Page 1 Operator’s Manual Light Tower LTV4K, LTV6K LTV6L, LTV8K Type LTV4K, LTV6K, LTV6L, LTV8K Document 5100030216 Date 0319 Revision Language 5 1 0 0 0 3 0 2 1 6...
Page 2 Copyright notice © Copyright 2019 by Wacker Neuson Production Americas LLC All rights, including copying and distribution rights, are reserved. This publication may be photocopied by the original purchaser of the machine. Any other type of reproduction is prohibited without express written permission from Wacker Neuson Production Americas LLC.
Page 3: California Proposition 65 Warning
CALIFORNIA Proposition 65 Warning CALIFORNIA Proposition 65 Warning WARNING The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm. WARNING Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm.
Page 4 CALIFORNIA Proposition 65 Warning Proposition 65 Warning Notes wc_tx004643en.fm...
Page 5: Foreword
Americas LLC will be referred to as Wacker Neuson. ■ Keep a copy of the Operator’s Manual with the machine at all times. ■ For spare parts information, please see your Wacker Neuson Dealer, or visit the Wacker Neuson website at http://www.wackerneuson.com/.
Page 6 ■ 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.
Page 7: Table Of Contents
Table of Contents CALIFORNIA Proposition 65 Warning Foreword Safety Information Signal Words Used in this Manual ..............13 Machine Description and Intended Use ............13 Operating Safety ...................15 Metal Halide Lamp Safety ................17 Service Safety ....................17 Operator Safety while Using Internal Combustion Engines ......19 Safety Guidelines for Lifting the Machine .............20 Safety Guidelines for Towing the Machine ...........20 Reporting Safety Defects ................21...
Page 8 Table of Contents 4.10 Raising the Tower—Power Winch System ...........49 4.11 Lowering the Tower—Power Winch System ..........51 Operation Generator Derating ..................54 Control Panels and Receptacles—KUBOTA ..........54 Control Panels and Receptacles—KOHLER ..........55 Control Panel and Receptacles—DeepSea ..........56 Machine Monitoring—DeepSea ..............57 Alarms and Shut-Down Conditions—DeepSea ..........59 Resetting the Maintenance Timers—DeepSea ..........60 Before Starting ....................61 Starting, Operating, Stopping the Machine—KUBOTA ........62...
Page 9 13 Emissions Control Systems Information and Warranty: KUBOTA 102 13.1 Emission Control System Background Information ........102 13.2 Limited Defect Warranty for Wacker Neuson Emission Control Systems ..................... 103 14 Emissions Control Systems Information and Warranty: KOHLER 106 14.1 Emission Control System Background Information ........106 14.2...
Page 10 Table of Contents 15.7 LTV—Metal Halide Lights Module ............. 112 15.8 Components ....................112 15.9 LTV—120V / 30A Receptacle Module ............113 15.10 Components ....................113 15.11 LTV—8 kW GFCI Receptacle Module ............114 15.12 Components ....................114 15.13 LTV—Trailer ....................115 15.14 Components ....................
Page 11: Safety Information
Note: A Note contains additional information important to a procedure. Machine Description and Intended Use Machine This machine is a mobile, trailer-mounted light tower. The Wacker Neuson Light description Tower consists of a trailer with a cabinet containing a diesel engine, a fuel tank, a control panel, and an electric alternator.
Page 12 Safety Information Intended use 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 machine specifications for the output voltage and frequency, and for the maximum output power limit of this machine.
Page 13: Operating Safety
To ensure safe operation of the machine: ■ Do not operate the machine if any safety devices or guards are missing or inoperative. ■ Do not modify or defeat the safety devices. ■ Only use accessories or attachments that are approved by Wacker Neuson. wc_si000704en.fm...
Page 14 Safety Information Safe When operating this machine: operating ■ Remain aware of the machine’s moving parts. Keep hands, feet, and loose practices clothing away from the machine’s moving parts. ■ Do not operate a machine in need of repair. ■ Do not consume the operating fluids used in this machine. Depending on your machine model, these operating fluids may include water, wetting agents, fuel (gasoline, diesel, kerosene, propane, or natural gas), oil, coolant, hydraulic oil, heat transfer fluid (propylene glycol with additives), battery acid, or grease.
Page 15: Metal Halide Lamp Safety
■ Only trained personnel shall troubleshoot or repair problems occurring with the machine. ■ Contact Wacker Neuson for additional training if necessary. When servicing or maintaining this machine: ■ Do not allow untrained or improperly trained people to service or maintain the machine.
Page 16 Machine When servicing or maintaining the machine: modifications ■ Use only accessories/attachments that are approved by Wacker Neuson. ■ Do not defeat safety devices. ■ Do not modify the machine without the express written approval of Wacker Neuson.
Page 17: Operator Safety While Using Internal Combustion Engines
Safety Information 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. ► Read and follow the warning instructions in the engine owner’s manual and the safety guidelines below.
Page 18: Safety Guidelines For Lifting The Machine
Safety Information Safety Guidelines for Lifting the Machine When lifting the machine: ■ Make sure slings, chains, hooks, ramps, jacks, forklifts, cranes, hoists, and any other type of lifting device used is attached securely and has enough weight- bearing capacity to lift or hold the machine safely. See the Technical Data chapter for machine weight.
Page 19: Reporting Safety Defects
If you believe your trailer has a defect which could cause a crash or could cause injury or death, you should immediately inform the National Highway Traffic Safety Administration (NHTSA) in addition to notifying Wacker Neuson. If NHTSA receives similar complaints, it may open an investigation; and if it finds that a safety defect exists in a group of trailers, it may order a recall and remedy campaign.
Page 20: Labels
Labels Labels Label Locations wc_gr013742 wc_si001039en.fm...
Page 21 Labels wc_gr013743 wc_si001039en.fm...
Page 22: Label Meanings
Labels Label Meanings California Proposition 65 Warning WARNING Cancer and Reproductive Harm - Cancer and Reproductive Harm www.P65Warnings.ca.gov. www.P65Warnings.ca.gov ADVERTENCIA Cáncer y daño reproductivo www.P65Warnings.ca.gov AVERTISSEMENT Cancer ou malformations congénitales www.P65Warnings.ca.gov 5100045462 DANGER PELIGRO DANGER STOP START 15 SEC. MAX. ARRANQUE 15 SEG.
Page 23 Labels See Operator’s Manual for light fixture information and troubleshooting. BEFORE STARTING THE ENGINE: 1. Check levels of: ■ Engine oil ■ Fuel ■ Coolant 2. Move the circuit breakers to the OFF position. TO START THE ENGINE: 1. On the engine control panel, turn the key switch to the PREHEAT position; the indicator light will illuminate during preheating.
Page 24 Labels 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 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.
Page 25 Labels Manual Winch TO RAISE TOWER 1. Lift pins and extend outriggers 2. Raise tower with winch. 3. Loosen mast rotation knob to aim tower. Tighten knob when tower is aimed. TO LOWER TOWER 1. Turn off breakers and engine. 2.
Page 26 Labels WARNING ADVERTENCIA AVERTISSEMENT WARNING 85 lb-ft ADVERTENCIA 115 Nm AVERTISSEMENT 5100031166 WARNING ADVERTENCIA AVERTISSEMENT WARNING 85 lb-ft ADVERTENCIA 115 Nm AVERTISSEMENT 5100031252 WARNING (On trailer, if equipped) Lights can prevent trailer from being hit by other vehicles. You must: 1.
Page 27 Labels WARNING ADVERTENCIA 839 kg (1850 LBS) AVERTISSEMENT WARNING ADVERTENCIA AVERTISSEMENT 5100031165 WARNING ADVERTENCIA 839 kg AVERTISSEMENT (1850 LBS) WARNING ADVERTENCIA AVERTISSEMENT 5100031251 WARNING (On trailer, if equipped) Uncoupling will cause trailer to come loose from tow vehicle. You must: 1.
Page 28 Labels This machine may be covered by one or more patents. U.S.PAT.Nos.: 6012285, 6471476, U.S.PAT.Nos.: 6012285, 6471476, D416858, D454357 OTHER U.S. AND D416858, D454357 OTHER U.S. AND FOREIGN PATENTS PENDING FOREIGN PATENTS PENDING UTILITY 159116 UTILITY 159116 WARNING WARNING WARNING Pressurized contents.
Page 29 Labels — (if equipped) Notification of National Association of Trailer Manufacturers (NATM) compliance — MANUFACTURED BY/FABRIQUÉ PAR: COLD INFL. PRESS./PRESS. DATE: GVWR/PNBV: DE GONF À FROID GAWR/PNBE (ALL AXLES) TIRE/PNEU RIM/JANTE KPA (PSI/LPC) SGL/DUAL THIS VEHICLE CONFORMS TO ALL APPLICABLE STANDARDS PRESCRIBED UNDER THE CANADIAN MOTOR VEHICLE SAETY REGULATIONS IN EFFECT ON THE DATE OF MANUFACTURE.
Page 30: Lifting And Transporting
Lifting and Transporting Lifting and Transporting Lifting the Machine Requirements ■ Properly rated lifting equipment (crane or hoist). See Technical Data. ■ Machine stopped. ■ All doors and access covers closed and secured. ■ Tower is completely lowered. ■ The winch (e) and lights are facing foward. ■...
Page 31: Preparing The Machine For Transport On A Truck Or Trailer
Lifting and Transporting Preparing the Machine for Transport on a Truck or Trailer Requirements ■ Machine stopped. ■ Flatbed truck or trailer capable of supporting the machine’s weight. ■ Chains, hooks, or straps capable of supporting the machine’s weight. WARNING Crushing hazard.
Page 32: Before Towing Checklist
Lifting and Transporting Before Towing Checklist For trailer machines only. Before towing the machine, check the licensing requirements for trailers in your area. Check the following items: Machine  All doors and access panels of the machine are closed.  All electrical connections are disconnected from the machine. ...
Page 33: Towing The Machine
Loss of wheels can cause an accident, severe injury or death. ► Tighten the lug nuts to the proper torque before towing the machine. NOTICE: Wacker Neuson recommends a maximum towing speed of 88 km/h (55 mph) on highways and paved roads and 16 km/h (10 mph) on rugged roads and terrain.
Page 34: Trailer
Lifting and Transporting Trailer Background The machine’s trailer is equipped with safety chains (a), tongue jack (b), lights, and a coupler (pintle or ball-type) (c). wc_gr011629 Licensing In most states, large trailers must be registered and licensed by the State requirements Department of Transportation.
Page 35: Flip-Up Tongue
Lifting and Transporting Flip-up Tongue Background The flip-up tongue allows the machine to be stored in a smaller space than a machine with a conventional tongue. Procedure Perform the procedure below to raise the flip-up tongue to the storage position. 1.
Page 36: Machine Setup
1. Make sure all loose packaging materials have been removed from the machine. 2. Check the machine and its components for damage. If there is visible damage, do not operate the machine. Contact your Wacker Neuson dealer immediately for assistance.
Page 37: Positioning The Machine
► Do not operate the machine near flammable vapors, fuels, or combustibles. CO alarms Because this machine produces carbon monoxide (CO), Wacker Neuson recommends that CO alarms be installed in all structures in close proximity to the machine. CO alarms provide an extra measure of protection against this poison that you cannot see or smell.
Page 38: Ground Connection
Machine Setup Ground Connection Location A ground connection (a) is located on the trailer frame. wc_gr013762 Function This ground connection is used for electrically grounding the Light Tower when necessary to comply with the National Electrical Code and other federal, state, and local regulations.
Page 39: Leveling The Trailer-Vertical Mast Light Towers
Machine Setup Leveling the Trailer—Vertical Mast Light Towers WARNING Tipping and falling hazard. Failure to level the trailer or extend the outriggers will reduce the stability of the unit. ► Level the trailer and extend the outriggers before raising the tower. The outriggers must remain extended while the tower is up.
Page 40: Refueling The Machine
Machine Setup Refueling the Machine Requirements ■ Machine shut down ■ Engine cool ■ Machine/fuel tank level with the ground ■ Fresh, clean fuel supply Procedure Perform the procedure below to refuel the machine. WARNING Fire hazard. Fuel and its vapors are extremely flammable. Burning fuel can cause severe burns.
Page 41: Aiming The Lights-Vertical Mast Light Towers
Machine Setup Aiming the Lights—Vertical Mast Light Towers Overview ■ Each individual light fixture can be independently aimed up, down, left, or right. There are four total light fixtures on each machine. ■ This procedure is not for rotating the lights as a single unit while the tower is raised.
Page 42 Machine Setup Continued from the previous page. Aiming Left or Right 1. Grasp the light fixture and aim it to the left or right. If necessary, loosen the bracket nut (c) to allow movement of the fixture. NOTICE: Do not loosen the nuts on the light fixture (b). Damage to the light fixture may occur.
Page 43: Manually Rotating The Light Bar
Machine Setup Manually Rotating the Light Bar Overview The operator can rotate the light bar 360° while the tower is lowered. Procedure Perform the procedure below to rotate the light bar. 1. Loosen out the locking knob (a). wc_gr013767 2. Rotate the light bar to the desired position. 3.
Page 44: Raising The Tower-Manual Winch System
Machine Setup Raising the Tower—Manual Winch System Background The Light Tower includes a telescoping winch for raising the tower. The 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. Requirements ■...
Page 45 Machine Setup Continued from the previous page. Reference graphic wc_gr013770 Procedure Perform the procedure below to raise the tower. NOTICES ■ Do not attempt to raise the tower if the winch is damaged or not operating properly, or if the winch cables are worn or damaged. ■...
Page 46: Lowering The Tower-Manual Winch System
Machine Setup Lowering the Tower—Manual Winch System Requirements ■ Lights are turned off ■ Engine is stopped ■ Outriggers are extended and locked in place WARNING Tipping/falling hazards. Certain actions may cause the tower to fall or the machine to tip over. ►...
Page 47: Raising The Tower-Power Winch System
Machine Setup Continued from the previous page. 2. If the light bar has been rotated, loosen the locking knob (b) and rotate the tower so the light bar and winch are facing toward the trailer tongue. See Manually Rotating the Light Bar. 3.
Page 48 Machine Setup Continued from the previous page. Procedure Perform the procedure below to raise the tower. NOTICES ■ Do not attempt to raise the tower if the winch is damaged or not operating properly, or if the winch cables are worn or damaged. ■...
Page 49: Lowering The Tower-Power Winch System
Machine Setup 4.11 Lowering the Tower—Power Winch System Requirements ■ Lights are turned off ■ Engine is stopped ■ Outriggers are extended and locked in place WARNING Tipping/falling hazards. Certain actions may cause the tower to fall or the machine to tip over.
Page 50 Machine Setup Continued from the previous page. 2. If the light bar has been rotated, loosen the locking knob (a) and rotate the tower so the light bar and winch are facing toward the trailer tongue. See Manually Rotating the Light Bar. 3.
Page 51 Machine Setup This page is intentionally left blank. wc_tx004430en.fm...
Page 52: Operation
Operation Operation Generator Derating Description All generator sets are subject to derating (reduced power output) depending on the altitude and ambient temperature. Derating should not affect the operation of the floodlights, although it will reduce the available reserve power to the receptacle. Derating Power ratings are typically reduced by the following percentages: percentages...
Page 53: Control Panels And Receptacles-Kohler
Operation Control Panels and Receptacles—KOHLER wc_gr013750 Ref. Description Ref. Description Low fuel indicator (not used) Tower winch rotary switch (optional) Safety shut-down indicator GFCI circuit breakers (optional) Low oil pressure shut-down indicator Air filter restriction indicator High coolant temperature shut-down indicator Auxiliary lights (not used) Alternator indicator Key switch...
Page 54: Control Panel And Receptacles-Deepsea
Operation Control Panel and Receptacles—DeepSea wc_gr013748 Ref. Description Ref. Description Menu navigation buttons (up/down) Start button Controller display Hour meter Main circuit breaker Control panel light 30A receptacle breaker GFCI circuit breaker (standard for 8K) Lights circuit breaker 20A GFCI receptacle Tower winch rotary switch (optional) 30A receptacle Stop/reset button...
Page 55: Machine Monitoring-Deepsea
Operation Machine Monitoring—DeepSea Description Engine and generator information is displayed on the the LCD panel The user can scroll through the screens to monitor machine parameters. Volts “V”- Displays the AC output voltage being produced by the generator. wc_gr012363 Volts “V”- Displays the AC output voltage being produced by the generator.
Page 56 Operation Displays the available voltage of the battery. wc_gr012357 Displays the maintenance interval as well as the time remaining until maintenance is required. Each parameter is displayed on a separate screen: ■ Oil change ■ Air filter ■ Fuel filter wc_gr012360 wc_tx004431en.fm...
Page 57: Alarms And Shut-Down Conditions-Deepsea
Operation Alarms and Shut-Down Conditions—DeepSea Background The Light Tower controller monitors variables of engine and machine function. The Light Tower controller has two types of alarms: warning alarms and shut-down alarms. Warning Warnings are non-critical alarm alarms conditions that do not affect the operation of the generator system.
Page 58: Resetting The Maintenance Timers-Deepsea
The maintenance timers are preset as follows: ■ Oil change interval: 1000 hours (LTV4K / 6L / 6K 60 Hz / 8K) ■ Oil change interval: 750 hours (LTV6K 50 Hz) ■...
Page 59: Before Starting
Operation Before Starting Before putting the Light Tower into service, review each item on the following checklist. Light Towers often run unattended for long periods of time. Therefore, it is important to make sure that the machine is set up properly to avoid possible operating problems.
Page 60: Starting, Operating, Stopping The Machine-Kubota
Operation Starting, Operating, Stopping the Machine—KUBOTA Requirements ■ Before starting checks completed. See Before Starting. ■ Electrical cables in good condition with no cuts or abrasions in the insulation. ■ Circuit breakers (a, b, c, and d, g for 8K) are in the OFF position. ■...
Page 61 Operation Continued from the previous page. Operating the Perform the procedure below to operate the lights. lights 1. Turn on the main circuit breaker (a). wc_gr013751 2. Turn on individual circuit breakers (c) one at a time. Notes ■ Metal halide floodlights require a warm-up time of 5–15 minutes before they reach full brightness.
Page 62: Starting, Operating, And Stopping The Machine-Kohler
Operation 5.10 Starting, Operating, and Stopping the Machine—KOHLER Requirements Check the following items before starting the machine. ■ Before starting checks completed. See Before Starting. ■ Electrical cables are in good condition with no cuts or abrasions in the insulation. ■...
Page 63 Operation Continued from the previous page. Operating the Perform the procedure below to operate the lights. lights 1. Turn on the main circuit breaker (a). wc_gr013753 2. Turn on individual circuit breakers (c) one at a time. Notes ■ Metal halide floodlights require a warm-up time of 5–15 minutes before they reach full brightness.
Page 64: Starting, Operating, Stopping The Machine-Deepsea
Operation 5.11 Starting, Operating, Stopping the Machine—DeepSea Prerequisites ■ Before starting checks completed. See Before Starting. ■ Electrical cables in good condition with no cuts or abrasions in the insulation. ■ Circuit breakers (a, b, c and d, h for 8K) are in the OFF position. ■...
Page 65 Operation Continued from the previous page. Operating the Perform the procedure below to operate the lights. lights 1. Turn on the main circuit breaker (a). wc_gr013779 2. Turn on individual circuit breakers (c) one at a time. Notes ■ Metal halide floodlights require a warm-up time of 5–15 minutes before they reach full brightness.
Page 66: Auto Mode (Remote Run)
Operation 5.12 Auto Mode (Remote Run) The engine controller is capable of automatically starting the engine. A scheduled run will begin only if the controller is in Auto Mode with no shut-down alarm present. If the controller is in Stop/Reset Mode or Manual/Start Mode when a scheduled run begins, the engine will not start.
Page 67 Operation 3. Press “Auto” to enter the selected editor. Note: If a PIN code has been set for the Configuration Editor, the PIN request appears. 4. Press the up and down arrows to adjust first digit to the correct value. 5.
Page 68 Operation Configuration Parameters – Scheduler Scheduler (3) Duration 0:00:00 Scheduler (4) Start Time 0:00:00 Scheduler (4) Start Day 0 (1=Monday) Scheduler (4) Start Week 1,2,3,4 Scheduler (4) Duration 0:00:00 Scheduler (5) Start Time 0:00:00 Scheduler (5) Start Day 0 (1=Monday) Scheduler (5) Start Week 1,2,3,4 Scheduler (5) Duration...
Page 69: Engine-Jump-Starting
Operation 5.13 Engine—Jump-Starting Background Jump-starting may occasionally be required if a battery is discharged. If jump- starting is necessary, the following procedure is recommended to prevent starter damage, battery damage, and personal injuries. WARNING Personal injury hazard. Jump-starting a battery incorrectly can cause the battery to explode, resulting in severe personal injury or death.
Page 70 Operation Continued from the previous page. Procedure Perform the procedure below to jump-start the battery. 1. In very cold weather, check the condition of the electrolytes. If it seems slushy or frozen, do not try jump-starting until it thaws. NOTICE: If a battery sits in extreme cold, the electrolytes inside the battery can freeze.
Page 71: Emergency Shutdown Procedure
Operation 5.14 Emergency Shutdown Procedure General Perform the procedure below if a breakdown or accident occurs while the machine procedures is operating: 1. Stop the engine. 2. Disconnect all loads from the machine. 3. Lower the tower. 4. Allow the machine to cool before opening the cabinet. 5.
Page 72: Using The Convenience Receptacles-50 Hz And 60 Hz
Operation 5.15 Using the Convenience Receptacles—50 Hz and 60 Hz Description This machine is equipped with one or more convenience receptacles (a) for running accessories and tools from the generator. Each receptacle is protected by its own circuit breaker (b). Power to the receptacle(s) is available any time the engine is running and the circuit breaker is set to the ON position.
Page 73 Operation Continued from the previous page. Testing a Perform the manual test procedure below before each use to test a GFCI GFCI receptacle. receptacle 1. Turn the power on at the control panel. ■ A green LED power on indication light (a) will illuminate on the GFCI receptacle.
Page 74: 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, and serial number is attached to each unit. Please have this information available when contacting Wacker Neuson Corporation.
Page 75: Battery Blanket
Factory-Installed Options 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 or frozen battery. Plug the cord into a 120V power supply. wc_gr007422 Oil Pan Heater Cold, thick engine oil does not flow freely and may cause engine starting...
Page 76: Fuel And Water Separator
Factory-Installed Options Fuel and Water Separator The fuel and water separator (a) removes water from the fuel supply. As fuel flows through the separator element, removed water collects in the bowl. wc_gr013983 Positive Air Shutoff Description Diesel engines may occasionally continue to run even after the machine has been turned off.
Page 77: Containment System Float Switch
Factory-Installed Options Containment System Float Switch Overview Machines equipped with a containment system protect the environment by collecting fluid leaks (fuel, coolant, or oil) which might otherwise contaminate the soil. The float switch (a) is normally closed, but when the collected fluid level in the containment tub rises high enough, the float switch opens.
Page 78: General Maintenance
General Maintenance General Maintenance WARNING A poorly maintained machine can malfunction, causing injuries or permanent damage to the machine. ► Keep the machine in safe operating condition by performing periodic maintenance and making repairs as needed. Preparing for Maintenance Do not perform even routine service (oil/filter changes, cleaning, etc.) unless all electrical components are shut down.
Page 79: Periodic Maintenance Schedule
General Maintenance 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. Every Every Every Daily 250 hours 500 hours 1000 hours...
Page 80: Inspecting The Machine
General Maintenance Inspecting the Machine When Daily Overview Inspect the machine before each use. A thorough inspection will help to identify mechanical faults or potentially unsafe operating conditions. Correct these problems before operating the machine. External Perform an external inspection of the machine. Check for: inspection ...
Page 81: Maintaining The Battery
General Maintenance Maintaining the Battery WARNING Explosion hazard. Batteries can emit explosive hydrogen gas. ► Keep all sparks and flames away from the battery. ► Do not short-circuit battery posts. Safety Observe the following safety precautions to prevent serious damage to the precautions electrical system.
Page 82: Removing And Replacing Lamps
General Maintenance Removing and Replacing Lamps Requirements ■ Engine shut down ■ Light circuit breakers turned OFF ■ Lamps and fixtures cool to the touch ■ Eye and hand protection WARNING Burn hazard. Lamps become extremely hot in use. ► Allow lamps and fixtures to cool 10–15 minutes before handling. WARNING Personal injury hazard.
Page 83 General Maintenance Continued from the previous page. Perform the procedures below to remove and install the lamp. Removing the 1. Remove the screws (a) securing the flange rings (b) and remove the flange lamp rings. wc_gr005881 2. Remove the lens (c) with the gasket (d) attached. 3.
Page 84: Checking And Draining The Containment System (If Equipped)
General Maintenance Checking and Draining the Containment System (if equipped) When Check and drain the containment system every 50 hours. Overview Certain machines are equipped with a containment system. The containment system protects the environment by collecting fluid leaks (fuel, coolant, or oil) which might otherwise contaminate the soil.
Page 85: Long-Term Storage
General Maintenance Long-Term Storage Extended storage of equipment requires preventive maintenance. Performing these steps helps to preserve machine components and ensures the machine will be ready for future use. While not all of these steps necessarily apply to this machine, the basic procedures remain the same. When Prepare your machine for extended storage if it will not be operated for 30 days or more.
Page 86: Machine Disposal And Decommissioning
General Maintenance 7.10 Machine Disposal and Decommissioning Introduction This machine must be properly decommissioned at the end of its service life. Responsible disposal of recyclable components, such as plastic and metal, ensures that these materials can be reused—conserving landfill space and valuable natural resources.
Page 87: Engine Maintenance: Kubota D1005 / D1105
Engine Maintenance: KUBOTA D1005 / D1105 Engine Maintenance: KUBOTA D1005 / D1105 The viscosity of the engine oil is an important factor when determining the correct engine oil to use in your machine. Use an engine oil of appropriate viscosity based on the expected outside air temperature.
Page 88 Engine Maintenance: KUBOTA D1005 / D1105 For additional information, see the engine owner’s manual. The table below lists service intervals for basic machine maintenance. Kubota 1005/1105 Service Intervals Service Item Every X Hours (Frequency) Every 1000 Annually 2 years (50 Hz) (60 Hz) Check fuel pipes and clamp bands *Initial oil and filter change...
Page 89 Engine Maintenance: KUBOTA Z482 Engine Maintenance: KUBOTA Z482 The viscosity of the engine oil is an important factor when determining the correct engine oil to use in your machine. Use an engine oil of appropriate viscosity based on the expected outside air temperature. See the following table. WARNING Most used liquids from this machine such as oil, gasoline, grease, etc., contain small amounts of materials that can cause cancer and other health problems if...
Page 90: Engine Maintenance: Kubota Z482
Engine Maintenance: KUBOTA Z482 The table below lists service intervals for basic machine maintenance. Kubota Z482 Service Intervals Service Item Every X Hours (Frequency) Yearly 1000 1500 3000 years Initial oil and filter change Check fuel pipes and clamp bands Clean the fuel filter Clean air cleaner element Check fan belt tension...
Page 91: Engine Maintenance: Kohler 1003
Engine Maintenance: KOHLER 1003 10 Engine Maintenance: KOHLER 1003 The viscosity of the engine oil is an important factor when determining the correct engine oil to use in your machine. Use an engine oil of appropriate viscosity based on the expected outside air temperature. See the following table. WARNING Most used liquids from this machine such as oil, gasoline, grease, etc., contain small amounts of materials that can cause cancer and other health problems if...
Page 92 Engine Maintenance: KOHLER 1003 For additional information, see the engine owner’s manual. The table below lists service intervals for basic machine maintenance. Kohler 1003 Service Intervals Service Item Hours (Frequency) Annually 4000 Every (every 6 1000 (4 years) 2 years checks) *Initial oil and filter change Clean air cleaner element...
Page 93: Troubleshooting
Fuel circuit failure Check fuel lines. No generator output Main circuit breaker open Close main circuit breaker. Voltage regulator malfunction Call Wacker Neuson for service. Low oil pressure Low oil level Fill engine sump with oil. Clogged oil filter Replace oil filter.
Page 94 Troubleshooting Problem Cause 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 Repair or replace the plug connection.
Page 95: Technical Data
Technical Data 12 Technical Data 12.1 Engine—KUBOTA Engine Power Rating Net power rating per ISO 3046 IFN. Actual power output may vary due to conditions of specific use. Machine LTV4K LTV6K LTV8K Make Kubota Model Z482 D1005 D1105 2-cylinder 3-cylinder...
Page 96: Engine-Kohler
Technical Data 12.2 Engine—KOHLER Engine Power Rating Net power rating per ISO 3046 IFN. Actual power output may vary due to conditions of specific use. Machine LTV6L Make Kohler Model LDW1003 Type 3-cylinder, 4-cycle, liquid-cooled diesel Max. power rating @ rated speed kW (hp) 8.0 (10.7) @ 1800 rpm Operating speed (no-load)
Page 97: Generator
Technical Data 12.3 Generator Machine LTV4 LTV6 LTV8 Frequency Continuous output volts, 6L: 120, 1Ø Voltage 120/240, 1Ø 230, 1Ø 120/240, 1Ø phase 6K: 120/240, 1Ø 6L: 50 Amps 24.5/12.3 26.1 66/33 6K: 50/25 Excitation type Capacitor / Brushless Power factor Voltage regulation - No load to full load Voltage regulation -...
Page 98: Machine
Technical Data 12.4 Machine Machine LTV4K LTV6K LTV6L LTV8K Frequency Metal Metal Metal Metal Lamp type halide halide halide halide Lamp wattage 1100 1100 1100 1100 Dimensions 2.56 X 1.46 X 2.51 (L x W x H) (in.) (101 X 58 X 99)
Page 99: Radiation Compliance
These lamps comply with FDA regulation performance standards 21 CFR 1040-30. 12.6 Dimensions—LTV4K, LTV6K, LTV8K, LTV6L 251 cm (99 in) 147 cm...
Page 100: Emissions Control Systems Information And Warranty: Kubota
Tampering and Altering Tampering with or altering the emission control system may increase emissions beyond the legal limit. If evidence of tampering is found, Wacker Neuson may deny a warranty claim. Among those acts that constitute tampering are: ■ Removing or altering of any part of the air intake, fuel, or exhaust systems.
Page 101: Limited Defect Warranty For Wacker Neuson Emission Control Systems
What is covered Wacker Neuson recommends the use of genuine Wacker Neuson parts, or the equivalent, whenever maintenance is performed. The use of replacement parts not equivalent to the original parts may impair the effectiveness of the engine/ equipment emission controls systems.
Page 102 The engine/equipment must be presented to an authorized Wacker Neuson dealer/ service center as soon as a problem exists. Contact Wacker Neuson Product Support Department (1-800-770-0957) or visit wackerneuson.com to find a dealer/ service center in your area, or to answer questions regarding warranty rights and responsibilities.
Page 103 For owners located more than 100 miles from an authorized dealer/service center (excluding the states with high-altitude areas as identified in 40 CFR Part 1068, Appendix III), Wacker Neuson will pay for pre-approved shipping costs to and from an authorized Wacker Neuson dealer/service center.
Page 104: Emissions Control Systems Information And Warranty: Kohler
Tampering and Altering Tampering with or altering the emission control system may increase emissions beyond the legal limit. If evidence of tampering is found, Wacker Neuson may deny a warranty claim. Among those acts that constitute tampering are: ■ Removing or altering of any part of the air intake, fuel, or exhaust systems.
Page 105: Schematics
Schematics 15 Schematics 15.1 LTV—Photo Sensor 15.2 Components Ref. Description Ref. Description Photocell unit Resistor Control module Neutral/ground terminal block Splice — — Wire Colors Black Yellow Orange Green Brown Purple Blue Violet Clear Shield Pink White Gray Lt. blue wc_gr015350 wc_tx004487en.fm...
Page 106: Ltv-Controller-Kubota Z482
Schematics 15.3 LTV—Controller-Kubota Z482 13 OR 15 16 17 18 19 20 21 22 25 26 36 38 39 40 41 42 43 44 8 RD 181 BK 155 OR 148 RD 139 YL 156 RD 23-WH 27-GN/YL 120 OHM 26-WH 137 BK 159 BK...
Page 107: Components
Schematics 15.4 Components Ref. Description Ref. Description Neutral/ground terminal block Shield Kubota ECU Starter To base harness Engine speed sensor Water temp sensor Power terminal block Splice Battery Resistor Glow plugs Control module Self ground engine block Alternator Oil switch Actuator solenoid Starter relay High CAN...
Page 108: Ltv-Base Schematic
Schematics 15.5 LTV—Base Schematic 20 WH RD 37 36 BR 35 RD 8 RD 15 RD 30 RD 31 BR 16 BR 14 BK/OR 9 PK 13 OR 33 PK 176 WH 32 BR GN/YL 12 GN/YL 11 12 ECU PU 34 GN/YL ECU WH 13 14...
Page 109: Components
Schematics 15.6 Components Ref. Description Ref. Description Trailer light harness Ground, control panel Dome light Ground, engine Splice Engine ECU Telematics connection Battery Control panel light Main breaker Hour meter Breaker, upper lights Terminal block Breaker, lower lights Neutral/ground terminal block Breaker Generator Receptacle...
Page 110: Ltv-Metal Halide Lights Module
Schematics 15.7 LTV—Metal Halide Lights Module 15.8 Components Ref. Description Ref. Description Work light Terminal block WL1 GN WL2 GN Ground, junction box Neutral/ground terminal block WL1 BK WL2 BK Wire Colors WL1 WH WL2 WH WL4 GN WL3 GN Black Yellow Orange...
Page 111: Ltv-120V / 30A Receptacle Module
Schematics 15.9 LTV—120V / 30A Receptacle Module 15.10 Components Ref. Description Ref. Description Terminal block Engine Neutral/ground terminal block Receptacle Generator Main breaker Wire Colors Black Yellow Orange Green Brown Purple Blue Violet Clear Shield Pink White Gray Lt. blue wc_tx004487en.fm...
Page 112: Kw Gfci Receptacle Module
Schematics 15.11 LTV—8 kW GFCI Receptacle Module 15.12 Components Ref. Description Ref. Description Neutral/ground terminal block Receptacle GFCI receptacle Main breaker Breaker — — Wire Colors Black Yellow Orange 120V Green Brown Purple 23 WH Blue Violet Clear Shield 22 GN/YL 27 GN/YL Pink White...
Page 113: Ltv-Trailer
Schematics 15.13 LTV—Trailer 15.14 Components Ref. Description Ref. Description Front right amber marker Trailer connector License plate light Front left amber marker Right tail light Left tail light Rear right red marker Rear left red marker Splice — — Wire Colors Black Yellow Orange...
Page 114: Ltv-Kubota Engine
Schematics 15.15 LTV—Kubota Engine 8 RD 96 BR 97 BR 75 RD/BK 83 BU 72 RD 74 YL 73 RD 98 BR 79 BR 87 BK 91 RD 33 PK 90 RD 80 RD 78 RD B ST 77 YL 89 RD 100 RD 86 WH...
Page 115: Components
Schematics 15.16 Components Ref. Description Ref. Description Neutral/ground terminal block 15A fuse Glow plug indicator Key run power Coil cord Alternator To base harness Battery Ground, engine block Glow plug timer Oil switch Oil and temp switch relay Temperature switch Fuel solenoid Splice Fuel pump...
Page 116: Ltv-Power Winch
Schematics 15.17 LTV—Power Winch 15.18 Components Ref. Description Ref. Description Neutral/ground terminal block Telescoping switch 60A fuse Engine Telescoping winch — — Wire Colors Black Yellow Orange Green Brown Purple Blue Violet Clear Shield Pink White Gray Lt. blue wc_tx004487en.fm...
Page 117: Ltv-Led Lights Module
Schematics 15.19 LTV—LED Lights Module 15.20 Components WL1 GN WL2 GN Ref. Description Ref. Description WL2 BK WL1 BK Work light Terminal block Ground, junction box Neutral/ground terminal block WL2 WH WL1 WH WL4 GN WL3 GN Wire Colors WL3 BK WL4 BK Black Yellow...
Page 118: Ltv-Auto Start Module
Schematics 15.21 LTV—Auto Start Module 15.22 Components Ref. Description Ref. Description Neutral/ground terminal block Splice Power terminal block Auto start relay Control module — — Wire Colors Black Yellow Orange Green Brown Purple Blue Violet Clear Shield Pink White Gray Lt.
Page 119: Ltv-Shore Power Module
Schematics 15.23 LTV—Shore Power Module 15.24 Components Ref. Description Ref. Description Neutral/ground terminal block Selector switch Main breaker Breaker, upper lights Shore power inlet Breaker, lower lights Wire Colors Black Yellow Orange Green Brown Purple Blue Violet Clear Shield Pink White Gray Lt.
Page 120: Ltv-Controller-Kubota D2005 / D1105
Schematics 15.25 LTV—Controller-Kubota D2005 / D1105 13 OR 8 RD 144 RD 155 OR 145 RD 156 RD 149 RD 23-WH 148 RD 27-GN/YL 141 WH 160 BK 26-WH 147 RD 142 RD 143 RD 131 BK 132 RD 133 VT 134 YL 146 RD 135 WH/RD...
Page 121: Components
Schematics 15.26 Components Ref. Description Ref. Description Neutral/ground terminal block Starter Splice Starter replay To base harness Power terminal block Fuel pump relay Battery Control module Fuel solenoid Alternator Fuel pump Temperature switch Glow plugs relay Ground, engine block Glow plugs Oil switch —...
Page 122: Ltv-230V / 50 Hz Module
Schematics 15.27 LTV—230V / 50 HZ Module 15.28 Components Ref. Description Ref. Description Neutral/ground terminal block Generator Power terminal block Engine Wire Colors Black Yellow Orange Green Brown Purple Blue Violet Clear Shield Pink White Gray Lt. blue wc_tx004487en.fm...
Page 123: Ltv-Containment Switch
Schematics 15.29 LTV—Containment Switch 15.30 Components Ref. Description Ref. Description Engine Containment float switch Fuel solenoid tab — — Wire Colors Black Yellow Orange Green Brown Purple Blue Violet Clear Shield Pink White Gray Lt. blue wc_tx004487en.fm...
Page 124: Ltv-Uri Telematics
Schematics 15.31 LTV—URI Telematics 15.32 Components Ref. Description Ref. Description Telematics connection Fuel sender Splice — — Wire Colors Black Yellow Orange Green Brown Purple Blue Violet Clear Shield Pink White Gray Lt. blue wc_tx004487en.fm...
Page 125: Standard Racked Assembly
Appendix I 16 Appendix I 16.1 Standard Racked Assembly Overview This set of assembly instructions applies to LTV machines shipped in a container rack as shown. wc_gr014331 Tasks To complete the assembly of your light tower, the following tasks must be performed in the order listed: Task Description...
Page 126: Installing The Axle
Appendix I Axle 16.2 Installing the Axle Materials Axle  needed Hardware bag 1  Installing the Perform the procedure below to install the axle. axle wc_gr014359 1. Lift the machine using appropriate lifting gear. See Lifting the Machine in the Safety Information chapter.
Page 127: Installing The Fenders
Fenders Appendix I 16.3 Installing the Fenders Materials Two fenders  needed Hardware bag 2  Installing the Perform the procedure below to install the fenders. fenders wc_gr014360 1. Locate the two fenders (a) and hardware bag 2. 2. Align each fender as shown in the illustration. 3.
Page 128: Installing The Wheels
Appendix I Wheels 16.4 Installing the Wheels Materials Two wheels  needed Hardware bag 3  Installing the Perform the procedure below to install the wheels. wheels wc_gr014376 1. Locate the two wheels (a) and hardware bag 3. 2. Attach the wheels to the axle using five lug nuts (b) per wheel. Note: Tighten the lug nuts in a star pattern to a torque of 115 Nm (85 ft.
Page 129: Installing The Outriggers And Swivel Jacks
Outriggers Appendix I 16.5 Installing the Outriggers and Swivel Jacks Materials Two outrigger  needed Two swivel jacks  Installing the Perform the procedure below to install the outriggers. outriggers wc_gr014377 1. Locate the locking pin (a) at the outrigger socket (b). 2.
Page 130: Installing The Tongue Assembly
Appendix I Tongue assembly 16.6 Installing the Tongue Assembly Materials Tongue assembly  needed Swivel jack  Hardware bag 4  Installing the Perform the procedure below to install the tongue assembly. tongue assembly wc_gr014386 1. Fasten the tongue assembly (a) to the light tower using the following hardware from bag 4 as shown in the illustration: Three M12 x 30 screws (b) on each side of the tongue assembly ...
Page 131 Tongue assembly Appendix I Continued from the previous page. Installing the Perform the procedure below to install the swivel jack. swivel jack wc_gr014387 1. Locate the swivel jack (e). 2. If necessary, remove the locking pin (f) from the holes in the tongue jack. 3.
Page 132: Installing The Mast
Appendix I Mast 16.7 Installing the Mast Materials Mast assembly  needed Hardware bag 5  Installing the Perform the procedure below to install the mast. mast wc_gr014397 1. Attach the light mount bracket (a) with two M16 x 40 serrated flange screws (b) and two M16-10.9 serrated flange nuts (c) at the top of the mast.
Page 133: Installing The Standard Winch
Winch Appendix I 16.8 Installing the Standard Winch Materials Standard winch  needed Hardware bag 6  Installing the Perform the procedure below to install the standard winch. standard winch wc_gr014398 1. Align the standard winch handle (a) to the side of the standard winch drum (b) and secure the winch handle with a nut (c).
Page 134 Appendix I Winch Continued from the previous page. Installing the Perform the procedure below to install the winch cable. winch cable wc_gr014404 1. Pass the winch cable (g) over the top of the standard winch drum (b) and through the side hole (h). 2.
Page 135: Installing The Power Winch
Power winch Appendix I 16.9 Installing the Power Winch Materials Power winch  needed Hardware bag 7  Installing the Perform the procedure below to install the power winch. power winch wc_gr014399 1. Remove the cover (a) from the power winch (b). 2.
Page 136 Appendix I Power winch Continued from the previous page. Installing the Perform the procedure below to install the winch cable. winch cable wc_gr014460 1. Pass the winch cable (g) over the top of the power winch drum (b) and through the side hole (h).
Page 137: Installing The Light Support Bracket And Light Bar
Light Bar Appendix I 16.10 Installing the Light Support Bracket and Light Bar Materials Light support bracket and light bar from mast assembly  needed Hardware bag 5  Installing the Perform the procedure below to install the light support bracket and light bar. light support bracket and light bar...
Page 138: Installing The Lights-240W Metal Halide Or 300W Led
Appendix I Metal Halide 16.11 Installing the Lights—240W Metal Halide or 300W LED Materials Four light fixtures - metal halide or 300W LED  needed Note: Use four light fixtures of the same kind. Do not combine metal halide light fixtures and 300W LED light fixtures on the light bar.
Page 139: Installing The Lights-240W Led
Appendix I 16.12 Installing the Lights—240W LED Materials Four LED light fixtures  needed Hardware bag 5  Installing the Perform the procedure below to install the LED light fixtures. LED light fixtures wc_gr014401 1. Install the lower LED light fixtures using the threaded studs (a) on the bottom of the light bar (b).
Page 140: Connecting The Wiring At The Junction Box
Appendix I Junction Box 16.13 Connecting the Wiring at the Junction Box Special tools Coiled cord  and materials Panduit crimper CT-100  needed Panduit crimper CT-1500  Hardware bag 5  Connecting Perform the procedure below to connect the wiring at the junction box. the wiring at Note: This procedure is the same for metal halide and LED light fixtures.
Page 141 Junction Box Appendix I Continued from the previous page. Installing the 1. Use two wrenches to loosen the four connectors (g) on the sides of the junction work light box. cords 2. Insert the light fixture cords through the appropriate four connectors (L1, L2, L3, L4).
Page 142 Appendix I Junction Box This page is intentionally left blank. wc_tx004503en.fm...
Page 143 Index Fuel stabilizing ..... . . 87 Abbreviations ......6 valve .
Page 144 Index engine ....89, 91, 93 Schematics engine schedule ....81 120V / 30A receptacle .
Page 145 Wacker Neuson Production Americas LLC, N92W15000 Anthony Ave., Menomonee Falls, WI. 53051 Tel.: (262) 255-0500 Fax: (262) 255-0550 Tel.: (800) 770-0957 Wacker Neuson Limited - Room 1701–03 & 1717–20, 17/F. Tower 1, Grand Century Place, 193 Prince Edward Road West, Mongkok, Kowloon, Hongkong. Tel: (852) 3605 5360, Fax: (852) 2758 0032...

This manual is also suitable for:

Ltv6k Ltv6l Ltv8k

Wacker Neuson LTV4K Operator's Manual

Quick Links

Need help?

Questions and answers

Related Manuals for Wacker Neuson LTV4K

Summary of Contents for Wacker Neuson LTV4K

This manual is also suitable for:

Table of Contents