DMI Light Towers - Light Tower Operational Manual and how to build light towers.

1. OPERATION MANUAL
DMI 16-LIGHT LIGHT TOWER
ALSO AVAILABLE ONLINE AT DMI-LT.COM
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2. You have purchased a very high quality piece of equipment that should
provide years of useful life. Following the instructions below and the
manufacturer’s generator operating instructions should provide years
of safe and reliable service.
UNLOADING THE TOWER/LIFTING THE TRAILER
When unloading the tower from the trailer, make sure lifting equipment and
rigging is sufficient. Note that the weight of the unit with fuel is 14,000 lbs./6350
kg. Attach rigging to the points marked “sling here” only. Failure to do so could
cause severe damage to the unit and injury/death to bystanders.
ATTACHING LIGHT FIXTURES
The 16 light fixtures will be shipped in a separate container. Carefully unwrap and
with the use of a stable platform or ladder, bolt the fixtures securely to the mast.
Note that they can be mounted in various directions, forward or rear-facing, to
light different areas. Tighten the bolts carefully and tightly, placing an included
washer between the nut and the fixture.
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3. Next, tighten the vertical adjustment lever on each fixture by pulling down on the
lever on each side of the fixture until snug.
The tower may be towed with the fixtures attached for short distances on smooth
roads. Bumpier roads may cause damage to the fixtures and the bulbs.
Make sure 3-prong wires from lights are firmly plugged into junction boxes on
the light mast.
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4. OPERATING THE UNIT
Inspect all electrical connections and wires and cables for damage that may have
been caused in transit. Do not operate the unit if damage to wiring or electrical
components is detected. Repairs should only be attempted by qualified electrical
personnel.
Leveling- Make sure the unit is on hard, level ground with the wheels chocked
from the front and the rear. Extend outriggers fully, which will be eleven feet/3.5
meters. The pins for the middle section of the outrigger will be stowed in the
forward tool compartment at the front of the trailer. Replace pins in both
locations and lower pad with crank handle until pads are firmly on the ground.
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5. When all six pads have been lowered, make adjustments to each according to the
two horizontal leveling indicators mounted near the mast. Insure the trailer is
securely level. DANGER- FAILING TO LEVEL UNIT CORRECTLY COULD CAUSE
TIPPAGE RESULTING IN DEATH!
Always disconnect trailer from towing vehicle before use. Remove mast traveling
pin, which secures the mast in the horizontal position, located above generator.
Remove mast locking pin at base of mast. . See pin locations in picture, below.
CHOCK TRAILER WHEELS!
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7. COLD WEATHER- Low-temp gear oil is available for the winch. Low temp (-60F)
Shell Tellus S4VX32 or Petro Canada Hydrex Arctic 15 hydraulic oil is available for
the hydraulic pump. If arctic operation is desired, insure unit was shipped with
low temp gear oil in the winch and low temp hydraulic oil in the hydraulic pump.
Open Louvers on Ballast Box- Louvers are designed to keep ice and mud from
entering vents in ballast box. Close units during transport but open during use to
ventilate ballast box.
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8. Start generator according to manufacturer’s instructions, attached. Do not
operate lights until boom is at desired height.
Never operate generator unless in a well ventilated
outdoor space as carbon monoxide death will occur. Carbon Monoxide is
colorless and odorless.
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9. Generator will shut off after 10 seconds if fuel level is below 15%. See engine self-
diagnostics on generator control panel.
The generator selector switch should be pre-set to “240/120v 1-Phase”
Turn main switch on generator panel to “on”.
MAST OPERATION
Plug 110 v cord from hydraulic pump into 110 outlet on generator control panel
and turn 20 amp outlet breaker to on position. This will allow the hydraulic pump
to operate. You should hear the pump activate when the power is turned on to
the receptacle. The other breakers are for use of the 220 or other 110 outlet for
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10. other applications such as tools, if desired. UNPLUG HYDRAULIC UNIT PUMP OR
TURN OFF BREAKER WHEN NOT OPERATING HYDRAULICS TO PREVENT
UNECESSARY USAGE OF HYDRAULIC MOTOR
Gently pull closest hydraulic lever (Mast Tilting Lever) towards the front of the
trailer to move mast from travelling position into its vertical position. If levers will
not activate the winch, the cap next to the levers may be removed to adjust the
lever sensitivity with an allen wrench. Always adjust lever sensitivity to lowest
pressure that will operate pump. When mast is vertical, replace mast locking pin.
Danger- Failure to replace mast locking pin could cause injury and damage to the
machine! Never try to move the tower unless mast is in horizontal and secured
position.
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11. Once mast is vertical, the top of the lights will be 25 feet or 7.6 meters off the
ground. This may be sufficient for certain lighting applications or when higher
wind conditions are present.
To Telescope the Mast- Again, make sure mast locking pin is in place, and check
cables and electric wires for fraying or signs of wear.
If any fraying or signs of wear are detected, discontinue use and contact a
qualified repairman. Make sure unit is leveled and all outriggers are down,
including front jack stand. Lowering the front jack stand will result in smoother
winch operation, especially on descent.
Pull handle farthest from operator towards the front of the trailer. This will
tighten the two cables and pull the three boom sections upward. Raise to desired
height. Stop operation if frayed cables are observed or in the event of irregular
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12. pump operation. Do not raise boom past red “55 feet” indicator when indicator
shows on mast. That means the boom is fully extended. Attempting to over
extend the boom can result in serious unit damage and injury.
Note: The hydraulic pressure is set by the adjustment screw by the levers and
by the gold safety valves on the boom tilting piston, to intentionally only allow
the minimum pressure required to activate the piston and winch. To fully raise
the winch to 55 feet (16.8 meters) should take 5-8 minutes. If the levers do not
activate the piston and/or the winch, or the boom will not telescope to the “55
Feet” mark, the pump pressure adjustments will have to be changed.
 Turn breaker for hydraulic pump off or unplug pump after unit is in
operation to avoid wear on pump.
 Lower unit if windy or severe weather is forecast or if lightning is possible.
TURNING ON LIGHTS
Throw main disconnect switch to “on”.
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13. Open glass cabinet door of ballast box to access 16 individual light switches.
Turn on four circuits in sequence and wait until those four lights are fully
illuminated. Then turn on the next 4 and wait until lit, until all 16 lamps are
illuminated or until desired number of lights are in use. Turning on more than
four lights without waiting for them to fully illuminate will shut down the
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14. generator on a safety override and the starting sequence will have to be
repeated.
LOWERING MAST
Turn off individual lamp switches in glass cabinet
Plug in hydraulic pump into 110 outlet in the generator cabinet and/or turn
breaker for the outlet back on. You should be able to hear the hydraulic pump
whirring.
Push lever farthest from operator towards rear of trailer to lower mast. The lever
is adjusted to cause the winch to lower the mast very slowly. It should take 5
minutes to fully lower the mast. If cable is frayed, discontinue use and contact a
properly credentialed repair technician.
Mast is designed to be held in place by one of the two cables should one break.
However, if one does break, discontinue use immediately, move personnel away
from trailer and contact a properly trained repair technician.
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15. Mast fully lowered when all mast sections are retracted and cables on both
pulleys show slack.
Mast should lower smoothly. If for some reason the mast hangs up, contact a
repair technician. Do not continue to attempt to lower mast.
When it is desired to stow the mast, such as when towing or in severe weather,
and the mast is fully retracted, then and only then, remove the mast locking pin
(see photo on page 9) near bottom of mast. Move hydraulic lever closest to
operator towards the rear of the trailer until boom is resting in the cradle. It will
be necessary to move the electric wiring out of the cradle before fully lowering
to avoid damaging the cables.
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16. Do not attempt to continue to lower the mast once it is sitting in the cradle as
damage will occur. Replace mast travelling pin.
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17. SHUTTING UNIT OFF
Turn off main disconnect, let generator run 1 minute without a load and shut
down generator according to generator directions, attached. Never shut the
generator down with a load as damage to generator and/or ballast box may
occur.
The metal halide floodlights require 5 minutes to reach full intensity and 15
minutes to fully cool.
WHEN REFUELING GENERATOR MAKE SURE UNIT IS
OFF AND THE TWO FUEL VALVES TO AUXILLARY TANK ARE TURNED
OFF OR OVERFLOW WILL OCCUR
TOWING
Always pull trailer with a proper vehicle at a very safe speed. Never
pull faster than 50 mph/80kph, much slower when towing down a hill.
Never pull a trailer utilizing vehicle cruise control as that allows slack
and swerving to occur, especially downhill. Towing vehicle must have a
pintle ring receiver and electric trailer break connector. Always use
anti-telescoping cable to prevent boom from sliding out during
transport.
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18. WIND INSTABILITY AND DANGER OF UNIT FALLING OVER
The following is a chart of when the unit becomes aerodynamically unstable. The
data assumes the wind is coming from the most vulnerable direction, which is
calculated to be a side wind with all of the bulbs turned to face in that direction.
The danger of flying debris from the light fixtures should also be considered in
high winds and appropriate safety precautions should always be considered in
light of predicted or anticipated weather conditions. These precautions could
include:
 Lowering the mast to an appropriate height for the weather condition
 Stowing the mast in its travelling position
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19.  Removing the fixtures from the mast and stowing it to its travelling
position.
 Never erecting mast in proximity of electric wires
Tower Height in Feet Toppling Wind Speed in
miles per hour
55 Feet 70 mph
45 Feet 90 mph
35 Feet 100 mph
25 Feet 120 mph
DAILY INSPECTION
 Tires are inflated to manufacturer’s recommended pressure and
lug bolts secure
 All trailer running light fixtures working and undamaged
 Dual safety chains securely attached to towing vehicle
 Check all wiring and breakers for damage
 Check all fluid levels: radiator, hydraulics, engine oils
 Check cables for evidence of fraying
 Make sure mast securing pin is properly installed
 Check outriggers are undamaged and in the correct position with
all pins securing the jacks and outriggers.
All Rights Reserved
Copyright 2012 © DMI Pipe Fabrication, LLC d/b/a DMI-LT
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