Atlas Copco HiLight V4 Instruction Manual
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Atlas Copco HiLight V4 Instruction Manual

Atlas Copco HiLight V4 Instruction Manual

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Instruction Manual
For Portable Light Tower Generator
English
HiLight V4 K
HiLight V4+ K
HiLight V5+ K
Instruction Manual
Engine Kohler KDW702

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Summary of Contents for Atlas Copco HiLight V4

  • Page 1 Instruction Manual Instruction Manual For Portable Light Tower Generator English HiLight V4 K Engine Kohler KDW702 HiLight V4+ K HiLight V5+ K...
  • Page 3 HiLight V5+ K 60HZ ROW HiLight V4 K 50HZ CE HiLight V4+ K 50HZ CE HiLight V5+ K 50HZ CE HiLight V4 K S 60HZ US HiLight V5+ K S 60HZ US Original instructions Printed matter No. 2960 2190 00 ATLAS COPCO - PORTABLE ENERGY DIVISION www.atlascopco.com...
  • Page 4 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.

  • Page 5: Table Of Contents

    Engine operation ........25 5.4.5 Lights ............. 26 Please read the obeying instructions carefully before Main parts - HiLight V4 ......6 starting to use your light tower. Floodlight lux level - HiLight V5+ ... 27 Main parts - HiLight V5+......7 It is a solid, safe and reliable machine, built Maintenance ..........
  • Page 6 (WEEE) ..............85 Dimension Drawing - HiLight V5+..86 Dimensional Drawing - HiLight V5+..87 Dimensional Drawing - HiLight V4 ..88 Data plate ..........90 Maintenance Log ........91 - 6 -...
  • Page 7 - 7 -...

  • Page 8: Main Parts - Hilight V4

    Main parts - HiLight V4 The light tower provides an undercarriage (frame, axle and towbar) and four floodlights of 1000 W each or four LED floodlights of 350 W each. The light tower is very useful for construction sites where neither electricity nor lighting is available.

  • Page 9: Main Parts - Hilight V5

    Main parts - HiLight V5+ - 7 -...

  • Page 10: Safety Information

    Do not position light tower unit and contact Atlas Copco. CAUTION under power lines. Crush hazard. Ensure the trailer is well grounded, per all...

  • Page 11: Engine Safety

    Engine safety CAUTION DANGER Operator safety Risk of severe burn. Asphyxiation hazard. Before handling lights, allow - Operate the engine outdoors DANGER lights to cool for 15 minutes. and keep away from engine exhaust. Explosion hazard. - If operating in an enclosed - Keep engine, fuel, and other area, vent exhaust fumes to combustibles away from...

  • Page 12: California Proposition 65

    Service safety During servicing CAUTION Risk of severe burn. • Keep hands, feet, and loose clothing away from Before servicing moving parts on engine and generator. - Do not touch the engine, exhaust pipes, or areas near • Keep the light tower and all its components clean. the exhaust at rear of trailer.

  • Page 13: Labels

    Labels Labels provide instructions and information. They also warn of hazards. For convenience and safety, keep all labels in legible condition, replacing labels when damaged or missing. Replacement labels are available from the factory. Samples of labels and their descriptions are provided in Table 1.1. Label locations - 11 -...
  • Page 14 Table 1.1 Label samples and descriptions Label Description Label Description 1092 6814 00 Decal: Electrical shock Decal: Tyre Pressure 1092 6819 00 Decal: Operation manual 1092 6805 00 Decal: Towing instruction - 12 -...
  • Page 15 Label Description Label Description 1092 6829 00 Decal: High voltage Decal: Flash 1092 6812 00 Decal: Light 1092 6813 00 Decal: Poison - 13 -...
  • Page 16 Label Description Label Description 1094 2280 00 Decal: Danger electrical 1079 9919 51 Decal: Rotation direction power line Decal: Replace wire or winch 1092 6822 00 Decal: Fan - 14 -...
  • Page 17 Label Description Label Description Fork lift Decal: Hot 1092 6806 00 Decal: Lifing hook 1092 6824 00 Decal: Grounding round - 15 -...
  • Page 18 Label Description Label Description Decal: ATLAS COPCO black Decal: ATLAS COPCO white - 16 -...

  • Page 19: Assembly

    Assembly Tow hitch Notice Check and unload loose parts before unloading units There are three options for tow hitch. from container. Pintle hook A - Drawbar with towing hitch (option) 2-inch-ball B - Lifting jack Combo hitch for a 2-inch-ball and pintle hook For combo hitch option only: When the light tower ships from the factory, the tow bar is set up to use the lunette ring for towing by a...

  • Page 20: Light Fixture Wiring

    Light fixture wiring - 18 -...

  • Page 21: Operation

    Operation Safety Towing and hoisting Before towing Before operating the light tower, read and be familiar with this instruction manual. Before towing, prepare the light tower as follows. Read and obey all safety instructions (see page 8). 1. Lower the light tower: a Make sure that the light tower mast is in the CAUTION down position and secured in place with the...

  • Page 22: During Towing

    After towing c Make sure that the rear and side levelling jacks are in the up position, the outriggers are contracted, and all are secured with their Release the trailer tow hitch from the tow vehicle as locking pins. follows: d Use the drawbar-mounted jack to raise the front 1.

  • Page 23: Location

    Location Figure 3.2 Hoisting ring and forklift slots • To achieve the best possible light coverage, locate the light tower on the same level as the area to be lighted, or higher. • To reduce the risk of personal injury, ensure the surrounding area is in good order and free of debris.

  • Page 24: Deployment

    Deployment 7. Pull the jack locking pin and rotate the jack e Take the weather into account: do not raise or downward until the locking pin engages. Do not use the tower in high winds or an electrical lower the jack foot yet. storm.
  • Page 25 2. To raise the tower, see Figure 3.5 and obey these instructions: a Remove the horizontal-lock pin from the transport cradle. b Rotate the handle of the drawbar-mounted winch to tighten the cable and raise the light tower mast. Raising the tower - 23 -...

  • Page 26: Lowering The Tower

    Lowering the tower Before moving or storing the light tower, lower the mast and lock it in place. To lower the tower, see Figure 3.6 and use the following instructions. 1. Turn off the tower lights and the engine. For increased lamp life, allow the lights to cool for 15 minutes before proceeding.

  • Page 27: Engine Operation

    Engine operation • Crank the engine immediately after the indicator light goes out. CAUTION Starting the engine 3. When the glow-plug indicator light goes out, turn and hold the key at the START position. The engine can overheat and damage the 1.

  • Page 28: Lights

    Stopping the engine • After the metal halide lamps are turned off, they Lamps that will not turn on will not turn on again until they are cool. The To stop the engine: If the lamps do not light when power is applied, lamps can take up to 15 minutes to cool.

  • Page 29: Floodlight Lux Level - Hilight V5

    Floodlight lux level - HiLight Lamps Rotation angle Inclination angle Case Angle Lamp 1 Lamp 2 Lamp 3 Lamp 4 Inclination Rotation Inclination Rotation 80-70 80-70 80-70 80-70 Inclination -180 Rotation Inclination Rotation - 27 -...
  • Page 30 Case 1 Case 2 60 m 50 m Average Lux: 23 Average Lux: 23 4000 m² 3600 m² - 28 -...
  • Page 31 Case 3 Case 4 Average Lux: 20 Average Lux: 33 5000 m² 2500 m² Lux level: - 29 -...

  • Page 32: Maintenance

    Maintenance Daily inspection Lamp replacement c Remove the screws securing the flange rings and remove the flange rings. When the light tower is in regular use, the following To replace a light bulb (lamp), obey the instructions d Remove the protective lamp cover with the items should be checked daily: below.

  • Page 33: Lamp Positioning

    Lamp positioning Transport mode • Horizontal position Tilting • Release the safety screw • Rotate the lamps as per your desired position - 31 -...

  • Page 34: Circuit Diagrams For Hilight V4

    Circuit Diagram Circuit diagrams for HiLight V4 9829 3552 00-01 - 32 -...
  • Page 35 9829 3552 00-02 - 33 -...
  • Page 36 9829 3552 00-03 - 34 -...
  • Page 37 9829 3552 00-04 - 35 -...
  • Page 38 9829 3552 00-05/01 - 36 -...
  • Page 39 9829 3552 00-05/02 - 37 -...
  • Page 40 9829 3552 00-06/01 - 38 -...
  • Page 41 9829 3552 00-06/02 - 39 -...
  • Page 42 9829 3552 00-07 - 40 -...
  • Page 43 9829 3552 00-08 - 41 -...
  • Page 44 9829 3552 60-01 - 42 -...
  • Page 45 9829 3552 60-02 - 43 -...
  • Page 46 9829 3552 60-03 - 44 -...
  • Page 47 9829 3552 60-04 - 45 -...
  • Page 48 9829 3552 60-05 - 46 -...

  • Page 49: Circuit Diagrams For Hilight V5

    Circuit diagrams for HiLight V5+ 9829 3552 50-01 - 47 -...
  • Page 50 9829 3552 50-02 - 48 -...
  • Page 51 9829 3552 50-03 - 49 -...
  • Page 52 9829 3552 50-04 - 50 -...
  • Page 53 9829 3552 50-05 - 51 -...
  • Page 54 9829 3552 50-06 - 52 -...
  • Page 55 9829 3552 50-07 - 53 -...
  • Page 56 9829 3552 65-01 - 54 -...
  • Page 57 9829 3552 65-02 - 55 -...
  • Page 58 9829 3552 65-03 - 56 -...
  • Page 59 9829 3552 65-04 - 57 -...
  • Page 60 9829 3552 65-05 - 58 -...

  • Page 61: Wiring Diagrams

    Wiring diagrams DANGER High voltage. Contact with live electrical circuits will cause severe injury or death. • Turn off power before servicing any component on the light tower. • Only a qualified electrician should service the light tower electrical system. - 59 -...
  • Page 62 Wiring Diagrams ELECTRICAL SYSTEM - 60 -...
  • Page 63 Wiring Diagrams ELECTRICAL SYSTEM - 61 -...

  • Page 64: Axle Maintenance Manual

    Axle maintenance manual Axle - 62 -...

  • Page 65: Safety Precautions

    Safety precautions Wheel bolt tightening torque Re-adjust axle bearing axial clearance: • Welding or drilling on shaft tube is not allowed. 1. Remove the wheels and wheel covers. Thread Hexagon Tightening torque • Select the matching wheel hub: wheel offset, PCD Size square 2.

  • Page 66: Setting The Lc1003™ Controller

    Setting the Lc1003™ controller DOWN: Is used for navigating the Controller settings should only be instrumentation, event log and performed by a qualified technician. STOP: Is used to activate Stop/Reset configuration screens and to go to the mode. When pressing the STOP next parameter level.

  • Page 67: Module Display

    Module display Icon overview Display Description Appears when the event log is Instrumentation icons Home page being displayed Display Description The home page is the page displayed when no other The default home page which Current time held in the unit page is selected: displays Generator voltage and the Auto Run icon...

  • Page 68: Mode Icons

    Front panel editor (FPE) / Auto Run icons Navigation menu Display Description To enter the navigation menu, press both the UP and Appears when the unit is in the Display Description DOWN buttons simultaneously. front panel editor. To navigate to the desired page, select the Appears when a remote start input corresponding icon by pressing the UP and DOWN is active.

  • Page 69: Event Log

    To view the event log: Display Description 1. Press the UP and DOWN buttons simultaneously Event Log to display the navigation menu. 2. Once entered, cycle to the event log section (1) and enter. Event log 3. To view the event log, repeatedly press the UP or The Lc1003™...
  • Page 70 Menu flow Configuration Parameters – Scheduler Enable Scheduler On (1), Off (0) Schedule Run On or Off On (1), Load Off (0) Schedule Period Weekly (0), Monthly (1) Scheduler (1) 0:00:00 Start Time Scheduler (1) Start Day (1=Monday) Scheduler (1) 1,2,3,4 Start Week Scheduler (1) Duration...
  • Page 71 Setting the Lc1003™ clock Setting the Lc1003™ timer 907 Scheduler duration Set the desired time period. When this value is set, 1. Enter the weekly timer menu by pressing the 1. Enter the weekly timer menu as described above. Event 1 is closed. STOP and AUTO button simultaneously.
  • Page 72 Setting the sensitivity regulator There are two blinking levels: ASM (Auto Rise and Lower Safety Mast) The photocell sensitivity regulator is used for -Level 1: Slow blinking The ASM option provides the possibility to not only switch on/off the floodlights automatically, but also regulating the luminosity sensitivity level of the The photocell detects enough light, according photocell.

  • Page 73: Maintenance

    3002 6088 90 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 administration costs and are offered at a reduced price, compared to individual components. Refer to the parts list for more information on the contents of the service kits.
  • Page 74 (5). Gummed or clogged filters means fuel starvation filter must be cleaned and replaced more frequently in and reduced engine performance. (2). HiLight V4 add 4.1L oil, use of CJ-4 (PAROIL very dusty conditions. Replaced the air filter element Extra) oil grade.

  • Page 75: Maintenance Schedule For V5

    3002 6088 90 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 administration costs and are offered at a reduced price, compared to individual components. Refer to the parts list for more information on the contents of the service kits.
  • Page 76 Every 1000 hrs Check emergency stop Clean radiator Replace air filter element (1), (8) Inspection by Atlas Copco service technician Inspect starter motor Inspect waterpump Inspect alternator Check engine protective devices Check valve in the fuel return line (for mechanical injection...
  • Page 77 Hilight V4/V5+ PACK & KIT AC PN SERVICE PACK 50H V5+ Kohler 3002608900 SERVICE PACK 250H V5+ Kohler 3002608870 SERVICE PACK 500H Kohler 3002608890 SERVICE PACK 50H V4 Kohler 3002608900 SERVICE PACK 250H V4 Kohler 3002608880 SERVICE PACK 500H Kohler...

  • Page 78: Fuel

    FUEL For fuel specifications, please contact your Atlas Misfueling with fuels of higher sulfur level can have the following negative effects: Copco Customer Center. • Shorten the time interval between aftertreatment DIESEL FUEL RECOMMENDATIONS device service intervals (cause the need for more frequent service intervals).

  • Page 79: Technical Specification

    Technical specification Unit Designation HiLight V4 HiLight V4 HiLight V5+ HiLight V5+ Reference conditions (see note 1 and 4) 1. Rated frequency 2. Rated speed 3000 3600 1500 1800 3. Generator service duty 4. Absolute inlet pressure 5. Relative air humidity 6.
  • Page 80 Designation Unit HiLight V4 HiLight V4 HiLight V5+ HiLight V5+ Fuel consumption at 2 lamps on kg/h 1.40 1.68 0.52 0.59 Fuel consumption at 3 lamps on kg/h 1.59 1.97 0.56 0.71 Fuel consumption at 4 lamps on kg/h 1.86 2.16...
  • Page 81 Designation Unit HiLight V4 HiLight V4 HiLight V5+ HiLight V5+ 3. Model EK 2 MCT EK 2 MCT ACA132BL ACA132BL 4. Rated output, class H temp. rise 5. Degree of protection °C 125/40 125/40 6. Rating type (acc. ISO 8528-3) 7.

  • Page 82: Circuit Breaker

    Designation Unit HiLight V4 HiLight V4 HiLight V5+ HiLight V5+ Power circuit Circuit-breaker 1. Number of poles 2. Thermal release 31.25 31.25 12.5 12.25 (b) (c) 3. Magnetic release 1.25xIn 1.25xIn 1.25xIn 1.25xIn Fault current protection 1. Residual current release 0.03...
  • Page 83 DERATING FACTOR LIGHT TOWER (%) 50 Hz 60 Hz LED 50/60 Hz For use of light tower outside these conditions, please contact Atlas Copco - 81 -...

  • Page 84: Options

    Options Spark arresters Tow hitch Towing hitch combo IMPORTANT! There are three options for tow hitch. State and local safety codes specify that, in certain - Pintle hook locations, internal combustion engines that use - 2-inch-ball hydrocarbon fuels must be used with spark arrestors. - Combo hitch for a 2-inch-ball and pintle hook A spark arresters is a device constructed of For combo hitch option only:...

  • Page 85: Cubicle Elcb With Universal Socket 230V 50Hz

    Towing hitch Ring 2.5 inch Cubicle ELCB with universal Road light system socket 230V 50Hz Cubicle ELCB without socket 230V 50Hz E-Stop Control panels The light tower control panel comprises: • Circuit breakers for engaging power • An electrical receptacle for powering external equipment (Option) Cubicle with Universal socket •...
  • Page 86 Earthing pin Battery isolator DC E-winch Adjustable towing support - 84 -...

  • Page 87: Disposal

    For more information check with your local waste and dispose it according the applicable local Your Atlas Copco generator consists for the most authority, customer center or distributor. disposal regulations. Do not drain into the sewage part of metallic materials, that can be remelted in system or surface water.

  • Page 88: Data Plate

    Data plate 1. Name of manufacturer 2. Model 3. Serial number 4. Vehicle identification number 5. Gross vehicle weight rating 6. Gross axle weight rating 7. Tire number 8. Cold pressure 9. Dimension 10. Manufacturing year WEEE symbol Code - 86 -...

  • Page 89: Dimension Drawing - Hilight V5

    Dimension Drawing - HiLight V5+ 1234,4 [48,598] Lifting eye(Ø50) Service Door Cleaning Cooler Cooling Air Inlet Emergency Stop(Option) Cooling Air Outlet Exhaust Outlet Earthing Pin(option) Frame Drain Frame Drain 252,5 [9,941] H=920 [36,220] I=1870 [73,626] K=1034 [40,722] B=1108 [43,628] Isometric View ( 1 : 10 ) Center of Gravity Maintenance Space ( 1 : 10 ) Coolant Filling...

  • Page 90: Dimensional Drawing - Hilight V5

    Dimensional Drawing - HiLight V5+ Extendion View ( 1 : 10 ) 2317,5 [91,241] - 88 -...
  • Page 91 Dimensional Drawing - HiLight V4 - 89 -...

  • Page 92: Data Plate

    Dimensional Drawing - HiLight V4 - 90 -...

  • Page 93: Maintenance Log

    Maintenance Log Light tower ......................Customer ........................Serial number................................................Service hours Maintenance action Date By: initials - 91 -...
  • Page 94 - 92 -...

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Hilight v5+Hilight v4 kHilight v5+ k

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