owner’s guide · revised 7/11/2007 owner’s guide: wvt3-07 6/51 p/n: 106945-306 e wanco, inc. 3....

Owner’s Guide

WVT3-07

Mini 3-Line Message Director

NTCIP Message Director

Wanco, Inc.

July, 2007

Revised 7/11/2007 Owner’s Guide: WVT3-07 2/51

P/N: 106945-306 E Wanco, Inc.

Table of Contents 1. INTRODUCTION .......................................................................................................................... 4

1.1 INSTRUCTIONS ............................................................................................................. 4 1.2 SCOPE .......................................................................................................................... 4 1.3 FOREWORD .................................................................................................................. 4 1.4 CONTACT SERVICE/SALES ........................................................................................... 4

2. RECEIVING ................................................................................................................................... 5

2.1 UNPACKING ................................................................................................................. 5 2.2 INSPECTION .................................................................................................................. 5 2.3 ASSEMBLY ................................................................................................................... 5 2.4 CLEANING .................................................................................................................... 5 2.5 CLEANING SOLUTIONS (FOR LEXAN DOOR) ................................................................. 5

3. TOWING ......................................................................................................................................... 6

3.1 SAFETY PRECAUTIONS ................................................................................................. 6 3.2 PREPARATIONS ............................................................................................................ 6

4. DEPLOYMENT .............................................................................................................................. 7

4.1 SAFETY PRECAUTIONS ................................................................................................. 7 4.2 PREPARATIONS ............................................................................................................ 7 4.3 MAST PHOTO ............................................................................................................... 7 4.4 CONTROL BOX PHOTO ................................................................................................. 8 4.5 SIGN OPERATION ......................................................................................................... 8 4.6 SOLAR OPERATION ...................................................................................................... 8 4.7 ENERGY CONSERVATION TIPS ..................................................................................... 9

5. BATTERIES ................................................................................................................................. 10

5.1 SAFETY PRECAUTIONS ............................................................................................... 10 5.2 GENERAL INSTRUCTIONS ........................................................................................... 10 5.3 BATTERY BOX PHOTO ............................................................................................... 10 5.4 BATTERY WATERING INFORMATION ......................................................................... 11 5.5 BATTERY CHARGING INFORMATION .......................................................................... 11 5.6 SPECIFIC GRAVITY TEST PROCEDURE ........................................................................ 11 5.7 VOLTAGE TEST PROCEDURE ...................................................................................... 11 5.8 FIELD MAINTENANCE & INSPECTION PROCEDURE ..................................................... 12 5.9 SERVICE YARD MAINTENANCE & CHARGING PROCEDURE ....................................... 13 5.10 BATTERY STATE TABLE ............................................................................................. 14 5.11 ELECTROLYTE FREEZING POINT TABLE ..................................................................... 15 5.12 SELF-DISCHARGE RATE TABLE ................................................................................. 15

6. CHARACTER DISPLAY CARDS ............................................................................................. 16

6.1 GENERAL INSTRUCTIONS ........................................................................................... 16 6.2 REPLACEMENT PROCEDURE ....................................................................................... 16 6.3 DISPLAY CARD MOUNTING PHOTO ............................................................................ 18 6.4 DISPLAY PANEL WIRING PHOTO ................................................................................ 19


P/N: 106945-306 E Wanco, Inc.

7. TROUBLESHOOTING ............................................................................................................... 20

7.1 MAIN CONTROL BOARD PHOTO (CIRCUIT CARD) ...................................................... 20 7.2 POWER CONTROL BOARD PHOTO (CIRCUIT CARD) ................................................... 21 7.3 CONTROL BOX WIRING PHOTO .................................................................................. 22 7.4 POWER SYSTEM ......................................................................................................... 22 7.5 MESSAGE DISPLAY .................................................................................................... 23 7.6 LEDS/PIXELS/BRIGHTNESS ....................................................................................... 24 7.7 TEMPERATURE ........................................................................................................... 24 7.8 CONSOLE LIGHT ........................................................................................................ 25 7.9 CONSOLE DISPLAY .................................................................................................... 25 7.10 KEYBOARD ................................................................................................................ 25 7.11 INDICATOR LEDS (OPTIONAL EQUIPMENT) ............................................................... 26 7.12 RADAR (OPTIONAL EQUIPMENT) ............................................................................... 26

8. FIRMWARE UPGRADES .......................................................................................................... 28

8.1 SAFETY PRECAUTIONS ............................................................................................... 28 8.2 REQUIRED EQUIPMENT .............................................................................................. 28 8.3 INSTRUCTIONS ........................................................................................................... 28

9. WIRING DIAGRAMS, MODEL WVT3 ................................................................................... 30

9.1 CONTROL BOX ........................................................................................................... 30 9.2 MODEM (OPTIONAL EQUIPMENT) .............................................................................. 31 9.3 RADAR (OPTIONAL EQUIPMENT) ............................................................................... 32 9.4 DISPLAY PANEL ......................................................................................................... 33 9.5 TRAILER AND TAIL LIGHTS ........................................................................................ 34 9.6 BATTERY BOX ........................................................................................................... 35

10. PARTS LISTS ............................................................................................................................... 36

10.1 MESSAGE DIRECTOR (LEFT SIDE VIEW) ...................................................................... 36 10.2 MESSAGE DIRECTOR (REAR VIEW) ............................................................................. 37 10.3 MESSAGE DIRECTOR PARTS LIST .............................................................................. 38 10.4 DISPLAY PANEL PARTS PHOTOS ................................................................................ 40 10.5 DISPLAY PANEL PARTS LIST ...................................................................................... 44 10.6 CONTROL BOX (FRONT VIEW) .................................................................................... 46 10.7 CONTROL BOX (REAR VIEW) ...................................................................................... 47 10.8 CONTROL BOX PARTS LIST ........................................................................................ 48

11. WINCH CABLE REPLACEMENT ........................................................................................... 50

11.1 CABLE PIN ................................................................................................................. 50 11.2 REQUIRED EQUIPMENT .............................................................................................. 50 11.3 REPLACEMENT PROCEDURE ....................................................................................... 50 11.4 TOWER DIAGRAM ...................................................................................................... 51


P/N: 106945-306 E Wanco, Inc.

1. Introduction 1.1 Instructions Before use, please read this manual carefully. For questions, contact Service/Sales.

1.2 Scope This manual covers mechanical operation, safety, maintenance, troubleshooting and parts diagrams, including standard optional features. Control of the message sign using the local software user interface is covered in the User’s Guide. Operation of the optional remote control software is covered separately.

1.3 Foreword Congratulations on the purchase of your Wanco message sign. This unit is the finest and most technically advanced on the market today. Wanco, Inc. has been producing roadside safety equipment since 1984 with an outstanding reputation for quality, reliability and service, and has several thousand units in operation throughout the world.

1.4 Contact Service/Sales For tech support, product questions, sales support, customer service or product service, contact the number below with the sign type, model number and software version. For trailer-mount signs, also have the VIN number ready. It is available on the label mounted on the front inside of the A-frame tongue of the trailer.

Address: Wanco, Inc. 5870 Tennyson St Arvada, CO 80003-6903 Phone: 303.427.5700 Fax: 303.427.5725 E-mail: [email protected] Web: www.wanco.com


P/N: 106945-306 E Wanco, Inc.

2. Receiving 2.1 Unpacking 2.1.1 Unload unit carefully. 2.1.2 Secure trailer, using forklift or another safe method. 2.1.3 Remove all banding and blocking. 2.1.4 Remove Owner’s Manual from battery box, and store in central office. 2.1.5 Do not store any items in battery box.

2.2 Inspection 2.2.1 Inspect for freight damage, preferably while driver is present. Record any damage, or any other

problems, on Bill of Lading. Notify freight company immediately of any damage. • Inspect solar panels. • Inspect Lexan display panel door. • Inspect wiring cables and tail lights.

2.3 Assembly 2.3.1 If the trailer hitch was removed for shipping, install it using the provided fasteners. 2.3.2 If the unit is equipped with a modem, verify the cellular antenna is properly installed.

2.4 Cleaning 2.4.1 Wash Lexan display panel door.

• Rinse sheet using warm water. • Using a mild soap, and soft cloth or sponge, cleanse gently. Do not use brushes or squeegees. • Rinse again. • Dry with soft or moist sponge to prevent spotting.

2.4.2 Remove any wet paint, glazing compound, or grease. • Rub lightly with VM&P naphtha or isopropyl alcohol. • Do not use gasoline. • Wash and rinse again.

2.5 Cleaning Solutions (for Lexan door) 2.5.1 Aqueous solutions of soaps and detergents:

• Fantastik • Formula 409 • Hexcel, F.O 554 • Joy • Lysol

• Mr. Clean • Neleco-placer • PineSol • Top Job • Windex

2.5.2 Organic Solvents: • Aliphatic Hydrocarbons • Kerosene

• Petroleum Spirits • Naphtha (VM&P Grade)

2.5.3 Alcohol: • Isopropyl Alcohol • Methanol

2.5.4 Graffiti Remover: • Butyl Cellosolve


P/N: 106945-306 E Wanco, Inc.

3. Towing 3.1 Safety Precautions

• Keep hands and equipment clear of pinch points when raising and lowering display panel. • Do not tow unit with additional materials or persons attached or loaded on it. • Do not tow multiple trailers in tandem. • Do not exceed 65 mph (110 kph). Take extra care in hilly, windy, wet or icy conditions.

Before towing: • Verify all tools and equipment are removed from unit. • Verify the display panel is lowered fully and resting on cradles. • Verify mast brake is set. • Verify tires are inflated to proper pressure. • Verify wheel lugs are tight. • Verify all stabilizing jacks (and outriggers) are up and locked. • Verify trailer hitch is properly engaged and locked. • Verify safety chains are attached to tow vehicle.

WARNING: if the trailer hitch is not properly seated on the ball and/or the safety chains are not attached, the trailer may come loose from tow vehicle and result in injury and/or property damage.

3.2 Preparations 3.2.1 Review the safety precautions. 3.2.2 Remove any additional tools or equipment from sign. 3.2.3 Close and secure the battery box cover. 3.2.4 Check tire pressure and wheel lugs. 3.2.5 Remove mast hitch pin and stow. 3.2.6 Use hand winch to lower display panel to just above the control box. 3.2.7 Unlock mast brake. WARNING: take care to secure display panel from uncontrolled rotation in

windy conditions. 3.2.8 Rotate display panel to travel position. 3.2.9 Set mast brake. 3.2.10 Lower display panel fully to the travel position. 3.2.11 Close and secure control box door. 3.2.12 Lower front jack to raise trailer hitch. 3.2.13 Position tow vehicle. 3.2.14 Raise front jack to lower trailer hitch onto towing vehicle. 3.2.15 Verify trailer hitch is completely seated on the ball. 3.2.16 Secure the front jack. Verify plunger pin is locked in place. 3.2.17 Attach the safety chains to the towing vehicle. 3.2.18 Connect the taillight plug to the towing vehicle’s receptacle. CAUTION: trailer's electrical

system uses negative (frame) ground. See trailer wiring diagram for color code. 3.2.19 Raise and secure the four corner stabilizer jacks and stow outriggers.


P/N: 106945-306 E Wanco, Inc.

4. Deployment 4.1 Safety Precautions

• Keep hands and equipment clear of pinch points when raising and lowering display panel. • Verify mast hitch pin is locked in position when display panel is raised. • Verify mast brake is always set, except when rotating display panel. • Verify display panel is higher than control box before rotating. • When rotating display panel in windy conditions, take extra care to ensure wind does not rotate

panel and cause injury or property damage. • Do not stand on unit until all four stabilizing jacks have been lowered and set.

4.2 Preparations 4.2.1 Review the safety precautions. 4.2.2 Tow trailer to desired location. Do not deploy sign where solar panels are shaded. If modem is

to be used, verify cellular network signal strength before deploying sign. 4.2.3 If on a hill or uneven ground, deploy outriggers (if equipped) and lower corner stabilizer jacks. 4.2.4 Lower front jack to lift trailer hitch from ball. 4.2.5 Unhitch trailer from tow vehicle. 4.2.6 Unplug taillight connector. Unhook and stow safety chains. 4.2.7 Remove tow vehicle. 4.2.8 Raise and secure front jack. Ensure plunger pin is locked in place. 4.2.9 If sign is not in final desired position, manually reposition sign. 4.2.10 Deploy outriggers (if equipped), lower corner stabilizer jacks and level trailer. 4.2.11 Verify sign is level, stable and parallel to road. 4.2.12 Use hand winch to raise display panel above control box. 4.2.13 Unlock mast brake. WARNING: take care to secure display panel from uncontrolled rotation in

windy conditions. 4.2.14 Rotate display panel to desired angle. Look through sighting tube (mounted to lower mast)

from rear of trailer to verify display panel is aimed correctly toward on-coming traffic. 4.2.15 Set mast brake. 4.2.16 Fully raise display panel. 4.2.17 Install mast hitch pin.

4.3 Mast Photo

Mast Brake

Sighting Tube


P/N: 106945-306 E Wanco, Inc.

4.4 Control Box Photo

4.5 Sign Operation 4.5.1 Open control box door. Control box light should turn on. 4.5.2 Set console switch to ACTIVE. Review console display (LCD) for alarms. 4.5.3 Log in to local console. Use keyboard to enter password. 4.5.4 Review console display, menu, control box silkscreen and User’s Guide (in control box) for

further instructions on message activation and sign operation. 4.5.5 Always visually check the display panel to ensure the desired message is active and displayed

correctly. Troubleshoot and/or replace any display cards that are not operating properly (see Display Card and Troubleshooting sections).

4.5.6 Local console display and control box light will turn off automatically after 20 minutes with no key pressed. Toggle console switch to INACTIVE, then back to ACTIVE and log in again, and/or close and open the control box door to reactivate console and/or light.

4.5.7 When finished, set console switch to INACTIVE, replace User’s Guide in storage position, close and secure control box door.

4.6 Solar Operation 4.6.1 The sign requires approximately 4 to 6 hours of good sunlight each day on the solar panels to

maintain battery capacity in normal operation. 4.6.2 Position the trailer so that the solar panels are never shadowed by nearby buildings, hills or

trees. Ensure the solar panels do not become covered in snow, leaves or debris. Periodically rinse dirt from solar panels.

4.6.3 Perform proper battery maintenance for maximum charge life, particularly in cold weather. See Battery section for proper field and service yard maintenance procedures. Replace defective batteries.

Reset Button

Modem Option

Control Box Light Contrast Knob Console Switch

Keyboard

User’s Guide

Console Display (Text LCD Option)

Door Sensor

Solar Panel Nut

LED Panel

Radar Option: Tuning Fork

Quick Reference Silkscreen


P/N: 106945-306 E Wanco, Inc.

4.6.4 If reduced sunlight is expected (e.g. due to seasonal changes or weather), follow the energy conservation tips to maximize charge life.

4.7 Energy Conservation Tips 4.7.1 Manually blank the message sign when not required (e.g. at night or weekends). 4.7.2 Use the schedule function to activate messages only as required, and to automatically blank the

message sign at other times. 4.7.3 Do not increase the illumination settings beyond the factory defaults. Decrease the settings

where possible. 4.7.4 Use multi-page messages to provide blank time between pages. Lengthen page blank time as

appropriate. 4.7.5 Use messages with fewer letters. Fewer pixels on means less power used. 4.7.6 Turn off auxiliary devices (e.g. radar) when not required. 4.7.7 Manually unplug modem power cable, if not required. Remember to reconnect modem power

before attempting remote operation. 4.7.8 In extreme conditions, rotate signs back to the service yard for battery charge and maintenance

every 3-6 weeks.


P/N: 106945-306 E Wanco, Inc.

5. Batteries 5.1 Safety Precautions

• WARNING: Avoid skin contact with battery acid. • Keep battery box cover closed except when performing maintenance or charging. • Keep hands and equipment clear of pinch points when closing battery box cover. • Do not allow positive power cable to short to ground while dis/connecting batteries. • Do not allow equipment or tools to short across battery terminals. • Tighten vent caps before charging batteries. • Charge batteries only in a well ventilated area. • Keep sparks and flames away from charging batteries.

5.2 General Instructions • See photo below for additional information. • The following procedures apply to Interstate batteries, other brands may differ slightly. • Perform regular maintenance (e.g. once per week), see Field Maintenance Procedure below. • Keep vent caps and cable connections tight. • Keep batteries and terminals clean (from corrosion and dirt). • Maintain proper battery fluid levels. Do not use additives. • Avoid letting batteries fully discharge. • Do not leave batteries in a discharged state. • Discharged batteries can freeze and split in cold weather, see Freezing Point Table below. • If batteries are to be stored or removed from service, fully charge them first, then store at 33° to

80° F. Batteries will drain faster at higher temperatures, see Self-Discharge Table below.

5.3 Battery Box Photo

Location of optional Ammeter &/or

Condition Meter

Battery Charger

Charger Cord

12V Battery Bank (6 Cell Option)


P/N: 106945-306 E Wanco, Inc.

5.4 Battery Watering Information • Maintaining proper battery fluid levels is critical to battery performance and longevity. • Never let the fluid level drop below the plates. If the plates are exposed to air, they will corrode

and shorten battery life. • Use distilled or de-ionized water only. • Never add acid or additives to a battery. • Do not use water with a mineral content, this can cause the plates to corrode. • Do not use a hose to water batteries. Watering guns or automatic watering systems are available

and recommended. • Do not overfill the batteries (beyond 1/8” from top of well). If the filling wells are completely

full, they will overflow acid in use, causing a corrosive mess and shortening battery life. • Overfull batteries may indicate overcharging, high temperature operation and/or battery is

nearing the end of its service life.

5.5 Battery Charging Information • Perform specific gravity and/or voltage tests, then use the Battery State Table to determine if

the batteries need charging and for how long. • Ensure batteries are fully charged before putting sign in operation. • A typical recharge will take up to 48 hours. A complete recharge may take up to 60 hours (from

a fully discharged condition). • Charge batteries immediately prior to each period of use, particularly in cold weather. • Charge batteries after each period of use, immediately prior to storage. • Charging between short intervals of nonuse is permissible. • Avoid charging at temperatures above 120° F. • Always charge batteries fully. Undercharging causes stratification. • Do not charge a frozen battery, thaw completely first. • Charge stored batteries every 30 days, or whenever their specific gravity reaches 1.210.

5.6 Specific Gravity Test Procedure 5.6.1 Take appropriate cautions when servicing batteries; review safety precautions. 5.6.2 Open vent cap. 5.6.3 Inspect fluid level. Add enough distilled water to cover the plates. 5.6.4 Fill and drain the hydrometer two to four times. 5.6.5 Pull out a sample. There should be enough sample fluid (electrolyte) to support the float. 5.6.6 Record the hydrometer reading. 5.6.7 Return the fluid to the cell. 5.6.8 Close and tighten vent cap. 5.6.9 Repeat for other cells. 5.6.10 Clean any spilled electrolyte. 5.6.11 Correct the hydrometer readings to 80° F. Using ambient air temperature, add 0.004 for every

10° above 80°, or subtract 0.004 for every 10° below 80°.

5.7 Voltage Test Procedure 5.7.1 For accurate voltage readings, batteries must remain idle for 6 to 24 hours. This allows the

voltage to equalize between the cells.


P/N: 106945-306 E Wanco, Inc.

5.7.2 Specific gravity testing is a more accurate indicator of battery charge level than voltage testing. 5.7.3 Take appropriate cautions when servicing batteries; review safety precautions. 5.7.4 Verify battery cables are disconnected and terminals are clean, see maintenance procedures. 5.7.5 Measure and record the DC voltage at each battery terminal, using a DC voltmeter. 5.7.6 Correct the voltage readings to 80° F. Using ambient air temperature, add 0.028 per cell for

every 10° above 80°, or subtract 0.028 per cell for every 10° below 80° (e.g. for a typical 3-cell battery, add or subtract 0.084 per 10°).

5.7.7 If the voltage varies between batteries, recharge unit and retest. Or obtain appropriate test equipment from battery manufacturer and follow instructions.

5.8 Field Maintenance & Inspection Procedure 5.8.1 Routinely inspect batteries and cables, clean surfaces and terminals, spot-check specific gravity

and maintain fluid levels. 5.8.2 Regular maintenance will indicate battery charge level, improper care, undercharging, over-

watering, and weak batteries. 5.8.3 Take appropriate cautions when servicing batteries; review safety precautions. 5.8.4 Open the battery box. 5.8.5 Inspect battery cables. Replace any cables with fraying, cracks, breakage or exposed wires. 5.8.6 Inspect batteries. Replace any cracked or leaking batteries. 5.8.7 Disconnect battery cables. Do not allow the cables to short (to chassis) while disconnecting the

battery. Do not allow any tools to short across the terminals. 5.8.8 Clean battery surfaces. Verify vent caps are tight; do not allow any cleaning solution, dirt or

foreign matter to get inside the battery well. If possible, wash battery with cleaning solution of baking soda and water, then rinse with water and dry with a clean cloth.

5.8.9 Clean battery terminals, particularly if visually corroded or warm/hot. Scour the terminals and the inside of the cable clamps using a battery post/clamp cleaner (or wire brush) until they have a bright metallic shine.

5.8.10 Perform specific gravity test on two or more cells on different batteries. Normal readings should be between 1.250 and 1.280. If low test readings are noted, check all other cells/batteries to determine if batteries are near the end of their operating life.

5.8.11 Verify terminal connections are clean and tight. 5.8.12 Replace problem batteries and/or recharge unit. Also verify charger is operating correctly. 5.8.13 Check fluid levels. Open battery vent caps and inspect fluid well for each cell. If necessary, add

enough distilled water to cover the plates. Close and tighten vent caps. 5.8.14 Reconnect the battery cables. 5.8.15 At least once per month, coat cable connections with a protective spray, non-metallic grease or

petroleum jelly (Vaseline) to prevent corrosion. Repaint hold-downs. 5.8.16 Verify cable connections are tight and making good contact. Loose connectors may allow

sparking, which can cause explosion and serious injury. 5.8.17 Verify vent caps are closed and tight. 5.8.18 Verify battery surfaces are clean and dry. 5.8.19 Verify all equipment and cleaning supplies have been removed from battery box. 5.8.20 Close and secure battery box.


P/N: 106945-306 E Wanco, Inc.

5.9 Service Yard Maintenance & Charging Procedure 5.9.1 Take appropriate cautions when servicing batteries; review safety precautions. 5.9.2 Open the battery box. 5.9.3 Inspect battery cables. Replace any cables with fraying, cracks, breakage or exposed wires. 5.9.4 Inspect batteries. Replace any cracked or leaking batteries. 5.9.5 Disconnect battery cables. Do not allow the cables to short (to chassis) while disconnecting the

battery. Do not allow any tools to short across the terminals. 5.9.6 Clean battery surfaces. Verify vent caps are tight; do not allow any cleaning solution, dirt or

foreign matter to get inside the battery well. 5.9.7 Clean the battery top with a cloth and a solution of baking soda and water. Rinse with water

and dry with a clean cloth. 5.9.8 Clean battery terminals. Scour the terminals and the inside of the cable clamps using a battery

post/clamp cleaner (or wire brush) until they have a bright metallic shine. 5.9.9 Check fluid levels. Open battery vent caps and inspect fluid well for each cell. If necessary, add

just enough distilled water to cover the plates, more water may be added after charging. 5.9.10 Perform specific gravity and/or voltage tests, then use the Battery State Table to determine if

the batteries need charging and for how long. 5.9.11 Close and tighten vent caps. 5.9.12 Reconnect the battery cables. 5.9.13 Coat cable connections with a protective spray, non-metallic grease or petroleum jelly

(Vaseline) to prevent corrosion. Repaint hold-downs. 5.9.14 Verify cable connections are tight and making good contact. Loose connectors may allow

sparking, which can cause explosion and serious injury. 5.9.15 Log in to the local console (if/when sign is not in low-voltage shutdown). Verify the message

sign is blanked/off and all auxiliary devices are off. Observe the system battery system voltage from the status screen and/or measure the voltage in the battery box. The voltage should increase when charging, and the charging ammeter, if used, should show positive charging current.

5.9.16 Locate the charger cord (in battery box) and plug into a standard 120V outlet. If line voltage is below 115V, charger may not operate properly. Contact the power company and/or an electrician for line testing and/or correction. If charger is not working, fuse on charger may be blown, or outlet may not be switched on.

5.9.17 Charge batteries fully, until the ammeter reads less than 5A (approx. 24-60 hours). The Wanco charger will not overcharge or damage batteries if left on for an extended time.

5.9.18 A typical recharge will take up to 48 hours. A complete recharge may take up to 60 hours (from a fully discharged condition).

5.9.19 Unplug charger. Stow charger cord in battery box. 5.9.20 Check fluid levels. Open battery vent caps and inspect fluid well for each cell. Add enough

distilled water to 1/8” below the top of each fill well. Close and tighten vent caps. 5.9.21 Verify vent caps are closed and tight. 5.9.22 Verify battery surfaces are clean and dry. 5.9.23 Verify all equipment and cleaning supplies have been removed from battery box. 5.9.24 Close and secure battery box.


P/N: 106945-306 E Wanco, Inc.

5.10 Battery State Table Determine the battery charge level from the specific gravity or voltage test readings. Specific gravity testing is recommended over voltage testing, as it is possible for batteries to exhibit a valid voltage (surface charge), yet have no capacity to drive a load.

• Each 12V battery consists of two 6V cells. • If battery is above 70%, no charging is required. • If battery is below 10%, it may need replacing. • Otherwise, determine the required charge time from the table. • With the Wanco charger:

use the 5A column for a 4-battery bank use the 20A column for a single battery.

Charge Level

(%)

Specific Gravity

(at 80°F)

Open-Circuit Voltage

Charge Time Required (hours)

6V 12V 5A 10A 20A 100 1.277 6.37 12.73 0 0 0

95 1.268 6.34 12.68 3 1 1

90 1.258 6.31 12.62 5 2 1

85 1.248 6.28 12.56 8 4 2

80 1.238 6.25 12.50 10 5 3

75 1.227 6.22 12.44 13 6 3

70 1.217 6.19 12.37 16 8 4

65 1.206 6.16 12.31 18 9 4

60 1.195 6.12 12.24 21 10 5

55 1.184 6.09 12.17 23 12 6

50 1.172 6.05 12.10 26 13 6

45 1.161 6.02 12.03 28 14 7

40 1.148 5.98 11.96 31 16 8

35 1.137 5.95 11.89 34 17 8

30 1.124 5.91 11.81 36 18 9

25 1.111 5.87 11.74 39 19 10

20 1.098 5.83 11.66 41 21 10

15 1.087 5.79 11.59 44 22 11

10 1.073 5.75 11.51 47 23 12

5 1.037 -- -- -- -- --

0 1.000 -- -- -- -- --


P/N: 106945-306 E Wanco, Inc.

5.11 Electrolyte Freezing Point Table At the following specific gravity readings, the electrolyte solution will freeze at the indicated temperature.

Specific Gravity

Freezing Pt (°F)

1.250 -62

1.200 -16

1.150 + 5

1.100 +19

1.000 +32

5.12 Self-Discharge Rate Table At the following temperatures, the specific gravity of the electrolyte solution will fall by the indicated amount each day (when idle).

Temperature (°F)

Specific Gravity

100 3.0

80 2.0

50 0.5

30 0.1


P/N: 106945-306 E Wanco, Inc.

6. Character Display Cards 6.1 General Instructions

• Always visually check the display panel to ensure the desired message is active and displayed correctly.

• VT3 character display cards are 5 x 7 pixels (horz. x vert.), each display a single letter, and include lens and sun shade assemblies mounted over the LEDs.

• Always fix “upstream” card problems first. If several cards exhibit problems, they may be due to the first card in the sequence.

• Access the Display Card Status screen (Alt-D) for diagnostics and card software versions. • Some problems may be transient and fixed by re-scanning the cards from the status screen,

blanking the message sign and then reactivating a message, and/or by pressing the reset button. • Other problems may be due to loose cable connections. Examine the status screen for location

of specific problem cards, then check the data cable and power cable connections. • When ordering replacement cards, request the card software version displayed on the status

screen. • Always remove cables by pulling on the plastic connector, never pull on the wires. Tight power

connectors will release with a slight wiggle. Data connectors have a locking latch. • IMPORTANT: Display card replacement (or swap) requires log in with “advanced” or

“service” level password privileges to reprogram the card addresses. Do not perform card replacement with “user” or “guest” level passwords. Also see User’s Guide.

• CAUTION: Blanking the message sign will disable all power to the display cards, making them safe to service: disconnecting the battery is not required. However, other accessories in the display panel cabinet (e.g. fans, radar, photocells) may still have low voltage. Take care not to short any electrical systems or drop screws, wiring or tools onto electronics or terminal strips.

6.2 Replacement Procedure 6.2.1 Examine mounting diagram and photo, below. 6.2.2 Log in to the local console with “advanced” or “service” level password. Do not perform card

replacement with “user” or “guest” level passwords. Also see User’s Guide. 6.2.3 Access the Display Card Status screen (Alt-D) to identify specific cards with problems.

Activate a message and/or re-scan the display, if necessary. Do not initialize the display. 6.2.4 Turn off all auxiliary devices (e.g. radar). Blank the message sign (Alt-B). Verify LEDs for

message sign, schedule and auxiliary device power are all off. 6.2.5 Verify trailer is level and stable, and four corner jacks are deployed. Do not stand on trailer

unless stable. 6.2.6 If necessary, lower display panel to serviceable height and/or rotate panel. See appropriate

instructions in Towing and/or Deployment sections. Ensure display panel is above control box and there is sufficient clearance to open panel door. Take extra care in windy conditions.

6.2.7 Open Lexan door. 6.2.8 Detach display card from vibration mounts.

• Use a 5/16" nut driver or box wrench to remove the 4 stand-off hex sticks. If a wrench is not available, a standard screwdriver (or a dime) may be used in the stand-off slot, however, take care not to break off the top of the standoff, particularly when the plastic is cold.


P/N: 106945-306 E Wanco, Inc.

• CAUTION: not all sun shade holes are used for stand-offs; do not insert tools into incorrect holes as damage to components may result. Do not attempt to remove sun shade or lenses.

6.2.9 Gently remove display card module a few inches from vibration mounts. Do not remove card entirely, data and power cables are still attached.

6.2.10 Disconnect the power cable located at top-center of module. Do not pull on the wires. Wiggle the connector gently to remove.

6.2.11 Disconnect the two data cables at top-left and top-right of module (cables wires are black and red twisted-pair). The bottom right card will have only one cable. Press in the locking tab while pulling out gently. Do not pull connector without releasing latch. Do not pull on wires. Damage to data cables will impair display panel function. Note where each cable belongs.

6.2.12 Fully remove the display card module and set aside. 6.2.13 Connect data cables and power cable to replacement card. It may be easier to hold card upside-

down against the upper row with one hand while attaching the cables with the other. Position card onto vibration mounts.

6.2.14 Activate a message to re-power the sign display (e.g. Alt-F1). Display will not be correct. 6.2.15 Access the Display Card Status screen (Alt-D). Press ‘I’ to initialize all the display cards. Wait

for the initialization process to complete, an alphabet test message should display automatically. Verify correct sign display.

6.2.16 Activate desired message, schedule, blank the sign, and/or restore power to desired auxiliary devices.

6.2.17 Set console switch to INACTIVE. 6.2.18 Re-attach card to vibration mounts. Do not insert stand-offs (or tools) into incorrect holes as

damage to electronic components may result. 6.2.19 Close Lexan door. 6.2.20 Return display panel to desired height and rotation. See appropriate instructions in Towing

and/or Deployment sections. Verify mast hitch pin is in place and mast brake is set. 6.2.21 Close and secure control box door.


P/N: 106945-306 E Wanco, Inc.

6.3 Display Card Mounting Photo

Display Card Assembly

(CCA/Visors/Lens)


P/N: 106945-306 E Wanco, Inc.

6.4 Display Panel Wiring Photo

Radar option terminal block Radar head mounts

to frame under display panel (radar head and wiring not shown)

Data Cables

Vibration Mounts

Power Cable


P/N: 106945-306 E Wanco, Inc.

7. Troubleshooting 7.1 Main Control Board Photo (Circuit Card)

Firmware Chip

(notched corner)

Vcc/+5V (test point)

Ground (test point)


P/N: 106945-306 E Wanco, Inc.

7.2 Power Control Board Photo (Circuit Card)

Solar Charging Voltage (test point)

Battery Voltage (test point)

Ground (test point)

Battery Fuse (20 A)

Solar Fuse (30 A)

Temperature Sensor (on cable)


P/N: 106945-306 E Wanco, Inc.

7.3 Control Box Wiring Photo

7.3.1 To access circuit cards, follow procedure in Firmware Upgrade section: • Be sure to touch grounded metal to discharge static electricity before handling electronics. • Be sure to disconnect the power cable. • Some electronics may retain low voltage charges; do not allow metal tools or screws to contact

circuit card components. • IMPORTANT: If any cables must be disconnected, note where each cable belongs for later

replacement, all of the serial connectors are the same style, but each device must be connected to the correct port.

7.3.2 Remove cable cover from rear of control box. 7.3.3 Disconnect battery power cable. 7.3.4 Open the control box door. 7.3.5 Remove the large retaining screws (x2) from the back of the control box, while supporting the

front of the console panel. Carefully lower the console panel to expose the circuit card.

7.4 Power System 7.4.1 If no message displayed on sign, console will not activate, no modem LEDs are lit, and/or

battery saver/shutdown LED is lit, sign power is completely shut down.

Fuse Box (Main Bd/Light Gnd)

(Aux Power) (Modem/Radar/Aux Gnd)

(Modem Power)

Main Control Board (Circuit Card)

LED/Switch Board (Circuit Card)

(w/ Radar Option)

Console Display (LCD Assy)

Power Board Fuses (Battery Power) (Solar Power)

Power Control Board (Circuit Card)

Radar Option: Power/Comm Cable

Temperature Sensor (on cable)

Main Bd to Power Bd Comm Cable

LED Board Fuse (Radar Power)

Door Sensor Comm Cable

Modem Option (Data Remote)

Photocells


P/N: 106945-306 E Wanco, Inc.

• Press reset button. If sign returns to shutdown mode, batteries probably need recharging or replacement. If sign starts normally, shutdown was probably deliberate for long-term storage.

• Note: if battery system voltage is extremely low, shutdown LED will not light. • Batteries may need recharging or replacement. See Battery section. • Battery cables and/or connections may be loose, damaged or corroded. • Fuse may be blown: check main ground fuse in fuse box and battery fuse on power board. • Power cable and/or display cable connections may be loose, damaged or corroded. Verify

connections to back of control box, under rain cover. 7.4.2 If sign is frequently in low-power or shutdown mode, or batteries do not hold a charge:

• Solar panels may be covered with dirt or snow. Clean panels. • Solar panels may be damaged from weather or vandalism, or stolen. Replace. • Insufficient sunlight due to shadowed location. Reposition sign. • Insufficient sunlight due to weather or season. Follow energy conservation tips. • Batteries may be bad. Perform maintenance, recharge and/or replace. • Solar power cabling may be loose or damaged. Repair or replace. • Fuse may be blown: check solar fuse on power board. • Power board may be bad. Replace. • Fan temperature settings may be too low, running too often. Verify and/or reset.

7.5 Message Display 7.5.1 If no message displayed on sign, console will not activate and/or battery saver/shutdown LED

is lit, sign power is completely shut down. See Troubleshooting Power System above. 7.5.2 If message turns on (or off) “by itself”, even if message sign has been blanked:

• Message may be activated by radar or other auxiliary device. Turn off device using config screen; blanking the message sign does not disable the devices.

• Message may be activated by remote control software. Contact remote software operator. • Message may be activated by scheduler function. Disable schedule. • Sign may be performing periodic self test. Message should reactivate.

7.5.3 If no message displayed on sign, activate local console to check alarms, display card diagnostics, battery system voltage, sign temperature and message status screens.

• Display may be turned off, either directly or by scheduler or remote software. • Displayed message may be all spaces. • Sign may be in low-voltage shutdown. Batteries may need recharge or replacement. • Sign may be in critical over-temperature shutdown. • Fuse may be blown: check main ground fuse in fuse box and battery fuse on power board. • Power cable and/or display cable connections may be loose, damaged or corroded. Verify

connections to back of control box, under cable cover. • Sign may be performing periodic self test. Message should reactivate.

7.5.4 If partial message displayed (missing, partial or duplicated characters), activate local console and check alarms and display card diagnostics:

• Display card power or data cable connections may be loose or broken. Repair or replace. • One or more display cards may be bad. Replace and/or temporarily swap the problem card with

one that is not used for this message (e.g. lower-right card). Always fix “upstream” card problems first. If several cards exhibit problems, they may be due to the first card in the sequence. See Display Card section for additional information and replacement instructions.


P/N: 106945-306 E Wanco, Inc.

7.6 LEDs/Pixels/Brightness 7.6.1 If LED brightness is incorrect (too dim or too bright):

• Check alarms and photocell readings on status screens. Typical daytime readings are 50-80%. • Lexan display panel door may be dirty/dusty. Rinse clean. • Verify LED brightness setting on status screen. • Verify correct illumination control setting. Typical daytime settings are 40-50%. Settings for

fixed-power units (non-solar) may be 80-90%. • If problem is isolated to a single display card, it may be bad. See Display Card section for

additional information and replacement instructions. • Photocell sensor or sensor board may be bad. Replace photocell sensor board (in the sign). • Sensor board cabling may be damaged or loose. Repair or replace.

7.6.2 If isolated LEDs or pixels are stuck on or off: • LED or pixel driver may be shorted. Examine card for damage, debris, moisture, or contact

with metal on front or back of card. • LED or pixel driver on display card may be bad. Replace and/or temporarily swap the problem

card with one that is not used for this message (e.g. lower-right card). See Display Card section for additional information and replacement instructions.

7.7 Temperature 7.7.1 Check alarms and temperature readings on status screens. 7.7.2 Verify ambient air temp. 7.7.3 If high sign temperature and/or over-temperature shutdown (e.g. 175°-190° F):

• Note that the temperature inside the display panel may be significantly higher than ambient due to solar heating (e.g. 120°-150° F).

• Open display panel door and inspect interior. • Fan vents/filters may be clogged with dust/debris. Clean filters. • Fan or fan cabling may be damaged. Repair or replace. • Fan temp settings may be too high, not running often enough. Verify or reset to 165° F.

7.7.4 If incorrect or suspicious sign cabinet temperature: • Open display panel door and inspect interior. • Temperature sensor or sensor board may be bad. Replace photocell sensor board (in the sign). • Sensor board cabling may be damaged or loose. Repair or replace.

7.7.5 If incorrect or suspicious control box temperature: • Open control box and inspect interior. • If evidence of smoke or burnt components, there may be a serious electrical problem with the

power board or control board. Take care. Contact service department. • Temperature sensor on the power board may be bad. Replace. • Power board may be bad. Replace.

7.7.6 If incorrect or suspicious ambient temperature: • Open control box and inspect interior. • Temperature sensor on the LED/Switch board or power board may be bad. Replace. • LED/Switch board or cabling may be loose or damaged. Tighten or replace.


P/N: 106945-306 E Wanco, Inc.

7.8 Console Light 7.8.1 If no console light, no message displayed on sign, console will not activate and/or battery

saver/shutdown LED is lit, sign power is completely shut down. See Troubleshooting Power System above.

7.8.2 If console light turns off: • Light may have timed out due to inactivity. Close and open console door.

7.8.3 If console light and display turns off: • Console may have timed out due to inactivity. Toggle switch slowly and log in again.

7.8.4 If console light is off when door is open, but on when console is active: • Door magnet may be misaligned or missing, reposition or replace as necessary. • Door switch lever may be bent, adjust as necessary. (Older units only.) • Door switch/sensor may be bad, replace as necessary.

7.8.5 If console light never turns on: • Bulb may have burned out. Replace.

7.9 Console Display 7.9.1 If console display will not activate, no message displayed on sign, and/or battery


7.9.2 If console display turns off: • Console may have timed out due to inactivity. Toggle switch slowly and log in again.

7.9.3 If console display is very dark or very bright, but turns on/off with the switch: • Contrast setting may need adjustment, rotate contrast knob. • Cable connection from LCD to control board may be loose or damaged. Repair or replace. • Contrast pot may be bad. Replace. • LCD screen may be bad. Replace.

7.9.4 If console will not activate, but other systems appear to have power: • Temperature may be too low. LCD may not operate below -4° F (-20° C). • Humidity may be too high. • Switch may be bad. Replace. • LCD screen may be bad. Replace. • Cable connection from LCD to control board may be loose or damaged. Repair or replace.

7.9.5 If console is slow to accept, display or respond to keystrokes: • Modem communications, radar communications, sign initialization, display card self-test,

flashing messages and multi-page messages may cause temporary slowdowns to the user interface.

• Temporarily turn off sign display and/or auxiliary devices when performing a large amount of console operations for optimum responsiveness.

7.10 Keyboard 7.10.1 If keyboard error displayed when activating console:

• Verify keyboard is plugged into console port. • Toggle console switch slowly and log in again. • Verify Caps and Num Lock lights turn on when activating console. This verifies the keyboard

is plugged in correctly and receiving power.


P/N: 106945-306 E Wanco, Inc.

• Press reset button, then retry. • Keyboard may be bad. Replace. • Keyboard port on control board may be bad. Replace control board.

7.10.2 If console does not accept or display keystrokes: • Verify keyboard is plugged into console port. • Toggle console switch slowly and log in again. • Press reset button, then retry. • Keyboard may be dirty or certain keys may be broken. Replace.

7.10.3 If console is slow to accept, display or respond to keystrokes, see Troubleshooting Console Display above.

7.11 Indicator LEDs (Optional Equipment) 7.11.1 Note, not all models have indicator LEDs (under the console display), or may not have all

indicator LEDs installed. 7.11.2 If no LEDs are lit, no message displayed on sign, console will not activate and/or battery


7.11.3 If alarm LED is lit, log on to console and check status screens. 7.11.4 If no LEDs are lit:

• May be a valid state, i.e. if message sign, scheduler, radar and all auxiliary devices are turned off, solar panels are not charging, and there are no alarms.

• If console display will not activate, see Troubleshooting Console Display. • If console light is also off, see Troubleshooting Console Light. • Fuse may be blown on LED/Switch board. Replace. • LED/Switch board cabling may be loose or damaged. Tighten or replace. • LED/Switch board may be bad. Replace.

7.11.5 If LEDs turn off: • May be a valid state, i.e. if message sign, scheduler, radar and all auxiliary devices are turned

off, solar panels are not charging, and there are no alarms. • LEDs may have timed out due to inactivity. Close and open console door. • Console may have timed out due to inactivity. Toggle switch slowly and log in again.

7.11.6 If single LED is off: • May be a valid state. • LED on the LED/Switch board may be bad. Replace.

7.12 Radar (Optional Equipment) 7.12.1 Radar power is under software control. See software User’s Guide for additional information.

• Verify radar mode is enabled (and desired messages are selected) on radar config screens. • Verify “Radar Power On” indicator LED is lit.

7.12.2 See radar wiring photo in Display Card section and control box wiring photo above. • Fuse may be blown: check radar ground fuse in fuse box and power fuse on LED/Switch board. • Radar cabling may be loose or damaged. Reconnect, repair or replace. • Radar cabling exists from the radar head to the terminals in the display panel; from the display

panel to the control box power connector; and from the power board to the LED/Switch board. • Radar head may be defective. Replace.


P/N: 106945-306 E Wanco, Inc.

7.12.3 Use the tuning fork to trigger a speed reading (55 mph). • Retrieve the tuning fork from the control box. • Log into the local console and turn radar power off, then on. • Within 30 seconds of power-on, strike the tuning fork and place in front of the radar head. • After 30 seconds, the tuning fork must also be moving toward the head to trigger a reading. • Verify the sign displays the correct radar message, then returns to the correct standby message.


P/N: 106945-306 E Wanco, Inc.

8. Firmware Upgrades 8.1 Safety Precautions

• Be sure to touch grounded metal to discharge static electricity before handling chips or electronics.

• Be sure to disconnect the power cable. • Some electronics may retain low voltage charges; do not allow metal tools or screws to contact

circuit card components.

8.2 Required Equipment 8.2.1 Obtain the following:

• Phillips screwdriver(s) 8.2.2 Check that the kit contains all these items:

• 1 Chip Extraction Tool (Puller) • 1 New Firmware Chip • 1 New Data Chip (if supplied)

8.3 Instructions 8.3.1 Review safety precautions. 8.3.2 Obtain required equipment. 8.3.3 Touch metal frame to discharge any static electricity. 8.3.4 On the back of the white control box, remove the cable cover (5 screws). 8.3.5 Disconnect (unscrew) the battery power cable.

8.3.6 Open the control box door. 8.3.7 Unplug all cables from the right side of the console cabinet: keyboard, modem, aux, radar,

and/or pager (if installed). IMPORTANT: Note where each cable belongs for later replacement, all of the serial connectors are the same style, but each device must be connected to the correct port.

8.3.8 Remove the large retaining screws (x2) from the back of the control box, while supporting the front of the console panel. Carefully lower the console panel to expose the circuit card.

Battery power cable

Cable cover

Cover screws (x5) Retaining screws (x2)


P/N: 106945-306 E Wanco, Inc.

8.3.9 Remove the circuit card screws (x4). Slide the circuit card to the left to clear the cable holes and gently flip circuit card over (with remaining cables attached).

8.3.10 Remove the firmware chip from its socket. It is the smaller, rectangular chip on the left. Use the chip puller by inserting the prongs into the corner slots, then squeeze the tool and pull up gently until the chip pops out. Take care not to damage the socket.

8.3.11 Press the new chip into the socket. Orient the chip so that the notched/angled corner matches the notched corner of the socket. Do not force the chip; if it feels tight, it may be backwards.

8.3.12 If new data chip is supplied, repeat the procedure to replace the chip on the right. 8.3.13 Gently flip the circuit card back over and reposition. Replace the circuit card screws (x4). 8.3.14 Raise the console panel. Replace the retaining screws (x2). 8.3.15 Re-connect the cables to the right side of the console cabinet: keyboard, modem, aux, radar

and/or pager. Verify cables are in proper locations. 8.3.16 Re-connect the battery power cable to the back of the control box. 8.3.17 At the console panel, toggle the console switch to ACTIVE. 8.3.18 Verify system powers on and password screen appears. Enter password and verify proper

software operation and desired message activated on the display panel. 8.3.19 Verify proper operation of any auxiliary devices (e.g. radar). 8.3.20 Have a remote operator call the unit to verify proper operation of any remote devices (e.g.

modem). If the unit does not respond correctly, verify serial cables are reconnected to their correct ports.

8.3.21 Toggle the console switch to INACTIVE. 8.3.22 Close and secure the control box door. 8.3.23 Replace the cable cover on the back of the control box (5 screws).

Circuit card screws (x4) Firmware chip

Notched corner (pin 1)

Data chip

Corner slots (for chip puller)


P/N: 106945-306 E Wanco, Inc.

9. Wiring Diagrams, Model WVT3 9.1 Control Box

CO

NS

OLE

DIS

PLA

Y AS

EMBL

Y

1

120

J3GRN

RED

J6

J2 J4

KEY

BOAR

D

DEBU

G (P

2)

MODE

M (P

3)

FROM

KEY

BO

ARD

J5

RED

WIR

E (R

EF)

DO

OR

S

EN

SO

R

1011

RED

YELRED/BLK

WHTRED/WHT

REDGRN

ORNRED/YEL

PINK

BLK

RED

23

4

RADA

R (P

1)

J4

BLK

GRN

CO

NS

OLE

LIG

HT

YEL

J3

J4J1

1 5106

WHT

RED/BLKRED/WHT

ORNRED/YEL

PINK

CONT

RAST

POT

CONS

OLE

ACTI

VE/IN

ACTI

VE

SWIT

CH

RESE

T SW

ITCH

3A F

USE

(MAI

N BO

ARD

GND/

CONS

OLE

LT G

ND)

MAIN

CON

TROL

BO

ARD

(CIR

CUIT

CAR

D)

POW

ER C

ONTR

OL B

OARD

(CIR

CUIT

CAR

D)

MESS

AGE

SIGN

LIFT

SW

ITCH

(NOT

USE

D W

ITH

HAND

WIN

CH O

PTIO

N)

LED/

SWIT

CH B

OARD

(CIR

CUIT

CAR

D)

RED

BLKREDBLK

J1


P/N: 106945-306 E Wanco, Inc.

9.2 Modem (Optional Equipment)

POW

ER C

ONTR

OL B

OARD

5A F

USES

(MOD

EM P

WR

AND

GND)

1020

23

41

GR

NR

ED

GRN

RED

GRNRED

11J3

1

J4

ANTE

NNA

ANTE

NNA

CABL

E

KEY

BOAR

DJ2J1

J6 SERI

AL C

OMMU

NICA

TION

CAB

LE

MAIN

CON

TROL

BO

ARD

(CIR

CUIT

CAR

D)

RADA

R (P

1)

MODE

M (P

3)

DEBU

G (P

2)

J4

J5

MODE

M(C

ONFI

GURA

TION

OF

CONN

ECTI

ONS

VARI

ESW

ITH

BRAN

D)

SERI

ALCO

NN.

POW

ERCO

NN.

ANTE

NNA

CONN

.PO

WER

SUP

PLY

WIR

ES


P/N: 106945-306 E Wanco, Inc.

9.3 Radar (Optional Equipment)

J3

J4J1

RED

WIR

E (R

EF)

GRN

RADA

R HE

AD,

MOUN

TED

TO B

OTTO

M OF

SIG

N BO

ARD

TO P

OSITI

ON 13

TO P

OSITI

ON 12

TO P

OSITI

ON 11

GRN

BLKRED

34 2 1

RE

DB

LKW

HT

BLK

WHT

TWIS

TED

PAIR

S

FOR F

UTUR

E US

E

GRN14

32

RED

3A F

USE

(W/O

MOD

EM)

5A F

USE

(W/ M

ODEM

)(R

ADAR

GRO

UND)

MAIN

CON

TROL

BO

ARD

(CIR

CUIT

CAR

D)

POW

ER C

ONTR

OL B

OARD

(CIR

CUIT

CAR

D)

REDGRN

RED

WHT

WHTRED

120

J3

J6

J1 J2 J4

KEY

BOAR

D

DEBU

G (P

2)

MODE

M (P

3)

J5

1011

RADA

R (P

1)

J4


P/N: 106945-306 E Wanco, Inc.

9.4 Display Panel

FAN

2

FM

WHT

FM

BLK

56

BLK

11BL

K

12

RED

RED

1920

BLK

13BL

K

14

RED

RED

2122

RED

RED

RED

BLK

BLK

RED

BLK

BLK

BLK

78

TEMP

SEN

SOR

23

1

GND

PWROUT

BLK

REDWHT

SOLA

R PA

NEL

RED

1516

2324

MFM

F

-+

RED TAN

SOLA

R PO

WERMM

FW

HTF

BLK

RED

BLK

12

910

1718

FAN

1

34

CONN

ECTO

R

+ 7- 10

4

+ 13

8

65

9

2

11

-

1312

1615

14

BATT

ERY

CHAR

GER

MESS

AGE

BOAR

D CO

NNEC

TOR

121+2

610

115

94

38

147

13

22-

1617

2015

1918

21BLK

BLKWHT

BLK

RED

WHT

RED, YELWHT/YEL1

WHT/GRN

WHT/BLU

WHT/VIOPNK, VIO

63

45

210

89

7BLKRED

BLU

GRN

RED,

WHT

/YEL

, YEL

WHT

/VIO

, PNK

, VIO

13NO

T US

ED

REDBLK

BLK

WHT

20

WHT/REDWHT/BLK

WHT/BRN

1513

1411

1219

1718

16

BRN

1PIN

COLO

R

7TA

N

42 3 5 6

NOT

USED

NOT

USED

NOT

USED

NOT

USED

NOT

USED

108 9 11 12

WHT

/RED

WHT

/BRN

BRN

WHT

/BLK

NOT

USED

20GR

N

171514 16 18 19

WHT

/BLU

NOT

USED

NOT

USED

NOT

USED

WHT

/GRN

BLU

21 22NO

T US

ED

114

,18,18

BATT

ERY

+

MESS

AGE

BOAR

D CO

NNEC

TOR

PIN

OUT

PURP

OSE

TERM

BLK

#GA

TEMP

SEN

SOR

POW

ERTE

MP S

ENSO

R IN

PUT

TEMP

SEN

SOR

GROU

NDDA

TA C

ABLE

RED

DATA

CAB

LE B

LACK

1118

12 1615131818 18 18

FAN

2 RE

TURN

FAN

2

FAN

1FA

N 1

RETU

RN

BATT

ERY

-

1018

8 9718 18 18

414

,18,18

COLU

MN

COLU

MN

COLU

MN

UPST

REAM

UPST

REAM

UPST

REAM

UPST

REAM

ROW

ROW

UPST

REAM

COLU

MNCO

LUMN

UPST

REAM

UPST

REAM

UPST

REAM

ROW

COLU

MNCO

LUMN

ROW

UPST

REAM

ROW

COLU

MN

ROW

COLU

MN

UPST

REAM

COLU

MN

ROW

ROW

UPST

REAM

COLU

MNCO

LUMN

ROW

ROW

UPST

REAM

UPST

REAM

COLU

MN

UPST

REAM

COLU

MN

UPST

REAM

COLU

MN

UPST

REAM

COLU

MNCO

LUMN

ROW

ROW

UPST

REAM

COLU

MN

ROW

COLU

MN

ROW

UPST

REAM

COLU

MN

ROW

ROW

UPST

REAM

UPST

REAM

COLU

MN

ROW

ROW

UPST

REAM

ROW

ROW

UPST

REAM

COLU

MN

COLU

MN

ROW

UPST

REAM

ROW

COLU

MN

ROW

UPST

REAM

ROW


P/N: 106945-306 E Wanco, Inc.

9.5 Trailer and Tail Lights

SCRE

W T

ERMI

NALS

TO

FRAM

E(W

HITE

WIR

ES)

RIGH

T TA

IL LIG

HT

LICEN

SE P

LATE

L LIG

HT

CRIM

P BR

OWN

WIR

E TO

BLAC

K W

IRE

FROM

LIGH

T


P/N: 106945-306 E Wanco, Inc.

9.6 Battery Box

COMP

UTER

BOX

INPU

TCO

NNEC

TOR,

BATT

ERY

AND

SOLA

R(A

S VI

EWED

FRO

MW

IRIN

G SI

DE)

TO T

ERMI

NAL B

LOCK

IN M

ESSA

GE B

OARD

(AND

SOL

AR P

ANEL

S)

RED

BLK

BLK

BLK

BLK

RED

BATT

ERY

BOX

RED

NEG

POSPOS

NEG

CHAS

SIS

GROU

ND

RED

1

105

96

34

7

2

8

1615

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1411

1312

SP

+R

ED

BLK

NEG

NEG

POS

POS

12 V

DC

BA

TTE

RY

CH

AR

GE

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POS

NEG

POS

NEG


P/N: 106945-306 E Wanco, Inc.

10. Parts Lists 10.1 Message Director (left side view)

1

42

4847

51

2151

5622

50

5254

5312

11

17b

1920 171817

a 55141516 13

5354

52910

55

4950

650

8 749

51

45 38 36

5 444 37

3 235

4046 39

41

3837

4357


P/N: 106945-306 E Wanco, Inc.

10.2 Message Director (rear view)


P/N: 106945-306 E Wanco, Inc.

10.3 Message Director Parts List ITEM PART No. DESCRIPTION QTY 1 108744-001P1 FRAME WLDMT-TRLR,WVT3-06, (ORANGE) 1 2 103239-002P1 SWIVEL BASE WLDMT-MB.TRK,W/BRK.LVR, 1 3 103331-002P1 FRAME-VT3,SIGN BOARD,LOW PROF,ORN 1 4 103329-002P1 TWR WLDMT-OUTER,VT3,LOW PROF,ORN 1 5 101007-001 WINCH-H.CRANK,1500 LB CAP'Y,11"HDL, 1 6 103330-002 TWR WLDMT-INNER,VT3,04 1 7 108707-001 BRD ASSY-WVT3-06 (14" LED) 1 8 104608-002 SOL.PNL-120W,KYOCERA 1 8a 107741-001 SOL.PNL.ASSY-85W,KYOCERA,PIG TL 3 8b 103430-001 CHAN-SOL.PAN.FR,3/8&5"FLGx77,W/ 2 9 101677-002 HITCH-BALL,2"DIA,FITS 3"DRAWBAR 1 10 100943-001 JACK-SWIVEL,2000#,TOP WIND,SHORT 1 11 103409-001 DRAWBAR WLDMT-T/D&VT3,3x72 1 12 105061-003 HARNESS-TAIL LIGHT,MAIN,128" LONG 1 13 102791-001 BUMPER-RBR,SCR,1.625ODx1.000H 1 14 100143-001 JACK-SWIVEL,2000#,TOP WIND,MED 4 15 107186-003 COMP BOX ASSY, LMB, NTCIP 1 16 101772-001 TIRE/WHL ASSY-ST205/75D15B,15"X5 2 17 107929-002 RADAR ASSY,DECATUR SI-2,MESS BRD 1 17a 106550-001P2 BKT-RADAR HEAD MOUNT,BLK 1 17b 103807-001 COVER-RADAR,FOR VT3 M/D 1 18 102317-001 CALIPER BRAKE-MECH,HVY.DUTY,CAST 1 19 102316-002 BRAKE LEVER-PARKING,FLG.MNT,MODIFIE 1 20 108624-001 HARN ASSY-COMP TO BRD,WVT3-04 1 21 100394-001 LATCH-SPR LDed,1/2DIA.ROD,LH 1 22 100166-001 PULLEY-SINGLE GROOVE,STL,3"OD 1 24 100783-001 LIGHT-LICENSE PLT,W/BRACKET 1 25 106052-001 WEAR PAD,UHMWPE,PSA,.040X4"X7-1/8BK 2 26 106169-001P1 CLAMP,CRADLE REST LINER 2 27 103825-001 SIGHT TUBE-MESSAGE BOARD,VT3 1 28 101987-001 CABLE ASSY-SUNLCR5,SW.B,1/4",DBW/SB 1 29 102409-002 TAIL LT-STOP,TURN&TAIL,SLT.RECESSED 2 30 106774-001 HARN ASSY-TAIL LIGHT,WVT3-04 1 31 101343-001 AXLE ASSY-2000 LB,60"TRK,46.5"SC 1 32 104183-002PC1 BATT.BOX ASSY-BASE UNIT,6 BATT 1 32a 104152-001PC1 COVER-BAT.BX,RVT DSGN 1 32b 106318-001 BATT BOX ASSY-TRLR,MMB 1 32c 106043-001P1 COVER,BAT BOX,RIV,MTRX BRD 1 33 104783-001 CHGR ASSY-BATT,45A 12VDC 1 34 104131-001 BAT- 6V,Dcycle,220AH 6 35 100673-007 SCR-HEX,.750(3/4)-10x2.000,G5,ZPS 1 36 100673-016 SCR-HEX,.750(3/4)-10x4.500,G5,ZPS 3 37 106258-001 WSHR,.812(3/4)x1.875x.1094,SS 9


P/N: 106945-306 E Wanco, Inc.

ITEM PART No. DESCRIPTION QTY 38 100214-001 NUT-HEX,NYLinsr,.750(3/4)-10,ZP 5 39 100677-001 WSHR-THRUST,1.250x1.937x.062 3 40 100678-001 BEARING-THRUST,1-1/4" (1.937"OD) 1 41 106015-001F GUIDE BLOCK-1"X1"X 5/16"THK,NYLON 2 42 105811-001F GUIDE BLOCK-3-1/8"X1"X 5/16"THK,NYL 3 43 106313-001 SCR-PAN,.250(1/4)-20x.375,PH,TC,ZPS 8 44 100072-004 SCR-HEX,.375(3/8)-16x1.250,G5,ZPS 3 45 104178-001 WSHR,.406(3/8)x.875x.045,SS 6 46 100073-001 NUT-HEX,NYLinsr,.375(3/8)-16,ZP 3 47 103422-003 PIN-CLV,.500DIA,MODIFIED FOR MB 1 48 101320-001 PIN-COTTER,1/8 DIA X 1-3/4 LG. 1 49 100216-012 SCR-HEX,.500(1/2)-13x3.250,G5,ZPS 8 50 104856-001 WSHR,.515(1/2)x .875x.062an960,SS 18 51 100217-001 NUT-HEX,NYLinsr,.500(1/2)-13,ZP 9 52 104064-017 SCR-HEX,.500(1/2)-13x5.000,G8,ZPS 4 53 100713-001 LKWSHR-SPT,.512(1/2)x.869x.125,ZP 4 54 100652-001 NUT-HEX,.500(1/2-13),ZPS 4 55 102919-003 RING-SNAP,FULTON SWIVEL JACKS,2.50" 5 56 100216-008 SCR-HEX,.500(1/2)-13x2.250,G5,ZPS 1


P/N: 106945-306 E Wanco, Inc.

10.4 Display Panel Parts Photos 10.4.1 Panel Wiring

1

29 22

28

23

24

27 (NOT SHOWN) 25

28


P/N: 106945-306 E Wanco, Inc.

10.4.2 Display Card Assembly

3

15

27


P/N: 106945-306 E Wanco, Inc.

10.4.3 Fan Assembly

10.4.4 Photocell Assembly

4 5 19 32 33

8 46

6 7 9

36 37 42


P/N: 106945-306 E Wanco, Inc.

10.4.5 Terminal Block

10


P/N: 106945-306 E Wanco, Inc.

10.5 Display Panel Parts List ITEM PART No DESCRIPTION QTY 0 108707-001 BOARD ASSEMBLY- WVT3-06 ITEMS

1-45 1 107552-001P2 CABINET ASSEMBLY- WVTM/WVT3-06 1 2 107553-001 DOOR ASSEMBLY- CABINET, WVTM/WVT3-06 ITEMS

2A-T 2A 106924-001P2 FRAME- CABINET DOOR, TOP, MMB 1 2B 106925-001P2 FRAME- CABINET DOOR, LH, MMB 1 2C 106926-001P2 FRAME- CABINET DOOR, RH, MMB 1 2D 106927-001P2 FRAME- CABINET DOOR, BOTTOM, MMB 1 2E 104739-002P2 BRACKET- CORNER, LH, MB DOOR FRAME 1 2F 104739-001P2 BRACKET- CORNER, RH, MB DOOR FRAME 1 2G 104739-004P2 BRACKET- CORNER, LH, TOP, MB DOOR FRAME 1 2H 104739-005P2 BRACKET- CORNER, RH, TOP, MB DOOR FRAME 1 2J 106928-001 WINDOW- CABINET DOOR, LEXAN, 129-1/4x71-1/4 1 2K 104738-000 WEATHER STRIP- TRIMSEAL, 3/8" BULB, 3/32"EDGE 34' 2L 101801-002P2 HINGE-BUTT, STAINLESS.STEEL, 3"SQx.093"LEAF 4 2M 102166-001 TUBING-ROUND, STEEL, 1/2" ODx.058x1/2" 2 2N 100627-007 SCREW- HEX, 5/16-18x2", GRADE 5, ZINC PLATED 2 2P 100237-001 WASHER, 5/16", STAINLESS STEEL 18 2Q 100239-001 NUT- HEX, NYLON INSERT, 5/16-18, ZINC PLATED 2 2R 105581-001 NUT- HEX, NYLON INSERT, 5/16-18, LOW PROFILE 2 2S 106368-001 SCREW- FLAT HEAD, 8-32x1", ZINC PLATED 2 2T 104606-001 RIVET-.187x.375-.625,STL 12 3 108345-001 CHARACTER ASSY-3 LINE, 14” LED 24 4 106850-001 PCB ASSEMBLY MATRIX PHOTOCELL 1 5 107794-001P2 BRACKET-P-CELL, MMB,TRAILER MOUNTED 1 6 107092-001 GUARD-FAN 2 7 102873-002 FAN ASSEMBLY-CABINET, BALL BEARING, 12VDC 2 8 106543-001 FAN HOLDER/COVER,MB CABINET 2 9 102284-001 FILTER AND GUARD, FAN 2 10 103097-001 TERMINAL STRIP, .438 PITCH, #6 SCREW, 20 POS 1 11 105421-001 LATCH-RUBBER HOOD, 4-7/8" L, W/A BRACKET 6 12 102275-001 LATCH & STAPLE-PADLOCK, STAINLESS.STEEL,

BOLT-ON 1

13 102406-002 HOLDER-DOOR, TELESCOPING, 17.00" OPEN 2 14 102314-001 BUMPER-RUBBER, SCREW, 9/16"ODx. 1/2" H 144 15 107557-001 NUT, MOLDED, PCB HOLDING, BLACK 146 16 103151-001 WEATHER STRIP-PSA RUBBER, 1/2x1-1/2x130" 1 17 106348-003 WEATHER STRIP- PSA 1/4x1x126" 1 18 106348-006 WEATHER STRIP- PSA 1/4x1x72-1/2" 2 19 106248-001 PLUG-WINDOW,.3/4"DIA, CLEAR, ABS 1 20 102269-001 BUSHING-SNAP, 1-5/8", BLACK (2"HOLE) 40 21 104175-001 DECAL-"WANCO, DENVER COLORADO" 1


P/N: 106945-306 E Wanco, Inc.

ITEM PART No DESCRIPTION QTY 22 108572-001 HARNESS ASSEMBLY-WVT3, TOP ROW 1 23 108573-001 HARNESS ASSEMBLY-WVT3, MIDDLE ROW 1 24 108574-001 HARNESS ASSEMBLY-WVT3, BOTTOM ROW 1 25 108628-001 HARNESS ASSEMBLY-PHOTOCELL/TEMP 1 26 108629-001 HARNESS ASSEMBLY-SOLAR PANEL, WVTM/WVT3 2 27 108624-001 HARNESS ASSEMBLY- COMPUTER TO BOARD,

HYDRAULIC/HAND WINCH,MB ITEMS 27A-J

27A 100518-001 PLUG-STRAIGHT, SER.4 CPC, 23-22M 1 27B 100519-001 CLAMP KIT-CABLE, #23, 703DIA CABLE MAX 1 27C 104126-001 CONT-FEM, AMP TYPE XII, 10AWG, TP 2 27D 100527-001 CONT-FEM, AMP TYPE VI, 18-16AWG, TP 12 27E 101062-000 CORD-ELECTRIC, 18GA/18 & 14GA/2, NONCOIL 14-1/2' 27F 101808-000 CORD-ELECTRIC, 10(19/23)/2, RED & BLK 14-1/2' 27G 106297-001 CONDUIT- 3/4,LIQUID TIGHT, BLACK 11-3/4' 27H 106299-001 CONNECTOR- 90 DEG, 3/4, LIQUID TIGHT, BLACK 2 27J 103667-001 NUT-CONDUIT, 3/4-14 NPT, ZINC PLATED 2 28 108625-001 CABLE ASSY-FAN 2 29 108626-001 CABLE ASSY, DATA, CHAR/TERM 1 30 108627-001 CABLE ASSY, DATA, CHAR/CHAR 1 32 105686-001 SCREW-PAN, .6-32 X 3/8, PHH, ISEM, ZINC PLATED 2 33 103534-001 NUT-HEX, KEPS, 8-32, ZINC PLATED 1 34 103712-001 SCREW-PAN, 8-32X1/2", PHH, SEM, ZINC PLATED 24 35 101491-001 WASHER, #8, ZINC PLATED 16 36 106781-001 SCREW-FLAT,.164(#8)-32x2.250,PH,ZPS 4 37 106363-001 SCREW-PAN,.164(#8)-32x.500,PH,SCSEM,Z 10 38 100207-003 SCREW-HEX, 1/4-20x1", GRADE 5, ZINC PLATED 4 39 100236-001 WASHER, 1/4, ZINC PLATED 8 40 100238-001 NUT-HEX, NYLON INSERT, 1/4-20, ZINC PLATED 4 41 104463-001 RIVET- 3/16", STEEL/ALUMINUM 12 42 101490-001 NUT-HEX, NYLON INSERT, #8-32, ZINC PLATED 6 43 105964-001P2 VENT-CABINET, MMB, TRAILER MOUNTED 6 44 105965-001F FILTER-VENT, CAB,1 1/4X14 3/8, MMB, TRAILER 6 45 106384-001 PLUG-HOLE, 1-3/4" DIA, BLACK PLASTIC 2 46 106992-001 GASKET SET,FAN COVER 2


P/N: 106945-306 E Wanco, Inc.

10.6 Control Box (front view)

5 12 50 34 45

47

2

4527

13

3 6 18 4 26

Manu

al22

2124

25

32

144035

4847

4815

46

117

23

35

3435

56 OPTI

ONAL

MOD

EMSH

OWN

29

419

44 358

AA

717

3641

37

54

5646


P/N: 106945-306 E Wanco, Inc.

10.7 Control Box (rear view)

30

1

3319

3320

31

4243

46 515544 53

4931

4847


P/N: 106945-306 E Wanco, Inc.

10.8 Control Box Parts List ITEM PART No. DESCRIPTION QTY 0 107186-003 COMP BOX ASSY, LMB, NTCIP ITEMS

1-55 EXCEPT ITEM 8

1 105470-001P3 ENCLOSURE WELDMENT, MAIN CONTROL PCB 1 2 104456-001P3 DOOR WELDMENT, STD MB 1 3 106116-001 PANEL WELDMENT, MAIN CONTROL, MMB 1 4 102295-001 KEYBOARD-COMPUTER, PS/2 1 5 105566-006 POWER CONTROL ASSY-TRAILER MOUNTED MCA

(SOFTWARE VERSION NUMBER IS REQUIRED WHEN ORDERING REPLACEMENT)

1

6 104865-002 PCB ASSY-MAIN CONTROL, MMB (SOFTWARE VERSION NUMBER IS REQUIRED WHEN ORDERING REPLACEMENT)

1

7 106400-001 TEXT DISPLAY ASSY-4x40 LCD,W/ADAPTER 1 8a 106402-004 PCB ASSY INDICATOR, NO RAD NO LIFT

(ORDERED SEPERATLY) 1

8b 106402-003 PCB ASSY INDICATOR, RADAR, NO LIFT (ORDERED SEPERATLY)

1

9 106376-001 CABLE ASSEMBLY-DISPLAY TO MAIN CONTROL, MMB

1

10 11 106374-001 REED SWITCH ASSEMBLY- MMB/LMB 1 12 106373-001 HARNESS ASSEMBLY-CONTROL PANEL, MMB 1 13 106946-001F CABLE ASSY-POWER TO MAIN CONTROL BOARD 1 14 106239-001 SWITCH, REED MAGNET 1 15 105546-001P3 BRACKET- CORNER, IBM09N554 KEYBOARD

RESTRAINT 2

16 17 106131-002 WINDOW, COMP BOX, TRAILER, LMB 1 18 100164-001 BUMPER-RUBBER, 1.500ODx.312IDx.625H 1 19 104452-001 HINGE- SJ, LH SET, 2.000x1.680x.080, MOD 1 20 104452-004 HINGE- SJ, RH SET, 2.000x1.680x.080, MOD 1 21 105720-001 HANDLE-T, 2.375 SHAFT, 2X K143 KEYS 1 22 103708-003 CAM-T HANDLE, UW 105720-001 1 23 103708-002 GASKET-T HANDLE, UW 105720-001 1 24 103705-001 SPACER-TUBING,1/2 SQx16GAx3/4 1 25 103707-001 BRACKET-LOCKING ARM FOR LOCKING 2 26 104220-000 WEATHER STRIP w/PSA,.500x.500PF, EPDM/ACRYLIC 6.58' 27 100191-001 LIGHT-LICENSE/PANEL, 12 VDC, WHITE 1 28 29 106310-001 FUSE BLOCK-ATC/ATO, 4 POSITION 1 30 104161-002 COVER-BACK, CONTROL BOX, WHITE, MMB 1 31 106278-001P3 BRACKET-TRAILER HARNESS, COMPUTER BOX,

MMB 1


P/N: 106945-306 E Wanco, Inc.

ITEM PART No. DESCRIPTION QTY 32 105653-001 NUT-SECURITY, SLOPED, 3/8-16, ZINC PLATED 1 33 104448-028 SCREW-BUTTON HEAD, PIN, HEX SOCKET, #10-

32x1/", STAINLESS STEEL 4

34 101805-001 SCREW-PAN, #10-32x1/2", PHH 4 35 105686-001 SCREW-PAN,6-32X3/8", PHH, ISEM, ZINC PLATED 11 36 104189-001 NUT-HEX, .138(6-32), NYLON 4 37 106242-001 SPACER-ROUND, NYLON 4 38 39 40 103124-001 NUT-HEX, KEPS, 6-32, ZINC PLATED 8

41 106240-001 GROMMET-RUBBER, FOR 3/8" DIA. HOLE 1 42 103169-001 WASHER-SEG,.275x.625x.109, STL/NPRN 2 43 101805-002 SCREW-PAN, 10-32x3/4", PHH, ZINC PLATED 2 44 104529-001 RVT- 1/8"x.126-.187, BUTTON HEAD, AL/AL 4 45 105619-001 SCREW-PAN, 4-40X3/8, PHH, SEM, ZINC PLATED 4 46 105688-001 SCREW-PAN, 8-32X3/8", PHH, ESEM, ZINC PLATED 9 47 100207-002 SCREW-HEX, 1/4-20x3/4", G5, ZINC PLATED 4 48 100236-001 WASHER, 1/4, ZINC PLATED 4 49 100208-001 LOCK WASHER-SPLIT, 1/4, ZINC PLATED 2 50 104881-001 FUSE-3A, FOR MINI FUSE HOLDER 1 51 106112- 12.000 PHOTOCELL ASSY-MOLDED,7/16x12 2 52 53 103828-001 NUT-HEX, KEPS, 4-40, ZINC PLATED 6 54 106406-001 PLUG-HOLE, .218 DIA, WHITE PLASTIC 7 55 102714-001 PLUG_HOLE, .875 DIA, BLACK PLASTIC 1 manual 106812-001 USER’S GUIDE, LAMINATED

OPTIONAL EQUIPMENT

106453-001 MODEM KIT-DATA REMOTE 107073-001 MODEM ASSY-GPRS RAVEN,ANT,CABLES,BR 107073-002 MODEM ASSY-CDMA RAVEN,ANT,CABLES,BR 106452-001 RADAR KIT, DECATUR SI-2, MESSAGE BOARD


P/N: 106945-306 E Wanco, Inc.

11. Winch Cable Replacement 11.1 Cable Pin

• If the winch cable is frayed due to normal use, the cable pin should not need replacement. • If the winch cable broke due to stress of having the mast hitch pin engaged while operating the

winch, then it is likely the cable pin is also damaged. • Crawl under the trailer with a flashlight and inspect the cable pin. If the pin is bent or in poor

condition, it must be replaced. If it is badly bent, it may need to be cut out.

11.2 Required Equipment 11.2.1 Obtain the following:

• 3/8” Wrench or socket & ratchet (to remove pulley nuts) • Needle-nose or vice-grip pliers (to remove the cotter pin) • Screwdrivers (to support guide blocks) • Bolt cutters or power saw (if cable pin is badly bent and must be severed) • Electrician’s fish tape/wire (optional, to help route new cable up the tower)

11.2.2 Order the following spare parts: • 1 Winch cable • 1 Cotter pin (do not reuse old pin) • 1 Cable pin (if necessary)

11.3 Replacement Procedure 11.3.1 Cable replacement generally requires two people to feed the new cable through the tower, one

above and one below. 11.3.2 Unwind and detach the old cable from the hand winch (use the wrench to loosen the U-bolt

cable clamp). 11.3.3 Remove the cable from the 3” pulley at the top of the tower. 11.3.4 If not using a fish tape, lodge a screwdriver through the cable opening to support one of the

guide blocks. Loosen and remove the guide block, taking care not to allow the block to fall into the tower.

11.3.5 Rotate the tower until the outer and inner cable pin holes align. See diagram. 11.3.6 Crawl under the tower. Using needle-nose pliers, remove the cotter pin from the cable pin and

discard. (Do not reuse the old cotter pin as it is usually damaged during removal. The old cable pin may be reused if in good condition.)

11.3.7 If cable pin is not being replaced, remove it from the right-side wall and release the cable. If cable pin is to be replaced, remove it entirely and discard. If it is badly bent, cut it in half.

11.3.8 Pull the old cable down through the tower (with second person guiding it from above) and remove it entirely.

11.3.9 Clean the opening in the swivel base of any dirt, rocks or metal fragments. 11.3.10If cable pin is being replaced, install new pin.


P/N: 106945-306 E Wanco, Inc.

11.3.11Insert the fish tape over the pulley and between the guide blocks. Fish the tape down through the tower sections, making sure it passes through the hole provided in the inner tower piece. Attach the cable to the fish tape. Pull the tape and cable up between the blocks and over the pulley. If not using a fish wire, manually push the cable up the tower, however this step can be quite difficult and requires care and patience.

11.3.12Once the cable is through the top opening, pull it through until the bottom end is positioned at the cable pin. Push the cable pin through the cable eye. Push the cable pin through the tower wall. Secure the cable pin with the new cotter pin, using needle-nose pliers.

11.3.13Re-attach the guide block(s). Again use a screwdriver to support the block and take care not to drop the block into the tower.

11.3.14Verify the new cable is routed over the pulley correctly. 11.3.15Attach the new cable to the hand winch and wind up the slack.

11.4 Tower Diagram

WITHDRAW CABLE PIN THROUGHHOLES IN SWIVEL BASE ANDOUTER TOWER SECTION

CABLE PIN COTTER PIN

FEED FISH TAPE INTO OUTER TOWERSECTION HERE (BETWEEN GUIDE BLOCKS)

ENLARGEDLEFT SIDE CROSS SECTION ENLARGED

REAR CROSS SECTION

HOLE ININNER TOWER

owner’s guide · revised 7/11/2007 owner’s guide: wvt3-07 6/51 p/n: 106945-306 e wanco, inc. 3....

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