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Appendix I—Assembly Instructions

LTN

68

wc_tx001218gb.fm

9

Appendix I—Assembly Instructions

9.1

Introduction

Scope

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

Hardware bags

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

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

Machine
identification

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

Bag No.

Contents

Bag No.

Contents

1

Axle hardware

5

Tower lock hardware

2

Fender hardware

6

Light fixture hardware

3

Wheel hardware

7

Tongue hardware

4

Tower cradle hardware

8

Tower installation hardware

Item No.

Description

Illustration

See Chapter:

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

Standard palletized

A

Appendix III

Optional

CE palletized

B

Appendix IV

0620550
0620551
0620552

Standard racked

C

Appendix V

0620119
0620120
0620557
0620558

CE racked

D

Appendix VI

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Summary of Contents for LTN 6L

Page 1: ...0171883en 007 1110 0 1 7 1 8 8 3 E N Operator s Manual Light Tower LTN 6L 60 Hz ...

Page 2: ... distribution not authorized by Wacker Neuson Corporation represents an infringement of valid copyrights Violators will be prosecuted Trademarks All trademarks referenced in this manual are the property of their respective owners Manufacturer Wacker Neuson Corporation N92W15000 Anthony Avenue Menomonee Falls WI 53051 U S A Tel 262 255 0500 Fax 262 255 0550 Tel 800 770 0957 www wackerneuson com Ori...

Page 3: ...nings 18 3 Lifting the Machine 30 3 1 Procedure 30 4 Operation 31 4 1 Locating Trailer 31 4 2 Leveling Trailer 32 4 3 Adjusting Lights 33 4 4 Preparing Trailer for Towing or Lifting 34 4 5 Raising Tower Manual Winch System 35 4 6 Lowering Tower Manual Winch System 38 4 7 Raising Tower Power Winch System 40 4 8 Lowering Tower Power Winch System 42 4 9 Emergency Crank Handle Power Winch System 43 4 ...

Page 4: ...enance 52 6 1 Periodic Maintenance Schedule 52 6 2 Installing Removing Light Fixtures 53 6 3 Replacing Removing Lamps 54 6 4 Daily Inspection 55 6 5 Air Cleaner 56 6 6 Engine Oil 56 6 7 Troubleshooting 57 7 Technical Data 58 7 1 Engine 58 7 2 Generator 59 7 3 Machine 59 8 Schematics 60 8 1 Electrical Schematic 60 8 2 Electrical Schematic 120 240 62 8 3 Trailer Wiring 64 8 4 Engine Wiring Lombardin...

Page 5: ...sembly 75 11 4 Installing the Upper Light Fixtures 77 11 5 Conclusion 78 12 Appendix IV CE Pallet Assembly 79 12 1 Installing the Side Jacks 80 12 2 Installing the Rear Jack 81 12 3 Conclusion 82 13 Appendix V Standard Racked Assembly 83 13 1 Installing the Axle 84 13 2 Installing the Fenders 85 13 3 Installing the Wheels 85 13 4 Installing the Outriggers and Outrigger Jacks 86 13 5 Installing the...

Page 6: ...cked Assembly 101 14 1 Attaching the Outriggers and Outrigger Jacks 103 14 2 Attaching the Rear Jack 104 14 3 Attaching the Tower Lock Bracket 105 14 4 Attaching the Tower Cradle 105 14 5 Installing the Tower 106 14 6 Installing the Tower Pivot Cable 108 14 7 Attaching the Light Mount Bracket and Light Bar 109 14 8 Attaching the Lights 110 14 9 Wiring the Junction Box 111 14 10 Routing the Coil Co...

Page 7: ...until the time of publication Wacker Neuson Corporation reserves the right to change any portion of this information without notice CALIFORNIA Proposition 65 Warning Engine exhaust some of its constituents and certain vehicle components contain or emit chemicals known to the State of California to cause cancer and birth defects or other reproductive harm Laws pertaining to spark arresters NOTICE S...

Page 8: ...parts attachments or modifications may have the following conse quences 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 9: ...personal hazards f Obey all safety messages that follow this symbol DANGER DANGER indicates a hazardous situation which if not avoided will result in death or serious injury f To avoid death or serious injury from this type of hazard obey all safety mes sages that follow this signal word WARNING WARNING indicates a hazardous situation which if not avoided could result in death or serious injury f ...

Page 10: ...anently damage the machine or seriously injure the operator or other persons in the area Machine damage caused by misuse is not covered under warranty The following are some examples of misuse Connecting a load that has voltage and frequency requirements that are incompatible with the machine output Overloading the machine with a device that draws excessive power during either continuous running o...

Page 11: ...the machine Machines operated improperly or by untrained personnel can be hazardous Read the operating instructions contained in this manual and the engine manual and familiarize yourself with the location and proper use of all controls Inexperienced operators should receive instruction from someone familiar with the machine before being allowed to operate it Operator qualifications Only trained p...

Page 12: ... handling 1 3 9 Keep the area behind the trailer clear of people while raising and lowering the tower Never raise lower or turn the tower while unit is operating 1 3 10 The trailer must be leveled and the outriggers extended before raising the tower The outriggers must remain extended while the tower is up 1 3 11 If for any reason any part of the tower hangs up or the winch cable develops slack wh...

Page 13: ...esent Move the machine away from the spill and wipe the machine dry before starting Refueling safety When refueling the engine Clean up any spilled fuel immediately Refill the fuel tank in a well ventilated area Replace the fuel tank cap after refueling Do not smoke Do not refuel a hot or running engine Do not refuel the engine near sparks or open flames WARNING Internal combustion engines present...

Page 14: ...s broken or punctured are commercially available 1 6 Service Safety HIGH VOLTAGE This unit uses high voltage circuits capable of causing serious injury or death Only a qualified electrician should troubleshoot or repair electrical problems occurring with this equipment Personal Protective Equipment PPE Wear the following Personal Protective Equipment PPE while servicing or maintaining this machine...

Page 15: ... loose clothing away from the moving parts on the generator and engine 1 6 6 Keep the machine clean and labels legible Replace all missing and hard to read labels Labels provide important operating instructions and warn of dangers and hazards 1 6 7 When replacement parts are required for this machine use only Wacker Neuson replacement parts or those parts equivalent to the original in all types of...

Page 16: ...Labels LTN 6L 16 wc_si000381gb fm 2 Labels 2 1 Label Locations wc_gr007036 B H D I G P O X J K Z Q S R T CC BB BB AA AA EE C A E V ...

Page 17: ...LTN 6L Labels wc_si000381gb fm 17 wc_gr007037 R S U V L H F B N J M D Y FF AA AA DD BB GG EE CC BB HH JJ ...

Page 18: ...g tower can cause serious injury or death if a person is hit To secure tower verify automatic locking pin has been engaged B WARNING Avoid crushing area C DANGER Contact with overhead electrical power lines will cause serious injury or death Do not position Light Tower under electrical power lines WARNING Completely lower tower BEFORE tilting tower Tilting an extended tower can cause serious injur...

Page 19: ...arks flames or burning objects near machine Stop the engine before adding fuel Use only diesel fuel G DANGER Asphyxiation hazard Engines emit carbon monoxide Do not run the machine indoors or in an enclosed area unless adequate ventilation through such items as exhaust fans or hoses is provided Read the Operator s Manual No sparks flames or burning objects near the machine Stop the engine before r...

Page 20: ...qualified electrician for service or to open electrical box I WARNING Read and understand the supplied Operator s Manual before operating the machine Failure to do so increases the risk of injury to yourself and others J WARNING Stand clear of front and rear of machine when tower is being tilted up or down K WARNING Hot surface L WARNING Hot surface ...

Page 21: ...o it will be available should the nameplate become lost or damaged When ordering parts or requesting service infor mation you will always be asked to specify the model number item number revision number and serial number of the unit N 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 fixtu...

Page 22: ...alide lamp information and troubleshooting Before starting engine Check levels of Engine oil Fuel Coolant Circuit breakers off Start engine Engine control panel Auto heating Preheat Light out Start 15 sec max Circuit breakers on Shut down Circuit breakers off Stop engine ...

Page 23: ...metal halide lamp information and troubleshooting Before starting engine Check levels of Engine oil Fuel Coolant Circuit breakers off Start engine Engine control switch Preheat 30 sec Start 15 sec max Circuit breakers on Shut down Circuit breakers off Stop engine ...

Page 24: ...nual Winch System To raise tower 1 Release transport lock 2 Tilt tower using winch 3 Tilt tower until automatic locking pin snaps into place To increase height of tower 4 Raise tower using winch To aim lights 5 Rotate tower and tighten knob ...

Page 25: ...ll lights and engine 2 Rotate tower and tighten knob 3 Lower tower using winch To tilt tower for transport 4 Release and hold spring loaded pin 5 Tilt tower using winch To secure tower for transport 6 Insert pin through transport lock and secure with pin 7 Position light fixtures down ...

Page 26: ...wer Winch System To raise tower 1 Release transport lock 2 Tilt tower using winch 3 Tilt tower until automatic locking pin snaps into place To increase height of tower 4 Raise tower using winch To aim lights 5 Rotate tower and tighten knob ...

Page 27: ...nob 3 Lower tower using winch To tilt tower for transport 4 Release and hold spring loaded pin 5 Tilt tower using winch To secure tower for transport 6 Insert pin through transport lock and secure with pin 7 Position light fixtures down U Coolant overflow bottle only not a return system V WARNING Pinching hazard Rotating machinery ...

Page 28: ...nd sharp turns when towing Al remolcar evite altas Al remolcar evite altas velocidades aceleracion velocidades aceleracion rapida y vueltas agudas rapida y vueltas agudas DANGER DE RETORNEMENT DANGER DE RETORNEMENT AVERTISSEMENT AVERTISSEMENT ADVERTENCIA ADVERTENCIA PELIGRO DE VUELCO PELIGRO DE VUELCO Avoid high speeds rapid Avoid high speeds rapid acceleration and sharp turns acceleration and sha...

Page 29: ...CAN KILL YOU IN MINUTES Light tower exhaust contains carbon monoxide This is a poison you cannot see or smell NEVER use inside a home or garage EVEN IF doors and windows are open Only use OUTSIDE and far away from windows doors and vents UTILITY 159116 UTILITY 159116 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 ...

Page 30: ...safety pin 3 1 2 Ensure that the tower is completely nested inside the transport cradle and the pin b is secure 3 1 3 Make sure the doors are properly latched 3 1 4 Return the outriggers to their travel position Check that the outrigger bars and jacks are locked in place 3 1 5 Crank the rear jack c all the way in and rotate it 90 The Light Tower is now ready to lift wc_gr005415 a c b ...

Page 31: ...on the trailer on a firm flat surface clear of overhead wires and obstructions Be sure that there is enough area for outrigger extensions to be fully extended 4 1 3 Connect the ground stud l located on the trailer frame to a good earthen ground Consult local codes for proper grounding techniques The tower extends up to 9 m 30 ft Make sure the area above the trailer is open and clear of overhead wi...

Page 32: ... fall 4 2 1 Pull the locking pin on the tongue jack a and rotate the tongue jack 90 as shown Block or chock the trailer wheels b Crank the tongue jack down to raise the trailer tongue off the vehicle 4 2 2 Pull the outrigger lock pin c to release the outrigger Pull both outrigger extensions d out until you feel outrigger lock pin lock back into place Rotate jacks e down 4 2 3 Rotate rear jack f do...

Page 33: ...oosening toolless light adjusters g and aiming the light up or down DO NOT loosen the inside nut x Loosening this nut could cause damage to the light fixture Loosen the nut h to turn light fixtures left or right Tighten adjusters and nuts after positioning the lights Always return the light fixtures to aim at the ground when the tower is in the cradle for towing ...

Page 34: ...The Light Tower is now ready to lift Use the designated lift points For towing continue 4 4 6 Use the tongue jack a to raise the trailer tongue up and then lower it over hitch on towing vehicle Lock the hitch to coupling and attach the safety chains Swivel the tongue jack 90 and lock it in place 4 4 7 Connect the trailer wiring to the towing vehicle Check the brake turn and tail lights for proper ...

Page 35: ...an automatic brake type winch that automatically brakes when the handle is released The handle must be rotated to wind in the cable as well as to unwind the cable NEVER touch the winch pawl Releasing the pawl may cause the tower to fall 4 5 1 Check winch cables n for wear or damage and make sure they are resting properly in pulleys Do not use the Light Tower if either winch cable is damaged 4 5 2 ...

Page 36: ...r 4 5 5 After the tower is in the vertical position check the operation of the telescoping winch q by rotating the winch handle 1 4 turn clockwise cable in direction The winch pawl must engage winch gear teeth When operating properly it will make a clicking sound when the winch handle is rotated clockwise Do not attempt to raise the tower if the winch is damaged or not operating properly Continue ...

Page 37: ...LTN 6L Operation wc_tx000766gb fm 37 o ...

Page 38: ...euson service representative immediately NEVER lower the tower while the unit is operating NEVER allow anyone to stand near the rear of the unit while lowering the tower 4 6 1 Turn the lights off Shut down the engine NOTICE Shutting down the engine before turning off the lights could damage floodlight ballasts or generator capacitor s NOTICE Observe power cord while lowering the tower Make sure th...

Page 39: ...etrates all sections of the tower NEVER pull the vertical tower locking pin e while the tower is raised Releasing the locking pin while the tower is raised may cause the tower to fall or the machine to tip over 4 6 5 After the tower is down secure it in the cradle by inserting the cradle lock pin j Insert the clip through the pin to secure it in place 4 6 6 Position the light fixtures to aim at th...

Page 40: ...or wear or damage and make sure they are resting properly in the pulleys Do not use the Light Tower if either winch cable is damaged 4 7 2 Remove the cradle locking pin j from the cradle 4 7 3 Check the operation of the tilt winch o Turn the vertical rotary switch v on the control panel to the up position Do not attempt to raise the tower if the winch is damaged or not operating properly NOTICE Co...

Page 41: ...nue to hold switch in the up position until tower is at the desired height Release switch when tower is fully extended NOTICE Continuous running of the winch in excess of 4 minutes will damage the winch motor NOTICE Do not extend tower beyond red marking on tower 4 7 6 Once the tower is at the desired height rotate the tower to the desired direction To rotate loosen rotation locking knob s Then ro...

Page 42: ... tower while the unit is operating NEVER allow anyone to stand near the rear of the unit while lowering the tower 4 8 1 Turn the lights off Shut down the engine NOTICE Shutting down the engine before turning off the lights could damage the floodlight ballasts or the generator capacitor s NOTICE Observe the power cord while lowering the tower Make sure the coiled cord is not damaged during the lowe...

Page 43: ...e cradle by inserting the cradle lock pin j Insert the clip through the pin to secure it in place 4 8 6 Position the light fixtures to aim at the ground NOTICE Allow the floodlights to cool 10 15 minutes before moving the trailer Moving the trailer while the lights are still hot could cause lamps to break 4 9 Emergency Crank Handle Power Winch System An emergency crank handle is provided for use i...

Page 44: ...ker k High coolant temperature shutdown b 30 Amp lights circuit breaker l Alternator indicator c 20 Amp GFI circuit breaker m Auxiliary lights not used d 20 Amp GFI receptacle n Glow plug indicator e Hour meter o Air filter restriction indicator f Low fuel indicator not used p Auxiliary lights not used g Safety shutdown indicator q Key access door h Low oil pressure shutdown ...

Page 45: ...r e Hour meter o Air filter restriction indicator f Low fuel indicator not used p Auxiliary lights not used g Safety shutdown indicator q Key access door h Low oil pressure shutdown r 30 Amp receptacle wc_gr006329 r WARNING WARNING WARNUNG WARNUNG ADVERTENCIA ADVERTENCIA AVERTISSEMENT AVERTISSEMENT NEUTRAL BONDED TO FRAME NEUTRAL BONDED TO FRAME CONDUCTOR NEUTRO CONDUCTOR NEUTRO CONECTADO AL CHASI...

Page 46: ...tor b 30 Amp lights circuit breaker m Auxiliary light not used c 20 Amp GFI circuit breaker n Glow plug indicator d 20 Amp GFI receptacle o Air filter restriction indicator e Hour meter p Auxiliary light not used f Low fuel indicator not used q Key access door g Safety shutdown indicator v Tilt rotary switch h Low oil pressure shutdown w Telescope rotary switch k High coolant temperature shutdown ...

Page 47: ...ot crank engine longer than 10 seconds This could cause starter motor to overheat Return switch to the off position and wait 15 30 seconds for starter motor to cool down before attempting to preheat and restart Note If oil pressure is not obtained within 30 seconds after key is turned to RUN the automatic shutdown system will shut off the fuel supply You must return the key to the off position to ...

Page 48: ...c wc_gr005140 wc_gr006328 wc_gr005141 wc_gr005142 4 17 1 Turn the circuit breakers a b c off and remove any other loads from the generator NOTICE Never shut down the engine without turning off the lights Damage to the generator will occur 4 17 2 Turn the key q to the off position 4 18 Derating All generator sets are subject to derating for altitude and temperature Although derating should not affe...

Page 49: ...with all of the lights on or the lights will turn off A circuit breaker c protects the Ground Fault Interrupt GFI receptacle d The GFI receptacle should be tested for proper operation each time it is used To test a GFI Push the test button in The reset button should pop out Power to the receptacle is now off To restore power to receptacle push reset button in NOTICE If the reset button does not po...

Page 50: ...er Revision and Serial Number is attached to each unit Please have this information available when contacting Wacker Neuson Corporation The illustrations shown in this chapter represent typical installations The factory installed options on your machine may look different 5 1 Block Heater The engine block heater option includes a block heater a with a cord b The function of the block heater is to ...

Page 51: ... frozen or discharged battery Plug the cord into a 120V power supply 5 3 Oil Pan Heater Cold thick engine oil does not flow freely and may cause engine starting difficulties An oil pan heater installed on the engine oil pan keeps the oil warm and flowing Heat from this electrical device warms the supply of engine oil contained in the pan while the machine is not in use Plug the cord into a 120V po...

Page 52: ...vel 3 Replace air filter if indicator light is on Change engine oil Check level of battery electrolyte Check condition and tension on fan belt Check condition of radiator hoses Replace oil filter Replace fuel filter Flush radiator Replace fan belt Check valve clearance Remove sediment in fuel tank Change radiator coolant Replace battery Replace radiator hoses and clamps Replace fuel pipes and clam...

Page 53: ...xture and bracket off stud NOTICE Only a trained technician should be allowed to install and remove fixture wiring Lamps become extremely hot in use Allow lamp and fixture to cool 10 15 minutes before handling Numbering Sequence of Floodlights Junction Box Wiring for Floodlights Wire Colors BK Black RD Red YL Yellow OR Orange GN Green TN Tan BR Brown PU Purple BU Blue VIO Violet CL Clear SH Shield...

Page 54: ...nutes before handling WARNING Personal injury hazard Ultraviolet radiation from the lamps can cause serious skin and eye irritation f Use only undamaged lamps f Use the lamps only with undamaged original equipment lenses and fixtures WARNING Explosion hazard Grease or oil residue on the lamp can cause the outer jacket to burst or shatter Hot flying glass particles can cause personal injury propert...

Page 55: ...tion Secure it with the lamp stabilizer 6 3 5 Install the gasket around the lens and secure the lens to the reflector with the flange rings and screws 6 4 Daily Inspection 6 4 1 Check for fluid leaks Check fluid levels 6 4 2 Inspect condition of electrical cords Do not use Light Tower if insulation is cut or worn through 6 4 3 Check that winch cables are in good condition Do not use a cable that i...

Page 56: ...ine Oil See Graphic wc_gr005394 Drain the oil while the engine is still warm Note In the interests of environmental protection place a plastic sheet and a container under the machine to collect any liquid which drains off Dispose of this liquid in accordance with environmental protection legislation 6 6 1 Locate the oil drain hose and remove the plug from the end of the hose 6 6 2 Allow the oil to...

Page 57: ...n or loose components in lamp envelope blackening or deposits inside lamp tube Circuit breaker turned on Turn off circuit breaker Circuit breaker loose or defective Have a licensed electrician repair or replace the circuit breaker Generator output incorrect Check incoming voltage to ballast Incoming voltage should be 120V 5V If voltage is incorrect engine speed may need to be adjusted or generator...

Page 58: ...ke Lombardini Model LDW1003 Type 3 cylinder 4 cycle liquid cooled diesel Max power rating rated speed kW Hp 10 0 13 4 1800 rpm Operating speed no load rpm 1800 Alternator V A W 12 45 540 Battery V Ah CCA 12 650 Air cleaner type Dry type element Fuel type No 2 diesel Fuel tank capacity l gal 123 32 5 Fuel consumption l gal hr 1 71 0 45 Running time hours 67 Coolant capacity l qts 4 7 5 0 Oil capaci...

Page 59: ...ation type Capacitor Brushless Power factor 1 0 Voltage regulation no load to full load 6 0 Speed no load rpm 1800 Item Number LTN 6L Machine Operating weight GVWR kg lbs 768 1693 Travel Dimensions l x w x h mm in 4600 x 1500 x 1900 180 4 x 59 3 x 73 2 Height tower extended m ft 9 30 Lighting system 1000W 4 Ballast Coil and core Max lighting coverage 0 5 ft candles m2 acres Metal Halide 30 400 7 5...

Page 60: ...0 AWG 15 BK 10 AWG 7 BK 10 AWG 7 BK 10 AWG 6 BK 10 AWG 6 BK 10 AWG 2 2 GN GN WH WH GN GN BL BL 4 4 PU PU WH WH BL BL WH WH BL BL d d d d d d d d m m l l m m l l m m l l m m l l b b i i b b e e g g f f f f c c n n a a j j h h b b k k 14 BK OR 14 BK OR 13 OR 13 OR 4 4 BK BK RD RD GN GN WH WH GN GN BL BL 1 1 OR OR WH WH BR BR 3 3 BL BL YL YL GN GN 2 2 YL YL YL YL BK YL BK YL 1 1 YL YL YL YL 3 3 BK YL...

Page 61: ...in circuit breaker 50 Amp j Engine d Floodlights k Hour meter e Receptacle 120V l Transformers f Circuit breaker 30 Amp m Capacitors 24 mF g Circuit breaker 20 Amp n Capacitor 25 mF Wire Colors BK Black RD Red YL Yellow OR Orange GN Green TN Tan BR Brown PU Purple BU Blue VIO Violet CL Clear SH Shield PK Pink WH White GY Gray LB Lt blue ...

Page 62: ...WG 2 2 GN GN W W GN GN BL BL 4 4 PU PU W W BL BL W W BL BL 14 14 13 13 4 4 BK BK RD RD GN GN W W GN GN BL BL 1 1 OR OR W W BR BR 3 3 BL BL YL YL GN GN 2 2 YL YL YL YL BK YL BK YL 1 1 YL YL YL YL 3 3 BK YL BK YL 11 GN YL 12 AWG 11 GN YL 12 AWG 5 BK 5 BK 10 AWG 10 AWG 10 WH 10 AWG 10 WH 10 AWG BK YL BK YL YL YL YL YL W W PU PU 8 WH 10 AWG 8 WH 10 AWG YL YL BK YL BK YL YL YL 7 BK 10 AWG 7 BK 10 AWG 9...

Page 63: ...reaker 25 Amp k Hour meter d Floodlights l Transformers e Receptacle 120V m Capacitors 24 mF f Circuit breaker 30 Amp n Capacitor 25 mF g Circuit breaker 20 Amp o Receptacle 120 240V h Battery Wire Colors BK Black RD Red YL Yellow OR Orange GN Green TN Tan BR Brown PU Purple BU Blue VIO Violet CL Clear SH Shield PK Pink WH White GY Gray LB Lt blue ...

Page 64: ...re Colors BK Black RD Red YL Yellow OR Orange GN Green TN Tan BR Brown PU Purple BU Blue VIO Violet CL Clear SH Shield PK Pink WH White GY Gray LB Light blue BR BR GN GN WH WH BL BL RD RD BL BL WH WH WH WH BL BL BL BL WH WH BL BL BL BL BR BR YL YL RD RD BL BL WH WH GN GN YL YL BR BR BL BL BL BL WH WH BL BL BL BL GN GN YL YL BR BR WH WH GN GN RD RD BL BL WH WH TONGUE WIRING TONGUE WIRING c a a e d ...

Page 65: ...mal open type 2 Glow plugs 8 Low fuel level switch not used normal open type 3 Starter motor 9 Low oil pressure switch normal closed type 4 Battery 10 Coolant high temperature switch nor mal open type 5 Alternator connector 11 Coolant temperature thermistor for preheat relay 6 Coolant temperature sending unit not used for remote temperature gauge or LED ...

Page 66: ...escription 1 System fuse 50 Amp 4 Key switch 2 Glow plug load relay 5 L E D Indicator lamp assembly 3 Auxiliary terminals rear view L B L W R Or B Pr R Gr W L P Br Y G G B W B Br Y G R R 86 85 30 87 4 2 7 6 5 12 10 9 50 30 1 5 5 4 wc_gr000658 1 2 5 3 4 1 2 3 4 5 6 7 8 9 10 11 12 13 14 ...

Page 67: ...ch b Battery f Tilt winch c 70A blade fuse g Telescope winch d Tilt switch 6 BK 6 BK 5 RD 5 RD a a c c d d e e g g f f b b B1 B1 A1 A1 8 BK 8 BK A2 A2 7 RD 7 RD 1 BK 1 BK B2 B2 2 RD 2 RD 3 BK 3 BK 2 RD 2 RD 3 BK 3 BK 1 BK 1 BK 4 RD 4 RD A1 A1 B1 B1 A2 A2 6 BK 6 BK 8 BK 8 BK B2 B2 7 RD 7 RD 4 RD 4 RD 5 RD 5 RD wc_gr005371 ...

Page 68: ...ginning of the instructions for that specific procedure Machine identification Use the following chart and the illustrations on the next page to determine which set of assembly procedures applies to your machine Bag No Contents Bag No Contents 1 Axle hardware 5 Tower lock hardware 2 Fender hardware 6 Light fixture hardware 3 Wheel hardware 7 Tongue hardware 4 Tower cradle hardware 8 Tower installa...

Page 69: ...LTN Appendix I Assembly Instructions wc_tx001218gb fm 69 Illustrations D wc_gr006517 ...

Page 70: ...dicates a hazardous situation which if not avoided will result in death or serious injury f To avoid death or serious injury from this type of hazard obey all safety messages that follow this signal word WARNING WARNING indicates a hazardous situation which if not avoided could result in death or serious injury f To avoid possible death or serious injury from this type of hazard obey all safety me...

Page 71: ...embly Checklist Before assembling the Light Tower take the following precautions Preparing the assembly area Make sure the area immediately surrounding the Light Tower is clean neat and free of debris The tower extends up to 9 m 30 ft Make sure the area above the machine is open and clear of overhead wires and obstructions Make sure the machine is on a firm level surface and will not tip roll slid...

Page 72: ...f assembly instructions Tasks To complete the assembly of your Light Tower the following tasks must be performed in the order listed Tools and materials The following tools and materials are needed Basic hand tools wrenches screwdrivers etc Torque wrench Hardware bag 7 wc_gr006467 Task Description See topic Outriggers and jacks assembly 1 Install the outriggers 11 1 2 Install the outrigger jacks 1...

Page 73: ...e B1 is aligned release the locking pin to fasten the outrigger in place Installing the outrigger jacks Follow the procedure below to Install the two outrigger jacks Use the same procedure for each outrigger jack 1 Locate the two 15 inch travel jacks outrigger jacks C 2 If necessary remove the locking pin C3 from the holes in the outrigger jack 3 Fit the socket C1 on the outrigger jack over the ci...

Page 74: ...ove the locking pin D4 from the holes in the jack 3 Fit the socket D1 over the circular boss D2 on the rear of the machine 4 Rotate the jack so that the foot D3 rests on the ground 5 Align the top hole in the socket with the top hole on the circular boss 6 Insert the locking pin into the holes Push the locking pin through both sets of holes top and bottom to fasten the outrigger jack in place D2 D...

Page 75: ...tongue jack and connecting the trailer wiring Installing the tongue Follow the procedure below to Install the tongue 1 Insert the tongue H into the sleeve at the front of the trailer 2 Fasten the tongue to the sleeve using the following hardware from Bag 7 3 M16 x 120 screws E 6 B17 flat washers F 3 M16 lock nuts G Torque the fasteners to 200 Nm 145 ft lbs H F G E wc_gr006523 ...

Page 76: ...mbly 4 Rotate the tongue jack so that the foot J2 rests on the ground 5 Align the top hole in the socket with the top hole on the circular boss 6 Insert the locking pin into the holes Push the locking pin through both sets of holes top and bottom to fasten the tongue jack in place Connecting the trailer wiring 1 Locate connectors K and L 2 Plug the tongue wiring harness connector K into tongue wir...

Page 77: ... the procedure below to install the upper light fixtures Install the two upper light fixtures CC on the light tube as follows 1 Position each light fixture on the mounting bolt CC1 so that the lamp is facing downward Make sure that the T handle CC4 faces outward 2 Fasten each light fixture to the light tube using an M18 lock nut CC3 and a B19 flat washer CC2 wc_gr007981 CC3 CC4 CC1 CC2 CC ...

Page 78: ...let Assembly LTN 78 wc_tx001214gb fm 11 5 Conclusion This completes the assembly procedure for your Light Tower Refer to your Operator s Manual for instructions on setting up operating maintaining and storing the machine Notes ...

Page 79: ...not look like the one shown in the illustration refer to Machine Identification in the Introduction chapter to identify the appropriate set of assembly instructions Tasks To complete the assembly of your Light Tower the following tasks must be performed in the order listed Tools and materials The following tools and materials are needed Appropriate machine lifting gear Basic hand tools wrenches sc...

Page 80: ... jacks C 2 If necessary remove the locking pin C3 from the holes in the jack 3 Fit the jack socket C1 over the circular end of the outrigger B 4 Rotate the jack so that the foot C2 rests on the ground 5 Align the top hole in the socket with the top hole on the outrigger 6 Insert the locking pin into the holes Push the locking pin through both sets of holes top and bottom to fasten the jack in plac...

Page 81: ...the locking pin D4 from the holes in the jack 3 Fit the socket D1 over the circular boss D2 on the rear of the machine 4 Rotate the jack so that the foot D3 rests on the ground 5 Align the top hole in the socket with the top hole on the circular boss 6 Insert the locking pin into the holes Push the locking pin through both sets of holes top and bottom to fasten the outrigger jack in place D2 wc_gr...

Page 82: ... Assembly LTN 82 wc_tx001215gb fm 12 3 Conclusion This completes the assembly procedure for your Light Tower Refer to your Operator s Manual for instructions on setting up operating maintaining and storing the machine Notes ...

Page 83: ...r Light Tower the following tasks must be performed in the order listed wc_gr006469 Task Description See topic Chassis assembly 1 Install the axle 13 1 2 Install the fenders 13 2 3 Install the wheels 13 3 4 Install the outriggers and outrigger jacks 13 4 5 Install the rear jack 13 5 6 Install the tongue assembly 13 6 Tower assembly 7 Install the tower lock bracket 13 7 8 Install the tower cradle 1...

Page 84: ...nd fabricated parts 13 1 Installing the Axle Procedure Follow the procedure below to install the axle 1 Lift the machine using appropriate lifting gear Refer to topic Lifting the Machine in the Safety Information chapter 2 Locate the axle Q and hardware bag 1 3 Install the axle on the trailer using the following hardware 4 Bolts Q1 8 Washers Q2 4 Nuts Q3 4 Torque the fasteners to 115 Nm 85 ft lbs ...

Page 85: ...3 M6 x 16 serrated flange screws but do not tighten the screws until the next step 4 Slide each fender backward until the mounting screws are located at the front end of the slots Torque the screws to 16 Nm 11 5 ft lbs 13 3 Installing the Wheels Installing the wheels Follow the procedure below to Install the wheels 1 Locate the two wheels U and hardware bag 3 2 Install the wheels on the axle using...

Page 86: ... B1 is aligned release the locking pin to fasten the outrigger in place Installing the outrigger jacks Follow the procedure below to Install the two outrigger jacks Use the same procedure for each outrigger jack 1 Locate the two 15 inch travel jacks outrigger jacks C 2 If necessary remove the locking pin C3 from the holes in the outrigger jack 3 Fit the socket C1 on the outrigger jack over the cir...

Page 87: ...ve the locking pin D4 from the holes in the jack 3 Fit the socket D1 over the circular boss D2 on the rear of the machine 4 Rotate the jack so that the foot D3 rests on the ground 5 Align the top hole in the socket with the top hole on the circular boss 6 Insert the locking pin into the holes Push the locking pin through both sets of holes top and bottom to fasten the outrigger jack in place D2 D ...

Page 88: ...ongue jack and connecting the trailer wiring Installing the tongue Follow the procedure below to Install the tongue 1 Insert the tongue H into the sleeve at the front of the trailer 2 Fasten the tongue to the sleeve using the following hardware from Bag 7 3 M16 x 120 screws E 6 B17 flat washers F 3 M16 lock nuts G Torque the fasteners to 200 Nm 145 ft lbs H F G E wc_gr006523 ...

Page 89: ...bly 4 Rotate the tongue jack so that the foot J2 rests on the ground 5 Align the top hole in the socket with the top hole on the circular boss 6 Insert the locking pin into the holes Push the locking pin through both sets of holes top and bottom to fasten the tongue jack in place Connecting the trailer wiring 1 Locate connectors K and L 2 Plug the tongue wiring harness connector K into tongue wiri...

Page 90: ...w the procedure below to Install the tower lock bracket 1 Locate the following in hardware bag 5 1 tower lock bracket M 3 M8 x 20 hex head mounting screws N 3 M8 flat washers O 3 M8 lock nuts P 2 Install the tower lock bracket on the tower as shown 3 Torque the mounting screws to 35 Nm 25 ft lbs wc_gr006526 M N O P ...

Page 91: ...ated flange screws Y4 install the radiator access cover Y2 and radiator cover plate Y3 to the tower cradle Torque the screws to 16 Nm 11 5 ft lbs 3 Using 2 M12 washers Y9 and the M12 locknut Y10 install the tower lock pin Y8 on the tower cradle Note Do not tighten locknut Y10 until the next assembly topic Installing the Tower 4 Place the tower damper Y7 over the tower lock pin Note The large hole ...

Page 92: ...ugh the holes in the tower support Z4 and the tower 4 Place the 1 inch flat washer Z3 over the end of the clevis pin Fasten the tower in place with the 3 16 x 2 cotter pin Z2 5 Adjust the alignment of the tower lock pin Y8 if necessary Torque lock nut Y10 to 48 Nm 35 ft lbs Reversing the winch handles The winch handles AA2 are installed backward to protect them from shipping damage Reverse each ha...

Page 93: ...e cotter pin AA6 3 Route the free end of the cable around the lower pulley and over the top of the upper pulley Refer to the directional arrows in the illustration above 4 Pass the cable below the winch drum and wind it two or three times around the winch drum 5 Pass the free end of the cable through the hole in the winch drum Wind the cable once around the bearing drum axle 6 Loosen the two nuts ...

Page 94: ...B on the tower using 2 M16 x 90 screws BB1 2 B17 flat washers BB2 and 2 M16 lock nuts BB3 Torque the screws to 83 Nm 60 ft lbs Install the four light fixtures CC on the light tube as follows 1 Position each light fixture so that the lamp is facing downward Make sure that the T handle CC3 faces outward 2 Install each light fixture on the light mount tube using an M18 lock nut CC1 and a B19 flat was...

Page 95: ...DD1 at the bottom of the junction box 3 Insert the end of the coil cord through the connector so that approximately 1 cm 3 8 in of coil cord jacket extends into the junction box Retighten connector DD1 Installing the fixture cords 4 Use two wrenches to loosen the four connectors DD2 on the sides of the junction box 5 Refer to the diagram below and insert the fixture cords through the appropriate c...

Page 96: ...100 7 Connect the green wires from the fixture cords and coil cord along with the green yellow ground wire using the large connector and Panduit wire crimper CT 1500 8 Install the ring terminal on the ground wire to the ground screw FF in the junction box Position Light wire Coil cord wire L1 Black Red White Orange Green L2 Black Black White Brown Green L3 Black Yellow White White Green L4 Black B...

Page 97: ...the coil cord through the connector so that approximately 1 m 3 ft of wires extend inside the Light Tower cabinet and re tighten the connector CN 3 Insert the red black brown and orange wires from the coil cord into one of the supplied looms Pass this loom through the ballast bracket on the right side of the machine R 4 Insert the yellow blue white purple and green wires from the coil cord into th...

Page 98: ...l grounding screw G 3 Locate the four capacitors as shown below 4 Connect four wires from the coil cord to the capacitors as follows 5 Connect the remaining wires to terminal strips A and B according to the diagram and tables on the next page Torque all screws to 2 25 Nm 20 in lbs 6 When all wires are connected to terminal strips A and B re install the ballast covers Torque the ballast cover mount...

Page 99: ...ellows 2 from ballast 1 J Yellows 2 from ballast 2 K White 9 from control box L Brown and orange from coil cord Position Wire description A Black yellow from ballasts 3 and 4 B Black 6 from control box C Yellows 2 from ballast 3 D Yellows 2 from ballast 4 E White 8 from control box F White and purple from coil cord G L Not used wc_gr006538 A A B B C C D D E E F F G G H H I I J J K K L L A A B B C ...

Page 100: ...d Assembly LTN 100 wc_tx001216gb fm 13 15 Conclusion This completes the assembly procedure for your Light Tower Refer to your Operator s Manual for instructions on setting up operating maintaining and storing the machine Notes ...

Page 101: ...ns Tasks To complete the assembly of your Light Tower the following tasks must be performed wc_gr006470 Task Description See topic Chassis assembly 1 Attach the outriggers and outrigger jacks 14 1 2 Attach the rear jack 14 2 Tower assembly 3 Attach the tower lock bracket 14 3 4 Attach the tower cradle 14 4 5 Attach the tower 14 5 6 Attach the tilt winch cable 14 6 Lights assembly 7 Attach the ligh...

Page 102: ...cked Assembly LTN Assembly wc_tx001217gb fm 102 Tools and materials The following tools and materials are needed Basic hand tools wrenches screwdrivers etc Torque wrench Hardware bags 1 2 3 4 5 6 8 and fabricated parts ...

Page 103: ...le B1 is aligned release the locking pin to fasten the outrigger in place Installing the outrigger jacks Follow the procedure below to Install the two outrigger jacks Use the same procedure for each outrigger jack 1 Locate the two 15 inch travel jacks outrigger jacks C 2 If necessary remove the locking pin C3 from the holes in the outrigger jack 3 Fit the socket C1 on the outrigger jack over the c...

Page 104: ...move the locking pin D4 from the holes in the jack 3 Fit the socket D1 over the circular boss D2 on the rear of the machine 4 Rotate the jack so that the foot D3 rests on the ground 5 Align the top hole in the socket with the top hole on the circular boss 6 Insert the locking pin into the holes Push the locking pin through both sets of holes top and bottom to fasten the outrigger jack in place D2 ...

Page 105: ...hardware bag 5 1 tower lock bracket M 3 M8 x 20 hex head mounting screws N 3 M8 flat washers O 3 M8 lock nuts P 2 Install the tower lock bracket on the tower as shown 3 Torque the mounting screws to 35 Nm 25 ft lbs 14 4 Attaching the Tower Cradle Materials needed Tower cradle Hardware bag 4 tower cradle hardware Procedure Follow the procedure below to assemble the tower cradle Y wc_gr006526 M N O ...

Page 106: ...ers Y9 and the M12 locknut Y10 install the tower lock pin Y8 on the tower cradle Note Do not tighten locknut Y10 until the next assembly topic Installing the Tower 4 Place the tower damper Y7 over the tower lock pin Note The large hole on the tower damper must face down 5 Install the hitch pin assembly Y11 to the tower cradle using the M5 x 16 screw Y5 and the M5 locknut Y6 14 5 Installing the Tow...

Page 107: ...er Z3 over the end of the clevis pin Fasten the tower in place with the 3 16 x 2 cotter pin Z2 5 Adjust the alignment of the tower lock pin Y8 if necessary Torque lock nut Y10 to 48 Nm 35 ft lbs Reversing the winch handles The winch handles AA2 are installed backward to protect them from shipping damage Reverse each handle orientation as follows 1 Remove the nut AA1 and remove the winch handle fro...

Page 108: ...the cotter pin AA6 3 Route the free end of the cable around the lower pulley and over the top of the upper pulley Refer to the directional arrows in the illustration above 4 Pass the cable below the winch drum and wind it two or three times around the winch drum 5 Pass the free end of the cable through the hole in the winch drum Wind the cable once around the bearing drum axle 6 Loosen the two nut...

Page 109: ... mount bracket 1 Attach the light mount bracket to the tower using the following hardware 2 M16 x 40 hex head screws JJ 2 M16 hex nuts KK 2 M8 x 20 hex head screws NN 2 B8 4 flat washers OO M8 lock nuts MM Torque the M16 screws to 83 Nm 60 ft lbs Torque the M8 screws to 24 Nm 18 ft lbs Attaching the light bar 2 Attach the light bar to the light mount bracket using 2 M16 x 90 screws BB1 2 B17 flat ...

Page 110: ...ts Hardware Procedure Follow the procedure below to attach the lights to the tower Attach the four light fixtures CC to the light bar as follows 1 Position each light fixture so that the lamp is facing downward 2 Attach each light fixture to the light bar using an M18 lock nut CC1 and a B19 flat washer CC2 wc_gr006533 BB BB CC3 BB3 CC1 CC2 BB1 BB2 CC ...

Page 111: ...the bottom of the junction box 3 Insert the end of the coil cord through the connector so that approximately 1 cm 3 8 in of coil cord jacket extends into the junction box Retighten connector DD1 Installing the fixture cords 4 Use two wrenches to loosen the four connectors DD2 on the sides of the junction box 5 Refer to the diagram below and insert the fixture cords through the appropriate connecto...

Page 112: ...T 100 7 Connect the green wires from the fixture cords and coil cord along with the green yellow ground wire using the large connector and Panduit wire crimper CT 1500 8 Install the ring terminal on the ground wire to the ground screw FF in the junction box Position Light wire Coil cord wire L1 Black Red White Orange Green L2 Black Black White Brown Green L3 Black Yellow White White Green L4 Black...

Page 113: ...f the coil cord through the connector so that approximately 1 m 3 ft of wires extend inside the Light Tower cabinet and re tighten the connector CN 3 Insert the red black brown and orange wires from the coil cord into one of the supplied looms Pass this loom through the ballast bracket on the right side of the machine R 4 Insert the yellow blue white purple and green wires from the coil cord into ...

Page 114: ...onal grounding screw G 3 Locate the four capacitors as shown below 4 Connect four wires from the coil cord to the capacitors as follows 5 Connect the remaining wires to terminal strips A and B according to the diagram and tables on the next page Torque all screws to 2 25 Nm 20 in lbs 6 When all wires are connected to terminal strips A and B re install the ballast covers Torque the ballast cover mo...

Page 115: ... Yellows 2 from ballast 1 J Yellows 2 from ballast 2 K White 9 from control box L Brown and orange from coil cord Position Wire description A Black yellow from ballasts 3 and 4 B Black 6 from control box C Yellows 2 from ballast 3 D Yellows 2 from ballast 4 E White 8 from control box F White and purple from coil cord G L Not used wc_gr006538 A A B B C C D D E E F F G G H H I I J J K K L L A A B B ...

Page 116: ...ed Assembly LTN Assembly wc_tx001217gb fm 116 Result This completes the assembly procedure for your Light Tower Refer to your Operator s Manual for instructions on setting up operating maintaining and storing the machine ...

Page 117: ......

Page 118: ... 390 Wacker Neuson Corporation 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 ...

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