Wacker Neuson LTN6 OMM PDF
Wacker Neuson LTN6 OMM PDF
Wacker Neuson LTN6 OMM PDF
Light Tower
LTN 6L
60 Hz
0 1 7 1 8 8 3 E N
Copyright © Copyright 2010 by Wacker Neuson Corporation.
notice All rights, including copying and distribution rights, are reserved.
This publication may be photocopied by the original purchaser of the machine. Any
other type of reproduction is prohibited without express written permission from
Wacker Neuson Corporation.
Any type of reproduction or 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.
Original This Operator’s Manual presents the original instructions. The original language of this
instructions Operator’s Manual is American English.
LTN 6L Foreword
Foreword
Machines
covered in Machine Item Number
this manual
LTN 6L 0620117, 0620727, 0620550, 0620553, 0620561,
0620554, 0620297
Machine Keep a copy of the Operator’s Manual with the machine at all times.
documentation Use the separate Parts Book supplied with the machine to order replacement
parts.
Refer to the separate Repair Manual for detailed instructions on servicing and
repairing the machine.
If you are missing any of these documents, please contact Wacker Neuson
Corporation to order a replacement or visit www.wackerneuson.com.
When ordering parts or requesting service information, be prepared to provide
the machine model number, item number, revision number, and serial number.
Expectations This manual provides information and procedures to safely operate and
for maintain the above Wacker Neuson model(s). For your own safety and to
information in reduce the risk of injury, carefully read, understand, and observe all instructions
this manual
described in this manual.
Wacker Neuson Corporation expressly reserves the right to make technical
modifications, even without notice, which improve the performance or safety
standards of its machines.
The information contained in this manual is based on machines manufactured
up until the time of publication. Wacker Neuson Corporation reserves the right
to change any portion of this information without notice.
CALIFORNIA Engine exhaust, some of its constituents, and certain vehicle components, contain
Proposition or emit chemicals known to the State of California to cause cancer and birth
65 Warning defects or other reproductive harm.
Laws NOTICE: State Health Safety Codes and Public Resources Codes specify that in
pertaining to certain locations spark arresters be used on internal combustion engines that use
spark hydrocarbon fuels. A spark arrester is a device designed to prevent accidental dis-
arresters charge of sparks or flames from the engine exhaust. Spark arresters are qualified
and rated by the United States Forest Service for this purpose. In order to comply
with local laws regarding spark arresters, consult the engine distributor or the local
Health and Safety Administrator.
Manufacturer’s This manual contains references to approved parts, attachments, and modifica-
approval tions. The following definitions apply:
Approved parts or attachments are those either manufactured or provided by
Wacker Neuson.
Approved modifications are those performed by an authorized Wacker
Neuson service center according to written instructions published by Wacker
Neuson.
wc_tx001571gb.fm 3
Foreword LTN 6L
Unapproved parts, attachments, and modifications are those that do not
meet the approved criteria.
Unapproved 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.
4 wc_tx001571gb.fm
LTN 6L Table of Contents
Foreword 3
1 Safety Information 9
2 Labels 16
3 Operation 31
wc_bo0171883en_006TOC.fm 5
Table of Contents LTN 6L
4 Schematics 50
5 Maintenance 58
6 Technical Data 65
6 wc_bo0171883en_006TOC.fm
LTN 6L Table of Contents
9 Appendix III—Standard Pallet Assembly 71
wc_bo0171883en_006TOC.fm 7
Table of Contents LTN 6L
8 wc_bo0171883en_006TOC.fm
LTN 6L Safety Information
1 Safety Information
1.1 Signal Words Used in this Manual
This manual contains DANGER, WARNING, CAUTION, NOTICE, and
NOTE signal words which must be followed to reduce the possibility
of personal injury, damage to the equipment, or improper service.
This is the safety alert symbol. It is used to alert you to potential 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 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 mes-
sages that follow this signal word.
CAUTION!
CAUTION indicates a hazardous situation which, if not avoided, could result in
minor or moderate injury.
f To avoid possible minor or moderate injury from this type of hazard, obey all safety mes-
sages that follow this signal word.
wc_si000227gb.fm 9
Safety Information LTN 6L
1.2 Machine Description and Intended Use
This machine is a mobile, trailer-mounted light tower. The Wacker
Neuson Light Tower consists of a trailer with a cabinet containing a
diesel engine, a fuel tank, a control panel, and an electric alternator. A
telescoping tower with four metal halide lights is mounted to the top of
the cabinet. Dual winches tilt, raise, and lower the telescoping tower.
As the engine runs, the generator converts mechanical energy into
electric power. The metal halide lights run off this power.
Receptacle(s) are also present to power auxiliary loads. The operator
uses the control panel to operate and monitor the machine.
This machine has been designed and built strictly for the intended use
described above. Using the machine for any other purpose could
permanently 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 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 ladder, support, or work surface
Using the machine to carry or transport passengers or equipment
Using the machine to tow other machines (unless factory equipped)
Using the machine as a hoist or hanging items from the tower
Operating the machine outside of factory specifications
Operating the machine in a manner inconsistent with all warnings
found on the machine and in the Operator’s Manual
This machine has been designed and built in accordance with the
latest global safety standards. It has been carefully engineered to
eliminate hazards as far as practicable and to increase operator
safety through protective guards and labeling. However, some risks
may remain even after protective measures have been taken. They
are called residual risks. On this machine, they may include exposure
to:
10 wc_si000227gb.fm
LTN 6L Safety Information
Heat, noise, exhaust, and carbon monoxide from the engine
Heat from the lights
Ultraviolet radiation from the lights
Fire hazards from improper refueling techniques
Fuel and its fumes
Electric shock and arc flash
Personal injury from improper lifting the trailer tongue
Glare from lights (lights may blind drivers of nearby motor vehicles if
the lights are incorrectly positioned)
Typical hazards related to towing a trailer on roads and highways
To protect yourself and others, make sure you thoroughly read and
understand the safety information presented in this manual before
operating the machine.
wc_si000227gb.fm 11
Safety Information LTN 6L
1.3.1 Do not remove, defeat, deface, or render inoperable any of the safety
devices, warnings, or labels on this equipment. If any safety devices,
warnings, or labels have been removed, defeated, defaced, or
rendered inoperable, do NOT use this equipment!
1.3.2 The area immediately surrounding the Light Tower should be clean,
neat, and free of debris.
1.3.3 Be sure the machine is on a firm, level surface and will not tip, roll,
slide, or fall while operating.
1.3.4 NEVER start a machine in need of repair.
1.3.5 Lower the tower when not in use, or if high winds or electrical storms
are expected in the area.
1.3.6 ALWAYS make certain the machine is well-grounded and securely
fastened to a good earthen ground per national and local regulations.
1.3.7 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.
1.3.8 The lamps become extremely hot in use! Allow the lamp and fixture to
cool 10–15 minutes before 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 while raising or lowering the tower, STOP immediately!
Contact an authorized Wacker Neuson service representative.
1.3.12 NEVER remove the tower locking pin while the tower is up!
1.3.13 NEVER use the machine if the insulation on the electrical cord is cut or
worn through.
1.3.14 NEVER operate the lights without the protective lens cover in place or
with a lens cover that is cracked or damaged!
1.3.15 NEVER adjust the tower while the unit is operating.
1.3.16 Do not move the Light Tower while it is operating.
1.3.17 NEVER raise the tower or operate the machine in high winds.
1.3.18 NEVER connect machine to other power sources, such as supply
mains of power companies.
1.3.19 ALWAYS replace or repair electrical components with components
that are identical in rating and performance as the original component.
12 wc_si000227gb.fm
LTN 6L Safety Information
1.4 Operator Safety while Using Internal Combustion Engines
WARNING
Internal combustion engines present special hazards during operation and fueling.
Failure to follow the warnings and safety standards could result in severe injury or
death.
f Read and follow the warning instructions in the engine owner’s manual and the
safety guidelines below.
DANGER
Asphyxiation hazard.
f NEVER use this generator inside a home or garage, EVEN IF doors and win-
dows are open. Only use OUTSIDE and far away from windows, doors, and
vents. Using a generator indoors CAN KILL YOU IN MINUTES. Generator
exhaust contains carbon monoxide. This is a poison you cannot see or smell.
f NEVER use a generator inside an enclosed area such as a tunnel or a trench.
Refueling safety
When refueling the engine:
• Do not smoke.
• Do not refuel if the generator is sitting in a truck fitted with a
plastic bed liner. Static electricity can ignite the fuel or fuel vapors.
• Do not refuel a hot or running engine.
• Do not refuel the engine near an open flame.
When refueling the engine, always:
• Refill the fuel tank in a well-ventilated area.
• Replace the fuel tank cap after refueling.
Operating safety
When operating the generator:
• Check the fuel lines and the fuel tank for leaks and cracks before
starting the engine.
• Do not run the machine if fuel leaks are present or the fuel lines
are loose.
• Do not run the engine near open flames.
• Do not start the engine if fuel has spilled or a fuel odor is present.
Move the generator away from the spill and wipe the generator
dry before starting.
• Do not smoke while operating the machine.
wc_si000227gb.fm 13
Safety Information LTN 6L
1.5 Lamp Safety
Description
The lamps provided with your Light Tower are electric discharge
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 regulation performance
standards 21 CFR 1040-30.
WARNING
Personal injury hazard. Lamps can cause serious skin burns and eye inflammation
from shortwave ultraviolet radiation if outer envelope of the lamp is broken or punc-
tured.
f Do not operate the Light Tower if a lamp is damaged.
Operating safety
• Do not operate the lamps where people will remain for more than
a few minutes unless adequate shielding or other safety
precautions are used.
• Replace damaged lamps according to the instructions in section
Removing / Replacing Lamps.
• Lamps that automatically extinguish when the outer envelope is
broken or punctured are commercially available.
14 wc_si000227gb.fm
LTN 6L Safety Information
1.6.2 Before servicing the Light Tower, make sure the engine start switch is
turned to the OFF position, the circuit breakers are open (off), and the
negative terminal on battery is disconnected. NEVER perform even
routine service (oil/filter changes, cleaning, etc.) unless all electrical
components are shut down.
1.6.3 DO NOT allow water to accumulate around the base of the machine.
If water is present, move the machine and allow the machine to dry
before servicing.
1.6.4 DO NOT service the machine if your clothing or skin is wet.
1.6.5 ALWAYS keep hands, feet, and 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 specifications, such as physical dimensions,
type, strength, and material.
1.6.8 ALWAYS make sure slings, chains, hooks, ramps, jacks, and other
types of lifting devices are attached securely and have enough weight-
bearing capacity to lift or hold the machine safely. Always remain
aware of the location of other people in the area when lifting the
machine.
1.6.9 ALWAYS turn off the light circuit breakers and shut down the engine
before disconnecting the light fixtures or changing the lamps.
wc_si000227gb.fm 15
Labels LTN 6L
2 Labels
2.1 Label Locations
H BB
C A
BB
H E
V
I
S Q
CC
Z EE
AA
O
AA
wc_gr007036
16 wc_si000381gb.fm
LTN 6L Labels
CC
EE
GG
BB D BB
N J
B
U
V
F
L H
R S
DD
AA AA
FF
wc_gr007037
wc_si000381gb.fm 17
Labels LTN 6L
2.2 Label Meanings
Wacker Neuson machines use international pictorial labels where
needed. These labels are described below.
A WARNING
Automatic locking pin.
A non-secured, falling 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
injury or death.
18 wc_si000381gb.fm
LTN 6L Labels
D NOTICE
Lifting point.
E WARNING!
Secure tower in transport lock before lifting or
towing. A loose swinging tower could cause per-
sonal injury or machine damage.
F DANGER!
No sparks, flames, or burning objects near
machine. Stop the engine before adding fuel. Use
only diesel fuel.
G DANGER!
Asphyxiation hazard.
wc_si000381gb.fm 19
Labels LTN 6L
H 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.
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.
20 wc_si000381gb.fm
LTN 6L Labels
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!
wc_si000381gb.fm 21
Labels LTN 6L
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 fixture.
22 wc_si000381gb.fm
LTN 6L Labels
O See Operator’s Manual for metal halide lamp
information and troubleshooting.
Start engine
Light out
Start, 15 sec. max.
Circuit breakers on
Shut down
Circuit breakers off
Stop engine
wc_si000381gb.fm 23
Labels LTN 6L
P See Operator’s Manual for metal halide lamp
information and troubleshooting.
Start engine
Shut down
Circuit breakers off
Stop engine
24 wc_si000381gb.fm
LTN 6L Labels
Q To raise tower:
Manual Winch System 1. Release transport lock.
2. Tilt tower using winch.
3. Tilt tower until automatic locking pin snaps into
place.
To aim lights:
5. Rotate tower and tighten knob.
wc_si000381gb.fm 25
Labels LTN 6L
R To lower tower:
Manual Winch System 1. Turn off all lights and engine.
2. Rotate tower and tighten knob.
3. Lower tower using winch.
26 wc_si000381gb.fm
LTN 6L Labels
S To raise tower:
Power Winch System 1. Release transport lock.
2. Tilt tower using winch.
3. Tilt tower until automatic locking pin snaps into
place.
To aim lights:
5. Rotate tower and tighten knob.
wc_si000381gb.fm 27
Labels LTN 6L
T To lower tower:
Power Winch System 1. Turn off all lights and engine.
2. Rotate tower and tighten knob.
3. Lower tower using winch.
28 wc_si000381gb.fm
LTN 6L Labels
V WARNING!
Pinching hazard. Rotating machinery.
Z Electrical ground.
wc_si000381gb.fm 29
Labels LTN 6L
CC WARNING
WARNING
ROLL-OVER HAZARD
To prevent injury or equipment damage, avoid
high speeds and sharp turns when towing.
ROLL OVER HAZARD
Avoid high speeds, rapid
acceleration and sharp turns
when towing.
ADVERTENCIA
PELIGRO DE VUELCO
Al remolcar, evite altas
velocidades, aceleracion
rapida, y vueltas agudas.
AVERTISSEMENT
DANGER DE RETORNEMENT
En remorquant, éviter des
vitesses rapides, acceleration
rapide, et virages tranchantes.
178647
EE Tie-down point.
30 wc_si000381gb.fm
LTN 6L Operation
3 Operation
WARNING
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Operation LTN 6L
3.2 Leveling Trailer
3.2.1 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.
3.2.2 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.
3.2.3 Rotate rear jack (f) down, as shown.
3.2.4 Extend the jack(s) on the highest side(s) of the trailer until they rest
firmly on the ground. Extend the remaining jacks until the trailer is
level.
32 wc_tx000766gb.fm
LTN 6L Operation
3.3 Adjusting Lights
wc_tx000766gb.fm 33
Operation LTN 6L
3.4 Preparing Trailer for Towing or Lifting
34 wc_tx000766gb.fm
LTN 6L Operation
3.5 Raising Tower (Manual Winch System)
NEVER raise the tower or operate the Light Tower in high winds.
NEVER raise the tower while the engine is running.
WARNING Do not move the Light Tower while it is operating.
NEVER allow anyone to stand near the rear of the unit while raising the
tower.
WARNING
The Light Tower includes two separate winches—one for lifting the
tower to the vertical position, the other for raising the tower. Each
winch is 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.
WARNING
3.5.1 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.
3.5.2 Remove the cradle locking pin (j) from the cradle.
3.5.3 Check the operation of the tilt winch (o) by rotating the winch handle
1/4-turn clockwise (“cable in” direction). The winch pawl must engage
winch gear teeth. When operating properly, the winch pawl 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.
Pinching/crushing hazards. Moving parts can crush or cut extremities.
Keep hands and fingers clear of pinch points when raising the tower
WARNING
wc_tx000766gb.fm 35
Operation LTN 6L
3.5.4 Continue to rotate the winch handle and raise the tower to the vertical
position until the vertical tower locking pin (p) locks the tower in place.
Be certain the vertical tower locking pin is fully engaged in the locking
position before raising the tower.
NOTICE: While raising the tower, pay close attention to the coil cord
and make sure that it does not tangle or become caught on any part of
the machine.
NEVER pull the vertical tower locking pin (p) while the tower is
raised! Releasing the vertical tower locking pin while the tower is
WARNING raised may cause the tower to fall or the machine to tip over.
3.5.5 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 rotating the
winch handle until tower is at the desired height. Do not over crank the
winch when the tower is fully extended.
NOTICE: Do not extend the tower beyond the red marking on the
tower!
3.5.6 Once the tower is at the desired height, rotate the tower to the desired
direction. To rotate, loosen rotation locking knob (s). Then rotate the
tower until the lights face the desired direction, and then retighten the
rotation locking knob.
36 wc_tx000766gb.fm
LTN 6L Operation
wc_tx000766gb.fm 37
Operation LTN 6L
3.6 Lowering Tower (Manual Winch System)
WARNING
NEVER allow anyone to stand near the rear of the unit while lowering
the tower.
WARNING
NEVER touch the winch pawl! Releasing the winch pawl may cause
the tower to fall.
WARNING
3.6.3 Loosen the rotation locking knob (s) and rotate the tower so the
winches are facing toward the trailer tongue.
38 wc_tx000766gb.fm
LTN 6L Operation
3.6.4 Pull and hold the tower locking pin (p). Rotate the handle on the tilt
winch (o) counterclockwise (“cable out” direction) until the tower spring
begins to pivot the tower down. Release the tower locking pin and
continue to rotate the handle until the tower is resting in the transport
cradle. Be sure that the secondary locking pin (t) penetrates 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
WARNING the tower to fall or the machine to tip over.
3.6.5 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.
3.6.6 Position the light fixtures to aim at the ground.
NOTICE: Allow the floodlights to cool 10–15 minutes before moving
trailer. Moving the trailer while the lights are still hot could cause the
lamps to break.
wc_tx000766gb.fm 39
Operation LTN 6L
3.7 Raising Tower (Power Winch System)
NEVER allow anyone to stand near the rear of the unit while raising the
tower.
WARNING
The Light Tower includes two separate winches—one for lifting the
tower to the vertical position, the other for raising the tower.
3.7.1 Check the winch cables (n) for 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.
3.7.2 Remove the cradle locking pin (j) from the cradle.
3.7.3 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: Continuous running of the winch in excess of 4 minutes will
damage the winch motor.
Note: It is normal for smoke to be produced during the first few
operations of a new power winch.
3.7.4 Hold the switch in the up position and raise the tower to the vertical
position until the vertical tower locking pin (p) locks the tower in place.
Be certain the vertical tower locking pin is fully engaged in the locking
position before raising the tower.
NEVER pull the vertical tower locking pin (p) while the tower is
raised! Releasing the vertical tower locking pin while tower is raised
may cause the tower to fall or the machine to tip over.
WARNING
40 wc_tx000766gb.fm
LTN 6L Operation
3.7.5 After the tower is in the vertical position, check the operation of the
telescoping winch (q). Turn the telescope rotary switch on the control
panel to the up position. Do not attempt to raise the tower if the winch
is damaged or not operating properly. Continue 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!
3.7.6 Once the tower is at the desired height, rotate the tower to the desired
direction. To rotate, loosen rotation locking knob (s). Then rotate the
tower until the lights face the desired direction and retighten the
rotation locking knob.
wc_tx000766gb.fm 41
Operation LTN 6L
3.8 Lowering Tower (Power Winch System)
NEVER allow anyone to stand near the rear of the unit while lowering
the tower.
WARNING
42 wc_tx000766gb.fm
LTN 6L Operation
3.8.4 Pull and hold the tower locking pin (p). Turn and hold the vertical rotary
switch (v) on the control panel in the down position until the tower is
resting in the transport cradle. Be sure that the secondary locking pin
(t) penetrates all sections of the tower.
NOTICE: Continuous running of the winch in excess of 4 minutes will
damage the winch motor.
NEVER pull the vertical tower locking pin (e) while the tower is
raised! Releasing the vertical tower locking pin while the tower is
raised may cause the tower to fall or the machine to tip over.
WARNING
3.8.5 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.
3.8.6 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.
wc_tx000766gb.fm 43
Operation LTN 6L
3.10 Control Panels (Manual Winch System)
44 wc_tx000766gb.fm
LTN 6L Operation
3.11 Control Panels (120/240, Manual Winch System)
WARNING
WARNUNG
ADVERTENCIA
AVERTISSEMENT
wc_gr006329
wc_tx000766gb.fm 45
Operation LTN 6L
3.12 Control Panels (Power Winch System)
46 wc_tx000766gb.fm
LTN 6L Operation
3.13 Starting
wc_tx000766gb.fm 47
Operation LTN 6L
3.16 Operating Lights
3.17 Stopping
3.18 Derating
All generator sets are subject to derating for altitude and temperature.
Although derating should not affect operation of the floodlights, it will
reduce the available reserve power to the receptacle.
Ratings are typically reduced 3% per 300 m (1000 feet) elevation from
sea level, and 2% per 10°F (5.5°C) increase in ambient temperature
above 78°F (25°C).
48 wc_tx000766gb.fm
LTN 6L Operation
3.19 Receptacle
wc_tx000766gb.fm 49
4
GN GN
BL BL
d 1 WH WH 2 d 4.1
GN GN
OR PU
WH
BR
YL BL
b
Schematics
RD BK 12 GN/YL
1
3
4
12 AWG
m m m m
10 WH 10 AWG
11 GN/YL 12 AWG
GN
14 BK/OR
3 1 2 4
l l l l k
13 OR 4 3 2 1
Electrical Schematic
BK/YL
j
BK/YL
YL
YL
YL
YL a
11 GN/YL 12 AWG
BK/YL
YL
2 BK 10 AWG
50
YL YL
BK/YL YL 4 BK 10 AWG
WH 3 BK
PU 10 AWG
1 BK 8 AWG
10 WH 10 AWG
+
e g f f c -
13 OR
5 BK
h
15 BK 10 AWG
b b 10 AWG n
i
6 BK 10 AWG
8 WH 10 AWG
7 BK 10 AWG
6 BK 10 AWG
BR 9 WH 10 AWG
OR 7 BK 10 AWG
wc_gr005366
LTN 6L
wc_tx000936gb.fm
LTN 6L Schematics
a Generator h Battery
b Terminal strip i Engine control panel
c Main 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 Light
blue
wc_tx000936gb.fm 51
4.2
GN GN
BL BL
1 2
d W W
d
GN GN
14 BK/OR
1 GN/YL 12 AWG
Schematics
9 WH 10 AWG
BL BL
d 3 W W 4
d 8 WH 10 AWG
16 BK 10 AWG
1 BK 10 AWG
OR PU
W
BR
YL BL
b
RD BK
3
2
4
10 WH 10 AWG
m m m m
11 GN/YL 12 AWG
22 GN/YL 10 AWG
GN
14
23 WH 10 AWG 12 GN/YL
12 AWG
3 1 2 l 4
l l l k
13 4 3 2 1
BK/YL
BK/YL
YL
j
Electrical Schematic (120/240)
YL
YL a
YL
52
11 GN/YL 12 AWG
BK/YL 2 BK 10 AWG
YL 19 BK 10 AWG
YL YL 18 BK 10 AWG
BK/YL YL 4 BK 10 AWG
W 3 BK
1 BK 10 AWG
10 AWG
16 BK 10 AWG
10 WH 10 AWG
PU
22 GN/YL 10 AWG
23 WH 10 AWG
+
e g f f c -
b b 13
17 BK 10
5 BK
h
15 BK 10
10 AWG n
i
6 BK 10 AWG
19 BK 10 AWG
7 BK 10 AWG
8 WH 10 AWG
o 18 BK 10 AWG
BR 9 WH 10 AWG
OR
6 BK 10 AWG
7 BK 10 AWG
wc_gr006324
LTN 6L
wc_tx000936gb.fm
LTN 6L Schematics
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 Light
blue
wc_tx000936gb.fm 53
Schematics LTN 6L
4.3 Trailer Wiring
c d
BL
BL
BL
BL
WH
BR
WH
BL
RD
a
WH
BR
GN
GN GN
BL
e
RD YL
BL BR
WH
WH WH
TONGUE WIRING WH
BL
RD a
YL
GN
YL
BR
WH
BL
BL
BL
BL
c d
wc_gr005372
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 Light
blue
54 wc_tx000936gb.fm
LTN 6L Schematics
4.4 Engine Wiring - Lombardini
wc_tx000936gb.fm 55
Schematics LTN 6L
4.5 Control Panel Wiring
1 B
2
L 30
86
87
2
85
3
W/R 1
4
Or Y/G
5
B R
6
Pr
7 R
8
Gr
9 W
10
R
4 2
7 6 5 3
12 10 9
11 L
12 P
13
Br 4
50
15
Y/G
/5
14
4
B 30
G B
Br
5
wc_gr000658
56 wc_tx000936gb.fm
LTN 6L Schematics
4.6 Power Winch Schematic
a
g 1 BK
e 5 RD
A1
7 RD B2 B1
8 BK
+ -
A2
1 BK
2 RD 2 RD
3 BK 3 BK 6 BK
4 RD
- +
7 RD
f
8 BK
A1
B2 B1
6 BK
4 RD
d
A2
+
b
5 RD
c
wc_gr005371
wc_tx000936gb.fm 57
Maintenance LTN 6L
5 Maintenance
WARNING
Remove fixtures by disconnecting electrical cords at the junction box
(b). Remove nuts (c) from fixture mounting brackets and remove both
fixture 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.
WARNING
GN GN
BL BL
1 WH WH 2
GN GN
BL BL
3 WH WH 4
wc_gr005376
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 Light
blue
58 wc_tx000767gb.fm
LTN 6L Maintenance
5.2 Replacing / Removing Lamps
Prerequisites
• Engine shut down
• Light circuit breakers turned OFF
• Lamps and fixtures cool to the touch
• Eye protection and gloves
WARNING
Burn hazard. Lamps become extremely hot in use.
f Allow lamps and fixtures to cool 10–15 minutes 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, property dam-
age, burns, or fire.
f Do not operate the lights with a lens that is cracked, damaged, or missing.
f Do not scratch the lamp or subject the lamp to excess pressure.
f Wear eye protection and gloves when removing or replacing lamps.
e
b
d
a f
wc_gr005881
wc_tx000767gb.fm 59
Maintenance LTN 6L
5.2.2 Remove the lens (c) with the gasket (d) attached.
5.2.3 Remove the hardware securing one side of the lamp stabilizer (e).
Once removed, swing the lamp stabilizer to the side and unscrew the
lamp (f).
60 wc_tx000767gb.fm
LTN 6L Maintenance
5.4 Air Cleaner
wc_gr000540
wc_gr005394
wc_tx000767gb.fm 61
Maintenance LTN 6L
5.6 Periodic Maintenance Schedule
Clean radiator.
Flush radiator.
Replace battery.
* Replace air filter after air filter restriction switch indication or one year. Lombardini does not rec-
ommend the removal of air filter elements for purposes of inspection.
** Change engine oil and filter after first 50 hours of operation.
62 wc_tx000767gb.fm
LTN 6L Maintenance
5.7 Troubleshooting
Low light output Lamp degraded Replace lamp due to normal lamp life.
Low ballast output Check ballast for proper voltage output.
Fixture or lens dirty Clean reflective surface inside fixture
and both inside and outside surface of
glass lens.
wc_tx000767gb.fm 63
Maintenance LTN 6L
Notes
64 wc_tx000767gb.fm
LTN 6L Technical Data
6 Technical Data
6.1 Engine
Engine Power Rating
Net power rating per ISO 3046 IFN. Actual power output may vary due
to conditions of specific use.
Engine
Make Lombardini
Model LDW1003
Type 3-cylinder, 4-cycle, liquid-cooled diesel
Max. power rating @
kW (Hp) 10.0 (13.4) @ 1800 rpm
rated speed
Operating speed
rpm 1800
(no-load)
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 capacity l (qts.) 2.4 (2.5)
wc_td000230gb.fm 65
Technical Data LTN 6L
6.2 Generator
Generator
Frequency Hz 60 ± 2
Continuous output kW 6.0
volts/
Output phase
120, 1Ø 120/240, 1Ø
Amps A 50
Excitation type Capacitor / Brushless
Power factor 1.0
Voltage regulation
% ± 6.0
- no load to full load
Speed (no-load) rpm 1800
6.3 Machine
Machine
Operating weight (GVWR) kg(lbs.) 768 (1693)
Travel Dimensions mm 4600 x 1500 x 1900
(l x w x h) (in.) (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 m2 Metal Halide - 30,400 (7.52)
@ 0.5 ft. candles (acres)
Sound level at 7 m (23 ft.) dB(A) 67
Tires size ST175 / 80D13
66 wc_td000230gb.fm
LTN Appendix I—Assembly Instructions
7 Appendix I—Assembly Instructions
7.1 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 Use the following chart and the illustrations on the next page to determine
identification which set of assembly procedures applies to your machine.
wc_tx001218gb.fm 67
Appendix I—Assembly Instructions LTN
Illustrations
wc_gr006517
68 wc_tx001218gb.fm
LTN Appendix II—Assembly Safety
8 Appendix II—Assembly Safety
8.1 Signal Words Found in this Manual
This is the safety alert symbol. It is used to alert you to potential 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 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 mes-
sages that follow this signal word.
CAUTION!
CAUTION indicates a hazardous situation which, if not avoided, could result in
minor or moderate injury.
f To avoid possible minor or moderate injury from this type of hazard, obey all safety mes-
sages that follow this signal word.
NOTICE: Used without the safety alert symbol, NOTICE indicates a situation
which, if not avoided, could result in property damage.
wc_si000344gb.fm 69
Appendix II—Assembly Safety LTN
8.2 Lifting Safety
Overview Some of the assembly procedures in this Manual require the machine to be
lifted or supported by slings, chains, hooks, ramps, jacks, or other types of
mechanical devices. Follow the guidelines below to avoid personal injury or
machine damage.
WARNING
Crushing hazard.
f Use OSHA-rated and -approved lifting devices capable of lifting the machine.
Refer to the general weight guidelines in the Technical Data chapter of the
Operator’s Manual.
Before assembly Make sure the engine start switch is turned to OFF.
Make sure the circuit breakers are OFF (open).
Make sure the negative terminal on the battery is disconnected.
Make sure water has not accumulated around the base of the machine. If
water is present, move the machine to a dry area and allow all components
to dry thoroughly before assembly.
70 wc_si000344gb.fm
LTN Appendix III—Standard Pallet Assembly
9 Appendix III—Standard Pallet Assembly
Scope This set of assembly instructions applies to standard machines shipped on a pallet
as shown below.
wc_gr006467
If your machine does 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:
Task Description See topic
Outriggers and jacks assembly
1 Install the outriggers 3.1
2 Install the outrigger jacks 3.1
3 Install the rear jack 3.2
Tongue assembly
4 Install the tongue 3.3
5 Install the tongue jack 3.3
Torque wrench
Hardware bag: 7
wc_tx001214gb.fm 71
Appendix III—Standard Pallet Assembly LTN
9.1 Installing the Outriggers and Outrigger Jacks
Installing the Follow the procedure below to Install the two outriggers. (Use the same procedure
outriggers for each side of the Light Tower.)
1. Locate the locking pin (A) at the outrigger socket.
C1
C2
A
B
B1
B2
C
C3
wc_gr006520
2. Position the outrigger (B) so that the holes (B1 and B2) face the same direction
as the locking pin.
3. Pull the locking pin and insert the square end of the outrigger into the outrigger
socket.
4. Align hole (B1) in the outrigger with the locking pin. When hole (B1) is aligned,
release the locking pin to fasten the outrigger in place.
Installing the Follow the procedure below to Install the two outrigger jacks. (Use the same
outrigger procedure for each outrigger jack.)
jacks
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 circular end of the outrigger
(B).
4. Rotate the outrigger jack so that the foot (C2) rests on the ground.
5. Align the top hole in the outrigger jack socket with the top hole on the outrigger.
72 wc_tx001214gb.fm
LTN Appendix III—Standard Pallet Assembly
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.
wc_tx001214gb.fm 73
Appendix III—Standard Pallet Assembly LTN
9.2 Installing the Rear Jack
Procedure Follow the procedure below to install the rear jack.
1. Locate the 5000 lb.10-inch side crank jack (D).
D2
D3
D
D1 D4
wc_gr006522
2. If necessary, remove 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.
74 wc_tx001214gb.fm
LTN Appendix III—Standard Pallet Assembly
9.3 Installing the Tongue Assembly
Scope Installing the tongue assembly consists of installing the tongue and the tongue
jack, and connecting the trailer wiring.
E
H F
wc_gr006523
2. Fasten the tongue to the sleeve using the following hardware from Bag 7:
(3) M16 x 120 screws (E)
wc_tx001214gb.fm 75
Appendix III—Standard Pallet Assembly LTN
Installing the Follow the procedure below to Install the tongue jack.
tongue jack
1. Locate the 2000 lb. 10-inch travel jack (“tongue jack”) (J).
J J1
J2
J3
wc_gr006524
2. If necessary, remove the locking pin (J3) from the holes in the tongue jack.
3. Fit the socket (J1) over the circular boss on the tongue assembly.
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.
L
K
wc_gr006525
2. Plug the tongue wiring harness connector (K) into tongue wiring harness
connector (L).
3. Insert connector plug body into the hole on the skid bracket. (See arrow.)
76 wc_tx001214gb.fm
LTN Appendix III—Standard Pallet Assembly
9.4 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:
wc_tx001214gb.fm 77
Appendix IV—CE Pallet Assembly LTN
10 Appendix IV—CE Pallet Assembly
Overview This set of assembly instructions applies to CE machines shipped on a pallet as
shown below. A palletized CE machine is intended to be mounted on a trailer that
meets local regulations. This Manual does not include instructions for mounting a
palletized CE machine on a trailer.
wc_gr006468
If your machine does 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:
Task Description See topic
Lift the machine
1 Lift the machine using appropriate lifting gear —
Install the jacks
2 Install the side jacks 3.1
3 Install the rear jack 3.2
78 wc_tx001215gb.fm
LTN Appendix IV—CE Pallet Assembly
10.1 Installing the Side Jacks
Procedure Follow the procedure below to attach the two side jacks. (Use the same procedure
for each side jack.)
1. Locate the two 15-inch travel jacks (C).
C2
C1
B C
C3
wc_gr006710
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 place.
wc_tx001215gb.fm 79
Appendix IV—CE Pallet Assembly LTN
10.2 Installing the Rear Jack
Procedure Follow the procedure below to install the rear jack.
1. Locate the 5000 lb.10-inch side crank jack (D).
D2
D3
D
D1 D4
wc_gr006711
2. If necessary, remove 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.
80 wc_tx001215gb.fm
LTN Appendix IV—CE Pallet Assembly
10.3 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:
wc_tx001215gb.fm 81
Appendix V—Standard Racked Assembly LTN
11 Appendix V—Standard Racked Assembly
Overview This set of assembly instructions applies to standard machines shipped on a
container rack as shown below.
wc_gr006469
If your machine does 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:
82 wc_tx001216gb.fm
LTN Appendix V—Standard Racked Assembly
Tools and The following tools and materials are needed:
materials Basic hand tools (wrenches, screwdrivers, etc.)
Torque wrench
wc_tx001216gb.fm 83
Appendix V—Standard Racked Assembly LTN
11.1 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.
Q1 Q2
Q
Q2
Q3
84 wc_tx001216gb.fm
LTN Appendix V—Standard Racked Assembly
11.2 Installing the Fenders
Procedure Follow the procedure below to Install the fenders.
1. Locate the two fenders (W) and hardware bag 2.
wc_gr006528
wc_tx001216gb.fm 85
Appendix V—Standard Racked Assembly LTN
11.3 Installing the Wheels
Installing the Follow the procedure below to Install the wheels:
wheels
1. Locate the two wheels (U) and hardware bag 3.
wc_gr006529
2. Install the wheels on the axle using five lug nuts per wheel. Torque the lug nuts
to 115 Nm (85 ft.lbs.).
86 wc_tx001216gb.fm
LTN Appendix V—Standard Racked Assembly
11.4 Installing the Outriggers and Outrigger Jacks
Installing the Follow the procedure below to Install the two outriggers. (Use the same procedure
outriggers for each side of the Light Tower.)
1. Locate the locking pin (A) at the outrigger socket.
C1
C2
A
B
B1
B2
C
C3
wc_gr006520
2. Position the outrigger (B) so that the holes (B1 and B2) face the same direction
as the locking pin.
3. Pull the locking pin and insert the square end of the outrigger into the outrigger
socket.
4. Align hole (B1) in the outrigger with the locking pin. When hole (B1) is aligned,
release the locking pin to fasten the outrigger in place.
Installing the Follow the procedure below to Install the two outrigger jacks. (Use the same
outrigger procedure for each outrigger jack.)
jacks
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 circular end of the outrigger
(B).
4. Rotate the outrigger jack so that the foot (C2) rests on the ground.
5. Align the top hole in the outrigger jack 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 outrigger jack in place.
wc_tx001216gb.fm 87
Appendix V—Standard Racked Assembly LTN
11.5 Installing the Rear Jack
Procedure Follow the procedure below to install the rear jack.
1. Locate the 5000 lb.10-inch side crank jack (D).
D2
D3
D
D1 D4
wc_gr006522
2. If necessary, remove 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.
88 wc_tx001216gb.fm
LTN Appendix V—Standard Racked Assembly
11.6 Installing the Tongue Assembly
Scope Installing the tongue assembly consists of installing the tongue and the tongue
jack, and connecting the trailer wiring.
E
H F
wc_gr006523
2. Fasten the tongue to the sleeve using the following hardware from Bag 7:
(3) M16 x 120 screws (E)
wc_tx001216gb.fm 89
Appendix V—Standard Racked Assembly LTN
Installing the Follow the procedure below to Install the tongue jack.
tongue jack
1. Locate the 2000 lb. 10-inch travel jack (“tongue jack”) (J).
J J1
J2
J3
wc_gr006524
2. If necessary, remove the locking pin (J3) from the holes in the tongue jack.
3. Fit the socket (J1) over the circular boss on the tongue assembly.
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.
L
K
wc_gr006525
2. Plug the tongue wiring harness connector (K) into tongue wiring harness
connector (L).
3. Insert connector plug body into the hole on the skid bracket. (See arrow.)
90 wc_tx001216gb.fm
LTN Appendix V—Standard Racked Assembly
11.7 Installing the Tower Lock Bracket
Procedure Follow the procedure below to Install the tower lock bracket.
1. Locate the following in hardware bag 5:
(1) tower lock bracket (M)
O P
wc_gr006526
wc_tx001216gb.fm 91
Appendix V—Standard Racked Assembly LTN
11.8 Installing the Tower Cradle
Materials Tower cradle
needed Hardware bag 4 (tower cradle hardware)
Procedure Follow the procedure below to assemble the tower cradle (Y).
Y7 Y4
Y8 Y3
Y9 Y2
Y Y1
Y6
Y11
Y5
Y9
Y10
wc_gr006530
1. Using (4) M10 x 16 serrated flange screws (Y1), install the tower cradle to the
Light Tower upper frame. Torque the screws to 58 Nm (42.8 ft.lbs.)
2. Using (2) M6 x 20 serrated 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 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).
92 wc_tx001216gb.fm
LTN Appendix V—Standard Racked Assembly
11.9 Installing the Tower
Materials Tower assembly
needed Hardware bag 8 (tower install assembly)
AA2
AA1
AA2 Z Y8
Y10
Z3
Z4
Z2
Z1
wc_gr006531
1. Align the tower assembly (Z) on top of the Light Tower enclosure as shown.
2. Place the tower assembly over the tower lock pin (Y8) and secure it with the
hitch pin. This will help to keep the tower in alignment for the next step.
3. Insert the clevis pin (Z1) through 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 The winch handles (AA2) are installed backward to protect them from shipping
winch handles damage. Reverse each handle orientation as follows:
1. Remove the nut (AA1) and remove the winch handle from the stem.
2. Turn the winch handle so that the handgrip is oriented as shown in the
illustration.
3. Re-install the winch handle and the nut.
wc_tx001216gb.fm 93
Appendix V—Standard Racked Assembly LTN
11.10 Installing the Tower Pivot Cable
Materials Tower pivot cable (AA8)
needed Hardware Bag 8 (Tower Install Assembly)
Installing the Follow the procedure below to install the tower pivot cable.
tower
AA6
AA AA9 AA5
AA7
AA8
wc_gr006532
1. One end of the tower pivot cable has a loop. Insert the retainer pin (AA5)
through the hole in the upper pulley mount (AA9) and pass it through the cable
loop.
2. Place the M12 washer (AA7) over the end of the retainer pin and secure it with
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 nuts on the cable retainer (AA) and insert the free end of the
cable through the retainer so that approximately 1 cm (3/8 in.) of cable extends
beyond the retainer. Torque the nuts to 3 Nm (20-30 in.lbs.).
7. Rotate the winch counter-clockwise to take up any slack in the cable.
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LTN Appendix V—Standard Racked Assembly
11.11 Installing the Lights
Materials Light fixtures (4)
needed Hardware bag 6 (tower lights hardware)
BB2 BB1
BB
CC2
BB3 CC1
CC CC3
wc_gr006533
1. Install the light mount tube (BB) 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 washer (CC2).
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Appendix V—Standard Racked Assembly LTN
11.12 Connecting the Wiring at the Junction Box
Special tools Coil cord (GG)
and materials Panduit® crimper CT-100
needed
Panduit® crimper CT-1550
Hardware bag 6
Procedure Follow the procedure below to connect the wiring at the junction box.
DD
DD2 DD2
DD1
wc_gr006534
Installing the 1. Remove the screws and the cover plate from the junction box (DD).
coil cord
2. Use two wrenches to loosen the connector (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 4. Use two wrenches to loosen the four connectors (DD2) on the sides of the
fixture cords junction box.
5. Refer to the diagram below and insert the fixture cords through the appropriate
connectors. Approximately 1 cm (3/8 in.) of each fixture cord jacket should
extend into the junction box. Retighten connectors DD2.
FF
L1 L2
L1 L2
L3 L4
L3 L4
wc_gr006535
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LTN Appendix V—Standard Racked Assembly
Connecting 6. Refer to the table below and connect the light fixture wires to the coil cord wires.
the wires Use the small connectors and Panduit wire crimper CT-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.
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Appendix V—Standard Racked Assembly LTN
11.13 Routing the Coil Cord
Procedure Follow the procedure below to route the coil cord.
CN
R L
wc_gr006536
1. At the base of the tower, wrap the coil cord around the tower twice, creating
loops of about 25 cm (10 in.) in diameter.
2. Loosen the connector (CN). Pass the end of 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 the
second loom. Pass this loom through the ballast bracket on the left side of the
machine (L).
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LTN Appendix V—Standard Racked Assembly
11.14 Wiring the Ballasts and Terminal Strips
Procedure Follow the procedure below to wire the ballasts and terminal strips.
BC
wc_gr006537
1. Remove the two ballast covers (BC) from the left and right sides of the Light
Tower.
2. Connect the green wire from the coil cord to the hexagonal grounding screw
(G).
3. Locate the four capacitors as shown below.
1
2
3
4
wc_gr006570
4. Connect four wires from the coil cord to the capacitors as follows:
Capacitor Wire from coil cord
1 Red
2 Black
3 Yellow
4 Blue
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 mounting screws to 5.0 Nm (3.5 ft.lbs.).
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Appendix V—Standard Racked Assembly LTN
A G A G
B H B H
C I C I
D J D J
E K E K
F L F L
A B
“A” “B”
wc_gr006538
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LTN Appendix V—Standard Racked Assembly
11.15 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:
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Wacker Neuson SE · Preußenstraße 41 · D-80809 München · Tel.: +49-(0)89-3 54 02-0 · Fax: +49 - (0)89-3 54 02-390
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