WACKER Group LTC 4 Operating instructions

www.wackergroup.com
Light Tower
LTC 4
REPAIR MANUAL
0160487en 003
0206
0160487EN

LTC Repair Foreword
wc_tx000424gb.fm i
Operating / Parts Information
You must be familiar with the operation of this machine before you
attempt to troubleshoot or repair it. Basic operating and maintenance
procedures are described in the Operator’s Manual supplied with the
machine. Keep a copy of the Operator’s Manual with the machine at all
times. Use the separate Parts Book supplied with the machine toorder
replacement parts. If you are missing either of the documents, please
contact Wacker Corporation to order a replacement.
Damage caused by misuse or neglect of the unit should be brought to
the attention of the operator to prevent similar occurrences from
happening in the future.
This manual provides information and procedures to safely repair and
maintain the above Wacker model(s). For your own safety and
protection from injury, carefully read, understand, and observe all
instructions described in this manual. THE INFORMATION
CONTAINED IN THIS MANUAL IS BASED ON MACHINES
MANUFACTURED UP TO THE TIME OF PUBLICATION. WACKER
CORPORATION RESERVES THE RIGHT TO CHANGE ANY
PORTION OF THIS INFORMATION WITHOUT NOTICE.
This manual covers machines with Item Number:
0009375, 0009376, 0620017, 0620018, 0620028

Foreword LTC Repair
wc_tx000424gb.fm ii
CALIFORNIA
Proposition 65 Warning:
Diesel engine exhaust, some of its constituents, and certain vehicle
components contain oremit chemicals known to the State of California
to cause cancer and birth defects or other reproductive harm.
All rights, especially copying and distribution rights, are reserved.
Copyright 2006 by Wacker Corporation
No part of this publication may be reproduced in any form or by any
means, electronic or mechanical, including photocopying, without
express written permission from Wacker Corporation.
Any type of reproduction or distribution not authorized by Wacker
Corporation represents an infringement of valid copyrights, and
violators will be prosecuted. We expressly reserve the right to make
technical modifications, even without due notice, which aim at
improving our machines or their safety standards.
WARNIN
G

LTC Repair Table of Contents
wc_br0160487en_003TOC.fm 1
1. Safety Information 6
1.1 Laws Pertaining to Spark Arresters ...................................................... 6
1.2 Operating Safety .................................................................................. 7
1.3 Operator Safety while using Internal Combustion Engines .................. 8
1.4 Towing Safety ....................................................................................... 9
1.5 Service Safety .................................................................................... 10
1.6 Label Locations .................................................................................. 11
1.7 Safety and Operating Labels .............................................................. 13
2. Technical Data 19
2.1 Engine ................................................................................................ 19
2.2 Generator ........................................................................................... 20
2.3 Machine .............................................................................................. 21
3. Operation 23
3.1 Information Regarding Operation ....................................................... 23
3.2 Locating Trailer ................................................................................... 23
3.3 Leveling Trailer ................................................................................... 24
3.4 Adjusting Lights .................................................................................. 24
3.5 Preparing Trailer for Towing or Lifting ................................................ 25
3.6 Raising Tower (Manual Winch System) ............................................. 26
3.7 Lowering Tower (Manual Winch System) ........................................... 28
3.8 Raising Tower (Power Winch System) ............................................... 30
3.9 Lowering Tower (Power Winch System) ............................................ 32
3.10 Emergency Crank Handle (Power Winch System) ............................. 33
3.11 Control Panels—Lombardini (Manual Winch System) ....................... 34
3.12 Control Panels—Lombardini (Power Winch System) ......................... 35
3.13 Control Panels—CAT (Manual Winch System) .................................. 36
3.14 Control Panel—CAT (Power Winch System) ..................................... 37
3.15 Starting—Lombardini .......................................................................... 38
3.16 Starting—CAT .................................................................................... 39
3.17 Automatic Shutdown .......................................................................... 39
3.18 Operating Lights ................................................................................. 40
3.19 Stopping—Lombardini ........................................................................ 40
3.20 Stopping—CAT .................................................................................. 40
3.21 Derating .............................................................................................. 40

Table of Contents LTC Repair
wc_br0160487en_003TOC.fm 2
3.22 Receptacles—60 Hz ............................................................................41
4. Maintenance 42
4.1 Periodic Maintenance Schedule—Lombardini ....................................42
4.2 Periodic Maintenance Schedule—CAT ...............................................43
4.3 Daily Inspection ...................................................................................43
4.4 Installing / Removing Light Fixtures ....................................................44
4.5 Precautions When Replacing / Removing Bulbs .................................45
4.6 Replacing Bulbs ..................................................................................46
4.7 Air Cleaner ..........................................................................................47
4.8 Engine Oil ............................................................................................48
4.9 Generator Capacitor Excitation Schematic 60 Hz ...............................49
4.10 Schematic for 60 Hz Metal Halide 4-Light Units ..................................50
4.11 Metal Halide Schematic Components .................................................51
4.12 Engine Wiring—Lombardini 1003 ........................................................52
4.13 Engine Wiring Components—Lombardini 1003 ..................................53
4.14 Engine Control Panel Internal Wiring—Lombardini 1003 ....................54
4.15 Engine Wiring—Lombardini 903 ..........................................................55
4.16 Engine Control Panel Internal Wiring—Lombardini 903 ......................56
4.17 Engine Control Panel Components—Lombardini ................................57
4.18 Engine Wiring—Item Number: 0009376 ..............................................58
4.19 Engine Wiring—Item Number: 0620017, 0620028 ..............................59
4.20 Power Winch Schematic .....................................................................60
4.21 Trailer Wiring .......................................................................................61
5. Lombardini Engine Troubleshooting 62
5.1 Troubleshooting Flowcharts ................................................................62
5.2 Engine Does Not Crank—Flowchart 3A ..............................................63
5.3 Checking Keyswitch and Wiring ..........................................................64
5.4 Replacing Keyswitch ...........................................................................66
5.5 Engine Cranks But Does Not Start—Flowchart 4A .............................67
5.6 Checking Fuel System ........................................................................68
5.7 Checking Voltage to Glow Plugs (Lombardini 903 engines) ...............69
5.8 Checking Voltage to Glow Plugs (Lombardini 1003 engines) .............70
5.9 Checking Glow Plug Relay ..................................................................71
5.10 Replacing Glow Plug Relay .................................................................71
5.11 Checking Glow Plugs ..........................................................................72

LTC Repair Table of Contents
wc_br0160487en_003TOC.fm 3
5.12 Engine Shuts Down—Flowchart 5A ................................................... 73
5.13 Checking Oil Pressure and Coolant Temperature Switches .............. 74
5.14 General Engine Troubleshooting ........................................................ 75
6. Caterpillar Engine Troubleshooting 78
6.1 Troubleshooting Flowcharts ............................................................... 78
6.2 Engine Does Not Crank—Flowchart 6A ........................................... 79
6.3 Checking Keyswitch and Wiring ......................................................... 80
6.4 Replacing Keyswitch .......................................................................... 81
6.5 Engine Cranks But Does Not Start—Flowchart 7A ............................ 82
6.6 Checking Fuel Flow ............................................................................ 83
6.7 Checking Glow Plug Wiring ................................................................ 84
6.8 Checking Glow Plugs ......................................................................... 84
6.9 Engine Shuts Down—Flowchart 8A ................................................... 85
6.10 Checking Oil Pressure and Coolant Temperature Switches .............. 86
6.11 General Engine Troubleshooting ........................................................ 87
7. Electrical Troubleshooting Procedures 90
7.1 Troubleshooting Methodology ............................................................ 90
7.2 Schematic Components ..................................................................... 90
7.3 Schematic for 60 Hz Metal Halide 4-Light Units ................................. 91
7.4 Checking Continuity ........................................................................... 92
7.5 Checking resistance ........................................................................... 92
7.6 Checking voltage ................................................................................ 92
7.7 Troubleshooting Flowcharts ............................................................... 92
7.8 Lights do not Illuminate—Flowchart 1A .............................................. 93
7.9 Lights do not Illuminate—Flowchart 1B .............................................. 94
7.10 Lights do not Illuminate—Flowchart 1C .............................................. 95
7.11 Lights do not Illuminate—Flowchart 1D ............................................. 96
7.12 Checking Engine Speed ..................................................................... 97
7.13 Checking Generator Voltage at Receptacle ....................................... 98
7.14 Replacing Receptacle ........................................................................ 99
7.15 Checking Voltage to the Main Circuit Breaker .................................. 100
7.16 Checking Voltage Between Main Circuit Breaker and Terminal Strip 102
7.17 Checking Individual Circuit Breakers ................................................ 104
7.18 Confirming a Malfunctioning Circuit Breaker .................................... 106
7.19 Checking Incoming Voltage to Control Panel Capacitor(s) .............. 107

Table of Contents LTC Repair
wc_br0160487en_003TOC.fm 4
7.20 Checking Outgoing Voltage from Control Panel Capacitor(s) ...........108
7.21 Confirming a Faulty Control Panel Capacitor ....................................109
7.22 Checking Wiring to/from Ballast(s) ....................................................110
7.23 Replacing Ballast ...............................................................................112
7.24 Restoring Rotor Magnetism (Flashing) / Checking Rotor Winding ....114
7.25 Checking Generator Capacitors ........................................................116
7.26 Alternative Capacitor Check ..............................................................117
7.27 Replacing Generator Capacitor(s) .....................................................118
7.28 Checking Stator Windings .................................................................120
7.29 Removing/Installing Caterpillar Engine with Generator .....................122
7.30 Removing/Installing Lombardini Engine with Generator ...................124
7.31 Separating Stator Assembly from Engine/Rotor Assembly ...............126
7.32 Remounting Stator Assembly to Rotor/Engine Assembly .................128
7.33 Checking Rotor Diodes .....................................................................129
7.34 Checking Rotor Windings ..................................................................130
7.35 Removing/Installing Rotor .................................................................131
7.36 No Voltage at Receptacle—Flowchart 2A .........................................132
7.37 Checking Voltage at Receptacle .......................................................133
7.38 Checking Receptacle’s Circuit Breaker .............................................134
7.39 Troubleshooting the Power Winch ....................................................136
8. Disassembly/Assembly Procedures 139
8.1 Tools ..................................................................................................139
8.2 Ordering Parts ...................................................................................139
8.3 Reference Numbers ( ) ......................................................................139
8.4 Weight Block .....................................................................................139
8.5 Light Assembly ..................................................................................140
8.6 Tower Assembly Exploded View .......................................................142
8.7 Tower Assembly List of Parts ............................................................143
8.8 Upper Mast ........................................................................................143
8.9 Mid Mast ............................................................................................146
8.10 Main Mast ..........................................................................................148
8.11 Replacing Cable and Winch on Power Winch Models ......................152
8.12 Replacing Fuel Tank .........................................................................154
8.13 Replacing Hour Meter .......................................................................156

LTC Repair Table of Contents
wc_br0160487en_003TOC.fm 5

Safety Information LTC Repair
wc_si000164gb.fm 6
1. Safety Information
This manual contains DANGER, WARNING, CAUTION, and NOTE
callouts which must be followed to reduce the possibility of personal
injury, damage to the equipment, or improper service.
This is the safety alert symbol. It is used to alert you to potential
personal injury hazards. Obey all safety messages that follow this
symbol to avoid possible injury or death.
DANGER indicates an imminently hazardous situation which, if not
avoided, will result in death or serious injury.
WARNING indicates a potentially hazardous situation which, if not
avoided, could result in death or serious injury.
CAUTION indicates a potentially hazardous situation which, if not
avoided, may result in minor or moderate injury.
CAUTION: Used without the safety alert symbol, CAUTION indicates
a potentially hazardous situation which, if not avoided, may result in
property damage.
Note: Contains additional information important to a procedure.
1.1 Laws Pertaining to Spark Arresters
Notice: State Health Safety Codes and Public Resources Codes
specify that in certain locations spark arresters be used on internal
combustion engines that use hydrocarbon fuels. A spark arrester is a
device designed to prevent accidental discharge of sparks or flames
from the engine exhaust. Spark arresters are qualified and rated by
the United States Forest Service for this purpose.
In order to comply with local laws regarding spark arresters, consult
the engine distributor or the local Health and Safety Administrator.
DANGER
WARNIN
G
CAUTION

LTC Repair Safety Information
wc_si000164gb.fm 7
1.2 Operating Safety
Familiarity and proper training are required for the safe operation of
equipment. Equipment operated improperly or by untrained personnel
can be dangerous. Read the operating instructions contained in both
this manual and the engine manual and familiarize yourself with the
location and proper use of allcontrols. Inexperienced operators should
receive instruction from someone familiar with the equipment before
being allowed to operate the machine.
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 not
tip, 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 storms
are expected in the area.
1.2.5 ALWAYS make certain the machine is well-grounded and securely
fastened 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 the
trailer is open and clear of overhead wires and obstructions.
1.2.7 The bulbs become extremely hot in use! Allow the bulb and fixture to
cool 10–15 minutes before handling.
1.2.8 Keep the area behind the trailer clear of people while raising and
lowering the mast! Never raise, lower or turn the mast while unit is
operating!
1.2.9 The trailer must be leveled and the outriggers extended before raising
the 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 cable
develops 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 NEVERuse the machine if the insulation on the electrical cord is cut or
worn through.
1.2.13 NEVER operate the lights without the protective lens cover in place or
with 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 Light Tower in high winds.
WARNIN
G

Safety Information LTC Repair
wc_si000164gb.fm 8
1.3 Operator Safety while using Internal Combustion Engines
Internal combustion engines present special hazards during operation
and fueling. Read and follow the warning instructions in the engine
owner’s manual and the safety guidelines below. Failure to follow the
warnings and safety guidelines could result in severe injury or death.
1.3.1 NEVER operate the machine indoors unless exhaust fumes can be
adequately 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 hot. The radiator 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 to
clean parts, especially in enclosed areas. Fumes from fuels and
solvents can become explosive.
1.3.8 ALWAYS keep the area around the muffler free of debris such as
leaves, paper, cartons, etc. A hot muffler could ignite the debris and
start a fire.
DANGER

LTC Repair Safety Information
wc_si000164gb.fm 9
1.4 Towing Safety
Towing a large trailer requires special care. Both the trailer and vehicle
must be in good condition and securely fastened to each other to
reduce the possibility of an accident.
1.4.1 ALWAYS check that the hitch and coupling on the vehicle are rated
equal 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 NOT
tow 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, and
condition. Replace worn tires.
1.4.5 ALWAYS connect the safety chains.
1.4.6 ALWAYS make sure directional and trailer lights are connected and
working properly.
1.4.7 ALWAYS check that the lug nuts holding the wheels are tight and that
none 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 16
km/hour (10 MPH) or less depending on terrain.
1.4.9 ALWAYS refer to the applicable Department of Transportation
regulations before towing.
WARNIN
G

Safety Information LTC Repair
wc_si000164gb.fm 10
1.5 Service Safety
HIGH VOLTAGE! This unit uses high voltage circuits capable of
causing serious injury or death. Only a qualified electrician should
troubleshoot or repair electrical problems occurring in this equipment.
1.5.1 ALWAYS replace the safety devices and guards after repairs and
maintenance.
1.5.2 Before servicing the Light Tower, make sure the engine start switch is
turned to OFF, the circuit breakers are open (off), and the negative
terminal on battery is disconnected. NEVER perform even routine
service (oil/filter changes, cleaning, etc.) unless all electrical
components 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 dry
before 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 moving
parts on the generator and engine.
1.5.6 ALWAYS keep the machine clean and labels legible. Replace all
missing and hard-to-read labels. Labels provide important operating
instructions and warn of dangers and hazards.
1.5.7 ALWAYS make sure slings, chains, hooks, ramps, jacks and other
types of lifting devices are attached securely and have enough weight-
bearing capacity to lift or hold the machine safely. Always remain
aware 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 engine
before disconnecting the light fixtures or changing the light bulbs.
WARNIN
G

LTC Repair Safety Information
wc_si000164gb.fm 11
1.6 Label Locations

Safety Information LTC Repair
wc_si000164gb.fm 12

LTC Repair Safety Information
wc_si000164gb.fm 13
1.7 Safety and Operating Labels
Wacker machines use international pictorial labels where needed.
These labels are described below:
Ref. Label Meaning
ADANGER!
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.
BWARNING!
Avoid crushing area.
CWARNING!
Completely lower tower before tilting
mast. Tilting an extended mast could
cause serious injury or death.
DDANGER!
Contact with overhead electrical power
lines will cause serious injury or death.
Do not position Light Tower under
electrical power lines.

Safety Information LTC Repair
wc_si000164gb.fm 14
ECAUTION!
Lifting point
FWARNING!
Secure mast in transport lock before
lifting or towing. A loose swinging mast
could cause personal injury or machine
damage.
GDANGER!
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.
HDANGER!
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.
IDANGER!
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

LTC Repair Safety Information
wc_si000164gb.fm 15
JElectrical ground
KWARNING!
Stand clear of front and rear of machine
when mast is being tilted up or down.
LWARNING!
Hot surface!
MA 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.
NWARNING!
Ultraviolet radiation from lamp can cause
serious skin and eye irritation. Use only
with providedundamaged lens cover and
fixture.
Ref. Label Meaning

Safety Information LTC Repair
wc_si000164gb.fm 16
Ref. Label
O
P
I N S T R U C T I O N S D E R E M O R Q U A G E
T O W I N G I N S T R U C T I O N S A B S C H L E P P I N S T R U K T I O N E N I N S T R U C C I O N E S D E R E M O L Q U E
1 . R E A D O P E R A T O R ' S M A N U A L .
2 . U S E H I T C H R A T E D F O R T R A I L E R ' S
" G R O S S V E H I C L E W E I G H T R A T I N G " .
3 . S E C U R E L Y A T T A C H T R A I L E R T O T O W
V E H I C L E .
4 . A T T A C H S A F E T Y C H A I N S U S I N G C R O S S
P A T T E R N .
. C H E C K T R A I L E R L I G H T S .
1 . B E T R I E B S V O R S C H R I F T L E S E N .
2 . A N H A N G E V O R R I C H T U N G V E R W E N D E N ,
D I E D E R G E S A M T B E T R I E B S G E W I C H T S K L A S S E
E N T S P R I C H T .
3 . A N H A N G E R S I C H E R A M Z U G F A H R Z E U G
B E F E S T I G E N .
4 . S I C H E R H E I T S K E T T E N K R E U Z W E I S E A N B R I N G E N .
. A N H A N G E R L E U C H T E N P R U F E N .
1 . L E A E L M A N U A L D E L O P E R A R I O .
2 . U T I L I C E U N A C O P L E C O R R E C T A M E N T E
C L A S I F I C A D O P A R A L A " C L A S E D E P E S O B U T O "
D E L V E H I C U L O D E L R E M O L Q U E .
3 . A S E G U R E S E D E A M A R R A R C O R R E C T A M E N T E
E L R E M O L Q U E A L V E H I C U L O D E R E M O L Q U E .
4 . F I J E E N C R U Z L A S C A D E N A S D E S E G U R I D A D .
. C O N T R O L E L A S L U C E S D E L R E M O L Q U E .
1 . L I R E L A N O T I C E D ' E M P L O I .
2 . U T I L I S E R U N G R O C H E T D ' A T T E L A G E C O N F O R M E A U
D E B I T N O M I N A L D U P O I D S B R U T D E V E H I C U L E D U
T R A C T E U R .
3 . A T T A C H E R L A R E M O R Q U E F E R M E M E N T A U V E H I C U L E
T R A C T E U R .
4 . A T T A C H E R L E S C H A I N E S D E S U R E T T E E N U T I L I S A N T
U N E M E T H O D E C R O I S E E .
. V E R I F I E R L E S L A M P E S D E L A R E M O R Q U E .
114894