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Halo Ex 1 Portable Mobile Light Tower
Halo Ex 1 Portable Mobile Light Tower
OPERATING MANUAL
Table of Contents
Introduction............................................................................................................................. 2
Record of Owner...................................................................................................................... 2
Section 1 - Safety
Safety Notes............................................................................................................................. 3
Operating Safety....................................................................................................................... 3
Engine Safety............................................................................................................................ 4
Service Safety........................................................................................................................... 5
Towing Safety........................................................................................................................... 5
General Safety Symbol Summary.............................................................................................. 6
Section 2 - General Information
Specifications........................................................................................................................... 7
Light Tower (Halo-1) Dimensions........................................................................................... 8
Light Tower (Halo-1) Name plate Locations........................................................................... 8
Component Locations............................................................................................................ 9
Control Panel.......................................................................................................................... 10
Emergency Stop Locations……………........................................................................................ 10
Prestart Checklist................................................................................................................... 11
Section 3 - Operation
DSE 4520 Program Set Up...................................................................................................... 11
Light Tower Set Up................................................................................................................. 11
Manually Raising the Mast................................................................................................... 11
Starting the Engine................................................................................................................. 12
Light Operation...................................................................................................................... 12
Shutting Down the Engine...................................................................................................... 12
Manually Lowering the Mast.................................................................................................. 13
Towing the Halo-1.................................................................................................................. 13
Section 4 - Maintenance
Daily Walk around Inspection................................................................................................ 13
General Maintenance............................................................................................................. 13
Winch Use, Operation and Maintenance............................................................................... 14
Section 5 – Troubleshooting…………………………………………………………………………………………….. 14
Indication Light measures…………………………………………………………………………………………………. 18
Section 6 - Wiring Diagrams…………………………………………………………………………………………..... 19
Service Log............................................................................................................................. 20
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Introduction
This manual provides information and procedures to safely operate and maintain the Halo-1,
for your own safety and protection from physical injury, carefully read, understand, and observe the
safety instructions described in this manual. Stroke Equipments India Pvt Ltd., reserves the right to
change any portion of this information without notice.
// DO NOT MODIFY or use this Halo-1 for any application other than for which it was designed. //
Halo-1 recommends that a trained and licensed professional perform all electrical wiring and testing
functions. Any wiring should be in compliance with the National Electrical Code (NEC), state and local
regulations and Occupational Safety and Health Administration (OSHA) guidelines.
RECORD OF OWNER
Take a few moments to record the information you need when you contact Stroke
Equipments India Pvt. Ltd. for service, parts or literature.
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Section 1 - Safety
SAFETY NOTES
This is the safety alert symbol. It is used to alert you to potential personal injury
hazards. Obey all safety messages that follow this symbol to avoid possible injury or death.
This manual contains DANGERS, WARNINGS, CAUTIONS, NOTICES and NOTES which
must be followed to prevent the possibility of improper service, damage to the equipment, personal
injury or death. The following formatting options will apply when calling the reader’s attention to
the DANGERS, WARNINGS, CAUTIONS, NOTICES and NOTES.
DANGER
Indicates a hazardous situation, if not avoided, will result in death or serious injury.
WARNING
Indicates a hazardous situation, if not avoided, could result in death or serious injury.
CAUTION
Indicates a hazardous situation, if not avoided, could result in minor or moderate injury.
NOTICE
Indicates a hazardous situation, if not avoided, could result in property or equipment
damage.
Notes: Notes contain additional information important to a procedure and will be found within the
regular text body of this manual.
OPERATING SAFETY
Before using the Light Tower, be sure to read and understand all of the instructions. This
equipment was designed for specific applications; DO NOT modifies or uses this equipment for any
application other than which it was designed for. Equipment operated improperly or by untrained
personnel can be dangerous. Read the operating instructions and familiarize yourself with the
location and proper use of all instruments and controls. Inexperienced operators should receive
instruction from someone familiar with the equipment before being allowed to operate. The
following points should be practiced at all times:
• The area immediately surrounding the Halo-1 should be dry, clean, and free of debris.
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• NEVER start a Halo-1 in need of repair.
• Keep all body parts, clothing and other loose items away from moving parts.
• ALWAYS lower the mast when not in use, or if high winds or electrical storms are expected in the
area.
• The mast extends up to 29.5ft (9m). ALWAYS make sure the area above the unit is open and clear
of overhead wires and obstructions.
• Keep area around the Halo-1 clear of people while raising and lowering the mast.
• Light become extremely hot during use. Allow light to cool 10-15 minutes before handling.
• NEVER raise, lower or turn the mast while the Halo-1 is operating.
• ALWAYS extend the outriggers jack while before raising the mast. DO NOT retracts the outriggers
jack while the mast is up.
• If for any reason any part of the mast hangs up or winch cable develops slack while raising or
lowering the Mast, STOP immediately and contact an authorized service representative.
• NEVER operate the lights without protective cover glass in place or with cover glass that is cracked
or damaged. Only use Dry clean cloth to clean the light cover glass. Other chemicals may have an
adverse effect on the Light cover glass.
• DO NOT fill fuel tank near an open flame, while smoking, or while engine is running. DO NOT fill
tank in an enclosed area with poor ventilation.
• Shut the engine down if any of the following conditions exist during operation:
ENGINE SAFETY
Failure to follow the safety guidelines described below could result in severe injury or death.
Read and follow all safety warnings described.
• DO NOT run engine indoors or in an area with poor ventilation unless exhaust hoses are used.
Engine exhaust contains carbon monoxide, a deadly, odourless and colourless gas which, if inhaled,
can cause nausea, fainting or death. Make sure engine exhaust cannot seep into closed rooms or
ventilation equipment.
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• DO NOT touch or lean against hot exhaust pipes or engine components.
• Protective eye wear and clothing are necessary when working on or around the battery. Always
disconnect the negative (-) battery cable from the corresponding terminal before performing any
service on the engine or other components.
• NEVER open the oil drain plug while the engine is running or before the engine has cooled down.
Allow the equipment to cool completely before attempting any service work.
• Keep area around exhaust pipes free of debris to reduce the chance of an accidental fire.
SERVICE SAFETY
All service work must be performed by qualified personnel who are familiar with the
equipment. Only a qualified electrician should troubleshoot or repair electrical problems occurring in
this equipment. Follow the safety guidelines described below to prevent hazardous situations which
could result in severe injury or death.
• NEVER wash the equipment with high pressure hoses, power washers, or steam cleaners. Water
may collect in the system, causing damage to electrical parts.
• ALWAYS use extreme caution when servicing this equipment in damp conditions. Do not service
the equipment if your skin or clothing is wet. Do not allow water to collect around the base of the
system.
• Before servicing the equipment, make sure the circuit breakers are in the OFF position, and the
negative (-) terminal on the battery is disconnected. NEVER perform even routine service (oil/filter
changes, cleaning, etc.) unless all electrical components are shut down.
• NEVER start the equipment under load. The circuit breakers must be in the OFF position when
starting the unit.
• Wear heavy leather gloves when handling winch cables. Never let cables slip through bare hands.
TOWING SAFETY
Towing a Halo-1 requires care. Both the Halo-1 and vehicle must be in good condition and
securely fastened to each other to reduce the possibility of an accident.
• Check that the hitch and coupling on the towing vehicle are rated equal to or greater than, the
Halo-1 Gross Vehicle Weight Rating (GVWR).
• NEVER tow Halo-1 using defective parts. Inspect the hitch and coupling for wear or damage.
• Make sure the Halo-1 hitch and the couplings are compatible. Make sure the coupling is securely
fastened to the vehicle.
• Make sure directional and brake lights on the vehicle are connected and working properly.
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• Check that the lug nuts holding the wheels are tight and that none are missing.
• Maximum use recommended speed for highway towing 20 km/h (on-road). Recommended off-
road towing speed is not to exceed 5 km/h or less.
• When towing, maintain extra space between vehicles and avoid soft shoulders, curbs and sudden
lane changes.
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Section 2 - General Information
SPECIFICATIONS
ENGINE SPECIFICATION
Engine KOHLER
Model No KD441-GSI2
Serial Number 5301101036
No of cylinders 1
Rated speed 3600 rpm
Power 6.1 kW
Oil Type 15W-40 CH4 / CI4
Oil capacity 1.5 Liters (To be change every 80 – 100 Running hours)
Cooling system AIR
ALTERNATOR SPECIFICATION
Model No KR100 FX
Power Factor 1~
Frequency 60 Hz
Output @ 3600 rpm 5.0 kVA
Number of poles & phases 2 pole / 1 phase
Voltage 230 V
Full Load current 21.7 Amps
Insulation Class H
Protection IP23
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Light Tower (Halo-1) Dimensions
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Component Locations
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Control Panel
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Prestart Checklist
All items in the prestart checklist must be completed before starting.
Read and understand ALL safety sections at the beginning of this manual.
Halo-1 must be level with jacks support in contact with the ground and wheels lifted
minimum clearance from the ground.
Halo-1 must be dry. Check for any water inside, on, or near.
Switch the Control Power switch to the OFF position.
Switch all circuit breakers to the OFF position.
Ensure Emergency Stop Push button must release.
Inspect all electrical wires, repair or replace - cut, worn or bare connection.
Ensure all winch cables are in good condition and placed centre on each pulley.
Check oil and fuel levels.
Ensure battery connections are secure.
Check the engine exhaust system (Silencer) for loose or rusted.
Section 3 - Operation
DSE 4520 Program Set Up
All programs are previously set in DSE 4520 before installation for User friendly. Use START,
STOP button to operate Engine. Manually you can set the values by pressing together STOP & AUTO
buttons, set what require (additionally).
Place the Halo-1 on firm ground that is relatively flat, and then block the wheels to keep
it from moving. This will make it easier to level the Halo-1.
Before raising the mast, it may be necessary to adjust the lights. The lights may be
adjusted up, down, left & right by loosening the wing nuts and aiming them in the
desired direction. Tighten the fasteners completely and make sure the lights are
connected to the junction box.
Loosen the Mast rotation locking screw until the Mast is able to rotate. Turn the Mast
using the handle provided to the required direction (Up to 350°). Once the Mast is in the
required position, turn the Mast rotation locking screw until the Mast is firmly locked in
position.
Turn the jack handles clockwise to start levelling the Halo-1. Adjust all three jacks by
turning their handles clockwise until they are firmly in contact with the ground and
continue until the wheels are lifted minimum clearance from the ground.
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Check the Mast cables for excessive wear or damage. Make sure the cables are properly
centred in each pulley. Check the electrical cord for damage.
Use the winch to extend the Mast slowly up to 9M by turn clockwise the Handle.
And use Locknut to arrest the Mast.
Rotate the Mast by loosening the Mast rotation knob at the bottom of the Mast. Turn the
Mast until the lights face in the desired direction and then tighten the Mast rotation knob to
secure the Mast in position.
Does not Towing Halo-1 while the Mast Raised Up.?
Light Operation
Once the engine is up to temperature and running smoothly, switch the Light main circuit
breaker to the ON position.
With the main circuit breaker on, switch each individual circuit breaker for the lights to the
ON position, one at a time.
Ensure continue to get brighter as the lights warm up, and then remain on.
The light tower uses four 400W LED. When checking or replacing the LED, wipe them with a
clean cloth to avoid leaving any grease, oil residue or fingerprints on the glass. Any residue
can create a hot spot on the LED, causing premature failure.
Close the Hood and clamp.
Open the Hood and insert the Hood resting hook into the hole provided.
Switch the individual circuit breakers for each light and each receptacle to the OFF position.
Press the red “STOP” button once on the DSE 4520, the Engine will be shutting down.
Switch OFF control power on the MCB located on the Electrical Panel box.
Ensure all switches are OFF and then close the Hood and clamp.
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Manually Lowering the Mast
Release the Locknut, and use the winch to reduce the Mast height slowly by turn
anticlockwise the Handle.
Check the electrical cord resting on position. And Ensure Mast cable returns its place
properly.
Turn all three jacks’ handles anticlockwise when the load comes on the wheels.
Set the Halo-1 into the travelling position.
Towing Halo-1 Connect to vehicle with soft shoulders and let it move.
Section 4 - Maintenance
Daily Walk around Inspection
Look for conditions that could hinder performance or safety, such as (but not limited to)
oil/fuel leakage, blocked vents, loose/missing fasteners, and electrical connections.
NOTICE
Failure to perform a daily inspection may result in serious damage to the prime mover.
General Maintenance
Poorly maintained equipment can become a safety hazard. In order for the equipment to
operate safely and properly over a long period of time, periodic maintenance and occasional repairs
are necessary. NEVER perform routine service (oil/filter changes, cleaning, etc.) unless all electrical
components are shut off. Before servicing the Halo-1, always follow the instructions listed below.
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Inspect condition of electrical cords. DO NOT uses the Halo-1 if insulation is cut or worn
through.
Check that winch cables are in good condition and are centred on each pulley. DO NOT use a
cable that is kinked or starting to unravel.
Check the wheel lug nuts.
Check the oil level daily.
DO NOT starts the Engine if the engine oil level is below.
Add Oil only if the oil level is below.
DO NOT OVERFILL.
Check the fuel level.
Section 5 - Troubleshooting
DANGER
This uses high voltage circuits capable of causing serious injury or death. Only a qualified
electrician should troubleshoot or repair electrical problems occurring in this equipment.
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Starter is defective Replace starter.
Solenoid is not getting Check wire to run solenoid and confirm
power (Yellow Indication 12V at pins. Call the service technician to
Light not glow). replace the solenoid.
3.Engine cranks but does not Air is trapped in the fuel
start. Remove the air from the fuel lines.
line
Fuel is not present in the Pump the hand pump to push fuel through
fuel line the fuel lines.
Fuel pipes are clogged Remove pipes and clean in clean diesel.
Remove and clean air filter. If it is very
Clogged air filter dirty and damaged, please replace with
new filter.
Remove and clean fuel lines. When
Clogged fuel lines refitting ensures that the clips are properly
installed.
4.Engine runs rough or keeps Fuel is not present in the Pump the hand pump to push fuel through
spluttering. fuel line the fuel lines.
Clean or replace fuel filter. Ensure fuel
Clogged fuel filters or lines do not have any cracks or tears and
leaking fuel lines are properly inserted on the filters with
clips properly installed.
Air is trapped in the fuel
Remove the air from the fuel lines.
line
Check oil level. If above the high mark,
drain oil thru drain plug. Crank engine
Oil level in very high without starting and then recheck oil level.
5.Engine runs with thick
Always ensure that the oil is between the
black smoke.
low and high mark.
Low Compression Call service technician for repair.
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Check fuel level in fuel tank. Top up diesel
in tank if necessary.
Fuel cut off alarms shows
on controller If diesel level is full and the indicator still
comes on, then call service technician for
repair.
There is an electrical fault in the engine
Engine MCB trips after circuit. Check all wires and connections for
starting the engine to ensure that there is no loose
connection or exposed wire.
10.Tower Mast does not rise After making sure the mast is completely
when the manual winch is retracted, gently pull the wire rope above
Wire rope connected to
operated. the winch drum to check if it comes loose
winch drum is broken
and out of the mast tube. If that does not
inside the tube
happen please contact service technician
for repair.
Winch gearbox is damaged Call service technician for repair.
Wire rope is jammed inside
Call service technician for repair.
a tube or over a pulley
Voltage may not be correct Check speed of the engine.
MCBs maybe faulty Replace MCB.
11.Lights do not turn on Check and fix all loose connections in
when MCBs are turned on. following locations, all wiring inside the
Loose connections canopy, all Wiring junctions in junction
boxes, all wiring inside conduits exiting the
canopy.
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PF capacitor maybe faulty Check capacitor and replace if necessary.
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Hinge bolts maybe missing Replace hinge bolts with new bolts. Call
or broken or loose service engineer for specification.
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Section 6 - Wiring Diagrams
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Service Log………………………………………………………………………………………………………
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STROKE EQUIPMENTS INDIA Pvt. Ltd.
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