Acuity Brands Lighting Holophane 05 User manual

Page 1of 1
IMPORTANT SAFETY INSTRUCTIONS
LOWERING DEVICES

To reduce the risk of death, personal injury or property damage from fire, electric shock, falling parts, cuts/abrasions, and other
hazards please read all warnings and instructions.
Before installing, servicing, or performing routine maintenance upon this equipment, follow these general precautions.
Installation and service of Lowering Devices should be performed by a qualified licensed electrician and mechanical technician.
Maintenance of the Lowering Devices should be performed by person(s) familiar with the Lowering Devices construction and
operation and any hazards involved.
DO NOT INSTALL DAMAGED PRODUCT! This Lowering Device has been properly packed so that no parts should have been
damaged during transit. Inspect to confirm. Any part damaged or broken during or after assembly should be replaced.
These instructions do not purport to cover all details or variations in equipment nor to provide every possible contingency to meet
in connection with installation, operation, or maintenance. Should further information be desired or should particular problems
arise which are not covered sufficiently for the purchaser’s or owner’s purposes, this matter should be referred to Acuity Brands
Lighting, Inc.
Failure to follow any of these instructions could void product warranties.
For a complete listing of product Terms and Conditions, please visit www.acuitybrands.com.
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Acuity Brands Lighting, Inc. assumes no responsibility for claims arising out of improper or careless installation or handling of its products.
© 2010 Acuity Brands Lighting, Inc. All rights reserved. 6/03/13 ABL General Warnings, Form No. 503.204
READ AND FOLLOW ALL SAFETY INSTRUCTIONS!
SAVE THESE INSTRUCTIONS AND DELIVER TO OWNER AFTER INSTALLATION
Disconnect or turn off power before installation or servicing.
Verify that supply voltage is correct by comparing it with the luminaire label information.
Make all electrical and grounded connections in accordance with the National Electrical Code (NEC) and any applicable local
code requirements.
All wiring connections should be capped with UL approved recognized wire connectors.
WARNING
RISK OF ELECTRIC SHOCK
Do not stand directly beneath the pole or lowering device during installation except as instructed to in this manual.
Do not depend on the lowering device cables to tether a slip-fit type pole. Failure to use a tethering cable may result in injury
or death.
Operate the lowering device only while standing at the maximum distance from the pole allowed by the twenty foot long
remote control cord. Failure to follow this procedure may result in injury or death.
Wear gloves, safety glasses, hardhats and safety shoes at all times when removing Lowering Devices from carton, installing,
servicing or performing maintenance.
Follow pole manufacture installation instruction.
Follow luminaire manufacture installation instruction when attaching to the lowering device.
Do not expose the torque limiter or shear pin to damaging elements or mistreatment such as sand, mud, salt spray or other
conditions which could render either safety mechanism inoperable. Do not attempt to adjust the torque limiting clutch or
replace the shear pin. If repairs are necessary, replace damaged equipment with replacement components from Holophane.
Failure to follow these warnings may result in injury or death.
CAUTION
RISK OF INJURY

HIGH MAST
LOWERING DEVICES 05 and 08
This manual must remain with the lowering device and always be available to the owner and
operator. Before operating the device, an operator must read and understand completely the
operating instructions in this Owner’s Manual.
Additional manuals are available from Holophane. Refer to the manual number in the lower
right corner of this page. Less detailed information regarding installation, operation and main-
tenance of Holophane Lowering Devices is available in VHS video format. For information or
service,call866-759-1577. Askfor the Order Service Departmentandreferto the sales order
numbershownbelow.
SALES ORDER NUMBER
....................................................
IM-185-D
OWNER’S
MANUAL
LD TYPE 05:
TOP LATCHING, CENTERING ARM, INTERNAL WINCH AND PORTABLE DRIVE MOTOR
LD TYPE 08:
TOP LATCHING, BUMPER, INTERNAL WINCH AND PORTABLE DRIVE MOTOR

PLEASE READ
THIS NOTICE
1. A copy of this manual is to remain with the lowering device at all times. Keep it in
the sealed plastic protective cover provided and store inside the pole handhole cover.
2. Operating and maintenance personnel must read and understand completely
Sections III and IV.
3. Additional copies of this manual are available from Holophane.
4. To expedite information and service, call [phone]. Ask for the Customer Service
Department and refer to the sales order number shown on the first page of this manual.
5. Electrical power is required during installation for final cable adjustments.
1

TABLE OF CONTENTS
Section I
Lowering Device Material List
Section II
Assembly Instructions
Section III
Operating Instructions
Section IV
Maintenance Instructions
4.1 LUBRICATION
4.2 REPLACING THE WINCH CABLE
4.3 PORTABLE DRIVE MOTOR SHAFT REPLACEMENT
4.4 POWER CORD REPLACEMENT
4.5 LUMINAIRE REMOVAL
4.6 LATCH SYNCHRONIZATION ADJUSTMENT AND LATCHING
Section V
Attachments
2

HOLOPHANE High Mast
Lowering Devices SECTION I
LOWERING DEVICE MATERIAL LIST
Assemblies Supplied With Each Device:
Headframe assembly with cover (one per)
Mounting ring assembly (one per)
Power cord and ring junction box (one per)
Clevis assembly with coiled hoisting cables (one per)
Winch and winch mounting plate with circuit breaker enclosure (one per)
Luminaire mounting arms (quantity as required)
Hardware box (one per)
Portable Power Unit (Ordered separately - normally one per installation):
Power Unit
Wooden leveling block assembly (three per)
Step-down transformer for other than 120 volt (one per)
3

GR1129
4

2.1 Pole Preparation
2.1.1 See pole supplier or contact Holophane Cus-
tomer Service to obtain instructions for proper pole
preparation and pole assembly.
CAUTION
Improper pole assembly will adversly affect the opera-
tion of the lowering device. For proper operation, the
pole sections must be completely seated before
installation of the lowering device.
2.1.2 During or after assembly of the pole, string a light
rope, wire or cable through the pole to aid in pulling
hoisting and power cables.
2.1.3 Orient the pole so that the handhole is facing up,
and support the pole without sag with the top end at
least three feet above the ground.
2.2 Installing the Headframe and Mounting Ring
Assemblies and Stringing the Hoisting Cables
2.2.1 Place the lowering device crate near the top of
the pole. After removing the top and sides of the
carton, remove the headframe assembly by lifting it
from the mounting ring assembly. Lift in one move-
ment, keeping the headframe plate level; otherwise, the
latches may catch. Place the headframe assembly
near the top of the pole on a clean surface.
2.2.2 Slide the LD ring over the top of the pole and
about 4 ft. down. (See Figure 1) The iris-type guide
arms or the bumper ring should be oriented toward the
bottom of the pole.
2.2.3 Unpack the junction box with the main power
cord and place near the top of pole. Uncoil the power
cord halfway down along the pole and back to the top.
Uncoil in a manner that will not leave the cord twisted.
2.2.4 Unpack the clevis assembly with the hoisting
cables and place clevis near the bottom of the head
frame. Uncoil the cables, (hand over hand), without
twisting, laying them along side the pole. It is helpful to
place the clevis inside the pole top during this opera-
tion.
CAUTION
The cables must be carefully rolled out straight, (hand
over hand), as if pulled from a reel; otherwise, they may
coil and kink when pulled tight, resulting in cable
damage.
2.2.5 Securely prop the head frame on its edge with
the large power cable slot oriented up. The head frame
must be fully supported while pulling cables to prevent
it from falling over and potentially causing damage.
2.2.6 Thread one of the hoisting cables up through one
of the small round holes in the cable divider plate inside
the headframe assembly (See Figure 2), then over the
top of the two sheaves in the sheave bracket and down
through the latch barrel. Do not allow the cable to go
outside the cable keepers on the outside edge of the
sheave. (See Figure 3). Pull the cable, to remove the
slack, with the clevis positioned near the bottom of the
triangular slipfitter.
HOLOPHANE High Mast
Lowering Devices SECTION II
ASSEMBLY INSTRUCTIONS
Figure 1 GR1130 Figure 2 GR1131
VIEWED FROM ABOVE
5

2.2.7 Locate the free end of the second cable. Without
wrapping or crossing the cables, especially with the
cable already installed, thread this cable through its
respective opening in the cable divider plate, over the
pulleys and through the latch barrel. Continue to pull
the cable to remove the slack. String the last hoisting
cable in the same manner. Check to see that the
positions of the cable attachments to the clevis are
aligned with the openings in the cable divider plate.
CAUTION
Be sure the cables are not crossed or wrapped around
each other. Fouled cables will cause cable damage
and improper device operation.
2.2.8 Thread the power cord through the power cord
slot, near the outside edge of head frame plate, over
the power cord rollers and through the slot of the cable
divider plate adjacent to the cord roller. (See Figure 4)
2.2.9 Feed the power cord through the large center
hole in the clevis approximately 2 feet, making certain it
is centered in the three hoisting cables.
CAUTION
The power cord and cables must not be crossed or
wrapped around each other.
2.2.10 Securely fasten the compression clamp on the
power cord just under the clevis plate. The location of
the clamp is not critical at this time. The clamp will be
repositioned after the pole is erected.
NOTE
Double-check for crossed or wrapped cables and cord
at this time. With the clevis located near the slipfitter it
is very simple to check for proper assembly. After the
pole is erected, it will be nearly impossible.
2.2.11 Attach the light rope, wire or cable, which was
strung through the pole, to the U-shaped bail of the
clevis and pull the clevis into the top of the pole. (See
Figure 5)
HOLOPHANE High Mast
Lowering Devices SECTION II
2.2.12 Pick up the headframe assembly and slide the
slipfitter over the top of the pole while pulling the clevis
down the pole to take up slack in the cables. (See
Figure6) Afterorientingtheheadframewiththepower
cordon the top, alignedwiththepole handhole tighten
the six set screws to 25 to 30 inch pounds .
2.2.13 Pull all cables down through the pole and stop
when the clevis is at the top of the handhole.
2.3 Installing the Winch
2.3.1 Install the winch assembly to the pole support
plate inside the base of the pole. Secure the assembly
at each corner with the four hex head machine bolts
and nuts. The nuts at the top two corners must be
placed behind the plate. The bottom bolts may be
Figure 5
Figure 4
Figure 3
CLEVIS
COMPRESSION
CLAMP
GR1132
GR1133
GR1134
6

2.4 Hoisting Cable Rigging and Adjustment
2.4.1 Rotate the winch drum, using a 5/8” socket or
wrench to adjust the position of cable-end swivel fitting.
The pin in the swivel should be 29 ±1 in. above the
center line of the winch drum.
2.4.2 Attach the winch cable swivel fitting to the U-
shaped bail of the clevis. Insert the swivel pin in the
direction so that the head of the pin is on the side of the
clevis bail with the power cord. Insert the cotter pin into
the hole in the pin and bend both ends to secure it.
(See Figure 8)
insertedfrombehind and nuts tightened at thefront.
When installed correctly the power unit mounting
bracket should be at the right side of the handhole.
(See Figure 7)
NOTE
If the winch assembly components were removed from
the plate to allow the plate to be inserted through the
handhole, realignment of the winch, power unit mount-
ing bracket and cable guide is required. To do so,
insert the power unit into the mounting bracket and
move the winch and/or bracket as required until the
power unit drive coupling slides freely onto the winch
input shaft. Center the cable guide over the winch
drum. Tighten all nuts securely.
HOLOPHANE High Mast
Lowering Devices SECTION II
Figure 6
Figure 9
2.4.3 At the top of the pole, orient the LD ring so that
the strain plate mounting hole on the top flange of the
ring aligns with the power cord slot on the headframe.
(See Figure 9)
Figure 7
GR1135
GR1136A GR1138
7
Figure 8
SWIVEL FITTING
U-SHAPED BAIL
OF CLEVIS
GR1137
COTTER PIN
OPPOSITE
POWER CORD
SWAGE FITTING
WINCH CABLE
CLEVIS

2.4.4 Insert the free end of each of the hoisting cables
down through its corresponding latch pin on the LD
ring. Be careful not to loop or kink the cables as they
are being pulled through.
2.4.5 Pull a hoisting cable just slightly tight and straight
out of the fitting below the iris arm. Install the adjust-
ment tube and locking nut onto the cable, threaded end
first, slide it up and thread it into the fitting below the iris
arm. (See Figure 10)
HOLOPHANE High Mast
Lowering Devices SECTION II
Figure 11
2.4.6.5 Force the cable
through the fitting. Do not
pull back on the cable once
it is started through the
fitting. As the cable exits,
the plastic sealing plug will
be forced out and may be
discarded.
2.4.7 Repeat the steps in
paragraphs 2.4.4 through
2.4.6.5 for the remaining two
cables.
CAUTION
Make sure all the hoisting
cables are seated in their
respective pulley grooves.
2.4.8 Install one large slotted washer on the top end of
each latch pin. (See Figure 12) A little black tape may
be helpful holding the washers in place while perform-
ing the next step. Lift the mounting ring and insert the
latch pins, complete with washers, into the latch
barrels. While workers hold the ring against the
headframe, pull one of the hoisting cables as tight as
possible by hand and slide the terminal fitting against
the fitting holder. Repeat for the other two hoisting
cables.
2.4.9 Repeat the tightening of the three cables with
one worker pulling as hard as possible on each cable
as another worker pushes the terminal fitting against
the fitting holder.
GR1139
2.4.6 Install the cable terminal fitting on the cable as
follows:
CAUTION
Handle carefully and do not drop the cable terminal
fittings into mud, dirt, sand, etc. The fittings are sealed
at both ends, oil lubricated, and encased in plastic bags
for the protection of their internal parts.
2.4.6.1 Inspect the end of the hoisting cable. Remove
any tape or wire seizing. The end should be clean-cut,
round, and have no frayed strands.
2.4.6.2 Remove the cable terminal fitting from the
plastic bag.
2.4.6.3 Grasp the cable with one hand about four or
five inches from the end. Hold the fitting firmly in the
other hand with the small tapered end toward the cable.
2.4.6.4 Carefully insert the end of the cable into the
aluminum guide cup in the small end of the fitting. (See
Figure 11)
Figure 10
Figure 12 GR1140
GR1234
8

2.4.10 Make a small loop in each cable below the fitting
and secure the loop with a U-bolt cable clamp. Position
the U-bolt clamp 1/2" to 3/4" below the terminal fitting.
Securely tighten the nuts on the U-bolt clamp. (See
Figure 13) Cut off the excess cable leaving about 6 in.
below the clamps. Tape the ends of the cables for a
distance of about one inch to prevent fraying.
adjustment nuts on the ends of the two spring guide
rods. Use two wrenches to lock the adjustment nuts in
place by jamming them together tightly. (See Figure
14)
2.5.3 Install the junction box arm on the ring at the
location immediately adjacent and to the right of the
power cord slot. (See Figure 15)
2.5.4 Install the junction box onto the left side of the
junction box arm using the four 1/4-20 locknuts sup-
plied in the bag attached to the strain plate.
CAUTION
Do not attempt to remove the nuts attached to the studs
protruding from the back of the junction box.
HOLOPHANE High Mast
Lowering Devices SECTION II
Figure 13 GR1141
2.4.11 Use a 5/8” torque wrench and rotate the winch
input shaft to approximately 40 Ft. Lbs. to put tension on
the cables. Check the terminal cable fittings to insure
that they have set properly. Cable should not be pulled
into the terminal cable fitting more than 1/4”.
CAUTION
If the cable has moved more than 1/4” through any of the
cable terminal fittings, the fitting has not set properly.
Contact the Field Service Department. (740-345-9631).
2.5 Completing the Pole-top Assembly
2.5.1 If the device is equipped with a bumper ring
instead of iris-type guide arms, proceed to paragraph
2.5.3. Otherwise, attach both angle brackets to the ring.
(See Figure 14) The double washers must be installed
between the brackets and the ring to avoid possible
interference with the luminaire mounting brackets which
will be mounted to the ring later. Tighten each locknut
until it is snug and then loosen it about one half turn to
allow the bracket to pivot. The bolt, with nut installed,
should turn freely when properly adjusted.
2.5.2 Adjust the guide arms so the distance between
each wheel and the surface of the pole is 1/4 - 1/2 in. It
will be necessary to lift the ring to center the wheels
while checking the clearance between the wheels and
the pole. The adjustment is made by rotating the two Figure 15 GR1224
Figure 14
WASHERS (2) ANGLE
BRACKET ADJUSTMENT
NUTS
RING
LOCKNUT
GR1142
9

HOLOPHANE High Mast
Lowering Devices SECTION II
LUMINAIRE CONFIGURATION
(TOP VIEW OF RING)
*FAA Marker locations. Mount the FAA marker at these locations on lowering devices with 2,
3, 4, and 6 luminaires. For devices with 8, 9, or 10 luminaires, mount the FAA marker at any
vacant luminaire mounting position.
**Counterweight locations. Mount counterweight at these locations for lowering devices with 2,
3, and 4 luminaires.
IMPORTANT! The configurations as shown above must be maintained. If other than the
above locations are used, latching problems may result due to improper ring balance.
Figure 16
JUNCTION BOX (TYP)
VACANT LUMINAIRE MOUNTING LOCATIONS (TYP)
GR1144
10

2.5.5 Install the power cord strain plate, attached to the
power cord, to the underside of the top flange of the
ring using the 3/8” bolt and locknut supplied. (See
Figure 17)
HOLOPHANE High Mast
Lowering Devices SECTION II
2.5.9 Tie a rope to the LD ring near the power cord
strain plate. The rope length must be at least the length
of the pole. This will be used to apply downward force
on the ring in the event that the size and length of the
power cord is sufficient to impair the lowering of the
relatively light-weight mounting ring. (See Figure 19).
2.5.10 Secure the circuit breaker cord inside the
handholetopreventdamageduringpole erection.
2.5.11 Install the luminaire mounting arms at the
appropriate location with the bolt heads on the inside of
the ring. (See Figure 16) Do NOT mount the lumi-
naires at this time.
2.5.6 Pull the power cord down the pole until tightly
seated onto its rollers. If the cord extends below the
pole base, it is advisable to move the clamp toward the
clevis plate and then secure the excess cord to protect
it during the pole erection.
2.5.7 If the optional lightening rod is supplied, find the
dimple located on the top surface of the headframe
cover. Otherwise, proceed to step 2.5.8.
2.5.7.1 Punch a 7/8" hole in the cover at the dimple
location and install the rubber grommet.
2.5.7.2 Thread the lightning rod into the lightning rod
bracket, tightening securely.
2.5.7.3 Make sure all the hoisting cables and power
cord are seated in their respective pulley grooves.
2.5.7.4 Align the grommet in the headframe cover with
the lightning rod and slide the cover over the lightning
rod, down to the headframe. (See Figure 18).
NOTE
It may be helpful to apply a thin coat of oil to the
lightning rod before installing the headframe cover.
2.5.8 Make sure all the hoisting cables and power cord
are seated in their respective pulley grooves. Install the
headframe cover on to the headframe and secure it
with the screws and lock nuts provided. Tighten screws
and lock nuts to 15-20 inch pounds. Do not over torque.
Figure 17 GR1143
11
Figure 18 GR1280
Figure 19
TETHERING LINE
PULL ROPE GR1145

Do not leave this too long since it can become entangled
withthewinch cable. Reference the wiring diagram
inserted in this manual and install and wire the plug.
Installrubberplugcoverifrequired. Fordetailsofrubber
HOLOPHANE High Mast
Lowering Devices SECTION II
NOTE
Install the mounting arm bolts from the inside of the ring
toward the arm. Tighten the nut onto the bolt against
the mounting arm bracket.
2.6 Pole Erection and Wiring of the Base
2.6.1 Erect the pole in a manner normal for the rigger,
using a tethering cable to the base of the pole, if the
pole joints are a slip-fit type. (See Figure 19)
WARNING
Do not depend on the lowering device cables to tether a
slip-fit type pole. Failure to use a tethering cable may
result in injury or death.
2.6.2 Plumb the pole and tighten the anchor bolt nuts
to AASHTOStandardSpecificationsforStructural
SupportsforHighwaySigns,LuminairesandTraffic
Signals - Fifth Edition 2009 Section 5.17.5.2 anchor bolt
pretensioning.
2.6.3 Referencethewiring diagrams inserted at the end
of this section to make the appropriate connections to
the circuit breaker. Install the circuit breaker cover.
2.6.4 Be sure the power cord is hanging freely through
the hole in the clevis. Position the cord clamp approxi-
mately two inches below the clevis plate and tighten the
cord clamp screws securely. (See Figure 20)
2.6.5 Cut off the power cord 8 to 10 in. below the clamp.
12
Figure 21
Before wiring twistlock plug to the power cord, install the
black rubber protective cover as follows;
1. Compare cord diameter with ring diameter on
end of cover. If cord diameter is greater than ring
diameters, cut off flush with next larger diameter
ring.
NOTE: Under no circumstances cut off more than
three rings.
2. After cutting off ring, if required, slip power cord
through cover and wire twistlock plug.
3. Slide rubber cover down over plug.
CUT HERE
GR1147
coverinstallation,seeFigure21. Therubberplugcover
is supplied for 30 amp plugs only.
2.7 Lower Ring to Ground for Luminaire Installa-
tion
2.7.1 Attach portable drive motor to mounting bracket
on winch assembly and secure with pin. See Section 3
for more details.
2.7.2 For voltages other than 120 volts, connect the
secondary of the transformer to the portable drive
motor. Plug the cord from the primary of the trans-
former into the circuit breaker cord. Turn on the circuit
breaker to energize the power unit. With 120 volt
systems there is no transformer and the portable drive
motor cord plugs directly into the circuit breaker cord.
WARNING
Do not break and make the circuit with the plug and
connector. Use the circuit breaker. Failure to use the
circuit breaker may result in electrical shock.
2.7.3 Uncoil the 20 ft. control cord. Rotate the power
CLEVIS
CORD
CLAMP
PLUG
2” TO 3”
8” TO 10”
Figure 20 GR1146
POWER
CORD

HOLOPHANE High Mast
Lowering Devices SECTION II
unit drum switch to the “REV” position. Since the
system is not latched, the mounting ring will lower. Do
notlower to less thanfourfeetabove pole base. (For
complete operating instructions refer to Section III of
this manual). Pull on the rope if it is necessary to bring
the mounting ring down smoothly. After the ring is
down, remove the slotted washers off the latch pins and
remove the rope. Turn off the circuit breaker.
2.7.4 Route luminaire cords from Junction Box, around
ring and through the arms.
2.7.5 If optional Fixed Wireway Covers are included,
install as follows:
2.7.5.1 Loosen luminaire mounting arms from ring.
2.7.5.2 Mount Wireway Cover, with notch for strain
plate, to left of the Junction Box Arm by slipping cover
between the ring and the arms.
2.7.5.3 Mountothercovers between ring and arms.
13
Figure 22 GR1423
2.7.5.4 Re-tighten arms to ring. (See Figure 22)
2.7.6 Mountand wire the luminaires, (andoptionalFAA
warninglightsif required), according to the instructions
supplied with the luminaires and FAAlights. Install the
proper lamps.
2.7.7 When included, mount the counter-weight to the
loweringring adjacent to thewiringboxusing the
stainless steel bolts and nuts supplied. (See Figure 16)
2.7.8 Plug the circuit breaker cord into the power inlet
on the junction box and turn on the circuit breaker.
Checkforproperoperationoftheluminaires. Turnoffthe
circuitbreaker.
WARNING
Do not break and make the circuit with the plug and
connector. Use the circuit breaker. Failure to use the
circuit breaker may result in electrical shock.
2.8 Latch Synchronization Adjustment
2.8.1 Attach a wooden cable marker assembly to each
hoisting cable with its top at least 24 in. above the top
of the latch pin. Bolt the two halves only tight enough so
thatthe marker can bemoveddownthe cable when a30
or 40 lbs. force is applied. Also center the marker and
keep its top edge square with cable. (See Figure 23)
2.8.2 Disconnect the circuit breaker cord from the power
inlet on the junction box and connect it to the portable
drivemotorortransformer,asrequired. Turn on the
breaker. Thedevice, complete with luminaires, is now
ready to be raised to the top of the pole.
2.8.3 Following the operating instructions of Section III,
raise the ring and luminaires to the top of the pole,
stopping just before the wooden cable markers contact
the latch barrels.
Figure 23 GR1148

2.8.4 Carefullymovethedeviceupwarduntilthethree
markers are just touching the latch barrels. At this
point,movethering upward another foot. This causes
the markers to slide down towards the latch pins and to
becomepositionedrelativeto the latch barrels.
HOLOPHANE High Mast
Lowering Devices SECTION II
14
2.8.7 Removethe cable markers from the hoisting
cablesandstorewithportabledrivemotor.
2.8.8 Rotate each latch and flag to be certain that they
rotate freely. Return them to the unlatched position,
tangent to the ring.
2.8.9 Raise the mounting ring to the top of the pole and
latch it to the headframe as instructed in Section III,
"OperatingInstructions."
WARNING
Be certain the swage fitting on the end of the winch
cable does not wrap onto the winch drum before the
torque limiter disengages the drive. If the swage fitting
begins to wrap onto the drum, stop the motor and lower
the ring. Mark the three hoisting cables an appropriate
and equal amount above the latch pins to insure the
swage fitting will not wrap onto the drum. Slide the
terminal fittings up until all three latch pins meet the
new marks. It may be necessary to tap on the bottom
of the terminal fittings to free them. Use the adjustment
nuts as necessary. Failure to do this can cause
damage to the swage fitting, potentially resulting in
property damage, injury or death.
CAUTION
Carry out the following step to remove any excessive
twist that may have been introduced into the cables
during installation.
2.8.10 When the ring is initially raised and latched with
the full weight of luminaires, the clevis with hoisting
cables and power cord may rotate and twist a few turns
due to the “constructional stretch” inherent in new
cables. With the device latched and the load off the
cables, remove the twist by rotating the clevis until the
hoisting cables and the power cord appear to be
hanging straight. Use a good flashlight or other hi-
power light source to visually check as you remove the
twist.
2.8.11 Turn off the circuit breaker. Disconnect the
circuit breaker cord from the portable drive motor or
transformer and connect it to the pole power cord and
turn on the circuit breaker.
2.8.12 Removetheportabledrivemotor, place the
manual in the plastic pouch provided and secure it inside
thepole. Installthehandholecover.
2.8.5 Lowerthe ring to nolessthan four feet abovepole
base. Make sure the ring is hanging free on the hoisting
cables. Accurately measure the distance from top of
each wooden cable marker to the top of the latch pin.
(SeeFigure24)
2.8.6 Rotate the adjustment tubes until the distances
from the top of the markers to the latch pins are the
same for all three hoisting cables within +/- 1/16”. Then
tighten the locking nut to secure adjusting tube in
position. Note that there is a small (1/4") flat on the
threaded end, DO NOT unthread down past this when
doing adjustments. (See Figure 25)
Figure 25 GR1150
Figure 24 GR1149

SINGLE CIRCUIT WIRING DIAGRAMS
15
GR1164
GR1165
GR1166

DOUBLE CIRCUIT WIRING DIAGRAMS
16
GR1167
GR1168

usingahighpoweredflashlight.
•Twistedand crossed hoisting cables
•Powercordtangled with hoisting cables
If nothing is found or it is not easily correctable, call
Holophane at [phone] and ask for the Field
Service Department.
3.1 Power Unit Set Up and Adjustment for Opera-
tion
3.1.1 Remove the handhole cover.
3.1.2 Lift the portable drive motor to the handhole and
slide its square support bracket into the power unit
support bracket on the winch mounting plate. Align
holes in the tubes and install the snap-lock pin through
the tubes. Be sure to engage the snap-lock over the
end of the pin. (See Figure 26)
HOLOPHANE High Mast
Lowering Devices SECTION III
OPERATING INSTRUCTIONS
EVERY PERSON WHO INTENDS TO OPERATE THE LOWERING DEVICE SHOULD READ COMPLETELY
AND UNDERSTAND FULLY THESE INSTRUCTIONS BEFORE OPERATING THE DEVICE.
3.1.3 Checkalignmentand fit of the portable drivemotor
drivecoupling onto the winchinputshaft. Duringthe first
operation of the power unit on a new pole installation, it
may be necessary to adjust the alignment by loosening
thenutsholding the power unit supportbracketand/or
the winch, moving them slightly and then tightening all
nuts securely. This should be done to insure that the
centerlinesofthewinch and the power unit drive shaft
areparallel and the couplingslidessquarely onto the
3.0 General Comments
3.0.1 The portable drive motor is provided with a twenty
foot long remote control cord and switch. This permits
the operator to stand a safe distance from the pole
while operating the device.
WARNING
Operate the lowering device only while standing at the
maximum distance from the pole allowed by the twenty
foot long remote control cord. Failure to follow this
procedure may result in injury or death.
3.0.2 The Holophane portable drive motor is supplied
with two built-in safety features which are incorporated
to prevent excessive torque from being applied to the
winch input shaft. These are:
a. a factory-set torque limiting clutch,
b. a shear pin which breaks below a predetermined
torque limit, higher than the torque limiting clutch
setting.
Thesetwotorquelimitingfeaturesarefor the protection
of both equipment and operating personnel.
WARNING
Do not expose the torque limiter or shear pin to damag-
ing elements or mistreatment such as sand, mud, salt
spray or other conditions which could render either
safety mechanism inoperable. Do not attempt to adjust
the torque limiting clutch or replace the shear pin. If
repairs are necessary, replace damaged equipment
with replacement components from Holophane. Failure
to follow these warnings may result in injury or death.
3.0.3 If the shear pin breaks, call Holophane at (740)
345-9631 and ask for the Field Service Department.
(See Paragraph 4.3 for the torque limiter assembly
replacement)
3.0.4 If the torque limiter releases before the mounting
ring reaches the top of the pole, this is an indication
that either there is something causing the lowering
device to require an abnormally high lift force to operate
or that the clutch is releasing at an abnormally low
torque level. Carefully try to determine if there is some-
thingwrongwith the lowering device thatiscausingan
abnormallyhighinputtorquerequirement. Acoupleof
possible problems are as follows and can be checked
17
Figure 26
SNAP
LOCK
PIN
GR1151

winch shaft. This adjustment should not be necessary
once it is originally aligned.
3.1.4 Turn off the circuit breaker.
WARNING
Do not break and make the circuit with the plug and
connector. Use the circuit breaker. Failure to use the
circuit breaker may result in electrical shock.
3.1.5 Disconnect the circuit breaker cord from the main
powercord and connect it to theportabledrivemotoror
transformer,asrequired.
3.1.6 Turn on the circuit breaker.
3.2 Unlatching and Lowering the LD Ring
3.2.1 Rotate the drum switch to “FOR” and raise the
device until the torque limiter slips. All latch flags should
haverotated 45°. (See Figure 27) If anyoftheflags
havenot rotated, lower theringnomorethan 6 in., now
raise the ring again to get the flags to rotate.
3.2.2 Turn the remote control switch to “REV” The
device will now be unlatched and descending the pole,
supported by the winch cable. The latch flags will align
with the ring.
3.2.3 Release the switch to “OFF” when the device
reaches the desired working height. Do not lower the
ring to less than four feet above the pole base.
HOLOPHANE High Mast
Lowering Devices SECTION III
Figure 27
UNIT BEING RAISED.
LATCH ENTERING BARREL. LATCH AT TOP OF BARREL. UNIT READY TO LOWER
INTO LATCHED POSITION.
UNIT LOWERED INTO
LATCHED POSITION.
CABLE IS SLACK.
LATCH RAISED TO TOP OF
BARREL.
UNIT READY TO BE LOWERED.
LATCH EXISTING BARREL.
UNIT UNLATCHED AND
BEING LOWERED.
LATCH ROTATION IS COUNTERCLOCKWISE
VIEWED FROM BOTTOM TOWARD TOP OF POLE
LD RING LATCH POSITION INDICATOR
GR1152
18