Wacker Neuson LTN 6L User manual

0171883en 007 1110
0171883EN
Operator’s Manual
Light Tower
LTN 6L
60 Hz

Copyright
notice
© Copyright 2010 by Wacker Neuson Corporation.
All rights, including copying and distribution rights, are reserved.
This publication may be photocopied by the original purchaser of the machine. Any
other type of reproduction is prohibited without express written permission from
Wacker Neuson Corporation.
Any type of reproduction or distribution not authorized by Wacker Neuson Corporation
represents an infringement of valid copyrights. Violators will be prosecuted.
Trademarks All trademarks referenced in this manual are the property of their respective owners.
Manufacturer Wacker Neuson Corporation
N92W15000 Anthony Avenue
Menomonee Falls, WI 53051 U.S.A.
Tel: [phone] · Fax: [phone] · Tel: [phone]
www.wackerneuson.com
Original
instructions
This Operator’s Manual presents the original instructions. The original language of this
Operator’s Manual is American English.

wc_bo0171883en_007TOC.fm 3
Table of ContentsLTN 6L
Foreword 7
1 Safety Information 9
1.1 Signal Words Used in this Manual ....................................................... 9
1.2 Machine Description and Intended Use ............................................. 10
1.3 Safety Guidelines for Operating the Machine ..................................... 11
1.4 Operator Safety while Using Internal Combustion Engines ............... 13
1.5 Lamp Safety ....................................................................................... 14
1.6 Service Safety .................................................................................... 14
2 Labels 16
2.1 Label Locations .................................................................................. 16
2.2 Label Meanings .................................................................................. 18
3 Lifting the Machine 30
3.1 Procedure ........................................................................................... 30
4 Operation 31
4.1 Locating Trailer ................................................................................... 31
4.2 Leveling Trailer ................................................................................... 32
4.3 Adjusting Lights .................................................................................. 33
4.4 Preparing Trailer for Towing or Lifting ................................................ 34
4.5 Raising Tower (Manual Winch System) ............................................. 35
4.6 Lowering Tower (Manual Winch System) ........................................... 38
4.7 Raising Tower (Power Winch System) ............................................... 40
4.8 Lowering Tower (Power Winch System) ............................................ 42
4.9 Emergency Crank Handle (Power Winch System) ............................. 43
4.10 Control Panels (Manual Winch System) ............................................. 44
4.11 Control Panels (120/240, Manual Winch System) .............................. 45
4.12 Control Panels (Power Winch System) .............................................. 46
4.13 Starting ............................................................................................... 47
4.14 Manual Shutdown ............................................................................... 47

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Table of Contents LTN 6L
4.15 Automatic Shutdown ...........................................................................47
4.16 Operating Lights ..................................................................................48
4.17 Stopping ..............................................................................................48
4.18 Derating ...............................................................................................48
4.19 Receptacle ..........................................................................................49
5 Factory Installed Options 50
5.1 Block Heater ........................................................................................50
5.2 Battery Blanket ....................................................................................51
5.3 Oil Pan Heater .....................................................................................51
6 Maintenance 52
6.1 Periodic Maintenance Schedule ..........................................................52
6.2 Installing / Removing Light Fixtures ....................................................53
6.3 Replacing / Removing Lamps .............................................................54
6.4 Daily Inspection ...................................................................................55
6.5 Air Cleaner ..........................................................................................56
6.6 Engine Oil ............................................................................................56
6.7 Troubleshooting ...................................................................................57
7 Technical Data 58
7.1 Engine .................................................................................................58
7.2 Generator ............................................................................................59
7.3 Machine ...............................................................................................59
8 Schematics 60
8.1 Electrical Schematic ............................................................................60
8.2 Electrical Schematic (120/240) ............................................................62
8.3 Trailer Wiring .......................................................................................64
8.4 Engine Wiring - Lombardini .................................................................65
8.5 Control Panel Wiring ...........................................................................66
8.6 Power Winch Schematic .....................................................................67

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Table of ContentsLTN 6L
9 Appendix I—Assembly Instructions 68
9.1 Introduction ......................................................................................... 68
10 Appendix II—Assembly Safety 70
10.1 Signal Words Found in this Manual .................................................... 70
10.2 Lifting Safety ....................................................................................... 71
10.3 Pre-Assembly Checklist ..................................................................... 71
11 Appendix III—Standard Pallet Assembly 72
11.1 Installing the Outriggers and Outrigger Jacks .................................... 73
11.2 Installing the Rear Jack ...................................................................... 74
11.3 Installing the Tongue Assembly ......................................................... 75
11.4 Installing the Upper Light Fixtures ...................................................... 77
11.5 Conclusion .......................................................................................... 78
12 Appendix IV—CE Pallet Assembly 79
12.1 Installing the Side Jacks ..................................................................... 80
12.2 Installing the Rear Jack ...................................................................... 81
12.3 Conclusion .......................................................................................... 82
13 Appendix V—Standard Racked Assembly 83
13.1 Installing the Axle ............................................................................... 84
13.2 Installing the Fenders ......................................................................... 85
13.3 Installing the Wheels .......................................................................... 85
13.4 Installing the Outriggers and Outrigger Jacks .................................... 86
13.5 Installing the Rear Jack ...................................................................... 87
13.6 Installing the Tongue Assembly ......................................................... 88
13.7 Installing the Tower Lock Bracket ...................................................... 90
13.8 Installing the Tower Cradle ................................................................. 91
13.9 Installing the Tower ............................................................................ 92
13.10 Installing the Tower Pivot Cable ......................................................... 93

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Table of Contents LTN 6L
13.11 Installing the Lights ..............................................................................94
13.12 Connecting the Wiring at the Junction Box .........................................95
13.13 Routing the Coil Cord ..........................................................................97
13.14 Wiring the Ballasts and Terminal Strips ..............................................98
13.15 Conclusion .........................................................................................100
14 Appendix VI—CE Racked Assembly 101
14.1 Attaching the Outriggers and Outrigger Jacks ..................................103
14.2 Attaching the Rear Jack ....................................................................104
14.3 Attaching the Tower Lock Bracket .....................................................105
14.4 Attaching the Tower Cradle ...............................................................105
14.5 Installing the Tower ...........................................................................106
14.6 Installing the Tower Pivot Cable ........................................................108
14.7 Attaching the Light Mount Bracket and Light Bar ..............................109
14.8 Attaching the Lights ...........................................................................110
14.9 Wiring the Junction Box .....................................................................111
14.10 Routing the Coil Cord ........................................................................113
14.11 Wiring the Ballasts and Terminal Strips ............................................114

LTN 6L Foreword
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Foreword
Machines
covered in
this manual
Machine
documentation
Keep a copy of the Operator’s Manual with the machine at all times.
Use the separate Parts Book supplied with the machine to order replacement
parts.
Refer to the separate Repair Manual for detailed instructions on servicing and
repairing the machine.
If you are missing any of these documents, please contact Wacker Neuson
Corporation to order a replacement or visit www.wackerneuson.com.
When ordering parts or requesting service information, be prepared to provide
the machine model number, item number, revision number, and serial number.
Expectations
for
information in
this manual
This manual provides information and procedures to safely operate and
maintain the above Wacker Neuson model(s). For your own safety and to
reduce the risk of injury, carefully read, understand, and observe all instructions
described in this manual.
Wacker Neuson Corporation expressly reserves the right to make technical
modifications, even without notice, which improve the performance or safety
standards of its machines.
The information contained in this manual is based on machines manufactured
up until the time of publication. Wacker Neuson Corporation reserves the right
to change any portion of this information without notice.
CALIFORNIA
Proposition
65 Warning
Engine exhaust, some of its constituents, and certain vehicle components, contain
or emit chemicals known to the State of California to cause cancer and birth
defects or other reproductive harm.
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 dis-
charge 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.
Manufacturer’s
approval
This manual contains references to approved parts, attachments, and modifica-
tions. The following definitions apply:
Approved parts or attachments are those either manufactured orprovided by
Wacker Neuson.
Approved modifications are those performed by an authorized Wacker
Neuson service center according to written instructions published by Wacker
Neuson.
Machine Item Number
LTN 6L 0620117, 0620727, 0620550, 0620553, 0620561,
0620554, 0620297

Foreword LTN 6L
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Unapproved parts, attachments, and modifications are those that do not
meet the approved criteria.
Unapproved parts, attachments, or modifications may have the following conse-
quences:
Serious injury hazards to the operator and persons in the work area
Permanent damage to the machine which will not be covered under warranty
Contact your Wacker Neuson dealer immediately if you have questions about
approved or unapproved parts, attachments, or modifications.

LTN 6L Safety Information
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1 Safety Information
1.1 Signal Words Used in this Manual
This manual contains DANGER, WARNING, CAUTION, NOTICE, and
NOTE signal words which must be followed to reduce the possibility
of personal injury, damage to the equipment, or improper service.
NOTICE: Used without the safety alert symbol, NOTICE indicates a
situation which, if not avoided, could result in property damage.
Note: A Note contains additional information important to a procedure.
This is the safety alert symbol. It is used to alert you to potential personal hazards.
fObey all safety messages that follow this symbol.
DANGER
DANGER indicates a hazardous situation which, if not avoided, will result in death
or serious injury.
fTo avoid death or serious injury from this type of hazard, obey all safety mes-
sages that follow this signal word.
WARNING
WARNING indicates a hazardous situation which, if not avoided, could result in
death or serious injury.
fTo avoid possible death or serious injury from this type of hazard, obey all safety
messages that follow this signal word.
CAUTION
CAUTION indicates a hazardous situation which, if not avoided, could result in
minor or moderate injury.
fTo avoid possible minor or moderate injury from this type of hazard, obey all
safety messages that follow this signal word.

Safety Information LTN 6L
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1.2 Machine Description and Intended Use
This machine is a mobile, trailer-mounted light tower. The Wacker
Neuson Light Tower consists of a trailer with a cabinet containing a diesel
engine, a fuel tank, a control panel, and an electric alternator. A
telescoping tower with four metal halide lights is mounted to the top of the
cabinet. Dual winches tilt, raise, and lower the telescoping tower. As the
engine runs, the generator converts mechanical energy into electric
power. The metal halide lights run off this power. Receptacle(s) are also
present to power auxiliary loads. The operator uses the control panel to
operate and monitor the machine.
This machine is intended for the illumination of outdoor areas. This
machine is also intended for the purpose of supplying electrical power to
connected loads. Refer to the product specifications for the output voltage
and frequency of this Light Tower, and for the maximum output power limit
of this Light Tower.
This machine has been designed and built strictly for the intended use
described above. Using the machine for any other purpose could
permanently damage the machine or seriously injure the operator or other
persons in the area. Machine damage caused by misuse is not covered
under warranty.
• The following are some examples of misuse:
• Connecting a load that has voltage and frequency requirements that
are incompatible with the machine output
• Overloading the machine with a device that draws excessive power
during either continuous running or start-up
• Operating the machine in a manner that is inconsistent with all
federal, state and local codes and regulations
• Using the machine as a ladder, support, or work surface
• Using the machine to carry or transport passengers or equipment
• Using the machine to tow other machines (unless factory equipped)
• Using the machine as a hoist or hanging items from the tower
• Operating the machine outside of factory specifications
• Operating the machine in a manner inconsistent with all warnings
found on the machine and in the Operator’s Manual
This machine has been designed and built in accordance with the latest
global safety standards. It has been carefully engineered to eliminate
hazards as far as practicable and to increase operator safety through
protective guards and labeling. However, some risks may remain even
after protective measures have been taken. They are called residual
risks. On this machine, they may include exposure to:

LTN 6L Safety Information
wc_si000227gb.fm 11
• Heat, noise, exhaust, and carbon monoxide from the engine
• Heat from the lights
• Ultraviolet radiation from the lights
• Fire hazards from improper refueling techniques
• Fuel and its fumes
• Electric shock and arc flash
• Personal injury from improper lifting the trailer tongue
• Glare from lights (lights may blind drivers of nearby motor vehicles if
the lights are incorrectly positioned)
• Typical hazards related to towing a trailer on roads and highways
To protect yourself and others, make sure you thoroughly read and
understand the safety information presented in this manual before
operating the machine.
1.3 Safety Guidelines for Operating the Machine
Familiarity and proper training are required for the safe operation of the
machine. Machines operated improperly or by untrained personnel
can be hazardous. Read the operating instructions contained in this
manual and the engine manual, and familiarize yourself with the
location and proper use of all controls. Inexperienced operators should
receive instruction from someone familiar with the machine before
being allowed to operate it.
Operator qualifications
Only trained personnel are permitted to start, operate, and shut down
the machine. They also must meet the following qualifications:
• have received instruction on how to properly use the machine
• are familiar with required safety devices
The machine must not be accessed or operated by:
•children
• people impaired by alcohol or drugs
Personal Protective Equipment (PPE)
Wear the following Personal Protective Equipment (PPE) while
operating this machine:
• Close-fitting work clothes that do not hinder movement
• Safety glasses with side shields
• Hearing protection
• Safety-toed footwear
WARNING

Safety Information LTN 6L
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1.3.1 Do not remove, defeat, deface, or render inoperable any of the safety
devices, warnings, or labels on this equipment. If any safety devices,
warnings, or labels have been removed, defeated, defaced, or
rendered inoperable, do NOT use this equipment!
1.3.2 The area immediately surrounding the Light Tower should be clean,
neat, and free of debris.
1.3.3 Be sure the machine is on a firm, level surface and will not tip, roll,
slide, or fall while operating.
1.3.4 NEVER start a machine in need of repair.
1.3.5 Lower the tower when not in use, or if high winds or electrical storms
are expected in the area.
1.3.6 ALWAYS make certain the machine is well-grounded and securely
fastened to a good earthen ground per national and local regulations.
1.3.7 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.
1.3.8 The lamps become extremely hot in use! Allow the lamp and fixture to
cool 10–15 minutes before handling.
1.3.9 Keep the area behind the trailer clear of people while raising and
lowering the tower! Never raise, lower or turn the tower while unit is
operating!
1.3.10 The trailer must be leveled and the outriggers extended before raising
the tower. The outriggers must remain extended while the tower is up.
1.3.11 If for any reason any part of the tower hangs up or the winch cable
develops slack while raising or lowering the tower, STOP immediately!
Contact an authorized Wacker Neuson service representative.
1.3.12 NEVER remove the tower locking pin while the tower is up!
1.3.13 NEVER use the machine if the insulation on the electrical cord is cut or
worn through.
1.3.14 NEVER operate the lights without the protective lens cover in place or
with a lens cover that is cracked or damaged!
1.3.15 NEVER adjust the tower while the unit is operating.
1.3.16 Do not move the Light Tower while it is operating.
1.3.17 NEVER raise the tower or operate the machine in high winds.
1.3.18 NEVER connect machine to other power sources, such as supply
mains of power companies.
1.3.19 ALWAYS replace or repair electrical components with components
that are identical in rating and performance as the original component.

LTN 6L Safety Information
wc_si000227gb.fm 13
1.4 Operator Safety while Using Internal Combustion Engines
Operating safety
When running the engine:
• Keep the area around exhaust pipe free of flammable materials.
• Check the fuel lines and the fuel tank for leaks and cracks before
starting the engine. Do not run the machine if fuel leaks are present
or the fuel lines are loose.
When running the engine:
• Do not smoke while operating the machine.
• Do not run the engine near sparks or open flames.
• Do not touch the engine or muffler while the engine is running or
immediately after it has been turned off.
• Do not operate a machine when its fuel cap is loose or missing.
• Do not start the engine if fuel has spilled or a fuel odor is present.
Move the machine away from the spill and wipe the machine dry
before starting.
Refueling safety
When refueling the engine:
• Clean up any spilled fuel immediately.
• Refill the fuel tank in a well-ventilated area.
• Replace the fuel tank cap after refueling.
• Do not smoke.
• Do not refuel a hot or running engine.
• Do not refuel the engine near sparks or open flames.
WARNING
Internal combustion engines present special hazards during operation and fueling. Failure to
follow the warnings and safety standards could result in severe injury or death.
fRead and follow the warning instructions in the engine owner’s manual and the
safety guidelines below.
DANGER
Exhaust gas from the engine contains carbon monoxide, a deadly poison. Expo-
sure to carbon monoxide can kill you in minutes.
fNEVER operate the machine inside an enclosed area, such as a tunnel, unless
adequate ventilation is provided through such items as exhaust fans or hoses.

Safety Information LTN 6L
14 wc_si000227gb.fm
1.5 Lamp Safety
Description
The lamps provided with your Light Tower are electric discharge
lamps. They are designed for use with metal halide ballasts only, and
require time to reach full brightness on initial startup and after a power
interruption. These lamps comply with FDA regulation performance
standards 21 CFR 1040-30.
Operating safety
• Do not operate the lamps where people will remain for more than
a few minutes unless adequate shielding or other safety
precautions are used.
• Replace damaged lamps according to the instructions in section
Removing / Replacing Lamps.
• Lamps that automatically extinguish when the outer envelope is
broken or punctured are commercially available.
1.6 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 with this
equipment.
Personal Protective Equipment (PPE)
Wear the following Personal Protective Equipment (PPE) while
servicing or maintaining this machine:
• Close-fitting work clothes that do not hinder movement
• Safety glasses with side shields
• Hearing protection
• Safety-toed footwear
In addition, before servicing or maintaining the machine:
• Tie back long hair.
• Remove all jewelry (including rings).
WARNING
Personal injury hazard. Lamps can cause serious skin burns and eye inflammation
from shortwave ultraviolet radiation if outer envelope of the lamp is broken or punc-
tured.
fDo not operate the Light Tower if a lamp is damaged.
WARNING

LTN 6L Safety Information
wc_si000227gb.fm 15
1.6.1 ALWAYS replace the safety devices and guards after repairs and
maintenance.
1.6.2 Before servicing the Light Tower, make sure the engine start switch is
turned to the OFF position, 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.
1.6.3 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.
1.6.4 DO NOT service the machine if your clothing or skin is wet.
1.6.5 ALWAYS keep hands, feet, and loose clothing away from the moving
parts on the generator and engine.
1.6.6 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.
1.6.7 When replacement parts are required for this machine, use only
Wacker Neuson replacement parts or those parts equivalent to the
original in all types of specifications, such as physical dimensions,
type, strength, and material.
1.6.8 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 in the area when lifting the
machine.
1.6.9 ALWAYS turn off the light circuit breakers and shut down the engine
before disconnecting the light fixtures or changing the lamps.

Labels LTN 6L
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2Labels
2.1 Label Locations
wc_gr007036
B
H
D
I
G
PO
X
J
K
Z
QS
RT
CC
BB BB
AA
AA
EE
CA
E
V

LTN 6L Labels
wc_si000381gb.fm 17
wc_gr007037
RS
U
V
LH
F
B
NJ
M
D
Y
FF AA AA
DD
BB
GG
EE
CC
BB
HH
JJ

Labels LTN 6L
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2.2 Label Meanings
Wacker Neuson machines use international pictorial labels where
needed. These labels are described below.
AWARNING
Automatic locking pin.
A non-secured, falling tower can cause serious
injury or death if a person is hit. To secure tower,
verify automatic locking pin has been engaged.
BWARNING!
Avoid crushing area.
CDANGER!
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 tower.
Tilting an extended tower can cause serious
injury or death.

LTN 6L Labels
wc_si000381gb.fm 19
DNOTICE
Lifting point.
EWARNING!
Secure tower in transport lock before lifting or
towing. A loose swinging tower could cause per-
sonal injury or machine damage.
FDANGER!
No sparks, flames, or burning objects near
machine. Stop the engine before adding fuel. Use
only diesel fuel.
GDANGER!
Asphyxiation hazard.
Engines emit carbon monoxide.
Do not run the machine indoors or in an
enclosed area unless adequate ventilation,
through such items as exhaust fans or hoses,
is provided.
Read the Operator’s Manual. No sparks,
flames, or burning objects near the machine.
Stop the engine before refueling.

Labels LTN 6L
20 wc_si000381gb.fm
HWARNING!
Electric shock and arc flash can cause serious
injury or death. Electrical storage device within.
Contact a qualified electrician for service or to
open electrical box.
IWARNING!
Read and understand the supplied Operator’s
Manual before operating the machine. Failure to
do so increases the risk of injury to yourself and
others.
JWARNING!
Stand clear of front and rear of machine when
tower is being tilted up or down.
KWARNING!
Hot surface!
LWARNING!
Hot surface!