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WACKER Group LTC 4 User Manual

WACKER Group LTC 4
166 pages
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www.wackergroup.com
Light Tower
LTC 4
REPAIR MANUAL
0160487en 003
0206
0160487EN

Table of Contents

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WACKER Group LTC 4 Specifications

General IconGeneral
BrandWACKER Group
ModelLTC 4
CategoryInverter
LanguageEnglish

Summary

Foreword

Operating / Parts Information

Details on operating and parts information, referring to Operator's Manual and Parts Book.

Safety Information

Laws Pertaining to Spark Arresters

Discusses state health safety codes and public resources codes regarding spark arresters.

Operating Safety

General safety guidelines for operating the light tower equipment.

Operator Safety while using Internal Combustion Engines

Hazards and safety precautions related to internal combustion engines.

Towing Safety

Safety measures and recommendations for towing the light tower trailer.

Service Safety

Safety precautions to be followed during maintenance and repair.

Label Locations

Illustrates the locations of various labels on the machine.

Safety and Operating Labels

Explains the meaning of different safety and operating labels.

Technical Data

Engine

Provides technical specifications for the engine (Make, Model, Power, etc.).

Generator

Details technical specifications for the generator (Frequency, Output, Power Factor, etc.).

Machine

Lists general machine specifications (Weight, Dimensions, Lighting System, etc.).

Operation

Information Regarding Operation

Condensed information on machine operation, referring to Operator's Manual.

Locating Trailer

Guidance on positioning the light tower for optimal light coverage.

Leveling Trailer

Procedures for leveling the trailer using outriggers and jacks.

Adjusting Lights

Instructions on how to aim and adjust the light fixtures.

Preparing Trailer for Towing or Lifting

Steps to prepare the trailer for safe towing or lifting.

Raising Tower (Manual Winch System)

Step-by-step guide for raising the tower using the manual winch.

Lowering Tower (Manual Winch System)

Procedures for safely lowering the tower with the manual winch.

Raising Tower (Power Winch System)

Guide for raising the tower using the power winch system.

Lowering Tower (Power Winch System)

Instructions for lowering the tower using the power winch system.

Emergency Crank Handle (Power Winch System)

Procedure for using the emergency crank handle for the power winch.

Control Panels—Lombardini (Manual Winch System)

Identifies components of the control panels for Lombardini engines.

Control Panels—Lombardini (Power Winch System)

Identifies components of control panels for Lombardini engines with power winches.

Control Panels—CAT (Manual Winch System)

Identifies components of control panels for CAT engines.

Control Panel—CAT (Power Winch System)

Identifies components of control panels for CAT engines with power winches.

Starting—Lombardini

Steps for starting the Lombardini engine.

Starting—CAT

Steps for starting the Caterpillar engine.

Automatic Shutdown

Explains the automatic shutdown system for low oil or high temperature.

Operating Lights

Instructions for operating the floodlights.

Stopping—Lombardini

Procedure for stopping the Lombardini engine.

Stopping—CAT

Procedure for stopping the Caterpillar engine.

Derating

Information on generator derating due to altitude and temperature.

Receptacles—60 Hz

Details on the convenience receptacle and GFI testing.

Maintenance

Periodic Maintenance Schedule—Lombardini

Maintenance schedule for Lombardini engines based on usage hours.

Periodic Maintenance Schedule—CAT

Maintenance schedule for Caterpillar engines based on usage hours.

Daily Inspection

Daily checks to perform on the light tower before operation.

Installing / Removing Light Fixtures

Procedure for installing and removing light fixtures.

Precautions When Replacing / Removing Bulbs

Safety precautions when handling light bulbs.

Replacing Bulbs

Step-by-step instructions for replacing light bulbs.

Air Cleaner

Instructions for inspecting and cleaning the air cleaner.

Engine Oil

Procedure for draining and refilling engine oil.

Generator Capacitor Excitation Schematic 60 Hz

Schematic diagram for generator capacitor excitation.

Schematic for 60 Hz Metal Halide 4-Light Units

Wiring schematic for the 4-light metal halide unit.

Metal Halide Schematic Components

Lists components used in the metal halide schematic.

Engine Wiring—Lombardini 1003

Engine wiring diagram for Lombardini 1003 engines.

Engine Wiring Components—Lombardini 1003

Lists components in the Lombardini 1003 engine wiring.

Engine Control Panel Internal Wiring—Lombardini 1003

Internal wiring diagram for the Lombardini 1003 engine control panel.

Engine Wiring—Lombardini 903

Engine wiring diagram for Lombardini 903 engines.

Engine Control Panel Internal Wiring—Lombardini 903

Internal wiring diagram for the Lombardini 903 engine control panel.

Engine Control Panel Components—Lombardini

Identifies components of the Lombardini engine control panel.

Lombardini Engine Troubleshooting

Troubleshooting Flowcharts

Introduction to troubleshooting flowcharts for engine issues.

Engine Does Not Crank—Flowchart 3A

Troubleshooting flowchart for engine not cranking issues.

Checking Keyswitch and Wiring

Procedure for checking the keyswitch and associated wiring.

Replacing Keyswitch

Step-by-step guide for replacing the keyswitch.

Engine Cranks But Does Not Start—Flowchart 4A

Troubleshooting flowchart for engine cranking but not starting.

Checking Fuel System

Procedure for checking the engine's fuel system.

Checking Voltage to Glow Plugs (Lombardini 903 engines)

How to check voltage to glow plugs on 903 engines.

Checking Voltage to Glow Plugs (Lombardini 1003 engines)

How to check voltage to glow plugs on 1003 engines.

Checking Glow Plug Relay

Procedure for checking the glow plug relay.

Replacing Glow Plug Relay

Step-by-step guide for replacing the glow plug relay.

Checking Glow Plugs

Procedure for checking the glow plugs themselves.

Engine Shuts Down—Flowchart 5A

Troubleshooting flowchart for engine shutdown issues.

Checking Oil Pressure and Coolant Temperature Switches

How to check oil pressure and coolant temperature switches.

General Engine Troubleshooting

Table of common engine problems and their possible causes.

Caterpillar Engine Troubleshooting

Troubleshooting Flowcharts

Introduction to troubleshooting flowcharts for Caterpillar engines.

Engine Does Not Crank—Flowchart 6A

Troubleshooting flowchart for engine not cranking issues.

Checking Keyswitch and Wiring

Procedure for checking the keyswitch and associated wiring.

Replacing Keyswitch

Step-by-step guide for replacing the keyswitch.

Engine Cranks But Does Not Start—Flowchart 7A

Troubleshooting flowchart for engine cranking but not starting.

Checking Fuel Flow

Procedure for checking fuel flow on Caterpillar engines.

Checking Glow Plug Wiring

Procedure for checking glow plug wiring on Caterpillar engines.

Checking Glow Plugs

Procedure for checking the glow plugs on Caterpillar engines.

Engine Shuts Down—Flowchart 8A

Troubleshooting flowchart for engine shutdown issues.

Checking Oil Pressure and Coolant Temperature Switches

How to check oil pressure and coolant temperature switches.

General Engine Troubleshooting

Table of common Caterpillar engine problems and their causes.

Electrical Troubleshooting Procedures

Troubleshooting Methodology

General approach to troubleshooting electrical issues.

Schematic Components

Lists and identifies components used in electrical schematics.

Schematic for 60 Hz Metal Halide 4-Light Units

Wiring schematic for the 4-light metal halide unit.

Checking Continuity

Procedure for testing continuity with a multimeter.

Checking resistance

Procedure for testing resistance with a multimeter.

Checking voltage

Procedure for testing voltage with a multimeter.

Troubleshooting Flowcharts

Introduction to electrical troubleshooting flowcharts.

Lights do not Illuminate—Flowchart 1A

Troubleshooting flowchart for lights not illuminating.

Lights do not Illuminate—Flowchart 1B

Troubleshooting flowchart for lights not illuminating (part 2).

Lights do not Illuminate—Flowchart 1C

Troubleshooting flowchart for lights not illuminating (part 3).

Lights do not Illuminate—Flowchart 1D

Troubleshooting flowchart for lights not illuminating (part 4).

Checking Engine Speed

Procedure for checking and adjusting engine speed.

Checking Generator Voltage at Receptacle

Procedure to check generator voltage at the receptacle.

Replacing Receptacle

Step-by-step guide for replacing a receptacle.

Checking Voltage to the Main Circuit Breaker

Procedure to check voltage at the main circuit breaker.

Checking Voltage Between Main Circuit Breaker and Terminal Strip

Procedure to check voltage between breaker and terminal strip.

Checking Individual Circuit Breakers

Procedure for testing individual circuit breakers.

Confirming a Malfunctioning Circuit Breaker

How to confirm a faulty circuit breaker.

Checking Incoming Voltage to Control Panel Capacitor(s)

Procedure to check incoming voltage to control panel capacitors.

Checking Outgoing Voltage from Control Panel Capacitor(s)

Procedure to check outgoing voltage from control panel capacitors.

Confirming a Faulty Control Panel Capacitor

How to confirm a faulty control panel capacitor.

Checking Wiring to/from Ballast(s)

Procedure for checking wiring connected to ballasts.

Replacing Ballast

Step-by-step guide for replacing a ballast.

Restoring Rotor Magnetism (Flashing) / Checking Rotor Winding

Procedures for restoring rotor magnetism and checking rotor winding.

Checking Generator Capacitors

Procedure for checking generator capacitors.

Alternative Capacitor Check

Alternative method for checking capacitors.

Replacing Generator Capacitor(s)

Step-by-step guide for replacing generator capacitors.

Checking Stator Windings

Procedure for checking stator windings.

Removing/Installing Caterpillar Engine with Generator

Procedures for removing and installing the Caterpillar engine.

Removing/Installing Lombardini Engine with Generator

Procedures for removing and installing the Lombardini engine.

Separating Stator Assembly from Engine/Rotor Assembly

How to separate the stator assembly from the engine/rotor.

Remounting Stator Assembly to Rotor/Engine Assembly

How to remount the stator assembly to the rotor/engine.

Checking Rotor Diodes

Procedure for checking rotor diodes.

Checking Rotor Windings

Procedure for checking rotor windings.

Removing/Installing Rotor

Procedures for removing and installing the rotor.

No Voltage at Receptacle—Flowchart 2A

Troubleshooting flowchart for no voltage at the receptacle.

Checking Voltage at Receptacle

Procedure for checking voltage at the receptacle.

Checking Receptacle’s Circuit Breaker

Procedure for checking the receptacle's circuit breaker.

Troubleshooting the Power Winch

Troubleshooting guide for the power winch system.

Disassembly/Assembly Procedures

Tools

General advice on tool selection for repairs.

Ordering Parts

Information on how to order replacement parts.

Reference Numbers ( )

Explanation of reference numbers used in procedures.

Weight Block

Symbol indicating approximate weight for lifting.

Light Assembly

Procedures for disassembling and assembling the light units.

Tower Assembly Exploded View

Exploded view diagram of the tower assembly.

Tower Assembly List of Parts

List of parts for the tower assembly.

Upper Mast

Procedures for disassembling and assembling the upper mast.

Mid Mast

Procedures for disassembling and assembling the mid mast.

Main Mast

Procedures for disassembling and assembling the main mast.

Replacing Cable and Winch on Power Winch Models

Procedures for replacing cable and winch on power winch models.

Replacing Fuel Tank

Procedures for replacing the fuel tank.

Replacing Hour Meter

Procedures for replacing the hour meter.

Threadlockers and Sealants

Threadlockers and Sealants

Specification and usage of threadlocking adhesives and sealants.

Torque Values

Torque Values Metric Fasteners (DIN)

Torque specifications for metric fasteners based on size and hardness.

Torque Values (continued) Inch Fasteners (SAE)

Torque specifications for inch (SAE) fasteners based on size.