps)...................20

3 Installation and

connection......................................21

3.1 Lifting ................................................21

3.2 Parking and towing..........................21

3.2.1 Unhooking the light tower...............21

3.2.2 Positioning the light tower ..............22

3.2.3 Positioning for transport..................23

3.2.4 Towing ..............................................24

3.2.5 Transportation and

positioning of the light tower

onto vehicles.....................................25

3.3 Installation ........................................25

3.3.1 Indoor installation ............................25

3.3.2 Outdoor installation .........................26

3.4 Connecting the light tower .............26

3.4.1 Precautions fornon-linear and

sensitive loads ..................................26

4 Operating instructions................27

4.1 Before starting..................................27

4.2 Operating the light tower ...............27

4.2.1 Before the engine is started ............27

4.2.2 Starting the engine...........................28

4.2.3 Positioning the floodlights ..............28

4.2.4 Extending the mast ..........................29

4.2.5 Rotating the mast .............................29

4.2.6 Switching on/off the

floodlights .........................................30

4.2.6.1 Switching on the floodlights

manually ...........................................30

4.2.6.2 Switching off the floodlights

manually ...........................................30

Congratulations on the purchase of your QLT on-site light tower. It is a solid, safe and reliable machine, built according to the latest technology. Follow the instructions

in this booklet and we guarantee you years of trouble free operation. Please read the following instructions carefully before starting to use your machine.

While every effort has been made to ensure that the information in this manual is correct, Atlas Copco does not assume responsibility for possible errors. Atlas Copco

reserves the right to make changes without prior notice.

- 6 -

4.2.6.3 Switching on/off the

floodlights automatically.................31

4.2.7 Lowering the mast ...........................31

4.2.8 Stopping the engine ........................32

4.3 Connecting appliances ....................33

4.4 Setting the Lc1003™ controller......34

4.4.1 Pushbutton and LED functions........34

4.4.2 Module display.................................35

4.4.2.1 Home page .......................................35

4.4.3 Icon overview ...................................35

4.4.3.1 Instrumentation icons......................35

4.4.3.2 Active configuration.........................36

4.4.3.3 Front panel editor (FPE) / Auto

Run icons ..........................................36

4.4.3.4 Mode icons .......................................36

4.4.3.5 Light output icons ............................36

4.4.3.6 Alarm icons.......................................36

4.4.4 Navigation menu..............................37

4.4.5 Event log ...........................................37

4.4.6 Setting the Lc1003™ timer ..............37

5 Periodic maintenance .................39

5.1 Maintenance schedule.....................39

5.1.1 Precautions ....................................... 44

5.1.2 Use of maintenance schedule.........44

5.1.3 Use of service paks ..........................44

5.2 Preventing low loads.......................45

5.2.1 General..............................................45

5.2.2 Risks of low load operation.............45

5.2.3 Best practices ...................................45

5.3 Maintenance of the alternator........45

5.3.1 Measuring the alternator

insulation resistance ........................45

5.4 Engine maintenance procedures....46

5.4.2 Engine oil level check.......................46

5.4.3 Engine oil and oil filter change .......47

5.4.4 Coolant check ...................................48

5.5 Adjustments and service

procedures........................................49

5.5.1 Battery care.......................................49

5.5.2 Replacing fuel filter and pre-

filter element.....................................51

5.5.3 Servicing air filter engine ................51

5.5.4 Air cooling circuit .............................52

5.5.5 Replacing the lamps.........................52

5.5.6 Ordering spare parts........................53

5.6 Resetting service alarms .................53

5.7 Engine consumable

specifications....................................53

5.7.1 Engine fuel specifications................53

5.7.2 Engine oil specifications ..................53

5.7.3 Engine coolant specifications..........54

6 Checks and trouble

shooting..........................................55

6.1 Engine troubleshooting...................56

6.2 Solving controller alarms................56

6.2.1 General..............................................56

6.2.2 Alarm overview ................................57

7 Options available for QLT

H50 units.........................................63

7.1 Overview of the mechanical

options ..............................................63

7.2 Description of the mechanical

options ..............................................63

7.2.1 Undercarriage...................................63

7.3 Overview of the electrical

options ..............................................64

7.4 Description of the electrical

options ..............................................64

7.4.1 Auto mast down system..................64

7.4.2 Photocell ...........................................65

7.4.3 External power input (230

VAC), with battery charger ..............66

7.4.4 Override fuel shutdown ...................68

7.4.5 Earth pin............................................68

8 Storage of the light tower.........69

8.1 Storage..............................................69

8.2 Preparing for operation after

storage ..............................................69

9 Disposal...........................................70

9.1 General..............................................70

9.2 Disposal of materials .......................70

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10 Technical specifications of

the light tower ..............................71

10.1 Technical specifications of the

engine/alternator/unit ....................71

10.2 Critical bolt connections .................75

10.3 Average illumination versus

distance.............................................76

10.4 Dimension drawings........................77

10.4.1 Dimension drawing for QLT

H50 with fixed towbar......................77

10.4.2 Dimension drawing for QLT

H50 with adjustable towbar ............78

10.4.3 Dimension drawing for QLT

H50 with not homologated

towbar ............................................... 79

10.5 Conversion list of SI units into

British units ......................................80

10.6 Data plate .........................................80

- 8 -

1 Safety precautions

To be read attentively and acted accordingly before towing, lifting, operating, performing maintenance or repairing the light tower.

1.1 Introduction

The policy of Atlas Copco is to provide the users of their

equipment with safe, reliable and efficient products.

Factors taken into account are among others:

- the intended and predictable future use of the

products, and the environments in which they are

expected to operate,

- applicable rules, codes and regulations,

- the expected useful product life, assuming proper

service and maintenance,

- providing the manual with up-to-date information.

Before handling any product, take time to read the

relevant instruction manual. Besides giving detailed

operating instructions, it also gives specific information

about safety, preventive maintenance, etc.

Keep the manual always at the unit location, easy

accessible to the operating personnel.

See also the safety precautions of the engine and

possible other equipment, which are separately sent

along or are mentioned on the equipment or parts of the

unit.

These safety precautions are general and some

statements will therefore not always apply to a particular

unit.

Only people that have the right skills should be allowed

to operate, adjust, perform maintenance or repair on

Atlas Copco equipment. It is the responsibility of

management to appoint operators with the appropriate

training and skill for each category of job.

Skill level 1: Operator

An operator is trained in all aspects of operating the unit

with the push-buttons, and is trained to know the safety

aspects.

Skill level 2: Mechanical technician

A mechanical technician is trained to operate the unit the

same as the operator. In addition, the mechanical

technician is also trained to perform maintenance and

repair, as described in the instruction manual, and is

allowed to change settings of the control and safety

system. A mechanical technician does not work on live

electrical components.

Skill level 3: Electrical technician

An electrical technician is trained and has the same

qualifications as both the operator and the mechanical

technician. In addition, the electrical technician may

carry out electrical repairs within the various enclosures

of the unit. This includes work on live electrical

components.

Skill level 4: Specialist from the manufacturer

This is a skilled specialist sent by the manufacturer or its

agent to perform complex repairs or modifications to the

equipment.

In general it is recommended that not more than two

people operate the unit, more operators could lead to

unsafe operating conditions. Take necessary steps to

keep unauthorized persons away from the unit and

eliminate all possible sources of danger at the unit.

When handling, operating, overhauling and/or

performing maintenance or repair on Atlas Copco

equipment, the mechanics are expected to use safe

engineering practices and to observe all relevant local

safety requirements and ordinances. The following list is

a reminder of special safety directives and precautions

mainly applicable to Atlas Copco equipment.

Neglecting the safety precautions may endanger people

as well as environment and machinery:

- endanger people due to electrical, mechanical or

chemical influences,

- endanger the environment due to leakage of oil,

solvents or other substances,

- endanger the machinery due to function failures.

All responsibility for any damage or injury resulting

from neglecting these precautions or by non-observance

of ordinary caution and due care required in handling,

operating, maintenance or repair, also if not expressly

mentioned in this instruction manual, is disclaimed by

Atlas Copco.

- 9 -

The manufacturer does not accept any liability for any

damage arising from the use of non-original parts and for

modifications, additions or conversions made without

the manufacturer’s approval in writing.

If any statement in this manual does not comply with

local legislation, the stricter of the two shall be applied.

Statements in these safety precautions should not be

interpreted as suggestions, recommendations or

inducements that it should be used in violation of any

applicable laws or regulations.

1.2 General safety precautions

1 The owner is responsible for maintaining the unit in

a safe operating condition. Unit parts and

accessories must be replaced if missing or

unsuitable for safe operation.

2 The supervisor, or the responsible person, shall at

all times make sure that all instructions regarding

machinery and equipment operation and

maintenance are strictly followed and that the

machines with all accessories and safety devices, as

well as the consuming devices, are in good repair,

free of abnormal wear or abuse, and are not

tampered with.

3 Whenever there is an indication or any suspicion

that an internal part of a machine is overheated, the

machine shall be stopped but no inspection covers

shall be opened before sufficient cooling time has

elapsed; this to avoid the risk of spontaneous

ignition of oil vapour when air is admitted.

4 Normal ratings (pressures, temperatures, speeds,

etc.) shall be durably marked.

5 Operate the unit only for the intended purpose and

within its rated limits (pressure, temperature,

speeds, etc.).

6 The machinery and equipment shall be kept clean,

i.e. as free as possible from oil, dust or other

deposits.

7 To prevent an increase in working temperature,

inspect and clean heat transfer surfaces (cooler fins,

intercoolers, water jackets, etc.) regularly. See the

maintenance schedule.

8 All regulating and safety devices shall be

maintained with due care to ensure that they

function properly. They may not be put out of

action.

9 Pressure and temperature gauges shall be checked

regularly with regard to their accuracy. They shall

be replaced whenever outside acceptable tolerances.

10 Safety devices shall be tested as described in the

maintenance schedule of the instruction manual to

determine that they are in good operating condition.

11 Mind the markings and information labels on the

unit.

12 In the event the safety labels are damaged or

destroyed, they must be replaced to ensure operator

safety.

13 Keep the work area neat. Lack of order will increase

the risk of accidents.

14 When working on the unit, wear safety clothing.

Depending on the kind of activities these are: safety

glasses, ear protection, safety helmet (including

visor), safety gloves, protective clothing, safety

shoes. Do not wear the hair long and loose (protect

long hair with a hairnet), or wear loose clothing or

jewellery.

15 Take precautions against fire. Handle fuel, oil and

anti-freeze with care because they are inflammable

substances. Do not smoke or approach with naked

flame when handling such substances. Keep a fire-

extinguisher in the vicinity.

16a On-site light towers (with earthing pin):

Earth the light tower as well as the load properly.

- 10 -

1.3 Safety during transport and

installation

To lift a unit, all loose or pivoting parts, e.g. doors and

towbar, shall first be securely fastened.

Do not attach cables, chains or ropes directly to the

lifting eye; apply a crane hook or lifting shackle meeting

local safety regulations. Never allow sharp bends in

lifting cables, chains or ropes.

Helicopter lifting is not allowed.

It is strictly forbidden to dwell or stay in the risk zone

under a lifted load. Never lift the unit over people or

residential areas. Lifting acceleration and deceleration

shall be kept within safe limits.

1 Before towing the unit:

- check the towbar, the brake system and the

towing eye. Also check the coupling of the

towing vehicle,

- check the towing and brake capability of the

towing vehicle,

- check that the towbar, jockey wheel or stand leg

is safely locked in the raised position,

- ascertain that the towing eye can swivel freely on

the hook,

- check that the wheels are secure and that the

tyres are in good condition and inflated correctly,

- connect the signalisation cable, check all lights

and connect the pneumatic brake couplers,

- attach the safety break-away cable or safety

chain to the towing vehicle,

- remove wheel chocks, if applied, and disengage

the parking brake.

2 To tow a unit use a towing vehicle of ample

capacity. Refer to the documentation of the towing

vehicle.

3 If a unit is to be backed up by a towing vehicle,

disengage the overrun brake mechanism (if it is not

an automatic mechanism).

4 In case of transporting a non-trailer unit on a truck,

fasten it to the truck by attaching straps via fork lift

holes, via the holes in the frame at the front and

back or via the lifting beam. To prevent damage,

never put straps on the roof surface of the unit.

5 Never exceed the maximum towing speed of the

unit (mind the local regulations).

6 Place the unit on level ground and apply the parking

brake before disconnecting the unit from the towing

vehicle. Unclip the safety break-away cable or

safety chain. If the unit has no parking brake or

jockey wheel, immobilize the unit by placing

chocks in front of and/or behind the wheels. When

the towbar can be positioned vertically, the locking

device must be applied and kept in good order.

7 To lift heavy parts, a hoist of ample capacity, tested

and approved according to local safety regulations,

shall be used.

8 Lifting hooks, eyes, shackles, etc., shall never be

bent and shall only have stress in line with their

design load axis. The capacity of a lifting device

diminishes when the lifting force is applied at an

angle to its load axis.

9 For maximum safety and efficiency of the lifting

apparatus all lifting members shall be applied as

near to perpendicular as possible. If required, a

lifting beam shall be applied between hoist and

load.

10 Never leave a load hanging on a hoist.

11 A hoist has to be installed in such a way that the

object will be lifted perpendicular. If that is not

possible, the necessary precautions must be taken to

prevent load-swinging, e.g. by using two hoists,

each at approximately the same angle not exceeding

30° from the vertical.

12 Locate the unit at least 1 meter away from walls.

Take all precautions to ensure that hot air exhausted

from the engine and driven machine cooling

systems cannot be re-circulated. If such hot air is

taken in by the engine or driven machine cooling

fan, this may cause overheating of the unit; if taken

in for combustion, the engine power will be

reduced.

13 light towers shall be stalled on an even, solid floor,

in a clean location with sufficient ventilation. If the

floor is not level or can vary in inclination, consult

Atlas Copco.

14 The electrical connections shall correspond to local

codes. The machines shall be earthed and protected

against short circuits by fuses or circuit breakers.

15 Never connect the light tower outlets to an

installation which is also connected to a public

mains.

16 Before connecting a load, switch off the

corresponding circuit breaker, and check whether

frequency, voltage, current and power factor

comply with the ratings of the light tower.

17 Before transportation of the unit, switch off all the

circuit breakers.

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