wc br0163722en 001 - Wacker Neusonproducts.wackerneuson.com/manuals/Repair/0163722en_001Rep.pdf · LTC Repair Table of Contents 7 6.5 Troubleshooting Flowcharts ..... 74 6.6 Lights

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Light Tower

LTC 4

REPAIR MANUAL

0163722en 001

0910

0 1 6 3 7 2 2 E N

LTC Repair Foreword
This manual covers the following machines:
Operating / Parts InformationYou must be familiar with the operation of this machine before youattempt to troubleshoot or repair it. Basic operating and maintenanceprocedures are described in the Operator’s Manual supplied with themachine. Keep a copy of the Operator’s Manual with the machine at alltimes. Use the separate Parts Book supplied with the machine to orderreplacement parts. If you are missing either of the documents, 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.

Item No. Revisions Covered

0009377 105 and higher



3

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.

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

Copyright 2007 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, andviolators will be prosecuted. We expressly reserve the right to maketechnical modifications, even without due notice, which aim atimproving our machines or their safety standards.

WARNING

4

LTC Repair Table of Contents

1. Safety Information 9

1.1 Laws Pertaining to Spark Arresters ...................................................... 91.2 Operating Safety ................................................................................ 101.3 Operator Safety while using Internal Combustion Engines ................ 111.4 Towing Safety ..................................................................................... 121.5 Service Safety .................................................................................... 131.6 Label Locations .................................................................................. 141.7 Safety and Operating Labels .............................................................. 16

2. Technical Data 22

2.1 Engine ................................................................................................ 222.2 Generator ........................................................................................... 242.3 Machine .............................................................................................. 25

3. Operation 27

3.1 Information Regarding Operation ....................................................... 273.2 Locating Trailer ................................................................................... 273.3 Leveling Trailer ................................................................................... 283.4 Adjusting Lights .................................................................................. 283.5 Preparing Trailer for Towing or Lifting ................................................ 293.6 Raising Tower (Manual Winch System) ............................................. 303.7 Lowering Tower (Manual Winch System) ........................................... 323.8 Control Panels—Item 0009377 .......................................................... 343.9 Control Panels—Items 0009379 and 0009485 .................................. 353.10 Starting ............................................................................................... 363.11 Automatic Shutdown .......................................................................... 363.12 Operating Lights ................................................................................. 373.13 Stopping ............................................................................................. 373.14 Receptacles—50 Hz ........................................................................... 37

4. Maintenance 38

4.1 Periodic Maintenance Schedule ......................................................... 384.2 Daily Inspection .................................................................................. 394.3 Installing / Removing Light Fixtures ................................................... 40

5

Table of Contents LTC Repair
4.4 Precautions When Replacing / Removing Bulbs .................................414.5 Replacing Bulbs ..................................................................................424.6 Air Cleaner ..........................................................................................434.7 Engine Oil ............................................................................................434.8 Lombardini Engine Wiring ...................................................................444.9 Engine Wiring Components .................................................................454.10 Engine Control Panel Internal Wiring—Lombardini .............................464.11 Engine Control Panel Components—Lombardini ................................474.12 Wiring Diagram: 50Hz 230V 0009377 .................................................484.13 Components: 50Hz 230V 0009377 .....................................................494.14 Wiring Diagram: 50Hz 115V 0009379 .................................................504.15 Components: 50Hz 115V 0009379 .................................................... 514.16 Wiring Diagram: 50 Hz 230V 0009485 ................................................524.17 Components: 50Hz 230V 0009485 .....................................................534.18 Generator Capacitor Excitation Schematic .........................................544.19 Trailer Wiring .......................................................................................55
5. Lombardini Engine Troubleshooting 56

5.1 Troubleshooting Flowcharts ................................................................565.2 Engine Does Not Crank—Flowchart 3A ..............................................575.3 Checking Keyswitch and Wiring ..........................................................585.4 Replacing Keyswitch ...........................................................................605.5 Engine Cranks But Does Not Start—Flowchart 4A .............................615.6 Checking Fuel System ........................................................................625.7 Checking Voltage to Glow Plugs (Lombardini 1003 engines) .............635.8 Checking Glow Plug Relay ..................................................................645.9 Replacing Glow Plug Relay .................................................................645.10 Checking Glow Plugs ..........................................................................655.11 Engine Shuts Down—Flowchart 5A ....................................................665.12 Checking Oil Pressure and Coolant Temperature Switches ...............675.13 General Engine Troubleshooting .........................................................68

6. Electrical Troubleshooting Procedures 72

6.1 Troubleshooting Methodology .............................................................726.2 Checking Continuity ............................................................................736.3 Checking resistance ............................................................................736.4 Checking voltage .................................................................................73

wc_br0163722en_001TOC.fm 6

LTC Repair Table of Contents
6.5 Troubleshooting Flowcharts ............................................................... 746.6 Lights do not Illuminate—Flowchart 1A .............................................. 756.7 Checking Engine Speed ..................................................................... 766.8 Checking Generator Voltage at the Short Terminal Strip ................... 786.9 Lights Do Not Illuminate—Flowchart 1B ............................................. 806.10 Checking the Stator Windings ............................................................ 826.11 Checking the Excitation Winding ........................................................ 846.12 Checking the Excitation Capacitor ..................................................... 866.13 Flashing the Generator ....................................................................... 886.14 Removing the Generator .................................................................... 906.15 Installing the Generator ...................................................................... 926.16 Checking the Rotor Diodes ................................................................ 946.17 Checking the Rotor Windings ............................................................. 966.18 Lights do not Illuminate—Flowchart 1C .............................................. 976.19 Checking Voltage at the Main Circuit Breaker .................................... 986.20 Checking Voltage to Long Terminal Strip ......................................... 1006.21 Checking Individual Circuit Breakers ................................................ 1026.22 Confirming a Malfunctioning Circuit Breaker .................................... 1046.23 Checking Incoming Voltage to Ballast Capacitor(s) ......................... 1066.24 Checking Outgoing Voltage from Ballast Capacitor(s) ..................... 1086.25 Confirming a Faulty Ballast Capacitor .............................................. 1106.26 Checking Wiring to/from Ballast Transformers ................................. 1126.27 Replacing Ballast Transformer(s) ..................................................... 1146.28 Checking Voltage at the Receptacle ................................................ 1166.29 Checking Receptacle’s Circuit Breaker ............................................ 1186.30 Checking the Emergency Stop Switch ............................................. 1196.31 Troubleshooting the Power Winch ................................................... 120
7. Disassembly/Assembly Procedures 123

7.1 Tools ................................................................................................. 1237.2 Ordering Parts .................................................................................. 1237.3 Reference Numbers ( ) ..................................................................... 1237.4 Weight Block .................................................................................... 1237.5 Light Assembly ................................................................................. 1247.6 Tower Assembly Exploded View ...................................................... 1267.7 Tower Assembly List of Parts ........................................................... 1277.8 Upper Mast ....................................................................................... 1277.9 Mid Mast ........................................................................................... 1307.10 Main Mast ......................................................................................... 1327.11 Replacing Cable and Winch on Power Winch Models ..................... 136

7

Table of Contents LTC Repair
7.12 Replacing Fuel Tank .........................................................................1387.13 Replacing Hour Meter .......................................................................140
wc_br0163722en_001TOC.fm 8

LTC Repair Safety Information

1. Safety Information

This manual contains DANGER, WARNING, CAUTION, NOTICE andNOTE callouts which must be followed to reduce the possibility ofpersonal injury, 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 a hazardous situation which, if not avoided, willresult in death or serious injury.

WARNING indicates a hazardous situation which, if not avoided, couldresult in death or serious injury.

CAUTION indicates a hazardous situation which, if not avoided, couldresult in minor or moderate injury.

NOTICE: Used without the safety alert symbol, NOTICE indicates ahazardous situation which, if not avoided, could result in propertydamage.

Note: Contains additional information important to a procedure.

1.1 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.

DANGER

WARNING

CAUTION

9

Safety Information LTC Repair

1.2 Operating Safety

Familiarity and proper training are required for the safe operation ofmachine. Machines 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 machine beforebeing allowed to operate it.

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

1.2.2 ALWAYS be sure the machine is on a firm, level surface and will nottip, roll, slide, or fall while operating.

1.2.3 NEVER start a unit in need of repair.

1.2.4 Lower the tower when not in use, or if high winds or electrical stormsare expected in the area.

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

1.2.6 The tower extends up to 9 m (30 ft.). Make sure the area above thetrailer is open and clear of overhead wires and obstructions.

1.2.7 The bulbs become extremely hot in use! Allow the bulb and fixture tocool 10–15 minutes before handling.

1.2.8 Keep the area behind the trailer clear of people while raising andlowering the mast! Never raise, lower or turn the mast while unit isoperating!

1.2.9 The trailer must be leveled and the outriggers extended before raisingthe tower. The outriggers must remain extended while the tower is up.

1.2.10 If for any reason any part of the mast hangs up or the winch cabledevelops slack while raising or lowering the tower, STOP immediately!Contact an authorized WACKER service representative.

1.2.11 NEVER remove the mast locking pin while the tower is up!

1.2.12 NEVER use the machine if the insulation on the electrical cord is cut orworn through.

1.2.13 NEVER operate the lights without the protective lens cover in place orwith a lens cover that is cracked or damaged!

1.2.14 NEVER adjust the mast while the unit is operating.

1.2.15 NEVER raise the mast or operate the machine in high winds.

WARNING

10


1.3 Operator Safety while using Internal Combustion Engines

Internal combustion engines present special hazards during operationand fueling. Read and follow the warning instructions in the engineowner’s manual and the safety guidelines below. Failure to follow thewarnings and safety guidelines could result in severe injury or death.

1.3.1 NEVER operate the machine indoors unless exhaust fumes can beadequately ventilated.

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

1.3.3 ALWAYS refill the fuel tank in a well-ventilated area.

1.3.4 DO NOT touch or lean against hot exhaust pipes.

1.3.5 ALWAYS replace the fuel tank cap after refueling.

1.3.6 DO NOT remove radiator cap when the engine is running or hot. Theradiator fluid is hot and under pressure and may cause severe burns!

1.3.7 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.

1.3.8 ALWAYS keep the area around the muffler free of debris such asleaves, paper, cartons, etc. A hot muffler could ignite the debris andstart a fire.

DANGER

11


1.4 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.

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

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

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

1.4.4 ALWAYS check the tires on the trailer for tread wear, inflation, andcondition. Replace worn tires.

1.4.5 ALWAYS connect the safety chains.

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

1.4.7 ALWAYS check that the lug nuts holding the wheels are tight and thatnone are missing.

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

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

WARNING

12


1.5 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.

1.5.1 ALWAYS replace the safety devices and guards after repairs andmaintenance.

1.5.2 Before servicing the Light Tower, make sure the engine start switch isturned to OFF, the circuit breakers are open (off), and the negativeterminal on battery is disconnected. NEVER perform even routineservice (oil/filter changes, cleaning, etc.) unless all electricalcomponents are shut down.

1.5.3 DO NOT allow water to accumulate around the base of the machine.If water is present, move the machine and allow the machine to drybefore servicing.

1.5.4 DO NOT service the machine if your clothing or skin is wet.

1.5.5 ALWAYS keep hands, feet, and loose clothing away from the movingparts on the generator and engine.

1.5.6 ALWAYS keep the machine clean and labels legible. Replace allmissing and hard-to-read labels. Labels provide important operatinginstructions and warn of dangers and hazards.

1.5.7 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 location of other people around when lifting the machine.

1.5.8 ALWAYS turn off the light circuit breakers and shut down the enginebefore disconnecting the light fixtures or changing the light bulbs.

WARNING

13


1.6 Label Locations

14


15


1.7 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 DANGER! Contact with overhead electrical power lines will cause serious injury or death. Do not position Light Tower under electrical power lines.

16


E CAUTION! Lifting point.

F WARNING! Secure mast in transport lock before lifting or towing. A loose swinging mast could cause personal injury or machine damage.

G 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.

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.

DANGER! Contact with overhead electrical power lines will cause serious injury or death. Do not position Light Tower under electrical power lines.

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

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

Ref. Label Meaning

17


J Electrical ground

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

L WARNING! Hot surface!

M A nameplate listing the model number, item number, revision number, and serial number is attached to each unit. Please record the information found on this plate so it will be available should the nameplate become lost or damaged. When ordering parts or requesting service information, you will always be asked to specify the model number, item number, revision number, and serial number of the unit.

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

Ref. Label Meaning

18


Ref. Label

O

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� � � $ � � � � � � # � � � � � � � � � � � � � � � � � � � � � �

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19


Q

Ref. Label

20


Ref. Label Meaning

R Coolant overflow bottle only, not a return system.

S WARNING!Pinching hazard. Rotating machinery.

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

21

Technical Data LTC 4L

2. Technical Data

2.1 Engine

Item Number: LTC 4L - 115V0009379

LTC 4L - 230V 0009485

Engine

Make Lombardini

Model LDW1003

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

Maximum power rating kW (Hp) 8.5 (11.4)

Operating power rating kW (Hp) 7.6 (10.2)

Operating speed (no-load)

rpm 1500

Alternator V / A / W 12 / 45 / 540

Battery V/Ah/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. 1.71 (0.45)

Running time hours 67.7

Coolant capacity l (qts.) 4.7 (5.0)

Oil capacity l (qts.) 2.4 (2.5)

Oil weight SAE 15W40 CD or higher

22

LTC 4L Technical Data

Item Number: LTC 4L - 50 Hz0009377

Engine

Make Lombardini

Model LDW1003

Type3-cylinder, 4-cycle, liquid-

cooled diesel

Maximum power rating kW (Hp) 8.5 (11.4)

Operating power rating kW (Hp) 7.6 (10.2)

Operating speed (no-load)

rpm 1550

Alternator V / A / W 12 / 45 / 540

Battery V/Ah/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. 1.70 (0.45)

Running time hours 66.7

Coolant capacity l (qts.) 4.7 (5.0)

Oil capacity l (qts.) 2.4 (2.5)

Oil weight SAE 15W40 CD or higher

23


2.2 Generator

Item Number: LTC 4L - 115V

0009379Rev. 104

and higher

LTC 4L - 115V

0009379Rev. 103and lower

LTC 4L - 230V

0009485Rev. 104

and higher

LTC 4L - 230V

0009485Rev. 103and lower

Generator

Frequency Hz 50 ± 2

Continuous output kW 6.0 5.0 6.0 5.0

Output volts 115 230

Amps A 43.5 21.7

Excitation type Capacitor / Brushless

Power factor 1.0

Voltage regulation - no load to full load

% ± 5.0

Speed rpm 1500

Item Number: LTC 4L - 50 Hz0009377

Generator

Frequency Hz 50 ± 2

Continuous output kW 5.0

Output volts/phase 230, 1Ø

Amps A 21.7

Excitation type Capacitor / Brushless

Power factor 1.0

Voltage regulation - no load to full load

% ± 5.0

Speed (no-load) rpm 1550

24

LTC 4L Technical Data

2.3 Machine

Item Number: LTC 4L - 115V0009379

LTC 4L - 230V 0009485

Machine

Height - mast extended m (ft.) 9 (29)

Lighting system (1000W)

4 metal halide light

Max. lighting coverage @ 0.5 ft. candles

m2 (ft2)acres

30,400 (2824)7

Sound level at 7 m(23 ft.)

dB(A)67

Sound pressure level at operator's location (LpA)

dB(A)91

Guaranteed sound power level (LWA)

dB(A)97

Item Number: LTC 4L0009377

Machine

Operating weight (GVWR) kg(lbs.)

818(1804)

Travel Dimensions (l x w x h)

cm (in.) 441 x 163 x 160(173 x 64 x 63)

Trailer length cm (in.) 335 (132)

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

Lighting system (1000W) 4

Ballast Coil and core

Max. lighting coverage@ 0.5 ft. candles

m2 (acres) 30,400 (7)

Sound level at 7 m (23 ft.) dB(A) 71

Tires size ST175 / 80D13

25


26

LTC 4L Operation

3. Operation

3.1 Information Regarding Operation

The information regarding the operation of the machine included in thismanual is condensed. Refer to the Operator’s Manual for completeoperating instructions. Always read, understand, and follow theprocedures in the Operator’s Manual when operating the machine.

3.2 Locating Trailer

See Graphic: wc_gr0001420

3.2.1 For maximum light coverage locate the Light Tower at ground level orin a spot higher than the area being lighted.

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

3.2.3 Connect the ground stud (l) located on the trailer frame, to a goodearthen ground. Consult local codes for proper grounding techniques.

The tower extends up to 9 m (30 ft.). Make sure the area above thetrailer is open and clear of overhead wires and obstructions.

3.2.1WARNING

27

Operation LTC 4L

3.3 Leveling Trailer

See Graphic: wc_gr001420, wc_gr001423

The trailer must be leveled and the outriggers extended before raisingthe tower. The outriggers must remain extended while the tower is up.Failure to level the trailer or extend the outriggers will severely reducethe stability of the unit and could allow the tower to tip and fall.

3.3.1 Pull the locking pin on the tongue jack (a) and rotate the tongue jack90° as shown. Make sure the tongue jack snaps into position.

Block or chock the trailer wheels (b). Crank the tongue jack down toraise the trailer tongue off the vehicle.

3.3.2 Pull the outrigger lock pin (c) to release the outrigger. Pull bothoutrigger extensions (d) out until you feel outrigger lock pin lock backinto place. Rotate jacks (e) down until they snap into position.

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

3.3.4 Extend the jack(s) on the highest side(s) of the trailer until they restfirmly on the ground. Extend the remaining jacks until the trailer islevel.

3.4 Adjusting Lights


Each light fixture can be aimed up, down, left or right. Position eachfixture by loosening toolless light adjusters (g) and aiming the light upor down. DO NOT loosen the inside nut (x). Loosening this nut couldcause damage to the light fixture. Loosen the nut (h) to turn lightfixtures left or right. Tighten adjusters and nuts after positioning thelights.

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

WARNING

28

LTC 4L Operation

3.5 Preparing Trailer for Towing or Lifting

See Graphic: wc_gr001423, wc_gr002166

3.5.1 Check that the mast cradle lock pin (j) is in place and secured with thesafety pin.

3.5.2 Ensure that the tower is completely nested inside the transport cradleand the pin (t) is secure.

3.5.3 Make sure the doors are properly latched.

3.5.4 Return the outriggers to their travel position. Check that the outriggerbars and jacks are locked in place.

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

The the Light Tower is now ready to lift. For towing, continue.

3.5.6 Use the tongue jack (a) to raise the trailer tongue up and then lower itover hitch on towing vehicle. Lock the hitch to coupling and attach thesafety chains. Swivel the tongue jack 90° and lock it in place.

3.5.7 Connect the trailer wiring to the towing vehicle. Check the brake, turn,and tail lights for proper operation.

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

3.5.9 Check the tire inflation.

3.5.10 Attach a red flag to the end of mast before towing.

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

29

Operation LTC 4L

3.6 Raising Tower (Manual Winch System)


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 the Light Tower if insulation onelectrical cord is cut or worn through. Repair or replace the cord beforeusing. Bare wires in contact with the metal frame of the trailer or towercan cause electrocution.

DO NOT position the 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.

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

3.6.2 Remove the cradle locking pin (j) from the cradle.

3.6.3 Check the operation of the tongue-mounted winch (o) by rotating thewinch handle 1/4-turn clockwise (“cable in” direction). The winch pawlmust engage winch gear teeth. When operating properly, the winchpawl will make a “clicking” sound when the winch handle is rotatedclockwise. Do not attempt to raise the mast if the winch is damaged ornot operating properly.

3.6.4 Continue to rotate the winch handle and raise the mast to the verticalposition until the vertical mast locking pin (p) locks the mast in place.Be certain the vertical mast locking pin is fully engaged in the lockingposition before raising the tower.

WARNING

WARNING

WARNING

WARNING

30

LTC 4L Operation

NEVER pull the vertical mast locking pin (p) while the tower israised! Releasing the vertical mast locking pin while the tower israised may cause the tower to fall or the machine to tip over.

3.6.5 After the mast is in the vertical position, check the operation of themast-mounted winch (q) by rotating the winch handle 1/4-turnclockwise (“cable in” direction). The winch pawl must engage winchgear teeth. When operating properly, it will make a “clicking” soundwhen the winch handle is rotated clockwise. Do not attempt to raise themast if the winch is damaged or not operating properly. Continuerotating the winch handle until mast is at the desired height. Do notover crank the winch when the tower is fully extended.

NOTICE: Do not extend the tower beyond the red marking on themast!

3.6.6 Once the tower is at the desired height, rotate the mast to the desireddirection. To rotate, loosen rotation locking knob (s). Then using thehandle (u), rotate the mast until the lights face the desired direction,and then retighten the rotation locking knob.

WARNING

o

n

j

wc_gr002166

q n

p

t

s

u

31

Operation LTC 4L

3.7 Lowering Tower (Manual Winch System)


Be sure to read and understand the operating instructions beforelowering the tower!

If for any reason a part of the mast hangs up or a winch cable developsslack before mast is fully lowered, stop immediately! Continuing toturn the winch handle will increase the slack in the cable. Too muchslack could cause the mast to collapse should it suddenly free up. If themast hangs up, level the trailer. Slightly shake or twist the towerassembly to free the bind. Contact an authorized WACKER servicerepresentative immediately.

NEVER lower the mast while the unit is operating.

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

3.7.1 Turn the lights off. Shut down the engine.

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

NOTICE: Observe power cord while lowering the tower. Make sure thecoiled cord is not damaged during the lowering process.

3.7.2 Lower the tower by turning the handle on the mast-mounted winch (q)counterclockwise (“cable out” direction).

NEVER touch the winch pawl! Releasing the winch pawl may causethe mast or tower to fall.

3.7.3 Loosen the rotation locking knob (s) and using the handle (u), rotatethe mast so the lights face the rear of the trailer and the mast-mountedwinch is facing toward the trailer tongue.

WARNING

WARNING

WARNING

WARNING

32

LTC 4L Operation
3.7.4 Pull and hold the mast locking pin (p). Rotate the handle on the tongue-
mounted winch (o) counterclockwise (“cable out” direction) until themast spring begins to pivot the mast down. Release the mast lockingpin and continue to rotate the handle until the mast is resting in thetransport cradle. Be sure that the secondary locking pin (t) penetratesall sections of the mast.

NEVER pull the vertical mast locking pin (e) while the tower israised! Releasing the locking pin while the tower is raised may causethe tower to fall or the machine to tip over.

3.7.5 After the mast is down, secure it in the cradle by inserting the cradlelock pin (j). Insert the clip through the pin to secure it in place.

3.7.6 Position the light fixtures to aim at the ground.

NOTICE: Allow the floodlights to cool 10–15 minutes before movingtrailer. Moving the trailer while the lights are still hot could cause thebulbs to break.

WARNING

o

n

j

wc_gr002166

q n

p

t

s

u

33

Operation LTC 4L

3.8 Control Panels—Item 0009377

Floodlight Control Panel Engine Control Panel

Ref. Description Ref. Description

a 50 Amp circuit breaker k High Coolant Temperature Shutdown

b 15 Amp lights circuit breaker l Alternator Indicator

c 20 Amp GFI circuit breaker m Auxiliary lights (not used)

d 250 V, 16 Amp Receptacle n Glow Plug Indicator

e Hour Meter o Air Filter Restriction Indicator

f Low Fuel Indicator (not used) p Auxiliary lights (not used)

g Safety Shutdown Indicator q Key Access Door

h Low Oil Pressure Shutdown

34

LTC 4L Operation

3.9 Control Panels—Items 0009379 and 0009485 Floodlight Control Panel Engine Control Panel

Note: On machine revisions 102 and 103, the generator neutral wireis not connected to the frame ground or Potential Earth (PE). Beinformed that this machine is wired with an IT Network. Beforeconnecting this machine to a distribution system, you must consult witha local electrician for wiring codes.


a 50 Amp circuit breaker k High Coolant Temperature Shutdown

b 15 Amp lights circuit breaker l Alternator Indicator

c 20 Amp GFI circuit breaker m Auxiliary lights (not used)

d Receptacle n Glow Plug Indicator

e Hour Meter o Air Filter Restriction Indicator

f Low Fuel Indicator (not used) p Auxiliary lights (not used)

g Safety Shutdown Indicator q Key Access Door

h Low Oil Pressure Shutdown t Emergency stop switch

d

wc_gr003766

t

STOP

EMERGENCY

d

t

STOP

EMERGENCY

0009485 0009379

35

Operation LTC 4L

3.10 Starting

See Graphic: wc_gr001068, wc_gr001426, wc_gr002758

3.10.1 Check the engine oil, fuel and coolant levels.

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

3.10.2 Check the condition of the electrical cable on the mast. Do not start thegenerator if the insulation on the cable is cut or worn through.

3.10.3 Check that the circuit breakers (a, b, c) are in their OFF position.

NOTICE: Starting the engine under load will damage the machine.

3.10.4 On machines equipped with the Lombardini engine, turn the key (q)one click to the right. The glow plug indicator (n) will illuminate until theengine is properly preheated. This is an automatic timer based on theengine temperature. Crank the engine immediately after the glow pluglight goes off.

3.10.5 Turn the key (q) to START and hold until the engine starts. Releasethe key after engine starts.

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

Note: If the oil pressure is not obtained within 30 seconds after the keyis turned 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.

3.10.6 Allow the engine to warm up before operating the floodlights.

3.11 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 the oil pressure drops too low or the engine exceeds normaloperating temperatures. Return the key switch to “OFF” to reset theunit after an engine shutdown.

36

LTC 4L Operation

3.12 Operating Lights


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

Metal halide floodlights require a warm-up time of 5–15 minutes beforethey reach full output. If the floodlights are shut down, a 10-minutecool-down period is required before turning them back on.

High pressure sodium floodlights require 1–2 minutes to start and 2–5minutes of cooldown time to restart.

3.13 Stopping


3.13.1 Turn the circuit breakers (a, b, c) off and remove any other loads fromthe generator.

NOTICE: Never shut down the engine without turning off the lights.Damage to the generator will occur.

3.13.2 Turn the key (q) to OFF.

3.14 Receptacles—50 Hz

See Graphic: wc_gr002933 and wc_gr003766

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”.

NOTICE: Do not draw more than 2000 Watts from the receptacle withall of the lights on.

A 20A circuit breaker (c) protects the 250V (0009485), 115V(0009379) receptacle (d).

37

Maintenance LTC Repair

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.

38

LTC Repair Maintenance

4.2 Daily Inspection

4.2.1 Check for fluid leaks. Check fluid levels.

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

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

4.2.4 Check that the vertical mast locking pin and its spring are secured,aligned, and operating properly.

39


4.3 Installing / Removing Light Fixtures


ALWAYS turn off the light circuit breakers and shut down the enginebefore disconnecting the light fixtures or changing the light bulbs.

The bulbs become extremely hot in use! Allow the bulb and thefixture to cool 10–15 minutes before handling them.

4.3.1 Remove the fixtures by disconnecting the electrical wiring at thejunction box (a). NOTICE: Only a trained technician should be allowedto install and remove the fixture wiring.

4.3.2 Remove the nuts (b) from the fixture mounting brackets and removeboth the fixture and the bracket off the stud.

4.3.3 Adjusting clamps (c) may be moved from side to side as desired byunscrewing them and swapping positions with the locknut on theoppositie side of the fixture.

WARNING

WARNING

wc_gr00390750Hz 60Hz

bb

a

a

c

c

40


4.4 Precautions When Replacing / Removing Bulbs

The Light Tower uses four 1000W bulbs. When replacing or removingthe bulbs, avoid leaving any grease or oil residue on the glass surface.This can create hot spots, reducing the service life of the bulb orcausing the outer jacket to burst.

ALWAYS turn off the light circuit breakers and shut down the enginebefore disconnecting the light fixtures or changing the light bulbs.

Bulbs become extremely hot in use! Allow the bulb and fixture tocool 10–15 minutes before handling.

NEVER operate the lights without the protective lens cover inplace or with a lens cover that is cracked or damaged! The lampsused in the 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 the lamp can cause serious skin and eyeirritation. Use the lamp only with provided undamaged lens cover andfixture.

WARNING

WARNING

WARNING

41


4.5 Replacing Bulbs


Removal:

4.5.1 Shut down the engine and allow the bulb to cool.

4.5.2 Remove the screws (a) securing the flange rings (b) and remove theflange rings.

4.5.3 Remove the lens (c) with the gasket (d) attached.

4.5.4 Remove the hardware securing one side of the bulb stabilizer (e).Once removed, swing the bulb stabilizer to the side and unscrew thebulb (f).

Installation:

4.5.5 Insert the bulb and secure it with the bulb stabilizer (e).

4.5.6 Install the gasket (d) around the lens (c) and secure the lens to thereflector with flange ring (b) and screws (a).

ad

c

b

e

f

wc_gr002464

42


4.6 Air Cleaner


Replace the air filter cartridge when the indicator (o) mounted on thecontrol panel appears.

4.6.1 Open air cleaner and remove element.

4.6.2 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.

4.6.3 Reassemble the filtering element and air cleaner.

4.7 Engine Oil


Drain the oil while the 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.

4.7.1 Remove the oil drain plug.

4.7.2 Allow the oil to drain.

4.7.3 Install the oil drain plug.

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

4.7.5 Install the oil filter cap.

wc_gr000540

wc_gr000541

43


4.8 Lombardini Engine Wiring

13

2

3

1

8

4

R

x

xx

x

7

16

17

11

910

12

14

5

B+

Pr

L

L

G

G

B

Or

Or

BB

D+

W

12V/45A

wc_gr003225

15

14

13

12

11

10

9

8

7

6

5

4

3

1

2

8

9

10

11

12

13

14

1

2

3

4

5

7

6

3

1 2

P/B

LL

B

6

44


4.9 Engine Wiring Components

Ref. Description Ref. Description Ref. Description

1 Emergency stop switch(50 Hz only)

7 Air filter restriction indicator (normal open type)

13 Harness connector (alternator)

2 Glow plugs 8 Terminal strip 14 Diode

3 Starter motor 9 Low oil pressure switch 15 Resistors(2x220 Ohm, 0.6 W)

4 Battery 10 High coolant temperature switch (normal open type)

16 Control panel

5 Alternator connector 11 Harness connector (control panel)

17 Control panel connector

6 Fuel pump 12 Alternator x Not used

45


4.10 Engine Control Panel Internal Wiring—Lombardini


a Key switch d Engine protection

b 15A fuse e Preheating

c 80A fuse f Relay

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

a

b

c

f

d

e

9 8 10 1 11 12 24

Or BrW Gr

G

Y

RR R R R RY

G Y L P W/L

S3

3

6

"A"

"A"

5

"B"

"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_gr003226

8

9

10

11

12

13

14

1

2

3

4

5

7

6

LL

B

46


4.11 Engine Control Panel Components—Lombardini


a1 Engine control panel, front view f System fuse—80A

a2 Engine control panel, rear view g Key access door

b Solid-state glow plug controller and indicating lamps

h Auxiliary connections

c Shutdown relay location i Light switch panel connection

d Glow plug relay j 15A fuse

e Key switch - --

b

c

d

f

e

86

30

85

87

50

30

wc_gr003227

a1 a2

j

g

47

4.12 Wiring Diagram: 50Hz 230V 0009377
G/Y

Or

Or

qr

W

LL

wc_

gr00

3769

b

p

h

i

48


4.13 Components: 50Hz 230V 0009377e


a Generator j Receptacle, 230V

b Main circuit breaker k Hour meter

c Junction box m Floodlight capacitor, 30µF

d Floodlights n Ballast/transformer

e Terminal strip, long o Battery

f Circuit breaker, 20A p Generator capacitor, 35µF

g Circuit breaker, 15A q Starter solenoid

h Engine r Alternator

i Terminal strip, short - ---

Wire Colors





49


4.14 Wiring Diagram: 50Hz 115V 0009379

wc_

gr00

3767

h

+–

Or

Or

P/B

Or

i

qo

W

LL

p

50


4.15 Components: 50Hz 115V 0009379


a Generator k Hour meter

b Terminal strip, long m Floodlight capacitor, 30µF

c Main circuit breaker n Ballast/transformer

d Floodlights o Alternator

e Receptacle p Terminal strip, short

f Circuit breaker, 20A q Starter solenoid

g Circuit breaker, 15A r Emergency stop switch

h Battery s Fuel solenoid

i Engine t Generator capacitor, 35µF

j Junction box - ---

Wire Colors





51


4.16 Wiring Diagram: 50 Hz 230V 0009485

wc_

gr00

3768

Or

Or

P/B

Or

i

h

p

qo

W

LL

+–

52


4.17 Components: 50Hz 230V 0009485


a Generator k Hour meter

b Terminal strip, long m Floodlight capacitor, 30µF

c Main circuit breaker n Ballast/transformer

d Floodlights o Alternator

e Receptacle p Terminal strip, short

f Circuit breaker, 20A q Starter solenoid

g Circuit breaker, 15A r Emergency stop switch

h Battery s Fuel solenoid

i Engine t Generator capacitor, 35µF

j Junction box - ---

Wire Colors





53


4.18 Generator Capacitor Excitation Schematic


1 Rotor winding 5 Rotor

2 Stator winding 6 Short terminal strip

3 Excitation winding 7 Stator

4 Excitation capacitor 8 Rotor diode

wc_gr003535

120V

240V

COMMON

120V

6

2

2

8

43

5 7

1

8

1

C1

RectifiedOutput

RectifiedOutput

Excitation

Excitation

+

–

+

–

T1T1

T2

T3T3

T4T4

54


4.19 Trailer Wiring

55

Lombardini Engine Troubleshooting LTC Repair

5. Lombardini Engine Troubleshooting

5.1 Troubleshooting Flowcharts

The troubleshooting flowcharts are designed to take you through theprocess of determining the source of a problem with engine starting ormachine operation. Many of the tests involve live voltages andtherefore should only be attempted by qualified personnel. Detailedprocedures for carrying out the tests are included in this manual. Allhighlighted text within the flowcharts have matching sections in thismanual.

56

LTC Repair Lombardini Engine Troubleshooting

5.2 Engine Does Not Crank—Flowchart 3A

Check battery voltage.

Is the black wire

connected?

Yes

No

wc_gr003502

Check for battery voltage betweenterminal 30 of keyswitch and ground.

Reconnect black wire.

Clean and tighten connections.

Repair wiring from terminal 30

to battery.

Are connections clean

and tight?

Yes

No

Recharge or replace battery.

Does battery measure

11.0–13.0V?

No

Yes

Check for battery voltage betweenterminal 50 and ground when keyis placed in the START position.

Engine Does Not Crank

Is batteryvoltage measuredbetween 30 and

ground?

Yes

No

Replace keyswitch.

Is batteryvoltage measuredbetween 50 and

ground?

Yes

No

Check for battery voltage between black wire at starter solenoid and ground whenkey is in START position.

Repair/replace black wire.

Consult Lombardini

Engine Repair Manual.

Is batteryvoltage measured

between black wire and ground?

Yes

No

Check connection of black wire atstarter solenoid. Also check wireconnections at back of keyswitch.

See Checking Keyswitch and Wiring.

57


5.3 Checking Keyswitch and Wiring


Electric shock hazard. Only qualified personnel should conduct thesetests.

5.3.1 When troubleshooting Lombardini engines that do not crank, checkthat the B (black) wire (a) is connected to the starter solenoid.

5.3.2 Remove the screws securing the control panel (b) to the mountingbracket and remove the control panel from the bracket.

5.3.3 Remove the back cover (c) of the control panel box and check that thethe wiring to the keyswitch (d) is clean and tight. Check that theappropriate wires are connected to the proper terminals of thekeyswitch.

5.3.4 Check for 12V (battery voltage approximately 12) between terminal 30of keyswitch and ground. If no voltage is measured, repair wiring backto battery. If voltage is measured, continue.

5.3.5 Place the keyswitch in the START position and check for 12V (batteryvoltage approximately 12) between terminal 50 of the keyswitch andground. If no voltage is measured, replace the keyswitch. If voltage ismeasured, continue.

5.3.6 Place the keyswitch in the START position and check for 12V (batteryvoltage approximately 12) between the B (black) wire (a) and groundat the starter solenoid. If no voltage is measured, repair the wiringbetween terminal 50 of the keyswitch and the starter solenoid. Ifvoltage is measured and the engine still will not crank, there is aproblem with the starter motor. See the Lombardini Engine RepairManual for further information.

WARNING

58


wc_gr003509

30

50

B

L

V15/54

a

b

dc

59


5.4 Replacing Keyswitch


Disassembly:

5.4.1 Shut down the engine and disconnect the battery.

5.4.2 Remove the six screws securing the control panel cover to the controlpanel.

5.4.3 Make note of the wire connections on the keyswitch and remove thewires (a) from the keyswitch.

5.4.4 Unscrew the locking ring (b) and remove the keyswitch from thecontrol panel.

Reassembly:

5.4.5 Insert the replacement keyswitch into the control panel and secure itwith the locking ring (b).

5.4.6 Attach the wires (a) to the appropriate terminals of the keyswitch.

5.4.7 Secure the control panel cover to the control panel with the six screws.

wc_gr003510

b

a

30

50

B

L

V15/54

60


5.5 Engine Cranks But Does Not Start—Flowchart 4A

Check battery condition.

Replace battery.

Does battery provide

correct voltage and CCA?

No Yes

Make sure that the machinehas fresh fuel and that the fuel filter and fuel hoses arein good condition.

Engine Cranks But Does Not Start

Check if fuel flows from inlet hose when engine is cranking.

See Checking Fuel System

Check glow plug relay.

See Checking Glow Plug Relay.

Check glow plugs.

See Checking Glow Plugs.

wc_gr003503

Gravity feed fuelthrough fuel intake

hose.

Does fuel flow from inlet

hose?

Yes

No

Doglow plugs operate

correctly?Yes

No

Doesglow plug relay operate

correctly?Yes

No

Check fuel solenoid wiring.

Is fuel pump solenoid

operating?Yes

No

Replace glow plugs.

Replace glow plug relay.

Consult Lombardini

Engine Repair Manual.

61


5.6 Checking Fuel System


Electric shock hazard. Only qualified personnel should conduct thesetests.

When troubleshooting Lombardini engines that crank but do not start,make the following checks.

5.6.1 Check that the battery is in good condition and that all connections areclean and tight. If the battery voltage falls below 11.5V, replace thebattery.

5.6.2 Fill the fuel tank with fresh fuel and check that the fuel hoses and fuelfilter are clean and in good condition.

5.6.3 Disconnect the fuel intake hose (a). Have a suitable container ready tocatch the fuel. Place the keyswitch in the START position and check ifthe fuel flows from the hose.

• If fuel flows from the hose, reconnect the hose.

• If fuel does not flow from the hose, continue.

5.6.4 Disconnect the power lead (b) to the fuel solenoid. Place the keyswitchin the START position and check for battery voltage between the leadand ground.

• If battery voltage is not measured, check the continuity of wiring. See the Lombardini Engine Repair Manual for further information.

• If battery voltage is measured, check the power to the glow plugs.

WARNING

wc_gr002470

a

b

62


5.7 Checking Voltage to Glow Plugs (Lombardini 1003 engines)


To check the voltage to the glow plugs, carry out the followingprocedure:

5.7.1 Disconnect the B (black) wire (a), place the keyswitch in the STARTposition, and measure the voltage between the black wire and ground.There should be 12V (battery voltage approximately 12) measured.

• If 12V is measured, check the function of the glow plug.

• If 12V is not measured, continue.

5.7.2 Disconnect the B (black) wire (b) and measure the voltage between itand ground. There should be 12V (battery voltage approximately 12)measured.

• If 12V is measured, clean the connection points of the wires. Reconnect the wires and check the function of the glow plug.

• If 12V is not measured, check the glow plug relay.

wc_gr003229

a

b

63


5.8 Checking Glow Plug Relay


5.8.1 Remove the screws securing the engine control panel. Leave all wiringconnected to the control panel.

5.8.2 Rotate the control panel to gain access to the rear of the control panel.Remove the enclosure cover to access the glow plug relay.

5.8.3 Place the keyswitch in the START position. A working relay will “click”when the keyswitch is in the START position.Check the continuity across the blue (L) and black (B) wires when thekeyswitch is in the START position. If there is no continuity, the relayis faulty; replace it.

5.9 Replacing Glow Plug Relay


5.9.1 Make note of the wire positions and disconnect all wires from the glowplug relay.

5.9.2 Bend back the tabs (a) securing the glow plug relay (b) and pull theglow plug relay from the enclosure.

64


5.10 Checking Glow Plugs


5.10.1 Remove the glow plug from the engine.

Burn hazard. Glow plugs can reach temperatures up to 1200°F(649°C). Do not touch the element of the glow plug. Be extremelycareful when testing the glow plug.

5.10.2 Using 10-gauge wire, apply 12VDC to the glow plug—positive on theupper portion and ground the base. If the glow plug does not heat(glow) within five seconds, replace the glow plug.

Note: If any one of the glow plugs needs replacing, replace all of them.

WARNING

65


5.11 Engine Shuts Down—Flowchart 5A

Check engine oil level.

wc_gr003504

Fill machine with oil.

Is machine oillevel correct?

Yes

No

Engine Shuts Down

Connect oil pressure switch

and/or repair wiring.

Is oil pressure

switch connectedcorrectly?

Yes

No

Check engine coolant level.

Fill engine withcorrect amount and

type of coolant.

Is engine coolantlevel correct?

No

Yes

Connect coolanttemperature switch and/or repair wiring.

Is coolant temperature

switch connectedcorrectly?

Yes

No

Refer to the Lombardini Engine Repair

Manual.

Call Wacker Corporation Service.

Check wiring of oil pressureswitch.

Check wiring of coolant temperature switch.

See Checking Oil Pressure andCoolant Temperature Switches.

66


5.12 Checking Oil Pressure and Coolant Temperature Switches


5.12.1 If the engine starts but shuts down after approximately 10 seconds,check the following.

5.12.2 Check the engine oil level and add oil if necessary. Also check thecoolant temperature. If the coolant temperature is high, allow theengine to cool. Flush and fill the radiator with the correct coolant.

5.12.3 Check the wiring of the oil pressure switch (a) and the coolanttemperature switch (b) (903 engines) or (c) (1003 engines). If thewiring of either switch is shorted to ground, the engine will shut down.Be sure the switches are functioning—check each for continuity. Theoil pressure switch is a normally closed (NC) switch that should havecontinuity when the engine is off. If the switch has no continuity whenthe engine is off, the switch is faulty; replace it. The high coolant temperature switch is a normally open (NO) switch.This switch should have no continuity when the engine is off. If thisswitch has continuity when the engine is off, it has shorted and is faulty;replace it.

wc_gr003230

a

c

b

67


5.13 General 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

Oil

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

68


Battery voltage too low

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


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

Oil

leve

l ris

ing

Exc

essi

ve o

il co

nsum

ptio

n

Wet

exh

aust

Ove

rhea

ting

Eng

ine

knoc

ks

69


Valves sticking

Bearings (main/rod) worn

Governor/governor linkage malfunctioning

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

Oil

leve

l ris

ing

Exc

essi

ve o

il co

nsum

ptio

n

Wet

exh

aust

Ove

rhea

ting

Eng

ine

knoc

ks

70

Notes
71

Electrical Troubleshooting Procedures LTC Repair

6. Electrical Troubleshooting Procedures

6.1 Troubleshooting Methodology

If a lighting problem is not an obvious burnt bulb, engine speed, or wirefault, the cause of the problem will be associated with one of twothings: 1) a malfunctioning generator, or 2) faults in the circuitsupplying voltage to the lights. By starting the troubleshootingprocedures with the smaller terminal strip (the terminal strip where thewires from the generator are connected) you can determine whetherthe problem lies within the generator, or if the problem lies with thecircuit supplying the lights.

For troubleshooting a malfunctioning generator, you will need to ruleout a demagnetized rotor or problems with: the generator’s excitationcapacitor, the stator windings, the rotor diodes, and finally the rotorwindings.

For troubleshooting the lighting circuit, you will need to rule outproblems with: the main circuit breaker, the long terminal strip, theindividual circuit breakers, the ballast transformer, the lighting ballastcapacitors, and the wiring that connects all the components.

Detailed procedures for making the tests are included in the upcomingsections of this manual.

72

LTC Repair Electrical Troubleshooting

6.2 Checking Continuity

Conduct continuity tests when the engine is shut down.

When checking continuity, use the Ohm setting on your multimeter.Place a lead of the multimeter on one end of the wiring or componentand the other lead on the opposite end. If your meter reads “OL” or“OPEN”, there is no continuity and the wiring or component must berepaired or replaced. Note: Some multimeters also have an audio signal setting fordetermining continuity. This setting may also be used.

• If your meter reads less than 1.0 Ohm, or the audio signalsounds, the wiring or component has continuity and should beOK.

• If your meter reads more than 1.0 Ohm, the wiring is faulty andmust be repaired or replaced.

6.3 Checking resistance

Conduct resistance checks when the engine is shut down.

Use the Ohm setting on your multimeter.

Conduct resistance checks when the machine is as close to 21°C(70°F) as possible. Higher temperatures can affect resistance values.

Most digital multimeters have some internal resistance. To obtain yourmultimeter’s internal resistance, simply cross the two leads of yourmultimeter and read the display. When conducting a resistance check,subtract your multimeter’s internal resistance from the value youmeasure to obtain the true resistance of the component you arechecking.

6.4 Checking voltage

Conduct voltage checks when the engine is running.

Use the Volt setting on your multimeter. To prevent damage to yourinstrument, start with the highest scale available on your multimeter.Adjust to a lower scale as readings dictate.

Use extreme caution when checking voltage to reduce the risk ofelectric shock.

73


6.5 Troubleshooting Flowcharts

The troubleshooting flowcharts are designed to take you through theprocess of determining the source of a problem with engine starting ormachine operation. Many of the tests involve live voltages andtherefore should only be attempted by qualified personnel. Detailedprocedures for carrying out the tests are included in this manual. Allhighlighted text within the flowcharts have matching sections in thismanual.

74


6.6 Lights do not Illuminate—Flowchart 1A

Light(s) Do Not illuminate

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.

Is/are circuitbreaker(s) in closed

position?Close circuit breaker(s).

Are bulbs black or

burnt?Replace bulbs.

No

No

Yes

Yes

See Flowchart 1B

See Flowchart 1C

Is wiring connected at quick-

disconnects?

Connectquick-disconnects.

Yes

No

Is engine speed

correct?No

Yes

Check engine speed.

See Checking Engine Speed.

Is 120V±10%

measured across eachwinding?

wc_gr003514

Yes

No

Check voltage from generator to the short terminal strip.

See Checking Generator Voltage at the Short Terminal Strip.

75


6.7 Checking Engine Speed

See Graphic: wc_gr001625, wc_gr001634, and wc_gr002441

Using either a photo (strobe) tachometer, a frequency meter (60Hz =1800 rpm; 50Hz = 1500 rpm), or a vibration tachometer such as aSirometer (a) (Wacker P/N 0053397), check engine rpm. Refer to theinstrument instructions. If necessary, adjust engine rpm usingadjusting screw [(b) Lombardini engines, (c) CAT engines]. No loadengine speed should be 1850 rpm for 60Hz and 1550 rpm for 50Hzmodels.

NOTICE: Do not adjust the engine speed to be higher than that listedabove. The electrical components are frequency sensitive. Running athigher speeds will lead to component damage.

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

76


wc_gr001625

aa

wc_gr001634

bb

wc_gr002441

c

77


6.8 Checking Generator Voltage at the Short Terminal Strip


Electric shock hazard. Only qualified personnel should conduct thistest.

A quick way to check the function of the generator is to check thevoltage at the short terminal strip (a). If the correct voltage is present,problems with the lights not functioning will be associated with thecircuit from the short terminal strip to the lights and not with thegenerator.

To check the voltage at the short terminal strip, carry out the followingprocedure:

6.8.1 Turn off the lights and shut down the machine.

6.8.2 Remove the screws that secure the control panel cover to the controlbox. Remove the control panel cover and place it securely on thefender of the trailer so it will not fall when the engine is started.

6.8.3 Place all circuit breakers in the OFF position and start the engine.

6.8.4 Using the AC volt scale on a multimeter, measure the voltage acrossthe wires labelled “1” and “2”. Also measure the voltage across thewires labelled “3” and “4”. There should be 120V±10% measured ineach position.

• If 120V±10% is measured, the generator is functioning properly.

• If 120V±10% is not measured, check the resistance of the stator windings. See section Checking the Stator Windings.

6.8.5 Measure the voltage across the wires labelled “1” and “4”. Thereshould be 230V±10% measured.

• If 230V±10% is measured, the wiring to the short terminal strip is functioning properly.

• If 230V±10% is not measured, repair the jumper across the termi-nals where wires “2” and “3” are connected.

WARNING

78


wc_gr003517

1000200

202200m

F V

A

V- COM

1000200

202200m

F V

A

V- COM

a

79


6.9 Lights Do Not Illuminate—Flowchart 1B

Check resistance of excitation winding.

See Checking Excitation Winding.

wc_gr003515

With wiring disconnected at shortterminal strip, check resistance ofstator windings.

See Checking Stator Windings.

No

Yes

Replace the stator.

Are statorwindings OK?

No

Yes

Replace bothdiodes.

Replace thestator.

Isexcitation winding

OK?

Check the excitation capacitor.

See Checking the Excitation Capacitor.

Yes

No

Replace the excitation capacitor.

Is theexcitation capacitor

OK?Flash the generator.

See Flashing the Generator.

Remove the generator and check the rotor diodes.

See Checking the Rotor Diodes.

Yes

No

Yes

Isthe generatorfunctioning?

No

No

Are thediodesOK?

Replace therotor.

Remove the generator and check the rotor windings.

See Checking the Rotor Windings.

NoAre thewindings

OK?

See Flowchart 1C

See Flowchart 1C

80

Notes
81


6.10 Checking the Stator Windings



The stator consists of three separate windings. Two of the windingsare tapped for power. The third provides excitation to the rotor. Thisthird winding is known as the excitation winding.

To check the stator windings, carry out the following procedure:


6.10.2 Remove the screws that secure the control panel cover to the controlbox. Remove the control panel cover and place it securely on thefender of the trailer. So it will not fall when the engine is started.

6.10.3 Disconnect the wires labelled “1”, “2”, “3”, and “4” from the shortterminal strip (a). These are the stator winding leads.

6.10.4 Using the Ohms scale on a multimeter, measure the resistance acrosswires labelled “1” and “2”. Also measure the resistance across wireslabelled “3” and “4”. There should be 0.4±0.2 Ohms measured acrosseach pair.

• If 0.4±0.2 Ohms is not measured, the winding has failed; replace the stator.

• If 0.4±0.2 Ohms is measured, continue.

6.10.5 Measure the resistance (continuity) between each winding lead (wire)and a common ground.

• If resistance (continuity) to ground exists, the winding has failed; replace the stator.

• If there is no continuity (resistance) to ground, the winding is OK.

6.10.6 Measure the resistance (continuity) across wires labelled “2” and “3”.

• If resistance (continuity) exists, the winding has failed; replace the stator.

• If there is no continuity (resistance) to ground, the stator windings are OK.

WARNING

82


wc_gr003518

a

F V

20M2M

200k 20k 2k 200A

V- COM

F V

20M2M

200k 20k 2k 200A

V- COM

83


6.11 Checking the Excitation Winding



The stator consists of three separate windings. Two of the windingsare tapped for power. The third provides excitation to the rotor. Thisthird winding is known as the excitation winding.

To check the excitation winding, carry out the following procedure:


6.11.2 Remove the screws that secure the control panel cover to the controlbox. Remove the control panel cover and place it securely on thefender of the trailer.

6.11.3 Disconnect the wires from the excitation capacitor (a). These are theexcitation winding leads.

6.11.4 Using the Ohms scale on a multimeter, measure the resistance acrossthe two wires. There should be 2.2±0.5 Ohms measured.

• If 2.2±0.5 Ohms is not measured, the winding has failed; replace the stator.

• If 2.2±0.5 Ohms is measured, continue.

6.11.5 Measure the resistance (continuity) between each winding lead (wire)and a common ground.

• If resistance (continuity) to ground exists, the winding has failed; replace the stator.

• If there is no continuity (resistance) to ground, the winding is OK.

WARNING

84


wc_gr003519

a

F V

20M2M

200k 20k 2k 200A

V- COM

F V

20M2M

200k 20k 2k 200A

V- COM

85


6.12 Checking the Excitation Capacitor



The excitation capacitor (a) is mounted inside the control panel.

To check the excitation capacitor, carry out the following procedure:


6.12.2 Remove the screws that secure the control panel cover to the controlbox.

6.12.3 Remove the leads from the capacitor and discharge it by placing theblade of an insulated screwdriver across the two spades of thecapacitor.

6.12.4 Using a multimeter set to the Farad (F) or capacitance (C) scale (200µF), measure the capacitor’s capacitance. The capacitor shouldmeasure 25±1.25 µF on 60Hz machines; 35±1.25 µF on 50Hzmachines.

• If the reading is not within this range, replace the capacitor.

• If the capacitor measures within the above range, it is OK.

An alternative capacitor check is to set the multimeter to the 10,000Ohm scale when checking the capacitor. Observe the reading. If thereading starts out very low (5.0 Ohms) and continues to climb to anoverload or open reading, the capacitor may be OK. Double check byinstalling the capacitor in a known-to-be-working Light Tower. If theknown-to-be-working Light Tower operates correctly, the capacitor isOK. A second 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.

WARNING

86


wc_gr003520

60Hz 50Hz

a

200

20

2200n

20n2n

200p

2000

20m

F V

A

V- COM

µ

µ

µ

µ

200

20

2200n

20n2n

200p

2000

20m

F V

A

V- COM

µ

µ

µ

µ

87


6.13 Flashing the Generator



These procedures require two 14-gauge jumper wires and a fully-charged 12V or 9V battery.

If you measured 0 (zero) volts at the short terminal strip, the generatormay have lost its residual magnetism. Try restoring the magnetism(flashing) to the generator before conducting in-depth tests. Flashingthe generatior serves two purposes: 1) it restores rotor magnetism and2) it confirms a working rotor (winding and diodes). By flashing thegenerator with a known DC voltage, a predictable output voltage isproduced. For example, using a 12V battery produces an outputvoltage of 20–30 Volts per winding; using a 9V battery produces 8–11Volts per winding.

Start this test with the engine shut down.

6.13.1 Remove the control panel cover.

6.13.2 Unplug the two wires from the excitation capacitor (a).

Electric shock and burn hazard. If using the machine’s 12V battery,check for continuity between the excitation capacitor leads andcommon ground. If continuity exists, do not continue this procedure.The battery will be shorted which will result in machine damage andpossible personal injury.

6.13.3 Using 14-gauge or larger wire, connect two jumper wires to the battery,one to each terminal. Once connected to the battery, do not allow thetwo jumpers to touch each other.

Explosion hazard. Do not create sparks near the battery.

6.13.4 Start the engine.

6.13.5 Connect the battery jumper leads to the excitation wires—connecteither lead to either wire. This is a non-polar connection.

6.13.6 Using the AC-voltage setting on the multimeter, check the voltageacross the winding wires labelled “1” and “2” of the short terminal strip.Also check across the winding wires labelled “3” and “4”. There shouldbe 20–30 Volts measured in both cases when using a 12V battery; 8–11 Volts when using a 9V battery. Note: For clarity, the winding wires normally connected to the shortterminal strip are shown disconnected; however, it is not necessary todisconnect them during this procedure.

WARNING

CAUTION

WARNING

88

• If you measure the correct voltage, the generator is functioning. 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, there is a problem. Shut down the machine and disconnect the jumpers, first at the capacitor wires then at the battery. Continue troubleshooting. See section Checking Rotor Windings.

wc_gr003521

a

+ –

12V

1000200

202200m

F V

A

V- COM

+ –

9V

1000200

202200m

F V

A

V- COM

89


6.14 Removing the Generator


This procedure requires a floor jack and a hoist capable of lifting 45 kg.(100 lbs.).

6.14.1 Turn off the lights, shut down the engine, and disconnect the battery.

6.14.2 Remove the screws securing the cradle (a) and remove the cradle.

6.14.3 Remove the ground wires (b) between the doors and the top.

6.14.4 Remove the doors (c).

6.14.5 Remove the screws that secure the top and remove the top.

6.14.6 Disconnect the generator wiring from the short terminal strip (d) andfrom the excitation capacitor (e). Also disconnect the ground wire (f)from the control box.

6.14.7 Remove the nut (g) that secures the wiring support harness. Removethe wiring support harness from the control box and slide the generatorwires out of the control box.

6.14.8 Disconnect the ground wire from the frame.

6.14.9 Remove the screws that secure the fuel tank and remove the fuel tank.

6.14.10 Support the engine, on the generator end, from underneath with a floorjack.

6.14.11 Remove the nut (h) (from underneath) that secures the generatorhousing to the support bracket.

6.14.12 Remove the screws (i) that secure the generator mounting flange tothe engine bell housing.

6.14.13 Using two pry bars or flat head screwdrivers, pry the generatormounting flange from the engine bell housing. The rotor will beseparated from the stator in the process. Slide the stator (j) off therotor.

6.14.14 Support the rotor with an appropriate sling and crane.

6.14.15 Remove the screws (k) that secure the flex plates of the rotor to theengine flywheel.

6.14.16 Lift the rotor up and out of the machine.

90


wc gr003777

a

b

c

d

e

f

g

h

i

jk

i

91


6.15 Installing the Generator


This procedure requires a floor jack and a hoist capable of lifting 45 kg.(100 lbs.). This procedure also requires an M10 screw, an M10 nut,and a heavy-duty washer to fit the M10 screw.

6.15.1 Support the engine, on the generator end, from underneath with thefloor jack.

6.15.2 With an appropriate crane or hoist, position the rotor (h) into themachine.

6.15.3 Install the screws (j) that secure the flex plates of the rotor to theengine flywheel. Torque the screws to 21 Nm (15 ft.lbs.).

6.15.4 Assemble the M10 nut tothe M10 screw followed bythe washer. Insert the M10screw assembly (x) throughthe stator and into the shaftof the rotor. Align the statorwith the bearing of the rotor.Using the M10 nut as apusher, push the stator ontothe rotor until the bearingreaches its home position.

6.15.5 Install the screws (i) thatsecure the mounting flange of the generator to the bell housing of theengine. Torque the screws to 35 Nm (26 ft.lbs.).

6.15.6 Install the nuts that secure the shock mounts to the underside of theframe.

6.15.7 Connect the ground wire to the frame.

6.15.8 Slide the wires into the control box and install the wiring supportharness to the control box with the nut (g).

6.15.9 Connect the generator wiring to the short terminal strip (d) and to theexcitation capacitor (e). Also connect the grounding wiring (f) to thecontrol box.

6.15.10 Install the top.

6.15.11 Install the doors (c).

6.15.12 Install the ground wires (b) between the doors and the top.

6.15.13 Install the cradle (a).

xM10

wc_gr003813

92


wc_gr003778

a

b

c

d

e

f

g

h

jk

i

i

93


6.16 Checking the 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 the function of the diodes. When checking, be sure tocheck both diodes.

6.16.1 Unsolder the two wires from the terminal end of each diode.

6.16.2 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 0.4–0.5V. With the meter leads reversed, the other readingshould be OL or a very large reading (for example, 2.0 MV).

6.16.3 If your readings do not match those listed above, replace both diodes.Unscrew the diode to remove it.

94


wc_gr002461F V

A

V- COM

95


6.17 Checking the 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 in order to check the rotor windings.

6.17.1 Unsolder the two rotor winding wires from the terminal end of eachdiode.

6.17.2 Using the Ohms setting on the multimeter, measure the resistanceacross the wires and the base of the corresponding diode. Each wirereading should be 2.9+0.5/-0.0 Ohms or greater. If your readings arenot 2.9+0.5/-0.0 Ohms or greater, replace the generator.

6.17.3 Check the resistance of all four rotor windings in the manner describedabove.

6.17.4 Also check the resistance across the wires and the rotor shaft. If thereadings are not OL, or greater than 2 megohms (2M Ohms), replacethe generator. Confirm with Wacker Corporation Service beforereplacing.

6.17.5 Check all four 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 the readings are 2megohms (2M Ohms) or greater, the rotor is good. If the readings areless than 2 megohms, replace the generator end. Consult WackerCorporation Service to confirm.

wc_gr002462F V

20M2M

200k 20k 2k 200A

V- COM

F V

20M2M

200k 20k 2k 200A

V- COM

96


6.18 Lights do not Illuminate—Flowchart 1C

wc_gr003814

Check voltage at the main circuit breaker.

See Checking Voltage at the Main Circuit Breaker.

No

Yes

Repair wiringbetween short

terminal strip and main circuit

breaker.

Repair wiringbetween main

circuit breaker andlong terminal

strip.

Repair wiringbetween long

terminal strip andindividual circuitbreakers and/or replace circuit

breaker(s).

Is 240V±10%measured?

Check voltage at the long terminal strip.

See Checking Voltage to Long Terminal Strip.

Yes

No Is 230±10%Vmeasured?

Check voltage at individual circuit breakers.

See Checking Individual Circuit Breakers.

No

Yes Is 230V±10%measured?

Repair wiringbetween individual circuit breakers and

ballast capacitorsand/or replacetransformer (s).

Check incoming voltage to ballast capacitors.

See Checking Incoming Voltage to Ballast Capacitor(s).

Yes

NoIs 400±10%Vmeasured?

Replaceballast capacitor(s).

Conduct continuity tests onthe wiring between the ballast capacitors

and the mast junction box. Repair orreplace the wiring as needed.

Check outgoing voltage from ballast capacitors.

See Checking OutgoingVoltage from Ballast Capacitors.

No

YesIs 400V±10%measured?

97


6.19 Checking Voltage at the Main Circuit Breaker


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.

6.19.1 Remove the control panel front cover.

6.19.2 Using the AC voltage setting on the multimeter, measure the voltagebetween the two incoming terminals (a) of the main circuit breaker.There should be 230V±10%.

• If 230V±10% was not measured, shut down the machine and check the continuity of the wiring back to the short terminal strip. Repair the wiring as necessary.

• If 230V±10% was measured, continue.

6.19.3 Place the main circuit breaker in the ON position and measure thevoltage between the two outgoing terminals of the main circuit breaker.

• If 230V±10% was not measured, shutdown the machine and replace the main circuit breaker.

• If 230V±10% was measured, the wiring and main circuit breaker are functioning properly.

WARNING

98


wc_gr003786

a

1000200

202200m

F V

A

V- COM

1000200

202200m

F V

A

V- COM

99


6.20 Checking Voltage to Long Terminal Strip





6.20.2 Place the main circuit breaker in the ON position.

6.20.3 Using the AC voltage setting on the multimeter, measure the voltagebetween the R/G wire (a) and any of the neutral wires connected to thelong terminal strip. There should be 120V±10%.

• If 120V±10% was not measured, shut down the machine and check the continuity of the wiring back to the main circuit breaker. Repair the wiring as necessary.

• If 120V±10% was measured, continue.

6.20.4 Using the AC voltage setting on the multimeter, measure the voltagebetween the B/G wire (b) and any of the neutral wires connected to thelong terminal strip. There should be 120V±10%.

• If 120V±10% was not measured, shut down the machine and check the continuity of the wiring back to the main circuit breaker. Repair the wiring as necessary.

• If 120V±10% was measured, the long terminal strip is receiving the correct voltage.

WARNING

100


wc_gr003787

a

1000200

202200m

F V

A

V- COM

101


6.21 Checking Individual Circuit Breakers



Complete this test with the machine running. Test power to all circuitbreakers or just the circuit breaker in question.

6.21.1 Unplug the light(s) at the upper mast quick-disconnect plugs ordisconnect the lights at the junction box.

6.21.2 Remove control panel front cover.

6.21.3 Place the main circuit breaker in the ON position.

6.21.4 Using the AC voltage setting on the multimeter, test for 230V±10%incoming voltage by measuring across the input wires (a) (R/B, R, Br,or Br/Y (Br/W on some models)) at the back of the circuit breaker(s)and the wires at the terminal strip (b).

• If 230V±10% is not measured, it indicates a problem with voltagereaching the circuit breaker. Check the continuity of the wiringbetween the terminal strip and the circuit breaker. Repair orreplace the wiring as needed.

• If 230V±10% is measured at the circuit breaker, continue.

6.21.5 Place the circuit breaker being tested in the ON position and measurethe voltage between the outgoing side of the circuit breaker (c) and thewires at the terminal strip (b).

• If 230V±10% is not measured, it indicates a problem with thecircuit breaker. Check the continuity of the circuit breaker.Replace the circuit breaker if needed.

• If 230V±10% is measured, voltage is being supplied through thecircuit breaker. Continue troubleshooting by checking the functionof control panel capacitors. See section Checking IncomingVoltage to Control Panel Capacitor(s).

WARNING

102


wc_gr003073

a

c

b

1000200

202200m

F V

A

V- COM

103


6.22 Confirming a Malfunctioning Circuit Breaker



Complete this test with the engine shut down.

6.22.1 Remove the circuit breaker(s) from the control panel.

6.22.2 Place the circuit breaker ON-OFF switch in the ON position.

6.22.3 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.

6.22.4 Place the ON-OFF switch in the OFF position.

WARNING

104


wc_gr002458

105


6.23 Checking Incoming Voltage to Ballast Capacitor(s)



Start this procedure with the machine shut down.


6.23.2 Disconnect the wiring to the lights by disconnecting the outgoing wires(a, b, c, & d) from the ballast capacitors.

6.23.3 Start the machine.

6.23.4 Place the main circuit breaker and the individual circuit breaker(s) inthe ON position.

6.23.5 Using the AC voltage setting on the multimeter, measure the incomingvoltage to the ballast capacitor(s) by measuring across the input wire(e) and the wires (f) of the terminal strip. There should be 400V±10%measured.

• If 400V±10% is not measured, it indicates: faulty wiring to theballast transformers, faulty wiring to the ballast capacitors, or afailed ballast transformer. See section Checking Wiring to/fromBallast Transformers.

• If 400V±10% is measured, the ballast transformer(s) isfunctioning. Shutdown the machine and continue troubleshootingby checking the ballast capacitors. See section CheckingOutgoing Voltage from Ballast Capacitor(s).

WARNING

106


ab

cd

wc_gr003788

e

ef

1000200

202200m

F V

A

V- COM

1

1 2

43

2 3 4

107


6.24 Checking Outgoing Voltage from Ballast Capacitor(s)



Start this procedure with the machine shut down.


6.24.2 Disconnect the wiring to the lights by disconnecting the outgoing wires(a, b, c, & d) from the ballast capacitors.

6.24.3 Start the machine.

6.24.4 Place the main circuit breaker and the individual circuit breaker(s) inthe ON position.

6.24.5 Using the AC voltage setting on the multimeter, measure the outgoingvoltage from the ballast capacitor(s) by measuring across the outputwire (e) and the wires (f) of the terminal strip. There should be400V±10% measured.

• If 400V±10% is not measured, it indicates a faulty ballastcapacitor. Double-check the ballast capacitor. See sectionConfirming a Faulty Ballast Capacitor.

• If 400V±10% is measured, the ballast capacitor is functioning.Shutdown the machine and continue troubleshooting by checkingthe continuity of the wiring from the ballast capacitor through thejunction box and on to the light fixtures.

WARNING

108


ab

cd

f

wc_gr003789

e

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F V

A

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1

1 2

43

2 3 4

109


6.25 Confirming a Faulty Ballast Capacitor


Carry out this procedure with the engine shut down.

6.25.1 Remove the input and output wires from the capacitor.

6.25.2 Discharge the capacitor by placing the blade of an insulatedscrewdriver across the two spades of the capacitor.

6.25.3 Using a multimeter set to the Farad (F) or capacitance (C) scale (200µF), measure the capacitor’s capacitance. Each capacitor shouldmeasure 30±1 µF. If the reading is not within this range, replace thecapacitor.

110


wc_gr003790

200

20

2200n

20n2n

200p

2000

20m

F V

A

V- COM

µ

µ

µ

µ

111


6.26 Checking Wiring to/from Ballast Transformers



To check the wiring to and from the ballast transformer(s):

6.26.1 Turn off the engine.


6.26.3 Remove the screws (a) that secure the control panel/cover of theballast box (b). Position the control panel/cover of the ballast box soyou can access the wiring to the ballast transformers.

6.26.4 Check the B/Y (black-yellow) wire(s) (c) that run from the circuitbreaker(s) to the ballast transformer(s). Repair the wiring as needed.

6.26.5 Check the R (red) wire(s) (d) that run from the ballast transformer(s) tothe ballast capacitor(s). Repair the wiring as needed.

6.26.6 Check the Y (yellow) wire(s) (e) labelled “COMMON” that run from theballast transformer(s) to the neutral of the long terminal strip. Repairthe wiring as needed.

6.26.7 If all wiring is OK and 400V±10% is not reaching the ballast capacitor,the ballast transformer has failed; replace it.

WARNING

112


wc_gr003528

a

b

c

c

d

d

e

e

113


6.27 Replacing Ballast Transformer(s)

See Graphic: wc _gr003529

Removal:


6.27.2 Open the control panel and snip the wire ties (a) holding the ballasttransformer wires to the long terminal strip.

6.27.3 Remove the six screws securing the control panel/ballast box cover.Pull the control panel/ballast box cover (b) off the ballast box justenough to allow access to the ballast transformers.

6.27.4 Remove the wiring (c, d, e) from the ballast box for each ballasttransformer being replaced.

6.27.5 Remove the hardware (f) securing the ballast transformer (g) andremove the ballast transformer from the ballast box.

Installation:

6.27.6 Secure the replacement ballast transformer (g) in the ballast box withthe hardware (f).

6.27.7 Run the wires (c, d, e) up through the control panel and secure themto the proper locations.

6.27.8 Secure the control panel/ballast box cover (b) to the ballast box withthe six screws.

6.27.9 Gather and organize the wires with new wire ties (a).

6.27.10 Secure the control panel cover to the control panel with six screws.

114


wc_gr003529

df

g

c

b

e

a

115


6.28 Checking Voltage at the Receptacle



Complete this test with the machine running and both the main circuitbreaker and the receptacle circuit breaker in the ON position.

6.28.1 Using the AC voltage setting on the multimeter, test the receptacle for115V±10% on 0009379 machines; 230V±10% on 0009377 and0009485 machines.

6.28.2 If the correct voltage is not measured at the front of the receptacle, testfor voltage at the back of the receptacle. If the correct voltage ismeasured at the back of the receptacle but not at the front, thereceptacle has failed; replace it.

WARNING

116


wc_gr003791

1000200

202200m

F V

A

V- COM

1000200

202200m

F V

A

V- COM

117


6.29 Checking Receptacle’s Circuit Breaker




6.29.1 Using the AC voltage setting on the multimeter, measure the incomingvoltage to the receptacle’s circuit breaker by measuring between thebrown-yellow wire (a) and the wires (b) of the terminal strip. Thereshould be 115V or 230V±10% depending on model.

• If the correct voltage is not measured, the receptacle’s circuitbreaker is not receiving voltage. Check the condition of the wiringbetween the receptacle’s circuit breaker and the terminal strip.Repair/replace the wiring as needed.

• If the correct voltage is measured, continue.

6.29.2 Make sure the receptacle’s circuit breaker is in the ON position.

6.29.3 Using the AC voltage setting on the multimeter, measure the outgoingvoltage from the receptacle’s circuit breaker by measuring between theoutgoing wire (c) and the wires (b) of the terminal strip. There shouldbe 115V or 230V±10% depending on model.

• If the correct voltage is not measured, the receptacle’s circuitbreaker is not functioning. Confirm that receptacle’s circuitbreaker is malfunctioning by checking its continuity. Replace thecircuit breaker if needed.

• If the correct voltage is measured, continue troubleshooting bychecking the earth-leakage circuit breaker.

WARNING

wc_gr003081

a

c

b

1000200

202200m

F V

A

V- COM

1000200

202200m

F V

A

V- COM

118


6.30 Checking the Emergency Stop Switch


Complete this test with the engine off.

6.30.1 Remove the cover of the small control panel where the emergencystop switch is mounted.

6.30.2 Place the emergency stop switch in the deactivated (out) position.

6.30.3 In the deactivated position, contacts NC1 and NC2 should havecontinuity. Both pairs of NO3 and NO4 should have no continuity(open).

6.30.4 Place the emergency stop switch in the activated position (in).Contacts NC1 and NC2 should be open. Both pairs of NO3 and NO4should have continuity.

6.30.5 If the emergency stop switch does not perform as above, replace it.

wc_gr003792

119


6.31 Troubleshooting the Power Winch


6.31.1 Lower the tower.

6.31.2 Lower the mast assembly into the cradle.


6.31.4 Be sure the machine’s battery is fully charged (approximately 12V).

6.31.5 Remove the four screws (a) which secure the cover of the winch andremove the cover.

Pinching hazard. Use extreme care when operating the winch with itscover removed.

6.31.6 Disconnect the red and black wires at the motor (b).

6.31.7 Place the appropriate winch switch (c) in the up or down position, andcheck for battery voltage (approximately 12) between the red andblack wires.

• If 12V is measured, the power winch is receiving the correct volt-age. Thus, the power winch should operate. If power winch does not operate, replace it.


6.31.8 Remove the control panel (d) from the control box.

6.31.9 Check for battery voltage (approximately 12V) between terminals B1and B2 of the winch switch (e).

• If 12V is measured, the winch switch is receiving the correct volt-age. Thus, the power winch switch should operate. Check for bat-tery voltage between terminals A1 and A2 for both the up and the down positions of the winch switch. If the winch switch does not operate, replace it.


6.31.10 Locate the circuit breaker (f). Remove the tape and check for batteryvoltage between the output side (g) of the circuit breaker and ground.

• If 12V is measured at the output side of the circuit breaker but not at the winch switch, the wiring between the circuit breaker and the winch switch has failed; repair or replace the wiring.


6.31.11 Check for battery voltage between the input side of the circuit breakerand ground.

• If 12V is measured between the input side and ground but not the output side and ground, the circuit breaker has failed; replace it.

CAUTION

120

• If 12V is not measured, the wiring from the starter solenoid or the
wiring from the battery to the starter solenoid has failed. Check the wiring and repair or replace it as necessary.

wc_gr003160

b

d

ce

f

a

g

h

1000200

202200m

F V

A

V- COM

1000200

202200m

F V

A

V- COM

121

Notes
122

LTC Repair Disassembly/Assembly Procedures

7. Disassembly/Assembly Procedures

7.1 Tools

Because all possible problems encountered while repairing themachine cannot be anticipated, it is up to the mechanic to use commonsense and good judgement 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.

7.2 Ordering Parts

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

If the original Parts Book has been lost, a replacement may be orderedfrom Wacker Corporation. When ordering a replacement Parts Book,please list the model number, item number, revision level, and serialnumber of the machine. Parts Books are also available on the WackerCorporation Web site. See www.wackergroup.com. Enter the site as avisitor.

7.3 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.

7.4 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

123

Disassembly/Assembly Procedures LTC Repair

7.5 Light Assembly


Removal:

7.5.1 Disconnect the light at the junction box.

7.5.2 Remove the T-handle (b) and the cone washer (c). Also remove thenut (d) and the washer (e) securing the opposite end.

7.5.3 Pull the light assembly (f) from the bracket (g).

7.5.4 Remove the screws (h) securing the flange rings (i) and remove theflange rings.

7.5.5 Remove the lens (j) with the gasket (k) attached. Remove the gasketfrom the glass if replacing the gasket or lens.

7.5.6 Remove the hardware securing the bulb stabilizer (l) on one side.Once removed, swing the bulb stabilizer to the side and unscrew thebulb (m).

7.5.7 Remove the four screws (n) and the flange (t) securing the ceramicfixture assembly (o) to the reflector and remove the ceramic fixtureassembly including the gasket (s).

7.5.8 Remove the two screws securing the cover to the connector box andcut the black (p) and white wires (q) near the crimp nuts.

7.5.9 Remove the two screws (r) securing the ceramic fixture to the housingand remove the ceramic fixture.

Installation:

7.5.10 Slide the wiring of the replacement ceramic fixture through the housingand into the connector box. Secure the ceramic fixture to the housingwith the two screws (r).

7.5.11 Connect the black wire (p) from the new ceramic fixture to the blackwire in the connector box. Connect the white wire (q) from the new lightfixture to the white wire of the connector box. Secure the wires withnew crimp nuts.

7.5.12 Replace the cover of the connector box and secure it with the twoscrews.

7.5.13 Secure the ceramic fixture assembly (o), the gasket (s), and the flange(t), to the reflector using the four screws (n).

7.5.14 Insert the bulb and secure it with the bulb stabilizer (l).

7.5.15 Install the gasket (k) around the lens (j) and secure the lens to thereflector with the flange ring (i) and the screws (h).

7.5.16 Mount the light assembly (f) to the bracket (g) and mount the assemblyto the upper mast. Connect the wiring at the junction box.

124


bc

d

g

f

eh

j

k

i

l

m

n

o

wc_gr003531

p

q

r

t

s

125


7.6 Tower Assembly Exploded View

wc_

gr00

3793

j

(550

lb

s.)

250

Kg

a

b

c

d

ef

gh

in

lm

k

p

126


7.7 Tower Assembly List of Parts

7.8 Upper Mast

See Graphic: wc_gr003793, wc_gr003794, and wc_gr003161

Disassembly:

Turn the lights off, turn the unit off, and lower the mast assembly intothe cradle before performing this procedure. Place the Light Tower ina position with enough room so that the masts may be extended fullywhile in the down position.

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.

7.8.1 Disconnect the wiring for each light fixture at the junction box. Then,remove each light fixture. Store the light fixtures in a safe place.

7.8.2 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 the box attached and place it near the trailer.

7.8.3 Using the tongue-mounted winch, raise the tower so that the masts areapproximately two inches (5 cm) above the cradle locking pin (aa).


a Main mast (4-inch tube) i Mid mast (3-inch tube)

b Winch j Cross member

c Main mast cable k Upper mast (2-inch tube)

d Main mast pulley l Junction box

e Main mast guide m Cross member wiring cable clamps

f Upper mast cable n Mid-mast wiring cable clamps

g Mid-mast guide o Retaining bolt

h Mid-mast pulley p Eyebolt or U-bolt

127

7.8.4 Remove the screws (bb) securing the five guides (g) to the mid mast.
7.8.5 Pull the upper mast partially (2–6 feet (1–2 m)) out of the mid mast.

7.8.6 Make note of the upper mast cable (cc) as it passes around the mid-mast pulley (dd) then between the mid-mast pulley and the guidehardware (ee). Remove the mid-mast pulley. Remove the guidehardware only if it requires replacement.

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

7.8.8 Remove the hardware securing the cable U-bolt (p) to the main mast.

7.8.9 Remove the hardware securing the cable to the upper mast. Once freefrom the upper mast, run the cable back through the opening near theguide screw in the mid mast and remove cable completely from themachine.

Reassembly:

Replacement cables must be of the exact length of the originalequipment. Using shorter cables may cause severe personal injury.

7.8.10 Mount the mid-mast pulley (dd). Run the upper-mast cable (cc) aroundthe mid-mast pulley (dd) and between the pulley and the guidehardware (ee). Attach the cable to the upper mast (k).

7.8.11 Slide the upper mast into the mid mast (i).

7.8.12 Attach the five guides (g) using new self-tapping screws. Position theguides so that the self-tapping screws thread themselves into thesmaller side of the tapered hole in the guide.

Note: Limit reuse of the guides to one time.

7.8.13 Secure the cable U-bolt (p) to the main mast.

7.8.14 Mount the light fixtures and reconnect the wiring.

WARNING

128


When installing the junction box, be sureto include the gasket (a) and use asilicon-based sealant on all hardwareand plugs (b).

wc_gr003794

aa

dd

eecc

bb

wc_gr003161

b

a

129


7.9 Mid Mast

See Graphic: wc_gr003793 and wc_gr003795

Disassembly:

Turn the lights off, turn the unit off, and lower the mast assembly intothe cradle before this performing procedure. Place the Light Tower ina position with enough room so that the masts may be extended fullywhile in the down position.

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 main mast.This second cable raises the upper mast as the mid mast is beingraised.

7.9.1 Disconnect the wiring at each light fixture’s quick-disconnect or at thejunction box. Then, remove each light fixture. Store the light fixtures ina safe place.

7.9.2 Using the tongue-mounted winch, raise the tower just so that the mastsare free from the cradle locking pin.

7.9.3 Remove the upper-mast cross member (j) with the junction boxattached.

7.9.4 Remove the upper-mast cable eyebolt (p).

7.9.5 Using the mast-mounted winch, back off the tension of the cable untilthe cable may be unwound from the mast-mounted winch. Unwind andremove the cable from the mast-mounted winch.

7.9.6 On machines using rivets*, drill out the rivets (ww) securing the fiveguides to the main mast. On machines using screws, remove thescrews to remove the five guides.*Note: Replacement screws will be required for reassembly.

7.9.7 Remove the stop screw (xx).

7.9.8 Remove the main-mast pulley (cc).

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

7.9.10 Remove the hardware securing the cable to the mid mast and removethe cable from the mid mast.

If the mid mast requires replacement, continue.

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

7.9.12 Remove the mid-mast pulley (h).

7.9.13 Pull the upper mast (k) free of the mid mast.

130


Reassembly:

Replacement cables must be of the exact length of the originalequipment. Using shorter cables may cause severe personal injury.

7.9.14 Attach the cable to the mid mast.

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

7.9.16 Attach the five guides (g) using the new self-tapping screws. Positionthe guides so that the self-tapping screws thread themselves into thesmaller side of the tapered hole in the guide.Note: Limit reuse of the guides to one time.

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.

7.9.17 Route cable (yy) around the main-mast pulley (zz) and install the main-mast pulley.

7.9.18 Slide the mid mast completely into the main mast.

7.9.19 Attach the cable to the winch.

7.9.20 See section Upper Mast for installing the upper mast.

WARNING

WARNING

wc_gr003795

xx

zz

cc

yy

ww

131


7.10 Main Mast


Disassembly:

Turn the lights off, turn the unit off, and lower the mast assembly intothe cradle before performing this procedure. Place the Light Tower ina position with enough room so that the masts may be extended fullywhile in the down position.

The mast cable system consists of two cables: one connected to thewinch mounted on the main mast that raises the mid mast; and asecond that is connected to both the upper mast and the main mast.This second cable raises the upper mast as the mid mast is beingraised.

7.10.1 Remove the upper mast and the mid mast from the main mast. Seesection Mid Mast.

7.10.2 Disconnect the wiring from the control panel by:

• Snipping the wire ties (a).

• Disconnecting the wires from the capacitors (b).

• Disconnecting the wires from terminal strip (c).

7.10.3 Loosen the clamps (d & e) securing the tower supply cable. One clampis located on the control box and the other is on the front enclosurepanel.

7.10.4 Thread the tower supply cable through the eyes (g) on the side of themain mast.

7.10.5 Remove the cable clip (h) attached to the end of the main mast.

7.10.6 Tighten the adjusting knob (i) so that the main mast will not spin whenloosening the nut (j) securing the main mast to the main cradle.Remove the nut securing the main mast to the main cradle.

7.10.7 Loosen the adjusting knob.

7.10.8 Using an appropriate crane or hoist, lift the main mast up and out of themain cradle and free from the machine.

132


ce

h

i

j

g

wc_gr003532

a

c

b

d

133



Reassembly:

7.10.9 Grease the adjusting point circle (a) of the main cradle and the bottompivot point (b) of the main mast.

7.10.10 Using an appropriate crane or hoist, lift the main mast onto the top ofthe generator enclosure. Slide the bottom of the main mast into themain cradle.

7.10.11 Secure the main mast to the main cradle with the washer and nut (c).

7.10.12 Position the cable clip (d), on the tower supply cable, just below thelower curled portion of the cable. Then, secure the cable clip to the endof the main mast.

7.10.13 Thread the tower supply cable through the eyes (e) on the main mast.

7.10.14 Thread the tower supply cable through the clamp (f) at the front of themachine; leave a loop (g) of cable large enough so there is enoughslack in the cable to raise the mast.

7.10.15 Feed the tower supply cable into the control box and connect the wiresto the appropriate locations (h & i). Refer to the wiring diagram.Tighten the cable clamp (j), organize the wires with new wire ties (k),and re-install the control panel cover.

134


k

h

i

d

a

fg

b

e

wc_gr003533

c

j

135


7.11 Replacing Cable and Winch on Power Winch Models


Removal:

7.11.1 Lower the tower.

7.11.2 Lower the mast assembly into the cradle.


7.11.4 Remove the four screws (a) which secure the cover of the winch andremove the cover.

Pinching hazard. Use extreme care when operating the winch with itscover removed.

7.11.5 Using the appropriate switch (b) or the auxiliary handle (c), run thewinch so that all remaining cable is unwound from the spool. Do notrun the winch for periods of longer than four minutes. Allow the winchto cool if necessary.

7.11.6 Position the spool so that the retaining clamp (d) is accessible.

7.11.7 Loosen the screw which secures the clamp and the cable, and removethe cable from the spool.

7.11.8 To remove the winch, disconnect the motor wires (f). Then, remove thescrews (g) which secure the winch to the machine and remove thewinch.

Installation:

7.11.9 To install the winch, position the winch on the machine and secure itwith the screws (g). Then, connect the motor wires (f).

7.11.10 Thread the cable through the hole in the spool (e) so that when thewinch reels in the cable, the cable winds around the top of the spool.

7.11.11 Secure the cable to the spool using the cable clamp (d) and screw. Besure to secure the cable in both sides of the clamp.

7.11.12 Use the appropriate switch (b) or auxiliary handle (c) to wind up thecable.

7.11.13 Reinstall the cover using the four screws (a).

CAUTION

136


wc_gr003159

b

c

d

e

a

f

g

137


7.12 Replacing Fuel Tank


Removal:

7.12.1 Turn off the lights, shut down the engine, and disconnect the battery.

7.12.2 Position the main mast in the vertical position. Note: It is not necessary to raise the tower.

7.12.3 Remove the screws securing the mast cradle (a) and remove the mastcradle.

7.12.4 Remove the ground wires (b) between the doors and the top.

7.12.5 Remove the doors (c).

7.12.6 Remove the screws (f) that secure the top and remove the top.

7.12.7 Drain any remaining fuel in the fuel tank.

7.12.8 Snip the wire ties (g).

7.12.9 Remove the bolts (h) securing the hold-down straps (i).

7.12.10 Disconnect the fuel intake (j) and return lines (k).

7.12.11 With the aid of a partner or appropriate hoist, lift the fuel tank from themachine.

Installation:

7.12.12 Position the fuel tank into the machine.

7.12.13 Slide the new wire ties (g) underneath the hold-down straps (i) andsecure the fuel tank to the machine with the hold-down straps using thebolts (h).

7.12.14 Reconnect the fuel intake (j) and return lines (k).

7.12.15 Reinstall the top with the screws (f).

7.12.16 Reinstall the doors.

7.12.17 Reinstall the ground wires (b) between the doors and the top.

7.12.18 Reinstall the cradle (a).

138


wc_gr003534

b

c

a

g k

h

ij

f

a

139


7.13 Replacing Hour Meter


Disassembly:


7.13.2 Remove the six screws securing the control panel cover to the controlpanel.

7.13.3 Make note of the wire connections on the hour meter and remove thewires (a) from the hour meter.

7.13.4 Pull out the tabs (b) on the locking bracket (c) and remove the hourmeter from the panel.

Reassembly:

7.13.5 Insert the replacement hour meter into the control panel and secure itwith the locking bracket (c).

7.13.6 Attach the wires (a) to the appropriate terminals of the hour meter.

7.13.7 Secure the control panel cover to the control panel with the six screws.

140

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 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


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


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


Threadlockers and Sealants (continued)

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

TYPE( ) = Europe COLOR USAGE

PART NO. –SIZE

Loctite 496Hernon 110Omnifit Sicomet 7000

Clear Instant adhesive for bonding rubber, metal and plastics; 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 - 1oz.

Loctite Primer THernon Primer 10Omnifit VC Activator

AerosolSpray

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

2006124-6 oz.

Torque Values

Torque Values

Metric Fasteners (DIN)

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

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

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

M4 2.9 *26 4.1 *36 4.9 *43 7 9/32 3 –

M5 6.0 *53 8.5 6 10 7 8 5/16 4 –

M6 10 7 14 10 17 13 10 – 5 –

M8 25 18 35 26 41 30 13 1/2 6 –

M10 49 36 69 51 83 61 17 11/16 8 –

M12 86 63 120 88 145 107 19 3/4 10 –

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

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

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

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

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

8.8 10.9 12.9

Torque Values

Torque Values (continued)

Inch Fasteners (SAE)

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

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

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

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

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

1/4 8.1 6 12 9 16 12 – 7/16 – 3/32

5/16 18 13 26 19 33 24 13 1/2 – 1/4

3/8 31 23 45 33 58 43 – 9/16 – 5/16

7/16 50 37 71 52 94 69 16 5/8 – 3/8

1/2 77 57 109 80 142 105 19 3/4 – 3/8

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

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

3/4 271 200 383 282 479 353 – 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)89-3 54 02 - 0 · Fax: +49 - (0)89-3 54 02-3 90Wacker Corporation · P.O. Box 9007 · Menomonee Falls, WI 53052-9007 · Tel. : (262) 255-0500 · Fax: (262) 255-0550 · Tel. : (800) 770-0957Wacker Asia Pacific Operations · Skyline Tower, Suite 2303, 23/F · 39 Wang Kwong Road, Kowloon Bay, Hong Kong · Tel. +852 2406 60 32 · Fax: +852 2406 60 21

Documents

wc br0163722en 001 - Wacker Neusonproducts.wackerneuson.com/manuals/Repair/0163722en_001Rep.pdf · LTC Repair Table of Contents 7 6.5 Troubleshooting Flowcharts ..... 74 6.6 Lights