Wacker Neuson Light Tower Ltc 4 Repair Manual

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Wacker Neuson Light Tower Ltc 4 Repair Manual – Download

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Wacker Neuson Light Tower Ltc 4 Repair Manual – Download

LANGUAGE:ENGLISH
PAGES:166
DOWNLOADABLE:YES
FILE TYPE:PDF

IMAGES PREVIEW OF THE MANUAL:

DESCRIPTION:

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

1 Safety Information 6
11 Laws Pertaining to Spark Arresters 6
12 Operating Safety 7
13 Operator Safety while using Internal Combustion Engines 8
14 Towing Safety 9
15 Service Safety 10
16 Label Locations 11
17 Safety and Operating Labels 13
2 Technical Data 19
21 Engine 19
22 Generator 20
23 Machine 21
3 Operation 23
31 Information Regarding Operation 23
32 Locating Trailer 23
33 Leveling Trailer 24
34 Adjusting Lights 24
35 Preparing Trailer for Towing or Lifting 25
36 Raising Tower (Manual Winch System) 26
37 Lowering Tower (Manual Winch System) 28
38 Raising Tower (Power Winch System) 30
39 Lowering Tower (Power Winch System) 32
310 Emergency Crank Handle (Power Winch System) 33
311 Control Panels—Lombardini (Manual Winch System) 34
312 Control Panels—Lombardini (Power Winch System) 35
313 Control Panels—CAT (Manual Winch System) 36
314 Control Panel—CAT (Power Winch System) 37
315 Starting—Lombardini 38
316 Starting—CAT 39
317 Automatic Shutdown 39
318 Operating Lights 40
319 Stopping—Lombardini 40
320 Stopping—CAT 40
321 Derating 40
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322 Receptacles—60 Hz 41
4 Maintenance 42
41 Periodic Maintenance Schedule—Lombardini 42
42 Periodic Maintenance Schedule—CAT 43
43 Daily Inspection 43
44 Installing / Removing Light Fixtures 44
45 Precautions When Replacing / Removing Bulbs 45
46 Replacing Bulbs 46
47 Air Cleaner 47
48 Engine Oil 48
49 Generator Capacitor Excitation Schematic 60 Hz 49
410 Schematic for 60 Hz Metal Halide 4-Light Units 50
411 Metal Halide Schematic Components 51
412 Engine Wiring—Lombardini 1003 52
413 Engine Wiring Components—Lombardini 1003 53
414 Engine Control Panel Internal Wiring—Lombardini 1003 54
415 Engine Wiring—Lombardini 903 55
416 Engine Control Panel Internal Wiring—Lombardini 903 56
417 Engine Control Panel Components—Lombardini 57
418 Engine Wiring—Item Number: 0009376 58
419 Engine Wiring—Item Number: 0620017, 0620028 59
420 Power Winch Schematic 60
421 Trailer Wiring 61
5 Lombardini Engine Troubleshooting 62
51 Troubleshooting Flowcharts 62
52 Engine Does Not Crank—Flowchart 3A 63
53 Checking Key switch and Wiring 64
54 Replacing Key switch 66
55 Engine Cranks But Does Not Start—Flowchart 4A 67
56 Checking Fuel System 68
57 Checking Voltage to Glow Plugs (Lombardini 903 engines) 69
58 Checking Voltage to Glow Plugs (Lombardini 1003 engines) 70
59 Checking Glow Plug Relay 71
510 Replacing Glow Plug Relay 71
511 Checking Glow Plugs 72
512 Engine Shuts Down—Flowchart 5A 73
513 Checking Oil Pressure and Coolant Temperature Switches 74
514 General Engine Troubleshooting 75
6 Caterpillar Engine Troubleshooting 78
61 Troubleshooting Flowcharts 78
62 Engine Does Not Crank—Flowchart 6A 79
63 Checking Key switch and Wiring 80
64 Replacing Key switch 81
65 Engine Cranks But Does Not Start—Flowchart 7A 82
66 Checking Fuel Flow 83
67 Checking Glow Plug Wiring 84
68 Checking Glow Plugs 84
69 Engine Shuts Down—Flowchart 8A 85
610 Checking Oil Pressure and Coolant Temperature Switches 86
611 General Engine Troubleshooting 87
7 Electrical Troubleshooting Procedures 90
71 Troubleshooting Methodology 90
72 Schematic Components 90
73 Schematic for 60 Hz Metal Halide 4-Light Units 91
74 Checking Continuity 92
75 Checking resistance 92
76 Checking voltage 92
77 Troubleshooting Flowcharts 92
78 Lights do not Illuminate—Flowchart 1A 93
79 Lights do not Illuminate—Flowchart 1B 94
710 Lights do not Illuminate—Flowchart 1C 95
711 Lights do not Illuminate—Flowchart 1D 96
712 Checking Engine Speed 97
713 Checking Generator Voltage at Receptacle 98
714 Replacing Receptacle 99
715 Checking Voltage to the Main Circuit Breaker 100
716 Checking Voltage Between Main Circuit Breaker and Terminal Strip 102
717 Checking Individual Circuit Breakers 104
718 Confirming a Malfunctioning Circuit Breaker 106
719 Checking Incoming Voltage to Control Panel Capacitor(s) 107
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720 Checking Outgoing Voltage from Control Panel Capacitor(s) 108
721 Confirming a Faulty Control Panel Capacitor 109
722 Checking Wiring to/from Ballast(s) 110
723 Replacing Ballast 112
724 Restoring Rotor Magnetism (Flashing) / Checking Rotor Winding 114
725 Checking Generator Capacitors 116
726 Alternative Capacitor Check 117
727 Replacing Generator Capacitor(s) 118
728 Checking Stator Windings 120
729 Removing/Installing Caterpillar Engine with Generator 122
730 Removing/Installing Lombardini Engine with Generator 124
731 Separating Stator Assembly from Engine/Rotor Assembly 126
732 Remounting Stator Assembly to Rotor/Engine Assembly 128
733 Checking Rotor Diodes 129
734 Checking Rotor Windings 130
735 Removing/Installing Rotor 131
736 No Voltage at Receptacle—Flowchart 2A 132
737 Checking Voltage at Receptacle 133
738 Checking Receptacle’s Circuit Breaker 134
739 Troubleshooting the Power Winch 136
8 Disassembly/Assembly Procedures 139
81 Tools 139
82 Ordering Parts 139
83 Reference Numbers ( ) 139
84 Weight Block 139
85 Light Assembly 140
86 Tower Assembly Exploded View 142
87 Tower Assembly List of Parts 143
88 Upper Mast 143
89 Mid Mast 146
810 Main Mast 148
811 Replacing Cable and Winch on Power Winch Models 152
812 Replacing Fuel Tank 154
813 Replacing Hour Meter 156