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Lombardini Engine Troubleshooting

LTC Repair

wc_tx000364gb.fm

62

5.

Lombardini Engine Troubleshooting

5.1

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. Detailed
procedures for carrying out the tests are included in this manual. All
highlighted text within the flowcharts have matching sections in this
manual.

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Summary of Contents for LTC 4

Page 1: ...www wackergroup com Light Tower LTC 4 REPAIR MANUAL 0160487en 003 0206 0 1 6 0 4 8 7 E N...

Page 2: ......

Page 3: ...ion 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 pro...

Page 4: ...ed 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 express written permission fro...

Page 5: ...Trailer 24 3 4 Adjusting Lights 24 3 5 Preparing Trailer for Towing or Lifting 25 3 6 Raising Tower Manual Winch System 26 3 7 Lowering Tower Manual Winch System 28 3 8 Raising Tower Power Winch Syste...

Page 6: ...trol Panel Internal Wiring Lombardini 1003 54 4 15 Engine Wiring Lombardini 903 55 4 16 Engine Control Panel Internal Wiring Lombardini 903 56 4 17 Engine Control Panel Components Lombardini 57 4 18 E...

Page 7: ...7 7 Electrical Troubleshooting Procedures 90 7 1 Troubleshooting Methodology 90 7 2 Schematic Components 90 7 3 Schematic for 60 Hz Metal Halide 4 Light Units 91 7 4 Checking Continuity 92 7 5 Checkin...

Page 8: ...7 31 Separating Stator Assembly from Engine Rotor Assembly 126 7 32 Remounting Stator Assembly to Rotor Engine Assembly 128 7 33 Checking Rotor Diodes 129 7 34 Checking Rotor Windings 130 7 35 Removin...

Page 9: ...LTC Repair Table of Contents wc_br0160487en_003TOC fm 5...

Page 10: ...y hazardous situation which if not avoided may result in minor or moderate injury CAUTION Used without the safety alert symbol CAUTION indicates a potentially hazardous situation which if not avoided...

Page 11: ...r national and local regulations 1 2 6 The tower extends up to 9 m 30 ft Make sure the area above the trailer is open and clear of overhead wires and obstructions 1 2 7 The bulbs become extremely hot...

Page 12: ...n the fuel tank near an open flame while smoking or while the engine is running 1 3 3 ALWAYS refill the fuel tank in a well ventilated area 1 3 4 DO NOT touch or lean against hot exhaust pipes 1 3 5 A...

Page 13: ...fective parts 1 4 3 ALWAYS make sure the coupling is securely fastened to the vehicle 1 4 4 ALWAYS check the tires on the trailer for tread wear inflation and condition Replace worn tires 1 4 5 ALWAYS...

Page 14: ...round the base of the machine If water is present move the machine and allow the machine to dry before servicing 1 5 4 DO NOT service the machine if your clothing or skin is wet 1 5 5 ALWAYS keep hand...

Page 15: ...LTC Repair Safety Information wc_si000164gb fm 11 1 6 Label Locations...

Page 16: ...Safety Information LTC Repair wc_si000164gb fm 12...

Page 17: ...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 B WARNING Avoid crushing area C WARNING Completely lower towe...

Page 18: ...xiation hazard Read the Opera tor s Manual for instructions No sparks flames or burning objects near machine Stop the engine before adding fuel Use only diesel fuel DANGER Contact with overhead electr...

Page 19: ...is attached to each unit Please record the information found on this plate so it will be available should the nameplate become lost or damaged When ordering parts or requesting service information you...

Page 20: ...E I T S K E T T E N K R E U Z W E I S E A N B R I N G E N 5 A N H A N G E R L E U C H T E N P R U F E N 1 L E A E L M A N U A L D E L O P E R A R I O 2 U T I L I C E U N A C O P L E C O R R E C T A M...

Page 21: ...LTC Repair Safety Information wc_si000164gb fm 17 Q Ref Label...

Page 22: ...ARNING 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 Vehic...

Page 23: ...esel Maximum power rating kW Hp 9 0 12 1 10 13 4 9 4 12 6 Operating power rating kW Hp 8 1 10 9 9 1 12 2 8 1 10 9 Operating speed no load rpm 1850 1850 1850 Alternator V A W 12 45 540 Battery V Ah CCA...

Page 24: ...L 60 Hz 0009375 0620018 LTC 4C 60 Hz 0009376 0620017 0620028 Generator Frequency Hz 60 2 Continuous output kW 6 0 Output volts phase 120 1 Amps A 50 25 Excitation type Capacitor Brushless Power factor...

Page 25: ...1811 817 1802 832 1834 Dimensions L x W x H cm in 389 x 122 x 160 153 x 48 x 63 439 x 162 x 160 173 x 64 x 63 389 x 122 x 160 153 x 48 x 63 439 x 162 x 160 173 x 64 x 63 Height mast extended m ft 9 3...

Page 26: ...Technical Data LTC 4 wc_td000157gb fm 22 Notes...

Page 27: ...phic wc_gr0001420 3 2 1 For maximum light coverage locate the Light Tower at ground level or in a spot higher than the area being lighted 3 2 2 Position the trailer on a firm flat surface clear of ove...

Page 28: ...outrigger Pull both outrigger extensions d out until you feel outrigger lock pin lock back into place Rotate jacks e down until they snap into position 3 3 3 Rotate rear jack f down as shown making su...

Page 29: ...r is now ready to lift For towing continue 3 5 6 Use the tongue jack a to raise the trailer tongue up and then lower it over hitch on towing vehicle Lock the hitch to coupling and attach the safety ch...

Page 30: ...handle must be rotated to wind in cable as well as unwind cable NEVER touch the winch pawl Releasing the pawl may cause the mast or tower to fall 3 6 1 Check winch cables n for wear or damage and mak...

Page 31: ...erly it will make a clicking sound when the winch handle is rotated clockwise Do not attempt to raise the mast if the winch is damaged or not operating properly Continue rotating the winch handle unti...

Page 32: ...lower the mast while the unit is operating NEVER allow anyone to stand near the rear of the unit while lowering the mast 3 7 1 Turn the lights off Shut down the engine CAUTION Shutting down the engine...

Page 33: ...penetrates all sections of the mast NEVER pull the vertical mast locking pin e while the tower is raised Releasing the locking pin while the tower is raised may cause the tower to fall or the machine...

Page 34: ...e sure they are resting properly in the pulleys Do not use the Light Tower if either winch cable is damaged 3 8 2 Remove the cradle locking pin j from the cradle 3 8 3 Check the operation of the tongu...

Page 35: ...up position until mast is at the desired height Release switch when tower is fully extended CAUTION Continuous running of the winch in excess of 4 minutes will damage the winch motor CAUTION Do not e...

Page 36: ...nit is operating NEVER allow anyone to stand near the rear of the unit while lowering the mast 3 9 1 Turn the lights off Shut down the engine CAUTION Shutting down the engine before turning off the li...

Page 37: ...le by inserting the cradle lock pin j Insert the clip through the pin to secure it in place 3 9 6 Position the light fixtures to aim at the ground CAUTION Allow the floodlights to cool 10 15 minutes b...

Page 38: ...t breaker k High coolant temperature shutdown b 15 Amp lights circuit breaker l Alternator indicator c 20 Amp GFI circuit breaker m Auxiliary light not used d 20 Amp GFI receptacle n Glow plug indicat...

Page 39: ...ndicator b 15 Amp lights circuit breaker m Auxiliary light not used c 20 Amp GFI circuit breaker n Glow plug indicator d 20 Amp GFI receptacle o Air filter restriction indicator e Hour meter p Auxilia...

Page 40: ...36 3 13 Control Panels CAT Manual Winch System Ref Description Ref Description a 25 Amp circuit breaker e Hour meter b 15 Amp lights circuit breaker n Glow plug indicator c 20 Amp GFI circuit breaker...

Page 41: ...T Power Winch System Ref Description Ref Description a 25 Amp circuit breaker n Glow plug indicator b 15 Amp lights circuit breaker r Key switch c 20 Amp GFI circuit breaker v Vertical rotary switch d...

Page 42: ...glow plug indicator n will illuminate until the engine is properly preheated This is an automatic timer based on the engine temperature Crank the engine immediately after the glow plug light goes off...

Page 43: ...RT and hold until the engine starts Release the key after the engine starts CAUTION Do not crank engine longer than 10 seconds This could cause starter motor to overheat Return switch to OFF and wait...

Page 44: ...ve any other loads from the generator CAUTION Never shut down the engine without turning off the lights Damage to the generator will occur 3 19 2 Turn the key q to OFF 3 20 Stopping CAT See Graphic wc...

Page 45: ...all of the lights on or the lights will turn off A circuit breaker c protects the Ground Fault Interrupt GFI receptacle d The GFI receptacle should be tested for proper operation each time it is used...

Page 46: ...trolyte Check condition and tension on fan belt Check condition of radiator hoses Replace oil filter Replace fuel filter Flush radiator Replace fan belt Check valve clearance Remove sediment in fuel t...

Page 47: ...Every 100 hours Every 250 hours Every 500 hours Every 1000 hours Visual walkaround inspection Check for fluid leaks Check engine oil and coolant level Check fuel level Replace air filter if indicator...

Page 48: ...mounting brackets and remove both fixture and bracket from the stud CAUTION Only a trained technician should be allowed to install and remove the fixture wiring Note When reinstalling the light fixtu...

Page 49: ...ecome extremely hot in use Allow the bulb and fixture to cool 10 15 minutes before handling NEVER operate the lights without the protective lens cover in place or with a lens cover that is cracked or...

Page 50: ...lange 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 Once removed swing the bulb stabilizer to the side and unscrew the b...

Page 51: ...red line Push and hold in the yellow rubber button on top of the indicator to reset it after replacing the main paper filter element Lombardini engines include a light b on the engine control panel wh...

Page 52: ...chine to collect any liquid which drains off Dispose of this liquid in accordance with environmental protection legislation 4 8 1 Remove the oil drain plug 4 8 2 Allow the oil to drain 4 8 3 Install t...

Page 53: ...citor Excitation Schematic 60 Hz Ref Description Ref Description 1 Rotor 4 Capacitor 2 Stator 5 Generator Terminal block 3 Excitation coils 6 Control box lights wc_gr000932 T1 T2 T3 T4 T5 T6 50 Hz 60...

Page 54: ...fm 50 4 10 Schematic for 60 Hz Metal Halide 4 Light Units B W G B W G B W G B W G G L Or R W W B B B a c d b e 1 5 50Hz 0 60Hz 2 6 4 3 W R G R B R B W B W B W B Or Or Or G G G B d d wc_gr002459 s P B...

Page 55: ...m Capacitor c Control box lights n Ballasts d Quick disconnects p 25 Amp 2 pole circuit breaker e Terminal strip q Hourmeter f 20 Amp GFI circuit breaker r Alternator g 15 Amp circuit breaker s Contr...

Page 56: ...00427gb fm 52 4 12 Engine Wiring Lombardini 1003 13 2 3 1 8 4 R x x x x 7 16 17 11 9 10 12 14 5 B Pr L L G G B Or Or B B D W 12V 45A wc_gr003225 15 14 13 12 11 10 9 8 7 6 5 4 3 1 2 8 9 10 11 12 13 14...

Page 57: ...r restriction indicator normal open type 13 Harness connector alternator 2 Glow plugs 8 Terminal strip 14 Diode 3 Starter motor 9 Low oil pressure switch 15 Resistors 2x220 Ohm 0 6 W 4 Battery 10 High...

Page 58: ...fuse f Relay Wire Colors B Black R Red Y Yellow Or Orange G Green T Tan Br Brown Pr Purple L Blue V Violet Cl Clear Sh Shield P Pink W White Gr Gray LL Light blue a b c f d e 9 8 10 1 11 12 2 4 Or Br...

Page 59: ...9 Low oil pressure switch normal closed type 15 Resistors 2x220 Ohm 0 6 W 4 Battery 10 Coolant high temperature switch normal open type 16 Blade connector 5 Alternator connector 11 Coolant temperatur...

Page 60: ...e e Preheating c 80A fuse f Relay Wire Colors B Black R Red Y Yellow Or Orange G Green T Tan Br Brown Pr Purple L Blue V Violet Cl Clear Sh Shield P Pink W White Gr Gray LL Light blue a b c f d e 9 8...

Page 61: ...ntrol panel rear view g Key access door b Solid state glow plug controller and indicating lamps h Auxiliary connections c Shutdown relay location i Light switch panel connection d Glow plug relay j 15...

Page 62: ...iption Ref Description 1 Glow plugs 9 Water temperature sensor 2 Starter solenoid 10 Low oil pressure indicator 3 Starter 11 Fuel solenoid 4 Alternator 12 Diode 5 Hour meter 13 Automatic shutdown 6 Au...

Page 63: ...escription Ref Description 1 Glow plugs 9 Water temperature sensor 2 Starter solenoid 10 Low oil pressure indicator 3 Starter 11 Fuel solenoid 4 Alternator 12 Diode 5 Hour meter 13 Automatic shutdown...

Page 64: ...nance LTC Repair wc_tx000427gb fm 60 4 20 Power Winch Schematic Ref Description Ref Description a Vertical winch d Vertical rotary switch b Telescope winch e Telescope rotary switch c Fuse breaker f S...

Page 65: ...Ref Description a Right stop turn and tail light d Side light red b Left stop turn and tail light e License plate light c Side light amber Wire Colors G Green Right stop and turn light Y Yellow Left...

Page 66: ...ed 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 qu...

Page 67: ...3 0V No Yes Check for battery voltage between terminal 50 and ground when key is placed in the START position Engine Does Not Crank Is battery voltage measured between 30 and ground Yes No Replace key...

Page 68: ...the keyswitch 5 3 4 Check for 12V battery voltage approximately 12 between terminal 30 of keyswitch and ground If no voltage is measured repair wiring back to battery If voltage is measured continue...

Page 69: ...LTC Repair Lombardini Engine Troubleshooting wc_tx000364gb fm 65 wc_gr003228 30 50 B L V 15 54 d c a b...

Page 70: ...control panel 5 4 3 Make note of the wire connections on the keyswitch and remove the wires a from the keyswitch 5 4 4 Unscrew the locking ring b and remove the keyswitch from the panel Reassembly 5...

Page 71: ...Cranks But Does Not Start Checking Fuel System Check if fuel flows from inlet hose when engine is cranking Checking glow plug relay Check glow plug relay Checking glow plugs Check glow plugs wc_gr0030...

Page 72: ...k that the fuel hoses and fuel filter are clean and in good condition 5 6 3 Disconnect the fuel intake hose a Have a suitable container ready to catch fuel Place the keyswitch in the START position an...

Page 73: ...ngines 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 co...

Page 74: ...ltage between the black wire and ground There should be 12V battery voltage approximately 12 measured If 12V is measured check the function of the glow plug If 12V is not measured continue 5 8 2 Disco...

Page 75: ...glow plug relay 5 9 3 Place the keyswitch in the START position A working relay will click when the keyswitch is in the START position Check the continuity across the blue L and black B wires when the...

Page 76: ...ach temperatures up to 1200 F 649 C Do not touch the element of the glow plug Be extremely careful when testing the glow plug 5 11 2 Using 10 gauge wire apply 12VDC to the glow plug positive on the up...

Page 77: ...pressure switch connected correctly Yes No Check engine coolant level Fill engine with correct amount and type of coolant Is engine coolant level correct No Yes Connect coolant temperature switch and...

Page 78: ...iring of oil pressure switch a and the coolant temperature switch b 903 engines or c 1003 engines If the wiring of either switch is shorted to ground the engine will shut down Be sure the switches are...

Page 79: ...onsumption Wet exhaust Overheating Engine knocks Low fuel level Fuel supply return lines clogged Clogged fuel tank vent Fuel pump faulty Fuel contaminated with air Unit injector s faulty worn Unit inj...

Page 80: ...on timing out of spec advanced Injection timing out of spec retarded Governor linkage adjustment incorrect Governor spring fatigued or defective Idle rpm too low Piston rings worn or stuck Piston worn...

Page 81: ...mostat stuck or malfunctioning Engine seized Radiator clogged external or internal Coolant pump faulty Turbocharger faulty Possible Cause Symptom Engine will not crank Engine does not start Engine sta...

Page 82: ...ned 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 q...

Page 83: ...o Yes Check for battery voltage between terminal AC of keyswitch and ground when key is placed in the START position Engine Does Not Crank Is battery voltage measured between 30 and ground Yes No Repl...

Page 84: ...se tests 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 keyswitc...

Page 85: ...control panel 6 4 3 Make note of the wire connections on the keyswitch and remove the wires a from the keyswitch 6 4 4 Unscrew the locking ring b and remove the keyswitch from the panel Reassembly 6...

Page 86: ...e fuel filter and fuel hoses are in good condition Engine Cranks But Does Not Start Checking Fuel Flow Check if fuel flows from banjo fitting when engine is cranking Checking glow plugs Check glow plu...

Page 87: ...in the START position and check for battery voltage between the fuel solenoid R W wire b and ground If battery voltage exists between the R W wire and ground gravity feed fuel through fuel intake line...

Page 88: ...sured check the function of the glow plugs 6 8 Checking Glow Plugs See Graphic wc_gr002033 6 8 1 Remove the glow plug from the engine Burn hazard Glow plugs can reach temperatures up to 1200 F 649 C D...

Page 89: ...pressure switch connected correctly Yes No Check engine coolant level Fill engine with correct amount and type of coolant Is engine coolant level correct No Yes Connect coolant temperature switch and...

Page 90: ...t coolant 6 10 3 Check the oil pressure switch a and coolant temperature switch b wiring If the wiring of either switch is shorted to ground the engine will shut down Be sure the switches are function...

Page 91: ...rd starting engine missing Debris in oil filter Dirty primary secondary air cleaner Overfueling Overloading Worn rings liners Worn seals Worn valve products Leaking head gasket Cracked head or liners...

Page 92: ...evel Malfunctioning temperature regulators Worn fuel injector pump Low octane level or water in fuel Low cranking speed Dirty entry Damaged bearings Coolant fuel leakage into crankcase Extended oil ch...

Page 93: ...LTC Repair Caterpillar Engine Troubleshooting wc_tx000476gb fm 89...

Page 94: ...re may be problems with the receptacle Therefore it is best to start troubleshooting at the main circuit breaker For troubleshooting a malfunctioning generator you ll need to rule out a demagnetized r...

Page 95: ...00429gb fm 91 7 3 Schematic for 60 Hz Metal Halide 4 Light Units B W G B W G B W G B W G G L Or R W W B B B a c d b e 1 5 50Hz 0 60Hz 2 6 4 3 W R G R B R B W B W B W B Or Or Or G G G B d d wc_gr002459...

Page 96: ...rs have some internal resistance To obtain your multimeter s internal resistance simply cross the two leads of your multimeter and read the display When conducting a resistance check subtract your mul...

Page 97: ...position speed control lever on injection pump Is circuit breaker s in closed position Close circuit breaker s Are bulbs black or burnt Replace bulbs No No Yes Yes See Flowchart 1B See Flowchart 1C Is...

Page 98: ...e ballast s the ballast s are malfunctioning replace the ballast s Checking individual circuit breaker s With lights disconnected at quick disconnects measure incoming and outgoing voltage to from ind...

Page 99: ...Replace stator Consult factory Is 30 40V measured Are all resistance values within range No Yes If you measure low resistance there is a short Replace the complete generator end Consult factory For a...

Page 100: ...ecking 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 me...

Page 101: ...t instructions If necessary adjust engine rpm using adjusting screw b Lombardini engines c CAT engines No load engine speed should be 1850 rpm for 60Hz and 1550 rpm for 50Hz models CAUTION Do not adju...

Page 102: ...on If your machine includes an earth leakage circuit breaker also place it in the ON position 7 13 1 Using the AC voltage setting on the multimeter test the receptacle for 120V 10 on 60Hz models 115V...

Page 103: ...ake note of the wire connections on the back of the receptacle Loosen the screws securing the wires and remove the wires 7 14 3 Remove the screws b securing the receptacle to the control panel cover a...

Page 104: ...ntinuity of the red wire back to the generator Then check the condition of the gen erator by remagnetizing the rotor flashing See section Restor ing Rotor Magnetism Flashing Checking Rotor Winding If...

Page 105: ...LTC Repair ElectricalTroubleshooting wc_tx000429gb fm 101 1000 200 20 2 200m F V A V COM wc_gr003095 b a c...

Page 106: ...ge is reaching the ter minal strip If 240V 10 was not measured continue 7 16 3 Measure the voltage between the R G wire a of the terminal strip and the neutral wires at the terminal strip b There shou...

Page 107: ...LTC Repair ElectricalTroubleshooting wc_tx000429gb fm 103 1000 200 20 2 200m F V A V COM 1000 200 20 2 200m F V A V COM c a wc_gr003096 c a b c a e d...

Page 108: ...the circuit breaker s and neutral wires at the terminal strip b If 120V 10 is not measured it indicates a problem with voltage reaching the circuit breaker Check the continuity of the wiring between t...

Page 109: ...LTC Repair ElectricalTroubleshooting wc_tx000429gb fm 105 wc_gr002472 1000 200 20 2 200m F V A V COM a c b...

Page 110: ...mplete 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 7 18 3 Using the Ohms scale on t...

Page 111: ...ual circuit breaker s to the light s in the ON position 7 19 3 Using the AC voltage setting on the multimeter test for 400V 10 incoming to the control panel capacitor s by measuring across the input w...

Page 112: ...tion 7 20 1 Remove the control panel front cover 7 20 2 Place the individual circuit breaker s to the light s in the ON position 7 20 3 Using the AC voltage setting on the multimeter test for 400V 10...

Page 113: ...wn with the resistor disconnected the resistor may be left connected if desired 7 21 2 Discharge the capacitor by placing the blade of an insulated screwdriver across the two spades of the capacitor 7...

Page 114: ...iled replace it To check the wiring 7 22 1 Turn off the engine 7 22 2 Remove the control panel front cover 7 22 3 Remove the screws a which secure the control panel and the cover of the ballast box Po...

Page 115: ...LTC Repair ElectricalTroubleshooting wc_tx000429gb fm 111 wc_gr003072 c d a b d c e e...

Page 116: ...ox just enough to allow access to the ballasts 7 23 4 Remove the wiring c d e for each ballast being replaced 7 23 5 Remove the hardware f securing the ballast g and remove the ballast from the ballas...

Page 117: ...LTC Repair ElectricalTroubleshooting wc_tx000429gb fm 113 wc_gr002442 a d f g c b e...

Page 118: ...firm a malfunctioning rotor Start this test with the engine shut down 7 24 1 Unplug the 60 and 0 leads from the generator capacitor 7 24 2 Using 14 gauge or larger wire connect two jumper wires to the...

Page 119: ...LTC Repair ElectricalTroubleshooting wc_tx000429gb fm 115 wc_gr002171 G R W B T5 T4 T6 60 0 T3 T2 1000 200 20 2 200m F V A V COM 12V T1...

Page 120: ...he unit off remove the screws securing the protective cover and remove the cover 7 25 2 Remove the leads from the capacitor and discharge it by placing the blade of an insulated screwdriver across the...

Page 121: ...tarts out very low 5 0 Ohms and continues to climb to an overload or open reading the capacitor may be OK Double check by installing the capacitor in a known to be working Light Tower If the known to...

Page 122: ...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 7 27 3 Cut the wire ties d and remove the ca...

Page 123: ...LTC Repair ElectricalTroubleshooting wc_tx000429gb fm 119...

Page 124: ...h cases the resistance measured should be 0 36 0 5 0 0 Ohms Measure the resistance 60 lead to 0 lead The resistance measured should be 1 7 0 5 0 0 Ohms If there is no continuity meter reads OPEN or OL...

Page 125: ...ng wc_tx000429gb fm 121 wc_gr003097 G R W B T5 T1 T4 T6 60 0 T3 T2 1000 200 20 2 200m F V A V COM 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 60 to...

Page 126: ...motor m 7 29 8 Disconnect the coolant overflow reservoir tube at the radiator n 7 29 9 Remove the four nuts and washers located underneath the frame that secure the shock mounts to the frame 7 29 10 U...

Page 127: ...LTC Repair ElectricalTroubleshooting wc_tx000429gb fm 123 wc_gr002446 c d a f h g j i e k l m R W B b n 250 kg 550 lbs wc_gr000843...

Page 128: ...nator 7 30 8 Disconnect the coolant overflow reservoir tube at the radiator 7 30 9 Remove the four nuts and washers located underneath the frame that secure the shock mounts to the frame 7 30 10 Using...

Page 129: ...LTC Repair ElectricalTroubleshooting wc_tx000429gb fm 125 wc_gr002451 c d a h g j i e e k j R W B L Br 50Hz 60Hz b d c 250 kg 550 lbs wc_gr000843...

Page 130: ...31 2 Using an appropriate strap a and hoist support the generator end 7 31 3 Using an approximately 3 x 3 8cm x 8cm piece of steel or aluminum plate b drill a pilot hole in the center of the plate to...

Page 131: ...0429gb fm 127 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 st...

Page 132: ...hrough the hole in the stator housing 7 32 4 Thread the nut against the stator housing and slowly tighten the nut to push the stator housing onto the rotor and bearing assembly f Continue until engine...

Page 133: ...both diodes 7 33 1 Unsolder the two wires from the terminal end of each diode 7 33 2 Using the diode setting on the multimeter measure the voltage across the diode terminal and the base of the diode R...

Page 134: ...ng diode Each wire reading should be 2 2 0 5 0 0 Ohms or greater If your readings are not 2 2 0 5 0 0 Ohms or greater replace the generator 7 34 3 Check the resistance of all four rotor windings in th...

Page 135: ...emoval 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...

Page 136: ...t breaker Check voltage to main circuit breaker No Yes Checking incoming voltage to receptacle Measure incoming voltage at back of receptacle If 120V 10 is not measured repair replace wiring between r...

Page 137: ...ultimeter test the receptacle for 120V 10 on 60Hz models 230V 10 on 50Hz models 7 37 2 If zero 0 Volts is measured check the receptacle reset button if equipped on your machine model Depress the butto...

Page 138: ...receiving voltage Check the condition of the wiring between the receptacle s circuit breaker and the terminal strip Repair replace the wiring as needed If 120V 10 is measured continue 7 38 2 Make sur...

Page 139: ...LTC Repair ElectricalTroubleshooting wc_tx000429gb fm 135 wc_gr003100 1000 200 20 2 200m F V A V COM b a c...

Page 140: ...9 8 Remove the control panel d from the control box 7 39 9 Check for battery voltage approximately 12 between terminals B1 and B2 of the winch switch e If 12V is measured the winch switch is receiving...

Page 141: ...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 wc_gr003160 b d c e f a g...

Page 142: ...Electrical Troubleshooting Procedures LTC Repair wc_tx000429gb fm 138 Notes...

Page 143: ...ation refer to the Parts Book originally supplied with the unit If the original Parts Book has been lost a replacement may be ordered from Wacker Corporation When ordering a replacement Parts Book ple...

Page 144: ...onnector box and cut the black p and white wires q near the crimp nuts 8 5 9 Remove the two screws r securing the ceramic fixture to the housing and remove the ceramic fixture Installation 8 5 10 Slid...

Page 145: ...LTC Repair Disassembly Assembly Procedures wc_tx000428gb fm 141 a b c d g f e h j k i l m n o wc_gr002430 p q r t s...

Page 146: ...Disassembly Assembly Procedures LTC Repair wc_tx000428gb fm 142 8 6 Tower Assembly Exploded View wc_gr002167 j 550 lbs 250 Kg a b c d e f g h i n l m k p...

Page 147: ...wiring at each light fixture s quick disconnect or at the junction box Then remove each light fixture Store the light fixtures in a safe place 8 8 2 When replacing the upper mast cross member j only d...

Page 148: ...uring the cable to the upper mast Once free from the upper mast run the cable back through the opening near the guide screw in the mid mast and remove cable completely from the machine Reassembly Repl...

Page 149: ...sembly Assembly Procedures wc_tx000428gb fm 145 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_gr002432 aa dd ee cc bb...

Page 150: ...he masts are free from the cradle locking pin 8 9 3 Remove the upper mast cross member j with the junction box attached 8 9 4 Remove the upper mast cable eyebolt p 8 9 5 Using the mast mounted winch b...

Page 151: ...ing screws Position the guides so that the self tapping screws thread themselves into the smaller side of the tapered hole in the guide Note Limit reuse of the guides to one time The guides must be in...

Page 152: ...Mid Mast 8 10 2 Disconnect the wiring from the control panel by Snipping the wire ties a Disconnecting the wires from the capacitors b Disconnecting the wires from terminal strip c 8 10 3 Loosen the c...

Page 153: ...LTC Repair Disassembly Assembly Procedures wc_tx000428gb fm 149 c a b c e d f h i j g wc_gr002434...

Page 154: ...lower curled portion of the cable Then secure the cable clip to the end of the main mast 8 10 14 Thread the tower supply cable through the eyes e on the main mast 8 10 15 Thread the tower supply cable...

Page 155: ...LTC Repair Disassembly Assembly Procedures wc_tx000428gb fm 151 h k i j l d a f g b e wc_gr002435 c...

Page 156: ...1 6 Position the spool so that the retaining clamp d is accessible 8 11 7 Loosen the screw which secures the clamp and the cable and remove the cable from the spool 8 11 8 To remove the winch disconne...

Page 157: ...LTC Repair Disassembly Assembly Procedures wc_tx000428gb fm 153 wc_gr003159 b c d e a f g...

Page 158: ...ire ties g 8 12 8 Remove the bolts h securing the hold down straps i 8 12 9 Disconnect the fuel intake j and return lines k 8 12 10 With the aid of a partner or appropriate hoist lift the fuel tank fr...

Page 159: ...LTC Repair Disassembly Assembly Procedures wc_tx000428gb fm 155 wc_gr002445 a b c e g k h i j d f...

Page 160: ...8 13 3 Make note of the wire connections on the hour meter and remove the wires a from the hour meter 8 13 4 Pull out the tabs b on the locking bracket c and remove the hour meter from the panel Reas...

Page 161: ...5 ml 17380 50 ml Loctite 271 277 Hernon 427 Omnifit 1550 220M Red High strength for all threads up to 25 mm 1 Heat parts before disassembly Temp range 54 to 149 C 65 to 300 F 29312 5 ml 26685 10 ml 7...

Page 162: ...ts follow instructions on container The sealants listed are recommended for use on Wacker equipment TYPE Europe COLOR USAGE PART NO SIZE Loctite 496 Hernon 110 Omnifit Sicomet 7000 Clear Instant adhes...

Page 163: ...5 M4 2 9 26 4 1 36 4 9 43 7 9 32 3 M5 6 0 53 8 5 6 10 7 8 5 16 4 M6 10 7 14 10 17 13 10 5 M8 25 18 35 26 41 30 13 1 2 6 M10 49 36 69 51 83 61 17 11 16 8 M12 86 63 120 88 145 107 19 3 4 10 M14 135 99 1...

Page 164: ...8 2 5 22 3 5 31 4 7 42 9 11 32 9 64 No 10 3 6 32 5 1 45 6 8 60 3 8 5 32 1 4 8 1 6 12 9 16 12 7 16 3 32 5 16 18 13 26 19 33 24 13 1 2 1 4 3 8 31 23 45 33 58 43 9 16 5 16 7 16 50 37 71 52 94 69 16 5 8...

Page 165: ......

Page 166: ...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 Skyline Tower Suite 2303 2...

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