LIGHT TOWER

PI 7.6 LP TL / PI 9.5 LP TL / PI 9.9 P TL / PI 14.3 P TL

50 Hz / 60 Hz

OPERATORS MANUAL

1
 Table Of Contents
OPERATORS MANUAL:

1. Introduction..3

2. Quality Policy...4

3. Safety Observation.5

4. General Safety..........6 - 9
4.1 Safety Symbol..6 - 7
4.2 Operating Safety8
4.3 Transport & Towing Safety..9

5. Model Number Identification...10

6. Receipt of Delivery Checklist .11

7. Specification..12

8. Dimension.13

9. Tower Light Setup .....14-37

9.1 Tilt Mast to Vertical Position16-21
9.2 Operating Instructions (Control Panel)..22-23
9.3 Light Operation..24-25
9.4 Light Tower Auxiliary Power.26
9.5 Controller Instruction....27-28
9.6 Main Screens Structure.......29-32
9.7 Lowering the Tower33
9.8 Tilt Vertical Mast to Travel Position34-36
9.9 Towing the Trailer...37
9.10 Lifting the Trailer...........38

10. Brake winch instruction.....39-42

11. Winch & Wire Rope Maintenance...43-45

12. Maintenance Procedure46-47

13. Wiring diagram.48

14. Tower Light Assembly Instruction...49-63

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 1. Introduction
Congratulation on choosing PI light tower, You have chosen a high quality self
contained portable wide area floodlighting system built from the latest design and
manufactured to the most precise standard.

The light tower consists of five major components groups are trailer, generator,
tower, metal halide and electrical system. These above groups are covered in this
manual.

An engine operators manual is supplied with the unit at the time of shipment
from the factory. The manual provides detailed operation and maintenance
procedures for the engine. Additional copies of the engine operators manual are
available from the engine manufacturer.

This manual contains information and procedures to safely operate and maintain
the light tower. For your own safety and protection from physical injury, carefully
read, understand, and observe the safety instructions described in this Operating
manual.
DO NOT MODIFY or use this equipment for any application other than which it was
designed for.

Keep a copy of this manual with the unit at all times. Additional copies are
available from PRECISION INDUSTRIES or can be found at www.pi-dubai.com

In line with our policy of continuous development. PRECISION INDUSTRIES

reserves the right to change specification without notice.

3
 2. Quality Policy

We are committed to satisfy our customers and continually

improve our quality by supplying products and services
without defects and delays. We emphasize on Doing the thing
rightly rather Doing the right thing.

As part of our quality policy, we strictly comply with the

following objectives:

Quality checks are done on ISO standards during the

stages of inspection, manufacturing, testing and service.
Immediate action over customer complaints.
Adoption of latest techniques for the enhancement of quality and
performance.

4
 3. Safety Observations

This safety symbol is used for important safety messages. It is

used to alert you to potential personal injury hazards. Obey
all safety messages that follow this symbol to avoid possible
injury or death.

This manual contains DANGERS, WARNINGS, CAUTIONS, and NOTICES which must
be followed to prevent the possibility of improper service, damage to the
equipment, personal injury or death.

The following formatting options will apply when calling the readers attention to
the DANGERS, WARNINGS, CAUTIONS, NOTICES and NOTES.

DANGER Indicates a hazard or unsafe practice that will result in severe

injury or death.

WARNING Indicates a hazard or unsafe practice that could result in

severe injury or death.

CAUTION Indicates a hazard or unsafe practice that could result in

minor injury or property damage

NOTICE Indicates an important installation, operation or

maintenance
Information.

5
 4. General Safety:

WARNING DO NOT operate the light tower without reading this

operators manual.

Whenever operating a light tower you should always exercise safety precautions
to avoid personal injury or equipment damage. The following is a list of
recommended safety precautions

4.1 Safety Symbol

Safety alert symbol; Used to Asphyxiation hazard;

alert you to potential Operate In well ventilated
personal injury hazards. area.

Use protective clothing DO NOT weld on any

and safety equipment structural member.

Hot surface(s) nearby. Dangerous voltage may

be Present.

Belt/entanglement
hazard; keep body Anchor/tie down point.
parts clear of this area.

Fan hazard; Keep body

Forklift here only.
parts Clear of this area.

Crush hazard; Keep body Use clean diesel fuel only.

parts clear of this area.

6
 Read and understand
Stop engine before fueling. the supplied operators
manual Before operating
unit

Fire/explosion hazard; Keep Unit electrical ground.

Open flames away From unit.

DO NOT start the engine

Lift here only. near spilled fuel or
combustible fluids and fill
the fuel tank while the
engine is running or hot

ALWAYS wear approved eye ALWAYS wear approved

and hearing protection. respiratory Protection.

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 4.2 Operating Safety
This equipment operated improperly or by untrained personnel can be
dangerous. Read the operating instructions and familiarize yourself with
the location and proper use of all instruments and controls. Inexperienced
operators should receive instruction from someone familiar with the
equipment before being allowed to operate or set up the light tower.
The following points should be practiced at all times:
The area immediately surrounding the light tower should be dry, clean, and
free of debris.
Position and operate the light tower on a firm, level surface.
NEVER start a unit in need of repair.
Lower tower when not in use, or if high winds or electrical storms are
expected in the area.
Make certain light tower is well grounded and securely fastened to a good
earthen ground.
The tower extends up to 30 ft (9 m). Make sure area above trailer is open
and clear of overhead wires and obstructions.
Bulbs become extremely hot during use! Allow bulb and light fixture to cool
10-15 minutes before handling.
Keep area behind trailer clear of people while raising and lowering mast.
Keep all body parts and other loose items clear of winch and cable during
operation and while in tension.
NEVER raise, lower or turn mast while unit is operating.
Trailer must be leveled and outriggers extended before raising tower.
Outriggers must remain extended while tower is up.
If, for any reason any part of mast hangs up or winch cable develops slack
while raising or lowering tower, STOP immediately, and Contact an
authorized service representative.
NEVER remove safety pin or pull mast locking pin while tower is up.
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.
Only use mild soap and water to clean the lens covers. Other chemicals may
have an adverse effect on the glass.
NEVER operate a unit while tired, distracted, or under the influence of
drugs or alcohol

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 4.3 Transport & Towing Safety

Towing a trailer requires care! Both the trailer and vehicle must be in good
condition and securely fastened to each other to reduce the possibility of an
accident. Also, some states require that large trailers be registered and
licensed. Contact your local Department of Transportation office to check on
license requirements for your particular unit.

Check that the hitch and coupling on the towing vehicle are rated equal to,
or greater than, the trailer's Gross Vehicle Weight Rating (GVWR).
Check tires on trailer for tread wear, inflation, and condition.
DO NOT tow trailer using defective parts, Inspect the hitch and coupling for
wear or damage.
Make sure the trailer hitch and the coupling are compatible. Make sure the
coupling is securely fastened to the vehicle.
Connect safety chains in a crossing pattern under the tongue and Attach
the Breakaway Cable to the Rear Bumper of the Towing Vehicle. Do not
attach the cable to the trailer hitch.
Make sure directional and brake lights on the trailer are connected and
working properly.
Check that all lug nuts holding wheels on are tight and that none are
missing.
Maximum recommended speed for highway towing is 80 km/h.
Recommended off-road towing speed is not to exceed 15 km/h or less,
depending on terrain.
When towing, maintain extra space between vehicles and avoid soft
shoulders, curbs and sudden lane changes. If you have not pulled a trailer
before, practice turning, stopping, and backing up in an area away from
heavy traffic.
A film of grease on the coupler will extend coupler life and eliminate
squeaking. Wipe the coupler clean and apply fresh grease each time the
trailer is towed.

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 5. Model Number Identification

Example: - PI 7.6 LP TL

PI 7.6 LP TL

Precision Industries

(Company Name)

Standby Rating (kva)

(7.6 kva, 9.5 kva and 14.3 kva)

Engine Brand

(Lister Petter & Perkins)

Tower light

Note: - When requesting technical help and ordering replacement

parts the Model and serial number are necessary. Refer to the
Precision Industries serial number tag on the unit for correct
model number and Serial number.

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 6. Receipt of Delivery Checklist

The tower will be serviced, tested and ready for operation upon delivery
PI recommends the following checks:

Insure there is no freight handling damage which should be charged against

the carrier.
Make sure the telescoping mast is secure.
Make sure the crosshead assembly is secure.
Check the front and rear jacks for security and proper operation.
Check the outriggers for security and proper operation.
Check that the tires are not damaged, under inflated or that any lugs are
loose.
Check the engine/generator for obvious damage, loose connections, or
leaks.
Check the control panel for damage or loose connections.
Check the boom wires for obvious damage or loose connections.
Check the light fixtures for damage to the lamps, lenses, reflector or etc.
Check the winches, cables and pulleys for damage and proper operation.
Check the exhaust system for damage.
Check all fluid levels, battery, radiator, and engine oils.
Insure manuals are in the pocket provided inside the unit

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 7. Specifications
Dimensions

Maximum height of tower ft (m) 30 ( 9.14)

Length with mast stowed inch (mm) 148.3 (3767)
Width inch (mm) 66.93 (1700)
Width outriggers extended inch (mm) 118.11 (3000)
Height with mast stowed inch (mm) 76.06 (1932)

Trailer

Number of Axles 1
Tire Size (inch) 13
Hitch Standard (inch) 2
Maximum Tire Pressure (psi) 65

Light
Read this manual carefully before attempting to use this light tower. The potential
for property damage, personal injury or death exists if this equipment is misused
or installed incorrectly. Read all of the manuals included with this unit. Each
manual detail specific information regarding items such as set up.
Light features
4 X 1000w Metal Halide Floodlight
Light source with high photosynthetic efficiency:100lm/W
Heatproof silicon sealing gasket. Working in -40C~240C.
Reflector surface with polishing and oxidation treatment,
with high reflectivity.
High strength steal bracket, surface with powder spraying
treatment, firm, wind resistance, and antirust.
The light fixture and the gear box are separated, convenient for
maintenance.
For a 4x1000w tower light, it can illuminate areas greater than 4500m at
an average 20 lux.
Applicable places:
Parking, air port, mining, construction sites, rental and large area tower
Lighting.

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 8. Dimension

Travel Position

Operating Position

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 9. Tower Light Setup

The tower extends up to 30 ft (9.14 m). Make sure area above fig.1
The trailer is open and clear of overhead wires and
obstructions (see the fig.1)
The light tower should not be placed where those working
under the light are either:
a) Forced to look into the light regularly.
b) Forced to work with their backs to the light
(shadows will block the light from the work area).

The area where the tower is positioned should be relatively

level for safe and proper operation of the unit.
The light tower should be located on the same level or on ground higher
than the work area.

1. Move the light tower to desired location keeping the above in mind.
2. Disconnect the towing chain and electrical socket from vehicle.
(see below fig.2)

Towing chain

Electrical
Socket

fig.2

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3. Pull the locking pin on the tongue jack and rotate it 90 until the spring
loaded pin snaps back into place. Turn the jack handle clockwise to raise the
trailer tongue off of the towing vehicle.

4. Connect a good earthen ground to the grounding stud under the control
panel. (Grounding rod not included)

5. Pull the locking pins on the outriggers and extend each outrigger until the
spring loaded locking pin snaps back into place. (see below fig.3)

Locking pin
Jack stand
Outriggers

fig.3
Outriggers are not designed to lift the tires off the ground.

Insure that all jacks are down to prevent the tower from tipping over
backwards when raised.

Never attempt to move the tower while the leveling jacks are
down. Serious machine damage will result.

6. Pull the locking pin on the outrigger jacks and rotate them until the jack
pads are facing down and the spring loaded pin snaps back into place.
(see the fig.3)

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7. Turn the jack handle clockwise to start leveling the trailer. Adjust all four
jacks by turning their handles clockwise until they are firmly in contact with
the ground and the trailer is as level as possible (see the fig.3).

9.1 Tilt Mast To Vertical Position

fig.4

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1. Unlock the mast travel toggle lock from rear of the cabinet. (see the fig.5)

Toggle lock

fig.5

2. Before raising the tower it may be necessary to adjust the lamps. The lamps
may be adjusted up, down, left or right by loosening the handle bolts on
the lamp fixtures and aiming them in the desired direction. Tighten the
handle bolts completely and make sure the lamps are connected to the
junction box. (see the fig.6)

fig.6
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3. Check both sets of mast cables for excessive wear or damage. Make sure
the cables are properly centered in each pulley. Check the mast electrical
cord for damage.

Do not start the unit if the insulation on the electrical cord is cut or
worn through. Bare wires in contact with the mast or frame may
energize the trailer and cause electrocution. Repair or replace cord.

4. Make sure the area behind the unit is clear before tilt the mast to the
vertical position.

5. Make sure mast tilt lock is released. (see the fig.7)

Make sure this

Lock Released

fig.7

6. Rotate the handle clockwise for the lower mast winch, to tilt the mast until
vertical and the tilt mast lock bar should snap into place automatically.
Make sure tilt lock engaged properly. (see the fig. 8)

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 Lower mast winch

If there is any difficulty in tilting the boom vertically, check the mast
Travel toggle lock. May lock need to be released. To release the toggle
Lock by pull up the lock handle on the crosshead assembly until
the lock is disengaging from the hook angle.

Do not attempt to lean the tower down below 45 degrees when it is

extended - serious damage may happen.

Make sure
This Lock
Properly
Locked

fig.8

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7. Rotate the handle clockwise for the upper mast winch to extend the tower
to the desired Height. Extend the mast slowly; making sure that the
electrical cord is extending at the top sections of the mast. If, for any
reason, the cable begins to develop slack or any of the tower sections get
stuck, STOP IMMEDIATELY and contact an authorized service
Center. (see the fig.9).

Upper mast winch

fig.9
Do not extend the mast away from the red colored mark on the middle
mast tube or buzzer from control panel. (see the fig.10)

Height limit (Red color area)

fig.10
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 The automatic brake must be working on the lower & upper
telescoping winch. The winch should not allow the tower to drop down
when the handle is released.

Never raise or lower the mast while the unit is operating! Never
remove the mast tilt lock while the tower is up. Releasing the Lock will
cause the mast to fall and serious injury.

8. The mast can be rotated by pull down and twist the rotational lock at
between two winches and turn the mast until the lights face in the desired
direction. Then release the lock pin to lock the mast Rotation.
(see the fig.11&12)

fig.11 fig.12

Note: Tower can rotate maximum 330

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 9.2 Operating Instructions (Control Panel)

Starting the Gen-Set

(C)

1. Unlock and open the Engine access doors

(A)

2. Check the oil, fuel, and coolant levels.

Note: Refer To Engine Manual.

3. Check that the tower has been properly

grounded.
(B)

4. Unlock and open the Control Panel access

doors.

5. Switch on interior lamp (A).

6. Tern ON the main breaker on the Control panel (B), the LED screen must
turn on (C).

Do not start the unit if the insulation on the electrical cord is cut or
worn through. Bare wires in contact with the mast or frame may
energize the trailer and cause electrocution. Repair or replace cord.

NEVER START THE ENGINE WITH LIGHTS & SOCKET CIRCUIT

BREAKERS SWITCHED ON!(see below image) Any load on the
generator during start up Will cause severe damage or destroy the
generator!

22
 7. Press the Start button on the controller to ignition the engine and listen for
any unusual sounds or vibrations.

Note: Refer To pages (28 to 32) for Controller Instructions.

23
 9.3 Light Operation

1. Once the engine is up to temperature and running smoothly,

Switch ON each individual circuit breaker one by one at a time. (See
below image)

2. The ballast indicator lights will come on momentarily as the lights strike. As
the lights warm up, the ballast indicator lights will continue to get brighter
and then remain on. This confirms that power is coming from the ballasts
to the lights.

3. If an indicator light does not come on, the ballast may need to be serviced.
If the indicator light comes on and stays lit but the related light is not
illuminated, check the bulb or the mast wiring.

24
4. The lights require a warm up period of 5-10 minutes before they reach full
output. If the lights are shut down, they require a cool-down period of
approximately 10-15 minutes before they can be switched on again.

5. The light tower uses four 1000W bulbs. When checking or replacing the
bulbs, wipe them with a clean cloth to avoid leaving any grease, oil residue
or fingerprints on the glass. Any residue can create a hot spot on the bulb,
causing premature bulb failure.

NEVER OPERATE THE LIGHTS WITHOUT THE PROTECTIVE LENS

COVER OR WITH A LENS COVER THAT IS CRACKED OR DAMAGED!

The bulbs in the light fixtures produce high temperatures and operate
Under pressure. A broken or missing lens cover could cause the
Bulbs to shatter, causing injury.

Bulbs become extremely hot in use! Allow bulb fixture to cool 10-15
Minutes before handling.

25
 9.4 Light Tower Auxiliary Power

1. Two 32 amp, 220 VAC receptacle is provided for auxiliary power.

2. Total auxiliary power cannot exceed main circuit breaker rating. Each lamp
operating consumes 4.1 amps of 220 volt power.

3. Before plugging in auxiliary power cords, feed them up through under the
trailer frame and Attach to receptacles. Close the cabinet doors to protect
control panel and other components from weather.

Do not use auxiliary socket power while using 4 lights,

May generator get shutdown.

26
 9.5 Controller Instructions

Controller Buttons

27
28
 9.6 Main screens structure

1st screen contains basic information about generator voltage and

frequency measurement and running hours counter. When any alarm occur
the general warning symbol will be displayed on the LCDs upper right
corner.
2nd screen contain detail voltage and frequency information.
3rd screen shows senders information oil pressure; coolant temperature;
fuel level and battery voltage.
4th screen shows last alarms or events.
Start and Stop

Manual Mode

Green LED above Auto button is off (controller is in MANUAL mode). When there
is no any active shut down alarm you can start the engine by pressing Start
button. Green LED above button will blink. LED is blinking during starting, cooling

29
or stopping procedure. When the engine is already started, the green LED will
stop blink and start lights continuously. The generator is ready to load.
Press Stop button to stop the engine. First press will open the GCB and next press
start cooling and stopping procedure. When you press this button again the
controller will stop the engine immediately for fast engine stop press and hold
Stop button till engine stops.
AUTO mode

Green LED above Auto button is on (controller is in AUTO mode). You cant start
the engine or connect the load by pressing Start button. The controller will start
automatically when all conditions for start and load connection will be reached.
The engine in AUTO mode cant be stopped by pressing Stop button.
Alarms, Events and History

Four records can be displayed simultaneously on the LCD screen. Total capacity is
10 records. To view further history records you have to wait 3 second till down
arrow stops blink, then press button.. And. For alarm (shutdown) confirmation
press Stop button.
Events

Every event listed in table below is saved in history with running hours stamp see
the Figure

Warnings

Active Warning
When a warning occurs, Alarm output will close and the red LED above Stop
button will blink. Warning symbol will blink in the upper-right corner of the LCD
and the proper warning symbol will be displayed in the history with running
hours stamp. Active warning cant be confirmed

30
Inactive Warning

When a warning becomes inactive, Alarm output will open, the red LED above
Stop button will stop blinking, and the warning symbol on main screen will go out.

Shutdowns

Shutdown procedure

The InteliNano controller opens outputs Starter, Prestart and Fuel Solenoid and
closes Stop Solenoid to stop the engine immediately. Alarm output is closed.
Active or not confirmed protection disables start.
Active unconfirmed Shutdown

When a shutdown occurs, the Shutdown procedure will start, the red LED above
Stop button blinks, the shutdown symbol will blink in the upper right corner of
LCD, and the proper shutdown symbol is displayed in history with running hours
stamp. The record in history is negative, for shutdown alarm confirmation press

Stop button.

Inactive confirmed Shutdown

Alarm output is opened. It is possible to start engine when all shutdowns are
inactive and confirmed.

Automatic Shutdown

This unit is equipped with a low oil pressure, over cranking, and high coolant
temperature auto-shutdown system. This system will automatically shut off the

31
fuel supply to stop the engine if oil pressure drops too low or the engine exceeds
normal operating temperature.

Shutting Down:
When you have finished using the light tower proceed with shut down as follows:

1. Switch the individual circuit breakers for each light and auxiliary to the
OFF position.

2. Remove any loads from the auxiliary outlets.

3. Press 3 times of controller red color stop button to shout down the engine.

Do not shutdown engine while on the load.

4. Turn OFF of the main breaker and interior lamp switch.

Emergency Switches use only in emergency purpose,

Dont use it to shutdown the unit.

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 9.7 Lowering the Tower

1. Shut down the lights and engine (Refer page 32). Allow the lights to cool
10-15 minutes before lowering the tower.

2. Pull down & twist mast rotation lock and rotate the tower so the mast
mounted winches face the front of the unit. The RED alignment arrow
points should line up on the mast sections and release the lock to lock the
rotation. (see the fig.13)

Red arrow

Red arrow

fig.13
3. Using the upper telescoping winch counter clockwise to telescope the
tower down to its fully retracted position. Make sure the electrical cord
returns to the storage tube properly.
Insure the coil cord does not become entangled with the lower tower
Sections. If the mast hangs up or the winch cable begins to develop
Slack, STOP IMMEDIATELY!

33
 9.8 Tilt Vertical Mast to Travel Position

1) Pull out and twist the mast tilt lock. (see the fig.14)

Mast tilt
loc lock

fig.14

Note: If the mast tilt lock does not pull free, operate lower
winch mast lock slightly to relieve pressure on the

Make sure the red indicated arrow front of face before tilt the mast
To travel position. (see the fig.13)

2) Rotate the lower winch to tilt tower into travel position.

Lower winch

fig.14

34
3) STOP when mast is fully rested on anti vibration rubber. (see the
fig.15)

anti
vibration
pad

fig.15

Lock the mast with toggle lock

fig.16
4) Lock the mast with travel toggle, after the mast is
Completely seated. (see the fig.16)

35
5) If the trailer is going to be moved, Precision Industries strongly
recommends that the lights assembly to be removed from the mast
crosshead and fix it to middle of the mast provision for
transportation. (see the fig.17)

fig.17

Lamp fixing location

36
 9.9 Towing the Trailer

Once the engine is shut down and the mast and lights are properly stowed, the
trailer can be made ready for transport.

1) Raise the outrigger jacks completely and release the jack locking
pin to swing the jacks up into the travel position. Make sure the
locking pins snap into place. Release the outrigger locking pins
and slide the outriggers into the trailer frame until the locking pins
snap into place automatically.

2) Use the drawbar jack to raise or lower the trailer onto the hitch of
the towing vehicle. Lock the hitch coupling and attach the safety
chains to the vehicle. Release the jack locking pin and rotate the
jack into the travel position. Make sure the locking pin snaps into
place.
3) To ensure proper operation of the jacks, lube the grease fittings
located on the leveling jacks.

4) Connect any trailer wiring to the tow vehicle. Check for proper
operation of the stop and signal lights.

5) Make sure the mast toggle lock is properly locked.

6) Make sure the access doors are properly latched.

7) If the trailer is going to be driven over rough ground, remove the

bulbs from the light fixtures.

8) Check for proper inflation of the trailer tires. The maximum tire
inflation is 65 PSI.

9) Attach a red flag to the end of the mast before towing.

10) Maximum recommended speed for highway towing is 80 km/h.

Recommended off-road towing speed is not to exceed 15 km/h or
less depending on terrain.

37
 9.10 Lifting the Trailer

When lifting the light tower and trailer, attach any slings, chains or hooks directly
to the two eyes.

1) The lifting eye is located on top of the enclosure.

2) Make sure the equipment being used to lift the light.

3) Make sure the mast lock is properly locked.

4) Always remain aware of the position of other people and objects

around you as you move the unit.

5) Use the forklift pockets with care and make sure the fork seated
properly.

6) Approach the unit as perpendicular as possible to avoid any

damage to the unit.

7) Make sure the mast winch handles or any other obstructions are
clear of The forklift tines before lifting

Do not lift unit from mast.

38
 10. Brake Winch

W06-D520G / W06-D525G

Solid gear construction

Black electrostatic discharge coating and zinc plated finish
With brake for easy operation

WARNING:

THIS EQUIPMENT SHOULD NOT BE INSTALLED, OPERATED OR

MAINTAINED BY ANY INDIVIDUAL WHO HAS NOT READ ALL THE
CONTENTS OF THIS OWNERS OPERATING MANUAL. FAILURE TO
READ AND APPLY INSTRUCTIONS AND WARNINGS CONTAINED
HEREIN CAN RESULT IN SUDDEN FAILURE OF EQUIPMENT,
PROPERTY DAMAGE AND SERIOUS INJURY.

39
I. Assembly Instructions

A.HANDLE. Insert handle (Item 5, Fig. 1) on

threaded brake assembly shaft. Thread
handle to point of engagement (touching) of
brake pad.
B.HANDLE RETAINER ASSEMBLY. Insert bolt
(Item 1, Fig. 1) through. flotwasher (Item 2,
Fig. 1), spacer (Item 3, Fig. 1), and spring
(Item 4, Fig. 1) spring will flt over spacer.
Recheck Fig. 1 to insure proper order of
assembly. Install bolt containing assembled
retainer parts (Fig. 1) Into threaded end of
brake shaft and tighten bolt securely.

Fig. 1: Handle Retainer

Assembly

II.Mounting Instructions

A.This winch is designed to be attached to a

mounting plate or structure capable of
supporting the load that it is intended to
pull (lift).

B.The winch should be mounted, using three

10mm dia. S.A.E. Grade 5 bolts (not supplied).
Two bolts should attach the winch to the
Fig. 2: Mounting Instruction
mounting structure utilizing the outside rear
holes or slots. The third bolt should be inserted through the
winch frame and mounting structure in a manner to utilize
the foremost remaining frame slot (hole) (Fig. 2).

40
III.Cable Assembly Instructions

A.CABLE ATTACHMENT. This winch is

designed for up to 20m x5mm (512G
/516G), 25m x 6mm(D520G / 525G),7 x 19
galvanized aircraft-quality cable.

1. Feed cable onto top of drum (Item 7,

Fig. 3). From inside drum,thread the cable
through one round hole in the drum side,
until it extends 1-1/2 past the two square
holes. Fig. 3: Cable Installation

2. Clamp the cable to the outside of the drum with keeper parts (Items 8, 9, 10,
Fig.3). Be sure that carriage bolt beads are on the inside of winch drum.

CAUTION:

1. Always be sure cable is strong enough to support the load be pulled or

lifted.
2. Always inspect cable and attachment hook before each use to insure they
are not damaged.
3. Replace cable if worn, frayed or kinked. If cable or hook breaks, the cable
can act like a whip and inflict serious injury to anyone in the path of its
movement.
4. Never stand alongside winch cable, or guide the cable with your hands.
5. Never fully extend cable and ALWAYS keep three (3) complete wraps of
cable around drum.

6. Always be sure cable is pulling straight off winch not at an angle. This will
prevent cable from rubbing against winch drum, avoiding cable damage.
7. Always keep the drum cannot over capacity, the broken strands stop use.
8. Always forbidden use of drum in explosive, corrosive, etc.
9. Always watch the brake system prolonged lowering of load have
overheating risk.

41
Operating Procedure

Ambient operating temperature between -10C and + 50C

A.TO REEL IN OR LIFT LOAD. This winch is designed to lift a load (reel in) by turning
the hand crank in a clockwise direction. This action will produce a clicking sound
inside the winch mechanism. To LOCK the load at any desired position, release
handle slowly.

B.TO REEL OUT OR LOWER LOAD. To lower load (reel out), turn the hand crank in
a counter-clockwise direction. To LOCK load in any desired position, turn handle
crank clockwise until at least two (2) clicks (approximately movement of handle)
are heard inside the winch mechanism before releasing handle.

The minimum load 30kgs, lift and lower operation stop, the brake device have
automatic brake function.

If hand slips off handle while turning counter-clockwise, the brake will
prevent the handle from spinning rapidly backwards. NOTE: The brake
is not fully locked until the handle is turned clockwise far enough to
hear two (2) clicks of the ratchet.

Sufficient load must be applied to the cable to overcome internal

resistance and operate brake properly. NEVER CONTINUE TURNING
THE HANDLE COUNTER-CLOCKWISE IF THE CABLE DOES NOT
KEEP MOVING OUT. This will disengage the brake mechanism and
can create an unsafe or hazardous condition.

The brake mechanism under continuous long periods of lift and lower
movement will get HOT. DO NOT TOUCH BRAKE MECHANISM UNDER
THESE CONDITIONS.

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 11. Winch &Wire Rope Maintenance

1. Inspect rope or cable and replace if damaged.

2. Check mounting hardware for proper tightness and re-torque if necessary.

3. Check that winch cables are in good condition and that they are centered
on each pulley. DO NOT use a cable that is kinked or starting to unravel.

4. Maintain a light film of automotive-type grease on the pinion, drum gear,

and the O.D. of the drum bearing at all times.

5. Keep the ratchet pawl pivot, pinion shaft bushings, and pinion threads
lubricated with automotive engine oil at all times.

6. Before each use, check the brake friction discs for wear. If less than 1/16
thick, cracked, or broken, replace IMMEDIATELY.

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 7. Ratchet pawl should click when tower is raised, and not when it is
lowered. Always be alert for any fraying of cables, and replace any
damaged cables IMMEDIATELY.

8. Never stand under any object lifted by the winch.

Do not get oil or grease on the friction discs.

The wire ropes used to raise and lower the masts on a PI Light Tower are probably
some of the most important mechanical parts used in day-to-day operation of the
machinery. It is therefore very important that the cables be inspected on a
frequent basis (two times per month) for wear and tear, and immediately in the
event of possible damage due to operator error in using the winch, or possible
damage from other equipment.

Normal Wear And Tear

If used properly, the wire ropes should give years of trouble-free service,
depending on how frequently the masts are raised and lowered. The rule of PI is
that if the tower is raised and lowered an average of twice per day that the cables
should be replaced every two years of service.

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Normal Inspection

The wire ropes are constructed of 7 strands of 19 plow stainless steel wires each
twisted together, the assembly of stainless steel 304 grad for resist corrosion.
Using a thicker cloth or heavy leather gloves (to avoid being puncture by a broken
wire), Run a hand up and down a length of the cable. If any exterior wires are
broken, they will lift up from main body of the cable and become visible. For any
given 1 foot of cable length; if there are 4 or more wires each, on any 2 or more
strands broken, the suspect rope should be replaced directly.

Operator Error Other Machinery Damage

One of the most common reasons for failure of a Light Tower wire rope is due to
operator error in using the winch, or damage to the cable by tools or other
machinery. Other reasons damage can occur are due to some outside force such
as forklift blade nicking or Crushing a cable when moving a unit, or an accidental
blow or damage by a hand tool, etc.

Damage Inspection

If any scratch (partial strand cut through), twist (permanent bends), or weld
spatter on the cable (from field service) are observed, the suspect wire rope
should be changed immediately. If there is a crushed spot somewhere on the wire
rope, it should be replaced only if the width of the crushed spot exceeds 1-1/4
times the nominal diameter of the cable (8mm (5/16) ), or if there are broken
wires at the point of damage.

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 12. Maintenance Procedures

The following maintenance intervals are only recommended by PI. You should
always check your engine owners manual for specific information. Should you
find any discrepancies between this Manual and the Engine Manufacturers
Manual always follow the Engine Manufacturers Manual.

Twice Daily

1. Check the crankcase oil and fill as required.

Daily

1. Check the engine and generator for any loose bolts, connections, and
fittings.
2. Check the coolant levels and fill as required.

Weekly

1. Check the air cleaner and clean as required.

2. Inspect the radiator fins for damage or clogging.

Bi-weekly

1. Check the engine oil quality and change as required.

Six months or every 250 hours

1. Replace the oil filter and fuel filter.

2. Check electrical components and clean as required.
3. Check electrical wiring for chafing, wear and replace as needed.

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Yearly or every 1,000 hours

1. Clean or replace the fuel filter and oil filter coolant.

2. Clean or replace the fuel pump strainer, if equipped.
3. Check the head and manifold bolts for tightness.

Cleaning

The Light Tower employs various electronic controls that may be damaged by
liquid spray washing or high pressure washing. Follow these procedures to
prevent any damage to these components.

DO NOT SPRAY WATER INTO THIS UNIT WHILE IT IS RUNNING. THIS MAY
RESULT IN INJURY OR DEATH BY ELECTRIC SHOCK.

Exterior Cleaning

1. The exterior housing may be washed by most conventional cleaners and

methods.
2. The exterior housing may be waxed using any conventional automotive
wax.

Interior Cleaning

1. Using a damp cloth covered with a mild soap, carefully clean around any
electric controls, generator, and thermostats.
2. The base and housing foam may be cleaned with a damp cloth covered with
mild soap.

Light Fixture Cleaning

1. The light fixtures and bulbs may be cleaned using any window cleaner.

THE LIGHT FIXTURES ARE VERY HOT; ALLOW COOLING BEFORE

PERFORMING ANY CLEANING TO THE FIXTURE, BULBS OR LENSES.

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 13. Wiring Diagram

Tail Light Circuit Diagram

48
 14. Tower light assembly instruction

Parts of Tower light:-

1. Genset 6.Trailer Tongue Unit

2. Outrigger 7. Mast Holder

3. Axle set 8. Mast set

4. Mudguard 9. Light Cross Member

5. Wheel 10. Light

Fig. 1

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Step-1:

Place the Genset unit on free surrounding area.

Fig. 2

Step-1:

Lift the Genset by forklift as shown below image.(Fig.3)

Fig. 3

50
Step-3:

Pull up the spring loaded lock and push the outrigger to the arrow direction
Until the spring loaded locking pin snaps back into the place. (See Fig .4)

Fig. 4

After install the outrigger in to the place. (see Fig.5)

Fig. 5

51
Step-4:

Follow the same above procedure for four sides and place the unit on the
ground then remove the forklift .(see Fig.6)

Fig.6

Step-5:

Place the axle unit to under the enclosure as shown in the arrow direction.

Fig. 7

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 Fig. 7

Fix the axle unit to under the chassis by M10 x 30 mm GI bolt.

(See the Fig.8)

Fig. 8

Now increase the unit height using four jack stands. (see the Fig.9)

Fig. 9

53
Step-6:

Raise the four jack stand to 450 mm from ground level to enclosure base
for easy to fix the tire. (see the Fig.10)

Fig. 10

Step-7:

Fix the mudguard on both side top of the axle bracket.(see Fig.10)

Fig. 11

54
Step -8:

Install the wheels on the hub and fix it by using four nuts.(see Fig.12 & 13)

Fig. 12

Fig. 13

55
Step-9:

Fix the towing tongue on the trailer frame as shown.

(See Fig.14)

Fig. 14

Step-10:

Remove the end pin and clevis pin as shown below image. (see Fig.15a)

Fig.15a Fig.15b

56
 Insert the gas spring bracket into the mast holder channel
As showing arrow direction. (See Fig.15b)
Insert clevis pin on pillar base with mast holder as shown below image.
(see Fig.15c)
And secure the clevis pin with end pin. (see Fig.15d)

Fig. 15c Fig. 15d

Step-11:

Install the mast set on top of the enclosure. (see Fig.16)

Fig. 16

57
 Rest the mast on the rubber pad and remove the fork lift. make sure the
rubber pad pin level to the mast base hole.(see Fig.17)

Fig. 17

lock the mast with enclosure.(see Fig.17)

Note: Do not lift whole unit from mast.

58
Step-11:

connect the mast set on the mast holder unit.(see Fig.18)

Fig. 18

Remove the clevis pin and end pin.(see Fig.18a)

Remove the pulley and place it on the cable.(see Fig.18b)

Fig. 18a Fig. 18b

59
 Insert the pulley into the place and insert clevis pin then secured with end
pin. (see Fig.18c)

Fig. 18c

Step-12:

Fix the light cross member on top of the mast set using four bolts
(See Fig.19)

Fig. 19

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Step-13:

Open Genset room doors and slack two bolts to remove the lights.(see
Fig.20)

Fig. 20

Then Fix the lights on cross member.(see Fig.21)

Fig. 21

61
Step-14:

Connect the power socket and lock it with knob. (See Fig.22a)
Connect the tail light cable with trailer. (See Fig.22b)
Finally connect the four light sockets on the mast.

Fig. 22a Fig. 22b

Now you have finished your assemble.

Thank you

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63
 Dubai Abu Dhabi Dammam Jeddah Riyadh

Head Office Dubai Tel: +971 4 338 4033 Fax: +971 4 338 3997

Abu Dhabi Tel: +971 2 645 0107 Fax: +971 2 645 0167

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