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

Atlas Copco HiLight V4 K Instruction Manual

Portable light tower
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Instruction Manual
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HiLight V4 K
HiLight V5+ K
Engine Kohler KDW702
HiLight V7+ K
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Summary of Contents for Atlas Copco HiLight V4 K

  • Page 1 Instruction Manual Instruction Manual For Portable Light Tower English HiLight V4 K HiLight V5+ K Engine Kohler KDW702 HiLight V7+ K...
  • Page 3 HiLight V7+ K 60Hz ROW HiLight V4 K 50Hz CE HiLight V5+ K 50Hz CE HiLight V7+ K 50Hz CE HiLight V4 K S 60Hz US HiLight V7+ K S 60Hz US Original instructions Printed matter No. 2962 0750 00 ATLAS COPCO - POWER AND FLOW 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

    6.4.1 Levelling the trailer........ 24 6.4.2 Raising the tower ........24 Please read the obeying instructions carefully before Main parts - HiLight V4 K ......7 6.4.3 Lowering the tower........ 26 starting to use your light tower. 6.4.4 Engine operation ........27 Main parts - HiLight V5+ K......
  • Page 6 11.3 U-bolt nut tightening torque ....... 76 Setting the Lc1003™ controller ....77 12.1 Push button and LED functions....77 12.2 Module display ........... 78 12.3 Home page..........78 12.4 Icon overview ..........78 12.5 Fuel............. 85 Technical specification ......86 Options ............

  • Page 7: Main Parts - Hilight V4 K

    Main parts - HiLight V4 K The light tower provides an undercarriage (frame, axle and towbar) and four floodlights of 1000 W each. The light tower is very useful for construction sites where neither electricity nor lighting is available. - 7 -...

  • Page 8: Main Parts - Hilight V5+ K

    Main parts - HiLight V5+ K The light tower provides an undercarriage (frame, axle and towbar) and 4 LED lamps of 250 W each. The light tower is very useful for construction sites where no electricity nor lighting is available. - 8 -...

  • Page 9: Main Parts - Hilight V7+ K

    Main parts - HiLight V7+ K The light tower provides an undercarriage (frame, axle and towbar) and 4 LED lamp of 350 W each. The light tower is very useful for construction sites where no electricity nor lighting is available. - 9 -...

  • 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 - 13 -...
  • Page 14 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 - 14 -...
  • Page 15 Label Description Label Description 1092 6829 00 Decal: High voltage Decal: Flash 1092 6812 00 Decal: Light 1092 6813 00 Decal: Poison - 15 -...
  • 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 - 16 -...
  • Page 17 Label Description Label Description Fork lift Decal: Hot 1092 6806 00 Decal: Lifing hook 1092 6824 00 Decal: Grounding round - 17 -...
  • Page 18 Label Description Label Description Decal: ATLAS COPCO black Decal: ATLAS COPCO white - 18 -...

  • 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 - 20 -...

  • 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 information. 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 horizontal-lock pin.

  • 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 - 25 -...

  • 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

    Floodlight lux level Lamps Rotation angle Inclination angle Lamp 1 Lamp 2 Lamp 1 Lamp 2 Lamp 3 Lamp 4 Lamp 3 Lamp 4 Case Angle Lamp 1 Lamp 2 Lamp 3 Lamp 4 Height Inclination 67.5 67.5 67.5 67.5 Rotation Inclination 67.5...

  • Page 30: Hilight V5+ K

    HiLight V5+ K Case 1 Case 2 69 m 63 m Average Lux: 21 Average Lux: 20 Light coverage: 5000 Light coverage: 4761 - 30 -...
  • Page 31 Case 3 Case 4 Average Lux: 20 Average Lux: 20 Light coverage: 4900 Light coverage: 5000 Lux level: - 31 -...

  • Page 32: Hilight V7+ K

    HiLight V7+ K Case 1 Case 2 82 m 92 m Average Lux: 20 Average Lux: 20 Light coverage: 7360 Light coverage: 6724 - 32 -...
  • Page 33 Case 3 Case 4 Average Lux: 20 Average Lux: 20 Light coverage: 7235 Light coverage: 7260 Lux level: - 33 -...

  • Page 34: Maintenance

    Daily inspection Lamp replacement QR code Scan the QR code to access into the Atlas Copco When the light tower is in regular use, the following To replace a light bulb (lamp), obey the instructions Power Connect site. Enter the machine serial number items should be checked daily: below.

  • Page 35: Servicing The Engine

    Lamp positioning c Remove the screws securing the flange rings and remove the flange rings. d Remove the protective lamp cover with the Transport mode gasket attached. • Horizontal position e Remove the hardware securing one side of the Tilting lamp stabilizer.

  • Page 36: Maintenance Schedule For Hilight V4 K

    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 37 Check rubber flexibles 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 38: Maintenance Schedule For Hilight V5

    3002 6091 00 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 reduces price, compared to the loose components. Refer to the parts list for more information on the contents of the service kit.
  • Page 39 Check rubber flexibles Check emergency stop Clean radiator Replace air filter element Check/Replace safety cartridge 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 system)
  • Page 40 Notes : (1) More frequently when operating in a dusty environment. (2) HiLight V5+ add 2L oil. (3) After a days work. (4) Change coolant every 2 years, coolant volume is 4L. (5) Gummed or clogged filters means fuel starvation and reduced engine performance. (6) See section Starting the engine.

  • Page 41: Maintenance Schedule For Hilight V7

    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 42 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 43 Hilight V4/HiLight V7+ PACK & KIT AC PN SERVICE PACK 50H V7+ Kohler 3002608900 SERVICE PACK 250H V7+ Kohler 3002608870 SERVICE PACK 500H Kohler 3002608890 SERVICE PACK 50H V4 Kohler 3002608900 SERVICE PACK 250H V4 Kohler 3002608880 SERVICE PACK 500H Kohler 3002608890 Oil filter 1094366900...

  • Page 44: Dimension Drawings

    Dimension drawings HiLight V4 K - 44 -...
  • Page 45 - 45 -...

  • Page 46: Hilight V5+ K

    HiLight V5+ K 9829 3911 02-01 1132 [44,567] Lifting Eye R20 [R0,791] Service door Cleaning Cooler Cooling Air Inlet Cooling Air Outlet Exhaust Air Outlet 711 [27,992] 1849 [72,797] 632 [24,863] 920 [36,220] 1076 [42,362] 819,8 [32,277] 1139 [44,856] Maintenance space Center of gravity Isometric View R686 [R27,008]...
  • Page 47 9829 3911 02-02 Extension View - 47 -...

  • Page 48: Hilight V7+ K

    HiLight V7+ K 9829 3989 02-01 1132 1270,4 Lifting eye( Service Door for 310,8 Cleaning Cooler Exhaust Air Outlet 1447 1044,3 1870,1 1076 2914,4 Isometric View ( 1 : 10 ) - 48 -...
  • Page 49 9829 3989 02-02 - 49 -...

  • Page 50: Circuit Diagrams

    Circuit Diagram HiLight V4 K 9829380189-01 - 50 -...
  • Page 51 9829380189-02 - 51 -...
  • Page 52 9829380190 - 52 -...
  • Page 53 9829355200-03 - 53 -...
  • Page 54 9829355200-04 - 54 -...
  • Page 55 9829355200-05 - 55 -...
  • Page 56 9829355200-06 - 56 -...
  • Page 57 9829355200-08 - 57 -...

  • Page 58: Hilight V5+ K And Hilight V7+ K

    HiLight V5+ K and HiLight V7+ K 9829380189-01 - 58 -...
  • Page 59 9829380189-02 - 59 -...
  • Page 60 9829380190 - 60 -...
  • Page 61 9829355290-01 - 61 -...
  • Page 62 9829355290-02 - 62 -...
  • Page 63 9829355290-03 - 63 -...
  • Page 64 9829355250-04 - 64 -...
  • Page 65 9829355250-05 - 65 -...
  • Page 66 9829355250-06 - 66 -...
  • Page 67 9829355250-07 - 67 -...
  • Page 68 9829355200-08 - 68 -...
  • Page 69 9829355251-01 Applicable for HILIGHT V5+, AC power circuit 230V 50Hz for no socket or Weipu socket; 240V 60Hz for Weipu socket 230V - 50Hz 240V - 60Hz Earth leakage connection diagram 60HZ 230V - 50Hz 60HZ 50HZ 240V - 60Hz 50HZ Note6 Note6...
  • Page 70 9829355251-02 Applicable for V5+, AC power circuit 120V 60Hz for no socket or Duplex socket Earth leakage connection diagram 120V - 60Hz 60HZ 120V - 60Hz 50HZ 60HZ 50HZ Note1 Alternator Main breaker 20A Q1.1 Earth leakage breaker 30mA Note1 Fuse 2A Fuse 2A Terminals...
  • Page 71 9829355251-03 Applicable for Hilight V5+, AC power circuit 120/240V 60Hz Legend 1 Wire size : Colour code : a = AWG16 0 = black b = AWG14 1 = brown 120/240V - 60Hz c = AWG12 2 = red d = AWG10 3 = orange 60HZ e = AWG8...

  • Page 72: 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. - 72 -...
  • Page 73 Wiring diagrams ELECTRICAL SYSTEM - 73 -...
  • Page 74 Wiring diagrams ELECTRICAL SYSTEM - 74 -...

  • Page 75: Axle Maintenance Manual

    Axle maintenance manual Axle - 75 -...

  • Page 76: Safety Precautions

    Wheel bolt tightening torque Safety precautions Re-adjust axle bearing axial clearance: • Welding or drilling on shaft tube is not allowed. 4. Remove the wheels and wheel covers. Thread Hexagon Tightening torque • Select the matching wheel hub: wheel offset, PCD Size square 5.

  • Page 77: 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 78: Module Display

    Module display Icon overview Display Description Instrumentation icons Appears when the event log is 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 79: 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 80: 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 81 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 82 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 83 Setting the sensitivity regulator There are two blinking levels: The photocell sensitivity regulator is used for -Level 1: Slow blinking regulating the luminosity sensitivity level of the The photocell detects enough light, according photocell. to its set sensitivity level. When the red LED (1) on the regulator is blinking, the -Level 2: Fast blinking regulator is reading the luminosity level measured by The photocell detects there is a prolonged...
  • Page 84 ASM (Auto Rise and Lower Safety Mast) The ASM option provides the possibility to not only switch on/off the floodlights automatically, but also to extend/lower the mast automatically. WARNING Before activating the ASM option, Make sure that the lighting tower is properly positioned, away from overhead power cables or other obstructions.

  • Page 85: Fuel

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

  • Page 86: Technical Specification

    Technical specification Unit Designation HiLight V4 K HiLight V4 K HiLight V7+ K HiLight V7+ K HiLight V5+ K HiLight V5+ K Reference conditions (see note 1 and 4) 1. Rated frequency 2. Rated speed 1500 1800 1500 1800 3000 3600 3.
  • Page 87 Unit Designation HiLight V4 K HiLight V4 K HiLight V7+ K HiLight V7+ K HiLight V5+ K HiLight V5+ K Fuel consumption at 3 lamps on kg/h 1.59 1.97 0.56 0.71 0.422 0.570 Fuel consumption at 4 lamps on kg/h 1.86...
  • Page 88 Designation Unit HiLight V4 K HiLight V4 K HiLight V7+ K HiLight V7+ K HiLight V5+ K HiLight V5+ K 2. Make Sincro Sincro Atlas Copco Atlas Copco Atlas Copco Atlas Copco 3. Model EK 2 MCT EK 2 MCT...
  • Page 89 Unit Designation HiLight V4 K HiLight V4 K HiLight V7+ K HiLight V7+ K HiLight V5+ K HiLight V5+ K Power circuit Circuit-breaker 1. Number of poles 1.25xIn or 2. Thermal release It (b) (c) 31.25 31.25 12.5 1.25xIn 1.45xIn 1.25xIn or...
  • Page 90 DERATING FACTOR LIGHT TOWER (%) MH 50 Hz MH 60 Hz LED 50/60 Hz For use of light tower outside these conditions, please contact Atlas Copco - 90 -...

  • Page 91: 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 92: Cubicle Elcb With Universal Socket 230V 50Hz

    Towing hitch Ring 2.5 inch Road light system Cubicle ELCB with universal 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).
  • Page 93 Earthing pin Battery isolator DC E-winch Adjustable towing support - 93 -...

  • Page 94: 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 95: 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 - 95 -...

  • Page 96: Maintenance Log

    Maintenance log Light tower ......................Customer ........................Serial number...................... Service hours Maintenance action Date By: initials - 96 -...
  • Page 98 Scan the QR code to access into the Atlas Copco Power Connect site. Enter the machine serial number to get the Atlas Copco Spare Parts List (ASL).

This manual is also suitable for:

Hilight v5+ kHilight v7+ k

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