hybrid tower led 444 manual diesel

8/10/2019 Hybrid Tower LED 444 Manual Diesel

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SP444D Light Tower

Signal Power

A wholly owned subsidiary of Signal Pump

229 Industrial Park DriveSoddy Daisy, TN 37379

Phone 423.332.1086 Fax 423.332.1090www.signal-power.com

For parts and updates, email [email protected]

Version

1.3

Operators and

Service Manual


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Table of Contents

Operators Manual .................................................................... 1To Prepare Hybrid Tower LED for Delivery or Rental ............... 1Checklist .................................................................................. 1Introduction .............................................................................. 2Safety Symbols ........................................................................ 2

Model Serial Number Locations .............................................. 3

Model Description .................................................................... 3Specifications ........................................................................... 4Hybrid Tower LED Dimensions ................................................ 5Operation Instructions .............................................................. 7Mast Operation Overview ......................................................... 8Warning .................................................................................... 8

To Erect Mast: ................................................................................. 8

To lower Mast: .............................................................................. 10

To Operate Lights .................................................................. 11Using front mount or remote tripod lights ...................................... 11

To Operate Alternative Power Sources .................................. 11Using Solar Panels ....................................................................... 12

Generator Operating Instructions .................................................. 12

To Use Other Electric Devices ............................................... 14Options Operation .................................................................. 15Timer Option .......................................................................... 15Using the Timer ......................... Error! Bookmark not defined.Service Manual ...................................................................... 20

Generator ...................................................................................... 20

Mast .............................................................................................. 21

Control Box ................................................................................... 21

Lights ............................................................................................ 23

Wiring Schematics ........................................................................ 25

Index ...................................................................................... 28


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H Y B R I D T O W E R L E D

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Operators ManualTo Prepare Hybrid Tower LED for Delivery or RentalThese procedures are designed to ensure years of service from your Hybrid Tower LED. Never

put a machine into service without performing this checklist and fixing any problems you find.

Always instruct your customer on basic operations and safety procedures. Always provide this

manual with equipment to the user.

Checklist1. Visually inspect the equipment for damage and repair if necessary. Ensure that all

instructions and decals are intact and legible.

2. Inspect the tower latch assembly which locks the tower in the vertical position for

proper operation.

3. Inspect the two manual winches and cable for proper mast function.

4. Check the hitch assembly and tow chains.

5. Check the outriggers and jacks to make sure they are functioning properly.

6. Inspect the LED light assemblies for damage and test.

7. Inspect wiring for damage.

8. Inspect battery cables and vent caps. Both should be tight. Fully charge batteries,

then check water levels and refill with distilled water where needed.

9. Check tires for wear and inflation.

10. Check for proper fluid levels (engine oil and diesel). Clean around air intake andmuffler.

11. Check that tail lights are functioning.

12. Check that ground rod cable and ground lug are undamaged and functional.

13. Check machine against scheduled maintenance log.

Section


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H Y B R I D T O W E R L E D

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14. Perform test operation: slide out outriggers, run mast up and down and crank

generator.

Introduction

This manual provides all the information necessary to operate the Hybrid Tower LEDsafely. Specific instructions in this manual will provide you with the correct

specifications for all the equipment contained within the tower. The tower is

configured with two manual crank winches to erect, extend and lower the light

mast. Take the time to read and familiarize yourself with the information contained

in this manual. If you are uncertain about operation, or have further questions

please contact the manufacturer or dealer before operating.

Safety Symbols

The Hybrid Tower LED has safety information symbols designed to ensure the safeoperation of the equipment. These symbols include:

DANGER

WARNING

CAUTION

FAILURE TO FOLLOW SAFETY INSTRUCTIONS COULD RESULT IN INJURY TO OPERATOR

OR OTHERS AND/OR DAMAGE TO EQUIPMENT. CONTACT YOUR DEALER OR

MANUFACTURERE PRIOR TO OPERATION IF YOU ARE UNSURE ABOUT SAFEOPERATION OF THE HYBRID TOWER LED.


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Model Serial Number Locations

Serial numbers are located in the following areas:

Trailerlocated on a plate found at the base of the mast, on the right

side of the unit.

Generatorlocated below the starter.

Model Description

The Hybrid Tower LED uses 4 LED light fixtures, each encased in a metal

housing. The lights are mounted on a manually operated tower, consisting of

two hand crank brake no pinch winches. The first winch raises the mastfrom its horizontal transport position to its vertical operating position. The

second winch extends the mast to its desired height. The boom is 30 feet

when fully extended. The tower power cord is the curly cord. The lights are

affixed to the tower on a steel swivel base that may be manually moved

into a horizontal or vertical position.

The heavy duty trailer shell is comprised of 4 doors providing easy access to

the interior of the unit. Paddle latches allow 4 trailer accessible doors to be

padlocked. The frame houses the 13wheels and tires, located under the

fenders. The Hybrid Tower LED uses three sources of power for light

operation. The primary source consists of four 12 volt batteries. These

batteries may be recharged by three means: a diesel powered generator

with a 8 gallon diesel tank, a solar panel array mounted to the top of the

unit, or through the use of standard household electrical current. The lights

will run while batteries are recharging.


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Specifications

The Hybrid Tower LED is comprised of the following equipment:

Electrical

i) Hard wired electrical circuits

ii) Ballast assemblies

iii) Grounding rod

iv) Hour meter

v) Battery level gauge

vi) External 120V outlet

vii)rocker switches

LED Light Assembly

Each light is rated at 150 watts. Assembly is sealed for all weather

use. Lamps have a laboratory rated life of 80,000 hours. Each lamp

contains 4 strips of LED lights and each strip is independently

replaceable. Lamps are mounted on a steel swivel base to allow

rotation on both the north/south (60) and east/west (80) axes.

Warm up time: instant on

Restart time: instant on

MastMast is composed of three section steel tube mast, which extends

to 30 feet. The mast is extended using two manual brake winches,

with two cables or an electric lift, depending on feature

configuration. The assembly includes UMHW wear plates and a

270 rotating assembly. The mast includes two forklift pockets and

a lifting eye for ease of trailer loading for transport.

Trailer

The complete power unit is housed in a lockable steel enclosure

mounted on a heavy gauge steel frame that sits on a two-wheel

leaf spring axle. Three jacks are mounted on the trailer to provide

stability to the unit when mast is extended in upright position. Unit

comes with a three position, adjustable hitch, which includes a 3

lunette eye. A 2 ball option is available.


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Stablilizers

Two outriggers and one tongue jack are attached to frame to

provide stability. When mast is fully extended and all jacks fully

engaged, this system provides stability to the unit in sustained

winds of up to 40 MPH.

Hybrid Tower LED Dimensions

Height lowered 6 feet (1.83 m)

Height extended 30 feet (9.14 m)

Unit length 14 feet (4.27 m)

Unit width 58 (1.77 m)

Outrigger width 11 feet (3.35 m)

Trailer composition 10 gauge

Axle 2500 LB

Wheels and tires 13 inch

Weight Approx. 1700lbs

Generator Specifications

Manufacturer Kohler

Model Number KD420

Max Angle of Operation 25

Displacement 442CC

Cooling Air cooled

Ignition system CDI type magneto

Oil Capacity 1.5 liters

Fuel tank capacity 8 gallons

Noise level 68 dBA


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Please see manufacturers operating manual, provided with Hybrid Tower

LED, for complete specifications, operating instructions and

maintenance schedule of the Kohler generator.

Battery Specifications

Voltage 12

Amp Hours 220

Weight 118 lbs

Reserve Capacity (minutes) 117

Terminal L type

Batteries should be kept free of dirt and corrosion at all times. Batteries

should be watered after charging unless plates are exposed before

charging. If exposed, plates should be covered by approximately 1/8 of

acid. Check acid level after charge. The acid level should be kept

below the bottom of the fill well in the cell cover. Water used to replenish

batteries should be distilled or treated not to exceed 200 TDS. Particular

care should be taken to avoid metallic contamination (iron).

Charging should not be done at temperatures above 120F. Extreme

temperatures can affect battery performance. Cold reduces batterycapacity and retards charging. Heat increases water usage and can

result in overcharging.


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Operation Instructions

Towing Instructions

Before every tow, the Hybrid Tower LED should be visually inspected to

ensure that the following operations have been completed.

1) Hitch is securely attached to towing vehicle and safety chains are

fastened.

2) All outriggers and jacks are fully retracted and secure.

3) Boom is fully lowered into the cradle and the locking pin is in place.

4) Light fixtures are positioned for transport.

5) Doors are closed and fully latched.6) Tire pressure is adequate.

7) Tail lights are operating.

8) Ground rod is removed from ground and secured inside trailer.

Ground Rod Instructions

1) Remove the ground rod stowed on passenger side of trailer inside

door housing electrical box.

2) Unroll the electrical wire lead from the ground rod.

3) Attach the ground rod lead to the grounding lug located underneaththe electrical door, at the back corner of the passenger side of the

tower.

4) Drive the ground rod into the earth a minimum of one foot for

adequate grounding. If this is not possible, consult a qualified

electrician.

5) After unit shut down, remove the rod from the earth, remove lead

from the lug nut and return to storage.


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Mast Operation Overview

The SP444D has a mast consisting of three sections of telescoping steel tubes

which can be erected using two manual crank brake winches. One brake

winch, mounted to the tongue, is used to raise the mast from horizontal tovertical. The second brake winch, located on the mast is used to extend the

boom to its full height.

A lock will hold the mast its vertical position. A brake winch will secure the

boom in its extended configuration.

After locking, the mast assembly can be rotated independent of the tower

body by pulling the lever at the bottom of the boom. The lights can then be

rotated as desired, up to 270 mast rotation.

Warning

ALWAYS CHECK FOR OBSTRUCTIONS OVERHEAD BEFORE RAISING THE

MAST. ENSURE A MINIMUM OF 35 FEET OF CLEARANCE FROM WIRES

OR OTHER OBSTRUCTION WHEN RAISING AND LOWERING THE BOOM.

ALWAYS CHECK THAT THE FRAME IS STABLE, WITH PROPER SUPPORTS

FULLY EXTENDED BEFORE RAISING MAST.

FAMILARIZE YOURSELF WITH ALL OPERATION STEPS PRIOR TO

OPERATING THE MAST.

To Erect Mast:

1. Fully extend both outriggers, located on either side of the frame

and lock into place.

2. Fully extend the tow jack located at the front on the unit and lock

into position.

Warning

WHEN EXTENDING THE REAR OUTRIGGERS, MAKE SURE YOU

ARE CLEAR OF THE MAST BEFORE STANDING UP.


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MAKE SURE THAT THE GROUND UNDER THE TOWER IS FIRM

AND THAT THE TOWER IS LEVEL.

THE GROUND ROD IS A SAFETY DEVICE THAT MAY REDUCE

THE POSSIBLITY OF INJURY FROM ELECTRICAL

CURRENT.

FAMILIARIZE YOURSELF WITH LOCAL, STATE AND FEDERAL

ELECTRICAL CODES REGULATING USE OF THE GROUND ROD.

3. Attach the ground rod to the grounding lug and drive rod into

ground fully, as required by local, state and federal codes.

4. To rotate the light frame, push slightly on the bottom of the frame

and pull up on the lever located in the middle of the two upper

lights. Rotate frame until it locks into place.

5. To adjust the individual light assemblies, position using the leversto the right of each light. Loosen, rotate to the desired position and

retighten.

6. Check to ensure tower stability on level ground, then remove the

red pin that secures the mast to the tower, located at the light end

of the boom.

7. Operate the manual no pinch winch located on the tongue of

the unit to raise the mast from horizontal to vertical position. The

winch will turn in a clockwise motion, producing a loud, sharp

clicking noise.

8. Crank until the winch locks the mast in place, verified by a clicking

sound and visual inspection of the mast locking pin engaging.

9. Move to second winch, located on mast and turn the crank

clockwise to raise the boom to its full height. The brake winch will

hold the tower in place when it is extended to its full height.

10.After mast is vertical, you may rotate mast to desired angle. To

rotate the mast, move lever located at the bottom of the mast to

release mast and rotate according to need, up to 270 degrees.

Release lever, ensuring lever is locked into a groove to secure

mast.

Warning


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1. IF THE TOWER WILL NOT ROTATE, CHECK TO ENSURE THAT

WINCH LOCKS ARE IN PLACE. TOWER WILL NOT ROTATE

UNLESS LOCKS ARE SECURELY IN PLACE.

To lower Mast:

Warning

1. VISUALLY INSPECT FOR DAMAGE TO EQUIPMENT PRIOR TO

LOWERING MAST. MAKE SURE THAT THERE IS ADEQUATE ROOM

AROUND TOWER FOR LOWERING AND NO PERSONS ARESTANDING IN FRONT OR BEHIND THE TOWER WHILE LOWERING

MAST.

1. Turn off lights using the master shut off switch located on the back,

upper right of the unit. This switch completely turns off power to the

unit, preventing premature battery drain.

2. Release lever and rotate the mast until the two arrows on the white

sticker align. Ensure lever locks into grooves, securing mast.

3. Operate hand crank winch on mast to lower the boom to its lowestposition. Turn in counterclockwise motion to lower.

4. Move to tongue winch. Pull pin located on the bottom of the mast to

release lock and operate hand crank winch, turning in a

counterclockwise motion. Once mast has moved beyond locking

mechanism, release pin and continue to crank winch in a clockwise

motion until mast is horizontal and rests in cradle.

5. Secure locking pin into mast at cradle.

6. Visually inspect light mounting pins on each light for loose hardware.Tighten if necessary.

7. Remove ground rod from earth and disconnect wire from ground lug.

Secure into specified place in trailer.

8. Raise jack stand, retract outriggers and secure for towing.


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To Operate Lights

To turn the lights on, depress rocker switches, located on back panel of thetower, on the upper right hand corner. To use the master switch, cycle the

switch off and then on again. This will reset the system.

To turn lights off, depress rocker switch to off position. There is no warm up

time required and lights may be cycled on and off without harm.

Lights are set to automatically power off of the battery system included with

the SP444D.

Using front mount or remote tripod lights

NOTE: Up to two additional lights can be powered by the SP444D.

1. When mast is in lowered position, unplug desired light from

tower control box at top of tower.

2. Unpin light from mast.

3. Remove light fixture.

4. Position light on desired front mount light bracket or optionaltripod.

5. Plug light power wire into receptacle located on the front of

the trailer.

6. To operate lights, use switch located inside right front door.

To Operate Alternative Power Sources

When batteries reach low voltage, a warning alarm will sound and lights will

begin flashing. Batteries may be recharged by three methods:

1. Plug the SP444D into a standard 120V electrical outlet using an

120V rated grounded extension cord. Plug for charging is

located at the upper right on back of the unit.


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2. Set up solar panels located on the top of the machine.

3. Start generator. Generator is located inside the left rear panel

door.

Using Solar Panels

1. Remove 5thpanel from top of machine and place on ground

in sunny area 810 feet from machine. Using kickstand, angle

panel 30 45 degrees, facing a southerly direction. When

using 5th panel, the rocker switch located next to the light

switches must be in the on position. If not using the 5thpanel,

then the switch must be in the middle position.

2. Two connecting cords are located in the right rearcompartment and are already wired to machine. Attach

opposite ends of cords to 5thsolar panel, taking proper care to

match connectors.

3. Unfurl remaining panels by tilting panels up from back of unit,

using the slide up brackets to secure. When selected angle is

reached, lock panels in place by securing lever into place.

Open panels outwards. Panels will automatically begin

charging.

Generator Operating Instructions

Using Manual Start

1. Check that oil and fuel levels are appropriate for operation.

Check that the air cleaner is not blocked.

Warning

DIESEL ONLY!


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2. Turn on the fuel shut off valve located below the fuel tank.

3. Confirm fuel lever is on.

4. Turn the key on engine to the run position. This will power onthe control panel.

5. Hit run button located on the Control Panel. After a brief

delay, engine should start.

6. To stop machine, hit the off switch button located on the

control panel.

Enabling The Auto-Start Function

1. Check that oil and fuel levels are appropriate for operation.

Check that the air cleaner is not blocked.

Warning

DIESEL ONLY!

2. Turn the fuel shut off valve located below the fuel tank to the

on position.

3. Confirm fuel lever is onat carburetor.

4. Turn key on engine to the runposition. This will power on the

control panel.

5. Hit the auto button located on the control panel. The

display will show the machine is in auto start mode. When low

voltage is detected at the battery bank, the engine will startautomatically and run for the set amount of time.

6. The engine may be stopped at any time using the offbutton

located on the control panel.

7. For troubleshooting your auto-start feature, please contact

Signal Power.


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NOTE: When the generator is not in use, battery power can be conserved by

turning the key to the off position.

To Use Other Electric Devices

Warning

TO USE THE SP444D AS A POWER GENERATION SOURCE, THE GENERATORMUST BE RUNNING.

After following the generator operating instructions, you may plug in any120V appliance into the outlets located in the generator control

compartment. Ensure that the rated load for the generator is not exceeded.


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Options OperationTimer Option

The timer is an option that allows the lights to be programmed to

automatically turn on and off.

Section


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By pressing the MODEbutton, the Time Switch will cycle through the menus

necessary for programming the current time, date, and timed events.

The basic procedure is to use the MODEbutton to move from one menu to

the next (e.g., DATE, TIME, etc.), the + orbuttons for the first part of a setting(e.g., MONTH), the ENTERbutton to move to the next part of the setting (e.g.,

YEAR), then MODEto exit and move to the next menu. To skip a menu, press

MODEto move ahead.

If you make a mistake, press the MODE button repeatedly to cycle back

around to the error, then make the correct entry.

NOTE: DATE and TIME must be set before you can access any other

programming menus.

Setting Date

1.Press the MODE button repeatedly until the words SET and

DATE appear in the upper area of the display.

2.Press the + orbuttons to enter the current Month.

3.Press the ENTER button when the Month is correct to save the

setting. The screen advances to current Date.

4.Again press the + orbuttons to enter the current Date,

followed by the ENTER button.

5.Repeat to set the correct Year.

6.Press the MODE button to exit and advance to setting the

time.


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Setting Time

1. If necessary, press the MODE button repeatedly until the wordsSET and CLOCK appear in the upper area of the display.

2.Press the + orbuttons to enter the current time.

NOTE: To go from AM to PM, keep pressing the + or buttons to

cycle through the day. You can hold the + or buttons down

for 3 seconds to make the time scroll quickly.

3.Press the MODE button to exit and advance to setting events.

Setting ON/OFF Events

1. If necessary, press the MODE button repeatedly until the words

SET ON/OFF EVENTS and EVENT 01 appear on the display.

2. If necessary, press the ENTER button to display ON @ or OFF @

(depending on what you want to set).

3.Press the + orbuttons to enter the time you want to set.

NOTE: To go from AM to PM, keep pressing the + or buttons to

cycle through the day. You can hold the + or buttons down

for 3 seconds to make the time scroll quickly.

4.When you have set the event correctly, you have two

choices: - Press the ENTER button to set the next ON/OFF event

(up to28 events).

Press the MODE button to exit.


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Operating the Time Switch

Press the MODE button repeatedly to select the desired operating mode onthe display.

There are 2 options:

AUTOwhere the Time Switch follows the events you have programmed,

turning the circuits ON and OFF at the time(s) set.

NOTE: You can override programmed events and force the

Time Switch ON or OFF by pressing the ON/OFF button.

MANUALwhere any events set are disabled and the TimeSwitch controls all circuits through the ON/OFF button.

NOTE: You can review or edit any programmed events at any time

by pressing the MODE button repeatedly to return to the appropriate

menu, then following programming instruction provided on this sheet.

Deleting (Clearing) an Event

Use this procedure to clear the settings programmed for an event.

1. If necessary, press the MODE button repeatedly until the words SET

ON/OFF EVENTS are shown on the display.

2. Press the ENTER button as necessary to cycle through events that

have been set until you see the event you want to delete.

3. Press the + orbuttons AT THE SAME TIME to display --:-- --.

4. Press the MODE button to exit.


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Battery Maintenance

Batteries can be easily replaced without removing the TimeSwitch mechanism or field wiring.

Press in and downward (in the direction of the arrows) on the

battery cover.

It is recommended to replace the batteries every One (1) Year with

2 AAA industrial grade alkaline cells as part of normal maintenance

on the Time Switch.

Be sure to observe battery polarity markings when installing

batteries.

No other battery maintenance is required.


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Service ManualGeneratorThe generator that powers the SP444D should be started every 14 days and

run for at least 20 minutes. Generator should be kept clean and free from

debris.

Maintenance Schedule

Initial oil change should occur at 50 hours of run time and following the

schedule below, thereafter. Run time should be logged to ensure proper

maintenance is followed.

Below is the maintenance schedule provided by the generator

manufacturer. For specific questions and instructions, please consult the

manufacturers owners manual provided with the SP444D.

Every 50 hours

Clean Air Filter

Every 250 hours (Six Months)

Change engine oil

Clean spark arrester

Clean fuel tank

Every 500 hours

Replace Air Filter, Part Number ED0021753060-S

Replace Oil Filter, Part NumberED0021751550-S

Replace Fuel Filter, Part Number ED0037300960-S

Section


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MastThe mast is made of three separate steel sections that nest inside each other

when lowered. The sections are raised and lowered using the winch, and

guided by the wear pads. These pads are designed to last the life of the lighttower under normal wear and tear conditions, however, replacement may

be necessary. An exploded diagram and step by step mast assembly

directions follows.

********************************************

Control BoxThe control box is located on the right side of the unit inside the large, back

door. The control box houses the battery charger, inverter, relays, and circuit

breakers.

The inverter converts the DC power from the battery bank into AC power for

the lights. The battery charger converts the AC power from either the

generator or household electrical current to DC power to recharge the

battery bank. This charger controls the rate of charge with a three stage

smart charging system.

The relays open and close the circuits, depending on which charging

method is used. Relay One is activated when external AC source is supplied

to the unit. It electrically isolates the battery charger to receive charge from

either the generator or household electrical current, but never both. It also

prevents power from the generator back feeding to the power plug. Relay

Two controls the flow of power from the inverter to the lights. When charging

through the generator or household electrical current, the relay connects

the lights to either the generator or external AC source for operation. When

the generator or household electrical current powers the lights, the full

output of the battery charger goes towards charging the batteries.

Five circuit breakers are included in the control box; a main circuit breaker,

with four circuit breakers wired to it, each individually connected to the four

LED lights.

The inverter has a push button switch to turn the unit off and on. There is a

green indicator light next to the switch that lights up when the inverter is on.

The inverter low voltage battery alarm sounds at 22 volts. If the voltage

drops lower than 21 volts, the inverter will automatically shut off. Within 5

minutes, if the voltage rises above 22.5 Volts, the unit automatically turns

itself back on. If recharging does NOT take place within 5 minutes, the

inverter has to be turned on manually. Once recharging begins, the inverter


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may be turned back on, however the lights will function via recharging

power.

If lights do not function, check to make sure that the batteries have more

than 22 volts remaining and that the inverter is on.

The battery disconnect switch, located inside the unit, on the wall that

separates the batteries from the control box, will also turn the inverter off.

CAUTION

Electrocution Risk

The control box should only be opened by an experienced servicetechnician who is qualified to work on electrical devices.

The battery switch should be switched to the offposition before opening

the box. This will disconnect the power from the box.

A photo labeling each component of the control box is provided, below.

The wiring schematic specifying how each component is wired together is

located at the end of this section.


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Lights

Each light box is comprised of four light strips and a LED driver. The light strips

are made up of 14 individual LED lights.

Each bar may be replaced within a light fixture by unscrewing the larger

screws located on the corners of the light, and unhooking the bar from the

harness. Insert the new bar, attach to harness and screw back into fixture.

The Lights are controlled by individual switches located in the back panel of

the light tower.


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The light intensity can also be controlled individually from the inside. This is

particularly effective when using the lights at ground level or when trying to

control battery capacity.


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Wiring Schematics


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Index

auto start, 13

battery specifications, 6

checklist, 1

dimensions, 5

electrical outlet, 14

frame, 3generator operations, 12

grounding rod, 7

light operation, 11

lights, service, 20

mast operation, 8

mast service, 19

picture, 2, 3, 4

service, 17

control box, 18

generator, 17

lights, 20

mast, 19serial numbers, 3

solar panels, 12

specifications, 4, 5

timer, 15

towing instructions, 7

Wiring diagrams, 22-24

Section

hybrid tower led 444 manual diesel

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