MULTIQUIP LT6KV Operation Manual
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MULTIQUIP LT6KV Operation Manual

Light tower/generator
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OPERATION MANUAL
MODEL LT6KV
LIGHT TOWER/GENERATOR
(KOHLER KDW 1003 DIESEL ENGINE)
Revision #2 (07/08/16)
To find the latest revision of this
publication, visit our website at:
www.multiquip.com
THIS MANUAL MUST ACCOMPANY THE EQUIPMENT AT ALL TIMES.
PN: 44229

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  • Page 1 OPERATION MANUAL MODEL LT6KV LIGHT TOWER/GENERATOR (KOHLER KDW 1003 DIESEL ENGINE) Revision #2 (07/08/16) To find the latest revision of this publication, visit our website at: www.multiquip.com THIS MANUAL MUST ACCOMPANY THE EQUIPMENT AT ALL TIMES. PN: 44229...

  • Page 2: Proposition 65 Warning

    PROPOSITION 65 WARNING Diesel engine exhaust and some of PAGE 2 — LT6KV LIGHT TOWER • OPERATION MANUAL — REV. #2 (07/08/16)

  • Page 3: Reporting Safety Defects

    1-888-327-4236 (TTY: 1-800-424-9153), go to http://www.safercar.gov; or write to: Administrator NHTSA 1200 New Jersey Avenue, SE Washington, DC 20590 You can also obtain information about motor vehicle safety from http://www.safercar.gov. LT6KV LIGHT TOWER • OPERATION MANUAL — REV. 2 (07/08/16) — PAGE 3...

  • Page 4: Table Of Contents

    Panel Light/Hour Meter Wiring Diagram ....72 Electronic Components Locator ......73 Wiring Diagram (Generator/Lights) ....74-75 Lights Locator Diagram ......... 76 Lights Wiring Diagram ........... 77 PAGE 4 — LT6KV LIGHT TOWER • OPERATION MANUAL — REV. #2 (07/08/16)

  • Page 5: Safety Information

    Indicates a hazardous situation which, if not avoided, COULD result in MINOR or MODERATE INJURY. NOTICE Rotating parts hazards Addresses practices not related to personal injury. Pressurized fluid hazards Electric shock hazards LT6KV LIGHT TOWER • OPERATION MANUAL — REV. 2 (07/08/16) — PAGE 5...
  • Page 6 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 PAGE 6 — LT6KV LIGHT TOWER • OPERATION MANUAL — REV. #2 (07/08/16)
  • Page 7 Disconnection of any of these bolts before starting. devices will void all warranties.  DO NOT use the equipment for any purpose other than its intended purposes or applications. LT6KV LIGHT TOWER • OPERATION MANUAL — REV. 2 (07/08/16) — PAGE 7...
  • Page 8  To prevent the light tower from overturning, NEVER use serious damage to the equipment or engine. in winds that exceed 65 mph (105 kmph). PAGE 8 — LT6KV LIGHT TOWER • OPERATION MANUAL — REV. #2 (07/08/16)
  • Page 9  NEVER tip the engine to extreme angles during lifting as it may cause oil to gravitate into the cylinder head, making the engine start diffi cult. LT6KV LIGHT TOWER • OPERATION MANUAL — REV. 2 (07/08/16) — PAGE 9...
  • Page 10  ALWAYS 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.” PAGE 10 — LT6KV LIGHT TOWER • OPERATION MANUAL — REV. #2 (07/08/16)
  • Page 11  DO NOT secure the unit by running a strap or chain over the tongue of the light tower. This may cause severe damage to the unit. LT6KV LIGHT TOWER • OPERATION MANUAL — REV. 2 (07/08/16) — PAGE 11...
  • Page 12 NOTICE  There is a permanent conductor between generator (stator winding) and the frame. PAGE 12 — LT6KV LIGHT TOWER • OPERATION MANUAL — REV. #2 (07/08/16)
  • Page 13  ALWAYS disconnect the NEGATIVE battery terminal before performing service on the generator.  ALWAYS keep battery cables in good working condition. Repair or replace all worn cables. LT6KV LIGHT TOWER • OPERATION MANUAL — REV. 2 (07/08/16) — PAGE 13...
  • Page 14 If there is any evidence of overloading, and motor to stall. immediately lower the mast and correct the situation.  Never allow a crane to "two block." PAGE 14 — LT6KV LIGHT TOWER • OPERATION MANUAL — REV. #2 (07/08/16)
  • Page 15  Always stand clear of the mast area during hoist operation.  Always make sure the controller and hoist assembly are installed, operated, adjusted, and serviced by qualifi ed personnel familiar with its construction and operation. LT6KV LIGHT TOWER • OPERATION MANUAL — REV. 2 (07/08/16) — PAGE 15...

  • Page 16: Lamp Footcandle Plot

    LAMP FOOTCANDLE PLOT Figure 1. Lamp Footcandle Plot PAGE 16 — LT6KV LIGHT TOWER • OPERATION MANUAL — REV. #2 (07/08/16)

  • Page 17: Specifications

    Tire Rim Size 13 x 4.5 in. (330 x 114 mm) Axle Capacity 2,000 lbs. (907 kg.) Hub Type 5-Lug Suspension Type 4-Leaf Electrical Tail-Light Connector 4-Wire Flat LT6KV LIGHT TOWER • OPERATION MANUAL — REV. 2 (07/08/16) — PAGE 17...
  • Page 18 Max. Layers of Wire Rope Gear Reduction 154:1 Brake Type Disc Contactor Type DPDT 230V 60A Drum Rotation (From Motor End) Clockwise to Extend ; Counterclockwise to Lower PAGE 18 — LT6KV LIGHT TOWER • OPERATION MANUAL — REV. #2 (07/08/16)

  • Page 19: Dimensions

    Height (Mast Fully Stowed Position) 96.8 in. (2.5 m) Ground Clearance (From Axle) 18.6 in. (0.5 m) Width (Tow Ready) 42.4 in. (1.08 m) Width (Outriggers Deployed) 79 in. (2.01 m) LT6KV LIGHT TOWER • OPERATION MANUAL — REV. 2 (07/08/16) — PAGE 19...

  • Page 20: General Information

    60 Hz. The bottom receptacle is a GFCI protected duplex receptacle which can supply 120 VAC at 15 Amps @ 60 Hz. These receptacles can be used for light power tools or other similar applications. PAGE 20 — LT6KV LIGHT TOWER • OPERATION MANUAL — REV. #2 (07/08/16)

  • Page 21: Light Tower Components

    When the cabinet door prevent rolling. is closed, the light will turn off. 6. Control Panel — Contains the auxiliary output receptacles, engine hour meter, excitation capacitor and circuit breakers. LT6KV LIGHT TOWER • OPERATION MANUAL — REV. 2 (07/08/16) — PAGE 21...
  • Page 22 Fuel tank capacity is 34 gallons (103.6 liters). 19. Battery — The 12-volt DC batter y (CA:550/ CCA:430) is shipped wet and is ready for use. Battery is shown here for clarity. PAGE 22 — LT6KV LIGHT TOWER • OPERATION MANUAL — REV. #2 (07/08/16)

  • Page 23: Components

    30. Tires — This light tower uses a ST175-80D size tire. Replace with only recommended tire size. NEVER tow light tower with bad or worn tires. LT6KV LIGHT TOWER • OPERATION MANUAL — REV. 2 (07/08/16) — PAGE 23...
  • Page 24 NOTES PAGE 24 — LT6KV LIGHT TOWER • OPERATION MANUAL — REV. #2 (07/08/16)

  • Page 25: Control Panel

    NEUTRAL BONDED TO FRAME LIEN NEUTRE AU CHÂSSIS 120/240 VAC MAX. 15A 120 VAC MAX. 25A P/N 44199 P/N 44214 P/N 44215 = NOT USED Figure 6. Control Panel/Ignition Switch LT6KV LIGHT TOWER • OPERATION MANUAL — REV. 2 (07/08/16) — PAGE 25...
  • Page 26 11. Oil Pressure Alarm Indicator — This alarm LED flashes when the oil pressure has fallen too low for normal engine operation. The LED will stay on until the problem is corrected. PAGE 26 — LT6KV LIGHT TOWER • OPERATION MANUAL — REV. #2 (07/08/16)

  • Page 27: Engine Components

    A loose or defective V-belt can adversely 11. Oil Dip Stick — Remove to check amount and affect the performance of the engine. condition of oil in crankcase. LT6KV LIGHT TOWER • OPERATION MANUAL — REV. 2 (07/08/16) — PAGE 27...

  • Page 28: Inspection

    OPEN and the lighttower has been operating in hard, gusty rains. Anytime there is fluid buildup within Figure 9. Oil Dipstick the tub area, drain immediately and handle and dispose fluids properly. PAGE 28 — LT6KV LIGHT TOWER • OPERATION MANUAL — REV. #2 (07/08/16)
  • Page 29 (-) terminal post. This may result in an electrical short circuit or an explosion. Figure 10. Adding Fuel LT6KV LIGHT TOWER • OPERATION MANUAL — REV. 2 (07/08/16) — PAGE 29...
  • Page 30 Figure 12. Engine Type Coolant Capacity Kohler KDW 1003 5.18 qt. (4.9 liters) Figure 12. Fan Belt Tension PAGE 30 — LT6KV LIGHT TOWER • OPERATION MANUAL — REV. #2 (07/08/16)

  • Page 31: Setup

    3. Pull the cable through the top of the mast and route the cable through the mast base pulley. Figure 13. Mast Cable Installation NOTICE The pulley may need to be disassembled to provide appropriate cable routing clearance. LT6KV LIGHT TOWER • OPERATION MANUAL — REV. 2 (07/08/16) — PAGE 31...
  • Page 32 T-bar hardware to secure the lights in the new pitch location. Table 8. Light Power Cable Connections Power Cable T-Bar Receptacle Light 1 Light 2 Light 3 Light 4 PAGE 32 — LT6KV LIGHT TOWER • OPERATION MANUAL — REV. #2 (07/08/16)
  • Page 33 The outriggers must remain fully extended while the tower is extended. Failure to level the trailer or extend the outriggers may severely reduce unit stability. LT6KV LIGHT TOWER • OPERATION MANUAL — REV. 2 (07/08/16) — PAGE 33...
  • Page 34 DO NOT overextend the mast. The magnetic limit switch on the main mast section will diconnect power to the electric hoist to prevent over extending the mast. PAGE 34 — LT6KV LIGHT TOWER • OPERATION MANUAL — REV. #2 (07/08/16)
  • Page 35 MAX. 15A 120 VAC MAX. 25A P/N 44199 P/N XXXXX P/N XXXXX MAST EXTENSION RAISE/LOWER MOTOR ROCKER SWITCH MAST ROTATION LOCKING KNOB Figure 20. Raising The Mast LT6KV LIGHT TOWER • OPERATION MANUAL — REV. 2 (07/08/16) — PAGE 35...

  • Page 36: Operation

    If any abnormal conditions occur, damage may result. shut down the engine and correct the problem. PAGE 36 — LT6KV LIGHT TOWER • OPERATION MANUAL — REV. #2 (07/08/16)
  • Page 37 9. Place outriggers in tow position, and remove chock blocks. 10. Store light tower in a clean, dry location out of the reach of children and unauthorized personnel. LT6KV LIGHT TOWER • OPERATION MANUAL — REV. 2 (07/08/16) — PAGE 37...
  • Page 38 2. Press and hold the mast control switch to the right side of the mast control switch below the control box. side until the mast is completely lowered. Observe that the mast begins lowering. PAGE 38 — LT6KV LIGHT TOWER • OPERATION MANUAL — REV. #2 (07/08/16)

  • Page 39: Maintenance

    Measure Insulation Resistance Over 3M ohms — Replace engine oil and filter at 50 hours, first time only. — Replace fuel filter at 250 hours, first time only. LT6KV LIGHT TOWER • OPERATION MANUAL — REV. 2 (07/08/16) — PAGE 39...
  • Page 40 Before Each Use 25 Hours of Operation Check Fasteners Check Electrical Connections Visually Inspect Rope Clean/Grease Brake Assembly Check Motor Brushes Visual Check of Hoist and Control PAGE 40 — LT6KV LIGHT TOWER • OPERATION MANUAL — REV. #2 (07/08/16)
  • Page 41 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 LT6KV LIGHT TOWER • OPERATION MANUAL — REV. 2 (07/08/16) — PAGE 41...
  • Page 42 Fuel Addition BOLT When adding diesel fuel, always use low sulfur No. 2 diesel Figure 29. Tub Access Cover Removal fuel. Always pour fuel through a mesh filter. PAGE 42 — LT6KV LIGHT TOWER • OPERATION MANUAL — REV. #2 (07/08/16)
  • Page 43 WEAR Figure 32. V-Belt Inspection 10. Run the engine at idling for a short time, then stop the engine. Recheck the oil level and fill as necessary. LT6KV LIGHT TOWER • OPERATION MANUAL — REV. 2 (07/08/16) — PAGE 43...
  • Page 44 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. PAGE 44 — LT6KV LIGHT TOWER • OPERATION MANUAL — REV. #2 (07/08/16)
  • Page 45 13. Fill radiator with water using a 50/50 coolant/water operation. ratio mixture of 50% coolant concentrate and 50% demineralized water. 14. Fill radiator to the top of the radiator filler neck, then tighten radiator cap. LT6KV LIGHT TOWER • OPERATION MANUAL — REV. 2 (07/08/16) — PAGE 45...
  • Page 46 3/16" countersunk rivets (64) to complete the reassembly fo the mast rollers. 11. Raise, extend, retract and lower the mast several times to verify correct operation. PAGE 46 — LT6KV LIGHT TOWER • OPERATION MANUAL — REV. #2 (07/08/16)
  • Page 47 Kohler distributor to have engine overhauled. 0°C (32°F), add antifreeze to the radiator. „ Cover the light tower and store in a clean, dry place away from children and unauthorized personnel. LT6KV LIGHT TOWER • OPERATION MANUAL — REV. 2 (07/08/16) — PAGE 47...

  • Page 48: Maintenance (Trailers)

    Figure 37. 2-Inch Adjustable Ball/Pintle Couplers „ Replace seals that have nicks, tears or wear. „ Lubricate the bearings with a high quality EP-2 automotive wheel bearing grease. PAGE 48 — LT6KV LIGHT TOWER • OPERATION MANUAL — REV. #2 (07/08/16)
  • Page 49 DO NOT repair cracked or broken welds unless you have a certified welder perform the repair. If not, have the welds repaired by your dealer. LT6KV LIGHT TOWER • OPERATION MANUAL — REV. 2 (07/08/16) — PAGE 49...

  • Page 50: Safety Guidelines (Trailers)

     Allow plenty of room for passing. A rule of thumb is that the passing distance with a trailer is 4 times the passing distance without the trailer. PAGE 50 — LT6KV LIGHT TOWER • OPERATION MANUAL — REV. #2 (07/08/16)
  • Page 51 Be sure your hitch and tow vehicle are rated for the that the tow rating of the tow vehicle is equal to or greater Gross Vehicle Weight Rating of your trailer. than that of the trailer. LT6KV LIGHT TOWER • OPERATION MANUAL — REV. 2 (07/08/16) — PAGE 51...
  • Page 52 Also, before you start towing, adjust the mirrors so you can see the trailer as well as the area to the rear of it. PAGE 52 — LT6KV LIGHT TOWER • OPERATION MANUAL — REV. #2 (07/08/16)
  • Page 53 To fi nd the weight of the trailer vehicle lights. using an axle scale, you must know the axle weights of LT6KV LIGHT TOWER • OPERATION MANUAL — REV. 2 (07/08/16) — PAGE 53...
  • Page 54 Other “Pin-type” connectors can be utilized with your light tower as shown in Figure C. Figure C. Tow Vehicle Electrical Wiring PAGE 54 — LT6KV LIGHT TOWER • OPERATION MANUAL — REV. #2 (07/08/16)
  • Page 55 Be sure the SIZE of the hitch ball matches the size of Figure D. Ball Coupler the ball coupler. LT6KV LIGHT TOWER • OPERATION MANUAL — REV. 2 (07/08/16) — PAGE 55...
  • Page 56 In the open position, the coupler is able to drop fully onto the hitch ball. PAGE 56 — LT6KV LIGHT TOWER • OPERATION MANUAL — REV. #2 (07/08/16)
  • Page 57 • Cross chains underneath hitch and coupler with enough slack to permit turning and to hold tongue up, if the trailer comes loose. LT6KV LIGHT TOWER • OPERATION MANUAL — REV. 2 (07/08/16) — PAGE 57...
  • Page 58  Be sure the coupler is secured tightly to the tongue of the trailer. All coupler fasteners must be visibly solid against the trailer frame. PAGE 58 — LT6KV LIGHT TOWER • OPERATION MANUAL — REV. #2 (07/08/16)
  • Page 59 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. LT6KV LIGHT TOWER • OPERATION MANUAL — REV. 2 (07/08/16) — PAGE 59...
  • Page 60 This certifi cation/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 PAGE 60 — LT6KV LIGHT TOWER • OPERATION MANUAL — REV. #2 (07/08/16)
  • Page 61 These actions, along with other care and maintenance activities, can also: LT6KV LIGHT TOWER • OPERATION MANUAL — REV. 2 (07/08/16) — PAGE 61...
  • Page 62 Figure K. UTQGS Tire Information Tire Ply Composition and Materials Used: The number of plies indicates the number of layers of rubber-coated fabric PAGE 62 — LT6KV LIGHT TOWER • OPERATION MANUAL — REV. #2 (07/08/16)
  • Page 63 (break off) with great force and cause serious eye or bodily injury. LT6KV LIGHT TOWER • OPERATION MANUAL — REV. 2 (07/08/16) — PAGE 63...
  • Page 64 Over-tightening lug nuts will result in breaking the studs or permanently deforming the mounting stud holes in Improper operating taillights, stoplights and turn signals the wheels. can cause collisions. Check all lights before each tow. PAGE 64 — LT6KV LIGHT TOWER • OPERATION MANUAL — REV. #2 (07/08/16)

  • Page 65: Troubleshooting (Generator)

    Practically all breakdowns can be prevented by proper handling and maintenance inspections, but in the event of a breakdown, please take remedial action following the diagnosis based on the troubleshooting tables. If the problem cannot be remedied, please leave the unit as is and consult Multiquip's technical support department or your local dealer. Table 11. Generator Troubleshooting...

  • Page 66: Troubleshooting (Engine)

    Replace starter 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. PAGE 66 — LT6KV LIGHT TOWER • OPERATION MANUAL — REV. #2 (07/08/16)
  • Page 67 Repair or replace the injection pump. Deficient output. Deficient nozzle injection? Repair or replace the nozzle. Replace head gasket, tighten cylinder head Compression leak? bolt, glow plug and nozzle holder. LT6KV LIGHT TOWER • OPERATION MANUAL — REV. 2 (07/08/16) — PAGE 67...

  • Page 68: 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. PAGE 68 — LT6KV LIGHT TOWER • OPERATION MANUAL — REV. #2 (07/08/16)
  • Page 69 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. LT6KV LIGHT TOWER • OPERATION MANUAL — REV. 2 (07/08/16) — PAGE 69...
  • Page 70 The capacitor is known to store an electrical charge, that when discharged could result in a harmful shock. Make sure to discharge capacitor. PAGE 70 — LT6KV LIGHT TOWER • OPERATION MANUAL — REV. #2 (07/08/16)

  • Page 71: Troubleshooting (Electric Hoist)

    Mounting surface is not flat. Tie rod or lifting or lowering of load. mm). Replace tie rod or tie bar id tie bar is bent. necessary. Check for bent or cracked housings. LT6KV LIGHT TOWER • OPERATION MANUAL — REV. 2 (07/08/16) — PAGE 71...

  • Page 72: Panel Light/Hour Meter Wiring Diagram

    NEUTRAL BONDED TO FRAME LIEN NEUTRE AU CHÂSSIS 120/240 VAC MAX. 15A 120 VAC MAX. 25A P/N 44199 PANEL LIGHT TO IGNITION SWITCH DOOR SWITCH + 12V DC PAGE 72 — LT6KV LIGHT TOWER • OPERATION MANUAL — REV. #2 (07/08/16)

  • Page 73: Electronic Components Locator

    ELECTRONIC COMPONENTS LOCATOR RIGHT MAIN GFCI LEFT NOTICE/AVIS NEUTRAL BONDED TO FRAME LIEN NEUTRE AU CHÂSSIS 120/240 VAC MAX. 15A 120 VAC MAX. 25A P/N 44199 LT6KV LIGHT TOWER • OPERATION MANUAL — REV. 2 (07/08/16) — PAGE 73...

  • Page 74: Wiring Diagram (Generator/Lights)

    BLK (LINE 2) YEL 12 AWG 15 AMP LINE 240/120 VAC NEU. AUX RECPT. 120 VAC GFCI RECEPT. LOAD CHASSIS (GND.) WHT 10 AWG WHT 10 AWG PAGE 74 — LT6KV LIGHT TOWER • OPERATION MANUAL — REV. #2 (07/08/16)
  • Page 75 12 AWG BALLAST #1 24µF@480V 120V IN CAPACITOR BLUE NEU. OUTPUT 12 AWG RED 12 AWG MOLEX P/N 50-84-1060 PIN CONNECTOR PIN CONNECTOR WIRE SIDE SOCKET SIDE LT6KV LIGHT TOWER • OPERATION MANUAL — REV. 2 (07/08/16) — PAGE 75...

  • Page 76: Lights Locator Diagram

    LIGHTS LOCATOR DIAGRAM REAR VIEW LEFT SIDE VIEW RIGHT SIDE VIEW PAGE 76 — LT6KV LIGHT TOWER • OPERATION MANUAL — REV. #2 (07/08/16)

  • Page 77: Lights Wiring Diagram

    BK W BK W BK W R BK W R BK W BK W BK W BK W R BK W SPLICE:TYPICAL 15 PLACES CONNECT TO TOWING VEHICLE LT6KV LIGHT TOWER • OPERATION MANUAL — REV. 2 (07/08/16) — PAGE 77...
  • Page 78 © COPYRIGHT 2016, MULTIQUIP INC. Multiquip Inc , the MQ logo and the Whiteman logo are registered trademarks of Multiquip Inc. and may not be used, reproduced, or altered without written permission. All other trademarks are the property of their respective owners and used with permission.

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