Atlas Copco HiLight H4 Kd ESF User manual

Instruction Manual
User and maintenance manual
for light towers
English
HiLight H4 Kd ESF D1105-EBG2
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ATLAS COPCO - PORTABLE ENERGY DIVISION
www.atlascopco.com
Printed matter N°
2954 9590 00
04/2015
HiLight H4 Kd ESF
User and maintenance manual
for light towers
User and maintenance manual ..............................................................5
Circuit diagrams .................................................................................... 81
Original instructions
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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 from modifications,
additions 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.
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.
Copyright 2016, Grupos Electrógenos Europa, S.A.U., Zaragoza, Spain.
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.
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Contents
1 Safety precautions.........................8
1.1 Introduction........................................8
1.2 General safety precautions ...............9
1.3 Safety during transport and
installation........................................10
1.4 Safety during use and
operation ..........................................11
1.5 Safety during maintenance
and repair..........................................13
1.6 Tool applications safety ..................14
1.7 Battery safety precautions..............14
2 Main parts ......................................15
2.1 General description .........................15
2.2 Markings ...........................................16
2.3 Mechanical features.........................17
2.3.1 Engine and alternator ......................17
2.3.2 Cooling system.................................17
2.3.3 Safety devices ..................................17
2.3.4 Bodywork..........................................17
2.3.5 Control panel ....................................17
2.3.6 Data plate and serial number..........17
2.3.7 Filler caps..........................................18
2.3.8 Spillage free frame...........................18
2.3.9 Mast and floodlights ........................18
2.3.10 Undercarriage, road lights
and reflectors....................................18
2.4 Electrical features.............................19
2.4.1 Control and indicator panel.............19
2.4.2 Outlet socket (10 Amps)...................20
3 Installation and
connection......................................21
3.1 Lifting ................................................21
3.2 Parking and towing..........................21
3.2.1 Unhooking the light tower...............21
3.2.2 Positioning the light tower ..............22
3.2.3 Positioning for transport..................23
3.2.4 Towing ..............................................24
3.2.5 Transportation and
positioning of the light tower
onto vehicles.....................................25
3.3 Installation........................................25
3.3.1 Indoor installation ............................25
3.3.2 Outdoor installation .........................26
3.4 Connecting the light tower .............26
3.4.1 Precautions for non-linear and
sensitive loads ..................................26
4 Operating instructions................27
4.1 Before starting..................................27
4.2 Operating the light tower ...............27
4.2.1 Before the engine is started ............27
4.2.2 Starting the engine...........................28
4.2.3 Positioning the floodlights ..............28
4.2.4 Extending the mast ..........................29
4.2.5 Rotating the mast .............................29
4.2.6 Switching on/off the
floodlights .........................................30
4.2.6.1 Switching on the floodlights
manually ...........................................30
4.2.6.2 Switching off the floodlights
manually ...........................................30
Congratulations on the purchase of your HiLight on-site 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 trouble free 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.
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4.2.6.3 Switching on/off the
floodlights automatically.................31
4.2.7 Lowering the mast ...........................31
4.2.8 Stopping the engine ........................32
4.3 Connecting appliances ....................33
4.4 Setting the Lc1003™ controller......34
4.4.1 Push button and LED
functions ...........................................34
4.4.2 Module display.................................35
4.4.2.1 Home page .......................................35
4.4.3 Icon overview ...................................35
4.4.3.1 Instrumentation icons......................35
4.4.3.2 Active configuration.........................36
4.4.3.3 Front panel editor (FPE) / Auto
Run icons ..........................................36
4.4.3.4 Mode icons .......................................36
4.4.3.5 Light output icons ............................36
4.4.3.6 Alarm icons.......................................36
4.4.4 Navigation menu..............................37
4.4.5 Event log ...........................................37
4.4.6 Setting the Lc1003™ timer ..............37
5 Periodic maintenance .................39
5.1 Maintenance schedule.....................39
5.1.1 Precautions .......................................44
5.1.2 Use of maintenance schedule.........44
5.1.3 Use of service packs ........................44
5.2 Preventing low loads.......................45
5.2.1 General..............................................45
5.2.2 Risks of low load operation.............45
5.2.3 Best practices ...................................45
5.3 Maintenance of the alternator........45
5.3.1 Measuring the alternator
insulation resistance ........................45
5.4 Engine maintenance procedures....46
5.4.2 Engine oil level check.......................46
5.4.3 Engine oil and oil filter change .......47
5.4.4 Coolant check ...................................48
5.5 Adjustments and service
procedures........................................49
5.5.1 Battery care.......................................49
5.5.2 Replacing fuel filter and pre-
filter element.....................................51
5.5.3 Servicing air filter engine ................51
5.5.4 Air cooling circuit .............................52
5.5.5 Replacing the lamps.........................52
5.5.6 Ordering spare parts........................53
5.6 Resetting service alarms .................53
5.7 Engine consumable
specifications....................................53
5.7.1 Engine fuel specifications................53
5.7.2 Engine oil specifications..................53
5.7.3 Engine coolant specifications..........54
6 Checks and trouble
shooting..........................................56
6.1 Engine troubleshooting...................56
6.2 Solving controller alarms................56
6.2.1 General..............................................56
6.2.2 Alarm overview ................................57
7 Options available for
HiLight H4 units ............................63
7.1 Overview of the mechanical
options ..............................................63
7.2 Description of the mechanical
options ..............................................63
7.2.1 Undercarriage...................................63
7.3 Overview of the electrical
options ..............................................64
7.4 Description of the electrical
options ..............................................64
7.4.1 Auto mast down system..................64
7.4.2 Photocell ...........................................65
7.4.3 External power input (230
VAC), with battery charger ..............66
7.4.4 Override fuel shutdown ...................68
7.4.5 Earth pin............................................68
8 Storage of the light tower.........69
8.1 Storage..............................................69
8.2 Preparing for operation after
storage ..............................................69
9 Disposal...........................................70
9.1 General..............................................70
9.2 Disposal of materials .......................70
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10 Technical specifications of
the light tower ..............................71
10.1 Technical specifications of the
engine/alternator/unit ....................71
10.2 Critical bolt connections .................75
10.3 Average illumination versus
distance.............................................76
10.4 Dimension drawings........................77
10.4.1 Dimension drawing for
HiLight H4 with fixed towbar ..........77
10.4.2 Dimension drawing for
HiLight H4 with adjustable
towbar...............................................78
10.4.3 Dimension drawing for
HiLight H4 with not
homologated towbar .......................79
10.5 Conversion list of SI units into
British units ......................................80
10.6 Data plate .........................................80
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1 Safety precautions
To be read attentively and acted accordingly before towing, lifting, operating, performing maintenance or repairing the light tower.
1.1 Introduction
The policy of Atlas Copco is to provide the users of their
equipment with safe, reliable and efficient products.
Factors taken into account are among others:
- the intended and predictable future use of the
products, and the environments in which they are
expected to operate,
- applicable rules, codes and regulations,
- the expected useful product life, assuming proper
service and maintenance,
- providing the manual with up-to-date information.
Before handling any product, take time to read the
relevant instruction manual. Besides giving detailed
operating instructions, it also gives specific information
about safety, preventive maintenance, etc.
Keep the manual always at the unit location, easy
accessible to the operating personnel.
See also the safety precautions of the engine and
possible other equipment, which are separately sent
along or are mentioned on the equipment or parts of the
unit.
These safety precautions are general and some
statements will therefore not always apply to a particular
unit.
Only people that have the right skills should be allowed
to operate, adjust, perform maintenance or repair on
Atlas Copco equipment. It is the responsibility of
management to appoint operators with the appropriate
training and skill for each category of job.
Skill level 1: Operator
An operator is trained in all aspects of operating the unit
with the push-buttons, and is trained to know the safety
aspects.
Skill level 2: Mechanical technician
A mechanical technician is trained to operate the unit the
same as the operator. In addition, the mechanical
technician is also trained to perform maintenance and
repair, as described in the instruction manual, and is
allowed to change settings of the control and safety
system. A mechanical technician does not work on live
electrical components.
Skill level 3: Electrical technician
An electrical technician is trained and has the same
qualifications as both the operator and the mechanical
technician. In addition, the electrical technician may
carry out electrical repairs within the various enclosures
of the unit. This includes work on live electrical
components.
Skill level 4: Specialist from the manufacturer
This is a skilled specialist sent by the manufacturer or its
agent to perform complex repairs or modifications to the
equipment.
In general it is recommended that not more than two
people operate the unit, more operators could lead to
unsafe operating conditions. Take necessary steps to
keep unauthorized persons away from the unit and
eliminate all possible sources of danger at the unit.
When handling, operating, overhauling and/or
performing maintenance or repair on Atlas Copco
equipment, the mechanics are expected to use safe
engineering practices and to observe all relevant local
safety requirements and ordinances. The following list is
a reminder of special safety directives and precautions
mainly applicable to Atlas Copco equipment.
Neglecting the safety precautions may endanger people
as well as environment and machinery:
- endanger people due to electrical, mechanical or
chemical influences,
- endanger the environment due to leakage of oil,
solvents or other substances,
- endanger the machinery due to function failures.
All responsibility for any damage or injury resulting
from neglecting these precautions or by non-observance
of ordinary caution and due care required in handling,
operating, maintenance or repair, also if not expressly
mentioned in this instruction manual, is disclaimed by
Atlas Copco.
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The manufacturer does not accept any liability for any
damage arising from the use of non-original parts and for
modifications, additions or conversions made without
the manufacturer’s approval in writing.
If any statement in this manual does not comply with
local legislation, the stricter of the two shall be applied.
Statements in these safety precautions should not be
interpreted as suggestions, recommendations or
inducements that it should be used in violation of any
applicable laws or regulations.
1.2 General safety precautions
1 The owner is responsible for maintaining the unit in
a safe operating condition. Unit parts and
accessories must be replaced if missing or
unsuitable for safe operation.
2 The supervisor, or the responsible person, shall at
all times make sure that all instructions regarding
machinery and equipment operation and
maintenance are strictly followed and that the
machines with all accessories and safety devices, as
well as the consuming devices, are in good repair,
free of abnormal wear or abuse, and are not
tampered with.
3 Whenever there is an indication or any suspicion
that an internal part of a machine is overheated, the
machine shall be stopped but no inspection covers
shall be opened before sufficient cooling time has
elapsed; this to avoid the risk of spontaneous
ignition of oil vapour when air is admitted.
4 Normal ratings (pressures, temperatures, speeds,
etc.) shall be durably marked.
5 Operate the unit only for the intended purpose and
within its rated limits (pressure, temperature,
speeds, etc.).
6 The machinery and equipment shall be kept clean,
i.e. as free as possible from oil, dust or other
deposits.
7 To prevent an increase in working temperature,
inspect and clean heat transfer surfaces (cooler fins,
intercoolers, water jackets, etc.) regularly. See the
maintenance schedule.
8 All regulating and safety devices shall be
maintained with due care to ensure that they
function properly. They may not be put out of
action.
9 Pressure and temperature gauges shall be checked
regularly with regard to their accuracy. They shall
be replaced whenever outside acceptable tolerances.
10 Safety devices shall be tested as described in the
maintenance schedule of the instruction manual to
determine that they are in good operating condition.
11 Mind the markings and information labels on the
unit.
12 In the event the safety labels are damaged or
destroyed, they must be replaced to ensure operator
safety.
13 Keep the work area neat. Lack of order will increase
the risk of accidents.
14 When working on the unit, wear safety clothing.
Depending on the kind of activities these are: safety
glasses, ear protection, safety helmet (including
visor), safety gloves, protective clothing, safety
shoes. Do not wear the hair long and loose (protect
long hair with a hairnet), or wear loose clothing or
jewellery.
15 Take precautions against fire. Handle fuel, oil and
anti-freeze with care because they are inflammable
substances. Do not smoke or approach with naked
flame when handling such substances. Keep a fire-
extinguisher in the vicinity.
16a On-site light towers (with earthing pin):
Earth the light tower as well as the load properly.
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1.3 Safety during transport and
installation
To lift a unit, all loose or pivoting parts, e.g. doors and
towbar, shall first be securely fastened.
Do not attach cables, chains or ropes directly to the
lifting eye; apply a crane hook or lifting shackle meeting
local safety regulations. Never allow sharp bends in
lifting cables, chains or ropes.
Helicopter lifting is not allowed.
It is strictly forbidden to dwell or stay in the risk zone
under a lifted load. Never lift the unit over people or
residential areas. Lifting acceleration and deceleration
shall be kept within safe limits.
1 Before towing the unit:
- check the towbar, the brake system and the
towing eye. Also check the coupling of the
towing vehicle,
- check the towing and brake capability of the
towing vehicle,
- check that the towbar, jockey wheel or stand leg
is safely locked in the raised position,
- ascertain that the towing eye can swivel freely on
the hook,
- check that the wheels are secure and that the
tyres are in good condition and inflated correctly,
- connect the signalisation cable, check all lights
and connect the pneumatic brake couplers,
- attach the safety break-away cable or safety
chain to the towing vehicle,
- remove wheel chocks, if applied, and disengage
the parking brake.
2 To tow a unit use a towing vehicle of ample
capacity. Refer to the documentation of the towing
vehicle.
3 If a unit is to be backed up by a towing vehicle,
disengage the overrun brake mechanism (if it is not
an automatic mechanism).
4 In case of transporting a non-trailer unit on a truck,
fasten it to the truck by attaching straps via fork lift
holes, via the holes in the frame at the front and
back or via the lifting beam. To prevent damage,
never put straps on the roof surface of the unit.
5 Never exceed the maximum towing speed of the
unit (mind the local regulations).
6 Place the unit on level ground and apply the parking
brake before disconnecting the unit from the towing
vehicle. Unclip the safety break-away cable or
safety chain. If the unit has no parking brake or
jockey wheel, immobilize the unit by placing
chocks in front of and/or behind the wheels. When
the towbar can be positioned vertically, the locking
device must be applied and kept in good order.
7 To lift heavy parts, a hoist of ample capacity, tested
and approved according to local safety regulations,
shall be used.
8 Lifting hooks, eyes, shackles, etc., shall never be
bent and shall only have stress in line with their
design load axis. The capacity of a lifting device
diminishes when the lifting force is applied at an
angle to its load axis.
9 For maximum safety and efficiency of the lifting
apparatus all lifting members shall be applied as
near to perpendicular as possible. If required, a
lifting beam shall be applied between hoist and
load.
10 Never leave a load hanging on a hoist.
11 A hoist has to be installed in such a way that the
object will be lifted perpendicular. If that is not
possible, the necessary precautions must be taken to
prevent load-swinging, e.g. by using two hoists,
each at approximately the same angle not exceeding
30° from the vertical.
12 Locate the unit at least 1 meter away from walls.
Take all precautions to ensure that hot air exhausted
from the engine and driven machine cooling
systems cannot be re-circulated. If such hot air is
taken in by the engine or driven machine cooling
fan, this may cause overheating of the unit; if taken
in for combustion, the engine power will be
reduced.
13 light towers shall be stalled on an even, solid floor,
in a clean location with sufficient ventilation. If the
floor is not level or can vary in inclination, consult
Atlas Copco.
14 The electrical connections shall correspond to local
codes. The machines shall be earthed and protected
against short circuits by fuses or circuit breakers.
15 Never connect the light tower outlets to an
installation which is also connected to a public
mains.
16 Before connecting a load, switch off the
corresponding circuit breaker, and check whether
frequency, voltage, current and power factor
comply with the ratings of the light tower.
17 Before transportation of the unit, switch off all the
circuit breakers.
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1.4 Safety during use and
operation
1 When the unit has to operate in a fire-hazardous
environment, each engine exhaust has to be
provided with a spark arrester to trap incendiary
sparks.
2 The exhaust contains carbon monoxide which is a
lethal gas. When the unit is used in a confined
space, conduct the engine exhaust to the outside
atmosphere by a pipe of sufficient diameter; do this
in such a way that no extra back pressure is created
for the engine. If necessary, install an extractor.
Observe any existing local regulations.
Make sure that the unit has sufficient air intake for
operation. If necessary, install extra air intake ducts.
3 When operating in a dust-laden atmosphere, place
the unit so that dust is not carried towards it by the
wind. Operation in clean surroundings considerably
extends the intervals for cleaning the air intake
filters and the cores of the coolers.
4 Never remove a filler cap of the cooling water
system of a hot engine. Wait until the engine has
sufficiently cooled down.
5 Never refill fuel while the unit is running, unless
otherwise stated in the Atlas Copco Instruction
Book (AIB). Keep fuel away from hot parts such as
air outlet pipes or the engine exhaust. Do not smoke
when fuelling. When fuelling from an automatic
pump, an earthing cable should be connected to the
unit to discharge static electricity. Never spill nor
leave oil, fuel, coolant or cleansing agent in or
around the unit.
6 All doors shall be shut during operation so as not to
disturb the cooling air flow inside the bodywork
and/or render the silencing less effective. A door
should be kept open for a short period only e.g. for
inspection or adjustment.
7 Periodically carry out maintenance works according
to the maintenance schedule.
8 Stationary housing guards are provided on all
rotating or reciprocating parts not otherwise
protected and which may be hazardous to
personnel. Machinery shall never be put into
operation, when such guards have been removed,
before the guards are securely reinstalled.
9 Noise, even at reasonable levels, can cause irritation
and disturbance which, over a long period of time,
may cause severe injuries to the nervous system of
human beings.
When the sound pressure level, at any point where
personnel normally has to attend, is:
- below 70 dB(A): no action needs to be taken,
- above 70 dB(A): noise-protective devices should
be provided for people continuously being
present in the room,
- below 85 dB(A): no action needs to be taken for
occasional visitors staying a limited time only,
- above 85 dB(A): room to be classified as a noise-
hazardous area and an obvious warning shall be
placed permanently at each entrance to alert
people entering the room, for even relatively
short times, about the need to wear ear
protectors,
- above 95 dB(A): the warning(s) at the
entrance(s) shall be completed with the
recommendation that also occasional visitors
shall wear ear protectors,
- above 105 dB(A): special ear protectors that are
adequate for this noise level and the spectral
composition of the noise shall be provided and a
special warning to that effect shall be placed at
each entrance.
10 The unit has parts of which the temperature can be
in excess of 80 °C (176 °F), and which may be
accidentally touched by personnel when opening
the machine during or just after operation.
Insulation or safety guards protecting these parts
shall not be removed before the parts have cooled
down sufficiently, and must be re-installed before
operating the machine. As it is not possible to
insulate or protect all hot parts by guards (e.g.
exhaust manifold, exhaust turbine), the operator /
service engineer must always be aware not to touch
hot parts when opening a machine door.
11 Never operate the unit in surroundings where there
is a possibility of taking in flammable or toxic
fumes.
12 If the working process produces fumes, dust or
vibration hazards, etc., take the necessary steps to
eliminate the risk of personnel injury.
13 When using compressed air or inert gas to clean
down equipment, do so with caution and use the
appropriate protection, at least safety glasses, for
the operator as well as for any bystander. Do not
apply compressed air or inert gas to your skin or
direct an air or gas stream at people. Never use it to
clean dirt from your clothes.
14 When washing parts in or with a cleaning solvent,
provide the required ventilation and use appropriate
protection such as a breathing filter, safety glasses,
rubber apron and gloves, etc.
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15 Safety shoes should be compulsory in any
workshop and if there is a risk, however small, of
falling objects, wearing of a safety helmet should be
included.
16 If there is a risk of inhaling hazardous gases, fumes
or dust, the respiratory organs must be protected and
depending on the nature of the hazard, so must the
eyes and skin.
17 Remember that where there is visible dust, the finer,
invisible particles will almost certainly be present
too; but the fact that no dust can be seen is not a
reliable indication that dangerous, invisible dust is
not present in the air.
18 Never operate the light tower in excess of its limits
as indicated in the technical specifications and
avoid long no-load sequences.
19 Never operate the light tower in a humid
atmosphere. Excessive moisture causes worsening
of the light tower insulation.
20 Do not open electrical cabinets, cubicles or other
equipment while voltage is supplied. If such cannot
be avoided, e.g. for measurements, tests or
adjustments, have the action carried out by a
qualified electrician only, with appropriate tools,
and ascertain that the required bodily protection
against electrical hazards is applied.
21 Never touch the power terminals during operation
of the machine.
22 Whenever an abnormal condition arises, e.g.
excessive vibration, noise, odour, etc., switch the
circuit breakers to OFF and stop the engine. Correct
the faulty condition before restarting.
23 Check the electric cables regularly. Damaged cables
and insufficient tightening of connections may
cause electric shocks. Whenever damaged wires or
dangerous conditions are observed, switch the
circuit breakers to OFF and stop the engine.
Replace the damaged wires or correct the dangerous
condition before restarting. Make sure that all
electric connections are securely tightened.
24 Avoid overloading the light tower. The light tower
is provided with circuit breakers for overload
protection. When a breaker has tripped, reduce the
concerned load before restarting.
25 Never remove the cover of the output terminals
during operation. Before connecting or
disconnecting wires, switch off the load and the
circuit breakers, stop the machine and make sure
that the machine cannot be started inadvertently or
there is any residual voltage on the power circuit.
26 Running the light tower at low load for long periods
will reduce the lifetime of the engine.
27 When operating the light tower in Remote or Auto
mode, observe all relevant local legislation.
28 When deploying the light tower mast, keep in mind
following safety precautions:
- Do not deploy the mast unless the machine is
standing on an even surface and the stabilizers
have been fully adjusted.
- Do not deploy the mast in the vicinity of
overhead power cables: DANGER OF
ELECTROCUTION.
- Make sure that nobody is standing too close to
the light tower when the mast is being deployed.
- Do not deploy the mast if the wind is stronger
than 80 Km/h.
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1.5 Safety during maintenance
and repair
Maintenance, overhaul and repair work shall only be
carried out by adequately trained personnel; if required,
under supervision of someone qualified for the job.
1 Use only the correct tools for maintenance and
repair work, and only tools which are in good
condition.
2 Parts shall only be replaced by genuine Atlas Copco
replacement parts.
3 All maintenance work, other than routine attention,
shall only be undertaken when the unit is stopped.
Steps shall be taken to prevent inadvertent starting.
In addition, a warning sign bearing a legend such as
“work in progress; do not start” shall be attached to
the starting equipment.
On engine-driven units the battery shall be
disconnected and removed or the terminals covered
by insulating caps.
On electrically driven units the main switch shall be
locked in open position and the fuses shall be taken
out. A warning sign bearing a legend such as “work
in progress; do not supply voltage” shall be attached
to the fuse box or main switch.
4 Prior to stripping an engine or other machine or
undertaking major overhaul on it, prevent all
movable parts from rolling over or moving.
5 Make sure that no tools, loose parts or rags are left
in or on the machine. Never leave rags or loose
clothing near the engine air intake.
6 Never use flammable solvents for cleaning (fire-
risk).
7 Take safety precautions against toxic vapours of
cleaning liquids.
8 Never use machine parts as a climbing aid.
9 Observe scrupulous cleanliness during maintenance
and repair. Keep away dirt, cover the parts and
exposed openings with a clean cloth, paper or tape.
10 Never weld on or perform any operation involving
heat near the fuel or oil systems. Fuel and oil tanks
must be completely purged, e.g. by steam-cleaning,
before carrying out such operations. Never weld on,
or in any way modify, pressure vessels. Disconnect
the alternator cables during arc welding on the unit.
11 Support the towbar and the axle(s) securely if
working underneath the unit or when removing a
wheel. Do not rely on jacks.
12 Do not remove any of, or tamper with, the sound-
damping material. Keep the material free of dirt and
liquids such as fuel, oil and cleansing agents. If any
sound-damping material is damaged, replace it to
prevent the sound pressure level from increasing.
13 Use only lubricating oils and greases recommended
or approved by Atlas Copco or the machine
manufacturer. Ascertain that the selected lubricants
comply with all applicable safety regulations,
especially with regard to explosion or fire-risk and
the possibility of decomposition or generation of
hazardous gases. Never mix synthetic with mineral
oil.
14 Protect the engine, alternator, air intake filter,
electrical and regulating components, etc., to
prevent moisture ingress, e.g. when steam-cleaning.
15 When performing any operation involving heat,
flames or sparks on a machine, the surrounding
components shall first be screened with non-
flammable material.
16 Never use a light source with open flame for
inspecting the interior of a machine.
17 When repair has been completed, the machine shall
be barred over at least one revolution for
reciprocating machines, several revolutions for
rotary ones to ensure that there is no mechanical
interference within the machine or driver. Check the
direction of rotation of electric motors when starting
up the machine initially and after any alteration to
the electrical connection(s) or switch gear, to check
that the oil pump and the fan function properly.
18 Maintenance and repair work should be recorded in
an operator’s logbook for all machinery. Frequency
and nature of repairs can reveal unsafe conditions.
19 When hot parts have to be handled, e.g. shrink
fitting, special heat-resistant gloves shall be used
and, if required, other body protection shall be
applied.
20 When using cartridge type breathing filter
equipment, ascertain that the correct type of
cartridge is used and that its useful service life is not
surpassed.
21 Make sure that oil, solvents and other substances
likely to pollute the environment are properly
disposed of.
22 Before clearing the light tower for use after
maintenance or overhaul, submit it to a testrun,
check that the AC power performance is correct and
that the control and shutdown devices function
correctly.
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1.6 Tool applications safety
Apply the proper tool for each job. With the knowledge
of correct tool use and knowing the limitations of tools,
along with some common sense, many accidents can be
prevented.
Special service tools are available for specific jobs and
should be used when recommended. The use of these
tools will save time and prevent damage to parts.
1.7 Battery safety precautions
When servicing batteries, always wear protecting
clothing and glasses.
1 The electrolyte in batteries is a sulphuric acid
solution which is fatal if it hits your eyes, and which
can cause burns if it contacts your skin. Therefore,
be careful when handling batteries, e.g. when
checking the charge condition.
2 Install a sign prohibiting fire, open flame and
smoking at the post where batteries are being
charged.
3 When batteries are being charged, an explosive gas
mixture forms in the cells and might escape through
the vent holes in the plugs.
Thus an explosive atmosphere may form around the
battery if ventilation is poor, and can remain in and
around the battery for several hours after it has been
charged. Therefore:
- never smoke near batteries being, or having
recently been, charged,
- never break live circuits at battery terminals,
because a spark usually occurs.
4 When connecting an auxiliary battery (AB) in
parallel to the unit battery (CB) with booster cables:
connect the + pole of AB to the + pole of CB, then
connect the - pole of CB to the mass of the unit.
Disconnect in the reverse order.
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2 Main parts
2.1 General description
The light tower provides an undercarriage (frame, axle and towbar) and 4 floodlights of 1000 W each. The light tower is very useful for construction sites where no
electricity nor lighting is available.
CP Control panel
DP Data plate
EP Earth pin (optional)
FCC Filling cap coolant
FCF Filling cap fuel
FL Floodlights
FS Forklift slots
HB Handbrake
LH Leveling handle, to adjust the height of the supporting
foot
LPS Locking pin stabilizer
MMast
RHM Rotating handles mast
ST Stabilizer and supporting foot
TB Towbar
U Undercarriage
FCC
M
FL FL
TB
CP
FS
FS
U
EP DP
FCF
DP
ST
HB
LPS
LH
RHM
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2.2 Markings
Markings provide instructions and information. They
also warn of hazards. For convenience and safety,
keep all markings in legible condition, replacing them
when damaged or missing. Replacement markings are
available from the factory.
A brief description of all markings provided on the
light tower is given hereafter. The precise location of
all markings can be found in the parts manual of this
light tower.
Indicates that an electric voltage,
dangerous to life, is present. Never
touch the electric terminals during
operation.
Indicates that the engine exhaust is a
hot and harmful gas, which is toxic in
case of inhalation. Always make sure
that the unit is operated outside or in a
well-ventilated room.
Indicates that these parts can become
very hot during operation (e.g. engine,
cooler, etc.). Always make sure that
these parts are cooled down before
touching them.
Indicates a risk of fire. This label is
required for On Road transport into the
European Union according to the
European agreement concerning
international carriage of Dangerous
goods by Road, Annex A.
3
Indicates that the mast should not be
extended near electric wires.
Indicates the forklift slots.
Indicates that the unit cannot be lifted
from the back part.
Indicates the locking pin of the
stabilizers.
Indicates the drain plug for the
engine fuel.
Indicates the drain for the
coolant.
Indicates the drain for the engine
oil.
Indicates that the generator may
be refuelled with diesel fuel only.
Indicates the sound power level in
accordance with Directive 2000/14/
EC (expressed in dB (A)).
Indicates that the alternator should not
be cleaned with high pressurised
water.
Indicates that the unit may
start automatically and that
the instruction book has to
be consulted prior to use.
Read the instruction manual
before using the lifting eye.
Indicates the location of the battery.
Avoid water ingress as this could cause
short circuits.
diesel
D
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2.3 Mechanical features
The mechanical features described in this chapter are
standard provided on this light tower. For all optional
mechanical features, see “Overview of the
mechanical options” on page 63.
2.3.1 Engine and alternator
The alternator is driven by a fluid-cooled diesel
engine. The engine’s power is transmitted through a
direct disc coupling.
The light tower houses a single bearing alternator
with a dedicated excitation system for light tower
application.
The synchronous brushless alternator has Class H
rotor and stator windings in an IP21 housing.
2.3.2 Cooling system
The engine is provided with a water cooler. The
cooling air is generated by a fan, driven by the engine.
2.3.3 Safety devices
The unit controller monitors the engine and electrical
parameters and generates warning and shutdown
signals when the parameters reach a preset treshold
value.
2.3.4 Bodywork
The alternator, the engine, the cooling system, etc. are
enclosed in a sound-insulated bodywork that can be
opened by means of side doors.
The light tower can be lifted by using the lifting eye
integrated in the bodywork (roof). To be able to lift
the HiLight H4 by means of a forklift, rectangular
holes are provided in the frame at the left and right
side of the unit.
2.3.5 Control panel
The control panel grouping the controller, fuses,
automatic switches sockets, etc., is placed at the right
side.
2.3.6 Data plate and serial number
The light tower is furnished with a data plate showing
the product code, the unit number and the power
output (see “Data plate” on page 80).
The serial number is located on the frame, on the left
side of the towbar.
Indicates the earthing connections on
the light tower.
Indicates the danger of touching
rotating parts of the unit.
Indicates the different
service packs, liquids and
critical parts. These parts
can be ordered to the
factory.
HiLight H4
Engine D1105-EBG2
Fuel tank capacity 109 L (28,85 U.S GALS)
Oil sump capacity 5,1 L (1,35 U.S GALS)
Cool. system capacity 3,1 L (0,82 U.S. GALS)
Hyd. oil capacity 5 L (1,32 U.S. GALS)
Alternator LT3N-160/4
Tyre pressure Full tank (load 575 kg)
3,5 Bar (51 Psi)
Fluids
Description Order Nr
PAROIL E 5L (1.1GAL) 1615 5953 00
PAROIL E 20L (4.4GAL) 1615 5954 00
PAROIL E 209L (45.98GAL) 1615 5955 00
PAROIL E XTRA 5L (1.1GAL) 16300135 00
PAROIL E XTRA 20L (4.4GAL) 1630 0136 00
PARCOOL EG 5L (1.1GAL) 16045308 00
PARCOOL EG 20L (4.4GAL) 1604 5307 01
PARCOOL EG CONCENTRATE
5L (1.1GAL) 1604 8159 00
Service Kits
Description Order Nr
SERVICE KIT 250H 1636 3103 31
SERVICE KIT 500H 1636 3103 32
SERVICE KIT 750H 1636 3103 33
Engine Parts
Description Order Nr
RADIATOR CAP 1636 3005 19
OIL DIPSTICK 1636 3004 01
OIL FILL CAP 1636 3004 02
ELECTRIC FUEL PUMP 2913 3086 00
OIL PRESSURE SWITCH 29133100 00
TEMPERATURE SWITCH 2914 8678 00
FUEL STOP SOLENOID 16363003 97
THERMOSTATIC VALVE 1636 3003 99
THERMOSTAT GASKET 1636 3004 16
ROCKER COVER GASKET 1636 3004 11
STARTER MOTOR 1636 3004 04
CHARGING ALTERNATOR 1636 3004 03
V-BELT 1636 3004 12
FUEL TANK CAP 1636 0000 15
RADIATOR 1636 3004 07
TOP TANK 1636 3004 14
SAFETY CARTRIDGES 1636 3005 80
Light Tower
Description Order Nr
LAMP 1636 0023 88
PROJECTOR (NO LAMP) 16360023 87
PROJECTOR GLASS 1636 3005 70
HYDRAULIC OIL TANK 1636 3005 07
HYDRAULIC OIL TANK CAP 1636 3005 08
HYDRAULIC CYLINDER KIT 1636 3005 72
MAST KIT PLATES 16363005 74
MAST STEEL CABLE 1636 0023 99
PUMP MOTOR 1636 3005 10
CAPACITOR 16363005 71
SOLENOID VALVE 1636 3004 95
BALLAST 1636 0023 80
IGNITOR 1636 0023 81
CAPACITOR 16360023 82
HYDRAULIC OIL SPEC. HVLP 46 (ISO 6743-4 HV)
Alternator Parts
Description Order Nr
ROTOR 1636 3005 22
STATOR 1636 3005 28
FAN 1636 3005 23
COUPLING DISC 16363005 26
BEARING 1636 3005 24
DIODE 1636 3005 25
CAPACITOR 1636 3005 27
Keys
Description Order Nr
FUEL TANK CAP KEYS 2914 9500 00
DOOR KEYS 16363001 88
1636 0029 45 www.atlascopco.com
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2.3.7 Filler caps
The fuel filler cap is located on the left side and
accessible from the outside. Oil filler cap and coolant
filler cap are easily accessible by opening
respectively the maintenance door or the access
cover.
2.3.8 Spillage free frame
A spillage free frame with forklift slots allows the
customer to transport the light tower easily with a
forklift. It avoids accidental spilling of engine fluids
and thus helps to protect the environment.
The leaking fluid can be removed via drain holes,
secured by drain plugs. Tighten the plugs firmly and
check for leakages. When removing the leaking fluid,
observe all relevant local legislation.
2.3.9 Mast and floodlights
The light tower mast consists of 7 mast sections and
can be extended up to 9 metres in 25 sec. It is operated
by up and down buttons. The mast can be rotated
through 340°.
The light tower provides 4 metal halide lamps of 1000
Watt with a maximum lighting capacity of 90.000
lumen/bulb. Each lamp can be separately positioned
and inclined.
2.3.10 Undercarriage, road lights and
reflectors
There are 3 variants of undercarriage available for
HiLight H4 lights towers:
– not homologated for road use (max. towing speed:
20 km/h)
– homologated for road use, fixed towbar
– homologated for road use, adjustable towbar
The homologated light tower undercarriages are
manufactured according to ISO/European road
standards currently applicable.
The undercarriage can be equipped with an adjustable
or fixed towbar and several towing eyes are available.
For more details on the available undercarriages, their
main features and available towing eyes, see
“Undercarriage” on page 63.
Road lights and reflectors are standard on the road
homologated version. For cable connections see the
connection table on wiring diagram 1636 0024 45/00,
page 89.
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2.4 Electrical features
The electrical features described in this chapter are
standard provided on this light tower. For all optional
electrical features, see “Overview of the electrical
options” on page 64.
2.4.1 Control and indicator panel
Overview control panel
To operate the light tower a control panel is installed.
A1 .......LC 1003™ digital controller
F10......Fuse 10A
The fuse trips when the current from the
battery to the engine control circuit exceeds
its setting. The fuse can be reset by pushing
the button.
H6 .......Light preheater
A yellow light signals that the glow plugs are
being heated.
Q1 .......General circuit breaker with ELCB or
differential protection
Interrupts the power supply when a short-
circuit occurs at the load side, or when the
earth leak detector (30 mA) or the
overcurrent protection are activated. It must
be reset manually after eliminating the
problem.
Q2-5....Circuit breakers for lamps
The control panel provides 4 circuit breakers
for the lamps (one for each lamp). The 4
lamps are controlled by the Lc1003™
controller, by means of contactors.
Q6 ....... Socket protection
The control panel provides socket protection
for outlet socket X1.
S2........Emergency stop button
Push the button to stop the light tower in case
of an emergency. When the button is
pressed, it must be unlocked, before the light
tower can be restarted. The emergency stop
button can be secured in the locked position
with the key, to avoid unauthorized use.
S20......REMOTE/ON/OFF switch
Position : REMOTE START, for Auto
Photocell start option
Position I: ON, for manual start
Position O: OFF, to isolate the controller
S50......UP button
Push the UP button to extend the mast.
S51......DOWN button
Push the DOWN button to lower the mast.
X1 .......Outlet socket
A1
S50
S51
F10 H6
S20
Q2 Q3 Q4 Q5Q1
40A/30mA
Q6 Q6
Q2-5 Q1
S2
X1
0
1
Q1 Q2 Q3 Q4 Q5 Q6
X1
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Features of the Lc1003™ controller
The dedicated Lc1003™ controller provides unique
features and benefits for light tower application, such
as:
– reliability/functionality: sequence 4 lighting
outputs
– 8 event scheduler: weekly timer
– fuel efficiency: auto lamps shutdown
– user friendly operation
– remote start with photocell as an option
2.4.2 Outlet socket (10 Amps)
A brief description of the outlet socket and circuit
breaker provided on the light tower is given hereafter:
X1 .......1-phase outlet socket (230 V)
Provides phase L, neutral and earthing.
3 different versions are available:
- Socket CE 2P 16A
- Socket RIM 2P 16A
- Socket PIN 2P 16A
Q6 .......Circuit breaker for X1
Interrupts the power supply to X1 when a
short-circuit occurs at the load side, or when
the overcurrent protection (10 A) is
activated. When activated, Q6 interrupts
phase F and the neutral towards X1. It can be
activated again after eliminating the
problem.
Q6X1
Q2 Q3 Q4 Q5Q1
40A/30mA
Q6
0
1
Q1 Q2 Q3 Q4 Q5 Q6
X1
Circuit breaker Q1 does not only
interrupt the power supply towards
X1, but also towards the 4 lamps.
Make sure to switch on circuit
breakers Q1 and Q6 after starting
the light tower when power supply is
done by means of X1.
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