Operator’s Manual Light Tower LTN 6L 50...

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Operator’s Manual

Light Tower

LTN 6L50 Hz

Copyright notice

© Copyright 2010 by Wacker Neuson Corporation.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.

Manufacturer Wacker Neuson CorporationN92W15000 Anthony AvenueMenomonee Falls, WI 53051 U.S.A.Tel: (262) 255-0500 · Fax: (262) 255-0550 · Tel: (800) 770-0957www.wackerneuson.com

Translated instructions

This Operator’s Manual presents a translation of the original instructions. The original language of this Operator’s Manual is American English.

CALIFORNIAProposition 65 Warning:

Engine exhaust, some of its constituents, and certain vehiclecomponents, contain or emit chemicals known to the State ofCalifornia to cause cancer and birth defects or other reproductiveharm.

Foreword

This manual provides information and procedures to safely operateand maintain this Wacker Neuson model. For your own safety andprotection from injury, carefully read, understand and observe thesafety instructions described in this manual.

Keep this manual or a copy of it with the machine. If you lose thismanual or need an additional copy, please contact Wacker NeusonCorporation. This machine is built with user safety in mind; however,it can present hazards if improperly operated and serviced. Followoperating instructions carefully! If you have questions about operatingor servicing this equipment, please contact Wacker NeusonCorporation.

The information contained in this manual was based on machines inproduction at the time of publication. Wacker Neuson Corporationreserves the right to change any portion of this information withoutnotice.

All rights, especially copying and distribution rights, are reserved.

Copyright 2010 by Wacker Neuson Corporation.

No part of this publication may be reproduced in any form or by anymeans, electronic or mechanical, including photocopying, withoutexpress written permission from Wacker Neuson Corporation.

Any type of reproduction or distribution not authorized by WackerNeuson Corporation represents an infringement of valid copyrightsand will be prosecuted. We expressly reserve the right to maketechnical modifications, even without due notice, which aim atimproving our machines or their safety standards.

WARNING

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LTN 6L Table of Contents

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Foreword 3

1. Safety Information 7

1.1 Laws Pertaining to Spark Arresters ...................................................... 71.2 Operating Safety .................................................................................. 81.3 Operator Safety while using Internal Combustion Engines .................. 91.4 Service Safety .................................................................................... 101.5 Label Locations .................................................................................. 111.6 Safety, Procedural, and Informational Labels .................................... 131.7 Safety labels ....................................................................................... 131.8 Procedural labels ................................................................................ 161.9 Informational labels ............................................................................ 22

2. Operation 23

2.1 Preparing for Lifting ............................................................................ 232.2 Adjusting Lights .................................................................................. 242.3 Operating Lights ................................................................................. 252.4 Raising Tower (Manual Winch System) ............................................. 262.5 Lowering Tower (Manual Winch System) ........................................... 292.6 Control Panels - 50 Hz - Manual Winch System ................................ 322.7 Starting ............................................................................................... 342.8 Automatic Shutdown .......................................................................... 342.9 Stopping ............................................................................................. 352.10 Emergency Stop Switch ..................................................................... 352.11 Derating .............................................................................................. 352.12 Receptacle - 50 Hz ............................................................................. 36

3. Maintenance 37

3.1 Installing / Removing Light Fixtures ................................................... 373.2 Replacing / Removing Lamps ............................................................ 383.3 Daily Inspection .................................................................................. 383.4 Air Cleaner ......................................................................................... 393.5 Engine Oil ........................................................................................... 393.6 Periodic Maintenance Schedule ......................................................... 403.7 Troubleshooting .................................................................................. 413.8 Control Panel Wiring .......................................................................... 43

Table of Contents LTN 6L

4. Schematics 44

4.1 Schematic for 50 Hz Metal Halide 4-Light Units-115 V .......................444.2 Schematic for 50 Hz Metal Halide 4-Light Units-230 V .......................464.3 Generator Capacitor Excitation Schematic 50 Hz ...............................484.4 Engine Wiring ......................................................................................49

5. Technical Data 50

5.1 Engine .................................................................................................505.2 Generator ............................................................................................515.3 Machine ...............................................................................................51

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LTN 6L Safety Information

1. Safety Information

This manual contains DANGER, WARNING, CAUTION, NOTICE, andNOTE callouts which must be followed to reduce the possibility ofpersonal injury, damage to the equipment, or improper service.

This is the safety alert symbol. It is used to alert you to potentialpersonal injury hazards. Obey all safety messages that follow thissymbol to avoid possible injury or death.

DANGER indicates a hazardous situation which, if not avoided, willresult in death or serious injury.

WARNING indicates a hazardous situation which, if not avoided, couldresult in death or serious injury.

CAUTION indicates a situation which, if not avoided, could result inminor or moderate injury.

NOTICE: Used without the safety alert symbol, NOTICE indicates asituation which, if not avoided, could result in property damage.

Note: Contains additional information important to a procedure.

1.1 Laws Pertaining to Spark Arresters

Notice: State Health Safety Codes and Public Resources Codesspecify that in certain locations spark arresters be used on internalcombustion engines that use hydrocarbon fuels. A spark arrester is adevice designed to prevent accidental discharge of sparks or flamesfrom the engine exhaust. Spark arresters are qualified and rated bythe United States Forest Service for this purpose.

In order to comply with local laws regarding spark arresters, consultthe engine distributor or the local Health and Safety Administrator.

DANGER

WARNING

CAUTION

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Safety Information LTN 6L

1.2 Operating Safety

Familiarity and proper training are required for the safe operation of themachine. Machines operated improperly or by untrained personnelcan be hazardous. Read the operating instructions contained in thismanual and the engine manual, and familiarize yourself with thelocation and proper use of all controls. Inexperienced operators shouldreceive instruction from someone familiar with the machine beforebeing allowed to operate it.

1.2.1 Do not remove, defeat, deface, or render inoperable any of the safetydevices, warnings, or labels on this equipment. If any safety devices,warnings, or labels have been removed, defeated, defaced, orrendered inoperable, do NOT use this equipment!

1.2.2 The area immediately surrounding the Light Tower should be clean,neat, and free of debris.

1.2.3 Be sure the machine is on a firm, level surface and will not tip, roll,slide, or fall while operating.

1.2.4 NEVER start a machine in need of repair.

1.2.5 Lower the tower when not in use, or if high winds or electrical stormsare expected in the area.

1.2.6 ALWAYS make certain the machine is well-grounded and securelyfastened to a good earthen ground per national and local regulations.

1.2.7 The tower extends up to 9 m (30 ft.). Make sure the area above thetrailer is open and clear of overhead wires and obstructions.

1.2.8 The lamps become extremely hot in use! Allow the lamp and fixture tocool 10–15 minutes before handling.

1.2.9 Keep the area behind the trailer clear of people while raising andlowering the tower! Never raise, lower or turn the tower while unit isoperating!

1.2.10 The trailer must be leveled and the outriggers extended before raisingthe tower. The outriggers must remain extended while the tower is up.

1.2.11 If for any reason any part of the tower hangs up or the winch cabledevelops slack while raising or lowering the tower, STOP immediately!Contact an authorized Wacker Neuson service representative.

1.2.12 NEVER remove the tower locking pin while the tower is up!

1.2.13 NEVER use the machine if the insulation on the electrical cord is cut orworn through.

1.2.14 NEVER operate the lights without the protective lens cover in place orwith a lens cover that is cracked or damaged!

1.2.15 NEVER adjust the tower while the unit is operating.

1.2.16 Do not move the Light Tower while it is operating.

WARNING

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1.2.17 NEVER raise the tower or operate the machine in high winds.
1.2.18 NEVER connect machine to other power sources, such as supplymains of power companies.

1.2.19 ALWAYS replace or repair electrical components with componentsthat are identical in rating and performance as the original component.

1.3 Operator Safety while using Internal Combustion Engines

Internal combustion engines present special hazards during operationand fueling. Read and follow the warning instructions in the engineowner’s manual and the safety guidelines below. Failure to follow thewarnings and safety standards could result in severe injury or death.

1.3.1 Do not run the machine indoors or in an enclosed area such as a deeptrench unless adequate ventilation, through such items as exhaustfans or hoses, is provided. Engine exhaust contains carbon monoxide.This is a poison you cannot see or smell. Exposure to carbonmonoxide can cause loss of consciousness and CAN KILL YOU INMINUTES.

1.3.2 Allow the engine to cool before refueling the machine.

1.3.3 Do not fill or drain the fuel tank near an open flame, while smoking, orwhile the engine is running.

1.3.4 Refill the fuel tank in a well-ventilated area.1.3.5 Do not touch or lean against hot exhaust pipes.

1.3.6 Replace the fuel tank cap after refueling.1.3.7 Do not remove the radiator cap when the engine is running or hot. The

radiator fluid is hot and under pressure and may cause severe burns!

1.3.8 Do not use gasoline or other types of fuels or flammable solvents toclean parts, especially in enclosed areas. Fumes from fuels andsolvents can become explosive.

1.3.9 Keep the area around the muffler free of debris such as leaves, paper,cartons, etc. A hot muffler could ignite the debris and start a fire.

WARNING

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1.4 Service Safety

HIGH VOLTAGE! This unit uses high voltage circuits capable ofcausing serious injury or death. Only a qualified electrician shouldtroubleshoot or repair electrical problems occurring with thisequipment.

1.4.1 ALWAYS replace the safety devices and guards after repairs andmaintenance.

1.4.2 Before servicing the Light Tower, make sure the engine start switch isturned to the OFF position, the circuit breakers are open (off), and thenegative terminal on battery is disconnected. NEVER perform evenroutine service (oil/filter changes, cleaning, etc.) unless all electricalcomponents are shut down.

1.4.3 DO NOT allow water to accumulate around the base of the machine.If water is present, move the machine and allow the machine to drybefore servicing.

1.4.4 DO NOT service the machine if your clothing or skin is wet.

1.4.5 ALWAYS keep hands, feet, and loose clothing away from the movingparts on the generator and engine.

1.4.6 Keep the machine clean and labels legible. Replace all missing andhard-to-read labels. Labels provide important operating instructionsand warn of dangers and hazards.

1.4.7 ALWAYS make sure slings, chains, hooks, ramps, jacks, and othertypes of lifting devices are attached securely and have enough weight-bearing capacity to lift or hold the machine safely. Always remainaware of the location of other people in the area when lifting themachine.

1.4.8 ALWAYS turn off the light circuit breakers and shut down the enginebefore disconnecting the light fixtures or changing the lamps.

WARNING

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1.5 Label Locations

wc_gr005350

J

ZAA

E

V

O/P

DA BB BBCB

X

AA

K

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wc_gr005351

WJNDBB BB

Q/S

G, H, I

R/T

H

U

V

L

F AA

H

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1.6 Safety, Procedural, and Informational Labels

Wacker Neuson machines use international pictorial labels whereneeded. These labels are described below:

1.7 Safety labels

Ref. Label Meaning

A WARNING! Automatic locking pin.A non-secured, falling tower will 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 could cause serious injury or death.

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E WARNING! Secure tower in transport lock before lifting or towing. A loose swinging tower could cause personal injury or machine damage.

F DANGER! Asphyxiation 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.

G DANGER! Asphyxiation hazard. Read the Opera-tor’s Manual for instructions.

H DANGER! Electrical storage device within. Contact a qualified electrician for service or to open electrical box. Electric shock will cause serious injury or death.

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 or others.

Ref. Label Meaning

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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!

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.

V WARNING!Pinching hazard. Rotating machinery.

W WARNING!Avoid crushing area.

Ref. Label Meaning

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1.8 Procedural labels

Ref. Label Meaning

O See Operator’s Manual for metal halide lamp information and troubleshooting.

Before starting engine

Check levels of:Engine oilFuelCoolant

Circuit breakers off

Start engine

Engine control panelAuto heatingPreheat

Light outStart, 15 sec. max.

Circuit breakers on

Shut downCircuit breakers offStop engine

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P See Operator’s Manual for metal halide lamp information and troubleshooting.

Before starting engine

Check levels of:Engine oilFuelCoolant

Circuit breakers off

Start engine

Engine control switchPreheat (30 sec.)

Start, 15 sec. max.Circuit breakers on

Shut downCircuit breakers offStop engine

Ref. Label Meaning

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Q To raise tower: 1. Release transport lock.2. Tilt tower using winch.3. Tilt tower until automatic locking pin snaps into place.

To increase height of tower:4. Raise tower using winch.

To aim lights:5. Rotate tower and tighten knob.

Ref. Label Meaning

Manual Winch System

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R To lower tower:1. Turn off all lights and engine.2. Rotate tower and tighten knob.3. Lower tower using winch.

To tilt tower for transport:4. Release and hold spring-loaded pin.5. Tilt tower using winch.

To secure tower for transport:6. Insert pin through transport lock and secure with pin.7. Position light fixtures down.

Ref. Label Meaning

Manual Winch System

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S To raise tower: 1. Release transport lock.2. Tilt tower using winch.3. Tilt tower until automatic locking pin snaps into place.

To increase height of tower:4. Raise tower using winch.

To aim lights:5. Rotate tower and tighten knob.

Ref. Label Meaning

Power Winch System

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T To lower tower:1. Turn off all lights and engine.2. Rotate tower and tighten knob.3. Lower tower using winch.

To tilt tower for transport:4. Release and hold spring-loaded pin.5. Tilt tower using winch.

To secure tower for transport:6. Insert pin through transport lock and secure with pin.7. Position light fixtures down.

AA Insert jack locking pin before extending jack.

BB Fork lift pocket.

Ref. Label Meaning

Power Winch System

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1.9 Informational labels

Ref. Label Meaning

D NOTICELifting point.

M A nameplate listing the model number, item number, revision number, and serial number 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 will always be asked to specify the model number, item number, revision number, and serial number of the unit.

U Coolant overflow bottle only, not a return system.

X Guaranteed sound power level in dB(A).

Z Electrical ground.

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LTN 6L Operation

2. Operation

2.1 Preparing for Lifting

See Graphic: wc_gr005415

2.1.1 Check that the tower cradle lock pin (a) is in place and secured withthe safety pin.

2.1.2 Ensure that the tower is completely nested inside the transport cradleand the pin (b) is secure.

2.1.3 Make sure the doors are properly latched.

2.1.4 Return the outriggers to their travel position. Check that the outriggerbars and jacks are locked in place.

2.1.5 Crank the rear jack (c) all the way in and rotate it 90°.

The Light Tower is now ready to lift.

wc_gr005415

a

c

b

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Operation LTN 6L

2.2 Adjusting Lights


Each light fixture can be aimed up, down, left or right. Position eachfixture by loosening toolless light adjusters (g) and aiming the light upor down. DO NOT loosen the inside nut (x). Loosening this nut couldcause damage to the light fixture. Loosen the nut (h) to turn lightfixtures left or right. Tighten adjusters and nuts after positioning thelights.

Always return the light fixtures to aim at the ground when the tower isin the cradle for towing.

wc_gr005352

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LTN 6L Operation

2.3 Operating Lights


Turn on circuit breaker (a) first, then turn on each circuit breaker (b),one at a time.

Metal halide floodlights require a warm-up of 5–15 minutes before theyreach full output. If floodlights are shut down, a 10-minute cool-downperiod is required before turning them back on.

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Operation LTN 6L

2.4 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.

Do not move the Light Tower while it is operating.

HIGH VOLTAGE! DO NOT use the Light Tower if insulation onelectrical cord is cut or worn through. Repair or replace the cord beforeusing. Bare wires in contact with the metal frame of the trailer or towercan cause electrocution.

DO NOT position the Light Tower under electrical power lines.

NEVER allow anyone to stand near the rear of the unit while raising thetower.

The Light Tower includes two separate winches—one for lifting thetower to the vertical position, the other for raising the tower. Eachwinch is an automatic brake-type winch that automatically brakeswhen the handle is released. The handle must be rotated to wind in thecable as well as to unwind the cable.

NEVER touch the winch pawl! Releasing the pawl may cause thetower to fall.

2.4.1 Check winch cables (n) for wear or damage, and make sure they areresting properly in pulleys. Do not use the Light Tower if either winchcable is damaged.

2.4.2 Remove the cradle locking pin (j) from the cradle.

2.4.3 Check the operation of the tilt winch (o) by rotating the winch handle1/4-turn clockwise (“cable in” direction). The winch pawl must engagewinch gear teeth. When operating properly, the winch pawl will makea “clicking” sound when the winch handle is rotated clockwise. Do notattempt to raise the tower if the winch is damaged or not operatingproperly.

Pinching/crushing hazards. Moving parts can crush or cut extremities.Keep hands and fingers clear of pinch points when raising the tower

WARNING

WARNING

WARNING

WARNING

WARNING

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LTN 6L Operation
2.4.4 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 lockingposition before raising the tower.

2.4.5 NOTICE: While raising the tower, pay close attention to the coil cordand make sure that it does not tangle or become caught on any part ofthe machine.

NEVER pull the vertical tower locking pin (p) while the tower israised! Releasing the vertical tower locking pin while the tower israised may cause the tower to fall or the machine to tip over.

2.4.6 After the tower is in the vertical position, check the operation of thetelescoping 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 thewinch handle is rotated clockwise. Do not attempt to raise the tower ifthe winch is damaged or not operating properly. Continue rotating thewinch handle until tower is at the desired height. Do not over crank thewinch when the tower is fully extended.

NOTICE: Do not extend the tower beyond the red marking on thetower!

2.4.7 Once the tower is at the desired height, rotate the tower to the desireddirection. To rotate, loosen rotation locking knob (s). Then rotate thetower until the lights face the desired direction, and then retighten therotation locking knob.

WARNING

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Operation LTN 6L

wc_gr005353

o

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LTN 6L Operation

2.5 Lowering Tower (Manual Winch System)


Be sure to read and understand the operating instructions beforelowering the tower!

If for any reason a part of the tower hangs up or a winch cable developsslack before tower is fully lowered, stop immediately! Continuing toturn the winch handle will increase the slack in the cable. Too muchslack could cause the tower to collapse should it suddenly free up. Ifthe tower hangs up, level the trailer. Slightly shake or twist the towerassembly to free the bind. Contact an authorized Wacker Neusonservice representative immediately.

NEVER lower the tower while the unit is operating.

NEVER allow anyone to stand near the rear of the unit while loweringthe tower.

2.5.1 Turn the lights off. Shut down the engine.

NOTICE: Shutting down the engine before turning off the lights coulddamage floodlight ballasts or generator capacitor(s).

NOTICE: Observe power cord while lowering the tower. Make sure thecoiled cord is not damaged during the lowering process.

2.5.2 Lower the tower by turning the handle on the telescoping winch (q)counterclockwise (“cable out” direction).

NEVER touch the winch pawl! Releasing the winch pawl may causethe tower to fall.

2.5.3 Loosen the rotation locking knob (s) and rotate the tower so thewinches are facing toward the trailer tongue.

WARNING

WARNING

WARNING

WARNING

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Operation LTN 6L
2.5.4 Pull and hold the tower locking pin (p). Rotate the handle on the tilt
winch (o) counterclockwise (“cable out” direction) until the tower springbegins to pivot the tower down. Release the tower locking pin andcontinue to rotate the handle until the tower is resting in the transportcradle. Be sure that the secondary locking pin (t) penetrates allsections of the tower.

NEVER pull the vertical tower locking pin (e) while the tower israised! Releasing the locking pin while the tower is raised may causethe tower to fall or the machine to tip over.

2.5.5 After the tower is down, secure it in the cradle by inserting the cradlelock pin (j). Insert the clip through the pin to secure it in place.

2.5.6 Position the light fixtures to aim at the ground.

NOTICE: Allow the floodlights to cool 10–15 minutes before movingtrailer. Moving the trailer while the lights are still hot could cause thelamps to break.

WARNING

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LTN 6L Operation
Notes:
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Operation LTN 6L

2.6 Control Panels - 50 Hz - Manual Winch System

Floodlight Control Panel Engine Control Panel

t

wc_gr002294

d

EMERGENCY

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LTN 6L Operation

Ref. Description Ref. Description

a 50 Amp circuit breaker k High coolant temperature shutdown

b 15 Amp lights circuit breaker l Alternator indicator

c 20 Amp GFI circuit breaker m Auxiliary lights (not used)

d Receptacle n Glow plug indicator

e Hour meter o Air filter restriction indicator

f Low fuel indicator (not used) p Auxiliary lights (not used)

g Safety shutdown indicator q Key access door

h Low oil pressure shutdown t Emergency stop switch

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Operation LTN 6L

2.7 Starting


2.7.1 Check engine oil, fuel and coolant levels.

Note: If fuel tank was drained or run dry it may be necessary to bleedfuel lines. Refer to Engine Operator’s Manual.

2.7.2 Check condition of electrical cable on mast. Do not start generator ifinsulation on cable is cut or worn through.

2.7.3 Check that the circuit breakers (a, b, c) are in their “OFF” position.

2.7.4 Check that the emergency stop switch (t) is pulled out.

NOTICE: Starting engine under load will damage the machine.

2.7.5 On machines equipped with the Lombardini engine, turn key (q) oneclick right. Glow plug indicator (n) will illuminate until engine is properlypreheated. This is an automatic timer based on engine temperature.Crank engine immediately after glow plug light goes off.

2.7.6 Turn key (q) to “START” and hold until engine starts. Release key afterengine starts.

NOTICE: Do not crank engine longer than 10 seconds. This couldcause starter motor to overheat. Return switch to “OFF” and wait 15-30 seconds for starter motor to cool down before attempting to preheatand restart.

Note: If oil pressure is not obtained within 30 seconds after key isturned to “RUN”, the automatic shutdown system will shut off the fuelsupply. You must return the key to the “OFF” position to restart the 30second timer before attempting to restart the engine.

2.7.7 Allow engine to warm up before operating floodlights.

NOTICE: Never use starting fluids to aid in starting of engine.

2.8 Automatic Shutdown

This unit is equipped with a low oil, high temperature auto-shutdownsystem. This system will automatically shut off the fuel supply to theengine if the oil pressure drops too low or the engine exceeds normaloperating temperatures. Return the key switch to the off position toreset the unit after an engine shutdown.

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LTN 6L Operation

2.9 Stopping


2.9.1 Turn the circuit breakers (a, b, c) off and remove any other loads fromthe generator.

NOTICE: Never shut down the engine without turning off the lights.Damage to the generator will occur.

2.9.2 Turn the key (q) to the off position.

2.10 Emergency Stop Switch


In case of emergency, push in the emergency stop switch (t) locatedon the front panel.

2.11 Derating

All generator sets are subject to derating for altitude and temperature.Although derating should not affect operation of the floodlights, it willreduce the available reserve power to the receptacle.

Ratings are typically reduced 3% per 300 m (1000 feet) elevation fromsea level, and 2% per 10°F (5.5°C) increase in ambient temperatureabove 78°F (25°C).

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Operation LTN 6L

2.12 Receptacle - 50 Hz


The machine is equipped with a convenience receptacle for runningaccessories and tools from the generator. Power to this receptacle isavailable any time the engine is running and the circuit breaker is on.

NOTICE: With the lights on, do not draw more than 400 Watts from the115V receptacle or 800 Watts from the 230V receptacle.

A circuit breaker (c) protects the receptacle (d).

NOTICE: Do not use frayed or damaged cords or plugs with auxiliaryoutlet.

NOTICE: Use only tough rubber-sheathed flexible cable or equivalent.(per 1EC245-4).

NOTICE: When using extension cords or mobile distribution networks,the total length of cords for a cross section of 1.5 mm2 should notexceed 60 m. For a cross section of 2.5 mm2, it should not exceed 100m.

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LTN 6L Maintenance

3. Maintenance

3.1 Installing / Removing Light Fixtures


Always turn off light circuit breakers and shut down engine beforedisconnecting light fixtures or changing lamps.

Remove fixtures by disconnecting electrical cords at the junction box(b). Remove nuts (c) from fixture mounting brackets and remove bothfixture and bracket off stud.

NOTICE: Only a trained technician should be allowed to install andremove fixture wiring.

.

Lamps become extremely hot in use! Allow lamp and fixture to cool10-15 minutes before handling.

Numbering Sequence of Floodlights Junction Box Wiring for Floodlights

Wire Colors

BK Black RD Red YL Yellow OR Orange

GN Green TN Tan BR Brown PU Purple

BU Blue VIO Violet CL Clear SH Shield

PK Pink WH White GY Gray LB Light blue

WARNING

WARNING

wc_gr005376

22

GNGN

WHWHGNGN

BLBL

4WHWHBLBL

GNGN

WHWHGNGN

BLBL1

WHWH3BLBL

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Maintenance LTN 6L

3.2 Replacing / Removing Lamps

The Light Tower uses four 1000W bulbs. When replacing or removingthe bulbs, avoid leaving any grease or oil residue on the glass surface.This can create hot spots, reducing the service life of the bulb orcausing the outer jacket to burst.

ALWAYS turn off the light circuit breakers and shut down the enginebefore disconnecting the light fixtures or changing the light bulbs.

Bulbs become extremely hot in use! Allow the bulb and fixture tocool 10–15 minutes before handling.

NEVER operate the lights without the protective lens cover inplace or with a lens cover that is cracked or damaged! The lampsused in the floodlights produce high temperatures and operate underpressure. They are subject to failures where the outer jacket burstsand shatters, resulting in a discharge of extremely hot glass particles.These particles pose a risk of personal injury, property damage, burnsand fire.

Ultraviolet radiation from the lamp can cause serious skin and eyeirritation. Use the lamp only with provided undamaged lens cover andfixture.

3.3 Daily Inspection

3.3.1 Check for fluid leaks. Check fluid levels.

3.3.2 Inspect condition of electrical cords. Do not use Light Tower ifinsulation is cut or worn through.

3.3.3 Check that winch cables are in good condition. Do not use a cable thatis kinked or starting to unravel.

3.3.4 Check that the vertical tower locking pin and its spring are secured,aligned, and operating properly.

WARNING

WARNING

WARNING

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LTN 6L Maintenance

3.4 Air Cleaner

See Graphic: wc_gr000540, wc_gr005144

Replace the air filter cartridge when the indicator (o) mounted on thecontrol panel appears.

3.4.1 Open air cleaner and remove element.

3.4.2 To clean the filter, lightly tap on a hard surface to eliminate all excessdirt. Do not blow the paper filter element with compressed air to clean.Clean the filter cover and support carefully.

3.4.3 Reassemble the filtering element and air cleaner.

3.5 Engine Oil


Drain the oil while the engine is still warm.

Note: In the interests of environmental protection, place a plastic sheetand a container under the machine to collect any liquid which drainsoff. Dispose of this liquid in accordance with environmental protectionlegislation.

3.5.1 Remove the oil drain plug.

3.5.2 Allow the oil to drain.

3.5.3 Install the oil drain plug.

3.5.4 Fill the engine crankcase through the oil filler opening, to the uppermark on the dipstick. See Technical Data for oil quantity and type.

3.5.5 Install the oil filter cap.

wc_gr000540

wc_gr005394

wc_tx000765gb.fm 39

Maintenance LTN 6L

3.6 Periodic Maintenance Schedule

Beforeeachuse

Every125

hours

Every250

hours

Every500

hours

Every1000 hours

or two years

Check for fluid leaks.

Check engine oil.

Check fuel level.

Replace air filter if indicator light is on.*

Change engine oil.**

Check level of battery electrolyte.

Check condition and tension on fan belt.

Check condition of radiator hoses.

Replace oil filter.*

Replace fuel filter.

Flush radiator.

Replace fan belt.

Check valve clearance.

Remove sediment in fuel tank.

Change radiator coolant.

Replace battery.

Replace radiator hoses and clamps.

Replace fuel pipes and clamps.

* Replace air filter after air filter restriction switch indication or one year. Lombardini does not recommend the removal of air filter elements for purposes of inspection.

** Change engine oil and filter after first 50 hours of operation.

wc_tx000765gb.fm 40

LTN 6L Maintenance

3.7 Troubleshooting

HIGH VOLTAGE! This unit uses high voltage circuits capable ofcausing serious injury or death. Only a qualified electrician shouldtroubleshoot or repair electrical problems occurring in this equipment.

Problem / Symptom Reason Remedy

Lamp will not light Lamp is too hot. Allow lamp to cool 10–15 minutes before restarting.

Faulty lamp connection Check that lamp is tight in socket. Check connections inside connection boxes on light fixtures and tower.

Plug connection at fixture is loose or damaged

Have a licensed electrician repair or replace the plug connection.

Lamp broken or burned out

Check for:• broken arc tube or outer lamp jacket• broken or loose components in lamp

envelope• blackening or deposits inside lamp

tube.

Circuit breaker turned on Turn off circuit breaker.

Circuit breaker loose or defective

Have a licensed electrician repair or replace the circuit breaker.

Generator output incorrect Check incoming voltage to ballast. Incoming voltage should be 120V ± 5V. If voltage is incorrect, engine speed may need to be adjusted or generator may require service.

Low or no ballast output With the fixture cord removed from its receptacle, the voltage should measure 400 to 445 VAC. If proper voltage is not achieved, perform capacitor check to determine if capacitor or coil needs to be replaced.

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.

WARNING

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Maintenance LTN 6L
Notes:
wc_tx000765gb.fm 42

LTN 6L Maintenance

3.8 Control Panel Wiring


1 System fuse, 50 Amp 4 Key switch

2 Glow plug load relay 5 L.E.D. Indicator lamp assembly

3 Auxiliary terminals (rear view)

L

BL

W/ROr

B

PrR

Gr

W

L

PBr

Y/G

GB

W

BBr

Y/G

R

R

86

85

30 87

4 27 6 5

12 10 9

50

30

15 / 54

wc_gr000658

1

2

5

3

4

1

2

3

4

5

6

7

8

9

10

11

12

13

14

wc_tx000765gb.fm 43

Schematics LTN 6L

4. Schematics

4.1 Schematic for 50 Hz Metal Halide 4-Light Units-115 V

14 B

K/O

R14

BK/

OR

9 W

H 1

0 AW

G9

WH

10

AWG

2

13

4

11 G

N/Y

L 12

AW

G11

GN

/YL

12 A

WG

12 G

N/Y

L12

GN

/YL

12 A

WG

12 A

WG

12

CO

NTR

OL

PAN

ELC

ON

TRO

L PA

NEL

G

RO

UN

D

GR

OU

ND

GN

/YL

12 A

WG

GN

/YL

12 A

WG

18 LB 18 LB

10 WH 10 AWG 10 WH 10 AWG

34

8 W

H 1

0 AW

G8

WH

10

AWG

1 BK

8 A

WG

1 BK

8 A

WG

16 P

U/B

K16

PU

/BK

17 Y

L17

YL

13 O

R13

OR

-

+

16 P

U/B

K16

PU

/BK

15 BK 15 BK

2 BK

10

AWG

2 BK

10

AWG

3 BK

3 BK

10 A

WG

10 A

WG

4 BK

10

AWG

4 BK

10

AWG

19 BK 10 AWG 19 BK 10 AWG


NONO

17 YL 17 YLNCNC

18 LB 18 LB



2

GN

GN

WH

WH

GN

GN

BLBL

4

PUPU

WH

WH

BLBLWH

WH

BLBL

14 BK/OR 14 BK/OR

13 O

R13

OR

4

BKBKR

DR

D

GN

GN

WH

WH

GN

GNBLBL

1

OR

OR

WH

WH

BRBR

3

BLBL

YLYL

GNGN

2

BK/YL BK/YL

YLYLYLYL

1

YLYLYLYL

3

BK/Y

LBK

/YL

11 G

N/Y

L 12

AW

G11

GN

/YL

12 A

WG

5 BK

5 BK

10 A

WG

10 A

WG

10 WH 10 AWG 10 WH 10 AWG

BK/Y

LBK

/YL

YLYLYLYL WH

WH PUPU

8 W

H 1

0 AW

G8

WH

10

AWG

YLYLBK

/YL

BK/Y

L

YLYL

9 W

H 1

0 AW

G9

WH

10

AWG

BRBR OR

OR

7 BK

10

AWG

7 BK

10

AWG

6 BK

10

AWG

6 BK

10

AWG

wc_

gr00

5368

dd m l

bi

b

eg

ff

c

r

t

as

j

hb

k

wc_tx000938gb.fm 44

LTN 6L Schematics


a Generator i Engine control panel

b Terminal strip j Engine

c Main circuit breaker, 25 Amp k Hour meter

d Floodlight receptacles l Transformers

e Receptacle, 115V m Capacitors, 30 mF

f Circuit breaker, 30 Amp r Emergency stop switch

g Circuit breaker, 16 Amp s Fuel solenoid

h Battery t Capacitor, 31.5 mF

Wire Colors





wc_tx000938gb.fm 45

Schematics LTN 6L

4.2 Schematic for 50 Hz Metal Halide 4-Light Units-230 V

wc_

gr00

5369

dd m l

b

b

eg

ff

c

t

r

js

a

i

hb

k

-

+

NONONCNC

17 YL 17 YL18 LB 18 LB

wc_tx000938gb.fm 46

LTN 6L Schematics


a Generator i Engine control panel

b Terminal strip j Engine

c Main circuit breaker, 50 Amp k Hour meter

d Floodlight receptacles l Transformers

e Receptacle, 120V m Capacitors, 30 mF

f Circuit breaker, 30 Amp r Emergency stop switch

g Circuit breaker, 20 Amp s Solenoid

h Battery t Capacitor, 31.5 mF

Wire Colors





wc_tx000938gb.fm 47

Schematics LTN 6L

4.3 Generator Capacitor Excitation Schematic 50 Hz


1 Rotor 4 Capacitor

2 Stator 5 Generator/Terminal block

3 Excitation coils 6 Control box-Main circuit breaker

P3

P2

P1

wc_tx000938gb.fm 48

LTN 6L Schematics

4.4 Engine Wiring


1 Fuel solenoid 7 Air filter restriction indicator (normal open type)

2 Glow plugs 8 Low fuel level switch (not used, normal open type)

3 Starter motor 9 Low oil pressure switch (normal closed type)

4 Battery 10 Coolant high temperature switch (nor-mal open type)

5 Alternator connector 11 Coolant temperature thermistor (for preheat relay)

6 Coolant temperature sending unit (not used, for remote temperature gauge or LED)

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Technical Data LTN 6L

5. Technical Data

5.1 Engine

Engine Power Rating

Net power rating per ISO 3046 IFN. Actual power output may vary dueto conditions of specific use.

Item Number: LTN 6L0620119 06201200620557 0620558

Engine

Make Lombardini

Model LDW1003

Type 3-cylinder, 4-cycle, liquid-cooled diesel

Max. power rating @ rated speed

kW (Hp) 8.5 (11.4) @ 1800 rpm

Operating speed rpm 1500

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. 1.68 (0.44)

Running time hours 68

Coolant capacity l (qts.) 4.7 (5.0)

Oil capacity l (qts.) 2.4 (2.5)

wc_td000229gb.fm 50

LTN 6L Technical Data

5.2 Generator

5.3 Machine

Item Number: LTN 6L0620119 06201200620557 0620558

Generator

Frequency Hz 50 ± 2

Continuous output kW 6.0

Output volts 230

Amps A 26.1

Excitation type Capacitor / Brushless

Power factor 1.0

Voltage regulation - no load to full load

% ± 6.0

Speed rpm 1500

Item Number: LTN 6L0620119 06201200620557 0620558

Machine

Shipping dimensions (l x w x h) cm (in.) 335.5 x 150.6 x 211.6(132.2 x 59.3 x 83.3)

Shipping weight without trailer kg. (lbs) 633 (1395)

Height - mast extended m (ft.) 9 (30)

Lighting system (1000W) 4 metal halide light

Max. lighting coverage @ 0.5 ft. can-dles

m2 (ft2)acres

30,400 (2824)7

Sound power level at operator's loca-tion (LpA)

dB(A)80

Guaranteed sound power level (LWA) dB(A) 97

wc_td000229gb.fm 51

William Lahner Dan DomanskiVice President of Engineering Manager, Product Engineering

WACKER NEUSON CORPORATION

2010

-CE

-LT

N6L

-50H

z_en

.fm

EC DECLARATION OF CONFORMITY

WACKER NEUSON CORPORATION, N92W15000 ANTHONY AVENUE, MENOMONEE FALLS, WISCONSIN USA

hereby certifies that the construction equipment specified hereunder:

has been sound tested per Directive 2000/14/EC:

AUTHORIZED REPRESENTATIVE IN THE EUROPEAN UNION Axel HäretWACKER NEUSON SEPreußenstraße 4180809 München

1. Category:Power Generator (Light Tower)

2. Machine function:This machine is a mobile, trailer-mounted light tower intended for the illumination of outdoor areas.

3. Type / ModelLight Tower LTN 6L

4. Item number of equipment:0620119, 0620120, 0620557, 0620558

5. Net installed power:6 kW

Conformity Assessment Procedure

Name and address of notified body Measured sound power level Guaranteed sound power level

ANNEX VIII Lloyds Register Quality Assurance Limited

(Notified Body No 0088)71 Fenchurch StreetLondon EC3M 4BS

United Kingdom

91 dB(A) 97 dB(A)

6. This machinery fulfills the relevant provisions of Machinery Directive 2006/42/EC and is also produced in accordance with these standards:2000/14/EC89/336/EEC98/37/EECIEC/EN 60204-1EN 60 598-2-5

The original language of this EC Declaration of Conformity is American English.

18.12.09Date

Wacker Neuson SE · Preußenstraße 41 · D-80809 München · Tel.: +49-(0)89-3 54 02-0 · Fax: +49 - (0)89-3 54 02-390Wacker Neuson Corporation · P.O. Box 9007 · Menomonee Falls, WI 53052-9007 · Tel. : (262) 255-0500 · Fax: (262) 255-0550 · Tel. : (800) 770-0957Wacker Neuson Limited - Room 1701–03 & 1717–20, 17/F. Tower 1, Grand Century Place, 193 Prince Edward Road West, Mongkok, Kowloon, Hongkong.Tel: (852) 3605 5360, Fax: (852) 2758 0032

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