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MQ Multiquip LT6K5 Operation Manual

50 hz light tower/generator (kohler kdw 1003 diesel engine)
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OPERATION MANUAL
MODEL LT6K5 50 HZ
LIGHT TOWER/GENERATOR
(KOHLER KDW 1003 DIESEL ENGINE)
Revision #0 (06/02/15)
To fi
the latest revision of this
publication, visit our website at:
www.multiquip.com
THIS MANUAL MUST ACCOMPANY THE EQUIPMENT AT ALL TIMES.
PN 34910

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Summary of Contents for MQ Multiquip LT6K5

  • Page 1 OPERATION MANUAL MODEL LT6K5 50 HZ LIGHT TOWER/GENERATOR (KOHLER KDW 1003 DIESEL ENGINE) Revision #0 (06/02/15) To fi the latest revision of this publication, visit our website at: www.multiquip.com THIS MANUAL MUST ACCOMPANY THE EQUIPMENT AT ALL TIMES. PN 34910...

  • Page 2: Fuel Chemical Warning

    FUEL CHEMICAL WARNING Diesel engine exhaust and some of its constituents are know to cause cancer, birth defects and other reproductive harm. PA GE 2 —LT6K5 50 HZ LIGHTTOWER• OPERA TION MANUAL —REV . #0 (06/02/15)

  • Page 3: Table Of Contents

    T roubleshooting (Lamps) ......62-64 Panel Light/Hour Meter Wiring Diagram ..... 66 Electronic Components Locator ....... 67 Wiring Diagram(Generator/Lights) ....68-69 Lights Locator Diagram ......... 70 Lights Wiring Diagram ........71 LT6K5 50 HZ LIGHTTOWER• OPERA TION MANUAL —REV . #0 (06/02/15) —PAGE 3...

  • Page 4: Safety Information

    Indicates a hazardous situation which, if not avoided, Addresses practices not related to personal injury. COULD result in MINOR or MODERA TE INJURY . Pressurized fluid hazards Electric shock hazards PA GE 4 —LT6K5 50 HZ LIGHTTOWER• OPERA TION MANUAL —REV . #0 (06/02/15)
  • Page 5 Possibility of electrocution exists causing severe bodily harm P/N 34621 even death! WARNING Crush/Pinch Hazard Keep hands clear. Moving parts can crush and pinch. P/N 34622 LT6K5 50 HZ LIGHTTOWER• OPERA TION MANUAL —REV . #0 (06/02/15) —PAGE 5...
  • Page 6  DONOT use the equipment for any purpose other than its intended purposes or applications. PA GE 6 —LT6K5 50 HZ LIGHTTOWER• OPERA TION MANUAL —REV . #0 (06/02/15)
  • Page 7  T oprevent thelight tower fromoverturning, NEVERuse serious damage to the equipment or engine. in winds that exceed 65 mph (105 kph). LT6K5 50 HZ LIGHTTOWER• OPERA TION MANUAL —REV . #0 (06/02/15) —PAGE 7...
  • Page 8  NEVER tip the engine to extreme angles during lifting as it may causeoil togravitateintothecylinder head, making the engine start difficult. PA GE 8 —LT6K5 50 HZ LIGHTTOWER• OPERA TION MANUAL —REV . #0 (06/02/15)
  • Page 9  ALWA YS shutdown engine before transporting.  Make sure the hitch and coupling of the towing vehicle are rated equal to, or greater than the trailer “gross vehicle weight rating.” LT6K5 50 HZ LIGHTTOWER• OPERA TION MANUAL —REV . #0 (06/02/15) —PAGE 9...
  • Page 10 FORKLIFT POCKETS  DONOTsecuretheunit byrunningastrapor chainover the tongue of the light tower. This may cause severe damage to the unit. PA GE 10 —LT6K5 50 HZ LIGHTTOWER• OPERA TION MANUAL —REV . #0 (06/02/15)
  • Page 11 NOTICE  There is a permanent conductor between generator (stator winding) and the frame. LT6K5 50 HZ LIGHTTOWER• OPERA TION MANUAL —REV . #0 (06/02/15) —PAGE...
  • Page 12 CAUTION  ALWA YS disconnect the NEGA TIVE battery terminal before performing service on the generator.  ALWA YSkeepbatterycablesingoodworkingcondition. Repair or replace all worn cables. PA GE 12 —LT6K5 50 HZ LIGHTTOWER• OPERA TION MANUAL —REV . #0 (06/02/15)
  • Page 13 The label must remain with the engine for its entire life. If a replacement emission label is needed, please contact your authorized Kohler Engine Distributor. LT6K5 50 HZ LIGHTTOWER• OPERA TION MANUAL —REV . #0 (06/02/15) —PAGE...

  • Page 14: Lamp Footcandle Plot

    LAMP FOOTCANDLE PLOT Figure 1. Lamp Footcandle Plot PA GE 14 —LT6K5 50 HZ LIGHTTOWER• OPERA TION MANUAL —REV . #0 (06/02/15)

  • Page 15: Specifi Ations

    13 x 4.5 in. (330 x 114 mm) Axle Capacity 2,000 lbs. (907 kg.) Hub T ype 5-Lug Suspension T ype 4-Leaf Electrical T ail-Light Connector 4-Wire Flat LT6K5 50 HZ LIGHTTOWER• OPERA TION MANUAL —REV . #0 (06/02/15) —PAGE...
  • Page 16 Cooling System Liquid-cooled Coolant Capacity 1.25 U.S. Quarts (4.75 Liters) Starting Method Electric Start Battery T ype Group 24 T otal Weight (Dry) 187.3 lbs. (85 Kg.) PA GE 16 —LT6K5 50 HZ LIGHTTOWER• OPERA TION MANUAL —REV . #0 (06/02/15)

  • Page 17: Dimensions

    Height (Mast Stowed Position) 73.7 in. (187 cm.) Ground Clearance (FromAxle) 18.6 in. (47.2 cm.) Width (T ow Ready) 42.4 in. (108 cm.) Width (Outriggers Deployed) 79 in. (201 cm.) LT6K5 50 HZ LIGHTTOWER• OPERA TION MANUAL —REV . #0 (06/02/15) —PAGE...

  • Page 18: General Information

    PANEL LIGHT A panel light automatically illuminates the control panel when the engine access door is opened (air filter side). This feature is convenient for night deployment. PA GE 18 —LT6K5 50 HZ LIGHTTOWER• OPERA TION MANUAL —REV . #0 (06/02/15)
  • Page 19 NOTES LT6K5 50 HZ LIGHT TOWER • OPERATION MANUAL - REV.#0 (06/02/15) - PAGE 19...

  • Page 20: Components

    5. Panel Light —When the cabinet door is raised, the prevent rolling. light will automatically turn on.When the cabinet door is closed, the light will turn off. PA GE 20 —LT6K5 50 HZ LIGHTTOWER• OPERA TION MANUAL —REV . #0 (06/02/15)
  • Page 21 23. Battery — The 12-volt DC battery (CA:550/ 17. Mast ExtensionWinch—Usethiswinchtoextendthe CCA:430) is shipped wet and is ready for use. mast tothedesiredheight.Maximumheight is31.5feet Battery is shown here for clarity. (9.60 meters). LT6K5 50 HZ LIGHTTOWER• OPERA TION MANUAL —REV . #0 (06/02/15) —PAGE...
  • Page 22 29. RearJackstands/Outriggers—Thereisonejackstand located at the rear of the trailer. Use this jackstand and outrigger to level and support the light tower. PA GE 22 —LT6K5 50 HZ LIGHTTOWER• OPERA TION MANUAL —REV . #0 (06/02/15)

  • Page 23: Control Panel

    CONTROL PANEL HOURS = NOT USED Figure 6. Control Panel/Ignition Switch LT6K5 50 HZ LIGHTTOWER• OPERA TION MANUAL —REV . #0 (06/02/15) —PAGE...
  • Page 24 9. Normal Operation Indicator —This alarm LED (green) lights when the engine is functioning normal. 10. Oil PressureAlarmIndicator —Thisalarm LEDflasheswhentheoil pressurehasfallen toolowfor normal engineoperation.TheLED will stay on until the problemis corrected. PA GE 24 —LT6K5 50 HZ LIGHTTOWER• OPERA TION MANUAL —REV . #0 (06/02/15)

  • Page 25: Engine Components

    19. V-Belt — ALWA YS make sure the V-belt is properly these lifting points. tensioned. A loose or defective V-belt can adversely 11. Oil Dipstick—Removetocheckamountandcondition affect the performance of the engine. of oil in crankcase. LT6K5 50 HZ LIGHTTOWER• OPERA TION MANUAL —REV . #0 (06/02/15) —PAGE...

  • Page 26: Inspection

    T able 2 for engine oil capacity. latchedOPENandthelighttower hasbeenoperatingin hard, gusty rains. Anytime there is fluid buildup within thetubarea, drainimmediatelyandhandleanddispose fluids properly. Figure 9. Oil Dipstick PA GE 26 —LT6K5 50 HZ LIGHTTOWER• OPERA TION MANUAL —REV . #0 (06/02/15)
  • Page 27 DO NOT allow the wrench or any metallic part to come in contact with the battery's negative (-) terminal post.This may result in an electrical short circuit or an explosion. Figure 10. Adding Fuel LT6K5 50 HZ LIGHTTOWER• OPERA TION MANUAL —REV . #0 (06/02/15) —PAGE...
  • Page 28 Kohler KDW1003 5.18 qt. (4.9 liters) OPERA TION INFREEZINGWEA THER Figure 12. Fan Belt Tension Whenoperatinginfreezingweather, makesuretheproper amount of antifreeze (T able 6) has been added. PA GE 28 —LT6K5 50 HZ LIGHTTOWER• OPERA TION MANUAL —REV . #0 (06/02/15)

  • Page 29: Setup

    3. On the corresponding male connector, locate the key between the two connectors. See Figure 15. tab (B) as shown in Figure 14. Figure 14. Male Connector LT6K5 50 HZ LIGHTTOWER• OPERA TION MANUAL —REV . #0 (06/02/15) —PAGE 29...
  • Page 30 5. Check behind the light tower and make sure all personnel and objects are clear of the mast. PA GE 30 —LT6K5 50 HZ LIGHTTOWER• OPERA TION MANUAL —REV . #0 (06/02/15)
  • Page 31 PULL SUPPORT FORKLIFT POCKET USED AS A MAST ROTATION HANDLE MAST MAST ROTATION VERTICAL MAST LOCKING WINCH KNOB MAST EXTENSION HANDLE MAST LOCK/RELEASE LEVER Figure 25. Mast Operation LT6K5 50 HZ LIGHTTOWER• OPERA TION MANUAL —REV . #0 (06/02/15) —PAGE...
  • Page 32 3. When the lights are facing in the desired direction, tighten the mast rotation lock knob to lock the mast in place. PA GE 32 —LT6K5 50 HZ LIGHTTOWER• OPERA TION MANUAL —REV . #0 (06/02/15)

  • Page 33: Operation

    LT6K5 50 HZ LIGHTTOWER• OPERA TION MANUAL —REV . #0 (06/02/15) —PAGE...
  • Page 34 LAMP(ON) (TURN ON) ON/OFF Figure 24. Resetting 230 VAC GFCI Breaker SWITCH (ON) CONTACT INDICATOR STATUS LAMP LAMP(ON) (OFF) Figure 22. 230 VAC GFCI Breaker (ON) PA GE 34 —LT6K5 50 HZ LIGHTTOWER• OPERA TION MANUAL —REV . #0 (06/02/15)
  • Page 35 2. Grab hold of the mast lock release lever and pull upwards. This will release the mast so that it can be placed in the horizontal (stow) position. LT6K5 50 HZ LIGHTTOWER• OPERA TION MANUAL —REV . #0 (06/02/15) —PAGE...

  • Page 36: Maintenance

    Generator Measure Insulation Resistance Over 3Mohms —Replace engine oil and filter at 100 hours, first time only. —Replace fuel filter at 250 hours, first time only. PA GE 36 —LT6K5 50 HZ LIGHTTOWER• OPERA TION MANUAL —REV . #0 (06/02/15)
  • Page 37 CAUTION PAPER FILTER ALWAYS allow the engine to cool ELEMENT before servicing. NEVER attempt any maintenance work on a hot engine. Figure 27. Cleaning Inner Paper Filter LT6K5 50 HZ LIGHTTOWER• OPERA TION MANUAL —REV . #0 (06/02/15) —PAGE...
  • Page 38 Always pour fuel through a mesh filter. Figure 29. Tub Access Cover Removal 3. Removetheretainingbolt andseal washer that secures the access cover to the tub bracket. Set cover and gasket aside. PA GE 38 —LT6K5 50 HZ LIGHTTOWER• OPERA TION MANUAL —REV . #0 (06/02/15)
  • Page 39 10. Run the engine at idling for a short time, then stop CRACKS the engine. Recheck the oil level and fill as necessary. SIDEWALL WEAR Figure 32. V-Belt Inspection LT6K5 50 HZ LIGHTTOWER• OPERA TION MANUAL —REV . #0 (06/02/15) —PAGE...
  • Page 40 3. Prepare a container to catch the coolant, then open drain plug of the radiator or heat exchanger and drain plug of the engine, and drain the coolant. PA GE 40 —LT6K5 50 HZ LIGHTTOWER• OPERA TION MANUAL —REV . #0 (06/02/15)
  • Page 41 3. Disconnect the cable from the ball socket pin and removefromthemast pulleyandcablesheave.Detach the cable fromthe hand winch as necessary. 4. Replace the pulley and the cable as needed. LT6K5 50 HZ LIGHTTOWER• OPERA TION MANUAL —REV . #0 (06/02/15) —PAGE...
  • Page 42 Connect the second cable to the bottom of the center mast and slide the center mast into the opening of the lower mast, observing proper lifting techniques. PA GE 42 —LT6K5 50 HZ LIGHTTOWER• OPERA TION MANUAL —REV . #0 (06/02/15)

  • Page 43: Maintenance -T Railers

    Adjustable Channel If trailer wheel bearings are immersed in water, they must Y our LT6K5 trailer comes standard with a fi ed 2" ball be replaced. coupler. The tow bar channel provides a fastening option to place other couplers as shown below and in If the trailer has not been used for an extended amount Figure37.Periodicallycheckthechannel boltsfor damage...
  • Page 44 Figure 39. Leaf Suspension Components DANGER Worn or broken suspension parts can cause loss of control, damagetoequipment andseverebodilyinjury, even death! Check suspension regularly. PA GE 44 —LT6K5 50 HZ LIGHTTOWER• OPERA TION MANUAL —REV . #0 (06/02/15)

  • Page 45: Safety Guidelines -T Railers

    • There is appropriate slack in the safety chains. due to speed. • Tires are not visibly low on pressure.  Allowplenty of roomfor passing. Aruleof thumb is that thepassingdistancewithatrailer is4timesthepassing distance without the trailer. LT6K5 50 HZ LIGHTTOWER• OPERA TION MANUAL —REV . #0 (06/02/15) —PAGE...
  • Page 46 Be sure your hitch and tow vehicle are rated for the that the tow rating of the towvehicle is equal to or greater Gross Vehicle Weight Rating of your trailer. than that of the trailer. PA GE 46 —LT6K5 50 HZ LIGHTTOWER• OPERA TION MANUAL —REV . #0 (06/02/15)
  • Page 47 Also, before you start towing, adjust the mirrors so you can see the trailer as well as the area to the rear of it. LT6K5 50 HZ LIGHTTOWER• OPERA TION MANUAL —REV . #0 (06/02/15) —PAGE...
  • Page 48 T o find the weight of the trailer when the battery is running both the trailer lights and tow vehicle lights. PA GE 48 —LT6K5 50 HZ LIGHTTOWER• OPERA TION MANUAL —REV . #0 (06/02/15)
  • Page 49 Be sure the LOADRA TINGof the hitch ball is equal or greater than the load rating of the coupler. Be sure the SIZE of the hitch ball matches the size of Figure C. Ball Coupler the ball coupler. LT6K5 50 HZ LIGHTTOWER• OPERA TION MANUAL —REV . #0 (06/02/15) —PAGE...
  • Page 50 In the open position, the coupler is able to drop fully onto the hitch ball. PA GE 50 —LT6K5 50 HZ LIGHTTOWER• OPERA TION MANUAL —REV . #0 (06/02/15)
  • Page 51 • Cross chains underneath hitch and coupler with enough slack to permit turning and to hold tongue up, if the trailer comes loose. LT6K5 50 HZ LIGHTTOWER• OPERA TION MANUAL —REV . #0 (06/02/15) —PAGE...
  • Page 52 Feel the inside of the coupler for worn spots and pits.  Besurethecoupler issecuredtightlytothetongueof the trailer.All coupler fasteners must bevisibly solidagainst the trailer frame. PA GE 52 —LT6K5 50 HZ LIGHTTOWER• OPERA TION MANUAL —REV . #0 (06/02/15)
  • Page 53 Using the trailer jack, test to see that you can raise the rear of the tow vehicle by1-inch after the coupler is locked to the hitch. LT6K5 50 HZ LIGHTTOWER• OPERA TION MANUAL —REV . #0 (06/02/15) —PAGE...
  • Page 54 This certification/VIN label will indicate the trailer’s Gross Vehicle Weight Rating (GVWR). This is the most weight the fully loaded trailer can weigh. It will also provide the PA GE 54 —LT6K5 50 HZ LIGHTTOWER• OPERA TION MANUAL —REV . #0 (06/02/15)
  • Page 55 These actions, along with other care and maintenance activities, can also: LT6K5 50 HZ LIGHTTOWER• OPERA TION MANUAL —REV . #0 (06/02/15) —PAGE...
  • Page 56 This information is used to contact consumers if a tire defect requires a recall. Figure J. UTQGS Tire Information TirePlyCompositionandMaterialsUsed:Thenumber of pliesindicatesthenumber of layersof rubber-coatedfabric PA GE 56 —LT6K5 50 HZ LIGHTTOWER• OPERA TION MANUAL —REV . #0 (06/02/15)
  • Page 57 If the rim is cracked, the air pressure in the inner tube may cause piecesof therimtoexplode(break off) withgreat force and cause serious eye or bodily injury. LT6K5 50 HZ LIGHTTOWER• OPERA TION MANUAL —REV . #0 (06/02/15) —PAGE...
  • Page 58 W ARNING Over-tighteninglugnutswill result inbreakingthestuds Improper operatingtaillights, stoplightsandturnsignals or permanently deforming the mounting stud holes in can cause collisions. the wheels. Check all lights before each tow. PA GE 58 —LT6K5 50 HZ LIGHTTOWER• OPERA TION MANUAL —REV . #0 (06/02/15)

  • Page 59: Troubleshooting (Generator)

    Are wiring connections loose? Check wiring and repair. Short Circuit in load? Check load and repair. Circuit Breaker T ripped Over current? Confirmload requirements and reduce. Defective circuit breaker? Check and replace. LT6K5 50 HZ LIGHTTOWER• OPERA TION MANUAL —REV . #0 (06/02/15) —PAGE...

  • Page 60: Troubleshooting (Engine)

    Burned fuse? Replace fuse. Broken preheat circuit? Check preheat circuit. Engine fails to start and No fuel? Add diesel fuel. starter engages Defective wiring? Check wiring. PA GE 60 —LT6K5 50 HZ LIGHTTOWER• OPERA TION MANUAL —REV . #0 (06/02/15)
  • Page 61 Repair or replace the injection pump. Defi ient output. Defi ient nozzle injection? Repair or replace the nozzle. Replace head gasket, tighten cylinder head Compression leak? bolt, glowplug and nozzle holder. LT6K5 50 HZ LIGHTTOWER• OPERA TION MANUAL —REV . #0 (06/02/15) —PAGE...

  • Page 62: Troubleshooting (Lamps)

    Under certain conditions new lights may "cycle". cycling. New Lamp? Usually after 3 tries to start at 30 to 60 second intervals, lights will stabilize and operate satisfactorily. Defective Lamp? Replace lamp. PA GE 62 —LT6K5 50 HZ LIGHTTOWER• OPERA TION MANUAL —REV . #0 (06/02/15)
  • Page 63 Ballast nameplate data should agree with lamp line voltage Improper Ballast? and lamp use. If improper ballast is used, the lamp life will be shortened. A mismatch may also cause the ballast to fail. LT6K5 50 HZ LIGHTTOWER• OPERA TION MANUAL —REV . #0 (06/02/15) —PAGE...
  • Page 64 The capacitor is known to storeanelectrical charge, that whendischargedcould result in a harmful shock. Make sure to discharge capacitor. PA GE 64 —LT6K5 50 HZ LIGHTTOWER• OPERA TION MANUAL —REV . #0 (06/02/15)
  • Page 65 NOTES LT6K5 50 HZ LIGHT TOWER • OPERATION MANUAL - REV.#0 (06/02/15) - PAGE 65...

  • Page 66: Panel Light/Hour Meter Wiring Diagram

    HOUR METER SPLICE WHITE OIL SENDER BLACK BLACK GROUND CONTROL PANEL PANEL LIGHT HOURS FRONT VIEW PANEL LIGHT TO IGNITION SWITCH DOOR SWITCH + 12V DC PA GE 66 —LT6K5 50 HZ LIGHTTOWER• OPERA TION MANUAL —REV . #0 (06/02/15)

  • Page 67: Electronic Components Locator

    ELECTRONIC COMPONENTS LOCATOR FEMALE CONNECT ORS RIGHT H OURS LEFT LT6K5 50 HZ LIGHTTOWER• OPERA TION MANUAL —REV . #0 (06/02/15) —PAGE...

  • Page 68: Wiring Diagram(Generator/Lights)

    15 AMP WHT 10 AWG (W6) GFCI BREAKER WHT 10 AWG (W3) LINE LOAD NEU. 230 VAC GFCI 9 10 11 12 RECEPTACLE WHT 10 AWG (W6) PA GE 68 —LT6K5 50 HZ LIGHTTOWER• OPERA TION MANUAL —REV . #0 (06/02/15)
  • Page 69 BLUE12 AWG (W12) RED12 AWG (W1) BLK 12 AWG (W2) BALLAST #4 30µF@440V 240V IN (LAMP 4) CAPACITOR NEU. OUTPUT BRN 14 AWG RED 12 AWG WHT 14 AWG LT6K5 50 HZ LIGHTTOWER• OPERA TION MANUAL —REV . #0 (06/02/15) —PAGE...

  • Page 70: Lights Locator Diagram

    LIGHTS LOCATOR DIAGRAM REAR VIEW LEFT SIDE VIEW RIGHT SIDE VIEW PA GE 70 —LT6K5 50 HZ LIGHTTOWER• OPERA TION MANUAL —REV . #0 (06/02/15)

  • Page 71: Lights Wiring Diagram

    BK W R BK W BK W BK W BK W R BK W R BK W SPLICE:TYPICAL 15 PLACES W BR Y G CONNECT TO TOWING VEHICLE LT6K5 50 HZ LIGHTTOWER• OPERA TION MANUAL —REV . #0 (06/02/15) —PAGE...
  • Page 72 OPERATION MANUAL HERE’S HOW TO GET HELP PLEASE HAVETHE MODEL AND SERIAL NUMBER ON-HAND WHEN CALLING UNITED STATES Multiquip Corporate Office MQParts Department 18910 Wilmington Ave. T el. (800) 421-1244 800-427-1244 Fax: 800-672-7877 Carson, CA 90746 Fax (310) 537-3927 310-537-3700 Fax: 310-637-3284 Contact: mq@multiquip.com Service Department...

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