Atlas Copco QLTS 4 ESF User manual

Instruction Manual
User and maintenance manual
for solar light towers
English
QLTS 4-6-8 ESF
01_00_Front Page AC_EN.fm Page 1 Monday, March 24, 2014 3:50 PM

ATLAS COPCO - PORTABLE ENERGY DIVISION
www.atlascopco.com
Printed matter N°
2954 7570 00
03/2014
QLTS 4-6-8 ESF
User and maintenance manual
for solar light towers
User and maintenance manual ..............................................................5
Circuit diagrams .................................................................................... 47
Original instructions

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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.
Copyright 2014, Grupos Electrógenos Europa, S.A., Zaragoza, Spain.
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.

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Contents
1 Safety precautions........................ 7
1.1 Introduction....................................... 7
1.2 General safety precautions .............. 8
1.3 Safety during transport and
installation......................................... 9
1.4 Safety during use and
operation ........................................... 9
1.5 Safety during solar light
tower operation .............................. 10
1.6 Safety during maintenance
and repair......................................... 10
1.7 Tool applications safety ................. 11
1.8 Battery safety precautions............. 11
2 Main parts ..................................... 12
2.1 General description ........................ 12
2.2 Markings .......................................... 13
2.3 Mechanical features........................ 14
2.3.1 Undercarriage, road lights
and reflectors................................... 14
2.3.2 Mast and floodlights ....................... 14
2.3.3 Compass .......................................... 14
2.3.4 Security features ............................. 14
2.3.5 Data plate.........................................14
2.4 Electrical features............................ 15
2.4.1 Control and indicator panel............15
2.4.2 Power system .................................. 17
2.4.2.1 Solar panels.....................................17
2.4.2.2 Batteries ........................................... 17
3 Installation and
connection..................................... 18
3.1 Deracking and assembly ................18
3.1.1 Overview.......................................... 18
3.1.2 General guidelines .......................... 18
3.1.3 Unloading racked light towers
from a container.............................. 18
3.1.4 Dismantling the rack .......................19
3.1.5 Preparing for assembly................... 20
3.1.6 Assembling the light towers ..........21
3.1.6.1 Installing the tires............................21
3.1.6.2 Assembling the solar panel array..21
3.1.6.3 Installing the mast...........................22
3.1.6.4 Installing the T-bar assembly .........23
3.1.6.5 Clamping the cable to the mast .....23
3.1.6.6 Installing the towbar .......................24
3.1.6.7 Extending the rear frame................24
3.1.7 Prepare light towers for use ...........24
3.2 Lifting ...............................................25
3.3 Parking and towing.........................25
3.3.1 Unhooking the solar light tower ....25
3.3.2 Positioning the solar light
tower for use....................................26
3.3.2.1 Location............................................26
3.3.2.2 Procedure.........................................26
3.3.3 Positioning for transportation ........ 27
3.3.4 Towing .............................................27
3.3.4.1 Before towing ..................................27
3.3.4.2 During towing..................................29
3.3.5 Transportation and
positioning of the solar light
tower onto vehicles.........................29
3.4 Installation.......................................30
3.4.1 Outdoor installation ........................30
Congratulations on the purchase of your QLTS on-site solar light tower. It is a solid, safe and reliable machine, built according to the latest technology. The QLTS solar
light tower requires no fuel, no oil and no coolant and is basically maintenance free. Follow the instructions in this booklet and we guarantee you years of troublefree
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.

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3.4.2 Indoor installation ........................... 30
4 Operating instructions............... 31
4.1 Before starting ................................ 31
4.2 Operating the solar light tower..... 31
4.2.1 Adjusting the lights......................... 31
4.2.2 Extending the mast ......................... 31
4.2.3 Switching on/off the
spotlights ......................................... 32
4.2.3.1 Switch on the lights manually ....... 32
4.2.3.2 Switch off the lights manually ....... 32
4.2.3.3 Switch on/off the spotlights
automatically ................................... 32
4.2.4 Lowering the mast .......................... 33
4.3 Operating the solar panels............. 33
5 Options........................................... 34
5.1 Additional lights.............................. 34
6 Periodic maintenance ................ 35
6.1 Precautions...................................... 35
6.2 Daily inspection............................... 35
6.3 Regular maintenance...................... 35
6.4 Ordering spare parts....................... 35
6.5 Battery care ..................................... 36
6.5.1 Battery charging.............................. 36
6.5.2 Battery cleaning .............................. 39
6.5.3 Battery replacement........................ 39
7 Storage of the solar light
tower...............................................40
7.1 Storage............................................. 40
7.2 Preparing for operation after
storage ............................................. 40
8 Disposal..........................................41
8.1 General............................................. 41
8.2 Disposal of materials ......................41
9 Technical specifications of
the solar light tower...................42
9.1 Technical specifications of the
QLTS 4.............................................. 42
9.2 Technical specifications of the
QLTS 6.............................................. 43
9.3 Technical specifications of the
QLTS 8.............................................. 44
9.4 Lighting area....................................45
9.5 Conversion list of SI units into
British units .....................................46
9.6 Datap late......................................... 46

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1 Safety precautions
To be read attentively and acted accordingly before towing, lifting, operating, performing maintenance or repairing the solar 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 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.

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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 Normal ratings (battery voltage levels, speeds, etc.)
shall be durably marked.
4 Operate the unit only for the intended purpose and
within its rated limits (speeds, etc.).
5 The machinery and equipment shall be kept clean,
i.e. as free as possible from dust or other deposits.
6 To prevent an increase in working temperature,
inspect and clean vents regularly. See the
maintenance schedule.
7 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.
8 Care shall be taken to avoid damage to batteries,
especially to avoid plugging by paint or dirt
accumulation, which could interfere with the
functioning of the device.
9 Safety devices shall be tested as described in the
maintenance schedule of the instruction manual to
determine that they are in good operating condition.
10 Mind the markings and information labels on the
unit.
11 In the event the safety labels are damaged or
destroyed, they must be replaced to ensure operator
safety.
12 Keep the work area neet. Lack of order will increase
the risk of accidents.
13 When working on the unit, wear safety clothing.
Depending on the kind of activities these are: safety
glasses, 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
jewelry.
14 Take precautions against fire. Keep a fire-
extinguisher in the vicinity.

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1.3 Safety during transport and
installation
To lift a unit, all loose or pivoting parts, towbar, shall
first be securely fastened.
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 retardation
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 hitch 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,
- attach the safety break-away cable or safety
chain to the towing vehicle,
- remove wheel chocks, if applied.
2 To tow a unit use a towing vehicle of ample
capacity. Refer to the documentation of the towing
vehicle.
3 Never exceed the maximum towing speed of the
unit (mind the local regulations).
4 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.
5 To lift heavy parts, a hoist of ample capacity, tested
and approved according to local safety regulations,
shall be used.
6 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.
7 Never leave a load hanging on a hoist.
8 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.
9 Locate the unit at least meter away from walls.
10 To reduce the risk of shifting, rolling, or
overturning, locate the light tower on a firm, level
surface.
1.4 Safety during use and
operation
1 When operating in a dust-laden atmosphere, place
the unit so that dust is not carried towards it by the
wind.
2 Periodically carry out maintenance works according
to the maintenance schedule.
3 When washing parts in or with a cleaning solvent,
provide the required ventilation and use appropriate
protection such as a breathing filter, safety glasses,
rubber apron and gloves, etc.
4 Safety shoes should be compulsory in any
workshop and if there is a risk, however small, of
falling objects, wearing of a safety helmet should be
included.
5 If there is a risk of inhaling hazardous gases, fumes
or dust, the respiratory organs must be protected and
depending on the nature of the hazard, so must the
eyes and skin.
6 Remember that where there is visible dust, the finer,
invisible particles will almost certainly be present
too; but the fact that no dust can be seen is not a
reliable indication that dangerous, invisible dust is
not present in the air.
7 Never operate the solar light tower in excess of its
limits as indicated in the technical specifications
and avoid long no-load sequences.
8 Never operate the solar light tower in a humid
atmosphere. Excessive moisture causes worsening
of the solar light tower insulation.

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9 Do not open the battery box while voltage is
supplied. If such cannot be avoided, e.g. for
measurements, tests or adjustments, have the action
carried out by a qualified electrician only, with
appropriate tools, and ascertain that the required
bodily protection against electrical hazards is
applied.
10 Check the electric cables regularly. Damaged cables
and insufficient tightening of connections may
cause electric shocks. Whenever damaged wires or
dangerous conditions are observed, switch the fuses
to OFF and stop the unit. Replace the damaged
wires or correct the dangerous condition before
restarting. Make sure that all electric connections
are securely tightened.
1.5 Safety during solar light
tower operation
1 When operating or working on the light tower, keep
hands and body parts clear of pinch points.
2 When deploying the solar light tower mast, keep in
mind following safety precautions:
- Do not deploy the mast unless the machine is
standing on an even surface and the stabilizers
have been fully adjusted.
- Make sure that nobody is standing too close to
the solar light tower when the mast is being
deployed.
- The light tower mast can be extended to 6,1 m
(20 feet) in height. Ensure the area above the
trailer is clear of obstructions.
- Do not deploy the mast in the vicinity of
overhead power cables: DANGER OF
ELECTROCUTION.
-Do not raise or use the mast in high winds or
an electrical storm.
- If the mast “hangs up” or the winch cable
develops slack while raising or lowering the
mast, stop immediately, move away from the unit
and contact Atlas Copco.
3 When using the light tower, ensure the vertical-lock
pin is properly engaged.
4 Do not collapse the outriggers or move the trailer
while the light tower mast is vertical.
5 Never raise, lower, or move the trailer while the
light tower is in use.
6 When not in use, or in case of high winds, lower the
light tower mast to the travel position.
1.6 Safety during maintenance
and repair
Maintenance, overhaul and repair work shall only be
carried out by adequately trained personnel; if required,
under supervision of someone qualified for the job.
1 Use only the correct tools for maintenance and
repair work, and only tools which are in good
condition.
2 Parts shall only be replaced by genuine Atlas Copco
replacement parts.
3 All maintenance work, other than routine attention,
shall only be undertaken when the unit is stopped.
On electrically driven units the main switch shall be
locked in open position and the fuses shall be taken
out. A warning sign bearing a legend such as “work
in progress; do not supply voltage” shall be attached
to the fuse box or main switch.
4 Never perform even routine service unless all
electrical components are shut down:
- Ensure all light tower power circuits are shut off.
- Disconnect cable from negative (–) terminal on
battery.
5 If the ground under or around the trailer is damp or
wet, move the trailer to a dry location and allow it to
dry before servicing. Do not allow water to
accumulate around the base of the light tower.
6 Make sure that no tools, loose parts or rags are left
in or on the machine.
7 Never use flammable solvents for cleaning (fire-
risk).
8 Take safety precautions against toxic vapours of
cleaning liquids.

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9 Never use machine parts as a climbing aid.
10 Observe scrupulous cleanliness during maintenance
and repair. Keep away dirt, cover the parts and
exposed openings with a clean cloth, paper or tape.
11 Never weld on or perform any operation
involving heat near batteries.
12 Support the towbar and the axle(s) securely if
working underneath the unit or when removing a
wheel. Do not rely on jacks.
13 Use only lubricating oils and greases recommended
or approved by Atlas Copco or the machine
manufacturer. Ascertain that the selected lubricants
comply with all applicable safety regulations,
especially with regard to explosion or fire-risk and
the possibility of decomposition or generation of
hazardous gases. Never mix synthetic with mineral
oil.
14 When performing any operation involving heat,
flames or sparks on a machine, the surrounding
components shall first be screened with non-
flammable material.
15 Never use a light source with open flame for
inspecting the interior of a machine.
16 Maintenance and repair work should be recorded in
an operator’s logbook for all machinery. Frequency
and nature of repairs can reveal unsafe conditions.
17 When hot parts have to be handled, e.g. hot light
fixtures, special heatresistant gloves shall be used
and, if required, other body protection shall be
applied.
18 Make sure that oil, solvents and other substances
likely to pollute the environment are properly
disposed of.
19 Before clearing the solar light tower for use after
maintenance or overhaul, submit it to a testrun,
check that the AC power performance is correct and
that the control and shutdown devices function
correctly.
1.7 Tool applications safety
Apply the proper tool for each job. With the knowledge
of correct tool use and knowing the limitations of tools,
along with some common sense, many accidents can be
prevented.
Special service tools are available for specific jobs and
should be used when recommended. The use of these
tools will save time and prevent damage to parts.
1.8 Battery safety precautions
For any operation on the batteries, from storage to
recycling, the following safety rules should be
observed:
1 Do not smoke near batteries.
2 When handling batteries, wear gloves and
protective eyewear.
3 Always use tools with isolated handles to tighten
connections.
4 Never place tools on top of the batteries (metal tools
are particularly dangerous).
5 Never lift the cells / monoblocs by the terminals.
6 Never use a synthetic cloth or sponge to clean the
casings.
7 Avoid shocks. Even when disconnected, a battery
remains charged.

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2 Main parts
2.1 General description
The QLTS 4/6/8 solar light tower provides an undercarriage (frame, axle and towbar), 2/3 solar panels and 4/6/8 spot lights of 208/312/416W each. The solar light tower
is very useful for construction sites and event locations, particularly in emission sensitive environments (cities, nature reserves,...), where no lighting is available.
CP Control panel
BBatterybox
HHSF Handle to adjust the height of the supporting foot
MMast
RF Rear frame (extendable)
SA Solar assembly
SF Supporting foot
SL Spotlights
SP Solar panel
TB Towbar
U Undercarriage
WWinch
SL
SP
RF
SF
HHSF
B U TB
W
CP
SA
M

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2.2 Markings
Markings provide instructions and information. They
also warn of hazards. For convenience and safety,
keep all markings in legible condition, replacing them
when damaged or missing. Replacement markings are
available from the factory.
A brief description of all markings provided on the
solar light tower is given hereafter.
Indicates that loose
equipment can cause
damage or serious injury.
Decal Solar light tower
check list
Decal Control switch
Indicates that before using
the solar light tower, the
rear frame should be
extended.
Indicates that the solar
panels could break during
transport. Lower the solar
panels and secure them
with the locking pin,
before towing.
Indicates that tower and
lights should be down and
secured with the locking
pin and locking knob
before transportation.
Indicates that solar panels
and lights should be down
and secured with the
locking pin and rotation-
lock knob before
transportation.
Indicates that solar panels
could break. Before
raising the panels, use the
locking pin. Before
towing, lower the panels
and secure them with the
locking pin.
Indicates that solar panels
should be kept clean for
porper operation.
Indicates that photocells
should be kept clean for
porper operation.

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2.3 Mechanical features
All standard models of QLTS solar light towers are
operationally similar. Differences between models
are:
– Output (wattage) of solar-panel array
– Number of light fixtures
– Output (luminosity) of light fixtures
– Type and number of batteries
The main mechanical features are descibed in this
chapter.
2.3.1 Undercarriage, road lights and
reflectors
The undercarriage is equipped with a removable
towbar with double pintle / 2-inch-ball hitch and an
extendable rear frame. Make sure that the towing
equipment of the vehicle matches the towing eye of
the trailer before towing the solar light tower.
2.3.2 Mast and floodlights
The solar light tower mast consists of 4 mast sections
and can be extended up to 6.1 m (20 ft). The mast can
be rotated through 359°.
The QLTS 4 provides 4 LED lights of 208 Watt
(18400 lumen), the QLTS 6 provides 6 LED lights of
312 Watt (27600 lumen) and the QLTS 8 provides 8
LED lights of 416 Watt (36800 lumen). Each lamp
can be separately positioned and inclined.
Additional lights are available as a kit for a maximum
of 8 lights. See also “Additional lights” on page 34.
2.3.3 Compass
A compass is provided inside the battery box of the
QLTS. This compass can be used for easy solar panel
alignement.
2.3.4 Security features
The battery box is thick steel plated.
Anti-theft screws are used for the battery box and the
solar panels.
2.3.5 Data plate
The solar light tower is furnished with a data plate
showing model number, machine type,
manufacturing year, mode of operation, etc...
The solar light tower trailer is
manufactured for off road use only!
1

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2.4 Electrical features
2.4.1 Control and indicator panel
To operate the solar light tower a control panel is
installed. It is located inside the battery box, and
includes:
Function selector
The function selector switch allows you to configure
the lights to turn on automatically at dusk. The system
uses input from a photocell to detect when the
ambient light is low enough to activate the lights.
When the selector switch is in any automatic-function
position and the photocell is exposed to daylight, the
lights cannot be turned on manually.
The functions are as follows:
1Function selector switch
2Eight light switches
3System status LED - solar-charging
4System status LED - battery-charging
3
1
2
4
1Off All lights are off, regardless of
whether their individual
switches are in the on (I) or off
(O) position.
2On The lights can be turned on
and off manually, any time of
day, using their individual
light switches. The lights will
not turn on automatically.
1
2
3
4

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Light switches
Use the light switches to turn each individual light on
or off.
– All control panels have switches for eight light
fixtures. If your light tower has fewer than eight
fixtures, the extra switches do not operate any
lights.
Additional light fixtures may be added to light
towers with fewer than eight. To order more
fixtures, contact the local Atlas Copco Customer
Service Center.
– If the function selector switch is in any position
other than MANUAL (I), the lights cannot be
turned on manually during daylight hours. For
more information, see “Operating the solar light
tower”.
Status LEDs
–Iftheamber solar-charging LED is lit, the
batteries are actively being charged by the solar
panels.
–Ifthered battery-charge LED is lit and not
blinking, the batteries must be charged
immediately.
–Ifthered battery-charge LED is blinking, the
battery charge fell below the minimum charge
voltage and the power system was automatically
shut down.
3 Dusk to
dawn
If light switches are on (I), the
lights will turn on
automatically at dusk and off
automatically at dawn, based
on input from the photocell. If
light switches are off (O), the
lights will not turn on.
4 Dusk plus
hours
If light switches are on (I), the
lights will turn on
automatically at dusk, based
on input from the photocell,
and off automatically after the
selected number of hours. If
light switches are off (O), the
lights will not turn on.

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2.4.2 Power system
The light tower is powered by batteries. Solar panels
are used for charging the batteries.
The charging system runs continuously, keeping the
batteries charged. The system automatically detects
when the batteries are fully charged and will not
overcharge them. While the charging system is active,
the amber solar-charging LED on the control panel is
lit (see “Status LEDs”).
Under optimal conditions, the batteries will remain
charged and the light tower can be used every night
without having to use an external charger. The solar
charging system's capacity to keep the batteries fully
charged is dependent on the power draw of the light
tower's lights and the solar panels' exposure to the
sun. If the power draw exceeds the solar yield from
the solar panels, then the solar charging system will
not be able to keep the batteries charged sufficiently.
If there is not enough sunlight to keep the batteries
fully charged, then they must be charged manually
using the AC-powered charger, located inside the
battery box.
The low-voltage-disconnect circuit detects when the
battery charge falls below 22.4 volts DC, and
automatically shuts down power to the light tower. If
a shutdown occurs, the red battery-charge LED on the
control panel will be lit (see “Status LEDs”) and the
light tower will not function until the batteries are
charged.
2.4.2.1 Solar panels
For the light tower's solar charging system to function
properly, the solar panels must be exposed to full
sunlight during daylight hours.
If the location where the light tower will be used is not
a sunny location, the light tower may be moved to a
sunny location while it is not in use, so that its
batteries will be charged by the solar charging system,
then returned to the desired work area at night.
2.4.2.2 Batteries
Although the light tower's solar charging system
helps maintain battery health by keeping batteries
charged when there is sufficient sunlight, and by
shutting down power automatically before full
discharge, regular maintenance as with a wet cell
battery is not necessary for the AGM (Absorbed
Glass Mat) batteries to function properly and for long
battery life. AGM batteries are sealed, maintenance
free batteries.

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3 Installation and
connection
3.1 Deracking and assembly
3.1.1 Overview
Two light towers are shipped from the factory in each
rack. The two light towers must be removed from the
rack and assembled before use. The process includes
four essential steps:
1. Unloading racked light towers from a container
(or truck)
2. Dismantling the rack
3. Preparing for assembly
4. Assembling the light towers
3.1.2 General guidelines
During the assembly process:
– Ensure clear access to all four sides of the rack and
the light towers.
– The forklift must have a clear path to the front of
the rack and the light towers.
– The forklift must be capable of lifting and moving
the racked light tower assembly, which weighs
approximately 4,500 pounds (2,040 kg).
3.1.3 Unloading racked light towers
from a container
1. Before unloading the light towers from the
container, remove any items that might limit
forklift access. Such items might include crates,
palettes, and boxes at the door of the container,
and items attached to the floor of the container,
such as tires, drawbars, and blocking, most of
which will be used when you assemble the light
towers.
2. Use a forklift to unload the container, taking care
to keep the light towers from colliding with the
container.
• Position the forklift under the bottom light
tower as indicated in the figure below,
centered under the light tower frame, with
forks spread as wide as possible.
The deracking and assembly
procedures described in chapters
3.1.1 to 3.1.6.3 are only applicable
for racked units.
For units that are already
assembled, please start with the
instructions in chapter 3.1.6.4
“Installing the T-bar assembly” on
page 23.
The deracking and assembly
procedures described in this chapter,
should be carried out with two to
four people.
Heavy parts can crush and cut.
– Keep clear of loose or unstable
equipment.
– Keep hands and body parts clear
of pinch points.
– Avoid sharp edges and corners.
To reduce the risk of personal injury,
ensure the surrounding area is in
good order and free of debris.
To reduce the risk of shifting, rolling,
or overturning, locate the light tower
on a firm, level surface.
For stability, always extend all four
jacks to level the trailer during
assembly.

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• Ensure the forks extend past the battery box
and fully support the light tower frame. Use
fork extenders if necessary.
• Do not place the forks under the light tower
axle.
• Ensure the forklift does not contact either light
tower other than where the forks touch the
frame. The solar panels are particularly
susceptible to damage if the forklift touches
them.
3. Place the racked light towers on a firm, level
surface, in the location where you will dismantle
the rack and assemble the light towers.
4. Back the forklift away from the racked light
towers until it is needed again, later in the
assembly process.
3.1.4 Dismantling the rack
1. Detach the two mast assemblies from the rack (1)
by removing the three bolts that hold each mast in
place, then set the masts aside for later assembly.
Retain the large nut and three washers (2) at the
bottom of each mast, which are required for
assembly.
• Place the masts near, but not in front of or
behind, the racked light towers.
• The rotation ring on the mast (3) is greased.
Ensure the grease does not become
contaminated by dirt, dust, or other debris.
• Each mast is associated with a specific light
tower. Do not remove the identifying label
from the masts or the light towers until after
assembly is complete.
2. Use a forklift to raise the racked light towers off
the ground.
• Position the forklift under the top light tower
as indicated in the figure below, centered
under the light tower frame, with forks spread
as wide as possible.
• Follow the fork lift instructions in “Unloading
racked light towers from a container”.
3. For each of the supprting feet at the four corners
of the bottom light tower (2), pull the supporting
foot locking pin and rotate the supporting foot
downward. Release the pin and continue rotating
the supporting foot until it is vertical.
When the supporting foot is properly set, the
locking pin snaps into position with an audible
"click."
1
2
1
3
2
2
1

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4. Use the hand-crank on each supporting foot to
extend the supporting foot downward until it rests
firmly on the ground.
5. Lower the forklift until the racked light towers are
on the ground with their full weight resting on the
bottom light tower's leveling supporting feet.
6. With the forklift still positioned and holding the
top light tower, dismantle the rack as follows:
• Remove the horizontal crossbars by removing
the four bolts that hold each crossbar in place.
First remove the two upper crossbars (1), then
remove the two lower crossbars (2).
• Remove the four vertical supports by pulling
them out of the light tower frames. During the
removal process, it might be necessary to use
the forklift to raise or lower the top light tower
slightly, to release tension on the vertical
supports and allow them to slip out of the
trailer frames.
7. Use the forklift to move the top light tower to the
location where it will be assembled.
8. Before setting the light tower on the ground, lower
the four supporting feet at the corners of the light
tower, as described above, then lower the forklift
until the light tower is on the ground, resting on its
supporting feet.
9. Back the forklift away from the light tower until it
is needed again, later in the assembly process.
10. Adjust the supporting feet for both light towers to
ensure the light towers are level before proceeding
with assembly.
3.1.5 Preparing for assembly
1. Remove the T-bar assembly (1) from the battery
box lock-bar (2) by removing the two nuts that
hold it in place (3), then set the T-bar aside for
later assembly.
• The T-bar assembly includes the lights for the
light tower. Use care to ensure the lights do not
become damaged.
• The T-bar assembly is hard-wired to the
battery box and should not be detached.
• For easier removal from the lock-bar, you may
remove the entire lock-bar and T-bar assembly
from the battery box before detaching the T-
bar.
• Before removing the T-bar assembly, you may
cut the strapping that holds the cable in place.
Use care not to damage the cable.
• After removing the T-bar assembly, place it
safely away from the light tower. It should be
to the side of, not in front of or behind, the
light tower.
1
2
2
3
1
2