Version

1.3
SP444D Light Tower

Operators and
Service Manual
Signal Power
A wholly owned subsidiary of Signal Pump
229 Industrial Park Drive
Soddy Daisy, TN 37379
Phone 423.332.1086 Fax 423.332.1090
www.signal-power.com
For parts and updates, email service@signalpump.com

Table of Contents
Operators Manual .................................................................... 1
To Prepare Hybrid Tower LED for Delivery or Rental ............... 1
Checklist .................................................................................. 1
Introduction .............................................................................. 2
Safety Symbols ........................................................................ 2
Model Serial Number Locations .............................................. 3
Model Description .................................................................... 3
Specifications ........................................................................... 4
Hybrid Tower LED Dimensions ................................................ 5
Operation Instructions .............................................................. 7
Mast Operation Overview ......................................................... 8
Warning.................................................................................... 8
To Erect Mast: ................................................................................. 8
To lower Mast: .............................................................................. 10

To Operate Lights .................................................................. 11

Using front mount or remote tripod lights ...................................... 11

To Operate Alternative Power Sources .................................. 11

Using Solar Panels ....................................................................... 12
Generator Operating Instructions .................................................. 12

To Use Other Electric Devices ............................................... 14

Options Operation .................................................................. 15
Timer Option .......................................................................... 15
Using the Timer ......................... Error! Bookmark not defined.
Service Manual ...................................................................... 20
Generator ...................................................................................... 20
Mast .............................................................................................. 21
Control Box ................................................................................... 21
Lights ............................................................................................ 23
Wiring Schematics ........................................................................ 25

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

Section
H Y B R I D

T O W E R

L E D

Operators Manual
To Prepare Hybrid Tower LED for Delivery or Rental
These 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.

Checklist
1.

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 and
muffler.

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.

H Y B R I D

14.

T O W E R

L E D

Perform test operation:

generator.

slide out outriggers, run mast up and down and crank

Introduction
This manual provides all the information necessary to operate the Hybrid Tower LED
safely. 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 safe
operation 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 SAFE
OPERATION OF THE HYBRID TOWER LED.

Model Serial Number Locations

Serial numbers are located in the following areas:

Trailer located on a plate found at the base of the mast, on the right
side of the unit.

Generator located 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 mast
from 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 13 wheels 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.

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:
Restart time:

instant on
instant on

Mast
Mast 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.

 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
Trailer composition

11 feet (3.35 m)
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
Ignition system

Air cooled
CDI type magneto

Oil Capacity

1.5 liters

Fuel tank capacity

8 gallons

Noise level

68 dBA

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 battery
capacity and retards charging. Heat increases water usage and can
result in overcharging.

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 underneath
the 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.

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 to
vertical. 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.

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 levers

to 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

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 ARE
STANDING 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 lowest
position. 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.

10

To Operate Lights
To turn the lights on, depress rocker switches, located on back panel of the
tower, 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 optional

tripod.

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.

11

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 5th panel from top of machine and place on ground

in sunny area 8 10 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 5th panel,
then the switch must be in the middle position.

2.

Two connecting cords are located in the right rear

compartment and are already wired to machine. Attach
opposite ends of cords to 5th solar 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!

12

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 on
the 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 on at carburetor.

4.

Turn key on engine to the run position. 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 start
automatically and run for the set amount of time.

6.

The engine may be stopped at any time using the off button
located on the control panel.

7.

For troubleshooting your auto-start feature, please contact

Signal Power.
13

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 GENERATOR
MUST BE RUNNING.
After following the generator operating instructions, you may plug in any
120V appliance into the outlets located in the generator control
compartment. Ensure that the rated load for the generator is not exceeded.

14

Section

Options Operation
Timer Option
The timer is an option that allows the lights to be programmed to
automatically turn on and off.

15

By pressing the MODE button, 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 MODE button to move from one menu to
the next (e.g., DATE, TIME, etc.), the + or buttons for the first part of a setting
(e.g., MONTH), the ENTER button to move to the next part of the setting (e.g.,
YEAR), then MODE to exit and move to the next menu. To skip a menu, press
MODE to 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 + or buttons 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 + or buttons 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.

16

Setting Time
1.

If necessary, press the MODE button repeatedly until the words

SET and CLOCK appear in the upper area of the display.

2.

Press the + or buttons 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 + or buttons 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.

17

Operating the Time Switch

Press the MODE button repeatedly to select the desired operating mode on
the 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 Time
Switch 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 + or buttons AT THE SAME TIME to display --:-- --.

4.

Press the MODE button to exit.

18

Battery Maintenance
Batteries can be easily replaced without removing the Time
Switch 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.

19

Section

Service Manual
Generator
The 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 Number ED0021751550-S
Replace Fuel Filter, Part Number ED0037300960-S

20

Mast
The 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 light
tower under normal wear and tear conditions, however, replacement may
be necessary. An exploded diagram and step by step mast assembly
directions follows.
********************************************

Control Box
The 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
21

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 service
technician who is qualified to work on electrical devices.
The battery switch should be switched to the off position 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.

22

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.

23

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.

24

Wiring Schematics

25

26

27

Section

Index
auto start, 13
battery specifications, 6
checklist, 1
dimensions, 5
electrical outlet, 14
frame, 3
generator 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, 19
serial numbers, 3
solar panels, 12
specifications, 4, 5
timer, 15
towing instructions, 7
Wiring diagrams, 22-24

28