User Manual
User Manual
Youngman Group Limited,
The Causeway, Maldon, Essex,
CM9 4LJ, United Kingdom
t +44 (0) 1621 745900
f +44 (0) 1621 859845
e [email protected]
youngmangroup.com
Contents
Contents
Preliminary
3
Foreword............................................................ 3
Warranty ............................................................ 3
Liability ........................................................... 3
Audits and Surveys ........................................ 3
Service and Warranty Training ...................... 3
Warranty Terms ............................................. 3
General Exclusions: ....................................... 3
Warranty Claim Submission Procedures....... 4
Certificate of Conformity .................................... 4
Hatz Engine Dealers .......................................... 4
Service Bulletins ................................................ 4
Machine Identification ........................................ 4
Theft Deterrence ................................................ 4
Recovery of a Stolen Machine....................... 5
Safety................................................................. 5
General .......................................................... 5
Fire Precautions............................................. 6
Flammable Fluid Precautions ........................ 6
Electrical Hazard............................................ 6
Pre-Starting.................................................... 6
Starting........................................................... 6
Lubrication and Servicing .............................. 7
Specifications..................................................... 7
Section 1 Operating Instructions
9
1.1 Features...................................................... 9
1.2 Positioning .................................................. 9
1.3 Stabilising the Unit .................................... 10
1.4 Using the Lights ........................................ 10
1.4.1 Lowering Mast if Battery is Flat ......... 12
2
1.5
1.6
1.7
1.8
Auxiliary Supply (Optional) ....................... 13
Moving the Unit ......................................... 13
Redirecting the Lights ............................... 13
Emergency Stop ....................................... 15
Section 2 Routine Maintenance
2.1
2.2
2.3
2.4
2.5
2.6
2.7
2.8
2.9
17
Schedule ................................................... 17
Engine Oil Check ...................................... 17
Engine Oil Change.................................... 18
Fuel Filters ................................................ 18
Oil Filter..................................................... 19
Air Filter..................................................... 20
Hydraulic Fluid .......................................... 21
Draining Fuel Tank.................................... 22
Engine Conditioning.................................. 22
Section 3 Lamp Replacement
23
Section 4 Fault-finding
25
4.1 Introduction ............................................... 25
4.2 Battery Light On ........................................ 25
4.3 Oil Pressure Light On................................ 25
4.4 High Temperature Light On ...................... 25
4.5 Starting...................................................... 25
4.5.1 Control Lights Off ............................... 25
4.5.2 Engine does not crank ....................... 25
4.5.3 Engine cranks as normal but engine
does not fire ................................................. 25
Section 5 Options
27
Appendix A Timer and Dusk –Dawn……...28
TCP EcoLite P User's Manual, Issue B July 2010
Preliminary
Preliminary
Foreword
Thank you very much for purchasing this
product. We believe that it will serve you
without fail. Ensure that you read the operating
instructions carefully before use. With proper
handling and maintenance, this product will
provide reliable, long-term service.
This manual is intended for users of the
equipment.
All information, illustrations and specifications
contained in this publication are based on the
latest product information available at the time
of publication. The right is reserved to make
changes at any time without notice.
Continuing improvement and advancement of
the design may cause changes to your
machine that may not be included in this
publication.
Please read the operating instructions carefully
and understand them before operating the
equipment.
Warranty
Liability
The warranty period begins when the product
is delivered to and installed at the first
purchaser. Only genuine parts may be used to
carry out repairs. Failure to use only genuine
parts may invalidate the manufacturers
warranty.
TCP Ltd will not be held responsible if:
• the machine has been used to perform
tasks that demand more than it’s design and
strength limitations, or
• the machine has undergone modifications
not approved by TCP Ltd, or
• conditions of use have been abnormal, or
• normal maintenance, with regard to
requirements as set out and detailed by the
manufacturer, have not been adhered to.
TCP EcoLite P User's Manual,Issue B July 2010
TCP Ltd will not pay for normal maintenance or
servicing nor any materials used to carry out
routine servicing.
The warranty liability of TCP Ltd is limited to
diagnosis, repair or replacement of the
defective part, and actuating the repair depending on the product terms and
conditions, this will be free of charge.
TCP Ltd shall be under no liability whatever to
the customer for any indirect loss and/or
expense (including loss of profit) suffered by
the customer arising out of a breach by TCP
Ltd of this contract.
Audits and Surveys
TCP Ltd reserves the right to carry out audits
and inspections from time to time in relation to
any reimbursed or outstanding warranty claims
in order to determine that all relevant details
and information is correct.
Service and Warranty Training
Service and warranty training for service fitters
can be provided at competitive rates if
required. Training can be carried out at a TCP
depot or at a venue of your choice, please
contact TCP with your requirements.
Warranty Terms
One year or 1000 hours whichever occurs first
from date of installation
All engine warranty issues must be directed to
the engine manufacturer, or the manufacturer’s
approved/appointed engine dealer.
General Exclusions:
THE FOLLOWING ARE WARRANTY
EXCLUSIONS AS DETERMINED BY HATZ:
Service items including lubricants, filters, glow
plugs, fuel injection equipment, stop
solenoid/relay, charge regulator, leaks (oil and
air).
IN ADDITION: paintwork and parts that wear.
3
Prelliminary
Warranty Claim Submission Procedures
Hatz Engine Dealers
Claims must be reported accurately and all
relevant details given, as follows:
To locate your nearest Hatz dealer, access the
HATZ Worldwide page from the
http://www.hatz-diesel.de web site.
OWNERS NAME AND ADDRESS: full name and
address of customer and site location, if
different
MACHINE TYPE: State machine type, i.e. Ecolite
Date of Failure:
SERIAL NUMBER: Serial number of unit
ENGINE NUMBER: Serial number of engine
HOURS USED: Sate hours used on hour clock.
Please do not guess the hours used
DETAILS OF FAILURE: Give a full report on the
failure
ORDER NUMBER: An order number will be
required
Note that the order number is to cover the
diagnostic and call out time, as well as to
determine the following:
• That the failure is to be covered under the
terms and conditions of warranty. If this is
the case, then the costs will be covered by
TCP Ltd and the order number will not be
used.
Service Bulletins
TCP Ltd may from time to time issue service
bulletins to keep you up to date as to any
improvements or changes that may take place
on the complete assembly or component parts.
Machine Identification
This manual may refer to controls and
equipment that are not present on your
particular machine. It is important that you
know your machine and its equipment and how
to operate it properly.
Information regarding the machine model, code
and chassis serial number is on the unit serial
number plate (Fig 1). This plate is on the front.
Always quote the machine model and serial
number in correspondence with your dealer or
the factory.
• If the failure is determined to be of a non-
warrantable nature, further authorisation to
continue will be sought before any
rectification work takes place.
The information above must be provided even
if your warranty claim is a “parts only” claim. An
invoice will be raised for the exchange parts.
The reported faulty/defective part must
immediately be returned to TCP Ltd and full
inspection of the parts carried out, if the failure
is covered under the terms and conditions of
warranty a credit note corresponding to the
invoice will be despatched to the customer. If
the failure is deemed to be of a nonwarrantable nature, the invoice should be
settled immediately.
Certificate of Conformity
Each machine is issued with a certificate of
conformity that is sent to the head office of the
purchaser. Further copies are available on
request
Fig 1 Data plate
Theft Deterrence
The owner/operator should take the following
precautions to discourage theft, to aid in
recovery in the event that the machine is
stolen, or to reduce vandalism.
• Remove all keys any time the machine is
left unattended.
• Immobilise the machine by removing a
critical electrical or starting system device.
• Upon receipt of a machine, record the
machine serial number and the serial
numbers of all-major components and
attachments. Keep this list up to date and
filed in a safe location for fast retrieval.
• Place a decal or notice on the machine
stating that all serial numbers are recorded.
4
TCP EcoLite P User's Manual, Issue B July 2010
Preliminary
• Discourage the thief! Inspect the gates and
fences of the machinery storage yard or
construction site. Keep machines in well-lit
areas and ask the local law enforcement
authorities to make frequent checks around
the storage yard or work site.
• Liaise with neighbours. Ask them to watch
equipment left at job sites and to report any
suspicious activities to local allow
enforcement authorities.
• Make frequent inventories of machines to
promptly detect losses or vandalism.
Recovery of a Stolen Machine
General
• Read this operator’s Handbook and learn
the operating characteristics and limitations
of the machine. Know what operating
clearances the machine requires.
• Know clearances of all side and overhead
obstructions such as wires, etc., for
operating safety.
• Be aware of operating hazards that weather
changes can create on the job. Know proper
procedures to follow when a severe rain or
electrical storm strikes.
In the event of theft, immediately notify the law
enforcement authorities having jurisdiction.
Provide the investigating officer with name,
type of equipment, chassis and serial numbers
of major attachments and components. It
would be helpful to show the investigating
officer an Operator’s Handbook, photographs,
and advertising, to familiarise him with the
appearance of the machine.
• Know what safety equipment is required and
Report the theft to the insurance company.
Provide the model and all serial numbers.
• Ensure that the area immediately surrounding
Report the model and serial numbers of the
stolen machine to a dealer handling the
respective line of equipment. Request that the
dealer forward this same information to the
equipment manufacturer.
use it. Such equipment may be hardhat,
safety glasses, reflector type vests,
respirators and earplugs.
• Handle fuels and lubricants carefully and
clean up spills to avoid fire and slipping
hazards.
• Never rush. Walk do not run.
the light tower is clean, neat and free of
debris.
• Position and operate light tower on a firm
I
level surface.
• NEVER start a unit that is in need of repair.
• Lower tower when not in use, or if high winds
Safety
Report all malfunctions to those responsible for
maintenance. Do not operate the equipment
until corrected. Normal service or maintenance
performed as required can prevent unexpected
and unnecessary down time. This handbook
describes general inspections, servicing and
operation with the normal safety precautions
required for normal servicing and operating
conditions. It is not a guide however, for other
than normal conditions or situations.
Operators and service engineers must be
safety conscious and alert to recognise
potential operating or servicing safety hazards
at all times, and take, necessary precautions to
ensure safe operation and servicing of the
machine.
TCP EcoLite P User's Manual,Issue B July 2010
or electrical storms are expected in the area.
• The tower extends up to 9 m (30 ft.). Make
sure area above the tower is open and clear of
overhead wires and obstructions.
• Bulbs become extremely hot is use! Allow bulb
and fixture to cool 10-15 minutes before handling.
• Keep area around tower clear of people while
raising and lowering mast!
• Tower must be levelled and outriggers ex-
tended before raising tower. Outriggers must
remain extended while tower is up.
• DO NOT use a lamp without the glass lens
of the lamp unit in place and undamaged.
Ceramic discharge metal halide lamps are
constructed of an outer glass bulb with an
internal arc tube made of ceramic. The arctubes operate at high pressure (up to 50
p.s.i.) and at very high temperatures. They
can rupture unexpectedly due to ballast
5
Prelliminary
failure or misapplication. If an arc-tube
ruptures, it can shatter the outer glass bulb
resulting in the discharge of glass fragments
and extremely hot ceramic particles (as high
as 18320F, 1000C). In the event of such
rupture, there is risk of personal injury,
property damage, burns and fire if the
protective lens is not fitted.
Fire Precautions
• DO NOT fill tank in an enclosed area with poor
ventilation.
• DO NOT run engine with the fuel tank cap
loose or missing.
Electrical Hazard.
• Never smoke or allow open flames or
sparks near batteries.
• Always disconnect batteries before repairing
• Clean all dirt, oil, grease and other fluids
from systems and components to minimise
fire hazards and aid in spotting loose or
leaking lines, fittings etc.
• Check the engine for rubbish, oily rags or
other debris that could cause fires before
starting the engine.
• Safely dispose of greasy, oily rags or similar
hazards.
Flammable Fluid Precautions
electrical system to avoid danger of firecausing sparks. Disconnect battery ground
cable first and reconnect last.
• Always disconnect batteries and alternator
leads before carrying out any welding on the
machine.
• Never check battery charge by placing
metal objects across battery posts to avoid
sparks at battery posts.
• Use jumper cables only as recommended.
Improper use can result in battery explosion.
• Make certain light tower is well grounded and
• Take due care when working with fuel.
Diesel fuel is a health hazard for contact
with eyes or sin, inhalation and ingestion.
There is also danger of fire and pollution.
• Don’t use diesel fuel or other flammable
fluids for cleaning purposes. Use approved
non-flammable solvents.
• Make sure all-fluid systems caps, drain,
valves, fittings, lines etc., are secure and
leak free.
• Shut off engine and use extra caution if
engine is hot when refuelling.
Never smoke while checking or adding fuel
or other fluid or handling fluid containers
and lines.
securely fastened to a good earth ground.
• NEVER use tower if insulation on electrical
cord is cut or worn through.
• NEVER operate lights without protective lens
cover in place or with a lens cover that is
cracked or damaged!
Pre-Starting
• If engine is to be started and run indoors,
ensure proper ventilation to remove deadly
exhaust gases.
• Always perform ‘Pre-Starting Inspection’
instructions described in this manual to
ensure the machine is ready for operation.
• Use care and do not stand downwind when
adding fuel or other flammable fluids to
tanks and reservoirs to avoid fluids being
blown or splashed onto clothing.
• When preparing machines or components
for storage, seal and tape all openings and
close containers tightly to seal in all volatile
inhibitor fluids and compounds used.
• DO NOT fill fuel tank near an open flame,
while smoking, or while engine is running.
6
Starting
• Do not start the engine or operate any
control if there is a ‘DO NOT OPERATE’ or
similar warning sign attached to any control.
• Use jumper cables only as recommended.
Improper use can result in battery explosion
or unexpected machine motion.
TCP EcoLite P User's Manual, Issue B July 2010
Preliminary
Lubrication and Servicing
• Do not allow unauthorised personnel to
service or maintain the machine. Study the
Operator’s handbook and Service Manual
before starting, operating or servicing the
machine.
• Always relieve pressure before servicing
any pressurised system.
• Use only the special hydraulic fluid supplied
by TCP. Unapproved or diluted fluid could
freeze in cold conditions resulting in
damage to the equipment and/or danger to
personnel.
• DO NOT touch or lean against hot exhaust
pipes or engine cylinder.
• HIGH VOLTAGE! This unit uses high voltage
circuits capable of causing serious injury or
death. Only a qualified electrician should
troubleshoot or repair electrical problems
occurring in this equipment.
• Replace all guards and safety devices
immediately after servicing.
• Before servicing light tower, make sure engine
start switch is turned to OFF, circuit breakers
are open (off) and the battery isolation key is
removed. NEVER perform even routine
service (oi/lfilter changes, cleaning, etc.) unless all electrical components are shut down.
• Never allow water to accumulate around the
base of the light tower set. If water is present,
DO NOT service!
Always remain aware of the position of other
people around you when lifting the equipment
Specifications
Length
1200 mm
Height
2050 mm
Overall height, floodlit position
9100 mm
Width
1200 mm
Overall width with jack legs
deployed
2700 mm
Lifting eye safe working load
1000 kg
Engine
Hatz IB20
Engine power
3.1 kW
Noise Level
85 dBA LWA
Engine oil capacity
2.6 l
Fuel capacity
95 l
Fuel consumption
0.5 l/hour
Fuel specification: Diesel meeting EN 590,
BS 2869 A1 / A2 or ASTM D 975 - 1D / 2D
Total run time
170 hours
Stabilising/levelling positions
4
Operating voltages
12V d.c.
220V a.c.
Max wind speed for safe
operation
100 kph
Lamps
4 x 150W
Auxiliary power option
220V or 110V
• Never service electrical components if clothing
or skin is wet. If the unit is stored outside,
check the engine and generator for any
moisture and dry the unit before use.
• Never wash the unit with a power washer or
high pressure hose.
• Open main circuit breaker before disconnect-
ing battery cables.
• Keep hands, feet, and loose clothing away
from moving parts on generator and engine.
• Replace all missing and hard-to-read labels.
Labels provide important operating instructions and warn of dangers and hazards.
• Make sure slings, chains, hooks, ramps, jacks,
and other types of lifting devices are attached
securely and have enough weight-bearing capacity to lift or hold the equipment safely.
TCP EcoLite P User's Manual,Issue B July 2010
7
Prelliminary
8
TCP EcoLite P User's Manual, Issue B July 2010
Section 1 Operating Instructions
Section 1 Operating Instructions
1.1 Features
• Four or six adjustable, ceramic discharge metal halide lamps mounted on a telescopic tower.
• 9m tower raised and lowered using hydraulics powered by a Hatz diesel engine.
• Lights powered from the diesel engine or (optionally) from a local mains supply.
• Mounted on a pallet-style frame that occupies the same floor area as a pallet for ease of
storage and transport.
1.2 Positioning
When choosing a location of the Ecolite, bear in mind the following:
• The light tower should not be placed where those working under the light are:
o
Forced to look into the light regularly or
o
Forced to work with their backs to the light (shadows will block the light from the work area).
• Assess site conditions carefully before positioning and operating the tower.
• Do not position the tower in the vicinity of overhead cables or power lines!
• Locate the light tower on the same or a higher level than the area being lit (the higher the light,
the less shadow length).
• The area where the tower is positioned should be relatively level. This will ensure smooth,
trouble-free telescoping of the mast. (The mast may not telescope down properly if the unit is
not level.)
• Do not move the tower with the mast raised!
• Never raise the mast or operate the tower without the jacklegs touching the ground!
TCP EcoLite P User's Manual,Issue B July 2010
9
Section 1 Operating Instructions
1.3 Stabilising the Unit
Fig 1-1 Jack components
Fig 1-2 Jack extended
Stabilise the unit as follows. Start with the jack that is on the highest ground.
1.
Pull up the Locking Pin (Fig 1-1) and pull the Jack Leg away from the body of the unit to its
fullest extent until the pin locks in the hole (Fig 1-2).
2.
Wind the foot of the jack down to the ground.
Repeat the procedure for all four jacks so that the unit is stable and level. Do not use the jacks to
raise the unit off the ground.
1.4 Using the Lights
1.
Check that the light lenses are clean and undamaged.
2.
Drive the earth spike (Fig 1-8) into the ground (earth) (follow any risk assessment). Check that
the earth spike cable is securely attached to the unit.
3.
Check that the Emergency Stop button is not pressed. If necessary, rotate the button
clockwise to release it.
4.
Open the cover to access the Control Panel.
5.
Check the fuel level and top up if necessary. (The fuel level can be seen through the
translucent fuel tank.)
10
TCP EcoLite P User's Manual, Issue B July 2010
Section 1 Operating Instructions
Fig 1-3 Control panel
Fig 1-4 Ignition panel
Note: Fig 1-3 shows a 230V machine with an auxiliary output. The mcb configuration on other
versions will be different.
6.
Check that the main switch and miniature circuit breakers (MCBs) are on (up) and the Light
switches are off. (The main switch is a residual current device (RCD) that can be tripped by
an earth leakage.)
7.
Set the Supply Selector Switch (if fitted) to Off.
8.
Insert the key in the Key Switch and turn it to position 1. The Battery and Oil Pressure lights
adjacent to the switch should light.
9.
Turn the key to position 2.
10. As soon as the engine starts, release the Key to position 1. Check that the Battery and Oil
Pressure lights go out and the green, Running light remains on.
Note: If the engine does not start, return the key switch to position 0 before retrying.
TCP EcoLite P User's Manual,Issue B July 2010
11
Section 1 Operating Instructions
11. Check that the lights on the tower are oriented so as to provide optimum illumination of the
site. The lights can be tipped up/down and rotated, as required. It is also possible rotate the
tower through 300 degrees. See Section 1.7 Redirecting the Lights.
12. Raise the tower by turning the Tower switch clockwise and holding it there.
Note: If the mast does not rise, check that the mast lowering valve is closed (see Section 1.4.1
Lowering Mast if Battery is Flat).
13. Release the Tower switch when the lights reach either the required height or maximum. You
will hear a change in the pitch of the hydraulic motor when the mast is fully extended.
Note: It is normal for the mast to appear wet as it is raised: the hydraulic fluid acts as a lubricant
for the seals between the telescopic sections. Subsequent leakage from a raised mast
could indicate a problem with a seal. Seals and O-rings can be replaced as detailed in the
workshop manual.
14. Set the Supply Selector switch (if fitted) to Generator.
15. Set the Light switches to On (clockwise). The lamps take a minute or two to warm up.
16. Close the cover to protect the Control Panel.
Closing down the unit is the reverse of this procedure.
Before lowering the tower, switch off the lights and allow time for them to cool.
To stop the engine, turn the Key Switch to 0.
1.4.1 Lowering Mast if Battery is Flat
Battery power is used to lower the mast as well as to raise it. If the battery is flat, the mast can be
lowered by manually opening the valve shown in Fig 1-5. Turn the knob counter-clockwise to open
the valve and lower the mast. Close the valve again after the mast has come down. The mast
cannot be raised while the valve is open..
Fig 1-5 Mast Lowering solenoid valve
12
TCP EcoLite P User's Manual, Issue B July 2010
Section 1 Operating Instructions
1.5 Auxiliary Supply (Optional)
Where an input plug is fitted (Fig 1-6), the lamps can be powered from a local mains supply instead
of from the generator. Connect the mains supply to the Aux input plug (Fig 1-6).
Fig 1-6 Auxiliary supply connectors
Note: To avoid depleting the battery, the unit is configured so that the mast can only be raised
with the engine running.
To use the auxiliary supply, follow the instructions given in Section 1.4 Using the Lights but set the
Supply Selector switch to Aux Input in Step 14. On completion, turn off the generator, leaving the
lights powered from the Auxiliary mains input.
Where an output socket is fitted, it provides either 110V centre-tap earth (cte) or 220V output
(depending on version/region) from the internal alternator.
1.6 Moving the Unit
To move the unit:
1.
Turn off the lights and allow time for them to cool.
2.
Lower the tower.
3.
Raise, retract and stow the four jacks.
1.7 Redirecting the Lights
The tower can be rotated through up to 300 degrees so as to direct the light as required.
Slacken the Rotation Lock (Fig 1-8) and turn the Rotation Handle so as to direct the lights as
required. Tighten the lock afterwards.
In addition to rotation of the mast, each of the lights can be rotated on two axes and tipped back
and forth (Fig 1-7). Thus the lights can be directed either downwards or horizontally (e.g. to
illuminate a facade (Fig 1-9)). For any adjustments, the mast must be lowered to allow access.
TCP EcoLite P User's Manual,Issue B July 2010
13
Section 1 Operating Instructions
Fig 1-7 Light manipulation
Fig 1-9 Façade illumination
14
Fig 1-8 Rotation lock
Fig 1-10 Earth Spike
TCP EcoLite P User's Manual, Issue B July 2010
Section 1 Operating Instructions
1.8 Emergency Stop
The Emergency Stop button shuts off the engine in
under 20 seconds.
The engine (and the power it generates) will remain
off until the Emergency Stop button is released. To
release the button, twist it in the direction of the
arrows on the button.
Note: When Ecolite power is supplied from
an outside source via the input socket
(engine not used and supply Selector
switch set to Auxiliary) the Emergency
Stop button is inoperative and will not
turn off the power.
The RCD provides protection against
electric shock.
TCP EcoLite P User's Manual,Issue B July 2010
Fig 1-10 Emergency Stop button
15
Section 1 Operating Instructions
16
TCP EcoLite P User's Manual, Issue B July 2010
Section 2 Routine Maintenance
Section 2 Routine Maintenance
2.1 Schedule
Operation
Engine Oil
Air filter
Fuel Filter – in-line
Fuel Filter – fixed
Hydraulic fluid
Engine oil filter
Drain water from fuel
tank
Engine conditioning
Daily
Check
Every
250 hr
Change
Check/replace
Replace
Service interval
Every
Every
500 hr
1000 hr
Every
1500 hr
Clean
Ref.
Page
17 & 18
19
18
18
21
19
Annually
22
Replace
Check
Decoke
22
*Check/clean air filter daily in dusty conditions.
2.2 Engine Oil Check
Check the engine oil after each day’s use.
1.
Ensure that the unit is level.
2.
Check the oil level with the engine cold.
3.
Clean the area around the oil filler
cap/dipstick.
4.
Remove the dipstick (Fig 2-1) and allow a
few moments for the oil level to settle.
5.
Check the oil level using the dipstick
(Fig 2-2).
6.
If necessary, top up the oil (see Fig 2-3).
Do not overfill.
Fig 2-1 Oil filler/dipstick and pump
Fig 2-2 Dipstick levels
TCP EcoLite P User's Manual,Issue B July 2010
17
Section 2 Routine Maintenance
2.3 Engine Oil Change
Change the oil every 250 operating hours.
Take care that no contamination enters the
sump
1.
Ensure that the unit is level.
2.
Run the engine until it is warm.
3.
Clean the area around the oil filler
cap/dipstick.
4.
Remove the filler cap/dipstick (Fig 2-1).
5.
Attach a suitable tube to the oil
evacuation pump and route it to a
suitable container.
6.
Use the hand pump to evacuate all the oil
from the sump.
7.
Disconnect the tube.
8.
Refill the sump with oil of the correct
grade for the conditions (Fig 2-3) to the
correct level, as indicated on the dipstick.
9.
Refit the filler cap/dipstick.
2.4 Fuel Filters
Parts:
In-line fuel filter
Fixed fuel filter
Fig 2-3 Oil SAE grades
Oil should meet at least one of the following
specifications:
ACEA – B2 / E2 or better
API – CD / CE / CF / CF-4 / CG-4 or better.
If engine oil of a poorer quality is used, reduce oil
change interval to 150 hours of operation.
TCP 14-0131
TCP 14-0128
Two fuel filters are fitted: one behind the battery, in the line to the fuel pump (Fig 2-4) and the
other mounted on the side of the engine (Fig 2-5). Replace the in-line filter after 250 hours of
operation and the fixed filter after 500 hours.
Fig 2-4 In-line fuel filter
18
Fig 2-5 Fixed fuel filter
TCP EcoLite P User's Manual, Issue B July 2010
Section 2 Routine Maintenance
2.5 Oil Filter
Clean the oil filter after every 1000 operating hours.
1.
2.
To gain access to the oil filter, remove the side panel
from the engine. Fig 2-6 shows the side panel and
some of the fixing screws. The oil filter is located
near the bottom of the engine (Fig 2-7). Remove the
filter as shown in Fig 2-8.
Fig 2-6 Engine side panel
Wash out oil filter with degreaser. Replace filter if damaged.
Fig 2-7 Engine oil filter
Fig 2-8 Oil filter removal
Fig 2-9 Oil filter refitting
3.
Check joint washers (Fig 2-9). Replace if necessary.
TCP EcoLite P User's Manual,Issue B July 2010
19
Section 2 Routine Maintenance
4.
Lubricate joint washer before fitting.
5.
Insert filter to limit of travel. Ensure that tension springs (Fig 2-9) sit close to filter before
tightening screw.
6.
Check oil level and top up as necessary.
2.6 Air Filter
Parts:
Air filter element
Safety element
TCP 10-0273
TCP 10-0274
Check the air filter every 250 operating hours - daily
under dusty conditions. The filter comprises an outer
filter element and an inner safety element, intended
to stop the filter element being sucked in.
1.
Open the cover to access the air filter assembly.
2.
Unscrew the air filter cover (Fig 2-10).
3.
Extract the filter element (Fig 2-11).
4.
Extract the inner, safety element (Fig 2-12).
5.
Replace filter if damaged or dirty.
Fig 2-11 Air filter element
20
Fig 2-10 Air filter cover removal
6.
Reassemble the filter assembly.
Fig 2-12 Safety element
TCP EcoLite P User's Manual, Issue B July 2010
Section 2 Routine Maintenance
2.7 Hydraulic Fluid
Check the fluid in the hydraulic tank daily.
Fig 2-13 Hydraulics
Remove the cap from the hydraulic tank and check the
level. The fluid should just reach the bottom of the filter
that is under the cap (Fig 2-14). If necessary, top up
with Ecolite Mast Fluid (TCP Part No. 80-0372).
Warning: Only use the specified TCP hydraulic fluid
(undiluted). This fluid is specially formulated for the
purpose. If the wrong fluid is used or the fluid becomes
diluted, it could freeze under cold conditions with
resultant structural damage to the equipment. This
could result in injuries to personnel and/or damage to
property.
If it is suspected that the fluid has become diluted,
drain the tank (as described for the fuel, in Section 2.8
Draining Fuel Tank) and refill with the prescribed TCP
fluid.
Fig 2-14 Hydraulic fluid level check
Take care not to mix fuel and hydraulic fluid.
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21
Section 2 Routine Maintenance
2.8 Draining Fuel Tank
When working on the fuel system, do not expose it to a naked flame; do not smoke.
Over time, condensation results in a layer of water forming at the bottom of the fuel tank, water
being heavier than diesel fuel. Once per year, remove the water as follows:
1.
Fit a polyethylene tube (diameter 4 mm, length 700mm approx.) to a commercial syringe (20
ml or larger).
2.
Remove the diesel filler cap and run the tube down to the bottom of the tank.
3.
Drain off the fuel/water mixture with the syringe.
4.
Repeat the procedure until the transparent syringe is found to contain only diesel fuel.
2.9 Engine Conditioning
After every 1500 hours of operation, the engine should be run under a 2.6 kW load for two hours in
order to clear it of accumulated carbon deposits. The 2.6 kW can comprise a 2 kW load connected
to the Auxiliary Supply output plus 600W for the lights.
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TCP EcoLite P User's Manual, Issue B July 2010
Section 3 Lamp Replacement
Section 3 Lamp Replacement
Note: Do not touch the lamp bulb with bare fingers. The grease deposited from skin will cause
the lamp to fail when it is turned on. Ensure that the new lamp is clean.
1.
Release the clips securing the lens (Fig 3-1) and remove the lens (Fig 3-2).
Fig 3-1 Lens clips
Fig 3-2 Lamp lens
2.
Unclip the lamp from the holder (Fig 3-3).
3.
Install the new lamp and refit the lens.
Fig 3-3 Lamp and holder
TCP EcoLite P User's Manual,Issue B July 2010
23
Section 3 Lamp Replacement
24
TCP EcoLite P User's Manual, Issue B July 2010
Section 4 Fault-finding
Section 4 Fault-finding
4.1 Introduction
The Hatz engine is a very reliable unit, dirty fuel being the most likely problem. This section covers
the remaining most likely problem areas. Any other faults should be handled by a competent
engineer referring to the Ecolite Workshop Manual.
4.2 Battery Light On
If the engine is running, this lamp indicates that the battery is not charging. Check the alternator
and regulator.
4.3 Oil Pressure Light On
Check the oil level (Section 2.2 Engine Oil Check).
4.4 High Temperature Light On
If the engine has been running for a while and the High Temperature light is on, check the cooling
fan. If the Fan indicator lamp (Fig 1-4) is lit, check the supply to the fan.
4.5 Starting
4.5.1 Control Lights Off
On turning the key switch to I (On), no
indicator lamps light.
•
Check that Emergency Stop button is
released. Turn button in direction of
arrows.
•
Check the battery voltage as detailed
below.
4.5.2 Engine does not crank
•
Fig 4-1 Battery voltage check
Check that Supply Selector switch is set to
Off. Engine will not start with this switch set to Auxiliary.
•
Check battery as follows.
Measure (12V) battery voltage at terminals on side of motor (Fig 4-1). Check voltage with start
switch in each of its three positions. The voltage should be around 12V off load (switch position 0)
and should not fall below 10V while cranking. (Fuel pump operation should be audible in switch
position 1.)
4.5.3 Engine cranks as normal but engine does not fire
• Check fuel level in tank.
• Check that the fuel pump operates when the start switch is set to I. Pump operation should be
audible.
• Check fuel and filters.
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25
Section 4 Fault-finding
26
TCP EcoLite P User's Manual, Issue B July 2010
Section 5 Options
Section 5 Options
TCP EcoLite P User's Manual,Issue B July 2010
27
Appendix A - Timer and Dusk-Dawn Functions
Appendix A - Timer and Dusk-Dawn Functions
A1. Introduction
This appendix describes two automatic operation options:
!
A timer can be fitted to turn the lights on and off at pre-determined times for every day of
the week.
!
A sensor can be fitted on top of the mast to turn the lights on at dusk and off at dawn.
Only one option can be fitted to a given unit.
Fig A1 Timer and ignition panel
A2. Ignition Panel
The key switch on the (Capricorn) ignition panel has three positions:
!
Manual on - engine starts and lights come on if selected. (If lights fail to come on, check
that dip-switch A4 is On. See Section A11. Ignition Unit Settings.)
!
Off - engine turns off and lights go off.
!
Auto on - engine and lights are controlled by the Dusk-dawn sensor or the Timer,
according to which is fitted.
Fig A2 Ignition panel
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TCP EcoLite P User's Manual, Issue B July 2010
Appendix A - Timer and Dusk-Dawn Functions
A3. Timer
A3.1. Introduction
The timer allows the engine and lights to be turned on and off at predetermined times on a weekly
basis. (The mast is not affected and remains in the set position.)
The front panel buttons can be used to set numerous On and Off switching points at particular
times on particular days or groups of days of the week, e.g. Monday to Friday or Saturday and
Sunday. There are also various options for dusk and dawn switching. Press the
button
repeatedly to see the switching points that are currently set. Examples:
On 19.00
Off 2100
Monday to Thursday
On 21.00 Monday
Off 05.00 Tuesday
On at Dusk
Every day
Off after 1 hr
Either manual or automatic daylight saving time (e.g. British Summer Time) can be implemented.
To access the timer, raise the control panel window and flip up the window covering the timer. The
timer window can be used to prop up the control panel window.
The timer normally shows the current time.
Use an implement such as a ball-point pen to press the buttons. Do not use a sharp-pointed
implement that could damage the meter.
A3.2. Display and Control Buttons
Fig A3 Timer front panel
TCP EcoLite P User's Manual,Issue B July 2010
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Appendix A - Timer and Dusk-Dawn Functions
A4. Preliminary Settings
A4.1. Initial Start-up
On a new unit or after the unit has been disconnected from the supply for some time, the display
will be off and the unit must be initialised, as follows.
4.
Press and hold
for 5s. The display will appear after approximately 2 minutes.
5.
Set the time, date etc. as detailed below.
A4.2. Time Setting
Check the displayed time. If necessary, set the time as follows:
1.
Press
2.
Use the
3.
Press
, The colon stops flashing.
,
and
buttons to set the day, hours and minutes.
to save your settings.
Daylight saving time (DST) adjustments will be made automatically.
A4.3. Setting Date and Automatic Daylight Saving Time
The date must be set if you wish to use automatic daylight saving time (DST) or dusk/dawn switching
functions.
1.
Press
for 5 seconds: 1. 1 appears in the display.
2.
Press
to enter day (default setting is 1).
3.
Press
to set the month (default setting is 1).
4.
Press
to switch to year setting (default setting is "01 ':) and then press
(01 = 2001).
5.
To save the settings WITH automatic summer/winter time adjustment, press
appears in the display.
6.
To save the settings WITHOUT automatic summer/winter time adjustment press
to set the year
. ±1h
.
A4.4. Deactivating Automatic DST Adjustment
Press
for 5 seconds, then press
±1h is removed from the display..
. Automatic DST adjustment is deactivated and the symbol
A4.5. Manual DST Adjustment
Press the
button until the correct time is displayed.
If the symbol ±1h appears in the display, the DST setting cannot be changed manually.
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Appendix A - Timer and Dusk-Dawn Functions
A5. Main Functions
A5.1. Setting a Switching Point
1.
Press
. The display shows the first ON switching point. .
2.
Press
repeatedly to obtain the required day or block of days for which this switching point
will apply.
3.
Press
to set hours for the switch-on point.
4.
Press
to set minutes for the switch-on point.
5.
Press
again. The display shows the OFF time for the switched period.
6.
Use the
point.
7.
Press the
8.
Repeat the procedure as necessary to set more switching points.
9.
Press
,
,
buttons again to set the day(s) hours and minutes for the switch-off
button again to confirm your setting. The next switching point will be displayed.
to exit the routine.
The current time is displayed again after 60 seconds or when
is pressed.
A5.2. Changing a Switching Point
1.
Press
repeatedly until the desired switching point appears in the display.
2.
Set the new times as described in Section A5.1. Setting a Switching Point .
The current time is displayed again after 60 seconds or when
is pressed.
A5.3. Deleting a Switching Point
1.
Press
repeatedly until the desired switching point appears in the display.
2.
Press
repeatedly until --:-- appears in the display.
3.
Press
. The switching point is deleted and the next switching point is displayed.
The current time is displayed again after 60 seconds or when
is pressed.
A5.4. Manual and permanent switching
Repeated pressing of
displays the following operating modes:
!
Automatic off (OFF),
!
Automatic on (ON),
!
Permanent off (OFF FIX),
!
Permanent on (ON FIX).
With the Permanently On (ON FIX) or Off (OFF FIX) settings, the stored program will be bypassed
without the loss of program values.
The current time is displayed again after 60 seconds or when
TCP EcoLite P User's Manual,Issue B July 2010
is pressed.
31
Appendix A - Timer and Dusk-Dawn Functions
A6. Special Functions
A6.1. Deactivating Individual Switching Points
Recall the switching point by pressing
and deactivate it by pressing the
button. [1] is
displayed above the colon. This switching point remains inactive until it is reactivated.
To reactivate a switching point, recall the switching point by pressing
appears in the display above the colon.
The current time is displayed again after 60 seconds or when
, then press
:[]
is pressed.
A6.2. Holiday switching
This function enables the switching channels to be set permanently ON or OFF for a maximum
period of up to 99 days without affecting the switching points programme.
Holiday switching is not possible in ON FIX and OFF FIX (permanent) switching modes. This is
indicated by the symbol FIX flashing on the display.
1.
Press the
button for five seconds until 0.d appears on the display. Press
until the desired number of holiday days appears in the display.
2.
Press
repeatedly
to set the desired switching mode OFF or ON.
Do not press any other button after this, or the holiday switching mode will be deactivated.
When the set holiday period has expired, the time switch resets automatically to the normal
display.
A6.3. Random Switching Points
The actual switching time can be varied in a random fashion about the set time within a time frame
of ± 1-59 minutes. To set random timing for a switching point, select the switching point using the
button and then press
. The symbol
appears, showing that the precise time of switching
will be selected at random.
To set the range of fluctuation, press
and then press
eight times.
is displayed. Use the
button to select the required range between ±1 and ±59 minutes. See Table A1(9).
A6.4. Reset button
Pressing the
button deletes the currently set clock time, day and date.
Pressing
and
together deletes the currently set time, day, date and all set switching points.
Settings revert to the defaults.
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Appendix A - Timer and Dusk-Dawn Functions
A6.5. Program button
The program modes are as follows:
Item
Function
Display/ settings
Default setting
1
Pulse function (not used)
P1, P2, P3
P1
2
1x
Dusk/Dawn Switching functions
AO, A1, A2, A3, A4, A5
AO
3
2x
Latitude for Dusk/Dawn Switching
S 90 to N 90
n 50
4
3x
Longitude for Dusk/Dawn Switching
E 180 to W 180
E10
5
4x
Time zone for Dusk/Dawn Switching
t -11 to t 12
+1 for CET
6
5x
Sun below Dusk/Dawn Switching
0° to 18°
6°
7
6x
Morning time Dusk/Dawn Switching
-2:59 to 2:59
0:00 h
8
7x
Evening time Dusk/Dawn Switching
-2:59 to 2:59
0:00 h
9
8x
Fluctuation range of random switching points
1 to 59
30 min
10
9x
Cycle error
-99 to 99
Varies
Table A1 Program functions
To select a program function, press
and then press
repeatedly to cycle through the
available functions. Having selected a function, use the
and
buttons to set or select the
parameters. Press
to confirm your setting. The display will show the next function in the list.
Press
to exit program mode without saving the displayed function.
A7. Pulse Function
A7.1. Pulse function P1
The Pulse function provides an option of generating a pulse at a switching point. This function,
controlled by the
button, is not used in this application,
A8. Dusk/Dawn Switching Function
This function provides for switching on at dusk and off at dawn. It operates by calculating the
morning and evening twilight times from the lat/long location and time of year. The twilight times
can, like the entered switching points, be used to execute switching functions. The clock varies the
switching times with the time of year.
A8.1. Setting a Dusk/Dawn Switching Function
The time switch provides five Dusk/Dawn Switching function A1-A5, as shown in Table A1(2).
Select A0 if Dusk/Dawn Switching is not required.
1.
Press
followed by
to select Dusk/Dawn Switching. The display will show A0.
2.
Press
repeatedly to select the desired function (A1-A5) - see Sections A8.4. Dusk/Dawn
Switching Function A1 to A8.8. Dusk/Dawn Switching Function A5.
3.
Press
to confirm your selection. The next function Latitude will be selected and the
display will show n xx (North) or S xx (South), where xx is the currently set latitude.
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Appendix A - Timer and Dusk-Dawn Functions
4.
Use the
button to set the parameter value. Press and hold the button to advance the
setting in increments of 10.
5.
Press
6.
Repeat steps 4 and 5 for each Dusk/Dawn Switching parameter, Longitude, Time zone, Sun
below horizon and Morning and Evening differentials, using the
and
buttons as
required.
to confirm your setting. The next parameter will be displayed.
When a Dusk/Dawn Switching function has been selected, the clock calculates the current twilight
times. These are recalculated at 0:00 h on each subsequent day.
A8.2. Dusk/Dawn Switching parameters
Latitude and Longitude: The twilight times depend on the geographical position of the place of
operation. The default setting is 50° north (latitude) and 10° east (longitude), corresponding
roughly to the geographical position of Frankfurt/Main, Germany.
Clock zone: The standard clock zone is set for Central Europe. The value must be changed
corresponding to the place of operation. (UK = 0.)
Sun below horizon: the time switch calculates the current twilight times based on the angles
entered. The default setting is an angle of 6°, corresponding to "civil twilight" (nautical twilight =
120, astronomic twilight = 18°).
Morning and evening time differential: the time differentials enable the twilight switching points
to be shifted and determine the morning and evening switch-on duration (see Table A1). The
setting 0:00 makes the time differentials ineffective. The time differential settings are only effective
for functions A1 and A2.
A8.3. Twilight Times Display
The twilight times are stored as special switching points and can be displayed by pressing the
button:
The time is displayed, the colon flashes.
The dawn switching point is displayed. Pressing
again displays the dusk switching point.
The date must be entered when using the automatic Daylight Saving Time switchover and
Dusk/Dawn Switching functions. If the Dusk/Dawn Switching function is deactivated (= AO), no
twilight switching points are displayed.
A8.4. Dusk/Dawn Switching Function A1
In Dusk/Dawn Switching function A1, the dusk switching point acts as a switch-on point and the
dawn switching point as a switch-off point.
Function A1 also allows for shifting the calculated twilight switching points. One time differential
each can be set for both the dawn and the dusk switching points, enabling execution of the twilight
switching points to be advanced or retarded. A negative differential value gives an earlier the
switching point and a positive value gives a later switching point. See Fig A4.
Activating Dusk/Dawn Switching function A1 renders other set switching points ineffective.
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TCP EcoLite P User's Manual, Issue B July 2010
Appendix A - Timer and Dusk-Dawn Functions
Fig A4 Functions A1 and A2
A8.5. Dusk/Dawn Switching Function A2
Function A2 enables the switching on of an item for a desired period of time after dusk or before
dawn.
The period during which the light is switched on after dusk is determined by the evening time
differential. The morning time differential determines the duration of switch-on time before dawn
(see Fig A4).
If one of the evening or morning switching sequences is not required, set the corresponding time
differential to 0:00.
Activating Dusk/Dawn Switching function A2 renders other set switching points ineffective.
A8.6. Dusk/Dawn Switching Function A3 (AND-linked)
Function A3 combines set switching points with the twilight times in an AND fashion. The switch is
On only when both sources call for power. See Fig A5.
A8.7. Dusk/Dawn Switching Function A4 (OR-linked)
Function A4 combines set switching points with the twilight times in an OR fashion. The switch is
On when either source calls for power. See Fig A5.
Fig A5 Functions A3 and A4
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Appendix A - Timer and Dusk-Dawn Functions
A8.8. Dusk/Dawn Switching Function A5
With Function A5, the switch comes On at the dusk switching point and off with the next switching
point on the following day, not by the dawn.
Example 1
On/Off
On/Off
7.00
9.00
Dusk/dawn summer
22.00
(6.00)
22.00
(6.00)
Executed switching time
22.00
7.00
22.00
9.00
Switching points
programmed
Example 2
On/Off
On/Off
7.00
9.00
Dusk/dawn winter
18.00
(8.00)
18.00
(8.00)
Executed switching time
18.00
7.00
18.00
9.00
Switching points
programmed
Table A6
Further additionally entered switching points are not executed.
A9. Setting Cycle Error Correction
Cycle error correction can only be set when mains voltage is connected.
Cycle correction value: the cycle precision of the time switches at room temperature (20° C) is
generally better than 1 second per day. Higher ambient temperatures, however, can cause an
additional cycle error. If the ambient conditions are constant to the greatest possible extent, the
error can be minimised by resetting the cycle correction value. To do this, the cycle error is
determined by comparing it with a time signal (e.g. radio or television) over a period of exactly one
week. The value in seconds of cycle deviation per week obtained in this manner is then taken into
account when resetting the cycle correction value.
If the time switch is fast, the cycle correction value is reduced by the number of seconds. If the time
switch is slow, the value is increased by the number of seconds.
The factory default setting for cycle error correction is for conditions of approx. 20°C. The newly
ascertained cycle deviation must be added to or subtracted from the default value.
Example:
Default value for cycle correction: +2 sec per week
Newly ascertained cycle deviation: +3 sec per week.
3 seconds must be deducted from the default setting, i.e. -1 must appear in the display (for setting,
see Table 1).
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Appendix A - Timer and Dusk-Dawn Functions
A10. Technical details
A10.9. Updating the Switching Outputs
If new switching points are entered or the current time is changed, the current switching status is
re-calculated and the entered switching points are updated accordingly within 1 minute.
A10.10. Behaviour in the Case of Electrical Supply Failure
In the supply voltage is lost, the switching relay(s) will be deactivated (OFF position) and
the digital display switched off.
The relays commence working again, as programmed, approximately one minute after the supply
voltage has been restored.
Should the reserve power supply be exhausted following a prolonged supply failure, the switching
points will be retained indefinitely but the time, day and date will have to be re-entered (see
A10.11. Technical data).
A10.11. Technical data
Electrical connection
see rating plate
Internal power consumption
1W
Switching output
see rating plate
Switching contact
Single pole changeover
Number of switching points
56
Shortest switching interval
1 min. (1s for pulse programming)
Cycle accuracy
<± 1 s/day; 20ºC
Reserve power supply
(charging time > 1h)
>38 hours at 20°C (Supercap)
5 years (lithium battery)
Temperature limits
-10 to +50 ºC
Protection category
II acc. to EN 60335 installed
Protection type
IP 20 acc. to EN 60529 installed
TCP EcoLite P User's Manual,Issue B July 2010
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Appendix A - Timer and Dusk-Dawn Functions
A11. Ignition Unit Settings
Fig A6 shows the Ignition Unit rear panel. All the dip switches, except A4, should be Off. Switch
A4 should be On to ensure that the selected lights are powered when the ignition switch is set to
Manual.
Fig A6 Capricorn Ignition Unit rear panel
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TCP EcoLite P User's Manual, Issue B July 2010
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