Wacker Neuson LTV 4L Operator'S Manual Download

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Maintenance

General Maintenance 8.1

[en-US] | 02/2023 | 5100065071 | LTV 4L/6L | Operator’s Manual

Maintenance

8.1

General Maintenance

WARNING

Injury and machine damage hazard

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.

8.2

Maintenance Table

Maintenance cycle

Personnel

For further information

Daily

Operating personnel

[

►

79]

Inspecting the Machine

[

►

80]

Maintaining the Trailer

50 hours

Operating personnel

[

►

81]

Checking and Draining the Containment Sys-
tem (if equipped)

250 hours

Operating personnel

Maintaining the Battery

As needed

Operating personnel

[

►

79]

Preparing for Maintenance

Service personnel

[

►

79]

Preparing for Maintenance

[

►

84]

Replacing/Removing Lamps

[

►

87]

Machine Disposal and Decommissioning

8.3

Preparing for Maintenance

Do not perform even routine service (oil/filter changes, cleaning, etc.) unless
all electrical components are shut down. Use the checklist below to prepare
this machine for maintenance.

• Press the Stop button.

• Open the circuit breakers (set to the OFF position).

• Disconnect the negative terminal on the battery.

• Attach a “DO NOT START” sign to the control panel.

• If the unit is connected to a remote start or transfer switch, make sure

the remote switch is also off and tagged.

8.4

Inspecting the Machine

When

Every 10 hours or daily

Summary of Contents for LTV 4L

Page 1: ...Operator s Manual Light Tower LTV 4L 6L Machine Type Light Tower Material Number 5100065071 3300031821 Version 03 Date 02 2023 Language en US 5100065071...

Page 2: ...on in whole or part is not permitted without the written consent of Wacker Neuson America Corporation Violations of legal regulations in particular of the copyright protection will be subject to civil...

Page 3: ...d some of its constituents are known to the State of California to cause cancer birth defects and other reproduc tive harm WARNING Cancer and Reproductive Harm www P65Warnings ca gov WARNING Batteries...

Page 4: ...This page is intentionally left blank...

Page 5: ...ng the Machine 13 3 5 Safety Guidelines for Maintenance 15 3 6 Operator Safety while Using Internal Combustion Engines 16 3 7 Reporting Safety Defects 17 4 Description of the Machine 4 1 Machine Descr...

Page 6: ...eling the Machine 55 7 3 Raising and Lowering the Tower 56 7 4 Adjusting the Power Winch Clutch 59 7 5 Control Panels and Receptacles Kohler 59 7 6 Control Panels and Receptacles Deep Sea 61 7 7 Befor...

Page 7: ...1 1 Overview 93 11 2 Cold Weather Package 93 11 3 Oil Pan Heater 93 11 4 Engine Block Heater 93 11 5 Battery Blanket 94 11 6 Fuel and Water Separator 94 11 7 Shore Power 94 11 8 Containment System Flo...

Page 8: ...ase see your Wacker Neuson dealer or visit the Wacker Neuson website at http www wackerneuson com When ordering parts or requesting service information be prepared to pro vide the machine model number...

Page 9: ...anufacturer Approved modifications are those performed by an authorized service center according to written instructions published by the manufacturer Unapproved parts attachments and modifications ar...

Page 10: ...ontinuous running or start up Operating the machine in a manner that is inconsistent with all federal state and local codes and regulations Using the machine as a hoist or hanging items from the tower...

Page 11: ...nual Personal injury from improper lifting techniques Typical hazards related to towing a trailer on roads and highways To protect yourself and others make sure you thoroughly read and under stand the...

Page 12: ...w this signal word WARNING WARNING indicates a hazardous situation which if not avoided could result in death or serious injury To avoid possible death or serious injury from this type of hazard obey...

Page 13: ...ischarge lamps They are designed for use with metal halide ballasts only and require time to reach full brightness on initial startup and after a power interruption These lamps comply with FDA regulat...

Page 14: ...els and attach ments must be in good condition before use Be sure the machine is on a firm level surface and will not tip roll slide or fall while operating Never connect machine to other power source...

Page 15: ...ersonnel servicing or maintaining the machine must be familiar with the associated potential risks and hazards Turn off the machine before performing maintenance or making repairs Remain aware of the...

Page 16: ...nts can become explosive 3 6 Operator Safety while Using Internal Combustion Engines DANGER Carbon monoxide hazard Exhaust gas from the engine contains carbon monoxide a deadly poison Exposure to carb...

Page 17: ...not refuel a hot or running engine Do not refuel the engine near sparks or open flames 3 7 Reporting Safety Defects If you believe your trailer has a defect which could cause a crash or could cause in...

Page 18: ...ith a cabinet containing a diesel engine a fuel tank a control panel and an electric alternator A telescoping tower with four metal halide or LED light fixtures is vertically mounted to the front of t...

Page 19: ...o antes de operar esta m quina Si no lo hace incrementar el riesgo de lesionarse o lesionar a otros Avant d utiliser cette machine lire attentivement et assimiler la Notice d Emploi Dans le cas contra...

Page 20: ...electricista capacitad lectrochoc et arc de court circuit peuvent r sulter en blessures graves ou mort Dispositif lectrique de stockage l int rieur Contacter un lectricien qualifi pour r parer ou ouvr...

Page 21: ...o lo hace incrementar el riesgo de lesionarse o lesionar a otros Avant d utiliser cette machine lire attentivement et assimiler la Notice d Emploi Dans le cas contraire le risque de se blesser ou de b...

Page 22: ...RE ULTRA LOW SULFUR FUEL ONLY NOTICE AVISO AVIS PELIGRO DANGER ULSD S15 STOP DANGER Danger No sparks flames or burning objects near the machine Stop the engine before refueling Notice Ultra low sulfur...

Page 23: ...when hot Pinching cutting hazard Rotating machinery AVERTISSEMENT 5200005890 ADVERTENCIA WARNING WARNING Explosion hazard diesel machines Do not use evaporative starting fluids such as ether on this...

Page 24: ...3 Lug nuts for tightness Lug nuts should be tightened to 85 ft lbs For new and remounted wheels tighten lug nuts at the first 10 25 and 50 miles of driving 839 kg 1850 LBS WARNING ADVERTENCIA AVERTIS...

Page 25: ...G WARNING Electric shock and arc flash can cause serious injury or death Electrical storage device within Contact a qualified electrician for service or to open electrical box 4 4 Information Label Me...

Page 26: ...Light cover 5100031248 Fork lift pocket Tie down point 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 whe...

Page 27: ...R DATE GVWR PNBV 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...

Page 28: ...ARNING Crushing hazard Improperly securing the machine can lead to a crushing hazard Use only the designated tie down points to secure the machine to a truck or trailer Requirements Machine stopped Fl...

Page 29: ...adequate clearance for overpasses road signs buildings etc Check local regulations regarding transporting and obey these regula tions 5 3 Lifting the Machine WARNING Crushing hazard You may be crushed...

Page 30: ...a safe distance from the moving load 5 4 Safety Guidelines for Towing WARNING Severe injury or death hazard Improper trailer condition and towing technique can lead to an accident Obey the instruction...

Page 31: ...achine For further informa tion see Machine on page 97 The hitch of the towing vehicle and coupler of the trailer are compatible Check the condition of both the coupler and the hitch All fasteners on...

Page 32: ...rough or off road transportation 5 6 Trailer Background The machine s trailer is equipped with safety chains 1 tongue jack 2 lights and a coupler pintle or ball type 3 wc_gr011629 1 1 2 2 3 3 Fig 5 T...

Page 33: ...ngue Background The flip up tongue allows the machine to be transported or stored in a smaller space than a machine with a conventional tongue Procedure 1 Remove the pin behind the tongue jack 1 wc_gr...

Page 34: ...s into a hole in the light bar Holes are positioned at 90 angles When towing maintain extra space between vehicles and avoid soft shoul ders curbs and sudden lane changes If you have not pulled a trai...

Page 35: ...needed and applicable including fuel engine oil and bat tery acid 6 Move the machine to its operating location 6 2 Standard Racked Assembly wc_gr014331 Fig 8 LTV in container rack Overview This set o...

Page 36: ...tools wrenches screwdrivers etc Torque wrench Panduit crimper CT 100 Panduit crimper CT 1550 Hardware bags 1 2 3 4 5 6 7 8 and fabricated parts 6 3 Installing the Axle Materials needed Axle Hardware b...

Page 37: ...5 ft lbs 6 4 Installing the Fenders Materials needed Two fenders Hardware bag 2 Installing the fenders 1 Locate the two fenders 1 and hardware bag 2 wc_gr014360 1 2 3 Fig 10 Installing the fenders 2 A...

Page 38: ...ardware bag 3 wc_gr014376 1 2 Fig 11 Installing the wheels 2 Attach the wheels to the axle using five lug nuts 2 per wheel 3 Tighten the lug nuts in a star pattern to a torque of 115 Nm 85 ft lbs 6 6...

Page 39: ...locking pin to fasten the outrigger in place 5 Repeat steps 1 through 4 to install the second outrigger on the other side Installing the swivel jacks on the outriggers 1 Locate a 10 inch swivel jack 5...

Page 40: ...mbly 1 to the light tower using the following hardware from bag 4 as shown in the illustration below Three M12 x 30 screws 2 on each side of the tongue assembly Three B13 flat washers 3 on each side o...

Page 41: ...assembly 4 Rotate the tongue jack so the foot 8 rests on the ground 5 Align the top hole in the swivel jack socket with the top hole on the cir cular boss 6 Insert the locking pin through the aligned...

Page 42: ...lange screws to a torque of 200 Nm 145 ft lbs 3 Attach the standard or power winch 4 The manual winch is shown For further information see Installing the Manual Winch on page 43 The power winch is not...

Page 43: ...2 Fasten the manual winch to the mast with the following hardware from bag 6 as shown in the illustration Three M10 x 25 screw 4 Three M10 lock washers 5 Three M10 lock nuts 6 3 Tighten the M10 x 25...

Page 44: ...3 Loosen the nut 9 on the winch cable retainer 10 and insert the free end of the winch cable through the winch cable retainer so approxi mately 2 5 cm 1 in of winch cable extends beyond the winch cabl...

Page 45: ...Tighten the screws to a torque of 48 Nm 35 ft lbs Installing the winch cable 1 Pass the winch cable 7 over the top of the power winch drum 2 and through the side hole 8 wc_gr014460 2 7 7 8 9 10 Fig 2...

Page 46: ...chine to the red positive wire of the power winch 2 Attach black wire 41 from the machine to the to the black negative wire of the power winch 3 Replace the cover on the power winch 6 11 Installing th...

Page 47: ...ction box 10 to the light support bracket with two M8 x 25 serrated screws 11 two B8 4 flat washers 12 and two M8 lock nuts 13 Tighten the M8 x 25 serrated screws to a torque of 24 Nm 18 ft lbs 5 Atta...

Page 48: ...eft and LED right lights 2 Install each light fixture on the light bar 2 using a disk 3 a B19 flat washer 4 and an M18 lock nut 5 6 13 Connecting the Wiring at the Junction Box Special tools and mater...

Page 49: ...oiled cord jacket extends into the junction box 4 Tighten the large connector 5 Slide the cord grip connector 5 into the winch bracket slot 6 and tighten the cord grip connector using two wrenches Ins...

Page 50: ...the light fixtures the green wire from the coiled cord and the green yellow ground wire found in hardware bag 5 into the large connector 2 Crimp the wires and the wire joint terminal found in hardware...

Page 51: ...s positioned on a hill or an incline may slide break away or roll over Do not position the machine on a hill or an incline WARNING Explosion and fire hazard Risk of severe injury or death Do not opera...

Page 52: ...quires the tower to be lowered and the engine stopped To rotate the lights see Manually Rotating the Light Bar on page 53 Requirements Before adjusting the lights make sure that the following conditio...

Page 53: ...to the desired position 3 Tighten the mast rotation knob 6 17 Leveling the Trailer WARNING Tipping and falling hazard Failure to level the trailer or extend the outriggers will reduce the stability of...

Page 54: ...023 en US 5 Pull the locking pins on the outrigger jacks 5 Move the jack to the lower mount Insert the pins once the jacks are in position 6 Extend the jack s on the highest side s of the trailer unti...

Page 55: ...ergized for example engine generator housing control panel trailer tower sections and light fixtures are bonded connected to the machine s frame The grounding wires of the machine s power outputs rece...

Page 56: ...h clean fuel supply Procedure 1 Remove the fuel cap 1 wc_gr013745 D 50 mm 2 in 1 Fig 29 Fuel cap location 2 Fill the fuel tank allowing a minimum of 50 mm 2 in expansion space between the fuel level a...

Page 57: ...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 The tower and light bar can be rotat...

Page 58: ...r using the manual winch Turn the handle on the telescoping winch 1 counterclockwise cable out direction until the tower is lowered completely Raising the tower using the power winch 1 Check the opera...

Page 59: ...ll nut adjustments must only be made when the tower is completely down 5 Tighten the nut 2 in 1 12th turn increments and attempt to raise the tower after each adjustment until the winch clutch does no...

Page 60: ...ant temperature shut down indicator 5 Alternator indicator 6 Auxiliary lights not used 7 Glow plug indicator 8 Main circuit breaker 9 GFCI circuit breaker 10 Lights circuit breaker 11 Tower winch rota...

Page 61: ...1 5 Fig 34 Control panel and receptacles Ref Description Ref Description 1 Menu navigation buttons up down 2 Controller display 3 Main circuit breaker 4 GFCI circuit breaker 5 Lights circuit breaker 6...

Page 62: ...ensure that glass is not broken or cracked Ensure that all electrical connections are tight Verify that all electrical cords are in serviceable condition with no ex posed wires cuts or cracks in the...

Page 63: ...not use evaporative starting fluids for example ether to start the engine Do not start the engine under load If the fuel tank was empty you may need to bleed the fuel lines Refer to the engine manufac...

Page 64: ...aker 1 2 Turn on individual circuit breakers 3 one at a time Notes Metal halide floodlights require a warm up time of 5 15 minutes before they reach full brightness After turning the lights off a cool...

Page 65: ...breakers 1 2 and 3 in the OFF position All loads disconnected from the machine Starting the machine 1 Press the Start button 6 This initiates the preheat timer energizes the fuel solenoid and energize...

Page 66: ...inutes before they reach full brightness After turning the lights off a cool down time of 10 minutes is necessary before they can be turned on again Stopping the machine NOTICE Failure to turn off lig...

Page 67: ...or wc_gr012362 Volts V Displays the AC output voltage being produced by the genera tor wc_gr012361 Hertz Hz Displays output frequency This gauge should read approxi mately 60 Hz under a no load condit...

Page 68: ...machine controller has two types of alarms warning alarms and shut down alarms wc_gr012354 a b c d e 1 2 3 4 5 Fig 39 Warning alarms Warning alarms Warnings are non critical alarm conditions that do n...

Page 69: ...ormal Warning Shutdown To Reset Overspeed 60 Hz 63 Hz 66 Hz Press Stop Underspeed 60 Hz 57 Hz 55 Hz Press Stop Overcrank After 3 attempts Press Stop Time to maintain1 Oil Air Fuel Values vary based on...

Page 70: ...f the controller is in Stop Reset Mode or Manual Start Mode when a scheduled run begins the engine will not start However if the controller is set to Auto Mode during a scheduled run the engine will s...

Page 71: ...the correct value 5 Press the Start button 5 when the first digit is correctly entered The digit changes to for security purposes 6 Enter each of the digits of the PIN code Press Stop to move back to...

Page 72: ...0 OFF 1 ON Must be on for Scheduler mode 902 Schedule Bank A Period 0 Weekly 1 Monthly 2 Daily 2 Daily Same every day 903 Auto Mode 1 Scheduler 0 Scheduler 1 Location 1 Clears all Scheduler entries 90...

Page 73: ...ay 6 Scheduler 1 M 2 TU 3 W 4 TH 5 FR 6 SA 7 SU 937 Start Week 6 Scheduler 1 2 3 4 2 3 4 are for Monthly mode only 938 Run Duration 6 Scheduler 00 00 00 Hrs Mins Sec 939 Auto Mode 7 Scheduler 0 Schedu...

Page 74: ...When the sun rises the machine will turn off the lamps and then shut down This cycle will continue until the machine is taken off Auto mode by pressing the red Stop button Configuration Editor Paramet...

Page 75: ...use frayed or damaged cords or plugs with the convenience re ceptacle For machines with metal halide lights the maximum wattage with the lights on drawn from the receptacles shall not exceed the valu...

Page 76: ...eceptacle should be off 3 Push the reset button in A green LED power on indication light illuminates on the GFCI recep tacle In addition to the manual test shown above the GFCI receptacle has a self t...

Page 77: ...es seek medical at tention immediately CAUTION Personal injury hazard Electrical arcing can cause severe personal injury Do not allow positive and negative cable ends to touch NOTICE Observe the follo...

Page 78: ...load 3 Use a booster battery of the same voltage as is used with your engine system 4 Attach one end of the positive cable clamp red to the positive ter minal of the dead battery Attach the other end...

Page 79: ...quipped 250 hours Operating personnel 82 Cleaning the Machine 83 Maintaining the Battery As needed Operating personnel 79 Preparing for Maintenance Service personnel 79 Preparing for Maintenance 84 Re...

Page 80: ...mps Fluid leaks Restricted air flow at the engine exhaust Problems with the trailer if equipped see Maintaining the Trailer on page 80 Internal inspection Open the access doors on both sides of the ma...

Page 81: ...ing and Draining the Containment System if equipped NOTICE It is important to check the containment system regularly A large amount of fluid collected in a 24 hour period indicates a significant leak...

Page 82: ...collection container beneath the machine Remove the drain plug 1 Drain accumulated fluid into a suitable container Apply pipe sealant to the drain plug Install the drain plug 8 7 Cleaning the Machine...

Page 83: ...Keep all sparks and flames away from the battery Do not short circuit battery posts When Every 250 hours Safety precautions Observe the following safety precautions to prevent serious damage to the el...

Page 84: ...Lamps WARNING Burn hazard Lamps become extremely hot in use Allow lamps and fixtures to cool 10 to 15 minutes before handling WARNING Personal injury hazard Ultraviolet radiation from the lamps can c...

Page 85: ...lector with the flange rings and screws 8 10 Routine Maintenance Any kind of maintenance work on the light tower must be carried out by au thorized and trained personnel It should be done in a safe wo...

Page 86: ...e 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 t...

Page 87: ...es that these materials can be reused conserving landfill space and valuable natural resources Responsible disposal also prevents toxic chemicals and materials from harming the environment The operati...

Page 88: ...No fuel Clogged fuel filter Fuel circuit failure Fill tank with fuel Bleed fuel lines Replace fuel filter Check fuel lines No generator output Main circuit breaker open Voltage regulator malfunction...

Page 89: ...the voltage should measure 400 to 445 VAC If proper voltage is not achieved perform capacitor check to determine if ca pacitor or coil needs to be replaced Low light output Lamp degraded Replace lamp...

Page 90: ...end of the LED light is poor Tighten the connection point to make sure the connection is firm There is insufficient output voltage at the output end of the drive power supply Replace the drive power...

Page 91: ...e Complete any needed repairs Replenish or change oils engine exciter hydraulic and gearcase per the intervals specified in the Periodic Maintenance Schedule table Grease all fittings and if applicabl...

Page 92: ...dations Storing the machine Perform these remaining steps to store your machine Wash the machine and allow it to dry Move the machine to a clean dry secure storage location Block or chock the wheels t...

Page 93: ...erent 11 2 Cold Weather Package The cold weather package includes the engine block heater battery blanket oil pan heater and 60 40 or cold weather coolant The Kohler cold weather package also includes...

Page 94: ...V power supply 11 6 Fuel and Water Separator wc_gr013983 1 Fig 51 Fuel and water separator The fuel and water separator 1 removes water from the fuel supply As fuel flows through the separator element...

Page 95: ...witch opens When the float switch opens electric power to the fuel solenoid is disconnected and the engine stops 11 9 Positive Air Shutoff Diesel engines may occasionally continue to run even after th...

Page 96: ...1800 rpm 1800 rpm 1800 rpm Alternator 37 5A 120V 18 8A 240V 4100W 37 5A 120V 18 8A 240V 4100W 50A 120V 25A 240V 6000W 50A 120V 25A 240V 6000W Battery 12V 650 ccA 12V 650 ccA 12V 650 ccA 12V 650 ccA Ai...

Page 97: ...ED Lamp LED LED Metal Halide LED Frequency 60 Hz 60 Hz 60 Hz 60 Hz Lamp Wattage 4 X 240W 4 X 300W 4 X 1100W 4 X 300W Dimensions 2 56 x 1 47 x 2 51 m 101 x 58 x 99 in 2 56 x 1 47 x 2 51 m 101 x 58 x 99...

Page 98: ...sions 98 Operator s Manual LTV 4L 6L 5100065071 02 2023 en US 12 4 Dimensions 147 cm 58 in 256 cm 101 in 251 cm 99 in wc_gr013764 Fig 54 Dimensions wc_gr014295 125 cm 49 in 140 cm 55 in 234 cm 92 in F...

Page 99: ...ed with all Wacker Neuson engines equipment at the time of purchase Exhaust emissions The combustion process produces carbon monoxide oxides of nitrogen and hydrocarbons Control of hydrocarbons and ox...

Page 100: ...ited Defect Warranty for Exhaust Emission Control System 100 Operator s Manual LTV 4L 6L 5100065071 02 2023 en US 13 3 Limited Defect Warranty for Exhaust Emission Control System See the supplied engi...

Page 101: ...ng 55 Emergency shutdown procedure 74 Emissions control systems Background information Kohler 99 Information and warranty Kohler 99 Limited defect warranty Kohler 100 Engine Block heater 93 Jump start...

Page 102: ...aining the containment system 81 cleaning the machine 82 Engine KDW 1003 86 Engine KDW 702 86 Preparation 79 Replacing removing metal halide lamps 84 safety 15 trailer 80 Maintenance timers Resetting...

Page 103: ...n Conditions 68 Emergency procedure 74 Limits 69 Spark arresters 9 Starting 63 Stopping 63 Swivel jacks Installation 39 T Technical data Engine Kohler 96 Tongue assembly Installation 40 Tower Raising...

Page 104: ...Index 104 Operator s Manual LTV 4L 6L 5100065071 02 2023 en US...

Page 105: ......

Page 106: ...Wacker Neuson America Corporation N92W15000 Anthony Ave Menomonee Falls WI USA 53051 Tel 01 262 255 0500 EMail info wackerneuson com www wackerneuson us Material Number 5100065071 Language en US...

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