OPERATION & MAINTENANCE

.!
MANUAL
FOR

TELESCOPIC TILTABLE MOVABLE

LIGHTING TOWER

MODEL: FOX- LIGHT ATM -9 (LOM - 5E-4FLSS- 400W SV)

ATM-9 (CPCB- 5E -4FLSS -400W SV)
ATM-9 (CPCB-IOE -4FLSS -400W SV)
ATM-9 (CPCB-IOE -4FLSS -lOOOW MH)
 "sk"
Aska Safety Devices

Corporate Office Works

Aska House (Gargashrya)
Plot No: C- 19/20, Dev Bhoomi

193, Deepali, Deepali Chowk

Industrial Estate,

Pitampura, New Delhi - 110034

Puhana-Iqbalpur Road, Village-

Ph No.-011-27014416-17
Bandakhedi,

Fax No. - 011-2701441

PO: Iqbalpur, Roorkee-247668.

E-Mail: [email protected]
Distt. Haridwar ( Uttarakhand)

Web Site: www.askagroup.com,

Ph No: 01332 - 231069,70,71

www.lighttower.in
Email: askasafetveaamail.com

.
Design & Specification are subject to change without prior notice
 Telescopic Tiltable Movable Lighting Tower

Dear Customer,

Aska Safety Devices one of the leading manufacture of lighting tower

combining up to the minute technology in our design and manufacturing,

together with a high standard of quality control.

We request you to read his manual and follow carefully the information on

installation and adjustment so that you may enjoy many years of dependable

trouble free operation.

Yours,

Aska Safety Devices

 INDEX

SR.NO. DESCRIPTION PAGE

1 Introduction 1
2 Product Information Data 2-3-4
3 Installation & Commissioning 5
4 Operation 6
5 Equipment Maintenance 7-8
6 Do & Don't 9
7 List of Required Spares 10
8 Drawings Showing General Arrangement of 11
Equipment.
9 Job Completion Certificate 12
10 Warranty Certificate 13
11 Test Certificate 14
12 Consumable Spare Parts List & Authorized 15
Service Center List of Lombardini Gen. Set
 1. INTRODUCTION
Trolley Mounted Tiltable Telescopic Lighting Towers are towing type
Movable compact in design & Lighting tower comprising of Movable
Trolley, lighting Tower, Tilting & Telescopic Winches, D.G. Set,
Lighting Control panel suitable for controlling 4/5/6 Nos. flood light
fitting and arranged in such a manner to cover the maximum area. The
fitting can be fitted on luminaire post.

The Telescopic Tiltable Lighting Masts are very popular in all

Infrastructure Industries because of simpler, Economic & User-friendly
design for applications in Yards, Boundary or Road Illumination. The
lighting tower is suitable for Open Cast Mining Industry, Cement
Industry, Refineries, Ports, and Textile units, Power Plants &
Construction Sites (Road, Airport and Dam projects). It is very much
suitable for Rescue Emergency operations.

These masts are Telescopically extended up to 9 meters height and can

be brought down in compact state & tilted to operational height where
Luminaires can be conveniently installed, repaired, replaced from
ground level, thus achieving maximum safety to operating personnel.

Before operating the equipment, please go through this manual

properly, so that you can be thoroughly familiar with the proper
operation of Mast, its control, features, capabilities and limitations. To
ensure a long trouble free life of the equipment by the carrying out
proper regular maintenance & using original & genuine spares as per
list enclosed in Operation & Maintenance manual.

In case of any breakdowns, please inform us immediately for sooner

action, remedy & to avoid further damages. For registering your
complaint of equipment, please write to our corporate office giving
details of Equipment Serial Number & Date of Commissioning.

1.
 2. PRODUCT INFORMATION DATA

The Telescopic & Tiltable Moveable Lighting Tower having height 9 mtr.
Consist of following main parts:

1. TROLLEY

The tower assembly is mounted on a ruggedly built trolley, which rests

on pneumatic tyres, spring leaf assembly for shock absorbing. The
lighting mast is hinged on the column post assembly of the trolley. The
trolley with complete mast assembly can be easily towed to different
locations with the help of any available light motor vehicle.
Five numbers of jackscrews are provided in the trolley.
In the front, the trolley is provided with a Towing Hook with Towing
arrangement.

2. TOWER

The tower is made of 2/3/4 numbers of M.S pipes having square shape
and sections, which are hinged with each other. The tower telescopic
and tilting action can be done with the help of winch. First it should be
brought to vertical position and then telescoped up to its maximum
permissible height i.e. 9 mtr

3. WINCH

For Tilting & Telescopic action of the lighting Mast substantially

designed robust construction winch are with
.:. GEARS: These are machine cut, ground and case hardened for
wearing strength.
•:. ROPE DRUM: Flange type rope Drum is made of ERW heavy
Duty tube and fabricated as per IS: 807, it is mounted on the Ball
bearing. The drum has wire Rope anchoring arrangement and
capacity to take the wire rope of approximately 20 meters.

2.
4. LUMINAIRE

The lighting tower comprises of the 4 I 5 I 6 Nos. of high intensity long

range energy saving search cum flood light.

The luminaire is provided with highly polished, mirror finish stainless

steel/glass reflectors. Its effective reflectivity is guaranteed for five
years. The reflectors are designed in such a way that the rear parabolic
portion gives a beam ray of light and front circular reflector a wide
spread light. The luminaries is with a ring with holder Having
automatic lamp locking arrangement. The luminaries is fitted with
toughened front glass and rubber gasket preventing ingress of dust,
Vermin and moisture. It is provided with special lamp focusing device,
which adjusts the focal distance of the lamp. Vibration isolators are
also provided for saving the lamps from fusing due to vibrations.

The lamp is easily replaceable from rear end, thus preventing soiling of
reflectors
and disturbance of optical axis. The luminaire can be set at any desired
angle, with a yellow passivated M.S. cradle.

The luminaries conforms to IS 10322 (Part-5/Sec-5) 1987 and is IP 55

classified

OR
The luminaire is provided with aluminum reflector cum body.

HOUSING: Pressure Die cast Aluminum alloy LM 24 with IP 65

protection.
COVER: Tempered & toughened protective front glass, 5mm thk.
Thermal Shock and impact resistant. Fixed to the housing by 6 nos.
SS toggles
REFLECTOR: Reflector made of spun aluminum, electro
chemically brightened & anodized ,
LANIP HOLDER: In ceramics & silver plated contacts re-lamping
from front.

3.

5. CONTROL PANEL:

A specially designed sleek control panel allows the operator to control

and monitor the lighting. Control gear of fittings and individual MCB
and indicator provided in the Control Panel.

6. D.G. SET:

Please read also DG set operation & maintenance manual.

Engine Specification:

Model: 15LD440

Cylinder: 1 No

Power: 10 BlIP

RPM: 3000

Swept Volume: 442 CM)

Warning:

Check always lube oil before starting the engine.

Use only lube oil SAE 15W40 for Lomardini Engine.

Clean air & fuel filter in every 50 HRS.

Spare Parts:

For requirement of any spares of lombardini engine please contact

to ADICO branch office (find Branch office list with this manual).

OR

Contact to Mr P T Guha (Lombardini)

Phone No: 09922504062

Email ID:[email protected]

4.
3. INSTALLATION & COMMISSIONING

ERECTION

• Unload the Movable Lighting System and other packages at site or at

stores or as directed by customer with the help of crane or expert
unloading team.

• Place the trolley and tower at the installation site.

• Pull out all Riggers and lock it by locking pin and Release all Jackscrews
to Ground which are provided for leveling the trolley. Please ensure the
level base with the help of Sprit Level.

• Check all nut bolts, (winches, tower hinge, shaft lock nut and bolt, D. G.
Set mounting bolts, wire rope, clamps - bolts of tilting and telescoping
wire ropes, panel mounting bolt) and tighten them.

• Fix the luminaire post (to the top truss now in horizontal position) the
hardware and spanner is provided in the toolbox.

• Fix the luminaires with lamp on to the luminaire post. Keep the
luminaires at desired angles.

• Connect the provided wires to the terminal block provided in the terminal
box.

• Check the alignment of D.G. Set and Bolts and Nuts of Coupling should
be tightened.

• Fill diesel in the diesel tank. Check the lubricant oil level in the engine
, (Oil is already filled in the engine. However, if required please top it up
with multi grade engine oil as recommended by engine manufacture).

• Check the wire connection of battery to D. G. Set.

• Check greasing of all hinges/pulleys etc., (which are already greased.)

5.

 4.0PERATION
• Start the engine with the key provided. The engine starting is electrical.
Alternatively it can be started manually also with the help of cranking
handle (in tool box).
• After the engine catches the desired 'speed & check voltage. If voltage is
less or more than 230 V, check engine speed.
• Release tower telescopic lock provided on top truss, Raise the tower to
vertical position by handle. Lock the tower in vertical position with the
locking pin.
• Raise the top truss to its position indicated by blue-red strip.
• Come back to control panel and Switch on the MCB. After that switch on
one by one all lamps by MCB.
• With the final steps above you have installed and commissioned the
movable tower.
• Shut off the D. G. Set or main supply.
• Switch 'Off the light with 'OFF' control switch.
• Down the telescopic mast. Remove the vertical position lock pin. Tilt the
mast to horizontal position.
• Push all riggers inside & Release all the jackscrews to up side.

MOVING THE TROLLEY TO OTHER POSITION:

VERY IMPORTANT!
• Telescope down the tower.
• Tilt the tower to horizontal resting position
• Lock the tower in horizontal position.
• Release all jackscrews to ground.
• Tow the trolley from front side with the help of towing hook provided.

6.

 5. EQUIPMENT MAINTENANCE

~ ROUTINE MAINTENANCE

TOWER MAINTENANCE

• Tower hanging shaft fixed at column post to be checked and ensure that
is tight.
• Telescopic winch nut bolt and wire rope mounting bolt should be
checked and ensure that it is tight.
• Grease the winches after every 15 days.
• Telescopic pulley mounted on the top section should be checked every
time before operation.
• Luminaire post and luminaries nut bolt should be checked and tightened
at least once in a month.
• Terminal box, nut bolts and cable connections should be checked once in
a fortnight.
TROLLEY MAINTENANCE

Please Check
• Disc nut bolt of tyre wheel should be tight.
• Door hinges of the trolley to be checked.
JACK SCREW MAINTENANCE

• Proper greasing at every after 15 days.

• Base plate of jackscrew should be checked at every operation including
base plate mounting bolts.
TITLING / TELESCOPIC WINCH & PULLEYS MAINTENANCE:

• Greasing of winches and pulley at a interval of every after 15 days.

• Greased the Winch operating shaft bearing of tilting & Telescopic winch
at every after 15 days.

7.

 PLEASE NOTE!! !

ENGINE FAILURE DUE TO FOLLOWING MAINTENANCE LAPSES ARE

NOT COVER UNDER W ARANTEE:

1. Usage of improper grade or recycled lubrication oil.

2. Less or no oil in the oil sump.
3. Less or no oil in the air cleaner element.
4. The engine running without the air cleaner.
5. Clogged air filter element or dirty oil in the air cleaner bowl.

8.

 6. Do & Don't

Do
• After erection tighten all nut bolts. Check the locking, split pins
etc. and fix them.
• Check the grease in all pulleys.
• Check wiring/cable termination in Junction Box on luminaire
post as well as incoming and outgoing of MLCP. Tighten the
connections.
• Tighten the jacks of trolley, which will make the Tyres free
from ground.
• Tighten nut bolts of ant vibrating pads and coupling every time
before starting the DG. Set.
• Check oil/diesel levels before starting DG. Set.
• While towing the trolley, release the all jackscrews to top
position giving maximum distance from ground.
• While towing remove the luminaire post if possible. Otherwise
tighten the bolts of the luminaire.
• Use special spanner provided for the Tyre bolts.

Don't
• Do not tilt the mast in fully erected condition (when the tower
is in 9 mtrs, heights). First bring the mast down by telescopic
winch then tilt the assembly parallel to ground level by tilting
winch.
• Do not release the Jackscrews to upside during erection.

9.

 IT.NO DESCRIPTION

~J
I TOWER SECTION

rnr
¥v..
Z
3
D.G.SET
TROLLEY

i II , ..~
4 COLUHN POST
I 5 RESTING POST
I I 6 RIGGER BOX
I I
I I 7 HUDGUARD
I I
I I 8 LEAF SPRING
I I
9 TYRE

~LtI
10 BooH
11 TOWING HOOK

-11
I
0 12 JACK SCREW
If)
I CO
I ~I ~
13 LUHINAIRE POST

-~.
I 14 LUHINAIRE
I
I I 15 TELESCOPIC WINCH

~
I : 16 TILTING WINCH
• I-f)
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~ II
I
I
1560 ~I ]lJ==! CIT 17
18
BODY
AIRVENTILATION
13
I 19 DG EXHAUSTER
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(k t"1I
0...
0... I 3360
« t 3600 ROTATABLE
~

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,
I
I
FRONT SIDE VIEW (FULL EXTENDED POSmON)

C!' I
I

\
I
I
I DIMENSION:
I

:1
I DESCRIPTION COMPRESSED EXTANDED
(MIN.) (MAX.)
LENGTH 4750 4750
LJ I WIDTH 1560 3360
HEIGHT 1850 9000

o
If)
co DGN BY
DATE I NAME
DRN BY 119.11.07ILR

CKD BY 120.11.07·­
"sk" SAFETY DEVICES.
C-19120,DEVBOOHMIINDUSTRIAL ESTATE, ROORKEE

-+
APPD BY·­
GENERAL ARRANGEMENT 100

4750
EJ­ DRG.NO.ASD/D/SOJ \REV NO
THIRD ANGLE PROJECTION SHEET NO. 01 OF 01 I MOVABLE LIGHTING TOWER- 9Mtr (LOM)
SIDE ELEVATION (FULL EXTENDED & TILTING pOSmON)
ALL DIMENSION ARE IN MMI SCALE NTS
 ASDIMLT/07/JC

JOB COMPLETION CERTIFICATE

This is to certify that Mis ASKA SAFETY DEVICES, has

supplied Movable Telescopic Tiltable Lighting Tower with
flood light, control panel, DO set etc. as per specification of
your purchase order which was received and successfully
commissioned at our site against the following reference.

Model · .

Purchase Order No. · .

Invoice No. · .

Equipment No. ·
• II •

Engine No. · .
Alternator No ·
• •••••• II .

Equipment Receiving Date · .

Commissioning Date · .

Also we have received following documents with above

equipment:

1. Test /Inspection Certificate.

2. Warranty /Guarantee Certificate.
3. Operation & Maintenance Manual of equipment and DO set.
For .

12

 Consumable Spare Part List for Lornbardlnl Engine (LD 440) for the Aska Make Mobile Lighting Tower

Qty.
Recomme
S.No. Part No. Part Name nded

Castrol / Veedol • or any make (APICF-4)

Engine Oil 15W40 (First replacement at 50 hours then thereafter
1 APICF-4 every 150 hours) 15 Ltrs
Air Filter Element Cartridge (42N)
2 0037008205 ( Replace every 250 hours) 1
Oil Filter Cartridge
3 0021751290 (Replace every 200 hours) 1
Oil Fiter "O"-Ring
4 0012002340 (Check and replace at every 200 hours) 1
"0"- Ring (Oil Cap)
(Check and replace if found damage during oil
5 0012000820 changing) 1
Fuel Filter Element (Primary)
9451037407 or Make MICO·· (easily available in the local
6 equivalent market thru MICO or BOSH Delears) 1
Fuel Filter Assembly (Secondary)
(Every 300 Hrs • 400 Hrs.(Mounted on the
7 0037300880 Engine in Plastic Body Complete» 1
Fuel Piping (For Fuel Filter Assembly)
(Needs to be replaced in case fuel filter
8 0007461930 assembly is changed) 1
9 0045011010 Exhaust Gasket 1
10 0046700610 Copper Washer (Drain Plug) 1
11 0044000580 Gasket (Tappet Cover) 1

The above consumable parts are to be procured for day to day maintenance and can be purchased in six
sets for the periodic maintenance from below locations

CastrollVeedol Available in Open Market

MICO Available with any of the mico dealer as listed on

their website: www.boschindia.com/mico

Recommended for: J2/1, MIDC Chikalthana. Aurangabad - 431210

Ph 0240-2471451 Ext. 134
Fax 0240-2486234
Lombardini Cell 09922504058
Mr Suhas Kulkarni
Emailld [email protected]

For any solution, please contact: Regd. Off.

Aska House, "Gargashraya",

193, Deepali, Deepali Chowk,

Outer Ring Road,

Aska Equipments Ltd. Pitampura,

New Delhi - 110034 (India)

Ph. : +91 1127014416/27014417

Fax +91 11 27014413

Website www.askagroup.com

EmaiIID.suDDort(a)askaarOUD.com

 ADICO BRANCH OFFICE DETAILS

SR.N
O.
I BRANCH
OPENING DATE
ADDRESS DEPOT / MARKETING
OFFICE
PHONE TIN NO. CST NO. E·MAll BRANCH MANAGER

NORTH ZONE BRANCHIMARKETING OFFICES

GHAZIABAD 0120·2834999, G.B.0439861 1-4·02 1GB63467674-4·02 [email protected] H.P.Upadhyay

0110412002 DEPOT 09312606779

GORAKHPUR MIS. ADICO SPARES PVT. LTO, Nr. SIRAJ CLINIC, 0661· 3091391
2 12610612004 PURDILPUR, GOLGHAR, GORAKHPUR
MARKETING OFFICE

DEHRADUN MIS. ADICO SPARES PVT. LTO JAY COMMERCIAL 0136·6464444 06001136896 l.N.Srivastava
02106106 COMPLEX, TYAGI ROAD, DEHRADOON (UTN) 09360262224
DEPOT

JODHPUR MlSADICO SPARES PVT. LTD. PANCHRATAN Manojbhai Oza

4 ,08.08.2006 BHAVAN, SHOP NO. 4-5, BIH. GULAB BHAVAN, CHOPASNI
ROAD, JODHPUR - 342 003.
DEPOT 0291·2638449 08692666742
EAST ZONE BRANCH/MARKETING OFFICES

KOlKATTA MIS. ADICO SPARES PVT. LTD, 2/1/1B, STRAND ROAD, 1ST 033·30222231, 19490720027 19490720221 [email protected] Alok Maitra
0110412002 FLOOR, KOLKATTA-700 001 (W.B.) DEPOT 09331066963

GAUHATI MIS. ADICO SPARES PVT. LTD., C/O. SRI RAM MARKET, 2ND 9864036989 0361·118670000019 GWDICSTI0041 [email protected] IShewli Bose
6 10110812003 FLOOR, CHATRIBARI ROAD GAUHATI-781 001 DEPOT 2608441

PATNA MIS. ADICOSPARESPVT.LTD, VIDYANILAY,BENI 0612·3298471 10122140024 10122140121 [email protected] Rajeev Ranjan
7 10110212004 DEPOT 09334113869
BAGICHA,RAJENDRA PATH.TELEEXA..PATANA.
RANCH' MIS. ADiCO SPARES PVT. LTD., BUIYA TOll, B. T. ROAD, 0661·2211280, 20590200141 [email protected] IPyarelal Pandey
8 11910112004 GARIKHANA RANCHI-834 001. DEPOT 09334436736

CENTRAL ZONE BRANCH/MARKETING OFFICE

RAIPUR MIS. ADICO SPARES PVT. LTO., 14/1394, BAMBLESHWARI 0771·6039096 22191201174 aspr [email protected]
2110712003 MARKET, STATION ROAD, Nr. DESH BANDHU SCHOOL, 09329101676
9 DEPOT
RAIPUR-492 009 (C.G.)

INDORE MIS. ADICO SPARES PVT. LTD., to-e, SHALIMAR PLAZA, 0731·2361604 23620601994 1·7·2003 [email protected] Sanjay Bajpayee
10 ,03/0812001 12-JAWAHAR MARG, Nr. PATEL BRIDGE CORNER, INDORE (M.P.) DEPOT 09302106309

NAGPUR 0710-4222177 27680074028 [email protected]

11 109/1012003 DEPOT 09373288022

CUTTUCK 0671· 3290746 21101201434 aspl [email protected] Ujjaval Chettarjee

12 103/1212003 DEPOT

seCUNDERABAD 040·27530473 28920109806 aspl [email protected] Virendra Bhatt

13 11610712003 DEPOT 09391045169

COIMBATORE MIS. ADICO SPARES PVT. LTD., MUBARAK COMPLEX, 124-G, 0422·2230196, 33782142441 [email protected] I Navin Kumar
14 11910412004 RANGA KONAR STREET, KATTOR. COIMBATORE- 641 009 DEPOT 09344832868

16 I HUBll MIS. ADICO SPARES PVT. LTD PUJARI BUILDING, SHOP NO. 04, 0836·2363616, 29160236688 S.S.Ghooli
0710712004 NEELIGIN ROAD, NEW COTTON MARKET, HUBLI-580 029 DEPOT 09343107243 [email protected]

16 ITHRISSUR ADICO SPARES PVT. LTD., 7, LAMEXARCADE, 0487-2423437 32080748804 Miss. Manju
24/09/2004 POST OFFICE ROAD, THRISSUR DEPOT [email protected]

17 !CHENNAI MIS. ADICO SPARES PVT. LTD., SHOP NO.-46/22, SRINVASA 044-4660622066162676
01.11.2004 READY STREET, T-NAGAR, CHENNAI ­ [email protected]
 ~

ADICO BRANCH OFFICE DETAILS

ADDRESS DEPOT I MARKETING PHONE TIN NO. CST NO. E·MAIL BRANCH MANAGER
SR.NI BRANCH
OFFICE
O. OPENING DATE
18 IVISAKHAPATNA IM/S.ADICO SPARES PVT. LTD. 30-14--11, DAEEIRU I 10891·6648902

M 16.06.06
MANSION, LEELAMAHAJN, VISAKHAPATNAM - 530 020 MARKETING OFFICE

WEST ZONE BRANCHIMARKETING OFFICE

19 IBARODA MIS.ADICOSPARES PVT. LTD, RAJTRADE 0266·6621810 0265.j24091100075 1·7·2002 Bhaskarbhai
01/01/2006 CENTRE,OF.NO-S, OOP.HOTEL SURYA DEPOT 2226359 adico [email protected]
---- SAYAJIGUNJ,BARODA
20 BHUJ Mis. ADICO SPARES PVT. LTD., SHOP NO.2, NEW STATON 02832·2395797 02832·124091100075 1·7·2002 Bhaskarbhai
08/03/2006 ROAD, MH PETROL PUMP, BHUJ (Guj) DEPOT 264001

21 AHMEDABAD 079·3093380 079·124091100076 1·7·2002 Bhaskarbhai

31/03/2006 26890196
DEPOT

22 jSURAT M/S.ADICO SPARES PVT. LTD. J-G­ 0261·2452248 24091100075 1·7·2002 Bhaskarbhai
14/07/05 66, JAPAN MARKET, NEAR BELGIUM SQUARE,RING ROAD, SURAT - 395 DEPOT
002.