Wacker Neuson LTW20Z1 User manual

Type
User manual
Operator’s Manual
Light Tower
LTW20Z-1
Machine Type LTW20Z-1
Material number 5100052099
Version
1
Date 11/2019
Language [en]
5100052099
All rights reserved, in particular the copyright, the right of reproduction and the right of distribution applicable
worldwide.
This document may be used by the recipient only for the designated purpose. It may in no way be duplicated or
translated in any other language, in whole or in part, without prior permission in writing from the manufacturer.
Reproduction or translation of this publication, in whole or part, is not permitted without the written consent of
Wacker Neuson Corporation.
Violations of legal regulations, in particular of the copyright protection, will be subject to civil and criminal prosecu-
tion.
Wacker Neuson Corporation keeps abreast of the latest technical developments and constantly improve their
products. For this reason, we may from time to time need to make changes to figures and descriptions in this doc-
umentation that do not reflect products that have already been delivered and that will not be implemented on
these machines.
The cover features the machine with (optional) special equipment.
Responsibility for errors or omissions not accepted.
WackerNeusonCorporation
N92W15000 Anthony Ave, Menomonee Falls, WI
53051, USA
www.wackerneuson.us
Printed in USA
Copyright © 2019
Table of Contents
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Table of Contents
1 Preface
1.1 Introduction ............................................................................................................................................ 7
1.2 Use of the Operator's Manual................................................................................................................ 7
1.3 Accident prevention regulations............................................................................................................. 8
1.4 Wacker Neuson Contact........................................................................................................................ 8
2 Usage
2.1 Intended Use ......................................................................................................................................... 9
2.2 Unintended Use ..................................................................................................................................... 9
2.3 Residual Risks ..................................................................................................................................... 10
3 Safety
3.1 Safety symbols and signal words ........................................................................................................ 11
3.2 Metal Halide Lamp Safety.................................................................................................................... 11
3.3 Radiation Compliance.......................................................................................................................... 12
3.4 Service Safety...................................................................................................................................... 12
3.5 Safety Guidelines for Using Combustion Engines ............................................................................... 14
3.6 Safety Guidelines for Lifting and Transporting..................................................................................... 15
3.7 Safety Guidelines for Towing............................................................................................................... 16
3.8 Reporting Safety Defects..................................................................................................................... 17
4 Description of the machine
4.1 Machine Description ............................................................................................................................ 18
4.2 Overview of the Labels ........................................................................................................................ 19
4.3 Safety Label Meanings ........................................................................................................................ 21
4.4 Information Label Meanings ................................................................................................................ 24
5 Transportation
5.1 Before Lifting and Transporting Checklist............................................................................................ 30
5.2 Lifting and Tie-Down Points................................................................................................................. 31
6 Commissioning
6.1 Leveling the Trailer—Vertical Mast Light Towers ................................................................................ 32
6.2 Aiming the Lights—Vertical Mast Light Towers ................................................................................... 33
6.3 Manually Rotating the Light Bar........................................................................................................... 35
7 Operation
7.1 Grounding the Light Tower .................................................................................................................. 36
7.2 Refueling the Machine ......................................................................................................................... 37
7.3 Control Panel—Lights.......................................................................................................................... 37
7.4 Engine Control Module ........................................................................................................................ 38
7.5 Machine Monitoring ............................................................................................................................. 38
7.6 Alarms and Shut-Down Conditions...................................................................................................... 40
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7.7 Resetting the Maintenance Timers ...................................................................................................... 41
7.8 Raising the Tower (Power Winch System) .......................................................................................... 42
7.9 Lowering the Tower (Power Winch System)........................................................................................ 44
7.10 Starting the Machine............................................................................................................................ 45
7.11 Stopping the Machine .......................................................................................................................... 47
7.12 Auto Mode (Remote Run).................................................................................................................... 47
7.13 Generator Derating .............................................................................................................................. 47
7.14 Receptacle Panel................................................................................................................................. 47
7.15 Emergency Stop Switch....................................................................................................................... 49
8 Maintenance
8.1 Periodic Maintenance Schedule .......................................................................................................... 50
8.2 Installing/Removing Light Fixtures....................................................................................................... 51
8.3 Replacing/Removing Lamps................................................................................................................ 52
8.4 Daily Inspection ................................................................................................................................... 53
8.5 Checking Engine Coolant .................................................................................................................... 54
8.6 Servicing the Air Cleaner ..................................................................................................................... 54
8.7 Changing the Engine Oil...................................................................................................................... 55
8.8 Maintaining the Fuel/Water Separator ................................................................................................. 57
8.9 Maintaining the Trailer ......................................................................................................................... 57
8.10 Maintenance Tier 4 Final Engines: Isuzu............................................................................................. 58
8.11 Coolant ................................................................................................................................................ 62
9 Malfunctions
9.1 Troubleshooting ................................................................................................................................... 63
10 Storage
10.1 Long-Term Storage.............................................................................................................................. 65
11 Accessories
11.1 Factory-Installed Options..................................................................................................................... 67
11.2 LED Lights ........................................................................................................................................... 67
12 Technical data
12.1 Engine—T4f......................................................................................................................................... 68
12.2 Generator............................................................................................................................................. 68
12.3 Machine—Tier 4f.................................................................................................................................. 69
12.4 Dimensions .......................................................................................................................................... 70
12.5 Metal Halide Radiation Compliance..................................................................................................... 70
13 Tire Safety Information
13.1 Tire Safety Information ........................................................................................................................ 71
13.2 Tire Safety Information Section Descriptions....................................................................................... 71
13.3 Steps for Determining Correct Load Limit—Trailer.............................................................................. 72
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13.4 Steps for Determining Correct Load Limit—Tow Vehicle .................................................................... 74
13.5 Glossary of Tire Terminology............................................................................................................... 74
13.6 Tire Safety—Everything Rides on It..................................................................................................... 79
13.7 Safety First—Basic Tire Maintenance ................................................................................................. 79
13.8 Tire Safety Tips.................................................................................................................................... 86
14 LTW20Z1 Schematics
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Preface
Introduction 1.1
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1 Preface
1.1 Introduction
This operator’s manual contains important information and procedures for
the safe, proper and economical operation of this Wacker Neuson machine.
Carefully reading, understanding and observing it helps to avoid dangers, re-
duce repair costs and downtimes and thus increase the availability and ser-
vice life of the machine.
This operator’s manual is not a manual for extensive maintenance or repair
work. Such work must be carried out by Wacker Neuson Service or by tech-
nically trained personnel. The Wacker Neuson machine must be operated
and maintained in accordance with the instructions in this operator’s manual.
Improper operation or maintenance can cause hazards.
Defective machine parts must be replaced immediately!
Wacker Neuson contact persons are always available to answer questions
about operation or maintenance.
1.2 Use of the Operator's Manual
This operator’s manual must be regarded as an integral part of the machine
and must be kept in a safe place throughout its service life. This operator’s
manual must be passed on to each subsequent owner or user of this ma-
chine.
This operator’s manual apply to various machine types from one product
range. For this reason, some illustrations may differ from the appearance of
the purchased machine. Variant-dependent components that are not in-
cluded in the scope of delivery can also be described.
The information contained in this operator’s manual is based on machines
manufactured up to the time it was printed. Wacker Neuson reserves the
right to make changes to this information without notice.
It must be ensured that any changes or additions made by the manufacturer
are immediately incorporated into this operator’s manual.
The following machines and variants/options are described:
Machine Item Number
LTW20Z-1 5100051571, 5100051572
1
Preface
1.3 Accident prevention regulations
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P.F.
177833
MON/YR
MADE IN USA
kW
RPMhz
V
kg
R
215429
For electrical
equipment only.
Pour material
electrique seulement.
lbs
For electrical
equipment only.
Pour material
electrique seulement.
Rev.
Item No.
Type/Model
Serial No.
A
MAX AMB 40 C
Fig.1: LTW Nameplate location
Machine identification
A nameplate listing the model number, item number, revision, and serial
number is attached to this machine. The location of the nameplate is shown
above.
Serial number (S/N)
For future reference, record the serial number in the space provided below.
You will need the serial number when requesting parts or service for this ma-
chine.
Serial number:
1.3 Accident prevention regulations
In addition to the notes and safety instructions in this operator’s manual, the
local accident prevention regulations and the national industrial safety regu-
lations apply.
1.4 Wacker Neuson Contact
Depending on the country, the Wacker Neuson contact is a Wacker Neuson
Service, a Wacker Neuson subsidiary or a Wacker Neuson dealer.
On the Internet at - http://www.wackerneuson.com.
Usage
Intended Use 2.1
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2 Usage
2.1 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 or LED lights is vertically mounted to the top of the cabinet.
As the engine runs, the generator converts mechanical energy into electric
power. The metal halide or LED lights run off this power. Receptacle(s) are
also provided to power auxiliary loads. The operator uses the control panel
to operate and monitor the machine.
2.2 Unintended Use
This machine has been designed and built strictly for the intended use de-
scribed 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 generator output
• Overloading the generator with a load that draws excessive power during
either continuous running or start-up
• Operating the generator 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
• 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
2
Usage
2.3 Residual Risks
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2.3 Residual Risks
This machine has been designed and built in accordance with the latest
global safety standards. It has been carefully engineered to eliminate haz-
ards 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 ex-
posure to:
• Heat, noise, exhaust, and carbon monoxide from the engine
• Fire hazards from improper refueling techniques
• Fuel and its fumes
• Electric shock and arc flash
• Personal injury from improper lifting the trailer tongue
• Typical hazards related to towing a trailer on roads and highways
To protect yourself and others, make sure you thoroughly read and under-
stand the safety information presented in this manual before operating the
machine.
Safety
Safety symbols and signal words 3.1
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3 Safety
3.1 Safety symbols and signal words
The following symbol identifies safety instructions. It is used for warning
against potential personal risk or danger.
DANGER
DANGER identifies a situation causing death or serious injury if it is
not avoided.
Consequences in case of non-observance.
â–º Avoidance of injury or death.
WARNING
WARNING identifies a situation that can cause death or serious injury if
it is not avoided.
Consequences in case of non-observance.
â–º Avoidance of injury or death.
CAUTION
CAUTION identifies a situation that can cause injury if it is not avoided.
Consequences in case of non-observance.
â–º Avoidance of injury.
NOTICE
INFORMATION identifies a situation that causes damage if it is not ob-
served.
Consequences in case of non-observance
â–º Avoidance of damage to property.
3.2 Metal Halide Lamp Safety
WARNING
Personal injury hazard
Broken or punctured lamps can cause serious skin burns and eye inflamma-
tion from shortwave ultraviolet radiation.
â–º Do not operate the light tower if a lamp is damaged.
â–º Replace damaged lamps immediately.
3
Safety
3.3 Radiation Compliance
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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 standard 21 CFR 1040-30.
Operating safety
• Replace damaged lamps according to the instructions in Removing/Re-
placing Lamps.
• Alternative lamps that automatically extinguish when the outer envelope
is broken or punctured are commercially available.
3.3 Radiation Compliance
This machine meets the radio interface radiated emission requirements of
European Standard EN13309 for Construction Machinery.
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 standard 21 CFR 1040-30.
3.4 Service Safety
Service training
Before servicing or maintaining the machine:
• Read and understand the instructions contained in all manuals delivered
with the machine.
• Familiarize yourself with the location and proper use of all controls and
safety devices.
• Only trained personnel shall troubleshoot or repair problems occurring
with the machine.
• Contact WackerNeuson for additional training if necessary.
When servicing or maintaining this machine:
• Do not allow improperly trained people to service or maintain the ma-
chine.
• Personnel servicing or maintaining the machine must be familiar with the
associated potential risks and hazards.
Safety
Service Safety 3.4
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Precautions
Follow the precautions below when servicing or maintaining the machine.
• Read and understand the service procedures before performing any ser-
vice to the machine.
• All adjustments and repairs must be completed before operating the ma-
chine. Do not operate the machine with a known problem or deficiency.
• All repairs and adjustments shall be completed by a qualified technician.
• Turn off the machine before performing maintenance or making repairs.
• Remain aware of the machine’s moving parts. Keep hands, feet, and
loose clothing away from the machine’s moving parts.
• Re-install the safety devices and guards after repair and maintenance
procedures are complete.
Machine modifications
When servicing or maintaining the machine:
• Use only accessories/attachments that are approved by WackerNeuson.
• Do not defeat safety devices.
• Do not modify the machine without the express written approval of
WackerNeuson.
Replacing parts and labels
• Replace worn or damaged components.
• Replace all missing and hard-to-read labels.
• When replacing electrical components, use components that are identi-
cal in rating and performance to the original components.
• When replacement parts are required for this machine, use only
WackerNeuson replacement parts or those parts equivalent to the origi-
nal in all types of specifications, such as physical dimensions, type,
strength, and material.
Cleaning
When cleaning and servicing the machine:
• Keep the machine clean and free of debris such as leaves, paper, car-
tons, etc.
• Keep the labels legible.
When cleaning the machine:
• Do not clean the machine while it is running.
• Never use gasoline or other types of fuels or flammable solvents to clean
the machine. Fumes from fuels and solvents can become explosive.
3
Safety
3.5 Safety Guidelines for Using Combustion Engines
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Personal protective equipment (PPE)
Wear the following personal protective equipment (PPE) while operating this
machine:
• Close-fitting work clothes that do not hinder movement
• Safety glasses with side shields
• Hearing protection
• Safety-toed footwear
In addition, before servicing or maintaining the machine:
• Tie back long hair.
• Remove all jewelry (including rings).
3.5 Safety Guidelines for Using Combustion Engines
DANGER
Risk of poisoning! Exhaust gas contains carbon monoxide, a deadly
poison.
Exposure to carbon monoxide can kill you in minutes.
â–º Never operate the machine inside an enclosed area, such as a tunnel,
unless adequate ventilation is provided through such items as exhaust
fans or hoses.
WARNING
Internal combustion engines present special hazards during operation
and fueling.
Failure to follow the warnings and safety standards could result in servere in-
jury or death.
► Read and follow the warning instructions in the engine owner’s manual
and the safety guidelines below.
Safety
Safety Guidelines for Lifting and Transporting 3.6
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Operating safety
When running the engine:
• Keep the area around the exhaust pipe free of flammable materials.
• 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 smoke while operating the machine.
• Do not run the engine near sparks or open flames.
• Do not touch the engine or muffler while the engine is running or immedi-
ately after it has been turned off.
• Do not operate a machine when its fuel cap is loose or missing.
• Do not start the engine if fuel has spilled or a fuel odor is present. Move
the machine away from the spill and wipe the machine dry before start-
ing.
• Do not use the machine in areas with a risk of explosion or fire.
Refueling safety
When refueling the engine:
• Clean up any spilled fuel immediately.
• Refill the fuel tank in a well-ventilated area.
• Replace the fuel tank cap after refueling.
• Use suitable tools for refueling (for example, a fuel hose or funnel).
When refueling the engine:
• Do not smoke.
• Do not refuel a hot or running engine.
• Do not refuel the engine near sparks or open flames.
3.6 Safety Guidelines for Lifting and Transporting
When lifting the machine:
• Make sure slings, chains, hooks, ramps, jacks, forklifts, cranes, hoists,
and any other type of lifting device used is attached securely and has
enough weightbearing capacity to lift or hold the machine safely. For ma-
chine weight, see Machine—Tier 4f on page 69.
• Remain aware of the location of other people when lifting the machine.
• Only use the lifting points and tie-downs described in the Operator’s
Manual.
• Make sure the transporting vehicle has sufficient load capacity and plat-
form size to safely transport the machine.
To reduce the possibility of injury:
• Do not stand under the machine while it is being lifted or moved.
• Do not get onto the machine while it is being lifted or moved.
3
Safety
3.7 Safety Guidelines for Towing
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3.7 Safety Guidelines for Towing
WARNING
Risk of servere injury or death.
Improper trailer condition and towing technique can lead to an accident.
► Obey the trailer manufacturer’s instructions below to reduce the risk of
an accident.
When towing the machine:
• Do not tow the machine if the towing vehicle’s hitch or the trailer’s cou-
pler are damaged.
• Do not tow the machine if safety chains are damaged.
• Do not tow the machine if any of the trailer’s lug nuts are missing.
• Do not tow the machine if the trailer’s tires have less than 1.5mm
(1/16inch) of tread.
• Do not tow the machine if trailer tires are underinflated.
• Do not tow the machine unless the trailer’s brakes are functioning prop-
erly.
• Do not tow the machine if trailer lighting is not functioning properly.
• Do not exceed the trailer manufacturer’s speed limitations.
• Only tow the machine when the trailer’s lug nuts are properly torqued.
• Only tow the machine when the trailer’s tires are properly inflated.
• Only tow the machine when all trailer lights are functioning correctly.
• Only tow the machine when the trailer’s safety chains are connected to
the towing vehicle in a crisscross pattern.
• Maintain extra distance between the towing vehicle and other vehicles.
• Avoid soft shoulders, curbs, and sudden lane changes.
• Abide by all licensing requirements for your area.
If you have not driven a towing vehicle with trailer before, practice turning,
stopping, and backing up the towing vehicle with trailer in an area away from
traffic. Only drive the towing vehicle with trailer when you are confident in
your ability to do so.
Safety
Reporting Safety Defects 3.8
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3.8 Reporting Safety Defects
If you believe your trailer has a defect which could cause a crash or could
cause injury or death, you should immediately inform the National Highway
Traffic Safety Administration (NHTSA) in addition to notifying WackerNeu-
son.
If NHTSA receives similar complaints, it may open an investigation; and if it
finds that a safety defect exists in a group of trailers, it may order a recall
and remedy campaign. However, NHTSA cannot become involved in individ-
ual problems between you, your dealer, or WackerNeuson.
To contact NHTSA, you may either contact the Vehicle Safety Hotline toll-
free at 1-888-327-4236 (TTY: 1-800-424-9153); go to http://www.safer-
car.gov; or write to:
Administrator
NHTSA
1200 New Jersey Avenue S.E.
Washington, DC 20590
You can also obtain other information about your motor vehicle safety from
http://www.safercar.gov
3
Description of the machine
4.1 Machine Description
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4 Description of the machine
4.1 Machine Description
This machine is intended for the illumination of outdoor areas. This machine
is also intended for the purpose of supplying electrical power to connected
loads. Refer to the product specifications for the output voltage and fre-
quency of this light tower, and for the maximum output power limit of this
light tower.
Description of the machine
Overview of the Labels 4.2
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4.2 Overview of the Labels
110164
AVERTISSEMENT
ADVERTENCIA
WARNING
179212
114474
DANGER
DANGER
PELIGRO
PERIGO
AVERTISSEMENT
5200005890
ADVERTENCIA
WARNING
Bouteille de trop-plein de l'agent réfrigérant seulement;
ce n'est pas un système de retour.
Coolant overflow bottle only, not a return system.
Botella de rebose del enfriador solamente -- no es un sistema de retorno.
176105
114891
AVERTISSEMENT
WARNING
ADVERTENCIA
178775
ADVERTENCIA
AVERTISSEMENT
WARNING
177123
Électrochoc et arc de court-circuit peuvent résulter en
blessures graves ou mort. Dispositif électrique de stockage
à l'intérieur. Contacter un électricien qualifié pour réparer
ou ouvrir le boitier électrique.
176080
AVERTISSEMENT
ADVERTENCIA
Choque eléctrico y arco voltaico de cortocircuito pueden
causar heridas personales o muerte. Dispositivo de
almacenaje eléctrico en el interior. Para trabajos de
mantenimiento o para abrir la caja eléctrica consulte
a un electricista capacitad
O choque elétrico ou o arco elétrico podem causar
ferimentos graves ou morte. Bateria interna. Entre em
contato com um técnico qualificado para realizar a
manutenção ou abrir a caixa elétrica.
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.
ATENÇÃO
WARNING
177124
WARNING
Operation of This Equipment May Create Sparks That Can Start Fires Around Dry
Vegetation. A Spark Arrestor May be Required. The Operator Should Contact Local
Fire Agencies For Laws or Regulations Relating to Fire Prevention Requirements.
Per CAL. PRC. CODE
177124
5200016729
1648 kg
(3632 LBS)
Cancer and Reproductive Harm
www.P65Warnings.ca.gov
Cáncer y daño reproductivo
www.P65Warnings.ca.gov
Cancer ou malformations
congénitales
www.P65Warnings.ca.gov
WARNING
AVERTISSEMENT
ADVERTENCIA
5100045462
Fig.2: Label locations
4
Description of the machine
4.2 Overview of the Labels
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177123
176367
AVERTISSEMENT
ATENÇÃO
ADVERTENCIA
WARNING
178775
ADVERTENCIA
AVERTISSEMENT
WARNING
177123
177124
177124
177123
WARNUNG
ADVERTENCIA
WARNING
AVERTISSEMENT
117037
160604
114886
Ultraviolet radiation from lamp can cause serious skin and
eye irritation. Use only undamaged lamps. Use only with
provided undamaged lens cover and fixture.
La radiación ultravioleta producida por la lámpara puede
causar irritación grave en los ojos y en la piel.
Solamente utilice lámparas no dañadas. Utilizar únicamente
con el portalámparas y el protector de la lente
suministrados intactos.
La radiation ultraviolette émise par le projecteur peut
causar une irritation sérieuse de la peau et des yeux.
Seulement utiliser les projecteurs pas endommagés. Ne pas
utiliser si le couvercle et la ferrure de lentille
fournis sont endommagé
A radiação ultravioleta da lâmpada pode provocar ferimentos
graves na pele e irritação nos olhos. Use apenas lâmpadas
não danificadas. Use apenas com tampas e acessórios de
lentes não danificados fornecidos.
AVERTISSEMENT
176097
ADVERTENCIA
ATENÇÃO
WARNING
5200016729
1648 kg
(3632 LBS)
DANGER
PELIGRO
DIESEL
STOP
176091
PERIGO
DANGER
Fig.3: Label locations, continued
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Wacker Neuson LTW20Z1 User manual

Type
User manual

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