Atlas Copco HiLight H4 Kd ESF Instruction Manual Download Page 6

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4.2.6.3 Switching on/off the

floodlights automatically.................31

4.2.7

Lowering the mast ...........................31

4.2.8

Stopping the engine ........................32

4.3

Connecting appliances ....................33

4.4

Setting the Lc1003™ controller......34

4.4.1

Push button and LED
functions ...........................................34

4.4.2

Module display.................................35

4.4.2.1 Home page .......................................35

4.4.3

Icon overview ...................................35

4.4.3.1 Instrumentation icons ......................35

4.4.3.2 Active configuration.........................36

4.4.3.3 Front panel editor (FPE) / Auto

Run icons ..........................................36

4.4.3.4 Mode icons .......................................36

4.4.3.5 Light output icons ............................36

4.4.3.6 Alarm icons.......................................36

4.4.4

Navigation menu..............................37

4.4.5

Event log ...........................................37

4.4.6

Setting the Lc1003™ timer ..............37

Periodic maintenance

.................39

5.1

Maintenance schedule.....................39

5.1.1

Precautions .......................................44

5.1.2

Use of maintenance schedule.........44

5.1.3

Use of service packs ........................44

5.2

Preventing low loads .......................45

5.2.1

General..............................................45

5.2.2

Risks of low load operation.............45

5.2.3

Best practices ...................................45

5.3

Maintenance of the alternator ........45

5.3.1

Measuring the alternator
insulation resistance ........................45

5.4

Engine maintenance procedures ....46

5.4.2

Engine oil level check.......................46

5.4.3

Engine oil and oil filter change .......47

5.4.4

Coolant check ...................................48

5.5

Adjustments and service
procedures ........................................49

5.5.1

Battery care.......................................49

5.5.2

Replacing fuel filter and pre-
filter element.....................................51

5.5.3

Servicing air filter engine ................51

5.5.4

Air cooling circuit .............................52

5.5.5

Replacing the lamps.........................52

5.5.6

Ordering spare parts ........................53

5.6

Resetting service alarms .................53

5.7

Engine consumable
specifications....................................53

5.7.1

Engine fuel specifications................53

5.7.2

Engine oil specifications ..................53

5.7.3

Engine coolant specifications..........54

Checks and trouble
shooting

..........................................56

6.1

Engine troubleshooting...................56

6.2

Solving controller alarms ................56

6.2.1

General..............................................56

6.2.2

Alarm overview ................................57

Options available for
HiLight H4 units

............................63

7.1

Overview of the mechanical
options ..............................................63

7.2

Description of the mechanical
options ..............................................63

7.2.1

Undercarriage...................................63

7.3

Overview of the electrical
options ..............................................64

7.4

Description of the electrical
options ..............................................64

7.4.1

Auto mast down system ..................64

7.4.2

Photocell ...........................................65

7.4.3

External power input (230
VAC), with battery charger ..............66

7.4.4

Override fuel shutdown ...................68

7.4.5

Earth pin ............................................68

Storage of the light tower

.........69

8.1

Storage..............................................69

8.2

Preparing for operation after
storage ..............................................69

Disposal

...........................................70

9.1

General..............................................70

9.2

Disposal of materials .......................70

00_00_HiLight H4_EN.book Page 6 Monday, April 18, 2016 2:10 PM

Summary of Contents for HiLight H4 Kd ESF

Page 1: ...Instruction Manual User and maintenance manual for light towers English HiLight H4 Kd ESF D1105 EBG2 01_00_Front Page AC_EN fm Page 1 Monday April 18 2016 12 06 PM ...

Page 2: ...00_00_HiLight H4_EN book Page 2 Monday April 18 2016 2 10 PM ...

Page 3: ...ascopco com Printed matter N 2954 9590 00 04 2015 HiLight H4 Kd ESF User and maintenance manual for light towers User and maintenance manual 5 Circuit diagrams 81 Original instructions 00_00_HiLight H4_EN book Page 3 Monday April 18 2016 2 10 PM ...

Page 4: ...g 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 prohi...

Page 5: ...he light tower onto vehicles 25 3 3 Installation 25 3 3 1 Indoor installation 25 3 3 2 Outdoor installation 26 3 4 Connecting the light tower 26 3 4 1 Precautions for non linear and sensitive loads 26 4 Operating instructions 27 4 1 Before starting 27 4 2 Operating the light tower 27 4 2 1 Before the engine is started 27 4 2 2 Starting the engine 28 4 2 3 Positioning the floodlights 28 4 2 4 Exten...

Page 6: ...nge 47 5 4 4 Coolant check 48 5 5 Adjustments and service procedures 49 5 5 1 Battery care 49 5 5 2 Replacing fuel filter and pre filter element 51 5 5 3 Servicing air filter engine 51 5 5 4 Air cooling circuit 52 5 5 5 Replacing the lamps 52 5 5 6 Ordering spare parts 53 5 6 Resetting service alarms 53 5 7 Engine consumable specifications 53 5 7 1 Engine fuel specifications 53 5 7 2 Engine oil sp...

Page 7: ...versus distance 76 10 4 Dimension drawings 77 10 4 1 Dimension drawing for HiLight H4 with fixed towbar 77 10 4 2 Dimension drawing for HiLight H4 with adjustable towbar 78 10 4 3 Dimension drawing for HiLight H4 with not homologated towbar 79 10 5 Conversion list of SI units into British units 80 10 6 Data plate 80 00_00_HiLight H4_EN book Page 7 Monday April 18 2016 2 10 PM ...

Page 8: ... 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 m...

Page 9: ...imits 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 ...

Page 10: ... 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 ...

Page 11: ...rvous 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 n...

Page 12: ...y 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 ...

Page 13: ...r tamper with the sound damping material Keep the material free of dirt and liquids such as fuel oil and cleansing agents If any sound damping material is damaged replace it to prevent the sound pressure level from increasing 13 Use only lubricating oils and greases recommended or approved by Atlas Copco or the machine manufacturer Ascertain that the selected lubricants comply with all applicable ...

Page 14: ...hecking 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 hou...

Page 15: ... Control panel DP Data plate EP Earth pin optional FCC Filling cap coolant FCF Filling cap fuel FL Floodlights FS Forklift slots HB Handbrake LH Leveling handle to adjust the height of the supporting foot LPS Locking pin stabilizer M Mast RHM Rotating handles mast ST Stabilizer and supporting foot TB Towbar U Undercarriage FCC M FL FL TB CP FS FS U EP DP FCF DP ST HB LPS LH RHM 00_00_HiLight H4_EN...

Page 16: ... risk of fire This label is required for On Road transport into the European Union according to the European agreement concerning international carriage of Dangerous goods by Road Annex A 3 Indicates that the mast should not be extended near electric wires Indicates the forklift slots Indicates that the unit cannot be lifted from the back part Indicates the locking pin of the stabilizers Indicates...

Page 17: ...ry HiLight H4 Engine D1105 EBG2 Fuel tank capacity 109 L 28 85 U S GALS Oil sump capacity 5 1 L 1 35 U S GALS Cool system capacity 3 1 L 0 82 U S GALS Hyd oil capacity 5 L 1 32 U S GALS Alternator LT3N 160 4 Tyre pressure Full tank load 575 kg 3 5 Bar 51 Psi Fluids Description Order Nr PAROIL E 5L 1 1GAL 1615 5953 00 PAROIL E 20L 4 4GAL 1615 5954 00 PAROIL E 209L 45 98GAL 1615 5955 00 PAROIL E XTR...

Page 18: ...e 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 tow...

Page 19: ...et 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 emergen...

Page 20: ...l and earthing 3 different versions are available Socket CE 2P 16A Socket RIM 2P 16A Socket PIN 2P 16A Q6 Circuit breaker for X1 Interrupts the power supply to X1 when a short circuit occurs at the load side or when the overcurrent protection 10 A is activated When activated Q6 interrupts phase F and the neutral towards X1 It can be activated again after eliminating the problem Q6 X1 Q2 Q3 Q4 Q5 Q...

Page 21: ...lots are provided in the frame at the left and right side of the unit 3 2 Parking and towing 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 Lifting acceleration and deceleration must be kept within safe limits max 2 g Helicopter lifting is not allowed The o...

Page 22: ...g 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 Towing on page 24 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 ...

Page 23: ...allation instructions see also Installation on page 25 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 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 Check the levels 6 on top of the light t...

Page 24: ... tower is correctly arranged for transport 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 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 a...

Page 25: ...t 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 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 runni...

Page 26: ...tics of the light tower Check that the cable end of the earth pin is connected to the earth terminal 3 4 Connecting the light tower 3 4 1 Precautions for non linear and sensitive loads 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 arra...

Page 27: ...onal External power input 230 VAC is installed select the desired operating mode with S10 Genset OFF Mains 2 See also External power input 230 VAC with battery charger on page 66 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 ...

Page 28: ...mperature 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 2 Check the tightness of the nuts on top of the lamps 2 Torque if necessary 3 Loosen the handle at the side of the floodlight 3 and adjust the inclination of the floodlight 4 Tighten the handle again when the floodlight is in the desired position 5...

Page 29: ... red indication on the mast 6 max 9 metres 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 Lock the mast again using its locking pin 1 If the Mast Down option is provided the mast can only be extended if the handbrake is engaged For ...

Page 30: ...tton on the Lc1003 module 1 to shut down the lamps 6 Place the 4 automatic switches Q2 5 2 in their OFF position 7 Wait for the lamps to cool down this will take about 10 minutes 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 Q2 Q3 Q4 ...

Page 31: ...r the mast using the DOWN button on the control panel 1 Only applicable with timer or optional Photocell Q2 Q3 Q4 Q5 Q1 40A 30mA Q6 X1 X2 0 1 P8 GE ON Q1 Q2 Q3 Q4 Q5 Q6 2 1 3 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 Mind your hea...

Page 32: ...omatic 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 Q2 Q3 Q4 Q5 Q1 40A 30mA Q6 X1 X2 0 1 P8 GE ON Q1 Q2 Q3 Q4 Q5 Q6 4 5 1 2 3 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 ...

Page 33: ...e 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 10 Stop the engine See section 4 2 8 Keep in mind that this machine is a light tower not a generator set Power is limited to 10 Amps Q2 Q3 Q4 Q5 Q1 40A 30mA Q6 X1 X2 0 1 P8 GE ON Q1 Q2 Q3 Q4 Q5 Q6 1 2 If...

Page 34: ...o 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 3 START Is used to start the unit in Manual mode It is also used to switch off the floodlights manually S20 ON 4 UP Is used for navigating the instrumentation event log and configuration screens and to go to the previous param...

Page 35: ... 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 Appears when the event log is being displayed Current time held in the unit The current valu...

Page 36: ...n 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 ...

Page 37: ...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 ...

Page 38: ...n or Off Load On 1 Off 0 903 Schedule Period Weekly 0 Monthly 1 904 Scheduler 1 Start Time 0 00 00 905 Scheduler 1 Start Day 0 1 Monday 906 Scheduler 1 Start Week 1 2 3 4 907 Scheduler 1 Duration 0 00 00 908 Scheduler 2 Start Time 0 00 00 00_00_HiLight H4_EN book Page 38 Monday April 18 2016 2 10 PM ...

Page 39: ...ave 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 x Check Fill fuel level x Empty air filter vacuator valve x Check engine oil level if necessary top up x Check coolant level x Check control panel for alarms and warnings x Check on abnorma...

Page 40: ...x Check electrolyte if applicable battery terminals 5 x x x x Analyse coolant x x Grease locks and hinges x x Check rubber flexibles 3 x x Drain Clean fuel tank water and sediments x Inspect clean fuel tank breather filter x x Replace fuel tank breather filter x x Adjust engine inlet and outlet valves 6 x Check engine protective devices x x Inspect starter motor x x Inspect charging alternator 7 x...

Page 41: ... of projectors x x x x Check Replace adjustable plates condition x x Check electrical cable condition and upper fixation clamp x x x x Grease the mast collar 8 x x Grease the mast adjustable plates contact surface only 8 x x Grease cylinder rotule 8 x x Change hydraulic oil 1 x x Undercarriage Check tyre pressure 1 x x x x Check tyres for uneven wear x x Check torque of wheel nuts x x Check torque...

Page 42: ...alisation x Check brake pads wear x Change wheel hub bearing grease 8 x Critical bolts connections torques values Lifting beam to frame x x Horizontal lifting beam to vertical lifting beam x x Coupling housing alternator to flywheel housing engine x Rotor disk alternator to flywheel engine x Engine to engine support x x Engine support to vibration damper engine x x Vibration damper engine to frame...

Page 43: ...r 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 Maintenance schedule Daily Every 250 hours Every 500 hours Every 750 hours Yearly Service pack 1636 3103 31 1636 3103 32 1636 3103 33 00_00_HiLight H4_EN book Page 43 Monday April 18 2016 2 10 PM ...

Page 44: ...hen 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 se...

Page 45: ...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 periodi...

Page 46: ... 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 For the intervals see section Maintenance schedule on page 39 Use Atlas Copco engine oil PAROIL E or PAROIL Extra Check the engine oil leve...

Page 47: ...ule 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 5 After the new cartridge has been replaced the engine oil level normally decreases a ...

Page 48: ...o 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 pH measurement Check the pH value of the coolant using a pH measuring device The pH meter can be ordered from Atlas Copco with part numb...

Page 49: ...nk 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 eng...

Page 50: ... 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 i...

Page 51: ...h 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 filt...

Page 52: ...ring 2 placed around the lamp and then unscrewing the lamp from its seat 3 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 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 Do not touch ...

Page 53: ...e ambient temperature and ISO 3448 as follows 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 specif...

Page 54: ...f performance and protection in standard ambient conditions as from 10 C 5 7 3 Engine coolant specifications 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 manufa...

Page 55: ...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...

Page 56: ... the same time the Alarm Icon automatically cycles through all the appropriate icons to indicate each alarm which is active 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 vibrati...

Page 57: ...easured from the W L terminal Low fuel level The level detected by the fuel level sensor is below the low fuel level setting Battery Under Voltage The DC supply has fallen below or risen above the low volts setting level Battery Over Voltage The DC supply has risen above the high volts setting level Generator Under Voltage The generator output voltage has fallen below the pre set pre alarm setting...

Page 58: ...configured trip level Delayed Over Current The measured current has risen above the configured trip level for a configured duration Low Current The measured current has fallen below the configured trip level This is used to detect lamp failure Oil Filter Maintenance Alarm Maintenance due for oil filter Air Filter Maintenance Alarm Maintenance due for air filter Fuel Filter Maintenance Alarm Mainte...

Page 59: ... 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 Reason Engine High Temperature 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 Low Fuel Level T...

Page 60: ...ns it is not possible to reset the unit Display Description Reason Fail To Start The engine has failed to start after the configured number of start attempts Low Oil Pressure 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 Under Speed The engine speed has fallen below the under speed pre alarm setti...

Page 61: ... risen above the pre set pre alarm setting Emergency Stop 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 Oil Sender Open Circuit The oil pressure sensor has been detected as being open circuit Coolant Temperature Sender Open Circuit The coolant temperature sensor has been detected as being o...

Page 62: ...ntenance due for oil filter Air Filter Maintenance Alarm Maintenance due for air filter Fuel Filter Maintenance Alarm Maintenance due for fuel filter Display Description Reason 00_00_HiLight H4_EN book Page 62 Monday April 18 2016 2 10 PM ...

Page 63: ...as 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 ...

Page 64: ...es please consult the parts manual 7 3 Overview of the electrical options The following electrical options are available Auto mast down system Photocell External power input 230 VAC with battery charger Override fuel shutdown Earth pin 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 h...

Page 65: ...rding 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 The recommended value to set the regulator is at 50...

Page 66: ... socket for connection to the mains 32A Setting the timer 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 Q2 Q3 Q4 Q5 Q1 40A 30mA Q6 X1 X2 0 1 P8 GE ON Q1 Q2 Q3 Q4 Q5 Q6 X2 S10 H15 P8 menu Press the menu key to enter the editing menu When in the editing ...

Page 67: ...OFF trigger follow the menu flow above and select OFF after selecting SWITCH pulse off copy 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 00_00_HiLight H4_EN book Page 67 Monday April 18 2016 2 10 PM ...

Page 68: ...3 switches off At 10 fuel level Lamp 4 switches off 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 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 00_00_...

Page 69: ...on 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 wrapp...

Page 70: ... future is foreseen 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 residua...

Page 71: ... developed 25 C Performance data 2 3 4 5 Rated active power PRP 1 ph 4 9 kW Rated power factor lagging 1ph 1 cos φ Rated apparent power PRP 1ph 4 9 kVA Rated voltage 1ph line to line voltage 230 V Rated current 1ph 21 3 A Performance class acc ISO 8528 5 1993 G2 Single step load acceptance 0 PRP 100 4 9 kW Frequency droop lower than isochronous isochronous Fuel consumption at no load 0 0 86 kg h F...

Page 72: ...nt Climatic exposure open air Status of neutral TT or TN earthed Design Data Engine Standard ISO 3046 ISO 8528 2 Make Kubota Model D1105 EBG2 Rated net output 8 4 kW Rating type acc ISO 3046 7 ICXN Coolant coolant Combustion system indirect injection Aspiration natural aspirated Number of cylinders 3 Swept volume 1 12 l Speed governing mechanical Capacity of oil sump Initial fill 5 1 l Capacity of...

Page 73: ...lectrical power circuit Circuit breaker 1ph Number of poles 2 Thermal release lt 40 A Fault current protection residual current release Idn 0 03 A Circuit breaker 1ph Number of poles 1 Thermal release lt 16 A Magnetic release lm 5 x In Circuit breaker 1ph Number of poles 1 Thermal release lt 10 A Magnetic release lm 5 x In Lights Number of lights 4 Type of lights Metal Halide Light output 1000 W L...

Page 74: ... 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 t...

Page 75: ...ine support to vibration damper engine M10 8 8 50 Vibration damper engine to frame M10 8 8 50 Alternator support to vibration damper alternator M10 8 8 50 Rotatory base to base frame M14 8 8 135 Floodlight support to top of the mast M12 8 8 85 Floodlight support to floodlight M10 8 8 50 Wheel to axle M12 8 8 120 Axle to frame M12 8 8 85 Towbar to frame M12 8 8 85 Towing eye to towbar M12 8 8 85 St...

Page 76: ... 76 10 3 Average illumination versus distance 00_00_HiLight H4_EN book Page 76 Monday April 18 2016 2 10 PM ...

Page 77: ...table I Rear cantilever mm 950 HiLight H4 HiLight H4 FIXED TOWBAR Type A E H AK160 HEAD Ø50 2709 5 947 5 1759 5 DIN EYE Ø 40 2734 972 1784 ITA EYE Ø 45 2741 5 979 5 1791 5 FRA EYE Ø 68 2736 974 1786 NATO EYE Ø 76 2744 982 1794 COUPLING SYSTEM 1 300 FIXED TOWBAR Maximum Technically Permissible Laden Mass Kg Maximum empty weight Kg Minimum empty weight Kg D C G I H F Isometric view 1 30 B A E TOTAL ...

Page 78: ...ilever mm 950 HiLight H4 ARTICULATED TOWBAR Maximum Technically Permissible Lade Mass Kg 1 300 HiLight H4 ARTICULATEDTOWBAR Maximum empty weight Kg Minimum empty weight Kg Type A mm E mm H mm AK160 HEAD Ø50 3233 5 1473 5 2283 5 DIN EYE Ø 40 3290 1530 2340 UK EYE Ø 30 3327 1567 2377 UK EYE Ø 40 3287 5 1527 5 2337 5 UK EYE Ø 50 8 3304 1544 2354 ITA EYE Ø 45 3285 1525 2335 FRA EYE Ø 68 3259 5 1499 5 ...

Page 79: ...295 C Total height mm 2240 D Base frame length mm 1700 E Towbar length mm 1395 F Towbar height mm 451 G Wheel track width mm 1029 H Front cantilever mm 2225 I Rear cantilever mm 870 HiLight H4 NOT HOMOLOGATED TOWBAR D C G Isometric view 1 30 F A B E I H 00_00_HiLight H4_EN book Page 79 Monday April 18 2016 2 10 PM ...

Page 80: ...ET ISOXXXX MODEL FN HZ XX Y KVA XXX SN COP Y KW XXX PN COP Y V XXX VN Y A XXX IN XXXX Cos ph xx ESFXXXX XXXX MADE IN XXXX CE 3 14 15 16 4 2 8 7 6 5 12 17 11 10 9 1 13 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 Generato...

Page 81: ... 81 Circuit diagrams 00_00_HiLight H4_EN book Page 81 Monday April 18 2016 2 10 PM ...

Page 82: ...bus Interface 0 Vdc Batt 12 24 Vdc Batt Genarator Voltage L1 Genarator Voltage L2 Genarator Voltage L3 Genarator Voltage Neutral Genarator Current Transfo L1 Genarator Current Transfo L2 Genarator Current Transfo L3 Genarator Current common COM Fuel Control Relay Output Start Relay Output Output Light 1 Control Output Light 2 Control Output Light 3 Control Output Light 4 Control Output 17 OUT 3 OU...

Page 83: ...c2 1 d2 2 1 a3 16 d2 17 d2 25 a3 12 a6 12 a6 12 a6 4 a3 25 a3 4 a3 12 a6 12 a6 e2 1 d2 1 d2 13 19 19 19 19 c2 8 12 a6 35 a3 64 a3 12 12 a6 a6 61 a3 62 a3 63 a3 12 a6 12 a6 12 a6 9 9 X10 1 1 5 5 12 a6 12 a6 12 a6 12 a6 12 a6 2 a3 10 a3 6 a3 7 a3 11 15 a3 a3 5 a3 25 a3 14 a3 26 a3 15 18 4 a3 4 a3 4 a3 20 a3 28 a3 11 12 11 14 29 a6 K5 S2 K100 K4 K4 KT10 H6 KT10 13 10 6 11 12 13 10 6 11 12 12 a6 12 a6...

Page 84: ...M1 Starter motor M6 Fuel feed pump P7 Photocell 1 S2 Emergency stop S8 High coolant temperature switch S9 Low oil pressure switch S20 REMOTE OFF ON switch S31 Brake on switch 2 S32 Mast down switch 2 S51 Mast down pushbutton X10 Connector wire harness X11 Auxiliary terminals X25 Customer s terminals Y1 Fuel stop solenoid Y10 Mast down solenoid Z1 Buzzer 2 0 x Optional mains connection see 1636 002...

Page 85: ... 85 00_00_HiLight H4_EN book Page 85 Monday April 18 2016 2 10 PM ...

Page 86: ...le for HiLight H4 Power Circuit C1 Capacitor alternator regulation C11 C14 Capacitor E1 E4 Ignitor F1 F2 Fuses 2A G3 Alternator K111 Mast up aux relay 2 L1 L4 Ballast M10 Pump Q1 Earth leakage 40A 30mA Q2 Circuit breaker 16A Q3 Circuit breaker 16A Q4 Circuit breaker 16A Q5 Circuit breaker 16A Q6 Circuit breaker 10A S50 Mast up pushbutton T1 Current transformer V1 V4 Floodlight lamp 1000W W10 Spira...

Page 87: ... 141 RD BK BU b6 b0 b6 b0 b6 b0 b6 b0 b6 b0 b0 b6 b54 b0 b0 b6 b0 b0 14 16 11 51 13 14 51 16 8 PE 16 8 U1 V1 W1 PE U2 W2 V2 PE 153 153 153 151 152 S50 b54 b6 Canopy Cubicle Cubicle Mast Cubicle Mast Cubicle Ballast housing Q2 Q3 L1 E1 X16 W10 X17 23 22 3 3 3 4 4 4 b0 123 PE 122 b6 b54 X17 33 32 43 42 5 5 5 7 7 7 8 8 8 PE PE PE PE 6 6 6 b0 133 PE 132 143 142 b6 b54 X17 V2 V3 b0 PE b6 b54 V4 V1 E2 E...

Page 88: ...41 31 21 11 1 2 3 4 X11 X11 X11 K103 K100 K101 K102 K104 K106 K106 44 e6 2 4 6 810 12 9 11 PE 5 7 1 3 1R e0 PE 4 V1 U1 e54 X2 X8 S10 X8 y54 d0 N1 N N L N L Q1_N Q1_PH e6 L1 e0 e6 e54 a54 a6 a0 a0 442 30 31 13 12 a0 442 a0 a3 a3 a2 a6 U1 P8 a6 H15 L L N N PE B B a6 N a6 PE L N 20 2 4 6 19 X15 X15 S10 P2 V1 U1 1 d0 e0 32A 1636 0024 44 00_03 Applicable for HiLight H4 Mains Connection optional H15 Mai...

Page 89: ...t Blue 2 S Common GND White 3 N N Flasher right Green 4 FL Tail light right Brown 5 TL Stop light Plate lamp Red 6 ST ST Tail light left Black 7 TL Reversing light Grey 8 R Not used 9 Not used 10 Not used 11 Not used 12 Not used 13 1636 0024 45 00 Applicable for HiLight H4 Wire Harness Homologated Road 00_00_HiLight H4_EN book Page 89 Monday April 18 2016 2 10 PM ...

Page 90: ... 90 00_00_HiLight H4_EN book Page 90 Monday April 18 2016 2 10 PM ...

Page 91: ...alth and Safety Requirements of this directive The machinery complies also with the requirements of the following directives and their amendments as indicated Directive on the approximation of laws of the Member States relating to Harmonized and or Technical Standards used Att mnt b Machinery safety 2006 42 EC EN ISO 12100 1 EN ISO 12100 2 UNE EN 12601 d Electromagnetic compatibility 2004 108 EC E...

Page 92: ...s Copco representative www atlas copco com p 2 10 Form 1636003857 ed 01 2014 12 09 Outdoor Noise Emission Directive 2000 14 EC 1 Conformity assessment procedure followed Full Quality Assurance 2 Name and address of the notified body 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 Ele...

Page 93: ...00_00_HiLight H4_EN book Page 93 Monday April 18 2016 2 10 PM ...

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