Atlas Copco QLT H40 User manual

QLT H40
User and maintenance manual
for EU-branded lighting towers
English

ATLAS COPCO - PORTABLE AIR DIVISION
www.atlascopco.com
Printed matter N°
2954 4950 01
05/2010
QLT H40
User and maintenance manual
for EU-branded lighting towers
User and maintenance manual ..............................................................5
Parts list ..................................................................................................29
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.
Copyright 2010, Atlas Copco Airpower n.v., Antwerp, Belgium.
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
Safety precautions........................................6
Leading particulars.......................................8
General description ..................................8
Markings....................................................9
Checks to be carried out before
starting the machine ..................................10
Engine oil ................................................10
Engine coolant ........................................11
Starting battery.......................................12
Room ventilation ....................................12
Starting and stopping the engine ...........13
Before the engine is started...................13
Electric start-up procedure for
the lighting tower ...................................13
Starting the engine.................................13
Switching off the engine........................14
Fuses and circuit breakers .....................15
Electrical connections and use.................15
Earthing ...................................................15
Appliances...............................................15
Protection against electric
shocks due to faulty isolation................15
Operating the lighting tower....................16
Unhooking the lighting tower................16
Positioning the lighting tower ...............16
Aligning the spotlights...........................17
Extending the mast.................................17
Switching on the spotlights...................18
Switching off the spotlights...................18
Positioning for transportation ...............19
Towing.....................................................20
Periodic maintenance.................................20
Instructions .............................................20
Precautions .............................................20
Maintenance schedule ...........................21
Maintenance of the alternator ...............23
Lighting tower engine ............................23
Air cooling circuit....................................23
Engine oil.................................................23
Fuel, oil and air filters.............................24
Replacing the lamps ...............................24
Ordering spare parts ..............................25
Storage..........................................................25
Storage of the lighting tower.................25
Transportation and
positioning of the lighting
tower onto vehicles ................................26
Technical specifications of the
lighting tower ..............................................27
Technical specifications .........................27
Dimension drawing ................................28
Congratulations on the purchase of your QLT lighting 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 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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Safety precautions
Electric shocks
– To avoid the risk of electric shocks never touch
the machine with wet hands or feet.
– Make sure that the generating set is connected to
earth (see “Earthing” on page 15).
– Check the efficiency of the safety device every
month by means of the test button of the
differential current device (when fitted).
Noise
– Depending on the level and exposure time, noise
is dangerous to the hearing.
– Never operate the machine without a muffler or
insulating panels.
– When using this machine, always comply with the
applicable local noise regulations .
– Always place the machine in an isolated location.
Fuel
– Always switch off the engine and leave it cool
down for at least 2 minutes before refuelling.
– Do not smoke during refuelling and keep at a safe
distance from flames or sparks.
– Be careful not to spill fuel onto the engine or the
muffler when refuelling.
– Do not operate the machine if you notice fuel
spills or in case of any other explosion risks.
– Contact a doctor immediately should fuel be
swallowed or if fuel has come into contact with
the eyes.
– If fuel accidentally comes into contact with the
skin or clothes, immediately wash the skin
carefully with soap and change your clothes.
Hot surfaces
– Place the machine in a fenced-off location so to
avoid possible harm to passers-by or animals.
– Do not allow children to operate the machine.
– Do not allow inflammable liquids and/or materials
(e.g. fuel, oil, paper, styrofoam, wooden chips etc)
to be placed close to the exhaust pipe while the
machine is running.
– Do not generate sparks when the glow plug is not
installed.
– The engine and exhaust will be hot after use,
therefore avoid any direct contact when checking
or repairing them. Always wait until they have
cooled down.
– Never operate the machine when the canopy or
panels are open or have been removed.
– Make sure that the machine is placed at least
1 metre away from walls or any machinery in
order to avoid possible overheating of the engine.
– Do not cover the machine during operation.
– Do not tamper with the engine's springs, levers or
any other parts in an attempt to change the
engine's speed.
– Do not start up the engine if the air filter or air
filter lid are not in place.
– Do not move the machine during operation and
always place it on solid ground or on a suitable
stable base made of non-inflammable material.
Exhaust gases
– Do not operate the engine indoors, inside closed
or little ventilated spaces (such as tunnels, tanks,
pits etc) unless these locations were established
specifically for the use of this machine.
– Exhaust gases can cause loss of consciousness and
death in humans within just a few minutes.
– A suitable exhaust discharge system (for instance
leak-proof pipes) must be provided if the machine
is operated inside closed rooms.
– The machine must be placed at least 1 metre away
from any wall or from the ceiling. Suitable
openings for ventilation must be provided to
ensure adequate cooling and efficient engine
combustion.

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Lighting tower mast
– Do not deploy the mast unless the machine is
standing on an even surface and the stabilizers
have been fully adjusted (see “Positioning the
lighting tower” on page 16).
– Do not deploy the mast if the wind is stronger than
90 Km/h.
– Do not deploy the mast in the vicinity of overhead
power cables: DANGER OF
ELECTROCUTION.
– Make sure that nobody is standing too close to the
lighting tower when the mast is being deployed.
– Make sure that the lighting tower has been earthed
by means of the relevant device (earth rod).
– Do not operate the lighting tower if the machine's
electrical isolation system is defective or if the
electric wires are worn or not properly insulated.
– Do not switch on the spotlights without their
protective lenses or if the lenses are cracked or
damaged.

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Leading particulars
General description
The lighting tower provides an undercarriage (frame, axle and towbar) and 4 spot lights of 1000 W each. The lighting tower is very useful for construction sites where no
electricity nor lighting is available.
CP Control panel
ER Earth rod
HHSF Handle to adjust the height of the supporting foot
LPS Locking pin stabilizer
MMast
RHM Rotating handles mast
RLP Rotating locking pin
SF Supporting foot
SL Spotlights
ST Stabilizer
TB Towbar
U Undercarriage

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Markings
A brief description of all markings provided on the
lighting tower is given hereafter.
Indicates that this manual should be
read carefully before putting the
machine into use.
Indicates that an electric voltage,
dangerous to life, is present. Never
touch the electric terminals during
operation.
Indicates that the engine exhaust is a
hot and harmful gas, which is toxic in
case of inhalation. Always make sure
that the unit is operated outside or in a
well-ventilated room.
Indicates that these parts can become
very hot during operation (e.g. engine,
cooler, etc.). Always make sure that
these parts are cooled down before
touching them.
Indicates that the machine may
produce noise at a sound pressure level
dangerous to the hearing. It is
recommended to use ear protection
when operating the lighting tower.
Indicates that during refuelling it
is prohibited to smoke and a safe
distance from flames or sparks
must be kept.
Indicates that the radiator cap should
not be opened if cooling liquid is too
hot.
Indicates that battery fluid contains
sulphuric acid that can cause burns.
Wear protective gloves and goggles
when handling the battery.
Indicates that positives battery
terminals should ALWAYS be
connected first.
Indicates the earthing connection
on the lighting tower.
Indicates moving parts.
Indicates that the key should be
removed before starting maintenance
operations
Indicates that you should disconnect
from the mains before starting
maintenance operations
Indicates the danger of touching
rotating parts of the unit.

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Checks to be carried out
before starting the machine
Engine oil
Checking level and adding engine oil
The engine oil level can be assessed by using the dip-
stick (1) common to all engines. It can be accessed
through the relevant side doors of the lighting tower.
Make sure that the oil level is always between the min
and max levels indicated on the dip-stick. Add oil if
necessary.
Engine oil specifications
High-quality, mineral, hydraulic or synthesized
hydrocarbon oil with rust and oxidation inhibitors,
anti-foam and anti-wear properties is recommended.
The viscosity grade should correspond to the ambient
temperature and ISO 3448, as follows.
Specifications PAROIL
PAROIL from Atlas Copco is the ONLY oil tested
and approved for use in all engines built into Atlas
Copco compressors and generators.
Extensive laboratory and field endurance tests on
Atlas Copco equipment have proven PAROIL to
match all lubrication demands in varied conditions. It
meets stringent quality control specifications to
ensure your equipment will run smoothly and
reliably.
The quality lubricant additives in PAROIL allow for
extended oil change intervals without any loss in
performance or longevity.
PAROIL provides wear protection under extreme
conditions. Powerful oxidation resistance, high
chemical stability and rust- inhibiting additives help
reduce corrosion, even within engines left idle for
extended periods.
PAROIL contains high quality anti-oxidants to
control deposits, sludge and contaminants that tend to
build up under very high temperatures.
PAROIL's detergent additives keep sludge forming
particles in a fine suspension instead of allowing them
to clog your filter and accumulate in the valve/rocker
cover area.
PAROIL releases excess heat efficiently, whilst
maintaining excellent bore-polish protection to limit
oil consumption.
PAROIL has an excellent Total Base Number (TBN)
retention and more alkalinity to control acid
formation.
PAROIL prevents Soot build-up.
PAROIL is optimized for the latest low emission
EURO -3 & -2, EPA TIER II & III engines running on
low sulphur diesel for lower oil and fuel consumption.
It is strongly recommended to use
Atlas Copco branded lubrication oils.
Engine Type of lubricant
between -25°C and 40°C PAROIL Extra

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PAROIL Extra
PAROIL Extra is a Synthetic ultra high performance
diesel engine oil with a high viscosity- index. Atlas
Copco PAROIL Extra is designed to provide
excellent lubrication from start-up in temperatures as
low as -25°C.
Engine coolant
Checking level and adding engine
coolant
The level of the engine coolant must be between the
min and max. levels Do not open the radiator cap if
the coolant is too hot.
If necessary, replenish the coolant in line with the
instructions in the engine's User's Manual.
Additives might be necessary in order to enable the
coolant to withstand lower temperatures.
Engine coolant specifications
The use of the correct coolant is important for good
heat transfer and protection of liquid-cooled engines.
Coolants used in these engines must be mixtures of
good quality water (distilled or de-ionised), special
coolant additives and if necessary freeze protection.
Coolant that is not tomanufacturer's specification will
result in mechanical damage of the engine.
The freezing point of the coolant must be lower than
the freezing point that can occur in the area. The
difference must be at least 5°C (41°F). If the coolant
freezes, it may crack the cylinder block, radiator or
coolant pump.
Consult the engine's operation manual and follow the
manufacturer's directions.
Specifications PARCOOL EG
PARCOOL EG is the only coolant that has been
tested and approved by all engine manufacturers
currently in use in Atlas Copco compressors and
generators.
Atlas Copco's PARCOOL EG extended life coolant is
the new range of organic coolants purpose designed
to meet the needs of modern engines. PARCOOL EG
can help prevent leaks caused by corrosion.
PARCOOL EG is also fully compatible with all
sealants and gasket types developed to join different
materials used within an engine.
PARCOOL EG is a ready to use Ethylene Glycol
based coolant, premixed in an optimum 50/50
dilution ratio, for antifreeze protection guaranteed to
-40°C (-40°F).
Because PARCOOL EG inhibits corrosion, deposit
formation is minimized. This effectively eliminates
the problem of restricted flow through the engine
coolant ducts andthe radiator, minimizing the risk for
engine overheating and possible failure.
It reduces water pump seal wear and has excellent
stability when subjected to sustained high operating
temperatures.
PARCOOL EG is free of nitride and amines to protect
your health and the environment. Longer service life
reduces the amount of coolant produced and needing
disposal to minimise environmental impact.
Liter US
gal Imp gal cu.ft Order number
can 5 1.3 1.1 0.175 1630 0135 00
barrel 20 5.3 4.4 0.7 1630 0136 00
Never remove the cooling system filler
cap while coolant is hot.
The system may be under pressure.
Remove the cap slowly and only when
coolant is at ambient temperature. A
sudden release of pressure from a
heated cooling system can result in
personal injury from the splash of hot
coolant.
It is strongly recommended to use
Atlas Copco branded coolant.
Never mix different coolants and
mix the coolant components outside
the cooling system.

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To ensure protection against corrosion, cavitation and
formation of deposits, the concentration of the
additives in the coolant must be kept between certain
limits, as stated by the manufacturer's guidelines.
Topping up the coolant with water only, changes the
concentration and is therefore not allowed.
Liquid-cooled engines are factory-filled with this
type of coolant mixture.
Starting battery
– Always wear protective gloves and goggles when
handling the battery - battery fluid contains
sulphuric acid that can cause burns. If your skin or
your clothes come in contact with the battery
fluid, rinse immediately with plenty of water. If
even a tiny quantity is swallowed, seek immediate
medical help.
– ALWAYS connect the positive (+) terminal first
and the negative (-) terminal second.
– Regularly check that the battery fluid is above the
recommended level. If necessary, add distilled
water.
– Always remove the battery and disconnect the
terminals before carrying out any operation
(charging or refilling).
– The machine must be placed on even ground both
when working and when idle.
– The maximum permissible slope is 30° on all 4
sides.
– Atlas Copco accepts no responsibility for any
damage to the lighting tower caused by spilling of
the battery fluid.
Room ventilation
If the machine is operated in a closed environment,
make sure that there is enough ventilation to remove
the exhaust gases from the room where the engine is
running; also ensure that the exhaust gases are
discharged at a distance that will not allow them to be
drawn back into the engine. It may be necessary to
provide suitable means for removing the exhaust
gases (e.g. leak-proof pipes).
Place the machine at least at 1m from each wall and
the ceiling and provide suitable openings to allow
sufficient air flow for adequate cooling and good
engine combustion.
Liter US
gal Imp gal cu.ft Order number
can 5 1.3 1.1 0.175 1604 5308 00
can 20 5.3 4.4 0.7 1604 5307 01
barrel 210 55.2 46 7.35 1604 5306 00
Never charge the battery or refill
the fluid when the battery is still
installed in the machine! Possible
spillage could damage vital parts of
the generating set.

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Starting and stopping the
engine
Before the engine is started
Electric start-up procedure for the
lighting tower
Connect the current by means of the Battery Isolator
Switch (1) placed inside the lighting tower and
accessible through the side door.
Starting the engine
1. Before starting the engine, check that all the auto-
matic switches (circuit breaker, general ELCB,
sockets protection and lamp circuit breaker) are in
the OFF position (1).
2. Before turning the ignition key (2) into the
START position to start the engine, please
remember that on diesel engines with indirect
injection it is necessary to first turn the key
anticlockwise to HEAT (4) to allow the glow
plugs to heat up. A yellow light (5) will signal that
the glow plugs are being heated (keep the key
turned to HEAT) until you release the key.
3. Never run the starter motor for longer than 8
seconds at each attempt; if the engine does not
start, wait at least 10 seconds and then try again.
4. Once the engine has started, release the starter so
to avoid any damage to the starter motor and leave
the key in the ON position (6)
Carefully follow all the starting
instructions in the engine's Manual
as well as those contained in this
Manual.
This procedure must be carried out
each time that you start the lighting
tower.
It is recommended that you isolate
the battery by repositioning the
battery isolator switch every time
the machine is moved and when it is
not in use.

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5. The controller (7) will activate the engine
protection systems. If any of the parameters
deviate from the norm (for example, low oil or
fuel level, etc) the controller will intervene and
signal the problem. The manual for the controller
that also accompanies the machine, will provide
you with more information on the error message
displayed.
Switching off the engine
Follow the instructions below to switch the engine off
correctly:
1. Disconnect all electrical appliances connected to
the sockets (1).
2. Place all the automatic switches in their OFF
position (2).
3. It is important tolet the engine run at zero load for
a few minutes before turning it off.
4. Turn the key counterclockwise into the OFF
position (3) to switch off the engine
7
Should an emergency arise, it is also
possible to stop the machine by
pressing the EMERGENCY 'STOP'
button (4). If the machine is stopped
in this way, the emergency stop
button must then be released by
rotating it clockwise.
3

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Fuses and circuit breakers
Fuses (1) are for the protection of the controller
against overloads and short circuits:
– F1: protection of the 12V circuit;
– F2, F3: 220V protection, instrumentation reading
(V, Hz).
The circuit breaker (2) is for the protection of the
relevant sockets against overload and short circuits.
To correctly disconnect the appliances from the
lighting tower generator, first position the switch to
OFF to isolate the electric load and only then remove
the plug.
Electrical connections and
use
Earthing
Use a cable of suitable section (at least 6 mm²) to
connect the PE terminal to an earth plate that can
ensure an earth resistance suited to the characteristics
of the lighting tower.
Appliances
1. Wait 3 or 4 minutes before connecting the appli-
ances to allow the engine to warm up enough.
Then plug in the socket.
2. Make sure that a correct voltage is displayed.
3. Close the current switch (position ON).
4. Switch on your appliance.
5. If the breaker trips, adjust the load until it falls
within the maximum power limit allowed for the
generating set.
6. Make sure that the load does not exceed the
nominal power of the generating set as indicated
in the technical data sheet and guaranteed with a
tolerance of ± 5% when the engine has run in.
Derating will be 1% for every 100 m of altitude,
2% for every 5°C above 20°C and 10% when used
continuously at constant load.
7. Make sure the load does not exceed the nominal
current capacity of the socket or the cable
connected to it.
8. Never connect the lighting tower directly to the
mains.
Protection against electric shocks
due to faulty isolation
Our lighting tower is manufactured in compliance to
the TT systems norms (earthed neutral) and with an
ELCB (differential protection).
A protection system against possible
isolation malfunctions is mandatory
on all electric installations to avoid
risks of electric shock.

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Operating the lighting tower
Unhooking the lighting tower
To release the lighting tower from the towing vehicle,
carefully follow the procedure below:
1. Engage the hand brake (1).
2. Disconnect the cable plug for the trailer lights (2).
3. Disconnect the safety wire from the towing
vehicle (3).
4. Uncouple the trailer from the towing vehicle by
releasing the locking lever of the tow-bar coupler
(4).
5. Proceed with positioning to set up the lighting
tower.
To reconnect the lighting tower to the towing vehicle,
proceed as above but in the reverse order (see
“Towing” on page 20).
Positioning the lighting tower
Follow the steps below to position the lighting tower:
1. Ensure that the hand brake (1) is engaged. The
end-of-drive sensor underneath the hand brake
must be fully pressed.
2. While firmly holding the supporting foot (2) of the
lighting tower with one hand, release the rotating
locking pin (3) and rotate the supporting foot
through 90°.
3. Once the supporting foot has been rotated (2),
reposition the rotating locking pin (3), making
sure that it locks the foot perpendicularly to the
bearing surface (5).
4. Release the rotating locking pin of the stabilizer
(4) by lifting it up and pull the foot into its initial
position at the maximum extension of the
stabilizer (6).
5. Once the stabilizer has been extended, release the
locking pin (4) to lock the stabilizer in position.
Never release the locking lever of
the towbar (5) while the wheel is
supporting the weight of the lighting
tower, otherwise the machine could
overbalance and harm whoever is
close.

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6. Turn the handle (7) at the top of the supporting
foot to lower the foot. Aligning the spotlights
1. Check that the glass panes of the lights are in good
condition (1)
2. Adjust the inclination of the spotlight using the
wheels (2) placed at the sides of the spotlight.
3. Adjust the rotation of the spotlight using the
adjusting lever (3) on the bracket of the support.
4. Proceed with the extension of the mast as
described below.
Extending the mast
1. Check that the emergency push button (1) has not
been pushed. (If it has been pushed, a message
will appear on the display and an acoustic alarm
will sound.)
Once the lighting tower is correctly
positioned, fix the earth rod (the
copper bar for earthing (9)) and
make sure that it is correctly
connected to the lighting tower.
The mast cannot be raised if the
hand brake is not applied.
If the hand brake is released while
the mast is still up, the mast will
descend to its initial position or until
the hand brake is applied (this will
be signalled through an intermittent
alarm sound).

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2. Open the door of the control panel and start the
engine as described in “Electric start-up procedure
for the lighting tower” and “Starting the engine”
on page 13. (If there is no fuel, there will be a
message on the display and an acoustic alarm.)
3. Put the general circuit breaker to the ON position
(2) and all other switches to the OFF position (3).
4. Use the UP (4) and DOWN (5) buttons on the
control panel to extend and adjust the mast to the
desired height (max 9 metres). When the mast is
being extended/lowered, an intermittent sound
will signal that the operation is in progress.
5. Release the locking pin (6) and the clutch locking
lever (7) of the mast (located on its rotating base)
and rotate the lighting tower using the handles
provided for this purpose (8) to further adjust the
light beam. The mast can be rotated through 350°.
6. Lock the mast again using its locking pin (6) and
lever (7).
Switching on the spotlights
1. Place the 4 automatic switches (LAMP 1, LAMP
2, LAMP 3 and LAMP 4) in the ON position (1).
2. Wait for the lights to heat up. This will take about
2-3 minutes.
3. Close the control panel door (2).
Switching off the spotlights
To switch the lights off, follow the procedure
described in “Switching on the spotlights” but in the
reverse order and proceed to lower the mast.
1. Open the control panel door.
2. Position the 4 automatic switches (LAMP 1,
LAMP 2, LAMP 3, LAMP 4) to the OFF position
(1).
3. Wait for the lamps to cool down - this will take
around 15 minutes.
4. If the spotlights are not to be used again, lower the
mast using the DOWN button on the control panel
(2).

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5. The mast is lowered completely when the end-of-
run button (3) is pushed down and the intermittent
siren stops.
Positioning for transportation
1. Push the DOWN button on the control panel (1) to
lower the mast. The mast is lowered completely
when the end-of-run button is pushed down and
the intermittent siren stops.
2. Make sure that the jockey wheel issafely fastened
by its own locking lever (2) to ensure that the
lighting tower is still stable once the stabilizing
feet are removed. Adjust the height of the jockey
wheel using the crank (3). The jockey wheel
should never touch the ground once the lighting
tower is coupled to the hook of the towing vehicle
(4).
3. Use the handle at the top of each foot to retract the
4 feet following the reverse order of the procedure
described in numbers 2-3-4-5 in “Unhooking the
lighting tower” on page 16. The feet must be
stowed as shown below.
Once all the above operations are complete, you will
have returned the lighting towerto the same state as it
was before the positioning procedure (see figure
above).At this point the lighting tower is correctly
arranged for transportation.
Once the lights are switched off
(switches in the OFF position),
remember not to switch them ON
again until the cooling-off time is
over.
If you do not wish to use the
generating set on its own, switch off
the engine (and therefore the
machine) as described on page 14.

- 20 -
Towing
Before commencing towing, ensure you follow the
procedure below:
1. Check that the coupler (1) of the undercarriage of
the lighting tower is safely coupled to the towing
hook of the hauling vehicle.
2. Connect the cabling plug to the hauling vehicle so
that the rear lights of the lighting tower work
(indicators, lights, brake lights) (2).
3. Check that the pressure and condition of the tyres
are suitable for the road and the climatic
conditions.
4. Release the hand brake (3).
Periodic maintenance
Instructions
– If the lighting tower is not going to be used for a
moderate period of time, it is suggested that you
start and run the engine for a few minutes every 8
to 10 days. This will ensure that the machine
remains operational and is ready to be used when
needed.
– Regular maintenance is essential for the optimum
performance, safe operation and a longer working
life of the machine.
Precautions
– Before proceeding with any type of maintenance,
please take all the necessary precautions to avoid
accidentally starting the engine: disconnect the
battery, remove the starter key and push the STOP
button.
– Do not carry out any change or modification to
any part of the lighting tower or its electric
system.
– Do not carry out any maintenance when the
engine is running.
– Be careful when close to any moving parts (e.g.
pulleys, fans …) and to any hot parts (e.g. muffler,
engine block, coolants, lubricants …).
Do not proceed with towing if you
notice any broken or faulty parts.
Drive carefully according to the
road and climatic conditions.