From: Bright Ideas
Towers in the Spotlight
All too often, light tower maintenance is shadowed by other equipment needs.
By Amy Willson
As the sun sets over a job site, various pieces of equipment and tools pound and buzz and move. It’s growing dark, then someone starts a barely noticed machine towering over the site and light illuminates the area. Work continues into the night, ensuring the project is completed by the deadline.
Ah, yes, that would be the light tower. It doesn’t do anything—no moving or pounding or compacting—so it really shouldn’t need any type of regular maintenance, right?
Even as it works late into the night, most people don’t realize the important job of a light tower until they suddenly need to work without it. Like any other piece of equipment, it needs to be maintained to continue operating well. Sure, quality light towers are built to provide thousands of hours of operation, but performing regular maintenance is required for the light tower to reach its potential. A number of routine daily checks coupled with regular maintenance will ensure towers outshine every other piece of equipment on the job site.
Lighten up. Preventative maintenance steps are simple and fast—and don’t need to be a downer. Here are some tips that should help shed some light on how to treat this oft-ignored piece of equipment.
Never Forget the Engine
Job sites would be left in the dark without an engine to power the light tower. Undoubtedly the most important part of the tower, the engine also is the component that requires the most frequent maintenance to ensure it continues to run smoothly.
Start by always keeping the engine and surrounding components clean, because fuel and oil leaks can easily be detected as soon as a problem starts.
Additionally, begin each day with checking the oil level. It only takes a few seconds to check, yet neglecting this simple step can lead to engine problems and cause premature wear. Check the coolant level at this time, as well. Ensure that it’s at the proper level before starting the machine, since it’s dangerous to remove the radiator cap when the engine is hot. While inspecting the coolant system, inspect the condition of the radiator hose and look at the condition and tension of the fan belt. Replace the parts or adjust the tension as necessary.
Once the fluid levels have been verified, check the air cleaner for dirt and debris. If it needs to be cleaned, pull the filter element out and tap it on a hard surface to remove excess dirt. Never use an air compressor to force dirt from the filter, since this may tear holes in the medium.
Air-cleaner elements will need to be changed based on hours of operation and, more importantly, application. Adverse weather and dusty conditions will require more frequent replacements. Use care when changing the element, since carelessness can introduce the element’s dirt into the engine.
The oil and oil filter also need to be changed regularly. Light-tower power units typically require oil and filter service every 200 to 300 hours, but check the owner’s manual for specific service recommendations. Always refill the system with the correct grade and type of oil as recommended by the engine manufacturer.
The fuel system needs to be inspected regularly and serviced, as well, again depending on manufacturer guidelines. Check for leaks daily and replace the fuel filter as recommended. Each year, take time to drain the fuel and clean sediment from the tank.
Rest of the Package
Although the engine requires the majority of a light tower’s maintenance checks, other components also need regular care. A quality generator in a light tower typically requires little maintenance and provides years of service. However, it is important to occasionally check the output voltage and frequency of the generator. If the voltage and frequency are not as specified by the manufacturer, typically 120 V at 60 hertz, the rpm of the engine should be adjusted. The rpm directly affects the voltage and frequency of the electric power produced. Operating the light tower with voltage too high or too low can lead to lamp and electrical component failures. It also is important to keep the generator clean and inspect the wiring for damage or loose connections.
A light tower’s electrical system also should be inspected and checked for proper performance. The components used for the typical metal halide lighting system are designed to provide dependable operation. However, it will only function correctly if the components, wiring and connections are undamaged, clean and secure. Visually examine the system regularly, checking for damage and loose connections.
Warning: Light towers contain high-voltage circuits capable of causing serious injury or death. Only a qualified electrician should troubleshoot or repair electrical systems.
Other components of a light tower that are critical to its function are the tower and lighting fixtures. Most towers consist of multiple telescoping sections that are extended and retracted as required to position the lights. The towers typically consist of steel tubing sections operated by a manual or electric winch, cable, and pulley system. All components of the tower system should be inspected and tested for correct operation. Cables can be worn or damaged and should be replaced before operation. The erecting winch also should be inspected for damage and serviced as recommended by the manufacturer. If designed for mobile applications, light fixtures typically require minimal service. Inspect the fixtures, along with the wiring, for physical damage and function.
As with any trailer-mounted products, the towing hitch, trailer lights, and running gear need to be inspected. Look for loose, damaged or missing parts. Check that the stop, turn, and brake lights are functioning. Be sure the tire condition and tire inflation pressures are correct according to the manufacturer’s recommendations. Stabilizing and leveling jacks and outriggers are unique features that need to be inspected for proper function. Repair or replace the jacks and outriggers as necessary before raising the tower.
One often overlooked but critical part of a light tower is the instruction and warning decals placed on the machine itself. The manufacturers install decals with information on proper and safe operation. A routine inspection should always include a review of the decals, ensuring that they are in place and readable. Manufacturers also provide operation manuals that are intended to stay with the product for correct operation and maintenance. A manual is not going to provide critical information required to operate and maintain the light tower if it is in buried in a desk drawer.
In addition to performing the recommended maintenance, selecting a quality light tower from a manufacturer with high-quality components will ultimately provide the most dependable performance. Although there are low-cost, low-quality components available, they may not provide the best choice when the light tower is being counted on to provide the light on a construction site or event.
In short, spending a little more money up front will pay dividends over the life of the equipment, especially in the harsh reality of the rental industry.
Preventative checks and services aren’t something to make light of. A few minutes a day and some recommended maintenance could add hours and years to a light tower’s existence. While there is no documented life expectancy for a light tower, well-built, well-maintained towers will certainly have the best chance of providing the highest level of dependability and performance. Regular, scheduled maintenance will bring light towers out of the shadow of equipment that can’t hold a candle to the towers’ lengthy service life.
October 2009
From: Bright Ideas
Towers in the Spotlight
All too often, light tower maintenance is shadowed by other equipment needs.
By Amy Willson
As the sun sets over a job site, various pieces of equipment and tools pound and buzz and move. It’s growing dark, then someone starts a barely noticed machine towering over the site and light illuminates the area. Work continues into the night, ensuring the project is completed by the deadline.
Ah, yes, that would be the light tower. It doesn’t do anything—no moving or pounding or compacting—so it really shouldn’t need any type of regular maintenance, right?
Even as it works late into the night, most people don’t realize the important job of a light tower until they suddenly need to work without it. Like any other piece of equipment, it needs to be maintained to continue operating well. Sure, quality light towers are built to provide thousands of hours of operation, but performing regular maintenance is required for the light tower to reach its potential. A number of routine daily checks coupled with regular maintenance will ensure towers outshine every other piece of equipment on the job site.
Lighten up. Preventative maintenance steps are simple and fast—and don’t need to be a downer. Here are some tips that should help shed some light on how to treat this oft-ignored piece of equipment.
Never Forget the Engine
Job sites would be left in the dark without an engine to power the light tower. Undoubtedly the most important part of the tower, the engine also is the component that requires the most frequent maintenance to ensure it continues to run smoothly.
Start by always keeping the engine and surrounding components clean, because fuel and oil leaks can easily be detected as soon as a problem starts.
Additionally, begin each day with checking the oil level. It only takes a few seconds to check, yet neglecting this simple step can lead to engine problems and cause premature wear. Check the coolant level at this time, as well. Ensure that it’s at the proper level before starting the machine, since it’s dangerous to remove the radiator cap when the engine is hot. While inspecting the coolant system, inspect the condition of the radiator hose and look at the condition and tension of the fan belt. Replace the parts or adjust the tension as necessary.
Once the fluid levels have been verified, check the air cleaner for dirt and debris. If it needs to be cleaned, pull the filter element out and tap it on a hard surface to remove excess dirt. Never use an air compressor to force dirt from the filter, since this may tear holes in the medium.
Air-cleaner elements will need to be changed based on hours of operation and, more importantly, application. Adverse weather and dusty conditions will require more frequent replacements. Use care when changing the element, since carelessness can introduce the element’s dirt into the engine.
The oil and oil filter also need to be changed regularly. Light-tower power units typically require oil and filter service every 200 to 300 hours, but check the owner’s manual for specific service recommendations. Always refill the system with the correct grade and type of oil as recommended by the engine manufacturer.
The fuel system needs to be inspected regularly and serviced, as well, again depending on manufacturer guidelines. Check for leaks daily and replace the fuel filter as recommended. Each year, take time to drain the fuel and clean sediment from the tank.
Rest of the Package
Although the engine requires the majority of a light tower’s maintenance checks, other components also need regular care. A quality generator in a light tower typically requires little maintenance and provides years of service. However, it is important to occasionally check the output voltage and frequency of the generator. If the voltage and frequency are not as specified by the manufacturer, typically 120 V at 60 hertz, the rpm of the engine should be adjusted. The rpm directly affects the voltage and frequency of the electric power produced. Operating the light tower with voltage too high or too low can lead to lamp and electrical component failures. It also is important to keep the generator clean and inspect the wiring for damage or loose connections.
A light tower’s electrical system also should be inspected and checked for proper performance. The components used for the typical metal halide lighting system are designed to provide dependable operation. However, it will only function correctly if the components, wiring and connections are undamaged, clean and secure. Visually examine the system regularly, checking for damage and loose connections.
Warning: Light towers contain high-voltage circuits capable of causing serious injury or death. Only a qualified electrician should troubleshoot or repair electrical systems.
Other components of a light tower that are critical to its function are the tower and lighting fixtures. Most towers consist of multiple telescoping sections that are extended and retracted as required to position the lights. The towers typically consist of steel tubing sections operated by a manual or electric winch, cable, and pulley system. All components of the tower system should be inspected and tested for correct operation. Cables can be worn or damaged and should be replaced before operation. The erecting winch also should be inspected for damage and serviced as recommended by the manufacturer. If designed for mobile applications, light fixtures typically require minimal service. Inspect the fixtures, along with the wiring, for physical damage and function.
As with any trailer-mounted products, the towing hitch, trailer lights, and running gear need to be inspected. Look for loose, damaged or missing parts. Check that the stop, turn, and brake lights are functioning. Be sure the tire condition and tire inflation pressures are correct according to the manufacturer’s recommendations. Stabilizing and leveling jacks and outriggers are unique features that need to be inspected for proper function. Repair or replace the jacks and outriggers as necessary before raising the tower.
One often overlooked but critical part of a light tower is the instruction and warning decals placed on the machine itself. The manufacturers install decals with information on proper and safe operation. A routine inspection should always include a review of the decals, ensuring that they are in place and readable. Manufacturers also provide operation manuals that are intended to stay with the product for correct operation and maintenance. A manual is not going to provide critical information required to operate and maintain the light tower if it is in buried in a desk drawer.
In addition to performing the recommended maintenance, selecting a quality light tower from a manufacturer with high-quality components will ultimately provide the most dependable performance. Although there are low-cost, low-quality components available, they may not provide the best choice when the light tower is being counted on to provide the light on a construction site or event.
In short, spending a little more money up front will pay dividends over the life of the equipment, especially in the harsh reality of the rental industry.
Preventative checks and services aren’t something to make light of. A few minutes a day and some recommended maintenance could add hours and years to a light tower’s existence. While there is no documented life expectancy for a light tower, well-built, well-maintained towers will certainly have the best chance of providing the highest level of dependability and performance. Regular, scheduled maintenance will bring light towers out of the shadow of equipment that can’t hold a candle to the towers’ lengthy service life.