Atlas Copco HiLight H4 Kd ESF Instruction Manual
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Instruction Manual
User and maintenance manual for light towers
English
HiLight H4 Kd ESF
D1105-EBG2
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HiLight H4 Kd ESF
User and maintenance manual for light towers
User and maintenance manual .............................................................. 5
Original instructions
Printed matter N°
2954 9590 00
04/2015
ATLAS COPCO - PORTABLE ENERGY DIVISION www.atlascopco.com
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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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1
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.
Contents
Safety precautions
Introduction........................................8
General safety precautions ...............9
Safety during transport and installation........................................10
Safety during use and operation ..........................................11
Safety during maintenance and repair..........................................13
Tool applications safety ..................14
Battery safety precautions..............14
2 Main parts
......................................15
General description .........................15
Markings ...........................................16
Mechanical features.........................17
Engine and alternator ......................17
Cooling system.................................17
Safety devices ..................................17
Bodywork..........................................17
Control panel ....................................17
Data plate and serial number ..........17
Filler caps ..........................................18
Spillage free frame...........................18
Mast and floodlights ........................18
2.3.10 Undercarriage, road lights and reflectors....................................18
Electrical features.............................19
Control and indicator panel.............19
Outlet socket (10 Amps)...................20
3 Installation and connection
......................................21
Lifting ................................................21
Parking and towing..........................21
Unhooking the light tower...............21
Positioning the light tower ..............22
Positioning for transport..................23
Towing ..............................................24
Installation ........................................25
Indoor installation ............................25
Outdoor installation .........................26
Connecting the light tower .............26
Precautions for non-linear and sensitive loads ..................................26
4
Operating instructions
Before starting..................................27
Operating the light tower ...............27
Before the engine is started ............27
Starting the engine...........................28
Positioning the floodlights ..............28
Extending the mast ..........................29
Rotating the mast .............................29
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
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4.2.6.3 Switching on/off the floodlights automatically.................31
Lowering the mast ...........................31
Stopping the engine ........................32
Connecting appliances ....................33
Setting the Lc1003™ controller......34
Push button and LED functions ...........................................34
Module display.................................35
4.4.2.1 Home page .......................................35
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
Navigation menu..............................37
Event log ...........................................37
Setting the Lc1003™ timer ..............37
5 Periodic maintenance
Maintenance schedule.....................39
Precautions .......................................44
Use of maintenance schedule.........44
Use of service packs ........................44
Preventing low loads .......................45
General..............................................45
Risks of low load operation.............45
Best practices ...................................45
Maintenance of the alternator ........45
Measuring the alternator insulation resistance ........................45
Engine maintenance procedures ....46
Engine oil level check.......................46
Engine oil and oil filter change .......47
Coolant check ...................................48
Adjustments and service procedures ........................................49
Battery care.......................................49
Replacing fuel filter and prefilter element.....................................51
Servicing air filter engine ................51
Air cooling circuit .............................52
Replacing the lamps.........................52
Ordering spare parts ........................53
Resetting service alarms .................53
Engine consumable specifications....................................53
Engine fuel specifications................53
Engine oil specifications ..................53
Engine coolant specifications..........54
6 Checks and trouble shooting
..........................................56
Engine troubleshooting...................56
Solving controller alarms ................56
General..............................................56
Alarm overview ................................57
7
Options available for
HiLight H4 units
............................63
Overview of the mechanical options ..............................................63
Description of the mechanical options ..............................................63
Undercarriage...................................63
Overview of the electrical options ..............................................64
Description of the electrical options ..............................................64
Auto mast down system ..................64
Photocell ...........................................65
VAC), with battery charger ..............66
Override fuel shutdown ...................68
Earth pin ............................................68
8
9
Storage of the light tower
Storage..............................................69
Preparing for operation after storage ..............................................69
Disposal
...........................................70
General..............................................70
Disposal of materials .......................70
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10 Technical specifications of the light tower
..............................71
Technical specifications of the engine/alternator/unit ....................71
Critical bolt connections .................75
Average illumination versus distance.............................................76
Dimension drawings........................77
HiLight H4 with fixed towbar ..........77
HiLight H4 with adjustable towbar ...............................................78
HiLight H4 with not homologated towbar .......................79
Conversion list of SI units into
British units ......................................80
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 fireextinguisher 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 noisehazardous 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 (firerisk).
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 sounddamping 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 nonflammable 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.
FL
FCF
LH
RHM
FL
FCC
DP
CP
DP
EP
FCC
FCF
FL
FS
HB
LH
LPS
M
RHM
ST
TB
U
Control panel
Data plate
Earth pin (optional)
Filling cap coolant
Filling cap fuel
Floodlights
Forklift slots
Handbrake
Leveling handle, to adjust the height of the supporting foot
Locking pin stabilizer
Mast
Rotating handles mast
Stabilizer and supporting foot
Towbar
Undercarriage
ST
LPS
HB
M
FS
CP
EP
U
DP
TB
FS
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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.
3
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.
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.
D
diesel
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.
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Indicates the earthing connections on the light tower.
Indicates the danger of touching rotating parts of the unit.
Service Kits
Engine
Fuel tank capacity
Oil sump capacity
Cool. system capacity
Hyd. oil capacity
Alternator
Tyre pressure
HiLight H4
D1105-EBG2
109 L (28,85 U.S GALS)
5,1 L (1,35 U.S GALS)
3,1 L (0,82 U.S. GALS)
5 L (1,32 U.S. GALS)
LT3N-160/4
Full tank (load 575 kg)
3,5 Bar (51 Psi)
Light Tower
SERVICE KIT 250H
SERVICE KIT 500H
SERVICE KIT 750H
Fluids
PAROIL E 5L (1.1GAL)
PAROIL E 20L (4.4GAL)
PAROIL E 209L (45.98GAL)
PAROIL E XTRA 5L (1.1GAL)
PAROIL E XTRA 20L (4.4GAL)
PARCOOL EG 5L (1.1GAL)
PARCOOL EG 20L (4.4GAL)
PARCOOL EG CONCENTRATE
5L (1.1GAL)
1636 3103 31
1636 3103 32
1636 3103 33
1615 5953 00
1615 5954 00
1615 5955 00
1630 0135 00
1630 0136 00
1604 5308 00
1604 5307 01
1604 8159 00
PROJECTOR (NO LAMP)
PROJECTOR GLASS
HYDRAULIC OIL TANK
HYDRAULIC OIL TANK CAP
HYDRAULIC CYLINDER KIT
MAST KIT PLATES
MAST STEEL CABLE
PUMP MOTOR
1636 0023 87
1636 3005 70
1636 3005 07
1636 3005 08
1636 3005 72
1636 3005 74
1636 0023 99
1636 3005 10
Engine Parts HYDRAULIC OIL SPEC. HVLP 46 (ISO 6743-4 HV)
Nr
RADIATOR CAP
OIL DIPSTICK
1636 3005 19
1636 3004 01
Alternator Parts
OIL FILL CAP 1636 3004 02
ELECTRIC FUEL PUMP
OIL PRESSURE SWITCH
TEMPERATURE SWITCH
FUEL STOP SOLENOID
THERMOSTATIC VALVE
THERMOSTAT GASKET
ROCKER COVER GASKET
STARTER MOTOR
CHARGING ALTERNATOR
FUEL TANK CAP
2913 3086 00
2913 3100 00
2914 8678 00
1636 3003 97
1636 3003 99
1636 3004 16
1636 3004 11
1636 3004 04
1636 3004 03
1636 0000 15
SOLENOID VALVE
IGNITOR
COUPLING DISC
Keys
1636 3004 95
1636 0023 81
1636 3005 26
TOP TANK
SAFETY CARTRIDGES
1636 0029 45
1636 3004 14
1636 3005 80
FUEL TANK CAP KEYS
DOOR KEYS
2914 9500 00
1636 3001 88 www.atlascopco.com
Indicates the different service packs, liquids and critical parts. These parts can be ordered to the factory.
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.
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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
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.
S2
A1
X1
0
1
Q1 Q2 Q3 Q4 Q5 Q6
Q1
40A/30mA
Q2 Q3 Q4 Q5 Q6
S50
S51
F10
H6
S20
Q2-5
Q6
Q1
X1
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 shortcircuit 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
Position I:
: REMOTE START, for Auto
Photocell start option
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
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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:
0
1
X1
Q1
Q1
40A/30mA
Q2 Q3 Q4 Q5 Q6
Q2 Q3 Q4 Q5 Q6
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.
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.
X1 Q6
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
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3 Installation and connection
3.1
Lifting
The lifting eye, to lift the light tower by means of a hoist, is integrated in the bodywork and easily accessible from the outside.
When lifting the light tower, the hoist has to be placed in such a way that the light tower, which must be placed level, will be lifted vertically.
To be able to lift the light tower by means of a forklift, forklift slots are provided in the frame at the left and right side of the unit.
3.2
Parking and towing
The operator is expected to apply all relevant safety precautions,
including those mentioned on page 9
3.2.1
Unhooking the light tower
1. Secure the support leg/jockey wheel (1) to support the light tower in a level position.
2. Adjust the height of the support leg/jockey wheel using the handle (2).
2
Lifting acceleration and deceleration must be kept within safe limits (max.
2 g).
Helicopter lifting is not allowed.
1
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To release the light tower from the towing vehicle, carefully follow the procedure below:
5. Uncouple the trailer from the towing vehicle.
Release the locking lever of the towbar coupler
(2), if applicable.
6. Proceed with positioning, to set up the light tower.
To reconnect the light tower to the towing vehicle, proceed as above but in the reverse order (see also
3.2.2
Positioning the light tower
Follow the steps below to position the light tower:
1. Ensure that the handbrake is engaged, if available, and make sure that the mast is down.
2. For the two front stabilizers; release the locking pin of the stabilizer (2) by lifting it up and pull the supporting foot (3) at the maximum extension of the stabilizer (4).
2
1
1. Engage the handbrake (1), if provided.
2. Disconnect the cable plug for the trailer lights.
3. Adjust the height of the support leg/jockey wheel to level the light tower and to support its weight.
4. Disconnect the safety wire from the towing vehicle.
5
4 2
1
3
2
4
5
3
3. Once the front stabilizers (4) have been extended, release the locking pin (2) to lock them in position.
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4. Turn the handle (5) at the top of the supporting feet anticlockwise to lower them and get the light tower in a level position.
5
5. Once the light tower is correctly positioned, install a suitable earthing (e.g. the optional earth pin (7)) and make sure that it is correctly connected to the light tower (8).
7
3.2.3
Positioning for transport
1. Make sure the mast is lowered completely and
turned 90° (1). See also “Lowering the mast” on page 31.
1
Check the levels (6) on top of the light tower to ensure that the unit is in a level position.
6
8
For more detailed installation instructions, see also
2. Make sure that the jockey wheel (if available) is safely fastened by its own locking lever to ensure that the light tower is still stable once the stabilizing feet are removed.
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3. Adjust the height of the support leg/jockey wheel using the handle (2) on top. The support leg/ jockey wheel (3) should never touch the ground once the light tower is coupled to the hook of the towing vehicle.
4
2
3.2.4
Towing
Before commencing towing, ensure you follow the procedure below:
1. Check that the coupler (1) of the undercarriage of the light tower is safely coupled to the towing hook of the towing vehicle.
2
3
4. Use the handle at the top of each foot to retract the
4 feet and retract the front stabilizers and ensure their locking pins following the reverse order of
the procedure described in “Positioning the light tower” on page 22.
Once all the above operations are complete, you will have returned the light tower to the same state as it was before the positioning procedure (see figure above). At this point the light tower is correctly arranged for transport.
1
2. Connect the cabling plug to the towing vehicle so that the rear lights of the light tower work
(indicators, lights, brake lights).
3. Check that the pressure and condition of the tires are suitable for the road and the climatic conditions.
4. Release the handbrake (2), if provided.
Do not proceed with towing if you notice any broken or faulty parts.
Drive carefully according to the road and climatic conditions.
Keep in mind that for the low speed off-road non-homologated trailer, the maximum speed is 20 Km/h!
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3.2.5
Transportation and positioning of the light tower onto vehicles
As well as the ability to be towed, the light tower can also be easily lifted and moved to difficult areas thanks to its central lifting eye and fork lift holes in its frame. All that is needed is a fork lift truck or a mechanical arm.
The fork lift holes and the lifting eye can also be used to place the light tower onto trucks for road transportation.
If the light towers are carried on trucks or similar vehicles:
1. Ensure that the machine is stable and secure.
2. Check that the light tower is placed perfectly horizontally (check the levels on top of the unit).
3. To ensure stability, use the fork lift slots (1) and lifting eye (2) to fix the light tower to the transport vehicle.
4. Use straps or other means of anchoring, provided that these do not affect the machine's safe transportation and integrity.
5. It is recommended that the machine is covered by a tarpaulin to protect it against bad weather conditions if it is transported on an open truck.
1
2
1
3.3
Installation
3.3.1
Indoor installation
If the machine is operated in a closed environment, make sure that there is enough ventilation to remove the exhaust gases from the room where the engine is running; also ensure that the exhaust gases are discharged at a distance that will not allow them to be drawn back into the engine. Install an exhaust pipe of sufficient diameter to duct the engine exhaust towards the outside. Check for sufficient ventilation so that the cooling air is not re-circulated.
Place the machine at least at 1m from each wall and the ceiling and provide suitable openings to allow sufficient air flow for adequate cooling and good engine combustion.
For more information about indoor installation, consult your local Atlas
Copco dealer.
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3.3.2
Outdoor installation
– Place the light tower on a horizontal, even and solid floor. Check the levels on top of the light tower to ensure its level position.
– The light tower should be kept with the doors closed, in order to avoid the ingress of water and dust. Dust ingress reduces the lifetime of filters and may reduce your light tower's performance.
– Check that the engine exhaust is not directed towards people.
– Locate the rear end of the light tower upwind, away from contaminated wind streams and walls.
Avoid re-circulation of exhaust air from the engine. This causes overheating and engine power decrease.
– Leave enough space for operation, inspection and maintenance (at least 1 meter at each side).
– Check that the inner earthing system is in compliance with the local legislation.
– Use PARCOOL EG for the engine cooling system.
– Use a cable of suitable section to connect the PE terminal to an earth plate that can ensure an earth resistance suited to the characteristics of the light tower.
– Check that the cable end of the earth pin is connected to the earth terminal.
The light tower is wired for a TNsystem to IEC 364-3, i.e. one point in the power source directly earthed in this case the neutral. The exposed conductive parts of the electric installation must be directly connected to the functional earth.
3.4
Connecting the light tower
3.4.1
Precautions for non-linear and sensitive loads
Non-linear loads draw currents with high contents in harmonics, causing distortion in the wave form of the voltage generated by the alternator.
The most common non-linear loads are thyristor/ rectifier-controlled loads, such as convertors supplying voltage to variable speed motors, uninterruptable power supplies and Telecom supplies. Gas-discharge lighting arranged in singlephase circuits generate high 3rd harmonics and risk for excessive neutral current.
Loads most sensitive to voltage distortion include incandescent lamps, discharge lamps, computers, Xray equipment, audio amplifiers and elevators.
Consult Atlas Copco for measures against the adverse influence of non-linear loads.
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4 Operating instructions
In your own interest, always strictly observe all relevant safety instructions.
Do not operate the light tower in excess of the limitations mentioned in the Technical Specifications.
Local rules concerning the setting up of low voltage power installations
(below 1000 V) must be respected when connecting site distribution panels, switch gear or loads to the light tower generator.
At each start-up and at any time a new load is connected, the earthing and protections (GB trip and earth leakage relay) of the light tower must be verified. Earthing must be done either by the earth pin or, if available, by an existing, suitable earthing installation. The protective system against excessive contact voltage is not effective unless a suitable earthing is made.
4.1
Before starting
– Perform all daily checks and maintenance as
specified in the “Maintenance schedule” on page 39.
– With the light tower standing level, check the engine oil level and top up if necessary. The oil level must be between the min and max levels on the engine oil level dipstick.
– Check the fuel level and top up if necessary. It is recommended to fill the tank after the day’s operation to prevent water vapour in a nearly empty tank from condensing.
– Check the tightness of all bolts and nuts. For
torque values, see “Critical bolt connections” on page 75.
– Check that circuit breaker Q1 is switched off.
– Check that the fuses have not tripped and that the emergency stop is in the OUT position.
– Check that the load is switched off.
4.2
Operating the light tower
Carefully read and follow in sequence all the operating instructions in the Engine's manual as well as those contained in this manual!
4.2.1
Before the engine is started
1. Before starting the engine, check that all the automatic switches (general ELCB, sockets protection and lamp circuit breakers) are in the
OFF position (1).
X1
0
1
Q1 Q2 Q3 Q4 Q5 Q6
Q1
40A/30mA
Q2 Q3 Q4 Q5 Q6
X2
GE
ON
P8
1
2
2. If the optional External power input (230 VAC) is installed, select the desired operating mode with
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4.2.2
Starting the engine
1. Put starter switch S20 in position I (ON) (1) to power the Lc1003™ module.
2. Push the START button (2) on the Lc1003™ module.
The pre-heater indicator (3) is lit. Auto preheating starts and the engine will start after preheating.
3. Once the machine starts, the controller will check that all functioning conditions are OK. If there is any failure (low oil pressure, high coolant temperature, etc...), the controller will display a signal.
4.2.3
Positioning the floodlights
1. Check that the glass panes of the lights (1) are in good condition.
1 2
3. Loosen the handle at the side of the floodlight (3) and adjust the inclination of the floodlight.
3
X1
X2
0
1
Q1 Q2 Q3 Q4 Q5 Q6
Q1
40A/30mA
Q2 Q3 Q4 Q5 Q6
GE
ON
P8
2
1
3
2. Check the tightness of the nuts on top of the lamps
(2). Torque if necessary.
4. Tighten the handle again when the floodlight is in the desired position.
5. Proceed with the extension of the mast as described below.
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4.2.4
Extending the mast
If the Mast Down option is provided, the mast can only be extended if the handbrake is engaged. For more
details on this option see “Auto mast down system” on page 64.
1. Check that the emergency push button has not been pushed. (If it has been pushed, a message will appear on the display.)
2. Check whether the plastic spacers on top of the mast sections (1) are in good condition. Replace if necessary.
X1
X2
0
1
Q1 Q2 Q3 Q4 Q5 Q6
Q1
40A/30mA
Q2 Q3 Q4 Q5 Q6
GE
ON
P8
4. Use the UP (4) and DOWN (5) buttons on the control panel to extend and adjust the mast to the desired height up to the red indication on the mast
(6) (max 9 metres).
2
3
4
5
4.2.5
Rotating the mast
1. Unlock the locking pin (1) of the mast (located on its rotating base) and rotate the light tower using the mast handles (2) to further adjust the light beam. The mast can be rotated through 340°.
2
1
2. Lock the mast again using its locking pin (1).
1
3. Switch ON the main circuit breaker Q1 (2) and make sure all other breakers are switched OFF (3).
6
Do not extend the mast at a wind speed stronger than 80 km/h.
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4.2.6
Switching on/off the floodlights
4.2.6.1
Switching on the floodlights manually
1. Make sure the mast is up and in the desired
operating position. See section 4.2.4.
2. Switch ON the 4 circuit breakers (Q2-5) (1).
4. Wait for the lights to heat up. - this will take about
10 minutes.
4.2.6.2
Switching off the floodlights manually
To switch the lights off manually, follow the procedure described below and proceed to lower the mast.
5. Push the START button on the Lc1003™ module
(1) to shut down the lamps.
6. Place the 4 automatic switches (Q2-5) (2) in their
OFF position.
2
0
1
X1
X2
Q1 Q2 Q3 Q4 Q5 Q6
Q1
40A/30mA
Q2 Q3 Q4 Q5 Q6
GE
ON
P8
1
0
1
1
X1
Q1 Q2 Q3 Q4 Q5 Q6
Q1
40A/30mA
Q2 Q3 Q4 Q5 Q6
3. Push the AUTO button on the Lc1003™ module
(2) to ignite the lamps.
In sequence, every 20 seconds one lamp will ignite automatically.
When the light tower is connected to
the mains (“External power input
(230 VAC), with battery charger”
option, S10 in position 2) all lights will ignite at the same time, as soon as circuit breakers Q2-Q5 are switched ON.
X2
GE
ON
P8
2
7. Wait for the lamps to cool down - this will take about 10 minutes.
- 30 -
Once the floodlights are switched
OFF (Q2-5 switches in the OFF position), do not to switch them ON again until the cooling-off time is over. The lamps will only ignite, after complete cool down!
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4.2.6.3
Switching on/off the floodlights automatically
Only applicable with timer or
1. Make sure the mast is up and in the desired
operating position. See section 4.2.4.
2. Put the starter switch S20 in position REMOTE
(1).
3. Switch ON the 4 circuit breakers (Q2-5) (2).
When the light tower is connected to
the mains (“External power input
(230 VAC), with battery charger”
option, S10 in position 2) all lights will ignite at the same time, as soon as circuit breakers Q2-Q5 are switched ON.
4.2.7
Lowering the mast
1. If the floodlights are not to be used again, lower the mast using the DOWN button on the control panel (1).
X1
X2
0
1
Q1 Q2 Q3 Q4 Q5 Q6
Q1
40A/30mA
Q2 Q3 Q4 Q5 Q6
GE
ON
P8
3
1
2
4. Push the AUTO button on the Lc1003™ module
(3) to activate AUTO mode.
The floodlights will ignite/switch off automatically depending on the luminosity
(optional Photocell) or a set time schedule.
X1
X2
0
1
Q1 Q2 Q3 Q4 Q5 Q6
Q1
40A/30mA
Q2 Q3 Q4 Q5 Q6
GE
ON
P8
1
Mind your head while lowering the mast!
- 31 -
When lowering the mast, check that the power cord on the mast (spiral cable) collapses freely into its holder and does not become pinched or tangled!
2
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4.2.8
Stopping the engine
Follow the instructions below to switch the engine off correctly:
1. Lower the mast. See section 4.2.7.
2. Disconnect the electrical appliances connected to the socket (1).
3. Push the STOP button on the Lc1003™ module
(2) to go into cool down.
4. After cool down, which takes approx. 30 sec., put the starter switch S20 in position O (OFF) (3).
5. Place all the automatic switches in their OFF position (4).
6. If the optional External power input (230 VAC) is installed, switch S10 to O (OFF) (5). See also
“External power input (230 VAC), with battery charger” on page 66.
Should an emergency arise, it is also possible to stop the machine by pressing the EMERGENCY 'STOP' button (6). If the light tower has been stopped in this way, the emergency stop button must be released by rotating it clockwise, for next operation.
6
0
1
X1
X2
0
1
Q1
Q1
40A/30mA
Q2 Q3 Q4 Q5 Q6
Q2 Q3 Q4 Q5 Q6
GE
ON
P8
2
3
4
5
1
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4.3
Connecting appliances
Keep in mind that this machine is a light tower, not a generator set!
1. Start the engine. See section 4.2.2.
2. Wait 3 or 4 minutes before connecting the appliances to allow the engine to warm up enough. Then plug in the socket (X1) (1).
1
X1
X2
0
1
Q1
Q1
40A/30mA
Q2 Q3 Q4 Q5 Q6
Q2 Q3 Q4 Q5 Q6
GE
ON
P8
3. Make sure that a correct voltage is displayed.
4. Switch on circuit breaker Q6.
5. Switch on your appliance.
Power is limited to 10 Amps!
2
6. If the breaker Q6 (2) trips (10 A), adjust the load until it falls within the maximum power limit allowed.
If the 4 lamps are switched ON and the load of the socket is exceeded, an
Under voltage alarm will be triggered and the engine will shutdown.
7. Make sure that the load does not exceed the nominal power of the generating set as indicated in the technical data sheet and guaranteed with a tolerance of ± 5% when the engine has run in.
For derating values, check the derating table on
8. Make sure the load does not exceed the nominal current capacity of the socket or the cable connected to it.
Avoid long low-load periods
(< 30%). In this case, an output drop and higher oil consumption of the engine could occur. Refer to
9. Only connect the light tower directly to the mains, if the optional External power input (230 VAC) is installed. In this case use the X2 socket (3). See
also “External power input (230 VAC), with battery charger” on page 66.
3
X1
X2
0
1
Q1 Q2 Q3 Q4 Q5 Q6
Q1
40A/30mA
Q2 Q3 Q4 Q5 Q6
GE
ON
P8
To correctly disconnect the appliances from the light tower generator, first position the switch to
OFF to isolate the electric load and only then remove the plug.
10. Stop the engine. See section 4.2.8.
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4.4
Setting the Lc1003™ controller
Controller settings should only be performed by a qualified technician.
2
4.4.1
Push button and LED functions
Following push buttons are used on the
Lc1003™:
3
4
5
1
4
1 2 3
STOP: Is used to activate Stop/Reset mode. When pressing the STOP button, the generator will unload
(Light Output 1, 2, 3 & 4 becomes inactive (if used)), the fuel supply deenergises and the engine shuts down.
Pressing the STOP button will also clear any alarm conditions for which the triggering criteria have been removed.
5
AUTO: Is used to activate Auto mode.
It is also used for floodlight operation:
– switch on the floodlights manually (S20: ON)
– switch on/off the floodlights automatically, in REMOTE mode (S20: REMOTE)
START: Is used to start the unit in
Manual mode.
It is also used to switch off the floodlights manually (S20: ON).
UP: Is used for navigating the instrumentation, event log and configuration screens and to go to the previous parameter level.
DOWN: Is used for navigating the instrumentation, event log and configuration screens and to go to the next parameter level.
Following Leds are used on the Lc1003™:
1
2
3
Stop
Auto
Start
1 2 3
LED indicates that the unit is in Stop/
Reset Mode.
LED indicates that the unit is in Auto
Mode.
LED indicates that the unit is in
Manual/Start Mode.
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4.4.2
Module display
4.4.2.1
Home page
The home page is the page displayed when no other page has been selected:
1
2
3
4
7
1 Instrumentation icon
2 Active configuration
3 FPE/Auto run
4 Light output icons
5 Alarm icon
6 Mode icon
7 Instrumentation and Unit e.g. voltage reading
5
6
4.4.3
Icon overview
4.4.3.1
Instrumentation icons
Display Description
The default home page which displays Generator voltage and the
Auto Run icon
Generator voltage and frequency instrumentation screen
Current and load instrumentation screen
Engine speed instrumentation screen
Hours run instrumentation screen
Battery voltage instrumentation screen
Oil pressure instrumentation screen
Coolant temperature instrumentation screen
Fuel sender instrumentation screen
Display Description
Appears when the event log is being displayed
Current time held in the unit
The current value of the scheduler run time and duration
ECU diagnostic trouble codes
Oil Filter maintenance timers
Air Filter maintenance timers
Fuel Filter maintenance timers
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4.4.3.2
Active configuration
Display Description
Appears when the main configuration is selected.
Appears when the alternative configuration is selected.
4.4.3.3
Front panel editor (FPE) / Auto Run icons
Display Description
Appears when a remote start input is active
Appears when a low battery run is active
Appears when a scheduled run is active
4.4.3.4
Mode icons
Display Description
Appears when the engine is at rest and the unit is in stop mode.
Appears when the engine is at rest and the unit is in auto mode.
Appears when the engine is at rest and the unit is waiting for a manual start.
Appears when a timer is active, for example cranking time, crank rest etc.
Appears when the engine is running, and all timers have expired, either on or off load.
The animation speed is reduced when running in idle mode.
Appears when the unit is in the front panel editor.
Appears when a USB connection is made to the controller.
Appears if either the configuration file or engine file becomes corrupted.
4.4.3.5
Light output icons
Display Description
Appears when the corresponding light output has been configured and is not active.
Appears when the corresponding light output has been configured and is active.
Appears when a timer to delay the light output activating or deactivating is in progress
4.4.3.6
Alarm icons
To indicate the alarm that is currently active on the controller, an icon is displayed in the Alarm Icon section.
For an overview of all controller alarms, see “Solving controller alarms” on page 56.
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4.4.4
Navigation menu
To enter the navigation menu, press both the UP and
DOWN buttons simultaneously.
To navigate to the desired page, select the corresponding icon by pressing the UP and DOWN button and press the AUTO (Accept) button to enter.
If the AUTO button is not pressed, the display automatically returns to the home page.
Display Description
Home and generator voltage and frequency instrumentation
Generator current and load instrumentation
1
2
3
Display
Event Log
Description
4.4.5
Event log
The Lc1003™ module’s event log contains a list of the last 15 record electrical trip or shutdown events and the engine hours at which they occurred.
Once the log is full, any subsequent electrical trip or shutdown alarms over writes the oldest entry in the log. Hence, the log always contains the most recent shutdown alarms. The module logs the alarm, along with the engine running hours.
4
5
6
To view the event log:
1. Press the UP and DOWN buttons simultaneously to display the navigation menu.
2. Once entered, cycle to the event log section (1) and enter.
3. To view the event log, repeatedly press the UP or
DOWN buttons until the LCD screen displays the desired event.
4. Continuing to press the UP or DOWN buttons will cycle through the past alarms.
5. To exit the event log, press the UP and DOWN buttons simultaneously.
4.4.6
Setting the Lc1003™ timer
The Lc1003™ controller provides a basic scheduler that allows the operator to set a detailed time schedule following which the igniting of the floodlights can be programmed.
To set the Lc1003™ timer, follow the flow on the next page.
i
Engine instrumentation
Module information
Engine DTCs (Diagnostic Trouble
Codes) if active
1 Icon to indicate that the event log is currently display
2 Number of event displayed out
3 Light output status
4 The engine hours at which the event occurred
5 Icon to indicate the electrical trip or shutdown alarm that has been recorded
6 Current operating state of the module
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Menu flow:
Configuration Parameters – Scheduler
901 Enable Scheduler
902 Schedule Run On or
Off Load
On (1),
Off (0)
On (1),
Off (0)
903 Schedule Period
904 Scheduler (1)
Start Time
905 Scheduler (1)
Start Day
906 Scheduler (1)
Start Week
Weekly (0),
Monthly (1)
0:00:00
0
(1=Monday)
1,2,3,4
907 Scheduler (1) Duration 0:00:00
908 Scheduler (2)
Start Time
0:00:00
...
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5 Periodic maintenance
5.1
Maintenance schedule
Before carrying out any maintenance activity, check that the ignition switch is in position OFF and that no electrical power is present on the terminals.
Maintenance schedule Daily Every 250 hours Every 500 hours Every 750 hours Yearly
Service pack 1636 3103 31 1636 3103 32 1636 3103 33 -
For the most important sub-assemblies, Atlas Copco has developed service kits that combine all wear parts. These service kits offer you the benefits of genuine parts, save on administration costs and are offered at reduced price, compared to the loose components. Refer to the parts list for more information on the contents of the service kits.
Engine
Drain water from fuel filter
Check/Fill fuel level
Empty air filter vacuator valve
Check engine oil level (if necessary top up)
Check coolant level
Check control panel for alarms and warnings
Check on abnormal noise
Replace air filter element
Check/Replace safety cartridge (1) (available as spare part)
Change engine oil (2)
Replace engine oil filter
Replace fuel (primary) filter
Replace fuel (secondary) filter x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x
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Maintenance schedule
Service pack
Inspect/Adjust fan/alternator belt
Replace fan/alternator belt (1)
Replace coolant (9)
Check/test emergency stop
Clean radiator
Drain condensate and water from spillage-free frame
Check for leaks on engine-air-, oil-, or fuel system
Hoses and clamps - Inspect
Check electrical system cables for wear
Check/Test glow plugs
Check torque on critical bolt connections (4)
Check electrolyte (if applicable) battery terminals (5)
Analyse coolant
Grease locks and hinges
Check rubber flexibles (3)
Drain/Clean fuel tank water and sediments
Inspect/clean fuel tank breather filter
Replace fuel tank breather filter
Adjust engine inlet and outlet valves (6)
Check engine protective devices
Inspect starter motor
Inspect charging alternator (7)
Daily
x
Every 250 hours Every 500 hours Every 750 hours
1636 3103 31 x
1636 3103 32 1636 3103 33 x x x x x x x x x x x x x x x x x x x x
Yearly
x x x x x x x x x x x x x x x x x x x
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Maintenance schedule
Service pack
Alternator
Measure alternator diodes
Measure alternator windings insulation resistance
Test Earth Leakage breaker
Check alternator and cubicle electrical system and cables for wear
Check alternator cable connections on terminals
Check Alternator vibration damper
Light tower
Check if mast cables are not frayed or damaged. Replace immediately if damaged.
Check support connection bolt of projectors
Check/Replace adjustable plates condition.
Check electrical cable condition and upper fixation clamp
Grease the mast collar (8)
Grease the mast adjustable plates (contact surface only) (8)
Grease cylinder rotule (8)
Change hydraulic oil (1)
Undercarriage
Check tyre pressure (1)
Check tyres for uneven wear
Check torque of wheel nuts
Check torque of coupling head
Daily
x
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Every 250 hours Every 500 hours Every 750 hours
1636 3103 31 1636 3103 32 1636 3103 33 x x x x x x x x
Yearly
x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x
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Maintenance schedule
Service pack
Check towbar handbrake lever spring actuator, reversing lever, linkage and all movable parts for ease of movement
Grease coupling head, towbar bearings and the housing of the overrun brake (8)
Check brake system (if installed) and adjust if necessary
Oil or grease brake lever and moving parts such as bolts and joints
Grease sliding points on height adjusting parts
Check safety cable for damage
Check electrical cable towards road signalisation
Check brake pads wear
Change wheel hub bearing grease (8)
Critical bolts connections: torques values
Lifting beam to frame
Horizontal lifting beam to vertical lifting beam
Coupling housing alternator to flywheel housing engine
Rotor disk alternator to flywheel engine
Engine to engine support
Engine support to vibration damper engine
Vibration damper engine to frame
Wheel to axle
Axle to frame
Towbar to frame
Daily
-
Every 250 hours Every 500 hours Every 750 hours
1636 3103 31 1636 3103 32 1636 3103 33 x x x x x x x x x x x x x x x x x x x x
Yearly
x x x x x x x x x x x
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Maintenance schedule
Service pack
Towing eye to towbar
Inspection by Atlas Copco Service technician
Daily
-
Every 250 hours Every 500 hours Every 750 hours Yearly
1636 3103 31 1636 3103 32 1636 3103 33 x x light towers in stand-by application have to be tested on a regular basis. At least once a month the engine should run for minimum 30 minutes at a high load (50% - 70%) that the engine reaches its operating temperature.
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Notes:
(1) Check the service label on the control panel door.
(2) Use PAROIL E or PAROIL Extra.
(3) Replace every 6 years.
(4) Critical bolt connections torque. See also
“Critical bolt connections” on page 75.
(5) Check electrolyte when using wet batteries.
(6) Replace gasket after valve clearance.
(7) Measure the battery voltage when machine is running.
(8) Please use the Atlas Copco grease as mentioned in the ASL (Spare part list).
When operating the light tower at low ambient temperatures or in a humid environment, we surface with a liquid, water repellent lubricant to ensure an effective performance of the hydraulic circuit of the mast.
(9) Replace PARCOOL every 5 years.
5.1.1
Precautions
– Before proceeding with any type of maintenance, please take all the necessary precautions to avoid accidentally starting the engine: disconnect the battery and switch off the control module.
– Do not carry out any change or modification to any part of the light tower or its electric system.
– Do not carry out any maintenance when the engine is running.
– Be careful when close to any moving parts (e.g.
pulleys, fans …) and to any hot parts (e.g. muffler, engine block, coolants, lubricants …).
5.1.2
Use of maintenance schedule
Regular maintenance is essential for the optimum performance, safe operation and a longer working life of the machine.
The maintenance schedule contains a summary of the maintenance instructions. Read the respective section before taking maintenance measures.
When servicing, replace all disengaged packing, e.g.
gaskets, O-rings, washers.
For engine maintenance refer to the Maintenance schedule and the Engine Operation Manual.
The maintenance schedule has to be seen as a guideline for units operating in a dusty environment typical to light tower applications. Maintenance schedule can be adapted depending on application, environment and quality of maintenance.
5.1.3
Use of service packs
Service Packs include all genuine parts needed for normal maintenance of both generator and engine.
Service Packs minimize downtime and keep your maintenance budget low.
The order number of the Service Packs are listed in the Atlas Copco Parts list (ASL). Order Service Packs at your local Atlas Copco dealer.
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5.2
Preventing low loads
5.2.1
General
All engine parts are designed with tolerances to allow work under full load conditions. When operating at low load, these tolerances allow more lube oil to pass between valve guides, stems, liners and pistons due to the lower engine temperatures.
Lower combustion pressure has an influence on the piston ring operation and the combustion temperature. Low boost pressure will cause oil leakage over the turbo shaft seal.
5.2.2
Risks of low load operation
– Cylinder glazing: the cylinder bore troughs become filled with lacquer, displacing oil and thus preventing correct ring lubrication.
– Bore polishing: the bore surface becomes polished, all peaks and most troughs become worn away, also preventing correct ring lubrication.
– Heavy carbon build-up: on pistons, piston ring grooves, valves and turbo charger. Carbon buildup on pistons can cause seizure when later operating at full load.
– High oil consumption: prolonged no-load/low load operation of the engine may cause it to blue/ gray smoke at low rpm with an associated increase in oil consumption
– Low combustion temperature: this will result in insufficiently burnt fuel, which will cause diluting of the lube oil. Also, unburnt fuel and lube oil can enter the exhaust manifold and eventually leak out through joints in the exhaust manifold.
– Risk for fire
5.2.3
Best practices
Reduce the low load periods to a minimum. This should be achieved by adequately sizing the unit for the application.
It is recommended that a unit is always used with a load > 30% of nominal. Corrective actions should be taken if due to circumstances this minimum load capacity cannot be obtained.
Operate the unit at full load capacity after any low load operating period. Therefore, connect the unit periodically to a load bank. Increase the load in steps of 25% every 30 minutes and allow the unit to run for
1 hour in full load condition. Gradually return the unit to the operating load.
The interval between load bank connections may vary according to the conditions present on site and the amount of load. However, a rule of thumb is to connect a unit to a load bank after every maintenance operation.
For more info, please contact your Atlas Copco
Service Center.
When a failure occurs and is deemed due to low load operation, the repairs fall outside warranty coverage.
5.3
Maintenance of the alternator
The alternator does not require any specific general maintenance. However, please follow the indications in the Engine Operation Manual that accompanies the light tower.
5.3.1
Measuring the alternator insulation resistance
A 500 V megger is required to measure the alternator insulation resistance.
If the N-terminal is connected to the earthing system, it must be disconnected from the earth terminal.
Disconnect the AVR.
Refer to the Alternator operating and maintenance instructions for more details.
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5.4
Engine maintenance procedures
5.4.1
General instructions
– Regularly perform maintenance work and replace parts as indicated in the Engine Operation
Manual.
– The engine should never run before filters have been correctly installed.
– Open the access doors of the light tower to access the engine and perform all necessary maintenance operations.
• Unlock the access doors by using the key.
• Open the access doors by pushing the black push button next to the key hole.
– Regularly check the controller display, to see if a service alarm icon (1) is present. In this case an urgent maintenance action is requested.
Example:
– Do not smoke and maintain a safe distance from flames and sparks while maintenance is being carried out and when fuels and solvents are being used.
– Carefully follow all the instructions contained in the Engine Operation Manual that accompanies the light tower.
5.4.2
Engine oil level check
PAROIL Extra.
Check the engine oil level before every time that the light tower is used. To do this you must ensure that the machine stands on an even surface and that the engine is not running.
1. Check the engine oil level before starting or more than 5 minutes after stopping the engine.
2 1 1
1
2. Remove the oil level gauge, wipe it clean and reinstall it.
3. Take the oil level gauge out again, and check the oil level.
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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 some time for the oil to drain down to the oil pan.
6. If the engine is operated with the oil level nearing the lower limit, however, oil may deteriorate quickly; keeping the oil level near the upper limit is thus recommended.
5.4.3
Engine oil and oil filter change
Regularly perform maintenance work and replace parts as indicated in the Engine Operation Manual.
Observe all relevant environmental and safety precautions.
Be sure to stop the engine before draining engine oil or changing the oil filter cartridge.
Allow the engine to cool down sufficiently, oil can be hot and cause burns.
Changing engine oil
When draining engine oil, place some container underneath the engine and dispose it according to local regulations.
Do not drain oil after running the engine. Allow engine to cool down sufficiently.
1. Change oil as instructed in the Maintenance schedule.
2. Remove plug and drain all the old oil. If the oil is warm, it is easier to drain.
3. Add new engine oil up to the upper limit of the oil level gauge.
Replacing the oil filter cartridge
1. Replace the oil filter cartridge as instructed in the
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. Because, if you tighten the cartridge with a wrench, it will be tightened too much.
1
5. After the new cartridge has been replaced, the engine oil level normally decreases a little. Thus, run the engine for a while and check for oil leaks through the seal before checking the engine oil level. Add oil if necessary.
6. Wipe off any oil sticking to the machine completely.
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5.4.4
Coolant check
5.4.4.1
Checking coolant level, adding coolant
1. Remove the radiator cap (1), after the engine has completely cooled, and check to see that coolant reaches the supply port.
Do not open the radiator cap if the coolant is too hot.
1
2
A
B
2. If the radiator is provided with a recovery tank (2), check the coolant level of the recovery tank.
When it is between the "FULL" (A) and "LOW"
(B) marks, the coolant will last for one day's work.
For more details, read the instructions in the Engine
Operation Manual.
5.4.4.2
Monitoring coolant condition
In order to guarantee the lifetime and quality of the product, thus to optimise engine protection, regular coolant-condition-analysis is advisable.
The quality of the product can be determined by three parameters.
Visual check
– Verify the outlook of the coolant regarding colour and make sure that no loose particles are floating around.
Long service intervals
5-year drain interval to minimize service costs (when used in accordance with the instructions).
pH measurement
– Check the pH value of the coolant using a pHmeasuring device.
The pH-meter can be ordered from Atlas Copco with part number 2913 0029 00.
Typical value for EG = 8.6.
– If the pH-level is below 7 or above 9.5, the coolant should be replaced.
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Glycol concentration measurement
– To optimise the unique engine protection features of the PARCOOL EG the concentration of the
Glycol in the water should be always above
33 vol.%.
– Mixtures with more than 68 vol.% mix ratio in water are not recommended, as this will lead to high engine operating temperatures.
– A refractometer can be ordered from Atlas Copco with part number 2913 0028 00.
In case of a mix of different coolant products this type of measurement might provide incorrect values.
5.4.4.3
Topping up of coolant
– Verify if the engine cooling system is in a good condition (no leaks, clean,...).
– Check the condition of the coolant.
– If the condition of the coolant is outside the limits, the complete coolant should be replaced (see section “Replacing the coolant”).
– Always top-up with PARCOOL EG.
– Topping up the coolant with water only, changes the concentration of additives and is therefore not allowed.
– Additives might be necessary in order to enable the coolant to withstand lower temperatures.
5.4.4.4
Replacing the coolant
Drain
– Completely drain the entire cooling system.
– Used coolant must be disposed or recycled in accordance with laws and local regulations.
Flush
– Flush twice with clean water. Used coolant must be disposed or recycled in accordance with laws and local regulations.
– From the Atlas Copco Instruction book, determine the amount of PARCOOL EG required and pour into the radiator top tank.
– It should be clearly understood that the risk for contamination is reduced in case of proper cleaning.
– In case a certain content of ‘other’ coolant remains in the system, the coolant with the lowest properties influences the quality of the ‘mixed’ coolant.
Fill
– To assure proper operation and the release of trapped air, run the engine until normal engine operation temperature is reached. Turn off the engine and allow to cool.
– Re-check coolant level and add if necessary.
5.5
Adjustments and service procedures
5.5.1
Battery care
Before handling batteries, read the relevant safety precautions and act accordingly.
Always wear protective gloves and goggles when handling the battery battery fluid contains sulphuric acid that can cause burns. If your skin or your clothes come in contact with the battery fluid, rinse immediately with plenty of water. If even a tiny quantity is swallowed, seek immediate medical help.
If the battery is still dry, it must be activated as described in section “Activating a dry-charged battery”.
The battery must be in operation within 2 months from being activated; if not, it needs to be recharged first.
5.5.1.1
Electrolyte
Read the safety instructions carefully.
Electrolyte in batteries is a sulphuric acid solution in distilled water.
The solution must be made up before being introduced into the battery.
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5.5.1.2
Activating a dry-charged battery
Always remove the battery and disconnect the terminals before carrying out any operation
(charging or refilling).
– Take out the battery.
– Battery and electrolyte must be at equal temperature above 10°C.
– Remove cover and/or plug from each cell.
– Fill each cell with electrolyte until the level reaches 10 to 15 mm above the plates, or to the level marked on the battery.
– Rock the battery a few times so that possible air bubbles can escape; wait 10 minutes and check the level in each cell once more; if required, add electrolyte.
– Refit plugs and/or cover.
– Place the battery in the light tower.
– ALWAYS connect the positive (+) terminal first and the negative (-) terminal second.
5.5.1.3
Recharging a battery
Before and after charging a battery, always check the electrolyte level in each cell; if required, top up with distilled water only. When charging batteries, each cell must be open, i.e. plugs and/or cover removed.
Use a commercial automatic battery charger according to its manufacturer’s instructions.
Apply with preference the slow charging method and adjust the charge current according to the following rule of thumb: battery capacity in Ah divided by 20 gives safe charging current in Amp.
5.5.1.4
Make-up distilled water
The amount of water evaporating from batteries is largely dependant on the operating conditions, i.e.
temperatures, number of starts, running time between start and stop, etc...
If a battery starts to need excessive make-up water, this points to overcharging. Most common causes are high temperatures or a too high voltage regulator setting.
If a battery does not need any make-up water at all over a considerable time of operation, an undercharged battery condition may be caused by poor cable connections or a too low voltage regulator setting.
5.5.1.5
Periodic battery service
– Keep the battery clean and dry.
– Keep the electrolyte level at 10 to 15 mm above the plates or at the indicated level; top up with distilled water only. Never overfill, as this will cause poor performance and excessive corrosion.
– Record the quantity of distilled water added.
– Keep the terminals and clamps tight, clean, and lightly covered with petroleum jelly.
– Carry out periodic condition tests. Test intervals of 1 to 3 months, depending on climate and operating conditions, are recommended.
– If doubtful conditions are noticed or malfunctions arise, keep in mind that the cause may be in the electrical system, e.g. loose terminals, voltage regulator maladjusted, poor performance of generator, etc...
Never charge the battery or refill the fluid when the battery is still installed in the machine! Possible spillage could damage vital parts of the generating set.
Atlas Copco accepts no responsibility for any damage to the light tower caused by spilling of the battery fluid.
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5.5.2
Replacing fuel filter and prefilter element
– Unscrew the filter element from the adapter head.
– Clean the adapter head sealing surface. Lightly oil the gasket of the new element and screw the latter onto the header until the gasket is properly seated, then tighten with both hands.
– Loosen the hose clamps and replace the plastic filter cartridge.
– Reconnect the hoses and tighten the clamps.
– Check for fuel leaks once the engine has been restarted.
5.5.3
Servicing air filter engine
5.5.3.1
Main parts
1 4
2 3
1 Dust trap
2 Safety cartridge
3 Filter element
4 Filter housing
5.5.3.2
Recommendation
The Atlas Copco air filters are specially designed for this application. The use of non-genuine air filters may lead to severe damage of engine and/or alternator.
Never run the light tower without air filter element.
– New elements must also be inspected for tears or punctures before installation.
– Discard the filter element (3) when damaged.
– In heavy duty applications it is recommended to install a safety cartridge which can be ordered with the part number mentioned on the service label on the control panel door.
– A dirty safety cartridge (2) is an indication of a malfunctioning air filter element (3). Replace the element and the safety cartridge in this case.
– The safety cartridge (2) cannot be cleaned.
5.5.3.3
Cleaning the dust trap
To remove dust from the dust trap (1), clean it with a dry rag.
5.5.3.4
Replacing the air filter element
– Remove the dust trap (1). Clean the trap.
– Remove the element (3) from the housing (4).
– Reassemble in reverse order of dismantling.
– Inspect and tighten all air intake connections.
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5.5.4
Air cooling circuit
Check every day that all the air cooling circuits are not clogged with dust or other particles. If any circuit is obstructed, it must be cleaned.
5.5.5
Replacing the lamps
Do not touch the lamps when they are still hot without having taken all necessary precautions. It is recommended that protective gloves are always worn.
1. Release the 4 clamps (1) and rotate them to open the protection glass. The glass must stay hinged on the bottom part of the floodlight.
1 1
2. Remove the lamp, first releasing the safety spring
(2) placed around the lamp and then unscrewing the lamp from its seat (3).
The air flows from the front (towbar side) towards the rear side of the machine. This means, cold air enters at the front side and hot air exits at the rear side of the machine.
1
- 52 -
1
3
2
3. Install the new lamp and re-install the safety spring (2).
4. Lock the protective glass using the 4 clamps and remember to carefully tighten the screws with a screwdriver.
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5.5.6
Ordering spare parts
It is possible to order spare parts for the light tower by making reference to the parts as mentioned in the enclosed Parts List manual.
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.
5.6
Resetting service alarms
The alarm must be accepted and the alarm condition cleared to reset the Lc1003™ module.
1. Stop the unit.
2. Scroll UP or DOWN through the maintenance alarms.
3. On each maintenance alarm screen press and hold the STOP/RESET button for 10 seconds.
4. A password will be requested.
5. Enter password 1968 and push the AUTO button to accept the alarm.
5.7
Engine consumable specifications
5.7.1
Engine fuel specifications
For fuel specifications, please contact your Atlas
Copco Customer Center.
5.7.2
Engine oil specifications
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 between -10°C and 50°C between -25°C and 50°C
Type of lubricant
PAROIL E or
PAROIL Extra
Never mix synthetic with mineral oil.
When changing from mineral to synthetic oil (or the other way around), you will need to do an extra rinse.
After doing the complete change procedure to synthetic oil, run the unit for a few minutes to allow good and complete circulation of the synthetic oil. Then drain the synthetic oil again and fill again with new synthetic oil. To set correct oil levels, proceed as in normal instruction.
Specifications PAROIL
PAROIL from Atlas Copco is the ONLY oil tested and approved for use in all engines built into Atlas
Copco compressors, generators and light towers.
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.
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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.
PAROIL prevents Soot build-up.
PAROIL is optimized for the latest low emission
EURO -3 & -2, EPA TIER II, III and IV engines running on low sulphur diesel for lower oil and fuel consumption.
PAROIL Extra
PAROIL Extra is a synthetic ultra high performance diesel engine oil with a high viscosity-index. Atlas
Copco PAROIL Extra is designed to provide excellent lubrication from start-up in temperatures as low as -25°C.
can barrel
Litre
5
20
US gal
1.3
5.3
Imp gal
1.1
4.4
cu.ft
Order number
0.175
1630 0135 00
0.7
1630 0136 00
PAROIL E
PAROIL E is a mineral based high performance diesel engine oil with a high viscosity-index. Atlas
Copco PAROIL E is designed to provide a high level of performance and protection in standard ambient conditions as from -10°C.
can can barrel
Litre
5
20
209
US gal
1.3
5.3
55.2
Imp gal
1.1
4.4
46 cu.ft
Order number
0.175
1615 5953 00
0.7
7.32
1615 5954 00
1615 5955 00
5.7.3
Engine coolant specifications
Never remove the cooling system filler cap while coolant is hot.
The system may be under pressure.
Remove the cap slowly and only when coolant is at ambient temperature. A sudden release of pressure from a heated cooling system can result in personal injury from the splash of hot coolant.
It is strongly recommended to use
Atlas Copco branded coolant.
The use of the correct coolant is important for good heat transfer and protection of liquid-cooled engines.
Coolants used in these engines must be mixtures of good quality water (distilled or de-ionised), special coolant additives and if necessary freeze protection.
Coolant that is not to manufacturer's specification will result in mechanical damage of the engine.
The freezing point of the coolant must be lower than the freezing point that can occur in the area. The difference must be at least 5°C (9°F). If the coolant freezes, it may crack the cylinder block, radiator or coolant pump.
Consult the engine's operation manual and follow the manufacturer's directions.
Never mix different coolants and mix the coolant components outside the cooling system.
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Specifications PARCOOL EG
PARCOOL EG is the only coolant that has been tested and approved by all engine manufacturers currently in use in Atlas Copco compressors, generators and light towers.
Atlas Copco's PARCOOL EG extended life coolant is the new range of organic coolants purpose designed to meet the needs of modern engines. PARCOOL EG can help prevent leaks caused by corrosion.
PARCOOL EG is also fully compatible with all sealants and gasket types developed to join different materials used within an engine.
PARCOOL EG is a ready to use Ethylene Glycol based coolant, premixed in an optimum 50/50 dilution ratio, for antifreeze protection guaranteed to
-40°C (-40°F).
Because PARCOOL EG inhibits corrosion, deposit formation is minimized. This effectively eliminates the problem of restricted flow through the engine coolant ducts and the radiator, minimizing the risk for engine overheating and possible failure.
It reduces water pump seal wear and has excellent stability when subjected to sustained high operating temperatures.
PARCOOL EG is free of nitride and amines to protect your health and the environment. Longer service life reduces the amount of coolant produced and needing disposal to minimise environmental impact.
PARCOOL EG can can
Litre
5
20
US gal
1.3
5.3
Imp gal
1.1
4.4
cu.ft
Order number
0.175
1604 5308 00
0.7
1604 5307 01
PARCOOL EG CONCENTRATE
Litre
US gal
1.3
Imp gal
1.1
cu.ft
Order number
0.175
1604 8159 00 can 5
To ensure protection against corrosion, cavitation and formation of deposits, the concentration of the additives in the coolant must be kept between certain limits, as stated by the manufacturer's guidelines.
Topping up the coolant with water only, changes the concentration and is therefore not allowed.
Liquid-cooled engines are factory-filled with this type of coolant mixture.
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6 Checks and trouble shooting
Never perform a test run with connected power cables. Never touch an electrical connector without a voltage check.
When a failure occurs, always report what you experienced before, during and after the failure.
Information with regard to the load
(type, size, power factor, etc.), vibrations, exhaust gas colour, insulation check, odours, output voltage, leaks and damaged parts, ambient temperature, daily and normal maintenance and altitude might be helpful to quickly locate the problem. Also report any information regarding the humidity and location of the light tower (e.g.
close to sea).
6.1
Engine troubleshooting
Refer to the Engine Operation manual for engine troubleshooting.
6.2
Solving controller alarms
6.2.1
General
If an alarm condition occurs, an icon is displayed in the Alarm Icon section of the Lc1003™ LCD to indicate the alarm that is current active on the controller.
In the event of a warning alarm , the LCD only displays the Alarm Icon.
In the event of an electrical trip or shutdown alarm , the module displays the Alarm Icon and the STOP button LED begins to flash.
If multiple alarms are active at the same time, the
Alarm Icon automatically cycles through all the appropriate icons to indicate each alarm which is active.
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6.2.2
Alarm overview
6.2.2.1
Warning alarm icons
Warnings are non-critical alarm conditions and do not affect the operation of the generator system, they serve to draw the operators attention to an undesirable condition.
By default, warning alarms are self-resetting when the fault condition is removed.
Display Description
Fail to stop
Reason
The module has detected a condition that indicates that the engine is running when it has been instructed to stop.
‘Fail to Stop’ could indicate a faulty oil pressure sensor. If the engine is at rest, check the oil sensor wiring and configuration.
Charge failure
Low fuel level
The auxiliary charge alternator voltage is low as measured from the W/L terminal.
The level detected by the fuel level sensor is below the low fuel level setting.
Battery Under Voltage
Battery Over Voltage
Generator Under Voltage
Generator Over Voltage
The DC supply has fallen below or risen above the low volts setting level.
The DC supply has risen above the high volts setting level.
The generator output voltage has fallen below the pre-set pre-alarm setting after the Safety On timer has expired.
The generator output voltage has risen above the pre-set pre-alarm setting.
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Display Description
Generator Under Frequency
Generator Over Frequency
Immediate Over Current
Delayed Over Current
Low Current
Oil Filter Maintenance Alarm
Air Filter Maintenance Alarm
Fuel Filter Maintenance Alarm
Reason
The generator output frequency has fallen below the pre-set pre-alarm setting after the Safety
On timer has expired.
The generator output frequency has risen above the pre-set pre-alarm setting.
The measured current has risen above the configured trip level.
The measured current has risen above the configured trip level for a configured duration.
The measured current has fallen below the configured trip level. This is used to detect lamp failure.
Maintenance due for oil filter.
Maintenance due for air filter
Maintenance due for fuel filter.
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6.2.2.2
Electrical trip alarm icons
Electrical trips are latching and stop the light tower, but in a controlled manner. On initiation of the electrical trip condition the Lc1003™ module de-energises all the
‘Light Output’ outputs to remove the load from the light tower. Once this has occurred the Lc1003™ module starts the Cooling timer and allows the engine to cool offload before shutting down the engine. The alarm must be accepted and cleared, and the fault removed to reset the Lc1003™ module.
Electrical trips are latching alarms and to remove the fault, press the STOP button on the Lc1003™ module.
The alarm condition must be rectified before a reset will take place. If the alarm condition remains, it is not possible to reset the unit.
Display Description
Engine High Temperature
Low Fuel Level
Delayed Over Current
Low Current
Reason
The module detects that the engine coolant temperature has exceeded the high engine temperature pre-alarm setting level after the Safety On timer has expired.
The level detected by the fuel level sensor is below the low fuel level setting.
The measured current has risen above the configured trip level for a configured duration.
The measured current has fallen below the configured trip level. This is used to detect lamp failure.
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6.2.2.3
Shutdown alarm icons
Shutdown alarms are latching and immediately stop the light tower. On initiation of the shutdown condition the Lc1003™ module de-energises all the ‘Light Output’ outputs to remove the load from the light tower. Once this has occurred, the Lc1003™ module shuts the light tower down immediately to prevent further damage. The alarm must be accepted and cleared, and the fault removed to reset the Lc1003™ module.
Shutdowns are latching alarms and to remove the fault, press the STOP button on the Lc1003™ module.
The alarm condition must be rectified before a reset will take place. If the alarm condition remains, it is not possible to reset the unit.
Display
Fail To Start
Low Oil Pressure
Description
Under Speed
Over Speed
Charge failure
Low fuel level
Battery Under Voltage
Reason
The engine has failed to start after the configured number of start attempts
The module detects that the engine oil pressure has fallen below the low oil pressure pre-alarm setting level after the Safety On timer has expired.
The engine speed has fallen below the under speed pre-alarm setting
The engine speed has risen above the over speed pre-alarm setting
The auxiliary charge alternator voltage is low as measured from the W/L terminal.
The level detected by the fuel level sensor is below the low fuel level setting.
The DC supply has fallen below or risen above the low volts setting level.
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Display Description
Battery Over Voltage
Generator Under Voltage
Generator Over Voltage
Generator Under Frequency
Generator Over Frequency
Emergency Stop
Oil Sender Open Circuit
Coolant Temperature Sender Open Circuit
Delayed Over Current
Low Current
Reason
The DC supply has risen above the high volts setting level.
The generator output voltage has fallen below the pre-set pre-alarm setting after the Safety On timer has expired
The generator output voltage has risen above the pre-set pre-alarm setting.
The generator output frequency has fallen below the pre-set pre-alarm setting after the Safety
On timer has expired.
The generator output frequency has risen above the pre-set pre-alarm setting.
The emergency stop button has been depressed. This fail-safe (normally closed to emergency stop) input immediately stops the set, should the signal be removed.
The oil pressure sensor has been detected as being open circuit.
The coolant temperature sensor has been detected as being open circuit.
The measured current has risen above the configured trip level for a configured duration.
The measured current has fallen below the configured trip level. This is used to detect lamp failure.
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Display Description
Oil Filter Maintenance Alarm
Air Filter Maintenance Alarm
Fuel Filter Maintenance Alarm
Maintenance due for oil filter.
Maintenance due for air filter
Maintenance due for fuel filter.
Reason
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7 Options available for HiLight H4 units
7.1
Overview of the mechanical options
The following mechanical options are available:
7.2
Description of the mechanical options
7.2.1
Undercarriage
There are 3 variants of undercarriage available for
HiLight H4 light towers. Each variant has its own specific features. An overview is given hereafter.
Not homologated for road use
(max speed 20 km/h)
This undercarriage provides:
– Fixed towbar, without inertia coupling
– Rigid axle, without brake
– Adjustable support
– Wheel
– Mudguard
Homologated for road use, fixed towbar
This undercarriage provides:
– Fixed towbar, with inertia coupling
– Axle with rubber suspension, with brake
– Wheel
– Jockey wheel
– Mudguard
– Electrical kit
– License plate support
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Homologated for road use, adjustable towbar
This undercarriage provides:
– Articulated towbar, with inertia coupling
– Axle with rubber suspension, with brake
– Wheel
– Jockey wheel
– Mudguard
– Electrical kit
– License plate support
The homologated light tower trolleys are manufactured according to ISO/European road standards currently applicable.
The undercarriage is equipped with an adjustable or fixed towbar with French-eye, DIN-eye, BNA-eye,
GB-eye, ITA-eye, NATO eye or ball coupling, with or without handbrake. For more detailed information on the different towing eyes, please consult the parts manual.
Make sure that the towing equipment of the vehicle matches the towing eye before towing the light tower.
7.3
Overview of the electrical options
The following electrical options are available:
– External power input (230 VAC), with battery charger
7.4
Description of the electrical options
7.4.1
Auto mast down system
When this option is installed, the mast can only be raised if the handbrake is engaged.
If the handbrake is released while the mast is still up, the mast will descend to its initial position or until the handbrake is engaged again (this will be signalled through an intermittent alarm sound).
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7.4.2
Overview
Photocell
Setting the sensitivity regulator
The photocell sensitivity regulator is used for regulating the luminosity sensitivity level of the photocell.
When the red LED (1) on the regulator is blinking, the regulator is reading the luminosity level measured by the photocell.
The recommended value to set the regulator is at
50 Lux.
– < 50 Lux: the floodlights switch on.
– > 50 Lux: the floodlights switch off.
The luminosity level can be adjusted to a desired higher/lower level, according to the specific operating conditions of the light tower.
P7.1
0
1
A1 A2 12 11 14
X1
Q1 Q2 Q3 Q4 Q5 Q6
Q1
40A/30mA
Q2 Q3 Q4 Q5 Q6
P7
P7
1
25
50
75
1
LX
100
B1 B2
P7.1..... Photocell
Measures the luminosity and can be activated by sunlight.
P7........ Photocell sensitivity regulator
Is used for regulating the luminosity sensitivity level of the photocell.
There are 2 blinking levels:
– Level 1: slow blinking
The photocell detects there is enough light, according to its set sensitivity level.
– Level 2: fast blinking
The photocell detects there is a prolonged luminosity change that falls below the set sensitivity level. Remote start will be triggered and the floodlights of the light tower will switch on automatically (if Remote start and Auto mode
are selected, see also “Operating the light tower” on page 27).
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7.4.3
External power input (230 VAC), with battery charger
Overview
S10 ..... Input power selector
Position 1: running on Diesel engine
Position 0: neutral position
Position 2: running on external mains
X2 ....... Inlet socket for connection to the mains (32A)
Setting the timer
0
1
X1
X2
Q1
Q1
40A/30mA
Q2 Q3 Q4 Q5 Q6
Q2 Q3 Q4 Q5 Q6
GE
ON
P8
X2
At first use (or after Reset):
– Choose the language (French, English,...).
– Choose to delete or to keep the default set program.
– Set the year, day and time.
– Choose the summer/winter time change over parameters.
S10 H15 P8
H15 ..... Indicator of Mains available
Illuminated LED indicates that the unit is running on external mains.
P8........ Timer (scheduler)
Is used for setting a time schedule for the lamps of the light tower to switch on / off.
menu
+ / ok
Press the menu key to enter the editing menu.
When in the editing menu, press the menu key to return to Auto mode, without saving the last change.
Navigation and value setting keys
Flashing information validation key.
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Setting the ON and OFF triggers of the timer
To program the ON trigger proceed as follows:
pulse off copy
- 67 -
To program the OFF trigger follow the menu flow above and select OFF after selecting ‘SWITCH’.
When both the photocell and the timer option are installed, the lamps of the light tower will switch on/off, depending on which of both options triggers first.
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7.4.4
Override fuel shutdown
With this option installed, the floodlights will switch off automatically one by one when the unit is running out of fuel (<20%).
– At 20% fuel level:
Lamp 1 switches off
– At 15% fuel level:
Lamp 2 switches off
– At 12% fuel level:
Lamp 3 switches off
– At 10% fuel level:
Lamp 4 switches off
7.4.5
Earth pin
The earth pin (1), to be connected to the light tower’s earth terminal is located at the bottom of the frame on the outside.
1
To instal this option wiring should be changed on customer terminal X25. Make a bridge between terminals 10.11, on X25-10 and X25-11.
Refer to circuit diagram 1636 0024 44/00_01 for the
correct connections.
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8 Storage of the light tower
8.1
Storage
– Store the light tower horizontally in a dry, frostfree room which is well ventilated.
– Run the engine regularly, e.g. once a week, until it is warmed up. This will ensure that the machine remains operational and is ready to be used when needed. If this is impossible, extra precautions must be taken:
• Consult the engine’s operator manual.
• Remove the battery. Store it in a dry, frost-free room. Keep the battery clean and its terminals lightly covered with petroleum jelly. Recharge the battery regularly.
• Clean the light tower and protect all electrical components against moisture.
• Place silica gel bags, VCI paper (Volatile
Corrosion Inhibitor) or another drying agent inside the light tower and close the doors.
• Stick sheets of VCI paper with adhesive tape on the bodywork to close off all openings.
• Wrap the generator, except the bottom, with a protective tarpaulin to avoid possible damage and corrosion due to environmental conditions.
8.2
Preparing for operation after storage
Before operating the light tower again, remove the wrapping, VCI paper and silica gel bags and check the light tower thoroughly (go through the checklist
“Before starting” on page 27).
– Consult the engine’s operator manual.
– Check that the insulation resistance of the alternator exceeds 5 M Ω .
– Replace the fuel filter and fill the fuel tank. Vent the fuel system.
– Reinstall and connect the battery, if necessary after being recharged.
– Submit the light tower to a test run.
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9 Disposal
9.1
General
When developing products and services, Atlas Copco tries to understand, address, and minimize the negative environmental effects that the products and services may have, when being manufactured, distributed, and used, as well as at their disposal.
Recycling and disposal policy are part of the development of all Atlas Copco products. Atlas
Copco company standards determine strict requirements.
Selecting materials the substantial recyclability, the disassembly possibilities and the separability of materials and assemblies are considered as well as the environmental perils and dangers to health during the recycling and disposal of the unavoidable rates of not recyclable materials.
Your Atlas Copco light tower consists for the most part of metallic materials, that can be re-melted in steelworks and smelting works and that is therefore almost infinite recyclable. The plastic used is labelled; sorting and fractioning of the materials for recycling in the future is foreseen.
This concept can only succeed with your help. Support us by disposing professionally. By assuring a correct disposal of the product you help to prevent possible negative consequences for environment and health, that can occur with an inappropriate waste handling.
Recycling and re-usage of material helps to preserve natural resources.
9.2
Disposal of materials
Dispose contaminated substances and material separately, according to local applicable environmental legislation.
Before dismantling a machine at the end of its operating lifetime drain all fluids and dispose of according the applicable local disposal regulations.
Remove the batteries. Do not throw batteries into the fire (explosion risk) or into the residual waste.
Separate the machine into metal, electronics, wiring, hoses, insulation and plastic parts.
Dispose all components according to the applicable disposal regulations.
Remove spilled fluid mechanically; pick up the rest with absorbing agent (for example sand, sawdust) and dispose it according the applicable local disposal regulations. Do not drain into the sewage system or surface water.
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10 Technical specifications of the light tower
10.1 Technical specifications of the engine/alternator/unit
Reference conditions 1)
Limitations 2)
Performance data 2) 3) 4) 5)
Rated frequency
Rated speed
Generator service duty
Absolute air inlet pressure
Relative air humidity
Air inlet temperature
Maximum ambient temperature
Altitude capability
Maximum relative air humidity
Minimum starting temperature
Minimum starting temperature, with coldstart equipment (optional - to be developed)
Rated active power (PRP) 1 ph
Rated power factor (lagging) 1ph
Rated apparent power (PRP) 1ph
Rated voltage 1ph line to line voltage
Rated current 1ph
Performance class (acc. ISO 8528-5:1993)
Single step load acceptance (0-PRP)
Frequency droop (lower than % /isochronous)
Fuel consumption at no load (0%)
Fuel consumption at 50% load
Fuel consumption at 75% load
Fuel consumption at full load (100%)
Specific fuel consumption
Fuel autonomy at full load (100%) with standard tank
Max. oil consumption at full load
- 71 -
50 Hz (230V - 1ph)
50 Hz
1500 rpm
PRP
1 bar(a)
30%
25°C
50°C
3500 m
85%
-5°C
-25°C
4.9 kW
1 cos φ
4.9 kVA
230 V
21.3 A
G2
100%
4.9 kW isochronous
0.86 kg/h
1.11 kg/h
1.30 kg/h
1.88 kg/h
0.324 kg/kWh
55 h
0.02 l/h
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Application data
Design Data Engine
Maximum sound power level (Lw) complies with 2000/14/EC
Capacity of standard fuel tank
Single step load capability
Mode of operation
Site
Operation
Start-up and control mode
Start-up time
Mobility/Config. acc. to ISO 8528-1:1993
(optional)
Mounting
Climatic exposure
Status of neutral (TT or TN)
Standard
Make
Model
Rated net output
Rating type acc. ISO 3046-7
Coolant
Combustion system
Aspiration
Number of cylinders
Swept volume
Speed governing
Capacity of oil sump - Initial fill
Capacity of cooling system
Electrical system
Maximum permissible load factor of PRP during 24h period
- 72 -
90 dB(A)
109 l
100%
4.9 kW
PRP land use single manual/auto unspecified transportable mobile fully resilient open air earthed
ISO 3046
ISO 8528-2
Kubota
D1105-EBG2
8.4 kW
ICXN coolant indirect injection natural aspirated
3
1.12 l mechanical
5.1 l
3.1 l
12 Vdc
100%
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Design Data Alternator 4)
Electrical power circuit
Lights
Standard
Make
Model
Rated output, class H temperature rise
Rating type acc. ISO 8528-3
Degree of protection (IP index acc. NF EN 60-529)
Insulation stator class
Insulation rotor class
Number of wires
Circuit-breaker 1ph:
Number of poles
Thermal release (lt)
Fault current protection, residual current release, Idn
Circuit-breaker 1ph:
Number of poles
Thermal release (lt)
Magnetic release (lm)
Circuit-breaker 1ph:
Number of poles
Thermal release (lt)
Magnetic release (lm)
Number of lights
Type of lights
Light output
Lamps type
Tower height
- 73 -
IEC34-1
ISO 8528-3
MECCALTE
LT3N-160/4
8 kVA
"BR" 125/40°C
IP 21
H
H
4
2
40 A
0.03 A
1
16 A
5 x In
1
10 A
5 x In
4
Metal Halide
1000 W
9.5 A
8.6 m
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Notes
1)
2)
3)
4)
5)
6)
Reference conditions for engine performance to ISO 3046-1.
See derating diagram below or consult the factory for other conditions.
At reference conditions unless otherwise stated.
Rating definition (ISO 8528-1):
LTP: Limited Time Power is the maximum electrical power which a generating set is capable of delivering (at variable load), in the event of a utility power failure (for up to 500 hours per year of which a maximum of 300 hours is continuous running). No overload is permitted on these ratings. The alternator is peak continuous rated (as defined in ISO 8528-3) at 25°C.
PRP: Prime Power is the maximum power available during a variable power sequence, which may be run for an unlimited number of hours per year, between stated maintenance intervals and under the stated ambient conditions. A 10% overload is permitted for 1 hour in 12 hours. The permissible average power output during a 24h period shall not exceed the stated load factor as indicated on the AML.
Specific mass fuel used: 0.86 kg/l.
Thermal release is higher at 25°C.
50 Hz - Derating Table (in %, 100% is declared power in “Performance Data”)
Height
(m)
0
500
1000
1500
2000
2500
3000
3500
85
80
75
70
65
0
100
100
95
5
100
100
90
85
80
75
70
65
10
100
95
90
85
80
70
65
60
15
100
95
90
80
75
70
65
60
20
100
95
85
80
75
70
65
60
Temperature
(°C)
25
100
90
85
80
75
70
65
60
For use of generator outside these conditions, please contact Atlas Copco.
80
70
65
60
55
30
95
90
85
35
95
90
80
75
70
65
60
NA
40
95
85
80
75
70
65
60
NA
45
90
85
80
75
65
NA
NA
NA
50
90
85
75
70
65
NA
NA
NA
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00_00_HiLight H4_EN.book Page 75 Monday, April 18, 2016 2:10 PM
10.2 Critical bolt connections
Applications
Lifting beam to frame
Horizontal lifting beam to vertical lifting beam
Coupling housing alternator to flywheel housing engine
Rotor disk alternator to flywheel engine
Engine to engine support
Engine support to vibration damper engine
Vibration damper engine to frame
Alternator support to vibration damper alternator
Rotatory base to base frame
Floodlight support to top of the mast
Floodlight support to floodlight
Wheel to axle
Axle to frame
Towbar to frame
Towing eye to towbar
Standard torques
Type
M12
M12
3/8" UNC
5/16" UNC
M10
M10
M10
M10
M14
M12
M10
M12
M12
M12
M12
M4
M5
M6
M8
M10
M12
M14
Screw / Bolt / Nut
Material
8.8
8.8
8.8
8.8
8.8
8.8
8.8
8.8
8.8
8.8
8.8
8.8
8.8
8.8
8.8
8.8
8.8
8.8
8.8
8.8
8.8
8.8
Torque (Nm)
85
50
120
85
50
50
50
135
85
85
85
85
35
21
50
10
25
3
6
50
85
135
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00_00_HiLight H4_EN.book Page 76 Monday, April 18, 2016 2:10 PM
10.3 Average illumination versus distance
- 76 -
00_00_HiLight H4_EN.book Page 77 Monday, April 18, 2016 2:10 PM
10.4 Dimension drawings
10.4.1
Dimension drawing for HiLight H4 with fixed towbar
D E
I
G
H
E
F
I
C
D
A
B
HiLight H4
Total length (mm)
T o t a l w i d t h ( m m )
T o t a l h e i g h t ( m m )
Base frame length (mm)
Towbar length (mm)
Towbar heigth (mm)
Wheel track width (mm)
Front cantilever (mm)
Rear cantilever (mm)
See coupling system table
1 2 9 5
2 3 1 0
1700
See coupling system table
390
1025
See coupling system table
950
Type
AK160 HEAD Ø50
DIN EYE Ø 40
ITA EYE Ø 45
FRA EYE Ø 68
NATO EYE Ø 76
COUPLING SYSTEM
A
2709,5
2734
2741,5
2736
2744
E
947,5
972
979,5
974
982
H
1759,5
1784
1791,5
1786
1794
HiLight H4
Maximum empty weight (Kg.)
Minimum empty weight (Kg.)
TOWBAR
TOTAL
1185
Weight on axle
1102
TOTAL
1051,5
Weight on axle
978
Maximum Technically Permissible Laden Mass (Kg.) 1.300
Weight on towing eye
83
Weight on towing eye
73.5
A
H
- 77 -
G
B
Isometric view (1:30)
00_00_HiLight H4_EN.book Page 78 Monday, April 18, 2016 2:10 PM
10.4.2
Dimension drawing for HiLight H4 with adjustable towbar
D E
E1
D
E
E1
F
F1
A
A1
B
C
G
H
H1
I
HiLight H4 ARTICULATED TOWBAR
Total length (mm)
Total length 1 (mm)
T o t a l w i d t h ( m m )
T o t a l h e i g h t ( m m )
Base frame length (mm)
Towbar length (mm)
Towbar length 1 (mm)
Towbar height (mm)
Towbar height 1 (mm)
Wheel track width (mm)
Front cantilever (mm)
Front cantilever 1 (mm)
Rear cantilever (mm)
See coupling system table
A+145
1 2 9 5
2 3 1 0
1700
See coupling system table
E+145
890
515
1025
See coupling system table
H+145
950
Type
AK160 HEAD Ø50
DIN EYE Ø 40
UK EYE Ø 30
UK EYE Ø 40
COUPLING SYSTEM
A (mm)
3233,5
3290
3327
3287,5
E (mm)
1473,5
1530
1567
1527,5
UK EYE Ø 50,8
ITA EYE Ø 45
FRA EYE Ø 68
NATO EYE Ø 76
3304
3285
3259,5
3288
1544
1525
1499,5
1528
H (mm)
2283,5
2340
2377
2337,5
2354
2335
2309,5
2338
HiLight H4 ARTICULATEDTOWBAR
Maximum empty weight (Kg.)
Minimum empty weight (Kg.)
TOTAL
1230
TOTAL
1096,5
Weight on axle
1144
Weight on axle
1020
Maximum Technically Permissible Lade Mass (Kg.)
Weight on towing eye
85
Weight on towing eye
76.5
1.300
I H
H1
A
A1
- 78 -
G
B
Isometric view (1:30)
00_00_HiLight H4_EN.book Page 79 Monday, April 18, 2016 2:10 PM
10.4.3
Dimension drawing for HiLight H4 with not homologated towbar
D E
E
F
G
H
I
C
D
A
B
HiLight H4 NOT HOMOLOGATED TOWBAR
Total length (mm)
Total width (mm)
Total height (mm)
Base frame length (mm)
Towbar length (mm)
Towbar height (mm)
Wheel track width (mm)
Front cantilever (mm)
Rear cantilever (mm)
3095
1295
2240
1700
1395
451
1029
2225
870
I
A
H
- 79 -
G
B
Isometric view (1:30)
00_00_HiLight H4_EN.book Page 80 Monday, April 18, 2016 2:10 PM
10.5 Conversion list of SI units into British units
1 bar
1 g
1 kg
1 km/h
1 kW
1 l
1 l
1 l
1 m
1 mm
1 m³/min
1 mbar
1 N
1 Nm t
°F t
°C
=
=
=
=
=
=
=
=
=
=
=
=
=
=
14.504 psi
0.035 oz
2.205 lbs
0.621 mile/h
1.341 hp (UK and US)
0.264 US gal
0.220 lmp gal (UK)
0.035 cu.ft
3.281 ft
0.039 in
35.315 cfm
0.401 in wc
0.225 lbf
0.738 lbf.ft
= 32 + (1.8 x t
°C
= (t
°F
- 32)/1.8
)
A temperature difference of 1°C = a temperature difference of 1.8°F.
10.6 Data plate
14
15
16
13
3
4
GENERATOR SET ISOXXXX
FN
SN COP
PN COP
VN
IN
Cos ph xx
ESFXXXX
Y
Y
Y
Y
MADE IN XXXX
CE
MASA (Kg)
MODEL
HZ XX
KVA XXX
KW XXX
V XXX
A XXX
XXXX
XXXX
1
2
7
8
9
5
6
10
11
12
17
1 Name of manufacturer
2 Maximum permitted total weight of the vehicle
3 Machine type
4 Mode of operation
5 Model number
6 Frequency
7 Apparent power - PRP
8 Active power - PRP
9 Nominal rated voltage
10 Nominal rated current
11 Generator class
12 Manufacturing year
13 Winding connections
14 Power factor
15 Serial number
16 EEC mark in accordance with Machine Directive
89/392E
17 Address of manufacturer
- 80 -
00_00_HiLight H4_EN.book Page 81 Monday, April 18, 2016 2:10 PM
- 81 -
Circuit diagrams
00_00_HiLight H4_EN.book Page 82 Monday, April 18, 2016 2:10 PM
1636 0024 44/00_01
Applicable for HiLight H4, Controller Circuit a2 a2
S20 - Configuration
P1 P0
ON
OFF
REMOTE
P2
X11
7
X11
5 a3 a3 a3 a3 to Circ. Diagr POWER
Fuses F1-F2, Current Transfo.
a6 a2
A1 1 2 a0 a0 c8 c8
21 22 23 24 29 30 31 32 3 4 6 7 8 9 a3 a3
Legend
Wire size : Colour code :
0 = black
1 = brown
2 = red
3 = orange
4 = yellow
5 = green
6 = blue
7 = purple
8 = grey
9 = white
54 = green/yel.
lx = 95 mm² EPR-CSP (BS6195-4C) bx = 1.5 mm² NSGAFOeU
A
X11
4 3 2 1 a3 a3
K103 a3 a3
K101
K104 K102
Lc1003
B C D E F
18 19 20 5 10 11 12 13 14 15 16 17
G H I J K L M N O P
S2
21
22
Q
- 82 -
00_00_HiLight H4_EN.book Page 83 Monday, April 18, 2016 2:10 PM
A O P a3
Q c2 c2 c2 a2 a2 a2 a2
13
S20
P1
14 a2
23
S20
P2
24 a2
33
S20
P0
34
S51
13 11
14 14
41
K110
44 (2) a3
K110
P7 a3
A1
B1 B2 A2 a3
X11 a3 10 a3
X11
11
P7.1
a3
11
P7
14 a3
K111
X11
8 c2
F10
10A c2 a3
K100 K5 c2 a3 a3
X10
Canopy
Cubicle
14
14
X11
32
X11 X11
30 31
X11
14 a6 a6 a6
X10
9
9 c2
X10
1
1 c2
5
5 a6 c2 c2
Y10 a3 a6
1
1
2
2 a3 a6
Z1
(2) a3 a3
S31
21 13
22 14
(2) a3
21
S32
22
(2)
G1 j0 j6
M1
K0 j0 j6
M c2
K0
B C a6 a6 a6
D E F G H I J K L M N a3 a3
K4
15
18 a3 a3 a3 a3 a3 a3 a3 a3 a3 a3 a3 a3
S2
11 a6
11
K100
14
12
K5 a6 a6 a3 a3 a3 a3 a3
X10
13 10 6 11 12
13 10 6 11 12 a6 a6 a6
X25
10 a6
11 a6 a3 a3 a3 d2
K1 d2
E1 d2 e2 a3
G2
B+
D+
W
GND
S9 S8
B7 a6 a6 d2
K2 a3 d2
Y1 a6
KT10 a6 a3
X10
M6 a3 a6
KT10
3
3 a3 a3
4 2
4 2
H6 a6 a3
K2 a6
Time scale Multipier
1-10s 2 a3
K1 a6
Canopy
Cubicle
H
Function
- 83 -
K1
K2
K4
K5
Generator control unit
Fuel level sensor
Preheat resistor
Fuse 10A DC
Battery 12Vdc
Charging alternator
Preheat light
Starter solenoid
Preheat relay
Starter relay (pull)
Fuel control relay
Starter relay
K100 Remote start relay
K101-K104 Light control relay
K110
K111
Mast down aux. relay (2)
Mast up aux. relay (2)
S2
S8
S9
S20
KT10
M1
M6
P7
S31
S32
S51
G1
G2
H6
K0
A1
B7
E1
F10
00_00_HiLight H4_EN.book Page 84 Monday, April 18, 2016 2:10 PM
(1)
(2)
(3)
X10
X11
X25
Y1
Y10
Z1
(0.x)
Connector wire harness
Auxiliary terminals
Customer’s terminals
Fuel stop solenoid
Mast down solenoid
Buzzer (2)
Optional mains connection
(see 1636 0024 44/00_03)
Optional photocell
Optional auto mast down system
Optional override fuel shutdown
Timer
Starter motor
Fuel feed pump
Photocell (1)
Emergency stop
High coolant temperature switch
Low oil pressure switch
REMOTE/OFF/ON switch
Brake on switch (2)
Mast down switch (2)
Mast down pushbutton
- 84 -
00_00_HiLight H4_EN.book Page 85 Monday, April 18, 2016 2:10 PM
- 85 -
00_00_HiLight H4_EN.book Page 86 Monday, April 18, 2016 2:10 PM
1636 0024 44/00_02
Applicable for HiLight H4, Power Circuit
G3
C1
U2 V2
230V
50Hz
U1 V1 d0
X8
U1
X8 d0 d0
V1
X8
N e0 e6 d0 y54
PE e54
Q1
40A
30mA
T1
A B C a0 a6
F1
F2 a0 a0 c8 c8 to Circ. Diagr ENGINE
Control Module
Legend
Wire size : Colour code :
0 = black
1 = brown
2 = red
3 = orange
4 = yellow
5 = green
6 = blue
7 = purple
8 = grey
9 = white
54 = green/yel.
lx = 95 mm² EPR-CSP (BS6195-4C) bx = 1.5 mm² NSGAFOeU
V1-V4
W10
X1
X8
X10
X15
X16
X17
(O)
Q1
Q2
Q3
Q4
Q5
Q6
S50
T1
C1
C11-C14
E1-E4
F1-F2
G3
K111
L1-L4
M10
(1)
(2)
Capacitor (alternator regulation)
Capacitor
Ignitor
Fuses 2A
Alternator
Mast up aux. relay (2)
Ballast
Pump
Earth leakage 40A/30mA
Circuit breaker 16A
Circuit breaker 16A
Circuit breaker 16A
Circuit breaker 16A
Circuit breaker 10A
Mast up pushbutton
Current transformer
Floodlight (lamp 1000W)
Spiral cable
Outlet socket 16A
Alternator power terminals
Connector wire harness
AC terminals
Connector lighting
Lighting terminals
Optional mains connection
(see 1636 0024 44/00_03)
Optional photocell
Optional auto mast down system
- 86 -
00_00_HiLight H4_EN.book Page 87 Monday, April 18, 2016 2:10 PM
A B C
Q2
16A b0 b0 b6
Q3
16A b0 b6 b0
Q4
16A b0 b6 b0
Q5
16A b0 b6
Q6
10A b0 b6 b0 b0
S50 b0
13
14 b6 b54 b0 b0
C11 b6 b0
C12 b6 b0
C13 b6 b0
C14
Cubicle
Ballast housing
E1
L1
RD
BK
BU b0
X15
13
Cubicle
Mast b0
X16
W10
1
1
1
X17
12 b6
13
2
2
2 b6
V1 b0 b54
X15
23
X15
33
X15
43
E2
L2
RD
BK
BU b0 b0
3
3
3
X17
22 b6
23
4
4
4 b6
V2 b0 b54
E3
L3
RD
BK
BU b0 b0
5
5
5
X17
32 b6
33
6
6
6 b6
V3 b0 b54
E4
L4
RD
BK
BU b0 b0
7
7
7 b6 b54
8
8
8 PE
PE
PE
V4 b0
42 b6
43 PE b54
X1 b0 b6
16A b54
X15 b6
51
X10 b0 b54
16 8 PE
16 8 PE b0 b6
M10
U1 V1 W1 PE
W2 U2 V2
X15
N
X15
L
X15
51 b0
11
K111
14 b0
X10
16
- 87 -
00_00_HiLight H4_EN.book Page 88 Monday, April 18, 2016 2:10 PM
1636 0024 44/00_03
Applicable for HiLight H4, Mains Connection (optional) a2 a3 a3 a3 a3
X11
7
14
S10a
P1
13
16
S10a
P2
15 a2 a2
X11
5 a2 a2
41
K100
44 a2 a2 a2 a2
42
41
44 32 34
31
22 24
21
12 14
11 K106
X11
4 3 2 1 a3 a3 a3 a3 a3
K106 K104
K103
K102
K101 d0 e0 d0
X8
U1
X8
V1 e6 y54
X2
32A Mains
230V - 50Hz e54 e0 e6
S10
1
0
2
2
1-3
4 6
5-7
8 10 12
9-11 e0 e6
PE e54 a54 a6 a0
PE
X15
X15
N
L a0
20
S10
P2 19 a6 a6 a6
S10 - Configuration
GENERATOR
OFF
MAINS a6 a6 a6 a6 a6 a6 a6
H15 a0
L
PE
B-
N
B+
U1 a0
L N
P8
2 4 6 a3 a3 a2 a6
- 88 -
U1
X2
X8
X11
X15
(O)
H15
K100
K101-K104
K106
P8
S10
Mains light (0)
Remote start relay
Light control relay
Mains aux. relay (0)
Timer (scheduler) (0)
GENSET/OFF/MAINS-switch (0)
(see 1636 0024 44/00_02)
Battery charger (0)
Inlet socket 32A (0)
Alternator power terminals
Auxiliary terminals
AC terminals
Optional mains connection
Legend
Wire size : Colour code :
0 = black
1 = brown
2 = red
3 = orange
4 = yellow
5 = green
6 = blue
7 = purple
8 = grey
9 = white
54 = green/yel.
lx = 95 mm² EPR-CSP (BS6195-4C) bx = 1.5 mm² NSGAFOeU
00_00_HiLight H4_EN.book Page 89 Monday, April 18, 2016 2:10 PM
1636 0024 45/00
Applicable for HiLight H4, Wire Harness, Homologated Road
Connector - ISO 114466
6
5
7
4
13
8
9
1
3
10
2
12
11
FUNCTION
Flasher left
Fog light
Common - GND
Flasher right
Tail light right
Stop light / Plate lamp
WIRE COLOUR CONNECTOR
PIN NUMBER
Yellow
Blue
1
2
White
3
Green 4
Brown 5
Red 6
Tail light left
Reversing light
Black
Grey
7
8
Not used
Not used
9
10
LEFT
REAR LIGHT
FL
S
N
ST
TL
11
Not used
Not used
Not used
12
13
RIGHT
REAR LIGHT
N
FL
TL
ST
R
- 89 -
00_00_HiLight H4_EN.book Page 90 Monday, April 18, 2016 2:10 PM
- 90 -
00_00_HiLight H4_EN.book Page 91 Monday, April 18, 2016 2:10 PM
Following documents are provided with this unit:
– Test Certificate
– EC Declaration of Conformity:
6
7
4
5
2
3
1
EC DECLARATION OF CONFORMITY
We, Grupos Electrogenos Europa S.A., declare under our sole responsibility, that the product
Machine name : Power Generator
Commercial name :
Serial number :
Which falls under the provisions of the 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. b.
Directive on the approximation of laws of the
Member States relating to
Machinery safety 2006/42/EC
Harmonized and/or Technical
Standards used
EN ISO 12100-1
EN ISO 12100-2
At t’ mnt d.
Electromagnetic compatibility 2004/108/EC
UNE EN 12601
EN 61000-6-2
EN 61000-6-4 e.
Low voltage equipment 2006/95/EC
EN 60034
EN 60204-1
EN 60439 f.
Outdoor noise emission
11
12
13
14
15
8.a
8.b
9
10
The harmonized and the technical standards used are identified in the attachments hereafter
Grupos Electrógenos Europa, S.A. is authorized to compile the technical file
Conformity of the specification to the
Directives
Conformity of the product to the specification and by implication to the directives
Issued by
Name
Product Engineering
Signature
Manufacturing
16
Place , Date Muel (Zaragoza), Spain
Grupos Electrógenos Europa, S.A.
Postal address
Poligono Pitarco II, Parcela 20
50450 Muel ZARAGOZA
Phone: +34 902 110 316
Fax: +34 902 110 318
A company within the Atlas Copco Group
Spain www.atlas copco.com
For info, contact your local Atlas Copco representative
V.A.T A50324680 p.1(10)
- 91 -
00_00_HiLight H4_EN.book Page 92 Monday, April 18, 2016 2:10 PM
– Outdoor Noise Emission
Directive 2000/14/EC:
Outdoor Noise Emission Directive 2000/14/EC
1. Conformity assessment procedure followed
2. Name and address of the notified body
: Full Quality Assurance
: Notified body number 0499
SNCH, Societé Nationale de Certification et d´Homologation
L-5201 Sandweiler
3. Measured sound power level
4. Guaranteed sound power level
5. Electric power
:
:
: dB(A) dB(A) kW
Grupos Electrógenos Europa, S.A.
Postal address
Poligono Pitarco II, Parcela 20
Phone: +34 902 110 316
Fax: +34 902 110 318
A company within the Atlas Copco Group
50450 Muel ZARAGOZA
Spain For info, contact your local Atlas Copco representative www.atlas copco.com
V.A.T A50324680 p.2(10)
- 92 -
00_00_HiLight H4_EN.book Page 93 Monday, April 18, 2016 2:10 PM

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