POW’R Lite Kit for Towable Generators TS25 through TS80 Installation & Operating Manual 9/09 MN2421
Any trademarks used in this manual are the property of their respective owners. WARNING: CALIFORNIA PROPOSITION 65 WARNING: Engine exhaust from this product contains chemicals known to the state of California to cause cancer, birth defects and other reproductive harm. WARNING: CALIFORNIA PROPOSITION 65 WARNING: Battery posts, terminals and related accessories are known to the state of California to cause cancer, birth defects and other reproductive harm.
Table of Contents Section 1 Product Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section 2 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Limited Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ii Table of Contents MN2421
Section 1 Product Safety Information This kit can be installed on several models of the Baldor Towable Generators. This manual contains Installation and Operation instructions for the POW’R LITE Kit and components only. Please refer to the manual for the generator for operation and maintenance instructions for the generator portion of the product.
WARNING: Never attempt to move the POW’R LITE when the mast is in the vertical position. All Outrigger and trailer jacks must remain in position and the trailer level until the mast is in its’ stowed position. Failure to follow this warning may result in severe injury and property damage if the trailer tips over. WARNING: Never move or reposition a light tower when the mast is extended or in the vertical position.
Section 2 General Information Thank you for purchasing your POW’R LITE Kit. This manual contains information you need to safely and efficiently install and operate your POW’R LITE Kit option. During the preparation of this manual every effort was made to ensure the accuracy of its contents. A separate owner’s manual for the generator is supplied with the generator for your use.
2-2 General Information MN2421
Section 3 Receiving & Installation Receiving & Inspection When you receive your generator, there are several things you should do immediately. 1. Observe the condition of the shipping container and report any damage immediately to the commercial carrier that delivered your system. 2. Verify that the part number of the system you received is the same as the part number listed on your purchase order. 3.
Table 3-1 POW’R LITE Option Dimensions A (max) 33’ 8” 33’ 8” 35’ 3−3/4” 35’ 3−3/4” 35’ 3−3/4” Generator TS25 TS35 TS45 TS60 TS80 A1 (min) 11’ 5−1/2” 11’ 5−1/2” 16’ 9−3/8” 16’ 9−3/8” 16’ 9−3/8” A2 (max) 92.20 92.20 112.25 112.25 112.25 B 159.04 159.04 162.25 162.25 162.25 C 134.13 134.13 135.89 135.89 135.
TS25/35 Control Box & Mast Support Figure 3-3 TS25/35 Mast Support Installation Mast Lock Pin Mast Support Bracket 3/ 8−16 x 1” 3/ 8−16 x 1.25” Control Box & Mast Support 1/ 2 x 3” x 7.5” U Bolt Mast Anchor 1/ 2−13 x 5.5” The Control box and Mast support is installed as follows: 1. Locate the Control Box and Mast Support assembly and associated hardware shown in Figure 3-3. (Cables and winch are not shown). 2. Remove the front cover and disconnect the connector for the switch cable. 3.
Figure 3-4 TS45/60/80 Mast Support Installation 3/ 8−16 x 1.25” 3/ -16 8 Control Box Support Plate x 1.5" Control Box Mast Support Spacers U-Bolt 1/ 2” x 3” x 7.5” Detail View Mast Anchor (2) 1/ 2−13 x 5.5” Figure 3-5 POW’R LITE Assembly Lift Winch Support Rotate Ring Mast 7/ 8−9 Winch Cable Tie Point x 7.
The POW’R LITE assembly Continued 8. Remove the cotter pin, washer and pin from the Winch Cable Tie Point of the mast. 9. Secure the loop end of the winch cable to the mast Winch Cable Tie Point using the pin, washer and cotter pin removed in step 8. POW’R LITE cable connections can now be made. 1. Route the POW’R LITE cable down the mast support into the bottom of the control box. Be sure to use the clamps, shown in Figure 3-2 to secure the cable to the generator.
3. 4. 5. 6. 7. 8. Connect the following POW’R LITE cable wires, see Figure 3-6: a. Yellow wire to 1st terminal (Top). b. Brown to the 2nd terminal. The Power Cord has a 240VAC connector on one end, the other end has flying leads. Route the Power Cable from the rear of the generator to the Control Box. Connect the plug to one of the 240VAC receptacles, see Figure 3-7. Use 3 cable clamps provided to secure the cable to the generator.
Installation of TS45/60/80 Electric Winch Since the TS45/60/80 is so tall, the lift winch is an electric winch to raise and lower the mast for light tower operation. It is mounted in the place of the mechanical winch and is shown in Figure 3-8. The switch for this electric winch is mounted inside the genset enclosure. Although this is standard for the TS45/60/80 kit, an electric winch kit PLEW12 can be added as a Lift or Tilt winch on any of the light tower kits.
8. Connect the Lift Winch Motor Switch as shown in Figure 3-9. (The + Battery connection can be made at the solenoid terminals.) The wiring harness contains a 100 amp fuse to protect the motor. 9. Locate and remove the Radiator Access cover. 10. Install the replacement cover plate shown in Figure 3-10. Figure 3-10 Radiator Access Cover Replacement Radiator Access Cover Opening for bushing and Winch Motor cable 11.
Section 4 Operation Light Tower Setup WARNING: The mast assembly must remain in the stowed position until the outriggers are properly set to stabilize the trailer . Erecting the mast without setting the outriggers can cause the light tower set to tip over when raising the mast. Before starting the generator, be sure to setup the Light Tower if it is to be used. If the generator is already running, shut down generator operation before you proceed. See Figure 4-1 for component identification.
Light Tower Setup Continued 1. With the Light Mast in its’ stowed position, install or reposition the four light fixtures to the desired placement when the tower is raised. 2. Pull the Mast Lock pin so the mast is no longer secured in the stowed position. 3. Pull the Tilt Lock pin so it is not in the way when the mast is raised. 4. Use the Tilt Winch to raise the mast to the vertical position. Figure 4-2 Mast Lock Pin Lift Winch Mast Rotation Lock Tilt Lock Pin must be installed before mast is raised.
Section 5 Troubleshooting and Maintenance Flood Light Bulb Replacement WARNING: Light fixtures become extremely hot during use. To prevent severe burns, do not touch light fixtures, bulbs or other components until they have cooled and no longer present a burn hazard. Wear protective clothing when placing the tower in the stowed position after use and do not allow any person to touch the light fixtures.
Green Red Black Figure 5-1 POW’R LITE Connection Diagram 5-2 Troubleshooting and Maintenance MN2421
Baldor District Offices
WARNING: CALIFORNIA PROPOSITION 65 WARNING: Engine exhaust from this product contains chemicals known to the state of California to cause cancer, birth defects and other reproductive harm. WARNING: CALIFORNIA PROPOSITION 65 WARNING: Battery posts, terminals and related accessories are known to the state of California to cause cancer, birth defects and other reproductive harm. World Headquarters P.O. Box 2400 Fort Smith, AR 72902−2400 USA Ph: (1) 479.646.4711, Fax: (1) 479.648.5792 www.baldor.
