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

Atlas Copco HiLight V4 WUX Instruction Manual

Portable light tower generator
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Instruction Manual
For Portable Light Tower Generator
English
HiLight V4 WUX
HiLight V5+ WUX
Instruction Manual
Engine Kubota Z482

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Summary of Contents for Atlas Copco HiLight V4 WUX

  • Page 1 Instruction Manual Instruction Manual For Portable Light Tower Generator English HiLight V4 WUX Engine Kubota Z482 HiLight V5+ WUX...
  • Page 3 Instruction Manual For Portable Light Tower Generator HiLight V4 WUX Engine Kubota Z482 HiLight V5+ WUX Original instructions Printed matter N° ATLAS COPCO - PORTABLE ENERGY DIVISION 2960 1130 00 www.atlascopco.com 09/2017...
  • 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

    Table of contents Preface 5.5.4 Engine operation ........25 5.5.5 Lights ............. 26 Please read the following instructions carefully before starting to use your light tower. Floodlight lux level ........27 Main parts - HiLight V4 ......6 It is a solid, safe and reliable machine, built Maintenance ..........

  • Page 6: Main Parts - Hilight V4

    Main parts - HiLight V4 "The light tower provides an undercarriage ( frame, axle and towbar ) and 4 floodlights of 1000 W each or 4 LED floodlights of 350 W each. The light tower is very useful for construction sites where neither electricity nor lighting is available." - 6 -...

  • Page 7: Main Parts - Hilight V5

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

  • Page 8: Safety Information

    Contact with overhead from the unit and contact Atlas Copco. electrical power lines will cause serious injury or death. CAUTION - Do not position light - Ensure the trailer is well grounded, per all...

  • Page 9: Engine Safety

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

  • Page 10: California Proposition

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

  • Page 11: 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. Figure 1.1 Label locations - 11 -...
  • Page 12 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 13 Label Description Label Description 1092 6829 00 Decal : High voltage Deacl : Flash 1092 6812 00 Decal : Light 1092 6813 00 Decal : Poison - 13 -...
  • Page 14 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 15 Label Description Label Description Fork lift Decal : Hot 1092 6806 00 Decal : Lifing hook 1092 6824 00 Decal : Grounding round - 15 -...
  • Page 16 Label Description Label Description Decal : ATLAS COPCO black Decal : ATLAS COPCO white - 16 -...

  • Page 17: Assembly

    Assembly Tow hitch Assemble loose parts before use Notice There are 3 options for tow hitch. Check and unload loose parts before unloading units - Pintle hook from container. - 2-inch-ball • A - Drawbar with towing hitch ( option ) - Combo hitch for a 2-inch-ball and pintle hook •...

  • Page 18: Light Fixtures

    Light fixture wiring - 18 -...

  • Page 19: 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 follow all safety instructions (see page 8). 1. Lower the light tower: a Verify the light tower mast is in the down CAUTION position and secured in place with the...

  • Page 20: During Towing

    c Verify the rear and side levelling jacks are in the 2. Pull the locking pin and rotate the jack downward. up position, the outriggers are contracted, and When the jack is properly set, the locking pin all are secured with their locking pins. snaps into position with an audible “click.”...

  • Page 21: 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 22: Deployment

    Deployment the locking pin snaps into position with an audible d Connect the trailer ground stud to earth ground “click.” (see Figure 3.3). 7. Pull the jack locking pin and rotate the jack e Take the weather into account: do not raise or Levelling the trailer downward until the locking pin engages.
  • Page 23 2. To raise the tower, see Figure 3.5 and follow 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. Figure 3.5 Raising the tower - 23 -...

  • Page 24: 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 25: Engine Operation

    Engine operation 3. When the glow-plug indicator light goes out, turn Starting the engine and hold the key at the START position. 1. Before starting the engine: 4. Release the key as soon as the engine starts, or after 10 seconds if the engine does not start. a Observe all engine safety precautions in page b Check engine oil, fuel, and coolant levels.

  • Page 26: 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 27: Floodlight Lux Level

    Floodlight lux level - HiLight V5+ 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 28 Case 1 Case 2 60 m 50 m Average Lux: 23 Average Lux: 23 4000 m² 3600 m² - 28 -...
  • Page 29 Case 3 Case 4 Average Lux: 20 Average Lux: 33 5000 m² 2500 m² Lux level: - 29 -...

  • Page 30: 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), refer to Figure 4.1 and d Remove the protective lamp cover with the items should be checked daily: follow the instructions below.

  • Page 31: Wiring Diagrams

    Wiring diagrams Lamp Positioning DANGER Transport mode High voltage. • Horizontal position Contact with live electrical circuits will cause severe injury or death. Tilting • Turn off power before • Release the safety screw servicing any component • Rotate the lamps as per your desired position on the light tower.

  • Page 32: Circuit Diagram

    Circuit diagram 9829 3552 00-01 Applicable for HiLight V4, HiLight V5+, engine circuit - 32 -...
  • Page 33 9829 3552 00-02 Applicable for HiLight V4, engine control circuit Preheat Start B(30) BR(AC) R1(19) C(17) R2(50) Notes, 1, When emergency stop switch is applied, this wire shall be replaced by switch wire 2. For standard and CE cubicles, wires should comply with CE. - 33 -...
  • Page 34 9829 3552 00-03 HiLight V4, HiLight V5+, - 34 -...
  • Page 35 9829 3552 00-04 HiLight V4, - 35 -...
  • Page 36 9829 3552 00-05/01 HiLight V4, HiLight V5+, AC - 36 -...
  • Page 37 9829 3552 00-05/02 HiLight V4 - 37 -...
  • Page 38 9829 3552 00-06/01 HiLight V4, HiLight V5+, - 38 -...
  • Page 39 9829 3552 00-06/02 HiLight V4, - 39 -...
  • Page 40 9829 3552 00-07 HiLight V4, HiLight V5+, - 40 -...
  • Page 41 9829 3552 50-01 Applicable for HiLight V4, HiLight V5+, ECU engine circuit - 41 -...
  • Page 42 9829 3552 50-02 Applicable for HiLight V4, HiLight V5+, ECU control circuit Preheat Start B(30) BR(AC) R1(19) C(17) R2(50) - 42 -...
  • Page 43 9829 3552 50-03 Applicable for HiLight V4, HiLight V5+, ECU control circuit Speed Speed Speed Speed Sensor Sensor Sensor Select Warning Water temp. Sensor Signal +12V +BP 12V -BP 0V, power ground IG-SW ST-SW Solenoid- Solenoid+ Lamp signal -S10 -B11 - 43 -...
  • Page 44 9829 3552 50-04 HiLight V4, HiLight V5+, - 44 -...
  • Page 45 9829 3552 50-05 HiLight V5+, - 45 -...
  • Page 46 9829 3552 50-06 HiLight V4, HiLight V5+, - 46 -...
  • Page 47 9829 3552 50-07 HiLight V5+, - 47 -...
  • Page 48 9829 3581 00-01 HiLight V4, - 48 -...
  • Page 49 9829 3581 00-02 Applicable for HiLight V5+, engine circuit Notes, 1. For standard and CE cubicles, wires should be comply with CE 2. Other circuit refer to 9829355250 except 9829355250-02 - 49 -...
  • Page 50 9829 3552 60-01 Applicable for control circuit HiLight V4, Preheat Start B(30) BR(AC) R1(19) C(17) R2(50) Notes, 1, When emergency stop switch is applied, this wire shall be replaced by switch wire 2. Engine control circuit refer to 9829355200-01. 3. All wires comply with CSA. - 50 -...
  • Page 51 9829 3552 60-02 Applicable for HiLight V4, AC power circuit 120/240V 60Hz Notes, 1. Only for controller cubicle LC1003 MKII 2. All wires comply with CSA. - 51 -...
  • Page 52 9829 3552 60-03 Applicable for HiLight V4, lamp circuit 120/240V 60Hz With Longxin coil cord, wire color 51 and 53 are black; 56 and 58 are red; 52,54,57 and 59 are white; 55 is green/yellow; or with Philatron coil cord, wire color 51 is red; 53 is black; 56 is brown; 58 is orange; 52 is blue; 54 is yellow; 57 is purple; 59 is white; 55 is green. Line Line White...
  • Page 53 9829 3552 65-01 Applicable for ECU control circuit HiLight V5+, Preheat Start B(30) BR(AC) R1(19) C(17) R2(50) Notes, 1. When emergency stop switch is applied, this wire shall be replaced by switch wire 2. Control circuit see page 9829355250-01,9829355250-03 3. All wires comply with CSA - 53 -...
  • Page 54 9829 3552 65-02 Applicable for V5+, AC power circuit 120/240V 60Hz Notes, 1, Only for controller cubicle LC1003 MKII 2, All wires comply with CSA. - 54 -...
  • Page 55 9829 3552 65-03 Applicable for HiLight V5+, LED circuit 120V 60Hz only With Longxin coil cord, wire color 51 and 53 are black; 56 and 58 are red; 52,54,57 and 59 are white; 55 is green/yellow; or with Philatron coil cord, wire color 51 is red; 53 is black; 56 is brown; 58 is orange; 52 is blue; 54 is yellow; 57 is purple; 59 is white; 55 is green. Line White Load...

  • Page 56: Wiring Diagram

    Wiring Diagrams ELECTRICAL SYSTEM - 56 -...
  • Page 57 Wiring Diagrams ELECTRICAL SYSTEM - 57 -...

  • Page 58: Axle Maintenance Manual

    Axle maintenance manual Axle - 58 -...

  • Page 59: Safety Precautions

    Safety Precautions • Check the wheel functioning - is free to rotate, and the wheel can not be detected with axial clearance. • Welding or drilling on shaft tube is not allowed. • Plug cotter pin. • Select the matching wheel hub: wheel offset, PCD Note: Adjust the bearing correctly.

  • Page 60: 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 61: 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 has been selected: displays Generator voltage and the Auto Run icon...

  • Page 62: Alarm 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 63: 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 64 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 65 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 66 Setting the sensitivity regulator There are 2 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 regulating the luminosity sensitivity level of the The photocell detects enough light, according to its switch on/off the floodlights automatically, but also photocell.

  • Page 67: Maintenance

    3002 6078 60 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 68 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 69 Maintenance schedule for undercarriage Maintenance schedule (km) Notes Daily Every 500 Km Every 1000 km Every 2000 km Check tyre pressure Check tyres for uneven wear Check torque of wheel nuts Notes : (1) More frequently when operating in a dusty environment. (2) HiLight V4 add 2L oil, HiLight V5+ add 2.5L oil.
  • Page 70 Hilight V4 Hilight V5+ PAK & KIT AC PN PAK & KIT AC PN SERVICE PAK 200H 3002607610 SERVICE PAK 200H 3002607840 SERVICE PAK 400H 3002607620 SERVICE PAK 400H 3002607850 SERVICE PAK 800H 3002607630 SERVICE PAK 800H 3002607860 KIT: STEEL CABLE 3002608400 KIT: STEEL CABLE 3002608400...

  • Page 71: Aml Data

    AML DATA Reference conditions 1) 4) Unit HiLight V4 50Hz HiLight V4 60Hz HiLight V5+ 50Hz HiLight V5+ 60Hz 1.Rated frequency 2.Rated speed 3000 3600 1500 1800 3.Generator service duty 4.Absolute inlet pressure 5.Relative air humidity 6.Air inlet temperature °C Limitations 2) 1.Maximum ambient temperature °C...
  • Page 72 Reference conditions 1) 4) Unit HiLight V4 50Hz HiLight V4 60Hz HiLight V5+ 50Hz HiLight V5+ 60Hz Fuel consumption at 2 lamps on kg/h 1.23 1.51 0.48 0.50 Fuel consumption at 3 lamps on kg/h 1.45 1.74 0.53 0.57 Fuel consumption at 4 lamps on kg/h 1.66 1.96...
  • Page 73 Reference conditions 1) 4) Unit HiLight V4 50Hz HiLight V4 60Hz HiLight V5+ 50Hz HiLight V5+ 60Hz 2.Make Sincro Sincro Mecc Alte Mecc Alte 3.Model EK 2 MCT EK 2 MCT LT3N-75 LT3N-75 4.Rated output,class H temp. rise 5.Degree of protection Engine ISO 3046 ISO 3046...

  • Page 74: Circuit Breaker

    Reference conditions 1) 4) Unit HiLight V4 50Hz HiLight V4 60Hz HiLight V5+ 50Hz HiLight V5+ 60Hz Power circuit Circuit-breaker 1.Number of poles 2.Thermal release 36.25 36.25 14.5 29 (b) (c) 3.Magnetic release 5..10xIn 5..10xIn 5..10xIn 5..10xIn Fault current protection 1.Residual current release 0.03 0.03...
  • Page 75 DERATING FACTOR LIGHT TOWER (%) 50 Hz 60 Hz LED 50/60 Hz For use of light tower outside these conditions, please contact Atlas Copco - 75 -...
  • Page 76 Options Spark arresters Tow hitch Towing hitch Combo IMPORTANT! There are 3 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 cambo hitch option only:...
  • Page 77 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) Cubicle with Universal socket •...

  • Page 78: Dimensional Drawing

    Earthing pin Battery isolator DC E-winch Adjustable towing support - 78 -...
  • Page 79 Dimensional drawing - HiLight V5+ - 79 -...
  • Page 80 Dimensional drawing - HiLight V5+ - 80 -...
  • Page 81 Dimensional drawing - HiLight V4 - 81 -...
  • Page 82 Dimensional drawing - HiLight V4 - 82 -...

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Hilight v5+ wux

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