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Table of Contents

LTC Repair

wc_br0160487en_003TOC.fm

3.22

Receptacles—60 Hz ............................................................................41

Maintenance

4.1

Periodic Maintenance Schedule—Lombardini ....................................42

4.2

Periodic Maintenance Schedule—CAT ...............................................43

4.3

Daily Inspection ...................................................................................43

4.4

Installing / Removing Light Fixtures ....................................................44

4.5

Precautions When Replacing / Removing Bulbs .................................45

4.6

Replacing Bulbs ..................................................................................46

4.7

Air Cleaner ..........................................................................................47

4.8

Engine Oil ............................................................................................48

4.9

Generator Capacitor Excitation Schematic 60 Hz ...............................49

4.10

Schematic for 60 Hz Metal Halide 4-Light Units ..................................50

4.11

Metal Halide Schematic Components .................................................51

4.12

Engine Wiring—Lombardini 1003 ........................................................52

4.13

Engine Wiring Components—Lombardini 1003 ..................................53

4.14

Engine Control 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

Engine Wiring—Item Number: 0009376 ..............................................58

4.19

Engine Wiring—Item Number: 0620017, 0620028 ..............................59

4.20

Power Winch Schematic .....................................................................60

4.21

Trailer Wiring .......................................................................................61

Lombardini Engine Troubleshooting

5.1

Troubleshooting Flowcharts ................................................................62

5.2

Engine Does Not Crank—Flowchart 3A ..............................................63

5.3

Checking Keyswitch and Wiring ..........................................................64

5.4

Replacing Keyswitch ...........................................................................66

5.5

Engine Cranks But Does Not Start—Flowchart 4A .............................67

5.6

Checking Fuel System ........................................................................68

5.7

Checking Voltage to Glow Plugs (Lombardini 903 engines) ...............69

5.8

Checking Voltage to Glow Plugs (Lombardini 1003 engines) .............70

5.9

Checking Glow Plug Relay ..................................................................71

5.10

Replacing Glow Plug Relay .................................................................71

5.11

Checking Glow Plugs ..........................................................................72

Содержание LTC 4

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

Страница 2: ......

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

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

Страница 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...

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

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 165: ......

Страница 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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