Wacker Neuson LTN 6L Operator's Manual

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Operator’s Manual

Light Tower

LTN 6L

60 Hz

0171883en 007 1110

0171883EN

other type of reproduction is prohibited without express written permission from Wacker Neuson Corporation.

Any type of reproduction or distribution not authorized by W acker Neuson Corp oration represents an infringement of valid copyrights. Violators will be prosecuted.

T ra d emarks

Manufacturer

All trademarks referenced in this manual are the property of their respective owners.

Wacker Neuson Corporation N92W15000 Anthony Avenue Menomonee Falls, WI 53051 U.S.A. Tel: (262) 255-0500 · Fax: (262) 255-0550 · Tel: (800) 770-0957 www.wackerneuson.com

Original instructions

This Operator’s Manual presents the original instructions. The original language of this Operator’s Manual is American English.

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

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LTN 6L Foreword

Foreword

Machines covered in this manual

Machine Item Number

LTN 6L 0620117, 0620727, 0620550, 0620553, 0620561,

0620554, 0620297

Machine documentation

Expectations for information in this manual

 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.

 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 rea d, understand, and obse rve 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

Laws pertaining to spark arresters

Manufacturer’s approval

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.

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.

This manual contains references to approved parts, attachments, and modifications. The following definitions apply:

 Approved parts or attachments are those either manufactured or provided by

Wacker Neuson.

 Approved modifications are those performed by an authorized Wacker

Neuson service center according to written instructions published by Wacker Neuson.

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Foreword LTN 6L

 Unapproved parts, attachments, and modifications are those that do not

meet the approved criteria.

Unapproved parts, attachments, or modifications may have the following consequences:

 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.

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LTN 6L Safety Information

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.

This is the safety alert symbol. It is used to alert you to potential personal hazards. f Obey all safety messages that follow this symbol.

DANGER

DANGER indicates a hazardous situation which, if not avoided, will result in death or serious injury.

f To 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.

f To 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.

f To avoid possible minor or moderate injury from this type of hazard, obey all

safety messages that follow this signal word.

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.

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Safety Information LTN 6L

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 volt age and frequency of this Light Tower, and fo r 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 Oper ator’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:

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LTN 6L Safety Information

• 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

WARNING

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

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Safety Information LTN 6L

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.

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LTN 6L Safety Information

1.4 Operator Safety while Using Internal Combustion Engines

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. f Read 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. Exposure to carbon monoxide can kill you in minutes.

f NEVER operate the machine inside an enclosed area, such as a tunnel, unless

adequate ventilation is provided through such items as exhaust fans or hoses.

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.

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Safety Information LTN 6L

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.

WARNING

Personal injury hazard. Lamps can ca use se rious skin burn s a nd e ye inflammatio n from shortwave ultraviolet radiation if outer envelope of the lamp is broken or punctured.

f Do not operate the Light Tower if a lamp is damaged.

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

• Lamps that automatically extinguish when the outer envelope is

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

WARNING

Personal Protective Equipment (PPE)

equipment.

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

Removing / Replacing Lamps.

broken or punctured are commercially available.

• Safety-toed footwear

In addition, before servicing or maintaining the machine:

• Tie back long hair.

• Remove all jewelry (including rings).

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LTN 6L Safety Information

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 weightbearing 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.

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Labels LTN 6L

2Labels

2.1 Label Locations

wc_gr007036

16 wc_si000381gb.fm

LTN 6L Labels

wc_si000381gb.fm 17

wc_gr007037

Labels LTN 6L

2.2 Label Meanings

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

WARNING 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.

WARNING! Avoid crushing area.

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 tower. Tilting an extended tower can cause serious injury or death.

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LTN 6L Labels

NOTICE Lifting point.

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

DANGER! No sparks, flames, or burning objects near machine. Stop the engine before adding fuel. Use only diesel fuel.

wc_si000381gb.fm 19

DANGER! 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

WARNING! 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.

WARNING! 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.

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

WARNING! Hot surface!

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LTN 6L Labels

A nameplate listing the model number, item number, revision number, and serial nu mber is attached to each unit. Please record the information found on this nameplate 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.

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

wc_si000381gb.fm 21

Labels LTN 6L

See Operator’s Manual for metal halide lamp information and troubleshooting.

Before starting engine Check levels of:

Engine oil Fuel Coolant

Circuit breakers off

Start engine Engine control panel

Auto heating Preheat

Light out Start, 15 sec. max.

Circuit breakers on Shut down

Circuit breakers off Stop engine

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LTN 6L Labels

See Operator’s Manual for metal halide lamp information and troubleshooting.

Before starting engine Check levels of:

Engine oil Fuel Coolant

Circuit breakers off

St art engine Engine control switch

Preheat (30 sec.) Start, 15 sec. max.

Circuit breakers on

Shut down Circuit breakers off Stop engine

wc_si000381gb.fm 23

Labels LTN 6L

Manual Winch System

To raise tower:

1. Release transport lock.

2. Tilt tower using winch.

3. Tilt tower until automatic locking pin snaps into place.

To increase height of tower:

4. Raise tower using winch. To aim lights:

5. Rotate tower and tighten knob.

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LTN 6L Labels

Manual Winch System

To lower tower:

1. Turn off all lights and engine.

2. Rotate tower and tighten knob.

3. Lower tower using winch. To tilt tower for transport:

4. Release and hold spring-loaded pin.

5. Tilt tower using winch. To secure tower for transport:

6. Insert pin through transport lock and secure with pin.

7. Position light fixtures down.

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Labels LTN 6L

Power Winch System

To raise tower:

1. Release transport lock.

2. Tilt tower using winch.

3. Tilt tower until automatic locking pin snaps into place.

To increase height of tower:

4. Raise tower using winch. To aim lights:

5. Rotate tower and tighten knob.

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LTN 6L Labels

Power Winch System

To lower tower:

1. Turn off all lights and engine.

2. Rotate tower and tighten knob.

3. Lower tower using winch. To tilt tower for transport:

4. Release and hold spring-loaded pin.

5. Tilt tower using winch. To secure tower for transport:

6. Insert pin through transport lock and secure with pin.

7. Position light fixtures down.

wc_si000381gb.fm 27

Coolant overflow bottle only, not a return system.

WARNING! Pinching hazard. Rotating machinery.

Labels LTN 6L

Al remolcar, evite altas velocidades, aceleracion rapida, y vueltas agudas.

DANGER DE RETORNEMENT

AVERTISSEMENT

ADVERTENCIA

PELIGRO DE VUELCO

Avoid high speeds, rapid acceleration and sharp turns when towing.

WARNING

ROLL OVER HAZARD

178647

En remorquant, éé

viter des vitesses rapides, acceleration rapide, et virages tranchantes.

Guaranteed sound power level in dB(A).

Read Operator’s Manual. Use hitch rated from trailer’s “Gross Vehicle Weight Rating”. Securely attach trailer to tow vehicle. Attach safety chains using cross pattern. Attach breakdown chain to vehicle. Check trailer lights.

Electrical ground

Insert jack locking pin before extending jack.

WARNING

ROLL OVER HAZARD Avoid high speeds, rapid acceleration and sharp turns when towing.

ADVERTENCIA

PELIGRO DE VUELCO Al remolcar, evite altas velocidades, aceleracion rapida, y vueltas agudas.

AVERTISSEMENT

DANGER DE RETORNEMENT En remorquant,

vitesses rapides, acceleration rapide, et virages tranchantes.

178647

Fork lift pocket

WARNING ROLL-OVER HAZARD To prevent injury or equipment damage, avoid high speeds and sharp turns when towing.

viter des

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LTN 6L Labels

UTILITY 159116

U.S.PAT.Nos.: 6012285, 6471476, D416858, D454357 OTHER U.S. AND FOREIGN PATENTS PENDING

Transport position of the jack

Tie-down point.

Low sulfur fuel or ultra low sulfur fuel only.

U.S.PAT.Nos.: 6012285, 6471476,

D416858, D454357 OTHER U.S. AND

FOREIGN PATENTS PENDING

UTILITY 159116

This machine may be covered by one or more patents.

DANGER Using a light tower indoors CAN KILL YOU IN

MINUTES. Light tower exhaust contains carbon monoxide. This is a poison you cannot see or smell.

NEVER use inside a home or garage, EVEN IF doors and windows are open.

Only use OUTSIDE and far away from windows, doors, and vents.

wc_si000381gb.fm 29

Lifting the Machine LTN 6L

3 Lifting the Machine

3.1 Procedure

See Graphic: wc_gr005415

3.1.1 Check that the tower cradle lock pin (a) is in place and secured with the safety pin.

3.1.2 Ensure that the tower is completely nested inside the transport cradle and the pin (b) is secure.

3.1.3 Make sure the doors are properly latched.

3.1.4 Return the outriggers to their travel position. Check that the outrigger bars and jacks are locked in place.

3.1.5 Crank the rear jack (c) all the way in and rotate it 90°. The Light Tower is now ready to lift.

wc_gr005415

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LTN 6L Operation

4 Operation

4.1 Locating Trailer

See Graphic: wc_gr005073

4.1.1 For maximum light coverage locate the Light Tower at ground level or in a spot higher than the area being lighted.

4.1.2 Position the trailer on a firm, flat surface clear of overhead wires and obstructions. Be sure that there is enough area for outrigger extensions to be fully extended.

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

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.

WARNING

wc_tx000766gb.fm 31

Operation LTN 6L

4.2 Leveling Trailer

See Graphic: wc_gr005073, wc_gr005074

The trailer must be leveled and the outriggers extended before raising the tower. The outriggers must remain extended while the tower is up. Failure to level the trailer or extend the outriggers will severely reduce

WARNING

4.2.1 Pull the locking pin on the tongue jack (a) and rotate the tongue jack

4.2.2 Pull the outrigger lock pin (c) to release the outrigger. Pull both

4.2.3 Rotate rear jack (f) down, as shown.

4.2.4 Extend the jack(s) on the highest side(s) of the trailer until they rest

the stability of the unit and could allow the tower to tip and fall.

90° as shown.

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

outrigger extensions (d) out until you feel outrigger lock pin lock back into place. Rotate jacks (e) down.

firmly on the ground. Extend the remaining jacks until the trailer is level.

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LTN 6L Operation

4.3 Adjusting Lights

See Graphic: wc_gr005074

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

Always return the light fixtures to aim at the ground when the tower is in the cradle for towing.

wc_tx000766gb.fm 33

Operation LTN 6L

4.4 Preparing Trailer for Towing or Lifting

See Graphic: wc_gr005073, wc_gr005074

4.4.1 Check that the tower cradle lock pin (j) is in place and secured with the safety pin.

4.4.2 Ensure that the tower is completely nested inside the transport cradle and the pin (t) is secure.

4.4.3 Make sure the doors are properly latched.

4.4.4 Return the outriggers to their travel position. Check that the outrigger bars and jacks are locked in place.

4.4.5 Crank the rear jack (f) all the way in and rotate it 90°. The Light Tower is now ready to lift. Use the designated lift points. For towing, continue.

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

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

4.4.8 Position the light fixtures (k) down. For rough, off-road transportation remove lamps from fixtures to avoid damage.

4.4.9 Check the tire inflation. NOTICE: 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.

34 wc_tx000766gb.fm

LTN 6L Operation

4.5 Raising Tower (Manual Winch System)

See Graphic: wc_gr005075

NEVER raise the tower or operate the Light Tower in high winds. NEVER raise the tower while the engine is running.

WARNING

Do not move the Light Tower while it is operating.

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

tower.

WARNING

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

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

WARNING

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

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

4.5.3 Check the operation of the tilt winch (o) by rotating the winch handle 1/4-turn clockwise (“cable in” direction). The winch pawl must engage winch gear teeth. When operating properly, the winch pawl will make a “clicking” sound when the winch handle is rotated clockwise. Do not attempt to raise the tower if the winch is damaged or not operating properly.

Pinching/crushing hazards. Moving parts can crush or cut extremities. Keep hands and fingers clear of pinch points when raising the tower

WARNING

wc_tx000766gb.fm 35

Operation LTN 6L

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

NOTICE: While raising the tower, pay close attention to the coil cord and make sure that it does not tangle or become caught on any part of the machine.

NEVER pull the vertical tower locking pin (p) while the tower is raised! Releasing the vertical tower locking pin while the tower is

WARNING

4.5.5 After the tower is in the vertical position, check the operation of the

raised may cause the tower to fall or the machine to tip over.

telescoping winch (q) by rotating the winch handle 1/4-turn clockwise (“cable in” direction). The winch pawl must engage winch gear teeth. When operating properly, it will make a “clicking” sound when the winch handle is rotated clockwise. Do not attempt to raise the tower if the winch is damaged or not operating properly. Continue rotating the winch handle until tower is at the desired height. Do not over crank the winch when the tower is fully extended.

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

4.5.6 Once the tower is at the desired height, rotate the tower to the desired direction. To rotate, loosen rotation locking knob (s). Then rotate the tower until the lights face the desired direction, and then retighten the rotation locking knob.

36 wc_tx000766gb.fm

LTN 6L Operation

wc_tx000766gb.fm 37

Operation LTN 6L

4.6 Lowering Tower (Manual Winch System)

See Graphic: wc_gr005075

Be sure to read and understand the operating instructions before lowering the tower!

If for any reason a part of the tower hangs up or a winch cable develops slack before tower is fully lowered, stop immediately! Continuing to

WARNING

turn the winch handle will increase the slack in the cable. Too much slack could cause the tower to collapse should it suddenly free up. If the tower hangs up, level the trailer. Slightly shake or twist the tower assembly to free the bind. Contact an authorized Wacker Neuson service representative immediately.

NEVER lower the tower while the unit is operating.

NEVER allow anyone to stand near the rear of the unit while lowering

the tower.

WARNING

4.6.1 Turn the lights off. Shut down the engine. NOTICE: Shutting down the engine before turning off the lights could

damage floodlight ballasts or generator capacitor(s). NOTICE: Observe power cord while lowering the tower. Make sure the

coiled cord is not damaged during the lowering process.

4.6.2 Lower the tower by turning the handle on the telescoping winch (q) counterclockwise (“cable out” direction).

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

WARNING

4.6.3 Loosen the rotation locking knob (s) and rotate the tower so the winches are facing toward the trailer tongue.

38 wc_tx000766gb.fm

LTN 6L Operation

4.6.4 Pull and hold the tower locking pin (p). Rotate the handle on the tilt winch (o) counterclockwise (“cable out” direction) until the tower spring begins to pivot the tower down. Release the tower locking pin and continue to rotate the handle until the tower is resting in the transport cradle. Be sure that the secondary locking pin (t) penetrates all sections of the tower.

NEVER pull the vertical tower locking pin (e) while the tower is raised! Releasing the locking pin while the tower is raised may cause

WARNING

4.6.5 After the tower is down, secure it in the cradle by inserting the cradle

4.6.6 Position the light fixtures to aim at the ground.

the tower to fall or the machine to tip over.

lock pin (j). Insert the clip through the pin to secure it in place.

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

wc_tx000766gb.fm 39

Operation LTN 6L

4.7 Raising Tower (Power Winch System)

See Graphic: wc_gr005076

ALWAYS observe the tower while raising and lowering the tower. NEVER raise the tower or operate the Light Tower in high winds.

WARNING

NEVER raise the tower while the engine is running.

Do not move the Light Tower while it is operating.

HIGH VOLTAGE! DO NOT use Light Tower if insulation on electrical cord is cut or worn through. Repair or replace cord before using. Bare

WARNING

wires in contact with the metal frame of the trailer or the Light Tower can 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 the

tower.

WARNING

The Light Tower includes two separate winches—one for lifting the tower to the vertical position, the other for raising the tower.

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

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

4.7.3 Check the operation of the tilt winch (o). Turn the vertical rotary switch (v) on the control panel to the up position. Do not attempt to raise the tower if the winch is damaged or not operating properly.

NOTICE: Continuous running of the winch in excess of 4 minutes will damage the winch motor.

Note: It is normal for smoke to be produced during the first few operations of a new power winch.

4.7.4 Hold the switch in the up position and raise the tower to the vertical position until the vertical tower locking pin (p) locks the tower in place. Be certain the vertical tower locking pin is fully engaged in the locking position before raising the tower.

NEVER pull the vertical tower locking pin (p) while the tower is raised! Releasing the vertical tower locking pin while tower is raised

may cause the tower to fall or the machine to tip over.

WARNING

40 wc_tx000766gb.fm

LTN 6L Operation

4.7.5 After the tower is in the vertical position, check the operation of the telescoping winch (q). Turn the telescope rotary switch on the control panel to the up position. Do not attempt to raise the tower if the winch is damaged or not operating properly. Continue to hold switch in the up position until tower is at the desired height. Release switch when tower is fully extended.

NOTICE: Continuous running of the winch in excess of 4 minutes will damage the winch motor.

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

4.7.6 Once the tower is at the desired height, rotate the tower to the desired direction. To rotate, loosen rotation locking knob (s). Then rotate the tower until the lights face the desired direction and retighten the rotation locking knob.

wc_tx000766gb.fm 41

Operation LTN 6L

4.8 Lowering Tower (Power Winch System)

See Graphic: wc_gr005076

ALWAYS observe the tower while raising and lowering the tower. Be sure you read and understand the operating instructions

WARNING

before lowering the tower!

If for any reason any part of the tower hangs up or the winch cable develops slack before the tower is fully lowered, stop immediately! Continuing to power the winch will increase slack in the cable. Too much slack could cause tower to collapse should it suddenly free up. If the tower hangs up, level the trailer. Slightly shake or twist the tower assembly to free the bind. Contact an authorized Wacker Neuson service representative immediately.

NEVER lower the tower while the unit is operating.

NEVER allow anyone to stand near the rear of the unit while lowering the tower.

WARNING

4.8.1 Turn the lights off. Shut down the engine. NOTICE: Shutting down the engine before turning off the lights could

damage the floodlight ballasts or the generator capacitor(s). NOTICE: Observe the power cord while lowering the tower. Make sure

the coiled cord is not damaged during the lowering process.

4.8.2 Lower the tower by turning and holding the telescope rotary switch on the control panel in the down position.

NOTICE: Continuous running of the winch in excess of 4 minutes will damage the winch motor.

Note: It is normal for smoke to be produced during the first few operations of a new power winch.

4.8.3 Loosen the rotation locking knob (s) and rotate the tower so the lights face the rear of the trailer and the winches are facing toward the trailer tongue.

42 wc_tx000766gb.fm

LTN 6L Operation

4.8.4 Pull and hold the tower locking pin (p). Turn and hold the vertical rotary switch (v) on the control panel in the down position until the tower is resting in the transport cradle. Be sure that the secondary locking pin (t) penetrates all sections of the tower.

NOTICE: Continuous running of the winch in excess of 4 minutes will damage the winch motor.

NEVER pull the vertical tower locking pin (e) while the tower is raised! Releasing the vertical tower locking pin while the tower is

raised may cause the tower to fall or the machine to tip over.

WARNING

4.8.5 After the tower is down, secure it in the cradle by inserting the cradle lock pin (j). Insert the clip through the pin to secure it in place.

4.8.6 Position the light fixtures to aim at the ground. NOTICE: Allow the floodlights to cool 10–15 minutes before moving

the trailer. Moving the trailer while the lights are still hot could cause lamps to break.

4.9 Emergency Crank Handle (Power Winch System)

An emergency crank handle is provided for use in the event of a power failure.

4.9.1 Remove the electrical power from the winch.

4.9.2 Remove the plug from the side of the winch cover. Insert the handle so that it completely engages with the drive shaft. The handle can be cranked in either direction.

4.9.3 Always remove the handle from the winch after use and replace the plug.

NEVER operate the winch electrically with the emergency crank handle in position.

WARNING

wc_tx000766gb.fm 43

Operation LTN 6L

4.10 Control Panels (Manual Winch System)

Floodlight Control Panel Engine Control Panel

Ref. Description Ref. Description

a 50 Amp circuit breaker k High coolant temperature shutdown

b 30 Amp lights circuit breaker l Alternator indicator

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

d 20 Amp GFI 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

44 wc_tx000766gb.fm

LTN 6L Operation

WARNING WARNUNG

ADVERTENCIA

AVERTISSEMENT

NEUTRAL BONDED TO FRAME

CONDUCTOR NEUTRO CONECTADO AL CHASIS CONDUCTEUR NEUTRE MIS A LA MASSE DU CHASSIS

NULL-LEITER AM RAHMEN ANGESCHLOSSEN

4.11 Control Panels (120/240, Manual Winch System)

Floodlight Control Panel Engine Control Panel

WARNING WARNUNG

ADVERTENCIA

AVERTISSEMENT

NEUTRAL BONDED TO FRAME NULL-LEITER AM RAHMEN ANGESCHLOSSEN CONDUCTOR NEUTRO CONECTADO AL CHASIS CONDUCTEUR NEUTRE MIS A LA MASSE DU CHASSIS

wc_gr006329

Ref. Description Ref. Description

a 25 Amp circuit breaker k High coolant temperature shutdown

b 30 Amp lights circuit breaker l Alternator indicator

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

d 20 Amp GFI 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 r 30 Amp receptacle

wc_tx000766gb.fm 45

Operation LTN 6L

4.12 Control Panels (Power Winch System)

Floodlight Control Panel Engine Control Panel

Ref. Description Ref. Description

a 50 Amp circuit breaker l Alternator indicator

b 30 Amp lights circuit breaker m Auxiliary light (not used)

c 20 Amp GFI circuit breaker n Glow plug indicator

d 20 Amp GFI receptacle o Air filter restriction indicator

e Hour meter p Auxiliary light (not used)

f Low fuel indicator (not used) q Key access door

g Safety shutdown indicator v

h Low oil pressure shutdown w

k High coolant temperature shutdown

Tilt rotary switch

Telescope rotary switch

46 wc_tx000766gb.fm

LTN 6L Operation

4.13 Starting

See Graphic: wc_gr005140, wc_gr006328, wc_gr005141, wc_gr005142

4.13.1 Check engine oil, fuel and coolant levels.

Note: If fuel tank was drained or run dry it may be necessary to bleed fuel lines. Refer to engine operator’s manual.

4.13.2 Check condition of electrical cable on tower. Do not start generator if insulation on cable is cut or worn through.

4.13.3 Check that the circuit breakers (a, b, c) are in their off position. NOTICE: Starting engine under load will damage the machine.

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

4.13.5 Turn key (q) to the start position and hold until engine starts. Release key after engine starts.

NOTICE: Do not crank engine longer than 10 seconds. This could cause starter motor to overheat. Return switch to the off position and wait 15-30 seconds for starter motor to cool down before attempting to preheat and restart.

Note: If oil pressure is not obtained within 30 seconds after key is turned to “RUN”, the automatic shutdown system will shut off the fuel supply. You must return the key to the off position to restart the 30-

second timer before attempting to restart the engine.

4.13.6 Allow engine to warm up before operating the floodlights.

NOTICE: Never use starting fluids to aid in starting of engine.

4.14 Manual Shutdown

To manually stop the machine in the event of an emergency:

4.14.1 Shut off the main circuit breaker.

4.14.2 Turn the starting key to the “off” (O) position.

4.15 Automatic Shutdown

This unit is equipped with a low oil, high temperature auto-shutdown system. This system will automatically shut off the fuel supply to the engine if the oil pressure drops too low or the engine exceeds normal operating temperatures. Return the key switch to the off position to reset the unit after an engine shutdown.

wc_tx000766gb.fm 47

Operation LTN 6L

4.16 Operating Lights

See Graphic: wc_gr005140, wc_gr006328, wc_gr005141, wc_gr005142

Turn on the main circuit breaker (a) first, then turn on each light circuit breaker (b), one at a time.

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

4.17 Stopping

See Graphic: wc_gr005140, wc_gr006328, wc_gr005141, wc_gr005142

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

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

4.17.2 Turn the key (q) to the off position.

4.18 Derating

All generator sets are subject to derating for altitude and temperature. Although derating should not affect operation of the floodlights, it will reduce the available reserve power to the receptacle.

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

48 wc_tx000766gb.fm

LTN 6L Operation

4.19 Receptacle

See Graphic: wc_gr005140, wc_gr006328, wc_gr005141

The control panel is equipped with a convenience receptacle for running accessories and tools from the generator. Power to this receptacle is available any time the engine is running and the circuit breaker is on.

NOTICE: Do not draw more than 1660 Watts from the receptacle with all of the lights on or the lights will turn off.

A circuit breaker (c) protects the Ground Fault Interrupt (GFI) receptacle (d). The GFI receptacle should be tested for proper operation each time it is used.

To test a GFI:

Push the test button in. The reset button should pop out. Power to the receptacle is now off. To restore power to receptacle, push reset button in.

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

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

wc_tx000766gb.fm 49

Factory Installed Options LTN

5 Factory Installed Options

This machine may be equipped with one or more of the following factory-installed options. To verify if any of these options are installed on your machine, contact Wacker Neuson Corporation at 1-800-770-0957. A nameplate listing the Model Number, Item Number, Revision, and Serial Number is attached to each unit. Please have this information available when contacting Wa cker Neuson Corporation.

The illustrations shown in this chapter represent typical installations. The factoryinstalled options on your machine may look different.

5.1 Block Heater

The engine block heater option includes a block heater (a) with a cord (b). The function of the block heater is to heat the engine coolant/ engine block to improve cold-weather engine starting. Plug the cord into a 120V power supply.

wc_gr006975

50 wc_tx001650gb.fm

LTN Factory Installed Options

5.2 Battery Blanket

An electrically powered blanket (a) warms the battery while the machine is not in use. The blanket eliminates engine starting difficulties caused by a cold, frozen, or discharged battery. Plug the cord into a 120V power supply.

wc_gr007422

5.3 Oil Pan Heater

Cold, thick engine oil does not flow freely and may cause engine starting difficulties. An oil pan heater installed on the engine oil pan keep s the oil warm and flowing. Heat from this electrical device warms the supply of engine oil contained in the pan while the machine is not in use. Plug the cord into a 120V power supply.

wc_tx001650gb.fm 51

Maintenance LTN 6L

6 Maintenance

6.1 Periodic Maintenance Schedule

The table below lists basic machine maintenance. Tasks designated with check marks may be performed by the operator. Tasks designated with square bullet points require special training and equipment.

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.

Before

each

use



Every

125

hours



Every

250

hours



Every

500

hours



Every

1000 hours

or two years

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.

* Replace air filter after air filter restriction switch indication or one year. Lombardini does not rec-

ommend the removal of air filter elements for purposes of inspection.

** Change engine oil and filter after first 50 hours of operation.

52 wc_tx000767gb.fm



LTN 6L Maintenance

WH GN

6.2 Installing / Removing Light Fixtures

See Graphic: wc_gr005376

Always turn off light circuit breakers and shut down engine before disconnecting light fixtures or changing lamps.

WARNING

Remove fixtures by disconnecting electrical cords at the junction box (b). Remove nuts (c) from fixture mounting brackets and remove both fixture and bracket off stud.

NOTICE: Only a trained technician should be allowed to install and remove fixture wiring.

Lamps become extremely hot in use! Allow lamp and fixture to cool 10-15 minutes before handling.

WARNING

Numbering Sequence of Floodlights Junction Box Wiring for Floodlights

GN BL

WH GN

BL WH

wc_gr005376

Wire Colors

BK Black RD Red YL Yellow OR Orange

GN Green TN Tan BR Brown PU Purple

BU Blue VIO Violet CL Clear SH Shield

PK Pink WH White GY Gray LB Lt. blue

wc_tx000767gb.fm 53

Maintenance LTN 6L

6.3 Replacing / Removing Lamps

Prerequisites

• Engine shut down

• Light circuit breakers turned OFF

• Lamps and fixtures cool to the touch

• Eye protection and gloves

WARNING

Burn hazard. Lamps become extremely hot in use. f Allow lamps and fixtures to cool 10–15 minutes before handling.

WARNING

Personal injury hazard. Ultraviolet radiation from the lamps can cause serious skin and eye irritation.

f Use only undamaged lamps. f Use the lamps only with undamaged original equipment lenses and fixtures.

WARNING

Explosion hazard. Grease or oil residue on the lamp can cause the outer jacket to burst or shatter. Hot flying glass particles can cause personal injury, property damage, burns, or fire.

Do not operate the lights with a lens that is cracked, damaged, or missin g.

f Do not scratch the lamp or subject the lamp to excess pressure. f Wear eye protection and gloves when removing or replacing lamps.

Follow the procedures below to remove and install the lamp.

Removing the lamp

6.3.1 Remove the screws

(a)

securing the flange rings

(b)

and remove the

flange rings.

wc_gr005881

54 wc_tx000767gb.fm

LTN 6L Maintenance

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

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

Installing the lamp

6.3.4 Screw the lamp in firmly, but not forcibly, to minimize loosening due to vibration. Secure it with the lamp stabilizer.

6.3.5 Install the gasket around the lens and secure the lens to the reflector with the flange rings and screws.

6.4 Daily Inspection

6.4.1 Check for fluid leaks. Check fluid levels.

6.4.2 Inspect condition of electrical cords. Do not use Light Tower if insulation is cut or worn through.

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

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

wc_tx000767gb.fm 55

Maintenance LTN 6L

6.5 Air Cleaner

See Graphic: wc_gr000540

Replace the air filter cartridge when the indicator mounted on the control panel illuminates.

6.5.1 Open air cleaner and remove element.

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

6.5.3 Reassemble the filtering element and air cleaner.

6.6 Engine Oil

See Graphic: wc_gr005394

Drain the oil while the engine is still warm.

Note: In the interests of environmental protection, place a plastic sheet and a container under the machine to collect any liquid which drains off. Dispose of this liquid in accordance with environmental protection legislation.

6.6.1 Locate the oil drain hose and remove the plug from the end of the hose.

6.6.2 Allow the oil to drain.

6.6.3 Re-install the oil drain plug.

6.6.4 Remove the oil filter cap and fill the engine crankcase through the oil filler opening, to the upper mark on the dipstick. See Technical Data for oil quantity and type.

6.6.5 Re-install the oil filter cap.

wc_gr000540

wc_gr005394

56 wc_tx000767gb.fm

LTN 6L Maintenance

6.7 Troubleshooting

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.

WARNING

Problem / Symptom Reason Remedy

Lamp will not light Lamp is too hot. Allow lamp to cool 10–15 minutes

before restarting.

Faulty lamp connection Check that lamp is tight in socket.

Check connections inside connection boxes on light fixtures and tower.

Plug connection at fixture

is loose or damaged

Lamp broken or burned

out

Circuit breaker turned on Turn off circuit breaker. Circuit breaker loose or

defective

Generator output incorrect Check incoming voltage to ballast.

Low or no ballast output With the fixture cord removed from its

Have a licensed electrician repair or

replace the plug connection.

Check for:

• broken arc tube or outer lamp jacket

• broken or loose components in lamp envelope

• blackening or deposits inside lamp tube.

Have a licensed electrician repair or

replace the circuit breaker.

Incoming voltage should be 120V ± 5V. If voltage is incorrect, engine speed may need to be adjusted or generator may require service.

receptacle, the voltage should measure 400 to 445 VAC. If proper voltage is no t achieved, perform capacitor check to determine if capacitor or coil needs to be replaced.

Low light output Lamp degraded Replace lamp due to normal lamp life.

Low ballast output Check ballast for proper voltage output. Fixture or lens dirty Clean reflective surface inside fixture

wc_tx000767gb.fm 57

and both inside and outside surface of glass lens.

Technical Data LTN 6L

7 Technical Data

7.1 Engine

Engine Power Rating

Net power rating per ISO 3046 IFN. Actual power output may vary due to conditions of specific use.

Item Number:

LTN 6L

Engine

Make Lombardini

Model LDW1003

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

Max. power rating @ rated speed

Operating speed (no-load)

Alternator

Battery

Air cleaner

Fuel

Fuel tank capacity

kW (Hp)

rpm

V / A / W

V/Ah/CCA

type

l (gal.)

10.0 (13.4) @ 1800 rpm

1800

12 / 45 / 540

12 / 650

Dry-type element

No. 2 diesel

123 (32.5)

Fuel consumption

Running time

Coolant capacity

Oil capacity

l (gal.) / hr.

hours

l (qts.)

1.71 (0.45)

4.7 (5.0)

2.4 (2.5)

58 wc_td000230gb.fm

LTN 6L Technical Data

7.2 Generator

Item Number:

LTN 6L

0620297 0620117 0620550 0620553 0620554 0620561

Generator

Frequency

Continuous output

Output

Amps

volts/

phase

60 ± 2

6.0

120, 1Ø 120/240, 1Ø

Excitation type Capacitor / Brushless

Power factor 1.0

Voltage regulation

- no load to full load

Speed (no-load)

rpm

± 6.0

1800

LTN 6L

0620727

7.3 Machine

Item Number:

Machine

Operating weight (GVWR)

Travel Dimensions (l x w x h)

Height - tower extended

kg(lbs.)

mm (in.)

m (ft.)

4600 x 1500 x 1900

(180.4 x 59.3 x 73.2)

Lighting system (1000W) 4

Ballast Coil and core

Max. lighting coverage @ 0.5 ft. candles

Sound level at 7 m (23 ft.)

Tires

(acres)

dB(A)

size

Metal Halide - 30,400 (7.52)

LTN 6L

768 (1693)

9 (30)

ST175 / 80D13

wc_td000230gb.fm 59

Schematics LTN 6L

14 BK/OR

1 BK 8 AWG

8 WH 10 AWG

9 WH 10 AWG

2 4 1 3

GN/YL 12 AWG

CONTROL PANEL

GROUND

12 GN/YL

12 AWG

1 2

11 GN/YL 12 AWG

10 WH 10 AWG

3 4

13 OR

2 BK 10 AWG

3 BK

10 AWG

4 BK 10 AWG

1 BK 8 AWG

15 BK 10 AWG

7 BK 10 AWG

6 BK 10 AWG

14 BK/OR

13 OR

BK/YL

11 GN/YL 12 AWG

5 BK

10 AWG

10 WH 10 AWG

BK/YL

8 WH 10 AWG

BK/YL

7 BK 10 AWG

9 WH 10 AWG

6 BK 10 AWG

8 Schematics

8.1 Electrical Schematic

CONTROL PANEL

GROUND

GN/YL 12 AWG

14 BK/OR

9 WH 10 AWG

8 WH 10 AWG

1 BK 8 AWG

12 AWG

11 GN/YL 12 AWG

2 4 1 3

10 WH 10 AWG

1 2 3

13 OR

wc_gr005366

13 OR

14 BK/OR

11 GN/YL 12 AWG

3 BK

10 AWG

4 BK 10 AWG

2 BK 10 AWG

1 BK 8 AWG

f f

10 WH 10 AWG

15 BK 10 AWG

5 BK

10 AWG

7 BK 10 AWG

6 BK 10 AWG

12 GN/YL

ddd

BK/YL

60 wc_tx000936gb.fm

8 WH 10 AWG

6 BK 10 AWG

9 WH 10 AWG

7 BK 10 AWG

LTN 6L Schematics

Ref. Description Ref. Description

a Generator h Battery

b Terminal strip i Engine control panel

c Main circuit breaker, 50 Amp j Engine

d Floodlights k Hour meter

e Receptacle, 120V l Transformers

f Circuit breaker, 30 Amp m Capacitors, 24 mF

g Circuit breaker, 20 Amp n Capacitor, 25 mF

Wire Colors

BK Black RD Red YL Yellow OR Orange

GN Green TN Tan BR Brown PU Purple

BU Blue VIO Violet CL Clear SH Shield

PK Pink WH White GY Gray LB Lt. blue

wc_tx000936gb.fm 61

Schematics LTN 6L

14 BK/OR

1 BK 10 AWG

8 WH 10 AWG

9 WH 10 AWG

1 GN/YL 12 AWG

12 GN/YL

12 AWG

1 2

11 GN/YL 12 AWG

10 WH 10 AWG

3 4

2 BK 10 AWG

4 BK 10 AWG

1 BK 10 AWG

15 BK 10

7 BK 10 AWG

6 BK 10 AWG

BK/YL

11 GN/YL 12 AWG

5 BK

10 AWG

10 WH 10 AWG

BK/YL

8 WH 10 AWG

BK/YL

7 BK 10 AWG

9 WH 10 AWG

6 BK 10 AWG

17 BK 10

22 GN/YL 10 AWG

23 WH 10 AWG

16 BK 10 AWG

18 BK 10 AWG

19 BK 10 AWG

18 BK 10 AWG

19 BK 10 AWG

3 BK

10 AWG

8.2 Electrical Schematic (120/240)

1 GN/YL 12 AWG

14 BK/OR

9 WH 10 AWG

8 WH 10 AWG

16 BK 10 AWG

ddd

1 BK 10 AWG

2 3

22 GN/YL 10 AWG

11 GN/YL 12 AWG

10 WH 10 AWG

12 GN/YL

12 AWG

23 WH 10 AWG

wc_gr006324

1 2 3

16 BK 10 AWG

1 BK 10 AWG

15 BK 10

3 BK

10 AWG

4 BK 10 AWG

18 BK 10 AWG

19 BK 10 AWG

2 BK 10 AWG

11 GN/YL 12 AWG

10 WH 10 AWG

17 BK 10

f f

5 BK

22 GN/YL 10 AWG 23 WH 10 AWG

10 AWG

7 BK 10 AWG

6 BK 10 AWG

19 BK 10 AWG

18 BK 10 AWG

BK/YL

8 WH 10 AWG

6 BK 10 AWG

9 WH 10 AWG

7 BK 10 AWG

62 wc_tx000936gb.fm

LTN 6L Schematics

Ref. Description Ref. Description

a Generator i Engine control panel

b Terminal strip j Engine

c Main circuit breaker, 25 Amp k Hour meter

d Floodlights l Transformers

e Receptacle, 120V m Capacitors, 24 mF

f Circuit breaker, 30 Amp n Capacitor, 25 mF

g Circuit breaker, 20 Amp o Receptacle, 120/240V

hBattery ––

Wire Colors

BK Black RD Red YL Yellow OR Orange

GN Green TN Tan BR Brown PU Purple

BU Blue VIO Violet CL Clear SH Shield

PK Pink WH White GY Gray LB Lt. blue

wc_tx000936gb.fm 63

Schematics LTN 6L

GN YL

GN RD

TONGUE WIRING

8.3 Trailer Wiring

GN RD

BL WH

TONGUE WIRING

GN YL

GN YL BR

wc_gr00537

Ref. Description Ref. Description

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

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

c Side light, amber

Wire Colors

BK Black RD Red YL Yellow OR Orange

GN Green TN Tan BR Brown PU Purple

BU Blue VIO Violet CL Clear SH Shield

PK Pink WH White GY Gray LB Light

blue

64 wc_tx000936gb.fm

LTN 6L Schematics

8.4 Engine Wiring - Lombardini

Ref. Description Ref. Description

1 Fuel solenoid 7 Air filter restriction indicator

(normal open type)

2 Glow plugs 8 Low fuel level switch

(not used, normal open type)

3 Starter motor 9 Low oil pressure switch

(normal closed type)

4 Battery 10 Coolant high temperature switch (nor-

mal open type)

5 Alternator connector 11 Coolant temperature thermistor (for

preheat relay)

6 Coolant temperature sending unit

(not used, for remote temperature gauge or LED)

wc_tx000936gb.fm 65

Schematics LTN 6L

8.5 Control Panel Wiring

W/R

Y/G

15 / 54

wc_gr000658

Ref. Description Ref. Description

1 System fuse, 50 Amp 4 Key switch

2 Glow plug load relay 5 L.E.D. Indicator lamp assembly

3 Auxiliary terminals (rear view)

66 wc_tx000936gb.fm

LTN 6L Schematics

6 BK

5 RD

8 BK

7 RD

1 BK

2 RD

3 BK

2 RD

3 BK

1 BK

4 RD

6 BK

8 BK

7 RD

4 RD

5 RD

8.6 Power Winch Schematic

2 RD

3 BK

--+

4 RD

++-

1 BK

7 RD

2 RD

3 BK

7 RD

4 RD

8 BK

6 BK

5 RD

Ref. Description Ref. Description

a Engine e Telescope switch

b Battery f Tilt winch

6 BK

5 RD

wc_gr005371

c 70A blade fuse g Telescope winch

d Tilt switch

wc_tx000936gb.fm 67

Appendix I—Assembly Instructions LTN

9 Appendix I—Assembly Instructions

9.1 Introduction

Scope

Hardware bags

Machine identification

This Manual contains assembly procedures for racked and palletized versions of Wacker Neuson Narrow-Body Light Towers (LTN). There are separate chapters for each version of the machine.

Assembly hardware is packaged in individual bags listed below . (De pending on the model, your Light Tower may or may not include all of these.)

Bag No. Contents Bag No. Contents

1 Axle hardware 5 Tower lock hardware 2 Fender hardware 6 Light fixture hardware 3 Wheel hardware 7 Tongue hardware 4 Tower cradle hardware 8 Tower installation hardware

Throughout this Manual, hardware bags needed for each assembly procedure will be identified at the beginning of the instructions for that specific procedure.

Use the following chart and the illustrations on the next page to determine which set of assembly procedures applies to your machine.

Item No. Description Illustration See Chapter:

0620117 0620118 0620121 0620297 0620298 0620553 0620555 0620559 0620727 0620728 0620734 0620893 0620938 0620939

Standard palletized A Appendix III

Optional CE palletized B Appendix IV 0620550

0620551 0620552

0620119 0620120 0620557 0620558

St andard racked C Appendix V

CE racked D Appendix VI

68 wc_tx001218gb.fm

LTN Appendix I—Assembly Instructions

Illustrations

wc_tx001218gb.fm 69

wc_gr006517

Appendix II—Assembly Safety LTN

10 Appendix II—Assembly Safety

10.1 Signal Words Found in this Manual

This is the safety alert symbol. It is used to alert you to potential personal hazards. f Obey all safety messages that follow this symbol.

DANGER

DANGER indicates a hazardous situation which, if not avoided, will result in death or serious injury.

To avoid death or serious injury from this type of hazard, obey all safety messages that follow this signal word.

WARNING

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

To avoid possible death or serious injury from this type of hazard, obey all safety mes-

sages that follow this signal word.

CAUTION!

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

To avoid possible minor or moderate injury from this type of hazard, obey all safety mes-

sages that follow this signal word.

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.

70 wc_si000344gb.fm

LTN Appendix II—Assembly Safety

10.2 Lifting Safety

Overview

Safety guidelines

Some of the assembly procedures in this Manual require the machine to be lifted or supported by slings, chains, hooks, ramps, jacks, or other types of mechanical devices. Follow the guidelines below to avoid personal injury or machine damage.

WARNING

Crushing hazard. f Use OSHA-rated and -approved lifting devices capable of lifting the machine.

Refer to the general weight guidelines in the Technical Data chapter of the Operator’s Manual.

When lifting the machine:

 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 support the machine safely.

 Remain aware of the location of other people when lifting the machine.

To reduce the possibility of injury:

 Do not stand under the machine while it is being lifted or moved.  Do not get onto the machine while it is being lifted or moved.

10.3 Pre-Assembly Checklist

Before assembling the Light Tower, take the following precautions:

Preparing the assembly area

Before assembly

 Make sure the area immediately surrounding the Light Tower is clean, neat,

and free of debris.

 The tower extends up to 9 m (30 ft). Make sure the area above the machine

is open and clear of overhead wires and obstructions.

 Make sure the machine is on a firm, level surface and will not tip, roll, slide,

or fall during the assembly process.

 Make sure the engine start switch is turned to OFF.  Make sure the circuit breakers are OFF (open).  Make sure the negative terminal on the battery is disconnected.  Make sure water has not accumulated around the base of the machine. If

water is present, move the machine to a dry area and allow all components to dry thoroughly before assembly.

wc_si000344gb.fm 71

Appendix III—Standard Pallet Assembly LTN

11 Appendix III—Standard Pallet Assembly

Scope

Tasks

This set of assembly instructions applies to standard machines shipped on a pallet as shown below.

wc_gr006467

If your machine does not look like the one shown in the illustration, refer to Machine Identification in the Introduction chapter to identify the appropriate set of assembly instructions.

To complete the assembly of your Light Tower, the following tasks must be performed in the order listed:

Tools and materials

Task Description See topic

Outriggers and jacks assembly

1 Install the outriggers 11.1 2 Install the outrigger jacks 11.1 3 Install the rear jack 11.2

Tongue assembly

4 Install the tongue 11.3 5 Install the tongue jack 11.3

Upper light installation

6 Install the upper light fixtures 11.4

The following tools and materials are needed:

 Basic hand tools (wrenches, screwdrivers, etc.)  Torque wrench  Hardware bag: 7

72 wc_tx001214gb.fm

LTN Appendix III—Standard Pallet Assembly

11.1 Installing the Outriggers and Outrigger Jacks

Installing the outriggers

Follow the procedure below to Install the two outrigge rs. (Use the same procedure for each side of the Light Tower.)

1. Locate the locking pin

(A)

at the outrigger socket.

Installing the outrigger jacks

wc_gr006520

(B)

2. Position the outrigger the locking pin.

3. Pull the locking pin and insert the square end of the outrigger into the outrigger socket.

B1)

4. Align hole ( release the locking pin to fasten the outrigger in place.

Follow the procedure below to Install the two outrigger jacks. (Use the same procedure for each outrigger jack.)

1. Locate the two 15-inch travel jacks (“outrigger jacks”)

2. If necessary, remove the locking pin

3. Fit the socket

4. Rotate the outrigger jack so that the foot

5. Align the top hole in the outrigger jack socket with the top hole on the outrigger.

in the outrigger with the locking pin. When hole

(C1)

on the outrigger jack over the circular end of the outrigger

so that the holes (B1 and B2) face the same direction as

(B1)

is aligned,

(C)

(C3)

from the holes in the outrigger jack.

(B)

(C2)

rests on the ground.

6. Insert the locking pin into the holes. Push the locking pin through both sets of holes (top and bottom) to fasten the outrigger jack in place.

wc_tx001214gb.fm 73

Appendix III—Standard Pallet Assembly LTN

11.2 Installing the Rear Jack

Procedure

Follow the procedure below to install the rear jack.

1. Locate the 5000 lb.10-inch side crank jack (D).

wc_gr006522

2. If necessary, remove the locking pin (D4) from the holes in the jack.

3. Fit the socket (D1) over the circular boss (D2) on the rear of the machine.

4. Rotate the jack so that the foot (D3) rests on the ground.

5. Align the top hole in the socket with the top hole on the circular boss.

6. Insert the locking pin into the holes. Push the locking pin through both sets of holes (top and bottom) to fasten the outrigger jack in place.

74 wc_tx001214gb.fm

LTN Appendix III—Standard Pallet Assembly

11.3 Installing the Tongue Assembly

Scope

Installing the tongue

Installing the tongue assembly consists of installing the tongue and the tongue jack, and connecting the trailer wiring.

Follow the procedure below to Install the tongue.

1. Insert the tongue (H) into the sleeve at the front of the trailer.

2. Fasten the tongue to the sleeve using the following hardware from Bag 7:

 (3) M16 x 120 screws (E)  (6) B17 flat washers (F)  (3) M16 lock nuts (G)

Torque the fasteners to 200 Nm (145 ft.lbs.)

wc_gr006523

wc_tx001214gb.fm 75

Appendix III—Standard Pallet Assembly LTN

Installing the tongue jack

Follow the procedure below to Install the tongue jack.

1. Locate the 2000 lb. 10-inch travel jack (“tongue jack”) (J).

wc_gr006524

2. If necessary, remove the locking pin (J3) from the holes in the tongue jack.

3. Fit the socket (J1) over the circular boss on the tongue assembly.

Connecting the trailer wiring

4. Rotate the tongue jack so that the foot (J2) rests on the ground.

5. Align the top hole in the socket with the top hole on the circular boss.

6. Insert the locking pin into the holes. Push the locking pin through both sets of holes (top and bottom) to fasten the tongue jack in place.

1. Locate connectors (K) and (L).

wc_gr006525

2. Plug the tongue wiring harness connector (K) into tongue wiring harness connector (L).

3. Insert connector plug body into the hole on the skid bracket. (See arrow.)

76 wc_tx001214gb.fm

LTN Appendix III—Standard Pallet Assembly

11.4 Installing the Upper Light Fixtures

Materials needed

Procedure

 Light fixtures (2)  Hardware bag 6 (tower lights hardware)

Follow the procedure below to install the upper light fixtures.

CC4

CC3

CC2

CC1

wc_gr007981

Install the two upper light fixtures (CC) on the light tube as follows:

1. Position each light fixture on the mounting bolt (CC1) so that the lamp is facing downward. Make sure that the “T” handle (CC4) faces outward.

2. Fasten each light fixture to the light tube using an M18 lock nut (CC3) and a B19 flat washer (CC2).

wc_tx001214gb.fm 77

Appendix III—Standard Pallet Assembly LTN

11.5 Conclusion

This completes the assembly procedure for your Light Tower. Refer to your Operator’s Manual for instructions on setting up, operating, maintaining, and storing the machine.

Notes:

78 wc_tx001214gb.fm

LTN Appendix IV—CE Pallet Assembly

12 Appendix IV—CE Pallet Assembly

Overview

This set of assembly instructions applies to CE machines shipped on a pallet as shown below. A palletized CE machine is intended to be mounted on a trailer that meets local regulations. This Manual does not include instructions for mounting a palletized CE machine on a trailer.

wc_gr006468

If your machine does not look like the one shown in the illustration, refer to Machine Identification in the Introduction chapter to identify the appropriate set of assembly instructions.

Tasks

Tools and materials

To complete the assembly of your Light Tower, the following tasks must be performed in the order listed:

Task Des cription See topic

Lift the machine

1 Lift the machine using appropriate lifting gear —

Install the jacks

2 Install the side jacks 12.1 3 Install the rear jack 12.2

The following tools and materials are needed:

 Appropriate machine lifting gear  Basic hand tools (wrenches, screwdrivers, etc.)

wc_tx001215gb.fm 79

Appendix IV—CE Pallet Assembly LTN

12.1 Installing the Side Jacks

Procedure

Follow the procedure below to attach the two side jacks. (Use the same procedure for each side jack.)

1. Locate the two 15-inch travel jacks (C).

wc_gr006710

2. If necessary, remove the locking pin (C3) from the holes in the jack.

3. Fit the jack socket (C1) over the circular end of the outrigger (B).

4. Rotate the jack so that the foot (C2) rests on the ground.

5. Align the top hole in the socket with the top hole on the outrigger.

6. Insert the locking pin into the holes. Push the locking pin through both sets of holes (top and bottom) to fasten the jack in place.

80 wc_tx001215gb.fm

LTN Appendix IV—CE Pallet Assembly

12.2 Installing the Rear Jack

Procedure

Follow the procedure below to install the rear jack.

1. Locate the 5000 lb.10-inch side crank jack (D).

wc_gr006711

2. If necessary, remove the locking pin (D4) from the holes in the jack.

3. Fit the socket (D1) over the circular boss (D2) on the rear of the machine.

4. Rotate the jack so that the foot (D3) rests on the ground.

5. Align the top hole in the socket with the top hole on the circular boss.

6. Insert the locking pin into the holes. Push the locking pin through both sets of holes (top and bottom) to fasten the outrigger jack in place.

wc_tx001215gb.fm 81

Appendix IV—CE Pallet Assembly LTN

12.3 Conclusion

This completes the assembly procedure for your Light Tower. Refer to your Operator’s Manual for instructions on setting up, operating, maintaining, and storing the machine.

Notes:

82 wc_tx001215gb.fm

LTN Appendix V—Standard Racked Assembly

13 Appendix V—Standard Racked Assembly

Overview

Tasks

This set of assembly instructions applies to standard machines shipped on a container rack as shown below.

wc_gr006469

If your machine does not look like the one shown in the illustration, refer to Machine Identification in the Introduction chapter to identify the appropriate set of assembly instructions.

To complete the assembly of your Light Tower, the following tasks must be performed in the order listed:

Task Des cription See topic

Chassis assembly

1 Install the axle 13.1 2 Install the fenders 13.2 3 Install the wheels 13.3 4 Install the outriggers and outrigger jacks 13.4 5 Install the rear jack 13.5 6 Install the tongue assembly 13.6

Tower assembly

7 Install the tower lock bracket 13.7 8 Install the tower cradle 13.8 9 Install the tower 13.9

10 Install the tower pivot cable 13.10

Lights assembly

11 Install the lights 13.11

Electrical assembly

12 Wire the junction box 13.12 13 Route the coil cord 13.13 14 Wire the ballasts and terminal strips 13.14

wc_tx001216gb.fm 83

Appendix V—Standard Racked Assembly LTN

Tools and materials

The following tools and materials are needed:

 Basic hand tools (wrenches, screwdrivers, etc.)  Torque wrench  Hardware bags: 1, 2, 3, 4, 5, 6, 8, and fabricated parts

13.1 Installing the Axle

Procedure

Follow the procedure below to install the axle:

1. Lift the machine using appro priate lifting gear . Refer to to pic Lifting the Machine in the Safety Information chapter.

2. Locate the axle (Q) and hardware bag 1.

3. Install the axle on the trailer using the following hardware: (4) Bolts (Q1), (8) Washers (Q2), (4) Nuts (Q3).

4. Torque the fasteners to 115 Nm (85 ft.lbs.).

84 wc_tx001216gb.fm

LTN Appendix V—Standard Racked Assembly

13.2 Installing the Fenders

Procedure

Follow the procedure below to Install the fenders.

1. Locate the two fenders (W) and hardware bag 2.

wc_gr006528

2. Align each fender as shown in the illustration.

3. Install each fender on the Light Tower using (3) M6 x 16 serrated flange screws—but do not tighten the screws until the next step.

4. Slide each fender backward until the mounting screws are located at the front end of the slots. Torque the screws to 16 Nm (11.5 ft.lbs.).

13.3 Installing the Wheels

Installing the wheels

Follow the procedure below to Install the wheels:

1. Locate the two wheels (U) and hardware bag 3.

2. Install the wheels on the axle using five lug nuts per wheel. Torque the lug nuts to 115 Nm (85 ft.lbs.).

wc_gr006529

wc_tx001216gb.fm 85

Appendix V—Standard Racked Assembly LTN

13.4 Installing the Outriggers and Outrigger Jacks

Installing the outriggers

Follow the procedure below to Install the two outriggers. (Use the same procedure for each side of the Light Tower.)

1. Locate the locking pin (A) at the outrigger socket.

Installing the outrigger jacks

wc_gr006520

2. Position the outrigger (B) so that the holes (B1 and B2) face the same direction as the locking pin.

3. Pull the locking pin and insert the square end of the outrigger into the outrigger socket.

4. Align hole (B1) in the outrigger with the locking pin. When hole (B1) is aligned, release the locking pin to fasten the outrigger in place.

Follow the procedure below to Install the two outrigger jacks. (Use the same procedure for each outrigger jack.)

1. Locate the two 15-inch travel jacks (“outrigger jacks”) (C).

2. If necessary, remove the locking pin (C3) from the holes in the outrigger jack.

3. Fit the socket (C1) on the outrigger jack over the circular end of the outrigger (B).

4. Rotate the outrigger jack so that the foot (C2) rests on the ground.

5. Align the top hole in the outrigger jack socket with the top hole on the outrigger.

6. Insert the locking pin into the holes. Push the locking pin through both sets of holes (top and bottom) to fasten the outrigger jack in place.

86 wc_tx001216gb.fm

LTN Appendix V—Standard Racked Assembly

13.5 Installing the Rear Jack

Procedure

Follow the procedure below to install the rear jack.

1. Locate the 5000 lb.10-inch side crank jack (D).

wc_gr006522

2. If necessary, remove the locking pin (D4) from the holes in the jack.

3. Fit the socket (D1) over the circular boss (D2) on the rear of the machine.

4. Rotate the jack so that the foot (D3) rests on the ground.

5. Align the top hole in the socket with the top hole on the circular boss.

6. Insert the locking pin into the holes. Push the locking pin through both sets of holes (top and bottom) to fasten the outrigger jack in place.

wc_tx001216gb.fm 87

Appendix V—Standard Racked Assembly LTN

13.6 Installing the Tongue Assembly

Scope

Installing the tongue

Installing the tongue assembly consists of installing the tongue and the tongue jack, and connecting the trailer wiring.

Follow the procedure below to Install the tongue.

1. Insert the tongue (H) into the sleeve at the front of the trailer.

2. Fasten the tongue to the sleeve using the following hardware from Bag 7:

 (3) M16 x 120 screws (E)  (6) B17 flat washers (F)  (3) M16 lock nuts (G)

Torque the fasteners to 200 Nm (145 ft.lbs.)

wc_gr006523

88 wc_tx001216gb.fm

LTN Appendix V—Standard Racked Assembly

Installing the tongue jack

Follow the procedure below to Install the tongue jack.

1. Locate the 2000 lb. 10-inch travel jack (“tongue jack”) (J).

wc_gr006524

2. If necessary, remove the locking pin (J3) from the holes in the tongue jack.

3. Fit the socket (J1) over the circular boss on the tongue assembly.

4. Rotate the tongue jack so that the foot (J2) rests on the ground.

Connecting the trailer wiring

5. Align the top hole in the socket with the top hole on the circular boss.

6. Insert the locking pin into the holes. Push the locking pin through both sets of holes (top and bottom) to fasten the tongue jack in place.

1. Locate connectors (K) and (L).

wc_gr006525

2. Plug the tongue wiring harness connector (K) into tongue wiring harness connector (L).

3. Insert connector plug body into the hole on the skid bracket. (See arrow.)

wc_tx001216gb.fm 89

Appendix V—Standard Racked Assembly LTN

13.7 Installing the Tower Lock Bracket

Procedure

Follow the procedure below to Install the tower lock bracket.

1. Locate the following in hardware bag 5:

 (1) tower lock bracket (M)  (3) M8 x 20 hex head mounting screws (N)  (3) M8 flat washers (O)  (3) M8 lock nuts (P)

2. Install the tower lock bracket on the tower as shown.

3. Torque the mounting screws to 35 Nm (25 ft.lbs.).

wc_gr006526

90 wc_tx001216gb.fm

LTN Appendix V—Standard Racked Assembly

13.8 Installing the Tower Cradle

Materials needed

Procedure

 Tower cradle  Hardware bag 4 (tower cradle hardware)

Follow the procedure below to assemble the tower cradle (Y).

Y11

Y10

wc_gr00653

1. Using (4) M10 x 16 serrated flange screws (Y1), install the tower cradle to the Light Tower upper frame. Torque the screws to 58 Nm (42.8 ft.lbs.)

2. Using (2) M6 x 20 serrated flange screws (Y4), install the radiator access cover (Y2) and radiator cover plate (Y3) to the tower cradle. Torque the screws to 16 Nm (11.5 ft.lbs.).

3. Using (2) M12 washers (Y9) and the M12 locknut (Y10), install the tower lock pin (Y8) on the tower cradle

Note: Do not tighten locknut Y10 until the next assembly topic (“Installing the Tower”).

4. Place the tower damper (Y7) over the tower lock pin. Note: The large hole on the tower damper must face down.

5. Install the hitch pin assembly (Y11) to the tower cradle using the M5 x 16 screw (Y5) and the M5 locknut (Y6).

wc_tx001216gb.fm 91

Appendix V—Standard Racked Assembly LTN

AA1

AA2

13.9 Installing the Tower

Materials needed

Installing the tower

 Tower assembly  Hardware bag 8 (tower install assembly)

Follow the procedure below to install the tower.

AA1

AA2

AA1

AA2

Y10

Reversing the winch handles

wc_gr006531

1. Align the tower assembly (Z) on top of the Light Tower enclosure as shown.

2. Place the tower assembly over the tower lock pin (Y8) and secure it with the hitch pin. This will help to keep the tower in alignment for the next step.

3. Insert the clevis pin (Z1) through the holes in the tower support (Z4) and the tower.

4. Place the 1-inch flat washer (Z3) over the end of the clevis pin. Fasten the tower in place with the 3/16-x-2 cotter pin (Z2).

5. Adjust the alignment of the tower lock pin (Y8) if necessary. Torque lock nut (Y10) to 48 Nm (35 ft.lbs.).

The winch handles (AA2) are installed backward to protect them from shipping damage. Reverse each handle orientation as follows:

1. Remove the nut (AA1) and remove the winch handle from the stem.

2. Turn the winch handle so that the handgrip is oriented as shown in the illustration.

3. Re-install the winch handle and the nut.

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LTN Appendix V—Standard Racked Assembly

13.10 Installing the Tower Pivot Cable

Materials needed

Installing the tower

 Tower pivot cable (AA8)  Hardware Bag 8 (Tower Install Assembly)

Follow the procedure below to install the tower pivot cable.

AA9

AA7

AA8

AA6

AA5

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1. One end of the tower pivot cable has a loop. Insert the retainer pin (AA5) through the hole in the upper pulley mount (AA9) and pass it through the cable loop.

2. Place the M12 washer (AA7) over the end of the retainer pin and secure it with the cotter pin (AA6).

3. Route the free end of the cable around the lower pulley and over the top of the upper pulley. Refer to the directional arrows in the illustration above.

4. Pass the cable below the winch drum and wind it two or three times around the winch drum.

5. Pass the free end of the cable through the hole in the winch drum. Wind the cable once around the bearing drum axle.

6. Loosen the two nuts on the cable retainer (AA) and insert the free end of the cable through the retainer so that approximately 1 cm (3/8 in.) of cable extends beyond the retainer. Torque the nuts to 3 Nm (20-30 in.lbs.).

7. Rotate the winch counter-clockwise to take up any slack in the cable.

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Appendix V—Standard Racked Assembly LTN

13.11 Installing the Lights

Materials needed

Procedure

 Light fixtures (4)  Hardware bag 6 (tower lights hardware)

Follow the procedure below to install the lights.

BB2

BB3

CC3

BB1

CC1

CC2

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1. Install the lig ht mount tu be (BB) on the tower using (2) M16 x 90 screws (BB1), (2) B17 flat washers (BB2), and (2) M16 lock nuts (BB3). Torque the screws to 83 Nm (60 ft.lbs.)

Install the four light fixtures (CC) on the light tube as follows:

1. Position each light fixture so that the lamp is facing downward. Make sure that the “T” handle (CC3) faces outward.

2. Install each light fixture on the light mount tube using an M18 lock nut (CC1) and a B19 flat washer (CC2).

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LTN Appendix V—Standard Racked Assembly

13.12 Connecting the Wiring at the Junction Box

Special tools and materials needed

Procedure

Installing the coil cord

 Coil cord (GG)  Panduit® crimper CT-100  Panduit® crimper CT-1550  Hardware bag 6

Follow the procedure below to connect the wiring at the junction box.

DD2

DD1

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1. Remove the screws and the cover plate from the junction box (DD).

2. Use two wrenches to loosen the connector (DD1) at the bottom of the junction box.

Installing the fixture cords

3. Insert the end of the coil cord through the con nector so that approximately 1 cm (3/8 in.) of coil cord jacket extends into the junction box. Retighten connector DD1.

4. Use two wrenches to loosen the four connectors (DD2) on the sides of the junction box.

5. Refer to the diagram below and insert the fixture cords through the appropriate connectors. Approximately 1 cm (3/8 in.) of each fixture cord jacket should extend into the junction box. Retighten connectors DD2.

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This procedure continues on the next page.

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Appendix V—Standard Racked Assembly LTN

Connecting the wires

6. Refer to the ta ble below and connect the light fixture wires to the coil cord wires. Use the small connectors and Panduit wire crimper CT-100.

Position Light wire Coil cord wire

L1 Black Red

White Orange Green —

L2 Black Black

White Brown Green —

L3 Black Yellow

White White Green —

L4 Black Blue

White Purple Green —

7. Connect the green wires from the fixture cords and coil cord, along with the green/yellow ground wire, using the large connector and Panduit wire crimper CT-1500.

8. Install the ring terminal on the ground wire to the ground screw (FF) in the junction box.

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LTN Appendix V—Standard Racked Assembly

13.13 Routing the Coil Cord

Procedure

Follow the procedure below to route the coil cord.

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1. At the base of the tower, wrap the coil cord around the tower twice, creating loops of about 25 cm (10 in.) in diameter.

2. Loosen the connector (CN). Pass the en d of the coil cord through the con nector so that approximately 1 m (3 ft) of wires extend inside the Light Tower cabinet, and re-tighten the connector (CN).

3. Insert the red, black, brown, and orange wires from the coil cord into one of the supplied looms. Pass this loom through the ballast bracket on the right side of the machine (R).

4. Insert the yellow, blue, white, purple, and green wires from the coil cord into the second loom. Pass this loom through the ballast bracket on the left side of the machine (L).

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Appendix V—Standard Racked Assembly LTN

13.14 Wiring the Ballasts and Terminal Strips

Procedure

Follow the procedure below to wire the ballasts and terminal strips.

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1. Remove the two ballast covers (BC) from the left and right sides of the Light Tower.

2. Connect the green wire from the coil cord to the hexagonal grounding screw (G).

3. Locate the four capacitors as shown below.

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4. Connect four wires from the coil cord to the capacitors as follows:

Capacitor Wire from coil cord

1Red 2Black 3 Yellow 4Blue

5. Connect the remaining wires to terminal strips “A” and “B” according to the diagram and tables on the next page. Torque all screws to 2.25 Nm (20 in.lbs.).

6. When all wires are connected to terminal strip s “A” and “B,” re-inst all the ballast covers. Torque the ballast cover mounting screws to 5.0 Nm (3.5 ft.lbs.).

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LTN Appendix V—Standard Racked Assembly

B C D E F

H I J K L

A B

H I J K

A B C D E

G H

“A” “B”

Terminal strip “A” (right side of machine)

Position Wire description

A–F Not used

G Black / yellow from ballasts #1 and #2 H Black (#7) from control box

I Yellows (2) from ballast #1 J Yellows (2) from ballast #2 K White (#9) from control box L Brown and orange from coil cord

A B

C D E

G H

I J K

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Terminal strip “B” (left side of machine)

Position Wire description

A Black / yellow from ballasts #3 and #4

B Black (#6) from control box C Yellows (2) from ballast #3 D Yellows (2) from ballast #4

E White (#8) from control box

F White and purple from coil cord

G–L Not used

Appendix V—Standard Racked Assembly LTN

13.15 Conclusion

This completes the assembly procedure for your Light Tower. Refer to your Operator’s Manual for instructions on setting up, operating, maintaining, and storing the machine.

Notes:

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Wacker Neuson LTN 6L Operator's Manual

Specifications and Main Features

Frequently Asked Questions

User Manual