Instruction Manual and Parts List

for Light Tower

QLT 4
 Instruction Manual and Parts List
for Light Tower

QLT 4

Instruction manual .................................................................................. 5

Parts list.................................................................................................. 25

Original instructions

Printed Matter N°
2954 3800 01
ATLAS COPCO - PORTABLE AIR DIVISION
01/2010 www.atlascopco.com
QLT 4

Warranty and Liability Limitation

Use only authorized parts.
Any damage or malfunction caused by the use of unauthorized parts is not covered by Warranty
or Product Liability.
The manufacturer does not accept any liability for any damage arising for modifications, addi-
tions or conversions made without the manufacturer's approval in writing.
Neglecting maintenance or making changes to the setup of the machine can result in major
hazards, including fire risk

Copyright 2009, Atlas Copco Airpower n.v., Antwerp, Belgium.

Any unauthorized use or copying of the contents or any part thereof is prohibited.
This applies in particular to trademarks, model denominations, part numbers and drawings.

4 2954 3800 01
 Instruction manual

Congratulations on the purchase of your AC light tower. It is a

solid, safe and reliable machine, built according to the latest
technology. Follow the instructions in this booklet and we
guarantee you years of troublefree operation. Please read the
following instructions carefully before starting to use your
machine.
While every effort has been made to ensure that the information
in this manual is correct, Atlas Copco does not assume
responsibility for possible errors. Atlas Copco reserves the right
to make changes without prior notice.

Contents

1 Specifications ...........................................................6 4 Maintenance and charging ...............................15

1.1. Description ............................................................6 4.1. Service intervals .................................................15
1.2. Reference conditions............................................6 4.2. Battery charging .................................................17
1.3. Overall limitations ................................................6 4.3. Fuel ......................................................................18
1.4. Performance..........................................................7 4.4. Air bleeding the fuel system ..............................18
1.5. Application ............................................................7 4.5. Checking the fuel pipes ......................................19
1.6. Design data ...........................................................7 4.6. Cleaning the fuel filter bowl...............................19
1.7. Cubicle ...................................................................8 4.7. Engine oil.............................................................20
1.8. Dimensions and weight .......................................8 4.8. Radiator ...............................................................22
1.9. Average lightening versus distance....................8

2 Identifying instruments and

controls ........................................................................8
2.1. Operation panel ....................................................8
2.2. Instruments description and function.................8

3 Light tower operation ...........................................9

3.1. Safe operation.......................................................9
3.2. Set up procedure light tower mast ...................10
3.3. Starting the engine .............................................14
3.4. Operating the lights............................................14
3.5. Shutting down the system.................................14

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QLT 4

1 Specifications

1.1 Description
The light tower QLT 4 comes completely assembled, fully tested
and ready to operate. The light mast is shown below in travel mode,
but the steady legs are shown in extended and locked down
position.

Before attempting to use your light tower, it is very

important to ensure that it has been set up on flat and
solid ground with the support legs extended, the jacks
locked down and adjusted correctly so the machine is
level.

The light tower QLT 4 is extremely light and manoeuvrable,

making it very simple to position at the desired location for optimal
work area lighting.

The light tower QLT 4 mast can be extended vertically up to 9,44

m (31 ft) using simple hand winch operations. The head (all 4 light
units) can be rotated 360°, and each light unit can be rotated
independently through 180° in two degrees of freedom for optimal
zone lighting.

1.2 Reference conditions

Rated frequency / speed 750 Hz / 2500 rpm
Service duty PRP
Absolute inlet pressure 100 kPa
Relative air humidity 30 %
Air inlet temperature 25ºC (77°F)

1.3 Overall limitations

Maximum ambient temperature 45°C (113°F)
Altitude capability 4000 m (13,124 ft)
Maximum relative air humidity 85 %
Minimum starting temperature -10°C (14°F)

De-rating:

The engine must be capable to handle all the lights in a night shift
operation (PRP):
– with an ambient temperature of 40 ºC (104°F) at sea level
– with an ambient temperature of 25 ºC (77°F) at 2500 m (8202.5 ft).

6 2954 3800 01
 Instruction manual

1.4 Performance 1.6.2 Engine

Rated active power - 4ph 4.4 kW (5.9 hp) Type 2 Cylinder, 4-Cycle,
Rated lamps power - 4 lamps 4.0 kW (5.36 hp) Liquid Cooled Diesel
Unloaded voltage at rated speed 550 V engine
Loaded voltage at rated speed 250 V Standard EPA Tier 4
Lighting source (lumen) Should be able to get EU stage III A
from lamp data source Make Yanmar
Maximum sound power level 93.5 dBA Model 2TNV70
Maximum sound pressure level at 10 m / 33 ft 65.5 dBA Rated net output at 2500 rpm 6.7 kW (8.98 hp)
Fuel capacity 114 liter (30 Us gal) Coolant PARCOOL
Fuel autonomy (run time) 85+ hours Number of cylinders 2
Speed control Mechanical

1.5 Application DC electric system 12 V

Emission compliant EPA Tier 4
Mode of operation Lighting only
Site Land use 1.6.3 Lamps
Operation Single
Type Metal Halide 1000/U/4K
Start-up an control mode Manual
Standard N/A
Mobility acc. ISO 8528-1:1993 Mobile / E
Make N/A
Mast operation Manual
Model - bulb MH1000/BT37/U/4K
Number of supports 4
Rated power 1000 W per lamp
Maximum wind speed in operation 105 km/h (65 mile/h)
Lighting capacity (lumen) 96,000 lumen per bulb
Mast rotation 360º
Color Temp 4200 K
Lamps adjustment 2 degrees of freedom
(horizontal / vertical Rated voltage 250 V
rotation) Ignition / peak voltage 550 V

1.6.4 Undercarriage
1.6 Design data
Type Welded frame with leaf
1.6.1 Alternator springs attached with U-
bolts
Type Permanent magnet Standard N/A
brushless Make Steel
Standard N/A Model QLT 4
Make LE Maximum speed 80 km/h (50 mile/h)
Model G24N1-001 Tires 5.30" x 12" 6 poly tire
Rated output, class H temp. rise (ISO8528-3) 105 kVA Road signalization Front and rear side lights
Electric characteristic E/I diagram at rated speed Braking signalisation 2 rear tail lights
Towing bar Hitch-ball trailer coupler
At least contain I=4 2"
following points Towing eye N/A
– Open voltage E=480

– normal operation
point (voltage and
current)
V=250
IX=410
– Short circuit current

• At operating tempetature
• Internal resistance ignored

Degree of protection IP54

Insulation class Class H
Number of phases 4
Number of wires 8
Efficiency at full load 89 %

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QLT 4

1.6.5 Controller 2 Identifying instruments and

Type Enclosed metal control
controls
box
Standard None 2.1 Operation panel
Make Deep Sea Electronics
Model DSE701
Protections Each lamp has a 10A LIGHTS IGNITION
fuse.
ON ON
12 V supply has a 3 A 7 1
fuse. OFF OFF

4 8
1

Visual alarms Low Oil Pressure, High 10

engine temperature, over 5

6 3
speed
Parameter setting None 2
Operator interface Ignition On/Off switch, 9
Lights On/Off switch
F5

1.7 Cubicle
1 Engine On/Off switch
Location Inside the canopy
2 Glow plug push button and light
Degree of protection (including canopy) IP55
3 Engine starter, push button
4 Low oil pressure warning light
1.8 Dimensions and weight 5 Low battery warning light
6 Engine high temperature warning light
Maximum length 4.45 m (14.7 ft)
Track width 1.29 m (4.3 ft) 7 Light On/Off switch
Maximum width (support legs extended) 3.04 m (10 ft) 8 Engine hour meter
Maximum height - transport 1.75 m (5.7 ft) 9 Engine wiring harness fuse
Maximum height - operation 9.44 m (31 ft)
Weight 621 kg (1370 lbs) 2.2 Instruments description and function
Note: Other dimensions shown on drawings, page 6.
2.2.1 Engine On/Off switch

1.9 Average lightening versus distance Turn ON the system by using the engine On/Off switch (1).

2.2.2 Engine glow plug activation

If the ambient air temperature is below 10ºC (50ºF) the engine glow
plugs (2) should be used. Push and hold the yellow push button
before attempting to START the engine. See table below for hold
times:
QLT 4 10m / 200 Lx 25m / 100 Lx 35m / 50 Lx
QLT 4 33ft / 200 Lx 82ft / 100 Lx 115ft / 50 Lx Ambient temperature Hold times
Above 10ºC (50ºF) No need
10ºC (50º F) to -5ºC (23ºF) Approx. 5 Seconds
Below -5ºC (23ºF) Approx. 10 Seconds
Limit of continuous use Do NOT exceed 20 Seconds

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2.2.3 Engine starter, push button
Press and hold down the engine starter (3) to crank the engine.
There will be a time delay before the engine starts to
crank.
If the engine does not start at first attempt, DO NOT
crank for more than 20 seconds. Switch off the Engine
Switch and repeat the starting proceduer.
2.2.4 Low oil pressure warning light
This LED (4) will light up if the engine oil pressure falls below a
safe limit at any time during engine operation. The engine should
immediately be shut down and the problem resolved to avoid costly
engine damage.
2.2.5 Low battery warning light
This LED (5) will light up when the battery voltage is low,
indicating the batterer is bad or is not being charged. The battery
must be in good condition for engine starting and for the electronics
control devices.
2.2.6 High temperature warning light
This LED (6) will light up if the engine water temperature is too
high. The engine should be shut down immediately and the
problem should be resolved to avoid costly engine damage.
2.2.7 Lights switch
Once the engine has reached a stable running condition all 4 light
can be turned on using this one switch (7). The UP position is ON
and the DOWN position is OFF.
Please note that although the lights will strike almost immediately
(a glow can be seen in bulbs) it will take several minutes for the
lights to emit their full luminosity.
2954 3800 01
Instruction manual
3 Light tower operation
3.1 Safe operation
For best results on the QLT 4 appropriate and safe operating
procedures are mandatory. Always read and apply the safety and
operating procedures before working with this equipment.
Replace damaged, thorn and unreadable safety and
instruction labels. Refer to page 29-31 for the correct
spare part numbers.
3.1.1 Observe safety instructions
– Read and carefully understand this manual and the labels on the
engine before attempting to start and operate the engine.
– Learn how to operate and work safely. Know your equipments and
its limitations. Always keep the engine in good conditions.
– Before allowing other people to use your engine, explain how to
operate and have them read this manual before operation.
– Do NOT modify the engine by yourself. Unauthorized
Modifications to the engine may impair the function and/or safety,
affect engine life and will void the manufacturer’s warrantee.
3.1.2 Wear safety clothing
– Do NOT wear loose, torn or bulky clothing around the machine that
may catch on working controls and projection causing personal
injury.
– Do NOT operate machine or any equipment attached to it while
under the influence of alcohol, medication, or any other drugs.
– Do NOT operate machine or any equipment attached to it while
fatigued.
3.1.3 Safe handling of fuel and lubricants (fire
prevention)
– Always stop the engine before refueling or/and lubricating.
– Do NOT smoke or allow flames or sparks in your working area.
Fuel is extremely imflammable and explosive under certain
conditions.
– Do NOT mix gasoline or alcohol with diesel fuel. The mixture can
cause a fire.
3.1.4 Check before operation and starting the
engine
– Do NOT start the engine by shorting across starter terminals.
– Do NOT allow children or livestock to approach the machine while
the engine is running.
9
QLT 4

3.1.5 Keep the engine and engine area clean
– Keep the engine clean and free of accumulated dirt, grease and trash
to avoid a fire. Store all imflammable fluids away from sparks and
fire.
– Do NOT stop the engine without idling, as temperatures around the
engine rise suddenly. Keep the engine idling for about five minutes
before stopping.
1. Place the light tower on a leveled and firm surface, making
sure that it is safe to work and operate without interference of
any obstacle including overhead cables or structures. Ensure
there are no overhead obstructions within 40 feet.
Before uncoupling from the carrier vehicle, make sure
that the light tower is secure on flat ground and will
not roll away!

3.1.6 Exhaust gasses and fire prevention

– Engine exhaust fumes can be very harmful if allowed to
accumulate. Be sure to run the engine in a well ventilated area.
– The exhaust from the muffler is very hot. To prevent a fire, do not
expose dry grass, mowed grass, oil and any other combustible
materials to the exhaust, engine or muffler.

3.2 Set up procedure light tower mast

The QLT 4 light tower assembly is constructed of a three section

telescopic mast that can be raised and lowered by using two hand 2. First lower the front leg (on the tong bar) so this will provide
crank winches. One winch controls the raising and lowering of the support once the hitch has been removed from the vehicle.
tower’s telescopic sections. The other winch controls the horizontal
and vertical positioning of the mast.

To be able to provide lighting as needed, the LT can also be rotated

by using a clamp located on the light tower.

Do NOT raise the tower or operate the machine if

wind speeds exceed 105 km/h (65 mph).
Do NOT operate the machine on a gradient of 5° or
more.
Do NOT move the machine if the tower is not fully
retracted and secured in the travel mode.
Inspect cables for potential damage. Do NOT use if
damaged.
3. Lower the remaining three support legs, starting at the radiator
end of the light tower.

Pull the post safety pin in order to be able to turn and lower the
post.

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 Instruction manual

Once the post is in vertical position, adjust the post height by Pull the post safety pin in order to be able to turn and lower the
handling the leveler clock wise until the post is in contact with post and return the pin to the safe position.
the ground.

4. Set the front legs by first extending the leg tubing as described
below.

Once the post is in vertical position, adjust the post height by

handling the leveler clock wise until the post is in contact with
the ground.

Pull the horizontal safety pin in order to be able to unfold the 5. Level the light tower by adjusting each jacking leg and using
post arm and lower the post. the bubble level located on the tong

2954 3800 01 11
QLT 4

6. Remove the vertical safety pin of the light tower mast in order
to be able to move the mast to its vertical position. 7. Pull and remove the horizontal mast safety pin in order to be
able to unfold the mast.
Pull the little cotter pin from the vertical safety pin in order to
be able to pull the vertical mast safety pin.

Pull and remove the vertical safety pin.

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 Instruction manual

8. Now you are able to unfold the mast.

9. Once the mast has been unfolded and is locked in the vertical
Unfold the light tower mast by handling the leveler and turning position, you can raise and set the height of lamps using the
clock wise until the mast is in vertical position. hand winch shown below. Clockwise to raise, counter-
clockwise to lower. The winch is self-locking.

Return the vertical safety pin to the safe position.

10. Rotate the mast as desired. First unlock the mast using the
clamp (1), rotate and then re-lock.
Do NOT rotate the mast more than 160° degrees in either
direction.

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QLT 4

3.3 Starting the engine 3.4 Operating the lights

1. Check fuel level and add fuel if appropriate to reach the FULL
level.
LIGHTS IGNITION
2. Set the fuel lever to ON. The lever points downwards.
ON ON

1
OFF OFF
1
10

F5

1. Once the engine is running smoothly, the lights can be

switched on (1). It will take several minutes before the lights
are fully illuminated.

3.5 Shutting down the system

3. Move the ignition switch (1) upwards to turn ON the system.

LIGHTS IGNITION

ON ON
LIGHTS IGNITION
1 2
OFF OFF
ON ON 1
10

1
OFF OFF
1
10

3
2
F5

F5
1. First switch off the lights (1).

4. If ambient temperature is below 10°C (50°F), push and hold 2. Then switch off the engine (2).
the glow plug button (2) for 5 seconds, before pressing and
holding the start button (3). Do not crank for more than 5
seonds. If the engine does not start, switch off the ignition
switch and repeat the process.

5. Check that there are no warning LEDs (Oil Pressure,

Temperature and Battery charge) lit. Immediately stop the
engine if any of these LED are lit. The cause must be fixed
before attempting to restart the system.

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 Instruction manual

3.6 Lowering the tower 4 Maintenance and charging

Allow the lamps to cool down for 10 minutes before
lowering the tower or moving the machine.
Do NOT lower the mast before lowering the tower.
1. Lower the light tower by cranking the hand winch so that all
three telescopic sections are fully retracted.
2. Rotate the mast so that arrows align with the lights facing
towards the rear end of the unit and lock in place.
3. Remove the safety locking pin and lower the mast by cranking
the leveler on the tong bar.
4. Put back both locking pins. The mast is now in travel position.
3.7 Moving the machine
Before moving the machine, the tower must be
lowered and locked in place.
1. Chock the tires and raise all posts.
2. Swivel support legs and lock in the horizontal travel position.
3. Pull the safety pin on each support leg and push the leg in until
the safety pin locks firmly into place.
4. Close all doors securely.
5. Lock the light fixture in place.
4.1 Service intervals
The service intervals shown below have been established for
operation under normal working conditions. Where equipment is
operated under severe conditions (very dusty, extreme heat or cold,
etc.) affected items should be serviced more frequently.
Refer to the engine manufacturers manual for more information
and full details on servicing.
The lubricating oil change intervals listed in the table below are for
Classes CF, CE and CD lubricating oils of API classification with
a low-sulfur fuel in use.
To avoid personal injury:
– Be sure to conduct daily checks, periodic
maintenance, refueling or cleaning on a level surface
with the engine shut off. Remove the key.
– Before allowing other people to use your engine,
explain how to operate the unit and have them read
this manual before operation.
– When cleaning any part, do not use gasoline but
regular cleanser.
– Always use proper tools, that are in good condition.
Make sure you understand how to use them, before
performing any service work.

6. Attach the towing hitch to the moving vehicle. – When installing, be sure to tighten all the bolts by
the specified torque.
– Do not put any tools on the battery. Battery
terminals may short out; this could lead to severe
burns or fire. Detach the battery from the engine
before maintenance.
– Do not touch the muffler or exhaust pipes while they
are hot; this could cause severe burns.

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QLT 4

4.1.1 Maintenance schedule

EVERY ITEM PROCEDURE
Mast cables Check that cables are not frayed or damaged. Replace immediately if damaged.
Diesel fuel Fill up. Always start with a full tank of fuel.
Fuel filter, Water separator Check for contamination. Service if needed.
Day
Engine oil Check level and condition. Top up as needed.
Coolant in overflow tank Check level. If low then check level in radiator and top up.
Engine warning lights Check at startup. Do not run until corrected.
Engine oil Drain oil and refill with new oil. (1st time only - 250 hrs thereafter)
Fan belt Check and adjust. (1st time only - 250 hrs thereafter)
Air cleaner Replace if needed. Dusty environments may require more frequent changes.
50 Hrs Fuel filter, Water separator Drain and flush.
Radiator fins Check and clean as needed.
Battery Check condition. Clean cable/battery terminals.
Mast collar Grease the mast collar using 4 pumps of a grease gun.
Engine oil Replace oil filter. See Engine manual for extreme climate conditions.
250 Hrs
Fan belt Check and adjust. Replace if needed.
Engine oil Drain lubricating oil, replace filter and fill engine with new oil (PAROIL 15W40).
See Engine manual for extreme climate conditions.

500 Hrs Fuel Filter Remove, flush bowl and replace element.
Water separator Remove bowl flush and replace.
Air cleaner Replace air cleaner element.
Engine vale clearance Adjust intake and exhaust valve clearance.
Cables and pulleys Check cables for wear, clean and lubricate pulleys.

1000 Hrs Radiator coolant Drain and flush. Refill with 50/50 antifreeze/water.
or year Radiator hoses Check and replace as needed.
Fuel hoses Check and replace as needed.
Fuel tank Check for sediment. Drain, remove and flush if needed.

4.1.2 Service paks

The following Service paks are available for QLT 4:

– 250 Hrs: 1310 3126 02 (including just the engine oil filter)
– 500 Hrs: 1310 3126 03 (including the engine oil, two fuel filters and the air filter)

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4.2 Battery charging Make sure each electrolyte level is to the bottom of vent-wells, if
necessary, add only distilled water in a well-ventilated place.
Correct battery maintenance will reduce the risk of premature
battery failure.
Incorrect handling of a battery can be extremely dangerous, so the
following precaution must be observed.

To avoid personal injury:

– When the battery is being activated, hydrogen and
oxygen gases in the battery are extremely explosive.
Keep open sparks and flames away from the
battery at all times, especially when charging the
battery.
– When charging the battery, remove the battery
vent plugs.
A Too low
– When disconnecting the cable from the battery,
start with the negative terminal, and when B Correct
connecting them, start with the positive terminal C Too high
first. To charge the battery slowly, connect the charger positive terminal
– DO NOT check the battery charge by placing a to the battery positive terminal, and negative to the negative.
metal object across the terminals. Use a voltmeter “Quick recharging” charges the battery at a high rate in a short
or hydrometer. time, and should only be used in emergencies.
Recharge the battery as early as possible, or battery life will be
The battery comes in two types: refillable and no extremely shortened.
refillable! When exchanging an old battery into a new one, use a battery of
– When using the refillable type battery follow these equal specifications.
instructions:
• Do not use or charge the battery if its fluid level
stands bellow the lower (lower limit level) mark.
Otherwise, the battery component parts may
deteriorate earlier than expected, which may
shorten the battery’s service life or cause an
explosion. Immediately, add distilled water until
the battery’s fluid level is between the UPPER
and LOWER levels.

To avoid personal injury:

– Be careful not to let the battery electrolyte contact
your body or clothing.
– Wear eye protection and rubber gloves, since the
diluted sulfuric acid solution burns skin and eats
holes in clothing. Should this occur, immediately
wash it off with running water and get medical
A Thick black cable
attention.
B Battery case
C Earth cable

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QLT 4

4.3.1 Fuel level check and refueling

1. Do not run the unit if there is less than 1” (2,5 cm) of fuel at the
bottom of the tank.

2. Do not overfill or cause fuel spillage.

To avoid personal injury:
– Use a strainer when filling the tank to prevent dirt
or sand entering the fuel which will cause costly
damage to the fuel injection system.
– Use only diesel fuel. Do not attempt to use
alternative fuels, which may cause damage to fuel
system or other engine components.
– Always keep the fuel tank from running close to
1 Plug
empty. If the engine stops due a shortage of fuel, the
system will need to be air-bled before operating
A Highest level
again.
B Lowest level

Connect the charger positive terminal to the battery positive 4.4 Air bleeding the fuel system
terminal, and negative to the negative.
When disconnecting the cable from the battery, start with the To avoid personal injury:
negative terminal first. When connecting the cable to the battery, – Do not bleed a hot engine as this could cause fuel to
start with the positive terminal first. If this procedure is reversed the spill onto a hot exhaust manifold creating a danger
contact of tools with the battery may cause a short. of fire.

Air bleeding of the fuel system is required:

4.3 Fuel
– After the fuel filter and pipes have been detached and refitted.
Fuel is flammable and can be dangerous. You should handle fuel – After the fuel tank has become empty.
with care.
– Before the engine is to be used after a long storage.
To avoid personal injury:
– Do not mix gasoline or alcohol with diesel fuel. This
mixture can cause an explosion.
– Be careful not to spill fuel during refueling. If fuel
should spill, wipe it off at once, or it may cause a
fire.
– Stop the engine before refueling. Keep the engine
and all equipment away from fire.
– Be sure to stop the engine while refueling or
bleeding and when cleaning or charging the fuel
filter or fuel pipes. Do not smoke when working
1 Fuel filter lever (A) “ON” / (B) “OFF”
around the battery or when refueling.
2 Fuel filter bowl
– Check the above fuel systems at a well ventilated
and wide place.
– Only refuel fuel, lubricant, or other liquid after
letting the engine cool off.
– Always keep spilled fuel and lubricant away from
the engine.

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1. Fill the fuel tank. Open the fuel filter lever (1). 4.6 Cleaning the fuel filter bowl

Every 100 hours of operation, clean the fuel filter in a clean place
to prevent dust intrusion.

1 Pump air bleed

2. Loosen bleed vent plug on the fuel injection pump and crank
engine.

3. When the fuel is free from bubbles re-tighten the bleed vent.
1 Fuel filter lever
4.5 Checking the fuel pipes 2 Fuel filter bowl

To avoid personal injury: 1. Close the fuel filter level.

– Check or replace the fuel pipes after stopping the 2. Remove the bowl, and rinse the inside with diesel fuel.
engine. Broken fuel pipes can cause fire.
3. Take out the element, and rinse it with diesel fuel.
Check the fuel hoses every 50 hours of operation.
4. After cleaning, reinstall the fuel filter keeping out of dust and
1. If a hose clamp is loose, apply oil to the screw, and tighten dirt.
securely.
5. Air-bleed the fuel system.
2. If any of the rubber fuel hoses looks worn or damaged replace
the hose and hose clamp immediately. Replace routinely at 2
year intervals.

3. After replacement of the fuel hoses it will be necessary to air-

bleed the fuel system.
When a fuel hose is not installed, plug the ends to
prevent dirt from entering. Dirt in the pipes can cause
fuel injection pump and injector damage.

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QLT 4

4.7 Engine oil 4.7.1 Checking level and adding engine oil

To avoid personal injury:

– Be sure to stop the engine before checking and
changing the engine oil and the oil filter cartridge.
– Do not touch the muffler or exhaust pipes while
they are hot. This could cause severe burns. Always
stop the engine and allow it to cool off before
conducting inspections, maintenance, or for a
cleaning procedure.
– Contact with engine oil can damage your skin. Put
on gloves when using engine oil. If you come in
contact with engine oil, wash it off immediately.

– Be sure to inspect the engine, locating it on a

horizontal place. If placed on gradients, oil quantity
may not be measured accurately. 1 Oil filler plug
– Be sure to keep the oil level between upper and 2 Oil level dipstick
lower limits of the oil gauge. Too much oil may A Oil level range
cause a droop in output or excessive blow-by gas.
On the closed breather type engine in which mist is 1. Check the engine oil level before starting or more than 5
sucked through port, too much oil may cause oil minutes after stopping the engine.
hammer. While too little oil, may seize the engine’s
2. Remove the oil level gauge, wipe it clean and reinstall it.
rotating and sliding parts
3. Take the oil level gauge out again and check the oil level.

4. If the oil level is too low, remove the oil filler plug and add new
oil to the prescribed level.

5. After adding oil, wait more than 5 minutes and check the oil
level again. It takes same the time for the oil to come down to
the oil pan.

Engine oil quantity

It is strongly recommended to use Atlas Copco

branded lubrication oils.

High-quality, mineral, hydraulic or synthesized hydrocarbon oil

with rust and oxidation inhibitors, anti-foam and anti-wear
properties is recommended.
The viscosity grade should correspond to the ambient temperature
and ISO 3448, as follows.

Engine Type of lubricant

1 O-ring between -15°C (-13°F) and 40°C (104°F) PAROIL 15W40

2 Filter element
3 Spring
4 Filter bowl
5 Screw ring

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Specifications PAROIL 4.7.2 Changing engine oil

PAROIL from Atlas Copco is the ONLY oil tested and approved
for use in all engines built into Atlas Copco compressors and
generators.
Extensive laboratory and field endurance tests on Atlas Copco
equipment have proven PAROIL to match all lubrication demands
in varied conditions. It meets stringent quality control
specifications to ensure your equipment will run smoothly and
reliably.
The quality lubricant additives in PAROIL allow for extended oil
change intervals without any loss in performance or longevity.
To avoid personal injury:
– Be sure to stop the engine before draining engine
oil.
– When draining engine oil place a container
underneath the engine and dispose it according to
local regulation.
– Do not drain oil immediately after running the
engine. Allow engine to cool down sufficiently.

PAROIL provides wear protection under extreme conditions.

Powerful oxidation resistance, high chemical stability and rust-
inhibiting additives help reduce corrosion, even within engines left
idle for extended periods.

PAROIL contains high quality anti-oxidants to control deposits,

sludge and contaminants that tend to build up under very high
temperatures.
PAROIL's detergent additives keep sludge forming particles in a
fine suspension instead of allowing them to clog your filter and
accumulate in the valve/rocker cover area.

PAROIL releases excess heat efficiently, whilst maintaining

excellent bore-polish protection to limit oil consumption.
PAROIL has an excellent Total Base Number (TBN) retention and
more alkalinity to control acid formation. 1 Oil drain plug

PAROIL prevents Soot build-up. 1. Change oil after the initial 50 hours of operation and every 100
hours thereafter.
PAROIL is optimized for the latest low emission EURO -3 & -2,
EPA TIER II & III engines running on low sulphur diesel for lower 2. Remove the drain plug at the bottom of the engine, and drain
all the old oil. Draining oil is easier while the engine is warm.
oil and fuel consumption.
3. Add new engine oil up to the upper limit of the oil level mark
PAROIL 15W40 on the dipstick. Run engine and recheck oil level.
PAROIL 15W40 is a mineral based high performance diesel engine
oil with a high viscosity- index. Atlas Copco PAROIL 15W40 is
designed to provide a high level of performance and protection in
standard ambient conditions as from -15°C (-13 °F).

US Imp
Liter cu.ft Order number
gal gal

can 5 1.3 1.1 0.175 1615 5953 00

can 20 5.3 4.4 0.7 1615 5954 00

barrel 210 55.2 46 7.35 1615 5955 00

2954 3800 01 21
QLT 4

4.7.3 Replacing the oil filter cartridge 4.8 Radiator

To avoid personal injury: Coolant will last for one day’s work if filled all the way up before
– Be sure to stop the engine before changing the oil operation start. Make it a rule to check the coolant level before
filter cartridge. every operation.
– Allow the engine to cool down sufficiently. Hot oil
To avoid personal injury:
will cause severe burns
– Do not stop the engine suddenly, stop it after about
5 minutes of no load.
– Work only after letting the engine and radiator cool
off completely (more than 30 minutes after it has
been stopped).
– Do not remove the radiator cap while coolant is hot.
When cool to the touch, rotate the cap to the first
stop to allow excess pressure to escape. Then
remove the cap completely. If overheats should
occur, steam may gush out from the radiator or
reserve tank. This could lead to severe burns.

4.8.1 Checking coolant level and adding

1 coolant

1 Oil filler cartridge

1. Replace the oil filter cartridge after the initial 50 hours of

operation and every 200 hours thereafter.

2. Remove the old oil filter cartridge with a filter wrench.

3. Apply a film of oil to the gasket for the new cartridge.

4. Screw in the cartridge by hand. When the gasket contacts the

seal surface, tighten the cartridge enough by hand. Do NOT
use a wrench to tighten the cartridge, this will cause over
tightening and damage. 1 Radiator pressure cap

5. After the new cartridge has been replaced, the engine oil level 1. Remove the radiator cap after the engine has completely
normally decreases a little. Therefore, run the engine for a cooled off, and check to see that coolant reaches the supply
while and check for oil leaks through the seal before checking port.
the engine oil level. Add oil if necessary.

Coolant will last for one day’s work if filled all the way up before
operation start. Make it a rule to check the coolant level before
every operation.

22 2954 3800 01
 Instruction manual

4. Check to see that two drain cocks are closed; one is in the
radiator bottom tank, and the other on the side of the crankcase.
– If the radiator cap has to be removed, follow the
caution and securely retighten the cap.
– If coolant should leak, consult your local KUBOTA
dealer.
– Make sure that contaminated or salt (sea) water
does not enter the radiator.
– Use clean, fresh water and 50% anti-freeze to fill
the recovery tank.
– Do not refill the recovery tank with coolant over the
“FULL” level mark.
– Be sure to close the radiator cap securely. If the cap
is loose or improperly closed, coolant may leak out
1 Reserve tank and decrease quickly.
A FULL – NEVER remove the radiator cap while the engine is
B LOW still hot.
2. The radiator is provided with a coolant overflow tank. The 4.8.2 Precaution at overheating
coolant level in the tanks must be between the low and high
marks to prevent loss of coolant.
Take the following actions in case the coolant temperature is
excessive as indicated by the LED warning light on the control
panel.

1. Immediately switch off the lights and let the engine run under
no load for only 30 seconds before switching off the engine.

2. If the engine stalls, use caution and let the engine cool down.
Leave the doors closed to the engine compartment for safety
reasons. Never attempt to loosen the hot radiator cap.

3. Only after the system has cooled off, diagnostics should be

attempted.

4. Never add coolant while the engine block is still hot.

5. Check for possible causes of overheating, such as radiator

blockage or low coolant, and eliminate the cause. Refer to the
3. When the coolant level drops below the “LOW” mark it must Engine Manual “Troubleshooting” section. Only restart the
be replenished with a 50/50 Antifreeze/water mix. Do not use engine when you are sure that the cause has been eliminated
water only. and that no resultant damage has occurred.

1 Coolant drain cock

2954 3800 01 23
QLT 4

24 2954 3800 01
 Parts list

2954 3800 01 25
26 2954 3800 01
 PARTS LIST
QLT 4

PARTS INDEX
PART PAGE PART PAGE
E
ELECTRICAL KIT ......................................................................................... 40
F
FUEL KIT........................................................................................................ 39
L
LABEL, MODEL ............................................................................................ 29
LABEL, OPERATING.................................................................................... 31
LABEL SHEET ............................................................................................... 30
LIGHTING TOWER ....................................................................................... 42
M
MAST FULL ASSEMBLY............................................................................. 32
MISC PURCHASED PARTS KIT .................................................................. 44
O
OUTRIGGER LEG WELDMENT ................................................................. 37
S
SUSPENSION KIT ......................................................................................... 41
T
TONGUE WELDMENT ................................................................................. 36
TRAILER ASSEMBLY .................................................................................. 34
Y
YANMAR BUILD KIT ................................................................................... 38

2954 3800 01 27
 ORDERING SPARE PARTS

QLT 4

ORDERING SPARE PARTS

Always quote the part number, the designation and the quantity of the
parts required, as well as the type and the serial number of the machine.
EXPLANATION OF THE COLUMNS
REF : REFERENCE CODE
Establishes the connection between a part in the list and a part in the illus-
tration.
"–" means that the part is not shown in the illustration.
PART NUMBER
If no part number is given, the part cannot be obtained as a spare part.
Parts marked with a dot are part of the assembly listed right above them.
DESIGNATION
Usually this is the name of the part. For standard parts, in addition to the
name, a number of characteristics are given.
QTY : QUANTITY
Indicates the quantity of the part concerned. "AR" stands for "As
Required".

28 2954 3800 01
 MODEL LABEL

10

REF PART NUMBER DESIGNATION QTY REF PART NUMBER DESIGNATION QTY

10 1310 4682 00 MODEL LABEL 2

2954 3800 01 1310 4682 00/00 29

 LABEL SHEET

10

REF PART NUMBER DESIGNATION QTY REF PART NUMBER DESIGNATION QTY

10 1310 4700 00 LABEL SHEET 1

30 1310 4700 00 /00 2954 3800 01

 OPERATING LABEL

10

REF PART NUMBER DESIGNATION QTY REF PART NUMBER DESIGNATION QTY

10 1310 4701 00 OPERATING LABEL 1

2954 3800 01 1310 4701 00/00 31

 MAST FULL ASSEMBLY

1310 0810 00_01

32 1310 0810 00/01 2954 3800 01

 MAST FULL ASSEMBLY

REF PART NUMBER DESIGNATION QTY REF PART NUMBER DESIGNATION QTY

10 1310 0810 17 BASE MAST WELDMENT 1

20 1310 0810 18 MAST LARGE TUBE WELDMENT 1
30 1310 0810 19 MAST MEDIUM TUBE WELDMENT 1
40 1310 0810 20 MAST SMALL TUBE WELDMENT 1
50 1310 0810 21 MAST LIGHT "T" BAR WELDMENT 1
60 1310 0810 22 MAST HOLDER WELDMENT 1
70 1310 0810 23 COVER CABLE CHANNEL 1
80 1310 0810 24 PLATE CABLE CHANNEL COVER 1
90 1310 0810 25 PLATE MAST SPRING 1
100 1310 0810 26 BLOCK MAST HOLDER 1
110 1310 0810 27 BLOCK 2
120 1310 0810 28 BLOCK 3
130 1310 0810 29 WASHER 1
140 1310 0810 30 WINCH 2 WAY 1
150 1310 0810 31 PULLEY 3
160 1310 0810 32 CABLE AR
170 1310 0810 33 ELLIPTICAL FLOOD LIGHT 4
175 1310 0811 03 BULB 4
180 1310 0810 34 FLOOD LIGHT RECOIL CORD 1
190 1310 0810 35 ENCLOSURE LIGHT JUNCTION BOX 1
200 1310 0810 36 CABLE GRIPS 4
210 1310 0810 37 CONNECTOR 1
220 1310 0810 38 MAST LOCKING KNOB 1
230 1310 0810 39 CONNECTOR BLOCK 2
240 1310 0810 40 PIN 1
250 1310 0810 41 FITTING GREASE 1
260 1310 0810 42 SLEEVE 5
270 1310 0810 43 CABLE SECURING THIMBLE 3
280 1310 0810 44 RIVET 12

2954 3800 01 1310 0810 00/01 33

 TRAILER ASSEMBLY

34 1310 0810 01/01 2954 3800 01

 TRAILER ASSEMBLY

REF PART NUMBER DESIGNATION QTY REF PART NUMBER DESIGNATION QTY

10 1310 0810 45 FRONT PANEL 1

20 1310 0810 46 BACK PANEL 1
30 1310 0810 47 LEFT PANEL 1
40 1310 0810 48 RIGHT PANEL 1
50 1310 0810 49 DOOR 2
60 1310 0810 50 TOP PANEL 1
70 1310 0810 51 FENDER 2
80 1310 0810 52 BRACKET TANK FRAME 2
90 1310 0810 53 BRACKET TANK HOLD-DOWN 2
100 1310 0810 54 GRILL 1
110 1310 0810 55 BOX DOCUMENT HOLDER 1
120 1310 0810 56 PLATE HANDLE LATCH 2
130 1310 0810 57 SHACKLE LEAF SPRING 4
140 1310 0810 58 HINGE 2
150 1310 0810 59 RUBBER PAD AR
160 1310 0810 60 LATCH DOOR HOLDER 2

2954 3800 01 1310 0810 01/01 35

 TONGUE WELDMENT

REF PART NUMBER DESIGNATION QTY REF PART NUMBER DESIGNATION QTY

10 1310 0810 12 WINCH 1

20 1310 0810 13 HITCH-BALL TRAILER COUPLER 1
30 1310 0810 14 SAFETY CHAIN 2

36 1310 0810 04/01 2954 3800 01

 OUTRIGGER LEG WELDMENT

REF PART NUMBER DESIGNATION QTY REF PART NUMBER DESIGNATION QTY

10 1310 0810 15 JACK STAND 4

2954 3800 01 1310 0810 05/01 37

 YANMAR BUILD KIT

REF PART NUMBER DESIGNATION QTY REF PART NUMBER DESIGNATION QTY

10 1310 0810 61 REAR LEG 2

20 1310 0810 62 FRONT LEG 2
30 1310 0810 63 TUBE RADIATOR SPACER MTG 2
40 1310 0810 64 TUBE AIR CLEANER BRACKET 1
50 1310 0810 65 PLATE AIR CLEANER MOUNTING 1
60 1310 0810 66 BRACKET RADIATOR MTG 1
70 1310 0810 67 BRACKET MUFFLER SUPPORT BLOCK 1
80 1310 0810 68 BRACKET MUFFLER SUPPORT 1
90 1310 0810 69 ISOLATOR ENGINE MOUNT 4
100 1310 0810 70 A/C KIT FOR YANMAR ENGINE 1
110 1310 0810 71 MUFFLER KIT FOR YANMAR 1
120 1310 0810 72 SEAL AR
130 1310 0810 73 SEAL AR

38 1310 0810 06/01 2954 3800 01

 FUEL KIT

REF PART NUMBER DESIGNATION QTY REF PART NUMBER DESIGNATION QTY

9 1310 0810 74 PUMP FUEL 1

10 1310 0810 75 TANK 1
20 1310 0810 76 HOSE AR
30 1310 0810 77 HOSE AR
40 1310 0810 78 HOSE CLAMP 8

2954 3800 01 1310 0810 07/01 39

 ELECTRICAL KIT

REF PART NUMBER DESIGNATION QTY REF PART NUMBER DESIGNATION QTY

10 1310 0810 79 HARNESS LT YANMAR ENGINE 1

20 1310 0810 80 HARNESS LT TAIL LIGHT 1
30 1310 0810 81 HARNESS LT POSITIVE DC CABLE 1
40 1310 0810 82 HARNESS LT SYSTEM 1
50 1310 0810 83 HARNESS LT NEGATIVE DC CABLE 1
60 1310 0810 84 ASSEMBLY FULL CONTROL BOX 1
70 1310 0810 85 LIGHT REAR TRAILER 2
80 1310 0810 86 LIGHT MARKER RED 2
90 1310 0810 87 LIGHT MARKER AMBER 2
110 1310 0810 88 PLUG 1

40 1310 0810 08/01 2954 3800 01

 SUSPENSION KIT

REF PART NUMBER DESIGNATION QTY REF PART NUMBER DESIGNATION QTY

10 1310 0810 89 WHEEL 2

20 1310 0810 90 AXLE ASSEMBLY 1
30 1310 0810 91 BOLT KIT 6
40 1310 0810 92 KIT LEAFSPRING U BOLTS 2

2954 3800 01 1310 0810 09/01 41

 LIGHTING TOWER

42 1310 0811 50/01 2954 3800 01

 LIGHTING TOWER

REF PART NUMBER DESIGNATION QTY REF PART NUMBER DESIGNATION QTY

A 1310 0810 00 MAST-FULL ASSEMBLY 1

B 1310 0810 01 TRAILER ASSEMBLY 1
C 1310 0810 02 FRAME WELDMENT 1
D 1310 0810 03 MAST-STAND WELDMENT 1
E 1310 0810 04 TONGUE WELDMENT 1
F 1310 0810 05 OUTRIGGER LEG WELDMENT 1
G 1310 0810 06 YANMAR BUILD KIT 1
H 1310 0810 07 FUEL KIT 1
J 1310 0810 08 ELECTRICAL KIT 1
K 1310 0810 09 SUSPENSION KIT 1
L 1310 0810 10 MISCELLANEOUS PURCHASED
PARTS KIT 1

2954 3800 01 1310 0811 50/01 43

 MISC PURCHASED PARTS KIT

REF PART NUMBER DESIGNATION QTY REF PART NUMBER DESIGNATION QTY

10 1310 0810 93 WASHER 2

20 1310 0810 94 BATTERY 1
30 1310 0810 95 LEVEL BUBBLE 1
40 1310 0810 96 CAP RADIATOR ACCESS HOLE 1
50 1310 0810 97 PIN 2
60 1310 0810 98 HANDLES 2
70 1310 0810 99 CLAMP BATTERY WITH J BOLTS 2
80 1310 0811 00 PIN 2
90 1310 0811 01 STRAIN RELIEF 3
100 1310 0811 02 CABLE CLAMP 6

44 1310 0810 10/01 2954 3800 01

 Following documents are provided with this unit:
– Test Certificate
– EC Declaration of Conformity:

1
EC DECLARATION OF CONFORMITY
2 We, Atlas Copco Airpower n.v., declare under our sole responsibility, that the product
3 Machine name : Power generator (< 400 kW)
4 Machine type :
5 Serial number :

6 Which falls under the provisions of article 12.2 of the EC Directive 2006/42/EC on the approximation of the
laws of the Member States relating to machinery, is in conformity with the relevant Essential Health and
Safety Requirements of this directive.

The machinery complies also with the requirements of the following directives and their amendments as
indicated.

7 Directive on the approximation of laws of the Harmonized and/or Technical Att’

Member States relating to Standards used mnt
a. Pressure equipment 97/23/EC x
EN ISO 12100-1
EN ISO 12100-2
EN 1012-1
EN 294
EN 349
EN 418
b. Machinery safety 2006/42/EC
EN 563
EN 842
EN 953
EN 1037
EN 1050
EN 13478
EN 61000-6-2
d. Electromagnetic compatibility 2004/108/EC
EN 61000-6-4
EN 60034
e. Low voltage equipment 2006/95/EC EN 60204-1
EN 60439
f. Outdoor noise emission 2000/14/EC ISO 3744 x

Atlas Copco Airpower n.v. is authorized to compile the technical file

8 The harmonized and the technical standards used are identified in the attachments hereafter

9 Conformity of the product to the

Conformity of the specification to the
10
specification and by implication to the
Directives
directives
11
12 Issued by Product engineering Manufacturing
13
14 Name
15 Signature

16 Date
Form 5009 0600 03
ed. 07, 2010-01-01

Atlas Copco Airpower n.v. A company within the Atlas Copco Group

Postal address Visitors address Phone: +32 (0)3 870 21 11 Com. Reg. Antwerp 44651
P.O. Box 100 Boomsesteenweg 957 Fax: +32 (0)3 870 24 43 V.A.T. 403.992.231
B-2610 Wilrijk-Antwerp B-2610 Wilrijk-Antwerp
Belgium Belgium For info, please contact your local Atlas Copco representative
www.atlascopco.com
p.1(3)

46
www.atlascopco.com
Printed in Belgium 01/2010 - 2954 3800 01