Light Tower - Wacker Neusonproducts.wackerneuson.com/manuals/Repair/158565en_001Rep.pdf · Light Tower LTC 4L REPAIR MANUAL 0158565en 001 0404 0158565 EN

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Light Tower

LTC 4L

REPAIR MANUAL

0158565en 001

0404

0 1 5 8 5 6 5 E N

LTC Repair Foreword

Operating / Parts InformationYou must be familiar with the operation of this machine before youattempt to troubleshoot or make any repairs to it. Basic operating andmaintenance procedures are described in the operator’s manualsupplied with the machine. Keep a copy of it with the machine at alltimes. Use the separate parts manual supplied with the machine toorder replacement parts. If either of the manuals becomes lost, pleasecontact Wacker Corporation to order a replacement.

Damage caused by misuse or neglect of the unit should be brought tothe attention of the operator, to prevent similar occurrences fromhappening in the future.

This manual provides information and procedures to safely repair andmaintain the above Wacker model(s). For your own safety andprotection from injury, carefully read, understand, and observe allinstructions described in this manual. THE INFORMATIONCONTAINED IN THIS MANUAL IS BASED ON MACHINESMANUFACTURED UP TO THE TIME OF PUBLICATION. WACKERCORPORATION RESERVES THE RIGHT TO CHANGE ANYPORTION OF THIS INFORMATION WITHOUT NOTICE.

This manual covers machines with Item Number:

0009311

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Foreword LTC Repair

CALIFORNIA

Proposition 65 Warning:

Diesel engine exhaust, some of its constituents, and certain vehiclecomponents contain or emit chemicals known to the State of Californiato cause cancer and birth defects or other reproductive harm.

Laws Pertaining to Spark Arresters

Notice: State Health Safety Codes and Public Resources Codesspecify that in certain locations spark arresters be used on internalcombustion engines that use hydrocarbon fuels. A spark arrester is adevice designed to prevent accidental discharge of sparks or flamesfrom the engine exhaust. Spark arresters are qualified and rated bythe United States Forest Service for this purpose.

In order to comply with local laws regarding spark arresters, consultthe engine distributor or the local Health and Safety Administrator.

All rights, especially copying and distribution rights, are reserved.

Copyright 2004 by Wacker Corporation.

No part of this publication may be reproduced in any form or by anymeans, electronic or mechanical, including photocopying, withoutexpress written permission from Wacker Corporation.

Any type of reproduction or distribution not authorized by WackerCorporation represents an infringement of valid copyrights and will beprosecuted. We expressly reserve the right to make technicalmodifications, even without due notice, which aim at improving ourmachines or their safety standards.

WARNING

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LTC Repair Table of Contents

1. Safety Information 5

1.1 Operating Safety .................................................................................. 61.2 Operator Safety while using Internal Combustion Engines .................. 71.3 Towing Safety ....................................................................................... 81.4 Service Safety ...................................................................................... 91.5 Label Locations .................................................................................. 101.6 Safety and Operating Labels .............................................................. 12

2. Technical Data 19

2.1 Trailer ................................................................................................. 192.2 Generator ........................................................................................... 192.3 Engine ......................................................................................... 20

3. Operation 21

3.1 Locating Trailer ................................................................................... 213.2 Leveling Trailer ................................................................................... 223.3 Adjusting Lights .................................................................................. 223.4 Preparing Trailer for Towing or Lifting ................................................ 233.5 Raising Tower .................................................................................... 243.6 Lowering Tower .................................................................................. 263.7 Control Panels .................................................................................... 293.8 Starting ............................................................................................... 303.9 Automatic Shutdown .......................................................................... 303.10 Operation ............................................................................................ 313.11 Stopping ............................................................................................. 313.12 Derating .............................................................................................. 313.13 Receptacles ........................................................................................ 32

4. Maintenance 33

4.1 Periodic Maintenance Schedule ......................................................... 334.2 Installing / Removing Light Fixtures ................................................... 344.3 Replacing / Removing Bulbs .............................................................. 354.4 Daily Inspection .................................................................................. 354.5 Air Cleaner ......................................................................................... 36

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Table of Contents LTC Repair
4.6 Engine Oil ............................................................................................374.7 Engine Fuel Delivery System Maintenance .........................................384.8 Fuel Filter ............................................................................................384.9 Priming the Fuel System .....................................................................394.10 Schematic for 60 Hz Metal Halide 4-Light Units ..................................404.11 Metal Halide Schematic Components .................................................414.12 Schematic for 60 Hz High Pressure Sodium 4-Light Units ..................424.13 High Pressure Sodium Schematic Components ................................434.14 Generator Capacitor Excitation Schematic 60 Hz. ..............................444.15 Engine Wiring – Lombardini ................................................................464.16 Engine Control Panel Internal Wiring—Older Engines ........................474.17 Control Panel Schematic Components—Older Engines ..................474.18 Engine Control Panel Internal Wiring—Newer Engines ......................484.19 Control Panel Schematic Components—Newer Engines ...................494.20 Engine Control Panel Internal Component Diagrams .........................504.21 Engine Control Panel Internal Components ........................................514.22 Auxiliary Connections ..........................................................................514.23 Trailer Wiring .......................................................................................52
5. Teardown/Rebuild Procedures 53

5.1 Tools ....................................................................................................535.2 Ordering Parts .....................................................................................535.3 Reference Numbers ( ) ........................................................................535.4 Weight Block .......................................................................................535.5 Light Fixture Exploded View ................................................................545.6 Light Fixture List of Parts .....................................................................555.7 Light Assembly ....................................................................................565.8 Tower Assembly Exploded View .........................................................585.9 Tower Assembly List of Parts ..............................................................585.10 Upper Mast .........................................................................................595.11 Mid Mast ..............................................................................................61

6. Electrical Troubleshooting Procedures 63

6.1 Troubleshooting Flowchart ..................................................................636.2 Checking Engine .................................................................................696.3 Checking GFI ......................................................................................706.4 Replacing GFI .....................................................................................71


LTC Repair Table of Contents
6.5 Checking Voltage from Ballast ........................................................... 726.6 Checking Voltage to Ballast ............................................................... 736.7 Replacing Ballast ................................................................................ 746.8 Checking Circuit Breaker .................................................................... 756.9 Checking Bus Bar ............................................................................... 766.10 Removing Floodlight Control Panel .................................................... 776.11 Installing Floodlight Control Panel ...................................................... 786.12 Checking Generator Capacitor(s) ....................................................... 796.13 Alternative Capacitor Check ............................................................... 806.14 Replacing Capacitor(s) ....................................................................... 816.15 Checking Wire Continuity ................................................................... 836.16 Restoring Rotor Magnetism ................................................................ 856.17 Checking Stator Windings .................................................................. 876.18 Removing Generator and Engine ....................................................... 896.19 Separating Stator from Engine/Rotor ................................................. 936.20 Remounting Generator Stator to Rotor/Engine .................................. 956.21 Checking Rotor Diodes ...................................................................... 976.22 Checking Rotor Windings ................................................................... 986.23 Removing/Installing Rotor .................................................................. 99
7. Engine Troubleshooting 100


Table of Contents LTC Repair


LTC Repair Safety Information

1. Safety Information

This manual contains DANGER, WARNING, CAUTION, and NOTEcallouts which must be followed to reduce the possibility of personalinjury, damage to the equipment, or improper service.

This is the safety alert symbol. It is used to alert you to potentialpersonal injury hazards. Obey all safety messages that follow thissymbol to avoid possible injury or death.

DANGER indicates an imminently hazardous situation which, if notavoided, will result in death or serious injury.

WARNING indicates a potentially hazardous situation which, if notavoided, could result in death or serious injury.

CAUTION indicates a potentially hazardous situation which, if notavoided, may result in minor or moderate injury.

CAUTION: Used without the safety alert symbol, CAUTION indicatesa potentially hazardous situation which, if not avoided, may result inproperty damage.

Note: Contains additional information important to a procedure.

DANGER

WARNING

CAUTION

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Safety Information LTC Repair

1.1 Operating Safety

Familiarity and proper training are required for the safe operation ofequipment! Equipment operated improperly or by untrained personnelcan be dangerous! Read the operating instructions contained in boththis manual and the engine manual and familiarize yourself with thelocation and proper use of all controls. Inexperienced operators shouldreceive instruction from someone familiar with the equipment beforebeing allowed to operate the machine.

1.1.1 The area immediately surrounding the Light Tower should be clean,neat, and free of debris.

1.1.2 ALWAYS be sure machine is on a firm, level surface and will not tip,roll, slide, or fall while operating.

1.1.3 NEVER start a unit in need of repair.

1.1.4 Lower tower when not in use, or if high winds or electrical storms areexpected in the area.

1.1.5 ALWAYS make certain machine is well-grounded and securelyfastened to a good earthen ground per national and local regulations.

1.1.6 The tower extends up to 9 m (30 ft.). Make sure area above trailer isopen and clear of overhead wires and obstructions.

1.1.7 Bulbs become extremely hot in use! Allow bulb and fixture to cool 10–15 minutes before handling.

1.1.8 Keep area behind trailer clear of people while raising and loweringmast! Never raise, lower or turn mast while unit is operating!

1.1.9 Trailer must be leveled and outriggers extended before raising tower.Outriggers must remain extended while tower is up.

1.1.10 If for any reason any part of mast hangs up or winch cable developsslack while raising or lowering tower, STOP immediately! Contact anauthorized WACKER service representative.

1.1.11 NEVER remove mast locking pin while tower is up!

1.1.12 NEVER use tower if insulation on electrical cord is cut or worn through.

1.1.13 NEVER operate lights without protective lens cover in place or with alens cover that is cracked or damaged!

1.1.14 NEVER adjust mast while unit is operating.

1.1.15 NEVER raise the mast or operate the light tower in high winds.

WARNING

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1.2 Operator Safety while using Internal Combustion Engines

Internal combustion engines present special hazards during operationand fueling! Read and follow warning instructions in engine owner’smanual and safety guidelines below. Failure to follow warnings andsafety guidelines could result in severe injury or death.

1.2.1 NEVER operate machine indoors unless exhaust fumes can beadequately ventilated.

1.2.2 DO NOT fill or drain fuel tank near an open flame, while smoking, orwhile engine is running.

1.2.3 ALWAYS refill fuel tank in well-ventilated area.

1.2.4 DO NOT touch or lean against hot exhaust pipes.

1.2.5 ALWAYS replace fuel tank cap after refueling.

1.2.6 DO NOT remove radiator cap when engine is hot. Contents are hotand under pressure.

1.2.7 DO NOT use gasoline or other types of fuels or flammable solvents toclean parts, especially in enclosed areas. Fumes from fuels andsolvents can become explosive.

1.2.8 ALWAYS keep area around muffler free of debris such as leaves,paper, cartons, etc. A hot muffler could ignite them, starting a fire.

DANGER

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1.3 Towing Safety

Towing a large trailer requires special care! Both the trailer and vehiclemust be in good condition and securely fastened to each other toreduce the possibility of an accident.

1.3.1 ALWAYS check that the hitch and coupling on the vehicle are ratedequal to, or greater than, the trailer's “gross vehicle weight rating”(GVWR).

1.3.2 ALWAYS inspect the hitch and coupling for wear or damage. DO NOTtow trailer using defective parts!

1.3.3 ALWAYS make sure the coupling is securely fastened to the vehicle.

1.3.4 ALWAYS check tires on trailer for tread wear, inflation, and condition.Replace worn tires.

1.3.5 ALWAYS connect the safety chains.

1.3.6 ALWAYS make sure directional and trailer lights are connected andworking properly.

1.3.7 ALWAYS check that lug nuts holding wheels are tight and that noneare missing.

1.3.8 Maximum recommended speed for highway towing is 72 km/hour (45MPH). Recommended off-road towing speed is not to exceed 16 km/hour (10 MPH) or less depending on terrain.

1.3.9 ALWAYS refer to the applicable Department of Transportationregulations before towing.

WARNING

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1.4 Service Safety

HIGH VOLTAGE! This unit uses high voltage circuits capable ofcausing serious injury or death. Only a qualified electrician shouldtroubleshoot or repair electrical problems occurring in this equipment.

1.4.1 ALWAYS replace safety devices and guards after repairs andmaintenance.

1.4.2 Before servicing Light Tower, make sure engine start switch is turnedto OFF, circuit breakers are open (off), and negative terminal onbattery is disconnected. NEVER perform even routine service (oil/filterchanges, cleaning, etc.) unless all electrical components are shutdown.

1.4.3 DO NOT allow water to accumulate around the base of the machine.If water is present, move the machine and allow it to dry beforeservicing.

1.4.4 DO NOT service machine if clothing or skin is wet.

1.4.5 ALWAYS keep hands, feet, and loose clothing away from moving partson generator and engine.

1.4.6 ALWAYS keep machine clean and labels legible. Replace all missingand hard-to-read labels. Labels provide important operatinginstructions and warn of dangers and hazards.

1.4.7 ALWAYS make sure slings, chains, hooks, ramps, jacks and othertypes of lifting devices are attached securely and have enough weight-bearing capacity to lift or hold the machine safely. Always remainaware of the position of other people around you when lifting themachine.

WARNING

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1.5 Label Locations

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1.6 Safety and Operating Labels

Wacker machines use international pictorial labels where needed.These labels are described below:

Ref. Label Meaning

A DANGER! A non-secured, falling mast will cause serious injury or death if a person is hit. To secure mast, verify automatic locking pin has engaged to secure tower upright.

B WARNING! Avoid crushing area.

C WARNING! Completely lower tower before tilting mast. Tilting an extended mast could cause serious injury or death.

D Telescoping Tower:Pull and hold tower automatic locking pin before cranking tower up. Release pin after one turn of winch handle.

Collapsing Tower:Ensure that the automatic locking pin engages all sections of tower before travel.

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E DANGER! Contact with overhead electrical power lines will cause serious injury or death. Do not position light tower under electri-cal power lines.

F CAUTION! Lifting point

G WARNING! Secure mast in transport lock before lift-ing or towing. A loose swinging mast could cause personal injury or machine damage.

H DANGER! Asphyxiation hazard. Read the opera-tor’s manual for instructions. No sparks, flames, or burning objects near machine. Stop the engine before adding fuel. Use only diesel fuel.

Ref. Label Meaning

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I DANGER! Asphyxiation hazard. Read the opera-tor’s manual for instructions. No sparks, flames, or burning objects near machine. Stop the engine before adding fuel. Use only diesel fuel.

DANGER! Contact with overhead electrical power lines will cause serious injury or death. Do not position light tower under electri-cal power lines.

WARNING! Completely lower tower before tilting mast. Tilting an extended mast could cause serious injury or death.

J DANGER! Electrical storage device within. Contact a qualified electrician for service or to open electrical box. Electric shock will cause serious injury or death.

K Electrical ground.

L WARNING! Stand clear of front and rear of machine when mast is being tilted up or down.

M WARNING! Hot surface!

Ref. Label Meaning

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N A nameplate listing the Model Number, Item Number, Revision, and Serial Num-ber is attached to each unit. Please record the information found on this plate so it will be available should the name-plate become lost or damaged. When ordering parts or requesting service infor-mation, you will always be asked to spec-ify the model, item number, revision number, and serial number of the unit.

O WARNING! Ultraviolet radiation from lamp can cause serious skin and eye irritation. Use only with provided undamaged lens cover and fixture.

Ref. Label Meaning

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Ref. Label

P

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Q

R

S

Ref. Label

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Ref. Label Meaning

This machine may be covered by one or more patents.

Certification Label (VIN Number)Also attached to each unit is a Certifica-tion Label. This label specifies that the trailer conforms with all Federal Motor vehicle standards in effect at the time of manufacture. It includes the Vehicle Identification Number (VIN) for the trailer.

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Light Tower Technical Data

2. Technical Data

2.1 Trailer

2.2 Generator

LTC 4L0009311

Trailer

Operating weight (GVWR)

kg (lbs.)875 (1929)

Travel Dimensions (l x w x h)

cm (in.) 390 x 125 x 160(153 x 48 x 63)

Trailer length cm (in.) 335 (132)

Height - mast extended m (ft.) 9 (30)

Lighting system (1000 W) 4

Ballast Coil and core

Max. lighting coverage @ 0.5 ft. candles

acres (m2) Metal Halide - 7 (30,400)High Pressure Sodium - 9 (39,000)

Tires size ST175 / 80D13

LTC 4L0009311

Generator

Frequency Hz 60 ± 2

Continuous output kW 6.0

Output volts/phase 120 / 1Ø

Amps A 50

Excitation type Capacitor / Brushless

Power factor 1.0

Voltage regulation - No load to full load

%± 5.0

Speed (no-load) rpm 1850

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Technical Data Light Tower

2.3 Engine

LTC 4L0009311

Engine

Make Lombardini

Model LDW903

Type 3-cylinder, 4-cycle, liquid-cooled diesel

Maximum power rating kW (Hp) 9.0 (12.1)

Operating power rating kW (Hp) 8.1 (10.9)

Operating speed (no-load)

rpm1850

Alternator V / A / W 12 / 45 / 540

Battery V/CCA 12 / 450

Air cleaner type dry-type element

Fuel type No. 2 diesel

Fuel tank capacity l (gal.) 114 (30)

Fuel consumption l (gal.) / hr. 1.67 (0.44)

Running time hours 68

Coolant capacity l (qts.) 4.7 (5.0)

Oil capacity l (qts.) 2.4 (2.5)

Oil weight SAE 15W40 CD or higher

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Light Tower Operation

3. Operation

3.1 Locating Trailer

See Graphic: wc_gr000531

3.1.1 For maximum light coverage locate tower at ground level or in a spothigher than the area being lighted.

3.1.2 Position trailer on a firm, flat surface clear of overhead wires andobstructions. Be sure that there is enough area for outriggerextensions to be fully extended.

3.1.3 Connect ground stud (l) located on trailer frame to a good earthenground. Consult local codes for proper grounding techniques.

The tower extends up to 9 m (30 ft.). Make sure area above trailer isopen and clear of overhead wires and obstructions.

WARNING

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Operation Light Tower

3.2 Leveling Trailer

See Graphic: wc_gr000531, wc_gr000534

Trailer must be leveled and outriggers extended before raising tower.Outriggers must remain extended while tower is up. Failure to leveltrailer or extend outriggers will severely reduce the stability of the unitand could allow tower to tip and fall.

3.2.1 Pull locking pin on tongue jack (a) and rotate jack down 90° as shownin illustration. Make sure jack snaps into position.

Block or chock trailer wheels (b). Crank jack down to raise trailertongue off vehicle.

3.2.2 Pull outrigger lock pin (c) to release outrigger. Pull both outriggerextensions (d) out until you feel pin lock back in place. Rotate jacks (e)down until they snap into position.

3.2.3 Rotate rear jack (f) down, as shown, making sure it snaps into place.

3.2.4 Extend jack(s) on the highest side(s) of the trailer until they rest firmlyon the ground. Extend remaining jacks until trailer is level.

3.3 Adjusting Lights


Each light fixture can be aimed up, down, left or right. Position eachfixture by loosening toolless light adjusters (g) and aiming light up ordown. Loosen nut (h) to turn light fixtures left or right. Tightenadjusters and nuts after positioning lights.

Always return light fixtures to aim at ground when mast is in the cradlefor towing.

WARNING

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3.4 Preparing Trailer for Towing or Lifting


3.4.1 On units using manual winches check that mast cradle lock pin (j) is inplace and secured with safety pin.

3.4.2 Ensure that tower section automatic locking pin (t) engages allsections of tower before travel.

3.4.3 Make sure doors are properly latched.

3.4.4 Return outriggers to their travel position (i). Check that outrigger barsand jacks are locked in place.

3.4.5 Crank rear jack (f) all the way in and rotate it up 90°.

The light tower is now ready to lift. For towing, continue.

3.4.6 Use tongue jack (a) to raise trailer tongue up and then lower it overhitch on towing vehicle. Lock hitch to coupling and attach safetychains. Swivel tongue jack up 90° and lock it in place.

3.4.7 Connect trailer wiring to towing vehicle. Check brake, turn, and taillights for proper operation.

3.4.8 Position light fixtures down (k). For rough, off-road transportationremove bulbs from fixtures to avoid damage.

3.4.9 Check tire inflation.

3.4.10 Attach red flag to end of mast before towing.

CAUTION: Maximum recommended speed for highway towing is 45MPH. Recommended off-road towing speed is not to exceed 10 MPHor less depending on terrain.

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3.5 Raising Tower


NEVER raise the mast or operate the Light Tower in high winds.

NEVER raise the mast while the engine is running.

HIGH VOLTAGE! DO NOT use Light Tower if insulation on electricalcord is cut or worn through. Repair or replace cord before using. Barewires in contact with the metal frame of the trailer or tower can causeelectrocution.

DO NOT position Light Tower under electrical power lines.

NEVER allow anyone to stand near the rear of the unit while raising themast.

The Light Tower includes two separate winches. One for lifting themast to the vertical position, the other for raising the tower. Each winchis an automatic brake-type winch that automatically brakes when thehandle is released. The handle must be rotated to wind in cable as wellas unwind cable.

NEVER touch the winch pawl! Releasing the pawl may cause themast or tower to fall.

3.5.1 Check winch cables (a, b) for wear or damage, and make sure they areresting properly in pulleys. Do not use the Light Tower if either winchcable is damaged.

3.5.2 Remove cradle locking pin (c) from cradle.

3.5.3 Check operation of tongue-mounted winch (d) by rotating the winchhandle 1/4-turn clockwise (“cable in” direction). The winch pawl mustengage winch gear teeth. When operating properly, it will make a“clicking” sound when handle is rotated clockwise. Do not attempt toraise the mast if the winch is damaged or not operating properly.

3.5.4 Continue to rotate the handle and raise the mast to the vertical positionuntil the vertical mast locking pin (e) locks mast in place. Be certain pinis fully engaged in the locking position before raising tower.

NEVER pull vertical mast locking pin (e) while tower is raised!Releasing locking pin while tower is raised may cause tower to fall ormachine to tip over.

WARNING

WARNING

WARNING

WARNING

WARNING

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3.5.5 After mast is in the vertical position and locked in place, pull and hold
out tower-section automatic locking pin (f). Check operation of mast-mounted winch (g) by rotating the winch handle 1/4-turn clockwise(“cable in” direction). The winch pawl must engage winch gear teeth.When operating properly, it will make a “clicking” sound when handleis rotated clockwise. Do not attempt to raise the mast if the winch isdamaged or not operating properly. Continue rotating winch handleand release locking pin after one full turn. Raise mast to the desiredheight. Do not over crank winch when tower is fully extended.

3.5.6 Once tower is at desired height, rotate mast to desired direction. Torotate, loosen rotation locking knob (h), and using handle (i), rotatemast until the lights face the desired direction, then retighten knob.

wc_tx000133gb.fm 25


3.6 Lowering Tower


Be sure you read and understand operating instructions beforelowering tower!

If for any reason any part of the mast hangs up or winch cable developsslack before mast is fully lowered, stop immediately! Continuing toturn the winch handle will increase slack in the cable. This could causemast to collapse should it suddenly free up. If mast hangs up, level thetrailer. Slightly shake or twist the tower assembly to free bind. Contactan authorized WACKER service representative.

NEVER lower mast while unit is operating.

NEVER allow anyone to stand near the rear of the unit while loweringthe mast.

3.6.1 Turn lights off. Shut down engine.

CAUTION: Shutting down engine before turning off lights coulddamage floodlight ballasts or generator capacitor(s).

3.6.2 CAUTION: Observe power cord while lowering tower. Make surecoiled cord is not damaged during lowering process.

Lower tower by turning handle on the mast-mounted winch (g)counterclockwise (“cable out” direction). Turn handle until slackappears in cable (a) and tower-section automatic locking pin (f) lockstower sections together.

NEVER touch the winch pawl! Releasing the pawl may cause themast or tower to fall.

3.6.3 Loosen rotation locking knob (h) and using handle (i), rotate mast solights face the rear of trailer and mast-mounted winch is facing towardtrailer tongue.

WARNING

WARNING

WARNING

WARNING

wc_tx000133gb.fm 26

3.6.4 Pull and hold mast locking pin (e). Rotate handle on tongue-mounted
winch (d) counterclockwise (“cable out” direction) until the mast springbegins to pivot the mast down. Release mast locking pin and continueto rotate handle until mast is resting in transport cradle.

NEVER pull vertical mast locking pin (e) while tower is raised!Releasing locking pin while tower is raised may cause tower to fall ormachine to tip over.

3.6.5 After mast is down, secure it in cradle by inserting cradle lock pin (c).Insert clip through pin to secure it in place.

3.6.6 Position light fixtures to aim at ground.

CAUTION: Allow floodlights to cool 10–15 minutes before movingtrailer. Moving trailer while lights are still hot could cause bulbs tobreak.

WARNING

wc_tx000133gb.fm 27


Ref. Description Ref. Description

a Tower cable f Tower section locking pin

b Mast cable g Mast-mounted winch

c Tower cradle pin h Rotation locking knob

d Tongue-mounted winch i Rotating handle

e Mast locking pin

wc_gr001773

9 m(30 ft)

a

be

f

gi

h

d

c

wc_tx000133gb.fm 28


3.7 Control Panels

Floodlight Control Panel Engine Control Panels


a 20 Amp GFI circuit breaker k High coolant temperature indicator

b 15 Amp light circuit breaker l Alternator indicator

c 20 Amp GFI receptacle m Low fuel indicator (not used)

d Hour meter n Safety shutdown indicator

e Key access door o Low oil pressure shutdown

f Glow plug indicator p High coolant temperature shutdown

g OK indicator q Auxiliary light (not used)

h Air filter restriction indicator r Auxiliary light (not used)

j Low oil pressure Indicator s System fuse/auxiliary connection access door (output terminals)

wc_gr001799

00 0

HOURS0 0 0

ON

ON

ON

OFF

15

OFF

OFF

15

15

ON

ON

OFF

OFF

15

15

RESET

TEST

(2)

(4)

(3)

(1)(2)

(3)

101979-002

(4)

FLOODLIGHT SWITCHES

(1)

a

b

d

c

m

h

q

e

n o p l r fg

n

o p rq

j k l m h

f

se

wc_tx000133gb.fm 29


3.8 Starting


3.8.1 Check engine oil, fuel and coolant levels.

Note: If fuel tank was drained or run dry it may be necessary to bleedfuel lines. Refer to Engine Operator’s Manual.

3.8.2 Check condition of electrical cable on mast. Do not start generator ifinsulation on cable is cut or worn through.

3.8.3 Check that the circuit breakers (a, b) are in their “OFF” position.

CAUTION: Starting engine under load will damage the machine.

3.8.4 On machines equipped with the Lombardini engine, turn key (e) oneclick right. Glow plug indicator (f) will illuminate until engine is properlypreheated. This is an automatic timer based on engine temperature.Crank engine immediately after glow plug light goes off.

3.8.5 Turn key (e) to “START” and hold until engine starts. Release key afterengine starts. On older model engines, indicator light (g) will light if allsystems are on.

CAUTION: Do not crank engine longer than 10 seconds. This couldcause starter motor to overheat. Return switch to “OFF” and wait 15-30 seconds for starter motor to cool down before attempting to preheatand restart.

Note: If oil pressure is not obtained within 30 seconds after key isturned to “RUN”, the automatic shutdown system will shut off the fuelsupply. You must return the key to the “OFF” position to restart the 30second timer before attempting to restart the engine.

3.8.6 Allow engine to warm up before operating floodlights.

3.9 Automatic Shutdown

This unit is equipped with a low oil, high temperature auto-shutdownsystem. This system will automatically shut off the fuel supply to theengine if oil pressure drops too low or engine exceeds normaloperating temperatures. Return key switch to “OFF” to reset unit afteran engine shutdown.

wc_tx000133gb.fm 30


3.10 Operation


Turn on circuit breaker (a) first then turn each circuit breaker (b) “ON”,one at a time.

Metal Halide Floodlights require a warm-up of 5–15 minutes beforethey reach full output. If floodlights are shut down, a 10-minute cool-down period is required before turning them back on.

High Pressure Sodium Floodlights require 1–2 minutes to start and 2–5 minutes of cooldown time to restart.

3.11 Stopping


3.11.1 Turn circuit breakers (a, b) off and remove any other loads fromgenerator.

CAUTION: Never shut down engine without turning off lights. Damageto the generator will occur.

3.11.2 Turn key (e) to “OFF”.

3.12 Derating

All generator sets are subject to derating for altitude and temperature.

Ratings are typically reduced 3% per 300 m (1000 feet) elevation fromsea level, and 2% per 10°F (5.5°C) increase in ambient temperatureabove 78°F (25°C).

wc_tx000133gb.fm 31


3.13 Receptacles


The control panel is equipped with a convenience receptacle forrunning accessories and tools from the generator. Power to thisreceptacle is available any time the engine is running and the circuitbreaker is “ON”.

CAUTION: Do not draw more than 2000 Watts (16.6 Amps) from thereceptacle with all of the lights on or the lights will turn off.

A 20A circuit breaker (a) protects the 120V GFI receptacle (c). The120V GFI receptacle should be tested for proper operation each timeit is used.

To test a GFI:

With the engine running, push the test button in. The reset buttonshould pop out. Power to the receptacle is now off. To restore powerto the receptacle, push reset button in.

CAUTION: If the reset button does not pop out, the GFI is defective.Do not use the receptacle until the problem can be corrected.

If the reset button pops out during use, check the generator andattachments for defects.

wc_tx000133gb.fm 32

LTC Repair Maintenance

4. Maintenance

4.1 Periodic Maintenance Schedule

Beforeeachuse

Every125

hours

Every250

hours

Every500

hours

Every1000 hours

or two years

Check for fluid leaks. •

Check engine oil. •

Check fuel level. •

Replace air filter if indicator light is on.** •

Change engine oil.* •

Check level of battery electrolyte. •

Check condition and tension on fan belt. •

Check condition of radiator hoses. •

Replace oil filter.* •

Replace fuel filter. •

Flush radiator. •

Replace fan belt. •

Check valve clearance. •

Remove sediment in fuel tank. •

Change radiator coolant. •

Replace battery. •

Replace radiator hoses and clamps. •

Replace fuel pipes and clamps. •

* Change engine oil and filter after first 50 hours of operation.** Replace air filter after air filter restriction switch indication or one year. Lombardini does not recommend

the removal of air filter elements for purposes of inspection.

wc_tx000362gb.fm 33

Maintenance LTC Repair

4.2 Installing / Removing Light Fixtures


Remove fixtures by disconnecting electrical cords using the quickdisconnects (a). Remove nuts (b) from fixture mounting brackets andremove both fixture and bracket off stud.

CAUTION: Only a trained technician should be allowed to install andremove fixture wiring.

NOTE: When reinstalling the lamp fixtures, make sure the drain holeis pointing down.

Bulbs become extremely hot in use! Allow bulb and fixture to cool10-15 minutes before handling.

Numbering Sequence of Floodlights Connection Box Wiring for Floodlights

Wire Colors

B Black R Red Y Yellow Or Orange

G Green T Tan Br Brown Pr Purple

L Blue V Violet Cl Clear Sh Shield

P Pink W White Gr Gray LL Light Blue

WARNING

wc_tx000362gb.fm 34


4.3 Replacing / Removing Bulbs

The light tower uses four 1000 W bulbs. When replacing or removingbulbs avoid leaving any grease or oil residue on glass surface. Thiscan create hot spots, reducing the service life of the bulb or causingouter jacket to burst.

Bulbs become extremely hot in use! Allow bulb and fixture to cool10–15 minutes before handling.

NEVER operate lights without protective lens cover in place orwith a lens cover that is cracked or damaged! The lamps used inthe floodlights produce high temperatures and operate underpressure. They are subject to failures where the outer jacket burstsand shatters, resulting in a discharge of extremely hot glass particles.These particles pose a risk of personal injury, property damage, burnsand fire.

Ultraviolet radiation from lamp can cause serious skin and eyeirritation. Use only with provided undamaged lens cover and fixture.

4.4 Daily Inspection

4.4.1 Check for fluid leaks. Check fluid levels.

4.4.2 Inspect condition of electrical cords. Do not use light tower if insulationis cut or worn through.

4.4.3 Check that winch cables are in good condition. Do not use a cable thatis kinked or starting to unravel.

4.4.4 Check that the vertical mast locking pin and the tower sectionautomatic locking pin are secured, aligned and operating properly.

4.4.5 Check that the springs located in the locking pins are not broken ormissing.

WARNING

WARNING

WARNING

wc_tx000362gb.fm 35


4.5 Air Cleaner


Replace the air filter cartridge when the indicator (l) mounted on thecontrol panel appears or once per year.

4.5.1 Open air cleaner and remove element.

4.5.2 To clean the filter, lightly tap on a hard surface to eliminate all excessdirt. Do not blow the paper filter element with compressed air to clean.Clean the filter cover and support carefully.

4.5.3 Reassemble the filtering element and air cleaner.

wc_gr000540

wc_tx000362gb.fm 36


4.6 Engine Oil


Drain oil while engine is still warm.

Note: In the interests of environmental protection, place a plastic sheetand a container under the machine to collect any liquid which drainsoff. Dispose of this liquid in accordance with environmental protectionlegislation.

4.6.1 Remove the oil drain plug.

4.6.2 Allow the oil to drain.

4.6.3 Install the drain plug.

4.6.4 Fill the engine crankcase through the oil filler opening, to the uppermark on the dipstick. See Technical Data for oil quantity and type.

4.6.5 Install oil filter cap

wc_gr000541

wc_tx000362gb.fm 37


4.7 Engine Fuel Delivery System Maintenance

Maintenance to the engine fuel delivery system should be performedby an experienced mechanic familiar with diesel engines. For detailedmaintenance procedures on the engine fuel system, refer to the enginemanual supplied with the machine at time of shipment.

4.8 Fuel Filter


Change engine fuel filter every 300 hours of operation.

To change fuel filter:

4.8.1 Remove filter (a) from engine block.

4.8.2 Install new filter. If necessary, prime fuel lines as described in nextsection.

wc_tx000362gb.fm 38


4.9 Priming the Fuel System


If the fuel tank has been run completely dry or drained for service, it willbe necessary to manually prime the fuel system.

To prime the fuel system:

4.9.1 Turn both the key switch on the machine, and the on-off switch oncontrol box, on. This will open the fuel valve.

4.9.2 Loosen the bleed screw on the fuel filter and pump the lever on the fuelpump (b) until fuel flows freely from the bleed screw. Tighten the bleedscrew.

4.9.3 Repeat this procedure for the fuel line bleed screw (c).

wc_tx000362gb.fm 39


4.10 Schematic for 60 Hz Metal Halide 4-Light Units

+

- wc_gr001774

d

L2 L

W W/B

W

OrW

W

W

W

W

W R/B

W

4

12 10 9

2

7 6 5

T5T2/T4 T

W

GND

GND

g

a

m

n

l

h

o

b

c

ef

g

g

g

d

d

d

h

h

h

h

m

n

k

l

n

n

l m

l m

i

j

4

1

3

2W

B

G

W

B

G

W

B

G

W

B

G

R/B L

W/B R W B GOr

wc_tx000362gb.fm 40


4.11 Metal Halide Schematic Components



a Generator i Auxiliary terminals of engine control panel

b Terminal strip j Ground bar

c Terminal input lugs k Hour meter

d Floodlight receptacles l Transformer

e 20 Amp GFI outlet m Capacitor

f 20 Amp GFI circuit breaker n Ballasts

g 15 Amp circuit breaker o Upper mast junction box

h Quick disconnect plugs

Wire Colors





wc_tx000362gb.fm 41


4.12 Schematic for 60 Hz High Pressure Sodium 4-Light Units

+

- wc_gr001775

l

L2 L

W W/B

W

OrW

W

W

W

W

W R/B

W

T5T2/T4 T

W

GND

GND

COM

TAP

CAP

COM

CAP

TAP

COM

CAP

TAP

COM

CAP

TAP 4

12 10 9

2

7 6 5

i

4

1

3

2W

B

G

W

B

G

W

B

G

W

B

G

R/B L

W/B R W B GOr

g

a

m d

h

n

n

h

o

b

c

ef

g

g

d

d

n

m

l m

l

g

h

hn

l md

h

k

j

wc_tx000362gb.fm 42


4.13 High Pressure Sodium Schematic Components



a Generator i Auxiliary terminals of engine control panel

b Terminal strip j Ground bar

c Terminal input lugs k Hour meter

d Floodlight receptacles l Transformer

e 20 Amp GFI outlet m Igniter

f 20 Amp GFI circuit breaker n Ballasts

g 15 Amp circuit breaker o Upper mast junction box

h Quick disconnect plugs

Wire Colors





wc_tx000362gb.fm 43


4.14 Generator Capacitor Excitation Schematic 60 Hz.

Serial Number 5409647 and below.


1 Rotor 4 Capacitor

2 Stator 5 Generator/Terminal block

3 Excitation coils 6 Control box-lights

wc_gr001632

wc_tx000362gb.fm 44


Serial Number 5409648 and above


1 Rotor 4 Capacitor

2 Stator 5 Generator/Terminal block

3 Excitation coils 6 Control box-lights

wc_tx000362gb.fm 45


4.15 Engine Wiring – Lombardini

Ref. Description Ref. Description Ref. Description

1 Fuel solenoid 7 Air filter restriction indicator (normal open type)

13 Harness connector

2 Glow plugs 8 Low fuel level switch (not used, normal open type)

14 Diode

3 Starter motor 9 Low oil pressure switch (normal closed type)

15 Resistors(2x220 Ohm, 0.6 W)

4 Battery 10 Coolant high temperature switch (normal open type)

16 Blade connector

5 Alternator connector 11 Coolant temperature thermistor (for preheat relay)

17 Spade ground connector(Not used. Provided for possible replacement fuel solenoid.)

6 Coolant temperature sending unit (Not used. Provided for remote temperature gauge or LED.)

12 Alternator

5

1 17

2

34

5

6

7

89 10

11

12

14

13

16

B+

Pr

G

G

Or

Or

L

D+

W

12V/45A

wc_gr001776

15

wc_tx000362gb.fm 46


4.16 Engine Control Panel Internal Wiring—Older Engines

4.17 Control Panel Schematic Components—Older Engines


1 System fuse, 50 Amp 4 Key switch

2 Glowplug load relay 5 L.E.D. Indicator lamp assembly

3 Auxiliary terminals (rear view)

L

BL

W/ROr

B

PrR

Gr

W

L

PBr

Y/G

GB

W

BBr

Y/G

R

R

86

85

30 87

4 27 6 5

12 10 9

50

30

15 / 54

wc_gr000658

1

2

5

3

4

1

2

3

4

5

6

7

8

9

10

11

12

13

14

wc_tx000362gb.fm 47


4.18 Engine Control Panel Internal Wiring—Newer Engines

a

b

c

f

d

e

9 8 10 1 11 12 24

Or BrW Gr

Gr

Y

R R R R RY

G Y L P W/L

S3

3

6

A

5

B

7 R

B

L

V

R/WEV

ACC

(Max 0,8A)

(Max 10A)

(12V)

(Max 12A)

(Max 50A)B

Y/G

70A

5030

15

14

S5

S1

S2S4

13

wc_gr001997

wc_tx000362gb.fm 48


4.19 Control Panel Schematic Components—Newer EnginesSee graphic: wc_gr001997


a Key switch d Engine protection

b 15A fuse e Preheating

c 80A fuse f Relay

Wire Colors





wc_tx000362gb.fm 49


4.20 Engine Control Panel Internal Component Diagrams

2

5 6

10 12

7

4

14

13

12

11

10

9

8

7

6

5

4

3

1

4

12 10 9

7 6 5

2

2

a1

f1

a2

f2

b

c

d

e

g

h

86

30

50

30

15/54

85

87wc_gr001778

1

2

b

c

d

g

e

86

30

85

87

50

30

wc_gr001800

14

13

12

11

10

9

8

7

6

5

4

3

1

2

1

2

1

2

i1 i2

jk

l

g

X

X

Or W

Br

Pr

Y/G Or

wc_tx000362gb.fm 50


4.21 Engine Control Panel Internal Components

See graphic: wc_gr001778 or wc_gr001800

4.22 Auxiliary Connections

See graphic: wc_gr001778


a1 Engine control panel, front view(older engines)

g System fuse

a2 Engine control panel, rear view(older engines)

h Key access door

b Solid state glowplug controller and indicating lamps

i1 Engine control panel, front view(newer engines)

c Shutdown relay location i2 Engine control panel, rear view(newer engines)

d Glowplug relay j Auxiliary connections(newer engines)

e Key switch k Light switch panel connection(newer engines)

f1 Auxiliary connections, front view(older engines)

l 15 A fuse

f2 Auxiliary connections, rear view(older engines)

Ref Description Ref Description

2 Coolant temperature sending unit (optional)

7 Low oil pressure switch

4 15/54 (key ON) circuit 9 Alternator light

5 Auxillary shutdown 10 Electronic tachometer connection (Alternator W)

6 Auxillary shutdown 12 Battery negative (B–)

wc_tx000362gb.fm 51


4.23 Trailer Wiring


a Right stop, turn and tail light d Side light, red

b Left stop, turn and tail light e License plate light

c Side light, amber

Wire Colors

G Green Right stop and turn light

Y Yellow Left stop and turn light

Br Brown License plate, tail and side light

W White Ground

wc_tx000362gb.fm 52

LTC Repair Teardown/Rebuild Procedures

5. Teardown/Rebuild Procedures

5.1 Tools

Since all possible problems encountered while repairing theequipment cannot be anticipated, it is up to the mechanic to usecommon sense and good judgment in tool selection.

The use of any special tools is recommended only for those operationswhere the use of conventional tools proves inadequate.

Before substituting another tool or procedure, you should be satisfiedthat neither personal injury nor damage to the component will result.

5.2 Ordering Parts

The repair procedures contained in this manual do not include partnumbers. For parts replacement information, refer to the Parts Manualoriginally supplied with the unit.

If the original Parts Manual has been lost, a replacement manual maybe ordered from Wacker Corporation. When ordering a replacementParts Manual, please list model number, item number, revision level,and serial number of machine. Parts manuals are also available on theWacker Corporation Web site. See www.wackergroup.com. Enter siteas visitor.

5.3 Reference Numbers ( )

Repair procedures contain reference numbers enclosed inparentheses ( ). These numbers refer to the item numbers shown onthe assembly drawings and other detailed drawings. They are includedto aid the mechanic in identifying parts and assembling components.

5.4 Weight Block


The weight block symbol gives an approximate weight measurementto aid the mechanic when lifting / hoisting larger components.

250 kg(550 lbs.)

wc_gr000843

wc_tx000348gb.fm 53

Teardown/Rebuild Procedures LTC Repair

5.5 Light Fixture Exploded View

h

j

ml

i

n

o

k

a b

c

d

e

f

wc_gr001502

g

wc_tx000348gb.fm 54


5.6 Light Fixture List of Parts


a Clamping ring screw i Reflector

b Outer clamping ring j Reinforcement ring

c Lens gasket k Gasket

d Lens l Screw

e Bulb positioner m Light socket assembly

f Bulb (high-pressure sodium) n Fixture

g Bulb (Metal Halide) o Reinforcement ring

h Bolt

wc_tx000348gb.fm 55


5.7 Light Assembly

See graphics: wc_gr001502 and wc_gr001523

Teardown

Allow light to cool before performing procedure. For easier handling,remove light assembly from upper mast.

5.7.1 Remove screw (a) from outer clamping ring (b) and remove ring.

5.7.2 Remove lens (d) and gasket (c).

5.7.3 Remove wire bulb positioners (e).

5.7.4 Using gloves, unscrew and remove the bulb (f).

5.7.5 Loosen the four bolts (g) securing the reflector (h). Rotate the reflectoruntil it and the reinforcement ring (i) may be removed. Remove thereflector and the ring. Also remove the gasket (j).

5.7.6 Loosen the strain relief fitting (k) and slide it back on the cordapproximately 8 inches (20 cm).

5.7.7 Remove the two screws (l) securing the light socket assembly (m) andpull the assembly from inside the fixture (n) to reveal the wiring. Thewiring from the light socket to the fixture is spliced together usingcrimp-type wire nuts. Cut the nuts at the shoulder to separate thewires. Cutting the nut at the shoulder conserves wire. Remove thescrew securing the ground wire to the light socket assembly. Also cutthe plastic wire tie. Pull the light socket assembly free of the fixture.

wc_tx000348gb.fm 56

See graphics: wc_gr001502, wc_gr001523, wc_gr001524, andwc_gr001525
Rebuild

5.7.8 Strip back insulation approximately 1/4" (6 mm) from the lead end ofthe wires that run from the fixture and the wires that lead from the lightsocket assembly. Using a crimp-type wire nut, splice the wirestogether; black to black, and white to white. Refer to the wiringschematic. Connect the ground wire to the bottom of the light socketassembly. Bundle the wiring together and secure with a wire tie.

5.7.9 Slide the strain relief fitting (k) back to the light socket assembly (m)and re-attach it to the assembly.

5.7.10 Re-install the reflector (h), gasket (i), and reinforcement ring (i).Tighten the four bolts (g).

5.7.11 Clean bulb with alcohol before installing. Using gloves, insert a bulb (f)into the light socket.Caution: Do not touch bulb with bare skin. Oils transferred from skincan develop hot spots on bulb which may lead to shorter bulb life.

5.7.12 Interlock the two bulb positioners by sliding them together (e) andinstall them over the bulb and onto the rim of the reflector (h).

5.7.13 Clean the glass lens (d) and insert it into the gasket (c). Set the lenswith gasket over the bulb positioners and onto the rim of the reflector.Wrap the clamping ring around the rim. Tap the ring into place with arubber mallet if necessary. Secure the clamping ring to the reflectorusing screw (a). If necessary, use a flat head screw driver to pry thegasket into place. Be careful not to damage gasket.

wc_gr001524

wc_tx000348gb.fm 57


5.8 Tower Assembly Exploded View

5.9 Tower Assembly List of Parts


a Main mast (4-inch tube) h Mid-mast pulley

b Winch i Mid mast (3-inch tube)

c Main mast cable j Cross member

d Main mast pulley k Upper mast (2-inch tube)

e Main mast guide l Junction box

f Upper mast cable m Cross member wiring cable clamps

g Mid-mast guide n Mid-mast wiring cable clamps

wc_gr001530

j

(550 lbs.)250 Kg

a

b

c

d

e f gh

i n lmk

wc_tx000348gb.fm 58


5.10 Upper Mast

See graphics: wc_gr001530, wc_gr001532

Upper Mast Teardown

Turn lights off, turn unit off, and lower mast assembly into cradle beforeperforming procedure. Place the Light Tower in a position with enoughroom so that the masts may be extended fully while in the downposition.

The mast cable system consists of two cables: one (c) connected tothe winch mounted on the main mast that raises the mid mast; and asecond (f) that is connected to both the upper mast and the lower mast.This second cable raises the upper mast as the mid mast is beingraised.

5.10.1 Remove all the lights from the upper mast.

5.10.2 When replacing the upper mast cross member (j) only, disconnect thewiring cable clamps (m) and the junction box (l), then simply replacethe cross member. When replacing cables or portions of the mast, thejunction box may remain mounted to the cross member. Disconnectthe wiring cable clamp (n) from the mid mast, then disconnect thecross member with box attached and place it near the trailer.

5.10.3 Using the winch, back off the tension of the cable until the cable maybe unwound from the winch. Unwind the cable.

5.10.4 Remove the five guides (e) from the inside of the end of the mid mast(i).

5.10.5 Pull the upper mast partially (2–6 feet (1–2 m)) out of the mid mast.

5.10.6 Make note of upper mast cable routing through mid-mast pulley and1/4" positioning hardware. Remove the pulley. Remove the positioninghardware only if it needs replacing.

5.10.7 Remove the upper mast (k) completely from the mid mast.

5.10.8 Remove the 3/8" hardware securing the cable to the upper mast.

5.10.9 Remove the 3/8" hardware securing the cable to the main mast.

wc_tx000348gb.fm 59

See graphic: wc_gr001530 and wc_gr001533
Upper Mast Rebuild

5.10.10 Attach cable (f) to upper mast (k) using 3/8" hardware.

5.10.11 Hold cable snug to lower side of upper mast and insert it into the midmast (i) 3/4 of the way, approximately 7 feet (2.3 m).

5.10.12 Position upper mast cable parallel to main mast (a) and connect it tothe main mast using 3/8" hardware.

5.10.13 Route cable around mid-mast pulley (h) and install the pulley.

5.10.14 If replacing 1/4" positioning hardware, install the hardware and wiringcable clip (n). Do not overtighten hardware; pulley may bind.

5.10.15 Re-install the five guides (g) into the end of mid mast.

Note: There are two different shapes of guides. Install the two smallerguides on the pulley side of the mast.

The guides must be installed because they serve as safety stops.Without them properly installed, the upper mast section could be pulledout of the mid-mast section, possibly causing severe bodily harm.

5.10.16 Slide the upper mast completely into the mid mast.

WARNING

wc_gr001533

wc_tx000348gb.fm 60


5.11 Mid Mast


Mid-Mast Teardown

Turn lights off, turn unit off, and lower mast assembly into cradle beforeperforming procedure. Place the Light Tower in a position with enoughroom so that the masts may be extended fully while in the downposition.

The mast cable system consists of two cables: one (c) connected tothe winch mounted on the main mast that raises the mid mast; and asecond (f) that is connected to both the upper mast and the lower mast.This second cable raises the upper mast as the mid mast is beingraised.

5.11.1 Remove all the lights from the upper mast.

5.11.2 Remove the upper mast cross member (j) with junction box attached.

5.11.3 Remove the 1/4" hardware securing the upper mast cable to the mainmast.

5.11.4 Using the winch, back off the tension of the cable until the cable maybe unwound from the winch. Unwind and remove the cable from thewinch.

5.11.5 Remove the five guides (e) from the inside of the end of the main mast(a).

5.11.6 Remove the main mast pulley (d).

5.11.7 Using the aid of an assistant or appropriate hoist, pull both the upperand mid-mast sections from the main mast.

5.11.8 Remove the 3/8" carriage bolt securing the cable to the mid mast.

The mid-mast cable may now be replaced. If the mid mast requiresreplacement, continue.

5.11.9 Remove the five guides (g) from the inside of the end of the mid mast(i).

5.11.10 Remove the mid-mast pulley (h).

5.11.11 Pull the upper mast free of the mid mast.

wc_tx000348gb.fm 61



Mid-Mast Rebuild

5.11.12 Attach cable (c) to mid mast (i) using 3/8" hardware.

5.11.13 Hold cable snug to upper side of mid mast and insert it into the mainmast (a) 3/4 of the way, approximately 7 feet (2.3 m).

5.11.14 Re-install the five guides (g) into the end of the mid mast.

Note: There are two different shapes of guides. Install the two smallerguides on the pulley side of the mast.

The guides must be installed because they serve as safety stops.Without them properly installed, the mid-mast section could be pulledout of the main mast section, possibly causing severe bodily harm.

5.11.15 Route cable around main mast pulley (d) and install the pulley.

5.11.16 Slide the mid mast completely into the main mast.

5.11.17 Attach the cable to the winch.

5.11.18 See Section Upper Mast Rebuild for installing upper mast.

WARNING

wc_tx000348gb.fm 62

LTC Repair Electrical Troubleshooting

6. Electrical Troubleshooting Procedures

6.1 Troubleshooting Flowchart

The troubleshooting flowchart is designed to step you through theprocess of determining the source of a problem with the electricalsystem if one should exist. Many of the tests mentioned involve livevoltages and therefore should only be attempted by qualifiedpersonnel. The procedures for carrying out the tests are listedfollowing the flowchart. The flowchart includes references (by sectionnumber) to the location of the specific procedure(s).

wc_tx000359gb.fm 63

Electrical Troubleshooting Procedures LTC Repair

Light(s) Not Working

Is engine running at proper

rpm?

Check engine rpm with a photo tach

or vibrotach (Sirometer (wire whip))If rpm is low:

1. Change engine air and fuel filters.2. If necessary, reposition speed control

lever on injection pump.

Circuitbreaker(s) in closed

position?Close circuit breaker(s).

Are bulbs black or

burnt?Replace bulbs.

No

No

No

Yes

Yes

Yes

Yes

Yes

Yes

YesReset

No

No

No

No

Is 120±10% V measured at

GFI?

If the button can't be reset or there is no power to GFI, check the wiring at back of GFI.

Discharge generator capacitor(s) and check for rated capacitance.

Is test button

"popped out"?

Replace GFI.

See Flowchart 1B.

Yes

See Flowchart 1D.

Replace capacitor.

Does capacitor measure

35 µF?

Unplug lights and check for voltage from ballast by measuring voltage across terminal strip white wires and neutral lug in control panel.

No

Electrical TroubleshootingFlowchart 1A

wc_gr001609

4.3

4.56.2

6.3

6.5

6.3

6.4

4.8

6.146.13

Is 120±10% V measured at

GFI?

Is 120±10% V

measured at back of GFI?

wc_tx000359gb.fm 64


Yes

NoIs there 400±10%V from

ballast?

Yes

NoIs there 120±10%V to

ballast?

Replace ballast.See Flowchart 1C.

Continued from Flowchart 1A.

With engine stopped,remove breaker(s) and check breaker(s) for continuity.

With machine running,check for voltage between breaker bus bar andneutral lug in control panel.

With machine running,check for voltage to ballast by measuringvoltage across black circuit breaker wiresand neutral lug.

No Replace breaker

Does breakerhave continuity?

Yes

Yes

No

Replace control panel.

Is there 120±10%V between bus bar and neutral

lug?

Electrical TroubleshootingFlowchart 1B

wc_gr001610

6.6

6.7

6.106.11

6.9

6.8

6.8

wc_tx000359gb.fm 65


Continued from Flowchart 1B

No

Yes

Does wiringhave continuity?

With engine shut down,check continuity of wiring from upper mast junction box to end of quick disconnect cable at light.

With engine shutdown, check continuity of wiring from control panel to end of quick disconnect cable at upper mast.

With engine shutdown,check continuity of wiring from quick disconnect cable to light socket.

With engine shut down,check continuity of wiring between main mast junction box and upper mast junctionbox.

No Repair or replace wiring.


Yes



Yes



Yes

NoRepair or

replace wiring and/or socket.

Replace bulb.


Yes

Electrical TroubleshootingFlowchart 1C

wc_gr001611

6.15

6.15

With engine shut down,check continuity of wiring between control panel andmain mast junction box .

6.15

6.15

4.3

4.25.7

6.15

wc_tx000359gb.fm 66


Continued from Flowchart 1A

No

Yes

Yes

With engine shut down, check condition of auxillary windings, diodes, and rotor windings by connecting a 12 V battery to capacitor leads 60 and 0.

Check stator windings.

With engine shut down, remove red, white, and black wiresfrom terminal strip near capacitor.

Measure resistance across terminalsT1 to T2: 0.36 +0.5/-0.0 OhmsT4 to T5: 0.36 +0.5/-0.0 Ohms60 to 0: 1.7 +0.5/-0.0 Ohms

With engine shut downMeasure continuity across terminals:

T1 to ground;T5 to ground.

Start the engine and check voltage at generator terminal strip:Red to white;Black to white.

No Replace stator.Consult factory.

Is 30–40 V measured?

Are allresistance values

within range?

Yes

No

If you measure low resistance, there is a short. Replace the complete generator end.Consult factory.

For a thorough check of winding insulation, use a megger meter at 500 V or have it tested by a motor repair shop. If after testing more than 2 M Ohms is not measured, replace the stator. Consult factory. If continuitytests are OK, stator is good. Check rotor and diodes,See Flowchart 1E.

If you measure low resistance,there is a short. Replace the complete generator end.

Consult factory.

NoDoes wiring have

continuity?

YesDoes wiringhave continuity?

Stop engine.Disconnect 12 V battery. Reconnect the 60 and0 leads to capacitor.

Start machine and againcheck power at GFI. SeeStep 4 of Flowchart 1A.

With engine shut down,measure continuity across terminals:60 terminal to ground;60 terminal to T1;60 terminal to T4.

Electrical TroubleshootingFlowchart 1D

wc_gr001612

6.16

6.16

6.16

6.16

6.176.18

6.18

6.17–6.20

6.17–6.20

wc_tx000359gb.fm 67


No

Yes

With engine shut down, unsolder the wires from both diodes.

Using diode scale on meter, measure voltage across diode.Both forward and reversed.

Is 0.4–0.5 V measured

in one direction and open (OL) in the other?

Replace bothdiodes.

No

Yes

Is 4.22 Ohms or more measured?

Replace rotor.Consult with factory.

Yes

No

Is there continuity? Replace rotor.

Check continuity of rotorwindings by measuring resistance across lead and base of diode. Check both diodes.

Check rotor winding continuity to ground by measuring resistance across lead wireand rotor shaft.

Electrical TroubleshootingFlowchart 1E

wc_gr001613

6.21

6.22

6.22

6.21

For a thorough check of winding insulation, use a megger meter at 500 V or have it tested by a motor repair shop. If after testing more than 2 M Ohms is not measured, replace the rotor. Consult factory. If continuitytests are OK, rotor is good. Return to Flowchart 1A.

6.186.196.23

6.186.196.23

wc_tx000359gb.fm 68


6.2 Checking Engine

See graphic: wc_gr001625, wc_gr001634

Using either a photo (strobe) tachometer, a frequency meter (60 Hz =1800 rpm), or a vibration tachometer such as a Sirometer (a) (WackerP/N 0053397), check engine rpm. Refer to the instrument instructions.If necessary, adjust engine rpm using adjusting screw (b). No loadengine speed should be 1850 rpm.

Also check the condition of the engine air, fuel, and oil filters. Changethe filters if necessary. See maintenance section.

wc_tx000359gb.fm 69


6.3 Checking GFI

See graphic: wc_gr001614, wc_gr001618, and wc_gr001622

Electric shock hazard. Only qualified personnel should conduct thistest.

Complete this test with the machine running and circuit breaker in “ON”position.

6.3.1 Using the AC voltage setting on the multimeter, test the GFI for 120+/-10% Volts.

6.3.2 If zero (0) Volts is measured, check the GFI reset button. Depress thebutton if it has “popped out”. If the reset button will not stay depressed,check the condition of the wiring to the GFI.

6.3.3 If the wiring is OK, test for voltage at the back of the GFI. If 120+/-10%Volts is measured, replace the GFI.

WARNING

wc_tx000359gb.fm 70


6.4 Replacing GFI


Carry out procedure with engine shut down.

Removal

6.4.1 Remove the screws (a) securing the control panel cover and removethe cover.

6.4.2 Make note of the wire connections on the back of GFI. Loosen thescrews securing the wires and remove the wires.

6.4.3 Remove the two screws (b) securing the GFI to the control panel coverand remove the GFI.

Instalation

6.4.4 Mount the GFI to the control panel cover.

6.4.5 Attach the wires to the appropriate terminals on the back of the GFI.

6.4.6 Attach the control panel cover to the control panel.

wc_gr001535

a

b

wc_tx000359gb.fm 71


6.5 Checking Voltage from Ballast


Electric shock hazard. Only qualified personnel should conduct thistest. Do not perform this test if you or the machine are wet.

Complete this test with the machine running. Test all ballast boxes orjust the corresponding ballast box in question.

6.5.1 Unplug the light(s) at the upper mast quick disconnect plugs.

6.5.2 Remove control panel front cover.

6.5.3 Using the AC voltage setting on the multimeter, test for 400±10% Voltscoming from ballast by measuring across white wires (a) of terminalstrip in control panel and the neutral lug (b).

If 400±10% Volts is measured, it indicates a problem with the wiringfrom the control panel to the lights or a problem with the light fixture.See Checking Wiring Continuity.

If 400±10% Volts is not measured, it indicates a problem with voltagegetting to the ballast or a possible failed ballast. See Checking Voltageto Ballast.

WARNING

123

4

wc_gr001780

wc_tx000359gb.fm 72


6.6 Checking Voltage to Ballast


Electric shock hazard. Only qualified personnel should conduct thistest. Do not perform tests if you or the machine are wet.

Complete this test with the machine running and circuit breakers in“ON” positions.

6.6.1 Using the AC voltage setting on the multimeter, test for 120±10% Voltsto the suspect ballast by measuring voltage across circuit breakerblack wires (a) and neutral lug (b).

6.6.2 A meter reading of 120±10% Volts indicates that there is power to theballast. If no power is coming from ballast white wire(s), the problem iswithin the ballast(s). Shut down the engine and replace the failedballast.

WARNING

123

4

wc_gr001780

wc_tx000359gb.fm 73


6.7 Replacing Ballast

See graphic: wc _gr001636 and wc_gr001637


Removal

6.7.1 Remove the screws securing the control panel cover and remove thecover.

6.7.2 Note the connection points of the wires from the affected ballast anddisconnect the wires from the control panel.

6.7.3 Note the routing of the electric cable. Loosen the strain relief (a) fromaffected ballast and remove the electric cable from the control panel.

6.7.4 Remove the screws (b) securing the affected ballast box and removethe box.

Installation

6.7.5 Secure the ballast box to the machine with screws removed in step 4.

6.7.6 Route the electric cable as the original cable was routed. Once routed,cut the cable to size making sure wires reach far enough into controlpanel.

6.7.7 Slide the strain relief over the cable and insert the cable into the controlpanel. Connect the wires to appropriate terminals inside the controlpanel.

6.7.8 Tighten the strain relief.

wc_tx000359gb.fm 74


6.8 Checking Circuit Breaker



Complete this test with the engine shut down.

6.8.1 Remove the circuit breaker(s) from the bus bar by applying left to rightpressure to the breaker and pulling it from the bus bar.

6.8.2 Place the breaker ON-OFF switch in the “ON” position.

6.8.3 Using the Ohms scale on the multimeter, test the circuit breaker forcontinuity. If you measure no continuity (“OL” or “OPEN”), replace thebreaker. If the breaker has continuity, re-install it. Place ON-OFF in“OFF” position.

WARNING

wc_gr001537

wc_tx000359gb.fm 75


6.9 Checking Bus Bar



Begin this test with the engine shut down.

6.9.1 Remove the circuit breaker(s) from the bus bar by applying left to rightpressure to the breaker and pulling it from the bus bar.

6.9.2 Start the engine.

6.9.3 Using the AC voltage scale on the multimeter, test for 120±10% Voltsacross bus bar (a) and neutral lug (b). Check both halves of lug.

6.9.4 Also check red and black (c) wire lugs to neutral lug (c) for 120±10%Volts.

WARNING

wc_tx000359gb.fm 76


6.10 Removing Floodlight Control Panel


Electric shock hazard. Only qualified personnel should perform thisprocedure.

Complete this procedure with engine shut down.

6.10.1 Remove the screws securing the panel cover and remove the cover.

6.10.2 Make careful note of all incoming electrical connections. Refer to theelectrical schematic.

6.10.3 Loosen all electric wiring connections inside the control panel.

6.10.4 Loosen all strain reliefs (a) and remove electric cables from controlpanel.

6.10.5 Remove the 5/16" hardware (b) securing the control panel to the panelextension and remove the panel.

WARNING

b

wc_tx000359gb.fm 77


6.11 Installing Floodlight Control Panel


Electric shock hazard. Only qualified personnel should perform thisprocedure.

Complete this procedure with engine shut down.

6.11.1 Mount the control panel to the control panel extension with 5/16”hardware (b).

6.11.2 Slide electric cables through holes in control panel and secure thecables with strain reliefs (a).

6.11.3 Reconnect all electrical wiring to appropriate terminals inside thecontrol panel. Refer to electrical schematic.

6.11.4 Re-install the control panel cover.

WARNING

wc_tx000359gb.fm 78


6.12 Checking Generator Capacitor(s)

See graphic: wc_gr001616, wc_gr001617, wc_gr001607, and wc_gr001782

Carry out this procedure with the engine shut down.

The capacitor(s) of the electrical system is mounted to the generator inone of two places. On older units it is located on the side of thegenerator (a) mounted to the inside of the protective cover. For thiscapacitor the ballast box (b) will need to be removed to access thecapacitor. On newer units, the capacitor(s) is mounted on top of thegenerator (c).

6.12.1 With the unit off, remove the screws securing the capacitor’s protectivecover and remove the cover.

6.12.2 Remove the leads from the capacitor and discharge it by placing theblade of an insulated screw driver across the two spades of thecapacitor.

6.12.3 Using a multimeter set to the Farad (F) or capacitance (C) scale (200µF), measure the capacitor’s capacitance. On systems with a singlecapacitor, a working capacitor will measure 35±2 µF. On systems withdual capacitors, the capacitors will measure 18±2 µF. If the reading isnot within this range, replace the capacitor. Also see AlternativeCapacitor Check.

wc_tx000359gb.fm 79


6.13 Alternative Capacitor Check


An alternative capacitor check is to set the multimeter to 10,000 Ohmscale when checking the capacitor. Observe the reading. If the readingstarts out very low (5.0 Ohms) and continues to climb to an overloador open reading, the capacitor may be OK. Double check by installingthe capacitor in a known-to-be-working Light Tower. If the known-to-be-working Light Tower operates correctly, the capacitor is OK. Asecond alternative check would be to try a known-to-be-workingcapacitor in the original Light Tower. If the Light Tower still does notproduce power, the problem is within the generator. Check the statorand rotor.

wc_tx000359gb.fm 80


6.14 Replacing Capacitor(s)

See graphic wc_gr001628, wc_gr001635, and wc_gr001643


Removal

6.14.1 Note the connection points of the #60 and #0 wires and remove thewires from the capacitor.

6.14.2 Loosen the clamp screws (a, b) securing the capacitor or cut the wireties (c) and remove the capacitor.

Installation

6.14.3 Insert the capacitor into the clamp and secure clamp by tighteningclamp screws. Or, resecure with new wire tie.

6.14.4 Attach the #60 and #0 wires to the appropriate terminals on thecapacitor.

6.14.5 Attach the capacitor’s protective cover.

wc_tx000359gb.fm 81


b

a

wc_tx000359gb.fm 82


6.15 Checking Wire Continuity


Complete this test when the engine is shut down.

6.15.1 When checking continuity of wiring running up the mast. Check wirecontinuity from light control box terminal strip to quick disconnect atlight. Then from quick disconnects at lights to light socket.

6.15.2 Use the Ohm setting on the multimeter. If your meter reads “OL” or“OPEN”, there is no continuity and the wiring must be repaired orreplaced.

6.15.3 If your meter reads more than 1.0 Ohm, the wiring is faulty and mustbe repaired or replaced.


1 Upper mast connection box 4 To engine control box

2Quick disconnect junction box cord (socket view)

5Quick disconnect light fixture cord (socket view)

3 Main mast junction box 6 Light socket (bulb-end view)

wc_tx000359gb.fm 83


wc_tx000359gb.fm 84


6.16 Restoring Rotor Magnetism



Start this test with the engine shut down.

If it becomes necessary to remagnetize (flash) the rotor windings,create a jumper between the machine’s 12-Volt battery and the #60and #0 leads normally connected to the capacitor.

6.16.1 Unplug the #60 and #0 leads from the generator capacitor.

6.16.2 Using 14 gauge or larger wire connect two jumper wires to the battery,one to each terminal. Do not allow the two jumpers to touch each otheronce connected to the battery.

Explosion hazard. Do not create sparks near battery.

6.16.3 Start the engine.

6.16.4 Connect the opposite end of the jumper wires to the #60 and #0 leads.Connect either wire to either lead. This is a non-polar connection.

6.16.5 Using the AC voltage setting on the multimeter, check the voltageacross the terminal strip: red to white; black to white. There should be30–40 Volts measured.

• If you measure the correct voltage, shut down the machine and disconnect the jumpers, first at the capacitor wires then at the battery.

• If you do not measure the correct voltage, shut down the engine and measure resistance values across terminal strip near capacitor. See Section Checking Stator Windings.

WARNING

WARNING

wc_tx000359gb.fm 85


wc_gr001630

G

BW

R

T5 T1

T4

T6

60

0

T3

T2

+ –

wc_tx000359gb.fm 86


6.17 Checking Stator Windings

See graphic: wc_gr001627, and wc_gr001643

The generator terminal block is located in one of two positions. On latermachines the block is mounted on top of the generator. On earliermachines the block is mounted to the inside of the generator coverpanel near the capacitor. On these machines, the ballast box nearestthe generator must be removed to access the generator terminal block.

If there is any evidence of burned windings such as melted wireinsulation or odor, replace the generator.

The following tests are made when engine is shut down.

6.17.1 Remove the RED, BLACK, and WHITE wires from the generatorterminal block.

6.17.2 Remove the leads from the capacitor and place an insulated screwdriver across the capacitor to discharge it.

6.17.3 Using the Ohm (resistance) setting on the multimeter, measure theresistance T1 to T2. Also measure resistance T4 to T5. In both casesthe resistance measured should be 0.36 +0.5/-0.0 Ohms. Measure theresistance #60 lead to #0 lead. The resistance measured should be 1.7+0.5/-0.0 Ohms. If there is no continuity (meter reads “OPEN” or “OL”),replace the stator.

6.17.4 Using the Ohm setting on the multimeter, measure the resistance T1to ground, and T5 to ground. The multimeter should read “OPEN” or“OL” for all three tests. If the meter does not read open, replace theentire generator.

6.17.5 Using the Ohm scale on the multimeter, measure resistance #60 leadto ground; #60 lead to T1; and #60 lead to T5. The multimeter shouldread “OPEN” or “OL” for all three tests. If the meter does not read open,replace the entire generator. Consult with factory to confirm.

Note: Do not touch machine frame when making this test. A readingerror will occur.

Note: A meter reading of 2 megohms (2 M Ohms) or larger isacceptable.

For a more thorough insulation test, use a megger meter capable of500 Volts or have a motor repair shop test it. If readings are 2megohms or greater, the stator is good. If readings are less than 2megohms, replace the generator end. Consult factory to confirm.

wc_tx000359gb.fm 87



1Single 35 µF capacitor side door location

3Dual 18 µF capacitors top-mounted location

2Single 35 µF capacitor top-mounted location

wc_gr001627

BT5

T2T4

T1RW

60 0

1

G

BW

R

T5 T1

T4

T6

60

0

T3

T2

2

G

BW

R

T5 T1

T4

T6

60

0

T3

T2

3

wc_tx000359gb.fm 88


6.18 Removing Generator and Engine


The generator and engine are removed as a unit. To remove them it isnecessary to remove the side hinged access panels and top panel ofthe enclosure assembly.

6.18.1 Position the main mast in the upright position but do not raise the midand upper masts.

6.18.2 Remove the screws (a) securing the hinged access panels andremove the hinged access panels from both sides of the machine.

6.18.3 Remove the hardware (b) securing the top panel to the front and rearpanels. Also remove the hardware (c) securing the main mast to theenclosure. Being careful not to let the top panel fall on the engine,remove the top panel.

wc_tx000359gb.fm 89


wc_gr001602

wc_tx000359gb.fm 90

See graphic: wc_gr001588 — wc_gr001590; wc_gr001594 — wc_gr001601,
and wc_gr001628

6.18.4 Disconnect the battery (d).

6.18.5 Disconnect fuel hoses at tank (e). Plug the hoses. Older machineshave fuel intake hose on underside of tank. On these machines cap thefuel intake fitting to prevent fuel spillage.

6.18.6 Remove the screws securing the generator terminal strip/capacitorprotective cover and remove the cover. Older machines have side-mounted terminal strips and capacitors integral with generator. Onthese machines, remove the ballast box next to generator panel foraccess to wiring. Disconnect power leads (red and black wires),neutral (white), and ground (green) at generator terminal strip (f).

6.18.7 Remove cable guide (g) on engine near generator.

6.18.8 Disconnect ground wire (h) leading from engine to frame at the engine.

6.18.9 Note location of wire (i) leading from light switch control panel toengine key switch box (#10) and remove the wire from the back of thekey switch box. On newer engines, simply unplug the wire connectorfrom the key switch box.

6.18.10 Remove light switch control panel/bracket (j) from engine.

6.18.11 Remove the hardware (k) securing the exhaust pipe to the frame of theunit. Loosen the U-bolt (l) securing the pipe to the engine and removethe exhaust pipe.

6.18.12 Working from underneath the machine, remove the nuts and washers(m) from the four shock mount studs.

6.18.13 Using an appropriate crane or hoist, lift the engine/generator assemblyfrom the frame. Place the assembly on a sturdy work bench or on thefloor.

LOMBARDINI

4

12 10 9

7 6 5

2

i

1

2

86

30

50

30

15/54

85

87

wc_gr001788

250 kg(550 lbs.)

wc_gr000843

wc_tx000359gb.fm 91


wc_gr001588

i

f

ff

he

e

d

l k

m

j

g

m

e

wc_tx000359gb.fm 92


6.19 Separating Stator from Engine/Rotor


Note: The fit between the rotor bearing and the stator housing is tight.The tight fit prevents the bearing from spinning in the housing.

6.19.1 There are two methods to separate the generator stator housing fromthe engine-rotor assembly. The first method involves creating a specialpusher tool. When using either method, support the stator with anappropriate strap and hoist.

Method 1

6.19.2 Using an appropriate strap (a) and hoist, support the generator end.

6.19.3 Using an approximately 3" x 3" (8cm x 8cm) piece of steel or aluminumplate (b), drill a pilot hole in the center of the plate to accommodate anM14 thread. Tap the hole in the plate with M14 threads.

6.19.4 Drill two holes in the plate whose placement matches those in thestator housing (f).

6.19.5 Tap the holes (f) in the stator housing and using two screws (c) of thesame thread, secure the 3" x 3" plate to the housing.

6.19.6 Remove the M8 bolts (d) securing the engine adapter flange to theengine.

6.19.7 Using an M14 bolt (e), thread it into the M14 threaded hole of the plateand slowly pull the stator housing assembly from the engine-rotorassembly.

wc_gr001640

a

bf

ce

d

wc_tx000359gb.fm 93

Method 2

6.19.8 Remove the M8 bolts (a) securing the engine adapter flange to theengine.

6.19.9 Using two screwdrivers (b) or equivalent pry bars, carefully pry thestator assembly from the engine-rotor assembly.

wc_tx000359gb.fm 94


6.20 Remounting Generator Stator to Rotor/Engine


Note: The fit between the rotor bearing and the stator housing is tight.The tight fit prevents the bearing from spinning in the housing.

6.20.1 While supporting the stator with an appropriate strap and hoist, slidethe stator over the rotor/engine assembly.

6.20.2 Assemble an M10 nut (a) and washer (b) to an M10x80 bolt (c).

6.20.3 Thread the bolt into the rotor through the hole in the stator.

6.20.4 Snug-up the nut against the stator housing and slowly tighten the nutto push the stator housing onto the rotor and bearing assembly (f).Continue until engine adapter flange comes into contact with engine.Do not overtighten.

6.20.5 Secure the engine adapter flange to the engine with M8 bolts (d).Torque the bolts to 25 ft.lbs. (35 Nm).

Note: Failure to install stator in the above manner may result in acocked rotor bearing which can result in premature bearing wear orengine bearing wear. If there is any doubt that the bearing is seatedcorrectly, place a block of wood over the end of the stator housing andstrike it firmly with a hammer. This will release the bearing.

wc_tx000359gb.fm 95


wc_gr001642

2 mm2 m+ 1.5-1

f

wc_tx000359gb.fm 96


6.21 Checking Rotor Diodes


There are two diodes on the rotor assembly. The engine/generatorassembly must be removed and the stator must be separated from therotor to check their function. When checking, be sure to check bothdiodes.

6.21.1 Unsolder the wire from the terminal end of each diode.

6.21.2 Using the diode setting on the multimeter, measure the voltage acrossthe diode terminal and the base of the diode. Reverse the leads of themeter and measure the voltage again. One of the readings should bebetween 0.4–0.5 Volts. With the meter leads reversed, the otherreading should be OL or a very large reading (for example, 2.0 MV).

6.21.3 If your readings do not match those listed here, replace both diodes.Unscrew the diode to remove.

wc_tx000359gb.fm 97


6.22 Checking Rotor Windings


After checking the two rotor diodes, check the rotor windings. Theengine/generator assembly must be removed and the stator must beseparated from the rotor to check the rotor windings.

6.22.1 Unsolder the rotor winding wire from the terminal end of each diode.

6.22.2 Using the Ohms setting on the multimeter, measure the resistanceacross the diode lead wire and the base of the diode. The readingshould be 4.22+0.5/-0.0 Ohms or greater. If your reading is not4.22+0.5/-0.0 Ohms or greater, replace the generator.

6.22.3 Check resistance of both rotor windings in this manner.

6.22.4 Also check the resistance across diode lead wire and shaft of rotor. Ifyour reading is not OL or greater than 2 megohms (2 M Ohms), replacethe generator. Confirm with factory before replacing.

6.22.5 Check both diode lead wires in this manner.

For a more thorough insulation test, use a megger meter capable of500 Volts or have a motor repair shop test it. If readings are 2megohms (2 M Ohms) or greater, rotor is good. If readings are lessthan 2 megohms, replace the generator end. Consult factory toconfirm.

wc_tx000359gb.fm 98


6.23 Removing/Installing Rotor


Removal

6.23.1 Remove the M8 bolts (a) securing the rotor flex discs (b) to the enginefly wheel (c) and remove the rotor assembly.

Installation

6.23.2 Secure the rotor flex discs to the engine using M8 bolts. Torque thebolts to 15 ft.lbs. (21 Nm). Make sure the discs are seated completelyand evenly into the engine flywheel.

wc_tx000359gb.fm 99

Engine Troubleshooting LTC Repair

7. Engine Troubleshooting

Possible Cause Symptom

Eng

ine

will

not

cra

nk

Eng

ine

does

not

sta

rt

Eng

ine

star

ts, b

ut s

tops

Poo

r ac

cele

ratio

n

Uns

tead

y rp

m

Bla

ck s

mok

e

Whi

te s

mok

e

Blu

e sm

oke

Low

oil

pres

sure

Oli

leve

l ris

ing

Exc

essi

ve o

il co

nsum

ptio

n

Wet

exh

aust

Ove

rhea

ting

Eng

ine

knoc

ks

Low fuel level • • •

Fuel supply/return lines clogged

• • • •

Clogged fuel tank vent • •

Fuel pump faulty • • •

Fuel contaminated with air • • • •

Unit injector(s) faulty/worn • • • • • • •

Unit injector settings incorrect • • • • • • •

Injection pump rack sticking • • •

Oil level too high • • • • • • •

Improper oil viscosity • • •

Oil diluted by fuel • • • • •

Oil pressure relief valve faulty •

Oil pick-up tube clogged •

Oil pump air contaminated at pick-up tube

•

Glow plugs faulty • •

Glow plug controller faulty •

Glow plug relay inoperable •

Starter defective •

Battery voltage too low •

wc_tx000364gb.fm 100

LTC Repair Engine Troubleshooting

Battery/battery cable connections corroded

•

Key switch defective •

Air filter clogged • • • • • • •

Excessive idle/light load operation

• • • •

Incomplete engine run-in • • •

Engine overloaded • • • • •

Excessive secondary load • • •

Valve lash insufficient/excessive

• • • •

Injection timing out of spec - advanced

• • • • •

Injection timing out of spec - retarded

• • •

Governor linkage adjustment incorrect

• • • •

Governor spring fatigued or defective

• • •

Idle rpm too low • •

Piston rings worn or stuck • • • • •

Piston worn or damaged • • • • • • •

Cylinders worn or damaged • • • • • • •

Valve/valve guides worn • • • • •

Valves sticking • • • • • • •


Eng

ine

will

not

cra

nk

Eng

ine

does

not

sta

rt

Eng

ine

star

ts, b

ut s

tops

Poo

r ac

cele

ratio

n

Uns

tead

y rp

m

Bla

ck s

mok

e

Whi

te s

mok

e

Blu

e sm

oke

Low

oil

pres

sure

Oli

leve

l ris

ing

Exc

essi

ve o

il co

nsum

ptio

n

Wet

exh

aust

Ove

rhea

ting

Eng

ine

knoc

ks


Engine Troubleshooting LTC Repair

Bearings (main/rod) worn • • •

Governor/governor linkage malfunction

• • • • •

Cylinder head gasket damaged

• • •

Thermostat stuck or malfunctioning

•

Engine seized •

Radiator clogged (external or internal)

•

Coolant pump faulty •

Turbocharger faulty • • • • • • •


Eng

ine

will

not

cra

nk

Eng

ine

does

not

sta

rt

Eng

ine

star

ts, b

ut s

tops

Poo

r ac

cele

ratio

n

Uns

tead

y rp

m

Bla

ck s

mok

e

Whi

te s

mok

e

Blu

e sm

oke

Low

oil

pres

sure

Oli

leve

l ris

ing

Exc

essi

ve o

il co

nsum

ptio

n

Wet

exh

aust

Ove

rhea

ting

Eng

ine

knoc

ks


Threadlockers and Sealants


Threadlocking adhesives and sealants are specified throughout thismanual by a notation of “S” plus a number (S#) and should be usedwhere indicated. Threadlocking compounds normally break down attemperatures above 175°C (350°F). If a screw or bolt is hard toremove, heat it using a small propane torch to break down the sealant.When applying sealants, follow instructions on container. The sealantslisted below are recommended for use on Wacker equipment.

TYPE( ) = Europe COLOR USAGE

PART NO. - SIZE

Loctite 222Hernon 420Omnifit 1150 (50M)

Purple Low strength, for locking threads smaller than 6 mm (1/4").Hand tool removable.Temp. range, -54 to 149 ° C (-65 to 300 ° F)

73287 - 10 ml

Hernon 423Omnifit 1350 (100M)

Blue Medium strength, for locking threads larger than 6 mm (1/4").Hand tool removable.Temp. range, -54 to 149 ° C (-65 to 300 ° F)

29311 - .5 ml17380 - 50 ml

Loctite 271/277Hernon 427Omnifit 1550 (220M)

Red High strength, for all threads up to 25 mm (1”).Heat parts before disassembly.Temp. range, -54 to 149 ° C (-65 to 300 ° F)

29312 - .5 ml26685 - 10 ml73285 - 50 ml

Loctite 290Hernon 431Omnifit 1710 (230LL)

Green Medium to high strength, for locking preassembled threads and for sealing weld porosity (wicking).Gaps up to 0.13 mm (0.005")Temp. range, -54 to 149 ° C (-65 to 300 ° F)

28824 - .5 ml25316 - 10 ml

Loctite 609Hernon 822Omnifit 1730 (230L)

Green Medium strength retaining compound for slip or press fit of shafts, bearings, gears, pulleys, etc.Gaps up to 0.13 mm (0.005")Temp. range, -54 to 149 ° C (-65 to 300 ° F)

29314 - .5 ml

Loctite 545Hernon 947Omnifit 1150 (50M)

Brown Hydraulic sealantTemp. range, -54 to 149 ° C (-65 to 300 ° F)

79356 - 50 ml

Loctite 592Hernon 920Omnifit 790

White Pipe sealant with Teflon for moderate pressures.Temp. range, -54 to 149 ° C (-65 to 300 ° F)

26695 - 6 ml73289 - 50 ml

Loctite 515Hernon 910Omnifit 10

Purple Form-in-place gasket for flexible joints.Fills gaps up to 1.3 mm (0.05")Temp. range, -54 to 149 ° C (-65 to 300 ° F)

70735 - 50 ml

Loctite 496Hernon 110Omnifit Sicomet 7000

Clear Instant adhesive for bonding rubber, metal and plas-tics; general purpose. For gaps up to 0.15 mm (0.006")Read caution instructions before using.Temp. range, -54 to 82 ° C (-65 to 180 ° F)

52676 - 1 oz.


Loctite Primer THernon Primer 10Omnifit VC Activator

AerosolSpray

Fast curing primer for threadlocking, retaining andsealing compounds. Must be used with stainless steel hardware. Recommended for use with gasket sealants.

2006124 - 6 oz.

TYPE( ) = Europe COLOR USAGE

PART NO. - SIZE

Torque Values

Torque Values

Metric Fasteners (DIN)

TORQUE VALUES (Based on Bolt Size and Hardness) WRENCH SIZE

Size ft.lb. Nm ft.lb. Nm ft.lb. Nm Inch Metric Inch Metric

M3 *11 1.2 *14 1.6 *19 2.1 7/32 5.5 - 2.5

M4 *26 2.9 *36 4.1 *43 4.9 9/32 7 - 3

M5 *53 6.0 6 8.5 7 10 5/16 8 - 4

M6 7 10 10 14 13 17 - 10 - 5

M8 18 25 26 35 30 41 1/2 13 - 6

M10 36 49 51 69 61 83 11/16 17 - 8

M12 63 86 88 120 107 145 3/4 19 - 10

M14 99 135 140 190 169 230 7/8 22 - 12

M16 155 210 217 295 262 355 15/16 24 - 14

M18 214 290 298 405 357 485 1-1/16 27 - 14

M20 302 410 427 580 508 690 1-1/4 30 - 17

1 ft.lb. = 1.357 Nm. * = in.lb. 1 Inch = 25.4 mm

8.8 10.9 12.9

Torque Values

Inch Fasteners (SAE)

Size ft.lb. Nm ft.lb. Nm ft.lb. Nm Inch Metric Inch Metric

No.4 *6 0.7 *14 1.0 *12 1.4 1/4 5.5 3/32 -

No.6 *12 1.4 *17 1.9 *21 2.4 5/16 8 7/64 -

No.8 *22 2.5 *31 3.5 *42 4.7 11/32 9 9/64 -

No.10 *32 3.6 *45 5.1 *60 6.8 3/8 - 5/32 -

1/4 6 8.1 9 12 12 16 7/16 - 3/32 -

5/16 13 18 19 26 24 33 1/2 13 1/4 -

3/8 23 31 33 45 43 58 9/16 - 5/16 -

7/16 37 50 52 71 69 94 5/8 16 3/8 -

1/2 57 77 80 109 105 142 3/4 19 3/8 -

9/16 82 111 115 156 158 214 13/16 - - -

5/8 112 152 159 216 195 265 15/16 24 1/2 -

3/4 200 271 282 383 353 479 1-1/8 - 5/8 -

1 ft.lb. = 1.357 Nm. * = in.lb. 1 Inch = 25.4 mm

Wacker Construction Equipment AG · Preußenstraße 41 · D-80809 München · Tel.: +49-(0)89-354 02 - 0 · Fax: +49 - (0)89-354 02-390Wacker Corporation · P.O. Box 9007 · Menomonee Falls, WI 53052-9007 · Tel. : +1-(1)(262) 255-0500 · Fax: +1-(1)(262) 255-0550 · Tel. : (800) 770-0957Wacker Asia Pacific Operations · Sunley Center, Unit 912, 9/F · 9 Wing Qin Street, Kwai Chung, N.T. · Hong Kong · Tel. + 852 2406 60 32 · Fax: + 852 2406 60 21

Documents

Light Tower - Wacker Neusonproducts.wackerneuson.com/manuals/Repair/158565en_001Rep.pdf · Light Tower LTC 4L REPAIR MANUAL 0158565en 001 0404 0158565 EN