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WACKER Group LTC 4 Repair Manual

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REPAIR MANUAL
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0160487en
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Light Tower
LTC 4
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Summary of Contents for WACKER Group LTC 4

  • Page 1 0160487en 0206 Light Tower LTC 4 REPAIR MANUAL...
  • Page 3 LTC Repair Foreword This manual covers machines with Item Number: 0009375, 0009376, 0620017, 0620018, 0620028 Operating / Parts Information You must be familiar with the operation of this machine before you attempt to troubleshoot or repair it. Basic operating and maintenance procedures are described in the Operator’s Manual supplied with the machine.
  • Page 4 Foreword LTC Repair CALIFORNIA Proposition 65 Warning: Diesel engine exhaust, some of its constituents, and certain vehicle components contain or emit chemicals known to the State of California WARNING to cause cancer and birth defects or other reproductive harm. All rights, especially copying and distribution rights, are reserved. Copyright 2006 by Wacker Corporation No part of this publication may be reproduced in any form or by any means, electronic or mechanical, including photocopying, without...

  • Page 5: Table Of Contents

    LTC Repair Table of Contents Safety Information Laws Pertaining to Spark Arresters ............6 Operating Safety .................. 7 Operator Safety while using Internal Combustion Engines ....8 Towing Safety ..................9 Service Safety ..................10 Label Locations .................. 11 Safety and Operating Labels .............. 13 Technical Data Engine ....................
  • Page 6 Table of Contents LTC Repair 3.22 Receptacles—60 Hz ................41 Maintenance Periodic Maintenance Schedule—Lombardini ........42 Periodic Maintenance Schedule—CAT ..........43 Daily Inspection ...................43 Installing / Removing Light Fixtures ............44 Precautions When Replacing / Removing Bulbs .........45 Replacing Bulbs ..................46 Air Cleaner ..................47 Engine Oil ....................48 Generator Capacitor Excitation Schematic 60 Hz .......49 4.10...
  • Page 7 LTC Repair Table of Contents 5.12 Engine Shuts Down—Flowchart 5A ........... 73 5.13 Checking Oil Pressure and Coolant Temperature Switches ....74 5.14 General Engine Troubleshooting ............75 Caterpillar Engine Troubleshooting Troubleshooting Flowcharts ............... 78 Engine Does Not Crank—Flowchart 6A ........... 79 Checking Keyswitch and Wiring ............
  • Page 8 Table of Contents LTC Repair 7.20 Checking Outgoing Voltage from Control Panel Capacitor(s) ...108 7.21 Confirming a Faulty Control Panel Capacitor ........109 7.22 Checking Wiring to/from Ballast(s) ............110 7.23 Replacing Ballast ................112 7.24 Restoring Rotor Magnetism (Flashing) / Checking Rotor Winding ..114 7.25 Checking Generator Capacitors ............116 7.26...
  • Page 9 LTC Repair Table of Contents wc_br0160487en_003TOC.fm...

  • Page 10: Safety Information

    Safety Information LTC Repair Safety Information This manual contains DANGER, WARNING, CAUTION, and NOTE callouts which must be followed to reduce the possibility of personal injury, damage to the equipment, or improper service. This is the safety alert symbol. It is used to alert you to potential personal injury hazards.

  • Page 11: Operating Safety

    LTC Repair Safety Information Operating Safety Familiarity and proper training are required for the safe operation of equipment. Equipment operated improperly or by untrained personnel can be dangerous. Read the operating instructions contained in both WARNING this manual and the engine manual and familiarize yourself with the location and proper use of all controls.

  • Page 12: Operator Safety While Using Internal Combustion Engines

    Safety Information LTC Repair Operator Safety while using Internal Combustion Engines Internal combustion engines present special hazards during operation and fueling. Read and follow the warning instructions in the engine owner’s manual and the safety guidelines below. Failure to follow the DANGER warnings and safety guidelines could result in severe injury or death.

  • Page 13: Towing Safety

    LTC Repair Safety Information Towing Safety Towing a large trailer requires special care. Both the trailer and vehicle must be in good condition and securely fastened to each other to reduce the possibility of an accident. WARNING 1.4.1 ALWAYS check that the hitch and coupling on the vehicle are rated equal to, or greater than, the trailer's “gross vehicle weight rating”...

  • Page 14: Service Safety

    Safety Information LTC Repair Service Safety HIGH VOLTAGE! This unit uses high voltage circuits capable of causing serious injury or death. Only a qualified electrician should troubleshoot or repair electrical problems occurring in this equipment. WARNING 1.5.1 ALWAYS replace the safety devices and guards after repairs and maintenance.

  • Page 15: Label Locations

    LTC Repair Safety Information Label Locations wc_si000164gb.fm...
  • Page 16 Safety Information LTC Repair wc_si000164gb.fm...

  • Page 17: Safety And Operating Labels

    LTC Repair Safety Information Safety and Operating Labels Wacker machines use international pictorial labels where needed. These labels are described below: Ref. Label Meaning DANGER! A non-secured, falling mast will cause serious injury or death if a person is hit. To secure mast, verify automatic locking pin has engaged to secure tower upright.
  • Page 18 Safety Information LTC Repair Ref. Label Meaning CAUTION! Lifting point WARNING! Secure mast in transport lock before lifting or towing. A loose swinging mast could cause personal injury or machine damage. DANGER! Asphyxiation hazard. Read the Opera- tor’s Manual for instructions. No sparks, flames, or burning objects near machine.
  • Page 19 LTC Repair Safety Information Ref. Label Meaning Electrical ground WARNING! Stand clear of front and rear of machine when mast is being tilted up or down. WARNING! Hot surface! A nameplate listing the model number, item number, revision number, and serial number is attached to each unit.
  • Page 20 Safety Information LTC Repair Ref. Label T O W I N G I N S T R U C T I O N S A B S C H L E P P I N S T R U K T I O N E N I N S T R U C C I O N E S D E R E M O L Q U E I N S T R U C T I O N S D E R E M O R Q U A G E 1 .
  • Page 21 LTC Repair Safety Information Ref. Label wc_si000164gb.fm...
  • Page 22 Safety Information LTC Repair Ref. Label Meaning Coolant overflow bottle only, not a return system. WARNING! Pinching hazard. Rotating machinery. Certification Label (VIN Number) Also attached to each unit is a Certification Label. This label specifies that the trailer conforms with all Federal Motor Vehicle Standards in effect at the time of manufacture.

  • Page 23: Technical Data

    LTC 4 Technical Data Technical Data Engine Item Number: LTC 4L LTC 4C LTC 4L 0009375 Rev. 0009376 0009375 Rev. 103 & above 0620017 102 & lower 0620018 0620028 Engine Make Lombardini Caterpillar Model LDW903 LDW1003 3003 Type 3-cylinder, 4-cycle, liquid-cooled diesel Maximum power rating 9.0 (12.1)

  • Page 24: Generator

    Technical Data LTC 4 Generator Item Number: LTC 4C - 60 Hz LTC 4L - 60 Hz 0009376 0009375 0620017 0620018 0620028 Generator Frequency 60 ± 2 Continuous output Output volts/phase 120 / 1Ø Amps 50 / 25 Excitation type...

  • Page 25: Machine

    LTC 4 Technical Data Machine LTC 4L LTC 4C Item Number 0009375 0620018 0009376 0620028 0620017 Machine Operating weight 815 (1800) 821 (1811) 817 (1802) 832 (1834) kg (lbs.) (GVWR) Dimensions cm (in.) 389 x 122 439 x 162 389 x 122...
  • Page 26 Technical Data LTC 4 Notes wc_td000157gb.fm...

  • Page 27: Operation

    LTC 4L Operation Operation Information Regarding Operation 3.1.1 The information regarding the operation of the machine included in this manual is condensed. Refer to the Operator’s Manual for complete operating instructions. Always read, understand, and follow the procedures in the Operator’s Manual when operating the machine. Locating Trailer See Graphic: wc_gr0001420 3.2.1...

  • Page 28: Leveling Trailer

    Operation LTC 4L Leveling Trailer See Graphic: wc_gr001420, wc_gr001423 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 the stability of the unit and could allow the tower to tip and fall.

  • Page 29: Preparing Trailer For Towing Or Lifting

    LTC 4L Operation Preparing Trailer for Towing or Lifting See Graphic: wc_gr001423, wc_gr002166 3.5.1 Check that the mast cradle lock pin (j) is in place and secured with the safety pin. 3.5.2 Ensure that the tower is completely nested inside the transport cradle and the pin (t) is secure.

  • Page 30: Raising Tower (Manual Winch System)

    Operation LTC 4L Raising Tower (Manual Winch System) See Graphic: wc_gr002166 NEVER raise the mast or operate the Light Tower in high winds. NEVER raise the mast while the engine is running. WARNING HIGH VOLTAGE! DO NOT use the Light Tower if insulation on electrical cord is cut or worn through.
  • Page 31 LTC 4L Operation NEVER pull the vertical mast locking pin (p) while the tower is raised! Releasing the vertical mast locking pin while the tower is raised may cause the tower to fall or the machine to tip over. WARNING 3.6.5 After the mast is in the vertical position, check the operation of the mast-mounted winch (q) by rotating the winch handle 1/4-turn...

  • Page 32: Lowering Tower (Manual Winch System)

    Operation LTC 4L Lowering Tower (Manual Winch System) See Graphic: wc_gr002166 Be sure to read and understand the operating instructions before lowering the tower! If for any reason a part of the mast hangs up or a winch cable develops slack before mast is fully lowered, stop immediately! Continuing to turn the winch handle will increase the slack in the cable.
  • Page 33 LTC 4L Operation 3.7.4 Pull and hold the mast locking pin (p). Rotate the handle on the tongue- mounted winch (o) counterclockwise (“cable out” direction) until the mast spring begins to pivot the mast down. Release the mast locking pin and continue to rotate the handle until the mast is resting in the transport cradle.

  • Page 34: Raising Tower (Power Winch System)

    Operation LTC 4L Raising Tower (Power Winch System) See Graphic: wc_gr002759, wc_gr002758 ALWAYS observe the tower while raising and lowering the mast. NEVER raise the mast or operate the Light Tower in high winds. NEVER raise the mast while the engine is running. WARNING HIGH VOLTAGE! DO NOT use Light Tower if insulation on electrical cord is cut or worn through.
  • Page 35 LTC 4L Operation 3.8.5 After the mast is in the vertical position, check the operation of the mast-mounted winch (q). Turn the telescope rotary switch (w) on the control panel to the up position. Do not attempt to raise the mast if the winch is damaged or not operating properly.

  • Page 36: Lowering Tower (Power Winch System)

    Operation LTC 4L Lowering Tower (Power Winch System) See Graphic: wc_gr002759, wc_gr002758 ALWAYS observe the tower while raising and lowering the mast. Be sure you read and understand the operating instructions before lowering the tower! WARNING If for any reason any part of the mast hangs up or the winch cable develops slack before the mast is fully lowered, stop immediately! Continuing to power the winch will increase slack in the cable.

  • Page 37: Emergency Crank Handle (Power Winch System)

    LTC 4L Operation 3.9.4 Pull and hold the mast locking pin (p). Turn and hold the vertical rotary switch (v) on the control panel in the down position until the mast is resting in the transport cradle. Be sure that the secondary locking pin (t) penetrates all sections of the mast.

  • Page 38: Control Panels-Lombardini (Manual Winch System)

    Operation LTC 4L 3.11 Control Panels—Lombardini (Manual Winch System) Floodlight Control Panel Engine Control Panel Ref. Description Ref. Description 50 Amp circuit breaker High coolant temperature shutdown 15 Amp lights circuit breaker Alternator indicator 20 Amp GFI circuit breaker Auxiliary light (not used) 20 Amp GFI receptacle Glow plug indicator Hour meter...

  • Page 39: Control Panels-Lombardini (Power Winch System)

    LTC 4L Operation 3.12 Control Panels—Lombardini (Power Winch System) Floodlight Control Panel Engine Control Panel Ref. Description Ref. Description 50 Amp circuit breaker Alternator indicator 15 Amp lights circuit breaker Auxiliary light (not used) 20 Amp GFI circuit breaker Glow plug indicator 20 Amp GFI receptacle Air filter restriction indicator Hour meter...

  • Page 40: Control Panels-Cat (Manual Winch System)

    Operation LTC 4L 3.13 Control Panels—CAT (Manual Winch System) Ref. Description Ref. Description 25 Amp circuit breaker Hour meter 15 Amp lights circuit breaker Glow plug indicator 20 Amp GFI circuit breaker Key switch 20 Amp GFI outlet wc_tx000543gb.fm...

  • Page 41: Control Panel-Cat (Power Winch System)

    LTC 4L Operation 3.14 Control Panel—CAT (Power Winch System) Ref. Description Ref. Description 25 Amp circuit breaker Glow plug indicator 15 Amp lights circuit breaker Key switch 20 Amp GFI circuit breaker Vertical rotary switch 20 Amp GFI outlet Telescope rotary switch Hour meter wc_tx000543gb.fm...

  • Page 42: Starting-Lombardini

    Operation LTC 4L 3.15 Starting—Lombardini See Graphic: wc_gr001426, wc_gr002758 3.15.1 Check the engine oil, fuel and coolant levels. Note: If the fuel tank was drained or run dry it may be necessary to bleed the fuel lines. Refer to the Engine Operator’s Manual. 3.15.2 Check the condition of the electrical cable on the mast.

  • Page 43: Starting-Cat

    LTC 4L Operation 3.16 Starting—CAT See Graphic: wc_gr001670, wc_gr002756 3.16.1 Check the engine oil, fuel and coolant levels. Note: If the fuel tank was drained or run dry it may be necessary to bleed the fuel lines. 3.16.2 Check the condition of the electrical cable on the mast. Do not start the generator if the insulation on cable is cut or worn through.

  • Page 44: Operating Lights

    Operation LTC 4L 3.18 Operating Lights See Graphic: wc_gr001426, wc_gr002758 Turn on the circuit breaker (a) first, then turn each circuit breaker (b) to “ON”, one at a time. Metal halide floodlights require a warm-up time of 5–15 minutes before they reach full output.

  • Page 45: Receptacles-60 Hz

    LTC 4L Operation 3.22 Receptacles—60 Hz See Graphic: wc_gr001426, wc_gr002758 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”.

  • Page 46: Maintenance

    Maintenance LTC Repair Maintenance Periodic Maintenance Schedule—Lombardini Before Every Every Every Every each 1000 hours hours hours hours or two years Check for fluid leaks. • Check engine oil. • Check fuel level. • Replace air filter if indicator light is on.** •...

  • Page 47: Periodic Maintenance Schedule-Cat

    LTC Repair Maintenance Periodic Maintenance Schedule—CAT Before Every Every Every Every each 1000 hours hours hours hours Visual walkaround inspection. • Check for fluid leaks. • Check engine oil and coolant level. • Check fuel level. • Replace air filter if indicator light is on.** •...

  • Page 48: Installing / Removing Light Fixtures

    Maintenance LTC Repair Installing / Removing Light Fixtures See Graphic: wc_gr001427, wc_gr000542 ALWAYS turn off the light circuit breakers and shut down the engine before disconnecting the light fixtures or changing the light bulbs. WARNING Remove the light fixtures by disconnecting the electrical cords using the quick disconnects (a).

  • Page 49: Precautions When Replacing / Removing Bulbs

    LTC Repair Maintenance Precautions When Replacing / Removing Bulbs The Light Tower uses four 1000W bulbs. When replacing or removing the bulbs, avoid leaving any grease or oil residue on the glass surface. This can create hot spots, reducing the service life of the bulb or causing the outer jacket to burst.

  • Page 50: Replacing Bulbs

    Maintenance LTC Repair Replacing Bulbs See Graphic: wc_gr0002464 Removal: 4.6.1 Shut down the engine and allow the bulb to cool. 4.6.2 Remove the screws (a) securing the flange rings (b) and remove the flange rings. 4.6.3 Remove the lens (c) with the gasket (d) attached. 4.6.4 Remove the hardware securing one side of the bulb stabilizer (e).

  • Page 51: Air Cleaner

    LTC Repair Maintenance Air Cleaner See Graphic: wc_gr002478 DO NOT attempt to clean or service the machine while it is running. WARNING CAUTION: DO NOT operate the engine without an air cleaner. Note: Caterpillar engines are equipped with a filter indicator (a), which indicates when a filter change is required.

  • Page 52: Engine Oil

    Maintenance LTC Repair Engine Oil See Graphic: wc_gr002479 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.

  • Page 53: Generator Capacitor Excitation Schematic 60 Hz

    LTC Repair Maintenance Generator Capacitor Excitation Schematic 60 Hz 120V 240V 120V 50 Hz 60 Hz wc_gr000932 Ref. Description Ref. Description Rotor Capacitor Stator Generator/Terminal block Excitation coils Control box-lights wc_tx000427gb.fm...

  • Page 54: Schematic For 60 Hz Metal Halide 4-Light Units

    Maintenance LTC Repair 4.10 Schematic for 60 Hz Metal Halide 4-Light Units G G G Or/B wc_gr002459 wc_tx000427gb.fm...

  • Page 55: Metal Halide Schematic Components

    LTC Repair Maintenance 4.11 Metal Halide Schematic Components Ref. Description Ref. Description Generator Transformer 20 Amp GFI outlet Capacitor Control box-lights Ballasts Quick disconnects 25 Amp 2-pole circuit breaker Terminal strip Hourmeter 20 Amp GFI circuit breaker Alternator 15 Amp circuit breaker Control panel Wire Colors Black...

  • Page 56: Engine Wiring-Lombardini 1003

    Maintenance LTC Repair 4.12 Engine Wiring—Lombardini 1003 12V/45A wc_gr003225 wc_tx000427gb.fm...

  • Page 57: Engine Wiring Components-Lombardini 1003

    LTC Repair Maintenance 4.13 Engine Wiring Components—Lombardini 1003 Ref. Description Ref. Description Ref. Description Emergency stop switch Air filter restriction Harness connector indicator (alternator) (normal open type) Glow plugs Terminal strip Diode Starter motor Low oil pressure switch Resistors (2x220 Ohm, 0.6 W) Battery High coolant Control panel...

  • Page 58: Engine Control Panel Internal Wiring-Lombardini 1003

    Maintenance LTC Repair 4.14 Engine Control Panel Internal Wiring—Lombardini 1003 (Max 0,8A) (Max 10A) "A" (12V) (Max 12A) "B" (Max 50A) "A" "B" wc_gr003226 Ref. Description Ref. Description Key switch Engine protection 15A fuse Preheating 80A fuse Relay Wire Colors Black Yellow Orange...

  • Page 59: Engine Wiring-Lombardini 903

    LTC Repair Maintenance 4.15 Engine Wiring—Lombardini 903 12V/45A wc_gr001776 Ref. Description Ref. Description Ref. Description Fuel solenoid Air filter restriction Harness connector indicator (normal open type) Glow plugs Low fuel level switch (not Diode used, normal open type) Starter motor Low oil pressure switch Resistors (normal closed type)

  • Page 60: Engine Control Panel Internal Wiring-Lombardini 903

    Maintenance LTC Repair 4.16 Engine Control Panel Internal Wiring—Lombardini 903 (Max 0,8A) (Max 10A) (12V) (Max 12A) (Max 50A) wc_gr001997 Ref. Description Ref. Description Key switch Engine protection 15A fuse Preheating 80A fuse Relay Wire Colors Black Yellow Orange Green Brown Purple Blue...

  • Page 61: Engine Control Panel Components-Lombardini

    LTC Repair Maintenance 4.17 Engine Control Panel Components—Lombardini wc_gr003227 wc_gr002474 Ref. Description Ref. Description Engine control panel, front view System fuse—80A Engine control panel, rear view Key access door Solid-state glow plug controller and Auxiliary connections indicating lamps Shutdown relay location Light switch panel connection Glow plug relay 15 A fuse...

  • Page 62: Engine Wiring-Item Number: 0009376

    Maintenance LTC Repair 4.18 Engine Wiring—Item Number: 0009376 Ref. Description Ref. Description Glow plugs Water temperature sensor Starter solenoid Low-oil pressure indicator Starter Fuel solenoid Alternator Diode Hour meter Automatic shutdown Automatic voltage regulator Battery Glow plug indicator 15 Amp fuse Ignition switch wc_tx000427gb.fm...

  • Page 63: Engine Wiring-Item Number: 0620017, 0620028

    LTC Repair Maintenance 4.19 Engine Wiring—Item Number: 0620017, 0620028 Ref. Description Ref. Description Glow plugs Water temperature sensor Starter solenoid Low-oil pressure indicator Starter Fuel solenoid Alternator Diode Hour meter Automatic shutdown Automatic voltage regulator Battery Glow plug indicator 15 Amp fuse Ignition switch wc_tx000427gb.fm...

  • Page 64: Power Winch Schematic

    Maintenance LTC Repair 4.20 Power Winch Schematic Ref. Description Ref. Description Vertical winch Vertical rotary switch Telescope winch Telescope rotary switch Fuse / breaker Starter wc_tx000427gb.fm...

  • Page 65: Trailer Wiring

    LTC Repair Maintenance 4.21 Trailer Wiring Ref. Description Ref. Description Right stop, turn and tail light Side light, red Left stop, turn and tail light License plate light Side light, amber Wire Colors Green Right stop and turn light Yellow Left stop and turn light Brown License plate, tail and side light...

  • Page 66: Lombardini Engine Troubleshooting

    Lombardini Engine Troubleshooting LTC Repair Lombardini Engine Troubleshooting Troubleshooting Flowcharts The troubleshooting flowcharts are designed to take you through the process of determining the source of a problem with engine starting or machine operation. Many of the tests involve live voltages and therefore should only be attempted by qualified personnel.

  • Page 67: Engine Does Not Crank-Flowchart 3A

    LTC Repair Lombardini Engine Troubleshooting Engine Does Not Crank—Flowchart 3A Engine Does Not Crank Check battery voltage. Checking Keyswitch and Wiring Does Check connection of black wire at battery measure starter solenoid. Also check wire 11.0–13.0V? connections at back of keyswitch. Reconnect the black wire black wire.

  • Page 68: Checking Keyswitch And Wiring

    Lombardini Engine Troubleshooting LTC Repair Checking Keyswitch and Wiring See Graphic: wc_gr003228 Electric shock hazard. Only qualified personnel should conduct these tests. WARNING 5.3.1 When troubleshooting Lombardini engines that do not crank, check that the B (black) wire (a) is connected to the starter solenoid. 5.3.2 Remove the screws securing the control panel (b) to the mounting bracket and remove the control panel from the bracket.
  • Page 69 LTC Repair Lombardini Engine Troubleshooting 15/54 wc_gr003228 wc_tx000364gb.fm...

  • Page 70: Replacing Keyswitch

    Lombardini Engine Troubleshooting LTC Repair Replacing Keyswitch See Graphic: wc_gr002469 Disassembly: 5.4.1 Shut down the engine and disconnect the battery. 5.4.2 Remove the six screws securing the control panel cover to the control panel. 5.4.3 Make note of the wire connections on the keyswitch and remove the wires (a) from the keyswitch.

  • Page 71: Engine Cranks But Does Not Start-Flowchart 4A

    LTC Repair Lombardini Engine Troubleshooting Engine Cranks But Does Not Start—Flowchart 4A Engine Cranks But Does Not Start Make sure that the machine has fresh fuel and that the fuel filter and fuel hoses are in good condition. Check battery condition. Does Checking Fuel System battery provide...

  • Page 72: Checking Fuel System

    Lombardini Engine Troubleshooting LTC Repair Checking Fuel System See Graphic: wc_gr002470 Electric shock hazard. Only qualified personnel should conduct these tests. WARNING When troubleshooting Lombardini engines that crank but do not start, make the following checks. 5.6.1 Check that the battery is in good condition and that all connections are clean and tight.

  • Page 73: Checking Voltage To Glow Plugs (Lombardini 903 Engines)

    LTC Repair Lombardini Engine Troubleshooting Checking Voltage to Glow Plugs (Lombardini 903 engines) See Graphic: wc_gr003314 5.7.1 Place the keyswitch in the ON position. 5.7.2 Check for battery voltage between the R/Or glow plug wire (a) and ground. If battery voltage is not measured, check the continuity and connections of wiring.

  • Page 74: Checking Voltage To Glow Plugs (Lombardini 1003 Engines)

    Lombardini Engine Troubleshooting LTC Repair Checking Voltage to Glow Plugs (Lombardini 1003 engines) See Graphic: wc_gr003229 To check the voltage to the glow plugs, carry out the following procedure: 5.8.1 Disconnect the B (black) wire (a), place the keyswitch in the START position, and measure the voltage between the black wire and ground.

  • Page 75: Checking Glow Plug Relay

    LTC Repair Lombardini Engine Troubleshooting Checking Glow Plug Relay See Graphic: wc_gr002475 5.9.1 Remove the screws securing the engine control panel. Leave all wiring connected to the control panel. 5.9.2 Rotate the control panel to gain access to the rear of the control panel. Remove the enclosure cover to access the glow plug relay.

  • Page 76: Checking Glow Plugs

    Lombardini Engine Troubleshooting LTC Repair 5.11 Checking Glow Plugs See Graphic: wc_gr002033 5.11.1 Remove the glow plug from the engine. Burn hazard. Glow plugs can reach temperatures up to 1200°F (649°C). Do not touch the element of the glow plug. Be extremely careful when testing the glow plug.

  • Page 77: Engine Shuts Down-Flowchart 5A

    LTC Repair Lombardini Engine Troubleshooting 5.12 Engine Shuts Down—Flowchart 5A Engine Shuts Down Check engine oil level. Is machine oil Fill machine level correct? with oil. Check engine coolant level. Checking oil pressure and coolant temperature switches engine coolant Check wiring of oil pressure level correct? switch.

  • Page 78: Checking Oil Pressure And Coolant Temperature Switches

    Lombardini Engine Troubleshooting LTC Repair 5.13 Checking Oil Pressure and Coolant Temperature Switches See Graphic: wc_gr003230 5.13.1 If the engine starts but shuts down after approximately 10 seconds, check the following. 5.13.2 Check the engine oil level and add oil if necessary. Also check the coolant temperature.

  • Page 79: General Engine Troubleshooting

    LTC Repair Lombardini Engine Troubleshooting 5.14 General Engine Troubleshooting Possible Cause Symptom Low fuel level • • • Fuel supply/return lines • • • • clogged Clogged fuel tank vent • • Fuel pump faulty • • • Fuel contaminated with air •...
  • Page 80 Lombardini Engine Troubleshooting LTC Repair Possible Cause Symptom Battery voltage too low • Battery/battery cable • connections corroded Key switch defective • Air filter clogged • • • • • • • Excessive idle/light load • • • • operation Incomplete engine run-in •...
  • Page 81 LTC Repair Lombardini Engine Troubleshooting Possible Cause Symptom Valves sticking • • • • • • • Bearings (main/rod) worn • • • Governor/governor linkage • • • • • malfunctioning Cylinder head gasket • • • damaged Thermostat stuck or •...

  • Page 82: Caterpillar Engine Troubleshooting

    Caterpillar Engine Troubleshooting LTC Repair Caterpillar Engine Troubleshooting Troubleshooting Flowcharts The troubleshooting flowcharts are designed to take you through the process of determining the source of a problem with engine starting or machine operation. Many of the tests involve live voltages and therefore should only be attempted by qualified personnel.

  • Page 83: Engine Does Not Crank-Flowchart 6A

    LTC Repair Caterpillar Engine Troubleshooting Engine Does Not Crank—Flowchart 6A Engine Does Not Crank Check battery voltage. Checking Keyswitch and Wiring Does Check connection of Or/B wire at battery measure starter solenoid. Also check wire 11.0–13.0V? connections at back of keyswitch. Reconnect the Or/B wire black wire.

  • Page 84: Checking Keyswitch And Wiring

    Caterpillar Engine Troubleshooting LTC Repair Checking Keyswitch and Wiring See Graphic: wc_gr002463 Electric shock hazard. Only qualified personnel should conduct these tests. WARNING 6.3.1 When troubleshooting CAT engines that do not crank, check that the Or/B wire (a) is connected to the starter solenoid. 6.3.2 Open the control panel and check that the wiring to the keyswitch is clean and tight.

  • Page 85: Replacing Keyswitch

    LTC Repair Caterpillar Engine Troubleshooting Replacing Keyswitch See Graphic: wc_gr002443 Disassembly: 6.4.1 Shut down the engine and disconnect the battery. 6.4.2 Remove the six screws securing the control panel cover to the control panel. 6.4.3 Make note of the wire connections on the keyswitch and remove the wires (a) from the keyswitch.

  • Page 86: Engine Cranks But Does Not Start-Flowchart 7A

    Caterpillar Engine Troubleshooting LTC Repair Engine Cranks But Does Not Start—Flowchart 7A Engine Cranks But Does Not Start Make sure that the machine has fresh fuel and that the fuel filter and fuel hoses are in good condition. Check battery condition. Does Checking Fuel Flow battery provide...

  • Page 87: Checking Fuel Flow

    LTC Repair Caterpillar Engine Troubleshooting Checking Fuel Flow See Graphic: wc_gr002476 To check the fuel flow on Caterpillar engines, carry out the following procedures. 6.6.1 Loosen the screw securing the banjo fitting (a). 6.6.2 Place the keyswitch in the START position and check for fuel flow from the banjo fitting.

  • Page 88: Checking Glow Plug Wiring

    Caterpillar Engine Troubleshooting LTC Repair Checking Glow Plug Wiring See Graphic: wc_gr002477 6.7.1 Place the keyswitch in the ON position. 6.7.2 Check for battery voltage between the R/Or glow plug wire (a) and ground. If battery voltage is not measured, check the continuity and connections of wiring.

  • Page 89: Engine Shuts Down-Flowchart 8A

    LTC Repair Caterpillar Engine Troubleshooting Engine Shuts Down—Flowchart 8A Engine Shuts Down Check engine oil level. Fill machine Is machine oil with oil. level correct? Check engine coolant level. Checking oil pressure and coolant temperature switches engine coolant Check wiring of oil pressure level correct? switch.

  • Page 90: Checking Oil Pressure And Coolant Temperature Switches

    Caterpillar Engine Troubleshooting LTC Repair 6.10 Checking Oil Pressure and Coolant Temperature Switches See Graphic: wc_gr002480 6.10.1 If the engine starts but shuts down after approximately 10 seconds, check the following. 6.10.2 Check the engine oil level and add oil if necessary. Also check the coolant temperature.

  • Page 91: General Engine Troubleshooting

    LTC Repair Caterpillar Engine Troubleshooting 6.11 General Engine Troubleshooting Possible Cause Symptom Dirty primary/secondary air cleaner • • • • Overfueling • Overloading • Worn rings/liners • Worn seals • • Worn valve products • Leaking head gasket • Cracked head or liners •...
  • Page 92 Caterpillar Engine Troubleshooting LTC Repair Possible Cause Symptom Incorrect adjustment of governor • linkage Slipping torque converter • • Improper set point • • Fuel leak • Plugged radiator core • Incorrect adjustment or worn belts/ • pulleys Low coolant level •...
  • Page 93 LTC Repair Caterpillar Engine Troubleshooting wc_tx000476gb.fm...

  • Page 94: Electrical Troubleshooting Procedures

    Electrical Troubleshooting Procedures LTC Repair Electrical Troubleshooting Procedures Troubleshooting Methodology See Graphic: wc_gr002459 If a lighting problem is not an obvious burnt bulb, engine speed, or wire fault, the cause of the problem will be associated with one of two things: a malfunctioning generator or faults in the circuit supplying voltage to the lights.

  • Page 95: Schematic For 60 Hz Metal Halide 4-Light Units

    LTC Repair Electrical Troubleshooting Schematic for 60 Hz Metal Halide 4-Light Units G G G Or/B wc_gr002459 wc_tx000429gb.fm...

  • Page 96: Checking Continuity

    Electrical Troubleshooting Procedures LTC Repair Checking Continuity Conduct continuity tests when the engine is shutdown. When checking continuity, use the Ohm setting on your multimeter. Place a lead of the multimeter on one end of the wiring or component and the other lead on the opposite end. If your meter reads “OL” or “OPEN”, there is no continuity and the wiring or component must be repaired or replaced.

  • Page 97: Lights Do Not Illuminate-Flowchart 1A

    LTC Repair Electrical Troubleshooting Lights do not Illuminate—Flowchart 1A Light(s) do not illuminate Is circuit Close circuit breaker(s). breaker(s) in closed position? Replace bulbs. bulbs black or burnt? Is wiring Connect connected at quick- quick-disconnects. disconnects? Checking engine speed Check engine speed. Check engine rpm with a photo tach or vibrotach (Sirometer (wire whip)).

  • Page 98: Lights Do Not Illuminate-Flowchart 1B

    Electrical Troubleshooting Procedures LTC Repair Lights do not Illuminate—Flowchart 1B Checking outgoing voltage from main circuit breaker With lights disconnected at quick- disconnects, check outgoing voltage from main circuit breaker. Checking individual circuit breaker(s) 230V±10% With lights disconnected at quick-disconnects, measured? measure incoming and outgoing voltage to/ from individual circuit breaker(s).

  • Page 99: Lights Do Not Illuminate-Flowchart 1C

    LTC Repair Electrical Troubleshooting 7.10 Lights do not Illuminate—Flowchart 1C Restoring Rotor Magnetism (Flashing) Checking stator windings. Remagnetize (flash) the rotor windings by connecting a 12V battery to With engine shut down, remove red, capacitor leads #60 and #0. white, and black wires from the terminal strip on the generator.

  • Page 100: Lights Do Not Illuminate-Flowchart 1D

    Electrical Troubleshooting Procedures LTC Repair 7.11 Lights do not Illuminate—Flowchart 1D Checking rotor diodes With engine shut down, unsolder the wires from both rotor diodes. Using the diode scale ( ) on a multimeter, measure voltage across the diode. Reverse positions of the meter's leads and measure voltage again.

  • Page 101: Checking Engine Speed

    LTC Repair Electrical Troubleshooting 7.12 Checking Engine Speed See Graphic: wc_gr001625, wc_gr001634, and wc_gr002441 Using either a photo (strobe) tachometer, a frequency meter (60Hz = 1800 rpm; 50Hz = 1500 rpm), or a vibration tachometer such as a Sirometer (a) (Wacker P/N 0053397), check engine rpm. Refer to the instrument instructions.

  • Page 102: Checking Generator Voltage At Receptacle

    Electrical Troubleshooting Procedures LTC Repair 7.13 Checking Generator Voltage at Receptacle See Graphic: wc_gr003075 Electric shock hazard. Only qualified personnel should conduct this test. WARNING A quick way to check the function of the generator is to check voltage at the receptacle. If the correct voltage is present, problems with the lights not functioning will be associated with the circuit from the main circuit breaker to the lights.

  • Page 103: Replacing Receptacle

    LTC Repair Electrical Troubleshooting 7.14 Replacing Receptacle See Graphic: wc_gr002453 Carry out this procedure with the engine shut down. Removal: 7.14.1 Remove the screws (a) securing the control panel cover and remove the cover. 7.14.2 Make note of the wire connections on the back of the receptacle. Loosen the screws securing the wires and remove the wires.

  • Page 104: Checking Voltage To The Main Circuit Breaker

    Electrical Troubleshooting Procedures LTC Repair 7.15 Checking Voltage to the Main Circuit Breaker See Graphic: wc_gr003095 Electric shock hazard. Only qualified personnel should conduct this test. Do not perform this test if you or the machine are wet. WARNING Complete this test with the machine running. 7.15.1 Remove the control panel front cover.
  • Page 105 LTC Repair Electrical Troubleshooting 1000 200m wc_gr003095 wc_tx000429gb.fm...

  • Page 106: Checking Voltage Between Main Circuit Breaker And Terminal Strip

    Electrical Troubleshooting Procedures LTC Repair 7.16 Checking Voltage Between Main Circuit Breaker and Terminal Strip See Graphic: wc_gr003096 Electric shock hazard. Only qualified personnel should conduct this test. Do not perform this test if you or the machine are wet. WARNING Complete this test with the machine running and the main circuit breaker in the ON position.
  • Page 107 LTC Repair Electrical Troubleshooting 1000 200m 1000 200m wc_gr003096 wc_tx000429gb.fm...

  • Page 108: Checking Individual Circuit Breakers

    Electrical Troubleshooting Procedures LTC Repair 7.17 Checking Individual Circuit Breakers See Graphic: wc_gr002472 Electric shock hazard. Only qualified personnel should conduct this test. Do not perform this test if you or the machine are wet. WARNING Complete this test with the machine running. Test power to all circuit breakers or just the circuit breaker in question.
  • Page 109 LTC Repair Electrical Troubleshooting 1000 200m wc_gr002472 wc_tx000429gb.fm...

  • Page 110: Confirming A Malfunctioning Circuit Breaker

    Electrical Troubleshooting Procedures LTC Repair 7.18 Confirming a Malfunctioning Circuit Breaker See Graphic: wc_gr002458 Electric shock hazard. Only qualified personnel should conduct this test. WARNING Complete this test with the engine shut down. 7.18.1 Remove the circuit breaker(s) from the control panel. 7.18.2 Place the circuit breaker ON-OFF switch in the ON position.

  • Page 111: Checking Incoming Voltage To Control Panel Capacitor(S)

    LTC Repair Electrical Troubleshooting 7.19 Checking Incoming Voltage to Control Panel Capacitor(s) See Graphic: wc_gr002456 Electric shock hazard. Only qualified personnel should conduct this test. WARNING Complete this test with the lights disconnected at the quick- disconnects (or disconnected at the junction box), the machine running, and the main circuit breaker in the ON position.

  • Page 112: Checking Outgoing Voltage From Control Panel Capacitor(S)

    Electrical Troubleshooting Procedures LTC Repair 7.20 Checking Outgoing Voltage from Control Panel Capacitor(s) See Graphic: wc_gr002454 Electric shock hazard. Only qualified personnel should conduct this test. WARNING Complete this test with the lights disconnected, the machine running, and the main circuit breaker in the ON position. Test all capacitors or just the capacitor in question.

  • Page 113: Confirming A Faulty Control Panel Capacitor

    LTC Repair Electrical Troubleshooting 7.21 Confirming a Faulty Control Panel Capacitor See Graphic: wc_gr002455 Carry out this procedure with the engine shut down. 7.21.1 Remove the input and output wires from the capacitor. Note: The capacitor is shown with the resistor disconnected; the resistor may be left connected if desired.

  • Page 114: Checking Wiring To/From Ballast(S)

    Electrical Troubleshooting Procedures LTC Repair 7.22 Checking Wiring to/from Ballast(s) See Graphic: wc_gr003072 Electric shock hazard. Only qualified personnel should conduct this test. Complete this test with the machine shut down. WARNING At this stage, you should have measured voltage (120V±10%) to the circuit breaker(s) and no incoming voltage (400V±10%) to the control panel capacitors.
  • Page 115 LTC Repair Electrical Troubleshooting wc_gr003072 wc_tx000429gb.fm...

  • Page 116: Replacing Ballast

    Electrical Troubleshooting Procedures LTC Repair 7.23 Replacing Ballast See Graphic: wc _gr002442 Removal: 7.23.1 Shut down the engine and disconnect the battery. 7.23.2 Open the control panel and snip the wire ties (a) holding the ballast wires to the control panel. 7.23.3 Remove the six screws securing the control panel/ballast box cover.
  • Page 117 LTC Repair Electrical Troubleshooting wc_gr002442 wc_tx000429gb.fm...

  • Page 118: Restoring Rotor Magnetism (Flashing) / Checking Rotor Winding

    Electrical Troubleshooting Procedures LTC Repair 7.24 Restoring Rotor Magnetism (Flashing) / Checking Rotor Winding See Graphic: wc_gr002171 Electric shock hazard. Only qualified personnel should conduct this test. WARNING These procedures require two 14-gauge jumper wires and a fully- charged 12V battery. If you measured 0 (zero) volts at the main circuit breaker, the generator may have lost its residual magnetism.
  • Page 119 LTC Repair Electrical Troubleshooting 1000 200m – wc_gr002171 wc_tx000429gb.fm...

  • Page 120: Checking Generator Capacitors

    Electrical Troubleshooting Procedures LTC Repair 7.25 Checking Generator Capacitors See Graphic: wc_gr002170 Carry out this procedure with the engine shut down. The capacitors of the electrical system are mounted to the top of the generator underneath the protective cover (a). 7.25.1 With the unit off, remove the screws securing the protective cover and remove the cover.

  • Page 121: Alternative Capacitor Check

    LTC Repair Electrical Troubleshooting 7.26 Alternative Capacitor Check See Graphic: wc_gr001607 and wc_gr001783 An alternative capacitor check is to set the multimeter to the 10,000 Ohm scale when checking the capacitor. Observe the reading. If the reading starts out very low (5.0 Ohms) and continues to climb to an overload or open reading, the capacitor may be OK.

  • Page 122: Replacing Generator Capacitor(S)

    Electrical Troubleshooting Procedures LTC Repair 7.27 Replacing Generator Capacitor(s) See Graphic: wc_gr002460 Carry out this procedure with the engine shut down. Removal: 7.27.1 Note the connection points of the #60 (#50 on 50Hz machines) and #0 wires and remove the wires (a) from the capacitor (b). 7.27.2 Remove the jumper wire (c) connecting the two capacitors.
  • Page 123 LTC Repair Electrical Troubleshooting wc_tx000429gb.fm...

  • Page 124: Checking Stator Windings

    Electrical Troubleshooting Procedures LTC Repair 7.28 Checking Stator Windings See Graphic: wc_gr003097 The generator terminal block is located on top of the generator. When checking the stator windings at the terminal block, if there is any evidence of burned windings (such as melted wire insulation or odor), replace the generator.
  • Page 125 LTC Repair Electrical Troubleshooting T1 to T2: 0.36 +0.5/-0.0 T4 to T5: 0.36 +0.5/-0.0 #0 to #60: 1.7 +0.5/-0.0 T1 to ground: OL T5 to ground: OL 1000 200m #60 to ground: OL #60 to T1: OL #60 to T5: OL wc_gr003097 wc_tx000429gb.fm...

  • Page 126: Removing/Installing Caterpillar Engine With Generator

    Electrical Troubleshooting Procedures LTC Repair 7.29 Removing/Installing Caterpillar Engine with Generator See Graphic: wc_gr002446 Removal: 7.29.1 Shut down the engine and disconnect the battery. 7.29.2 Remove the top enclosure cover. See section Replacing Fuel Tank. 7.29.3 Remove the four screws (a) securing the capacitor cover (b) and remove the capacitor cover.
  • Page 127 LTC Repair Electrical Troubleshooting 250 kg (550 lbs.) wc_gr000843 wc_gr002446 wc_tx000429gb.fm...

  • Page 128: Removing/Installing Lombardini Engine With Generator

    Electrical Troubleshooting Procedures LTC Repair 7.30 Removing/Installing Lombardini Engine with Generator See Graphic: wc_gr002451 Removal: 7.30.1 Shut down the engine and disconnect the battery. 7.30.2 Remove the top enclosure cover. See section Replacing Fuel Tank. 7.30.3 Remove the four screws (a) securing the capacitor cover (b) and remove the capacitor cover.
  • Page 129 LTC Repair Electrical Troubleshooting 50Hz 250 kg (550 lbs.) wc_gr000843 60Hz wc_gr002451 wc_tx000429gb.fm...

  • Page 130: Separating Stator Assembly From Engine/Rotor Assembly

    Electrical Troubleshooting Procedures LTC Repair 7.31 Separating Stator Assembly from Engine/Rotor Assembly See Graphic: wc_gr001640 Note: The fit between the rotor bearing and the stator housing is tight. The tight fit prevents the bearing from spinning in the housing. 7.31.1 There are two methods to separate the stator assembly from the engine/rotor assembly.
  • Page 131 LTC Repair Electrical Troubleshooting See Graphic: wc_gr001784 Method 2 7.31.8 Remove the M8 bolts (a) securing the engine adapter flange to the engine. 7.31.9 Using two screwdrivers (b) or equivalent pry bars, carefully pry the stator assembly from the engine/rotor assembly. wc_tx000429gb.fm...

  • Page 132: Remounting Stator Assembly To Rotor/Engine Assembly

    Electrical Troubleshooting Procedures LTC Repair 7.32 Remounting Stator Assembly to Rotor/Engine Assembly See Graphic: wc_gr001638 and wc_gr001642 Note: The fit between the rotor bearing and the stator housing is tight. The tight fit prevents the bearing from spinning in the housing. 7.32.1 While supporting the stator assembly with an appropriate strap and hoist, slide the stator assembly over the rotor/engine assembly.

  • Page 133: Checking Rotor Diodes

    LTC Repair Electrical Troubleshooting 7.33 Checking Rotor Diodes See Graphic: wc_gr002461 There are two diodes on the rotor assembly. The engine/generator assembly must be removed and the stator must be separated from the rotor to check the function of the diodes. When checking, be sure to check both diodes.

  • Page 134: Checking Rotor Windings

    Electrical Troubleshooting Procedures LTC Repair 7.34 Checking Rotor Windings See Graphic: wc_gr002462 After checking the two rotor diodes, check the rotor windings. The engine/generator assembly must be removed and the stator must be separated from the rotor to check the rotor windings. 7.34.1 Unsolder the two rotor winding wires from the terminal end of each diode.

  • Page 135: Removing/Installing Rotor

    LTC Repair Electrical Troubleshooting 7.35 Removing/Installing Rotor See Graphic: wc_gr001641 Removal 7.35.1 Remove the M8 bolts (a) securing the rotor flex discs (b) to the engine flywheel (c) and remove the rotor assembly. Installation 7.35.2 Secure the rotor flex discs to the engine using M8 bolts. Torque the bolts to 15 ft.lbs.

  • Page 136: No Voltage At Receptacle-Flowchart 2A

    Electrical Troubleshooting Procedures LTC Repair 7.36 No Voltage at Receptacle—Flowchart 2A No Voltage at Receptacle Make sure the main circuit breaker Checking voltage to main circuit breaker and the receptacle's circuit breaker Check voltage to main circuit breaker. are in the ON position. 120V±10% Checking voltage at receptacle Flowchart 1C...

  • Page 137: Checking Voltage At Receptacle

    LTC Repair Electrical Troubleshooting 7.37 Checking Voltage at Receptacle See Graphic: wc_gr002452 Electric shock hazard. Only qualified personnel should conduct this test. WARNING Complete this test with the machine running and both the main circuit breaker and the receptacle circuit breaker in the “ON” position. 7.37.1 Using the AC voltage setting on the multimeter, test the receptacle for 120V±10% on 60Hz models;...

  • Page 138: Checking Receptacle's Circuit Breaker

    Electrical Troubleshooting Procedures LTC Repair 7.38 Checking Receptacle’s Circuit Breaker See Graphic: wc_gr003100 Electric shock hazard. Only qualified personnel should conduct this test. WARNING Complete this test with the machine running. 7.38.1 Using the AC voltage setting on the multimeter, measure the incoming voltage to the receptacle’s circuit breaker by measuring between the black-yellow wire (a) and the neutral wires (b) of the terminal strip.
  • Page 139 LTC Repair Electrical Troubleshooting 1000 200m wc_gr003100 wc_tx000429gb.fm...

  • Page 140: Troubleshooting The Power Winch

    Electrical Troubleshooting Procedures LTC Repair 7.39 Troubleshooting the Power Winch See Graphic: wc_gr003160 7.39.1 Lower the tower. 7.39.2 Lower the mast assembly into the cradle. 7.39.3 Turn off the engine. 7.39.4 Be sure the machine’s battery is fully charged (approximately 12V). 7.39.5 Remove the four screws (a) which secure the cover of the winch and remove the cover.
  • Page 141 LTC Repair Electrical Troubleshooting • If 12V is not measured, the wiring from the starter solenoid or the wiring from the battery to the starter solenoid has failed. Check the wiring and repair or replace it as necessary. 1000 200m 1000 200m wc_gr003160...
  • Page 142 Electrical Troubleshooting Procedures LTC Repair Notes wc_tx000429gb.fm...

  • Page 143: Disassembly/Assembly Procedures

    LTC Repair Disassembly/Assembly Procedures Disassembly/Assembly Procedures Tools Because all possible problems encountered while repairing the equipment cannot be anticipated, it is up to the mechanic to use common sense and good judgement in tool selection. The use of any special tools is recommended only for those operations where the use of conventional tools proves inadequate.

  • Page 144: Light Assembly

    Disassembly/Assembly Procedures LTC Repair Light Assembly See Graphic: wc_gr002430 Removal: 8.5.1 Unplug the light at the quick disconnect (a). 8.5.2 Remove the T-handle (b) and the cone washer (c). Also remove the nut (d) and the washer (e) securing opposite end. 8.5.3 Pull the light assembly (f) from the bracket (g).
  • Page 145 LTC Repair Disassembly/Assembly Procedures wc_gr002430 wc_tx000428gb.fm...

  • Page 146: Tower Assembly Exploded View

    Disassembly/Assembly Procedures LTC Repair Tower Assembly Exploded View wc_tx000428gb.fm...

  • Page 147: Tower Assembly List Of Parts

    LTC Repair Disassembly/Assembly Procedures Tower Assembly List of Parts Ref. Description Ref. Description Main mast (4-inch tube) Mid mast (3-inch tube) Winch Cross member Main mast cable Upper mast (2-inch tube) Main mast pulley Junction box Main mast guide Cross member wiring cable clamps Upper mast cable Mid-mast wiring cable clamps Mid-mast guide...
  • Page 148 Disassembly/Assembly Procedures LTC Repair 8.8.3 Using the tongue-mounted winch, raise the tower so that the masts are approximately two inches (5 cm) above the cradle locking pin (aa). 8.8.4 On machines using rivets*, drill out the rivets (bb) securing the five guides (g) to the mid mast.
  • Page 149 LTC Repair Disassembly/Assembly Procedures wc_gr002432 When installing the junction box, be sure to include the gasket (a) and use a silicon-based sealant on all hardware and plugs (b). wc_gr003161 wc_tx000428gb.fm...

  • Page 150: Mid Mast

    Disassembly/Assembly Procedures LTC Repair Mid Mast See Graphic: wc_gr002167 and wc_gr002433 Disassembly: Turn the lights off, turn the unit off, and lower the mast assembly into the cradle before this performing procedure. Place the Light Tower in a position with enough room so that the masts may be extended fully while in the down position.
  • Page 151 LTC Repair Disassembly/Assembly Procedures Reassembly: Replacement cables must be of the exact length of the original equipment. Using shorter cables may cause severe personal injury. WARNING 8.9.14 Attach the cable to the mid mast. 8.9.15 Hold the cable snug to upper side of the mid mast and insert it into the main mast (a) 3/4 of the way, approximately 7 feet (2.3 m).

  • Page 152: Main Mast

    Disassembly/Assembly Procedures LTC Repair 8.10 Main Mast See Graphic: wc_gr02434 Disassembly: Turn the lights off, turn the unit off, and lower the mast assembly into the cradle before performing this procedure. Place the Light Tower in a position with enough room so that the masts may be extended fully while in the down position.
  • Page 153 LTC Repair Disassembly/Assembly Procedures wc_gr002434 wc_tx000428gb.fm...
  • Page 154 Disassembly/Assembly Procedures LTC Repair See Graphic: wc_gr002435 Reassembly: 8.10.10 Grease the adjusting point circle (a) of the main cradle and the bottom pivot point (b) of the main mast. 8.10.11 Using an appropriate crane or hoist, lift the main mast onto the top of the generator enclosure.
  • Page 155 LTC Repair Disassembly/Assembly Procedures wc_gr002435 wc_tx000428gb.fm...

  • Page 156: Replacing Cable And Winch On Power Winch Models

    Disassembly/Assembly Procedures LTC Repair 8.11 Replacing Cable and Winch on Power Winch Models See Graphic: wc_gr003159 Removal: 8.11.1 Lower the tower. 8.11.2 Lower the mast assembly into the cradle. 8.11.3 Turn off the engine. 8.11.4 Remove the four screws (a) which secure the cover of the winch and remove the cover.
  • Page 157 LTC Repair Disassembly/Assembly Procedures wc_gr003159 wc_tx000428gb.fm...

  • Page 158: Replacing Fuel Tank

    Disassembly/Assembly Procedures LTC Repair 8.12 Replacing Fuel Tank See Graphic: wc_gr002445 Removal: 8.12.1 Shut down the engine and disconnect the battery. 8.12.2 Position the main mast in the vertical position. Note: It is not necessary to raise the tower. 8.12.3 Remove the screws (a) securing the mast cradle (b) and remove the mast cradle.
  • Page 159 LTC Repair Disassembly/Assembly Procedures wc_gr002445 wc_tx000428gb.fm...

  • Page 160: Replacing Hour Meter

    Disassembly/Assembly Procedures LTC Repair 8.13 Replacing Hour Meter See Graphic: wc_gr002444 Disassembly: 8.13.1 Shut down the engine and disconnect the battery. 8.13.2 Remove the six screws securing the control panel cover to the control panel. 8.13.3 Make note of the wire connections on the hour meter and remove the wires (a) from the hour meter.
  • Page 161 Threadlockers and Sealants Threadlockers and Sealants Threadlocking adhesives and sealants are specified throughout this manual by a notation of “S” plus a number (S#) and should be used where indicated. Threadlocking compounds normally break down at temperatures above 175°C (350°F). If a screw or bolt is hard to remove, heat it using a small propane torch to break down the sealant.
  • Page 162 Threadlockers and Sealants Threadlockers and Sealants (continued) Threadlocking adhesives and sealants are specified throughout this manual by a notation of “S” plus a number (S#) and should be used where indicated. Threadlocking compounds normally break down at temperatures above 175°C (350°F). If a screw or bolt is hard to remove, heat it using a small propane torch to break down the sealant.
  • Page 163 Torque Values Torque Values Metric Fasteners (DIN) TORQUE VALUES (Based on Bolt Size and Hardness) WRENCH SIZE 10.9 12.9 Size ft.lb. ft.lb. ft.lb. Metric Inch Metric Inch 7/32 – 9/32 – 5/16 – – – – 11/16 – – – 15/16 –...
  • Page 164 Torque Values Torque Values (continued) Inch Fasteners (SAE) Size ft.lb. ft.lb. ft.lb. Metric Inch Metric Inch No.4 – 3/32 No.6 5/16 – 7/64 No.8 11/32 – 9/64 No.10 – – 5/32 – 7/16 – 3/32 5/16 – – 9/16 – 5/16 7/16 –...
  • Page 166 Wacker Construction Equipment AG · Preußenstraße 41 · D-80809 München · Tel.: +49-(0)89-3 54 02 - 0 · Fax: +49 - (0)89-3 54 02-3 90 Wacker Corporation · P.O. Box 9007 · Menomonee Falls, WI 53052-9007 · Tel. : (262) 255-0500 · Fax: (262) 255-0550 · Tel. : (800) 770-0957 Wacker Asia Pacific Operations ·...

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