MULTIQUIP LT6k Operation Manual
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MULTIQUIP LT6k Operation Manual

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OperatiOn Manual
MODel lt6k 60 hZ
liGht tOWer/GeneratOr
(kOhler kDW 1003 DieSel enGine)
Revision #2 (09/11/14)
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 34639

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  • Page 1 OperatiOn Manual MODel lt6k 60 hZ liGht tOWer/GeneratOr (kOhler kDW 1003 DieSel enGine) Revision #2 (09/11/14) 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 34639...

  • Page 2: Proposition 65 Warning

    65 warning Diesel engine exhaust and some of page 2 — LT6K LIgHT TOWeR • OpeRaTIOn manuaL — Rev. #2 (09/11/14)

  • 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 400 Seventh Street, SW., Washington, DC 20590 You can also obtain information about motor vehicle safety from http://www.safercar.gov. LT6K LIgHT TOWeR • OpeRaTIOn manuaL — Rev. 2 (09/11/14) — page 3...

  • Page 4: Table Of Contents

    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 page 4 — LT6K LIgHT TOWeR • OpeRaTIOn manuaL — Rev. #2 (09/11/14)

  • Page 5: Safety Information

    COuLd result in DEATH or seRIOus InJuRY. CauTIOn Indicates a hazardous situation which, if not avoided, COuLd result in mInOR or mOdeRaTe InJuRY. NOTICE Addresses practices not related to personal injury. LT6K LIgHT TOWeR • OpeRaTIOn manuaL — Rev. 2 (09/11/14) — page 5...
  • Page 6 „ dO nOT use the equipment for any purpose other than numbers of the nearest ambulance, doctor and fi re its intended purposes or applications. department. This information will be invaluable in the case of an emergency. page 6 — LT6K LIgHT TOWeR • OpeRaTIOn manuaL — Rev. #2 (09/11/14)
  • Page 7 „ ALWAYS lower the light tower when not in use, or if high winds or electrical storms are expected. LT6K LIgHT TOWeR • OpeRaTIOn manuaL — Rev. 2 (09/11/14) — page 7...
  • Page 8 United States Forest Service for this before servicing equipment. purpose. In order to comply with local laws regarding spark arresters, consult the engine distributor or the local Health and Safety Administrator. page 8 — LT6K LIgHT TOWeR • OpeRaTIOn manuaL — Rev. #2 (09/11/14)
  • Page 9 „ 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.” LT6K LIgHT TOWeR • OpeRaTIOn manuaL — Rev. 2 (09/11/14) — page 9...
  • Page 10 „ 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. page 10 — LT6K LIgHT TOWeR • OpeRaTIOn manuaL — Rev. #2 (09/11/14)
  • Page 11 „ neveR use gas piping as an electrical ground. LT6K LIgHT TOWeR • OpeRaTIOn manuaL — Rev. 2 (09/11/14) — page 11...
  • Page 12 „ 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. page 12 — LT6K LIgHT TOWeR • OpeRaTIOn manuaL — Rev. #2 (09/11/14)
  • 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. LT6K LIgHT TOWeR • OpeRaTIOn manuaL — Rev. 2 (09/11/14) — page 13...

  • Page 14: Lamp Footcandle Plot

    Figure 1. Lamp Footcandle Plot page 14 — LT6K LIgHT TOWeR • OpeRaTIOn manuaL — Rev. #2 (09/11/14)

  • Page 15: 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 LT6K LIgHT TOWeR • OpeRaTIOn manuaL — Rev. 2 (09/11/14) — page 15...
  • Page 16 2.64 U.S. Quarts (2.5 Liters) Cooling System Liquid-cooled Coolant Capacity 1.25 U.S. Quarts (4.75 Liters) Starting Method Electric Start Battery Type Group 24 Total Weight (Dry) 187.3 lbs. (85 Kg.) page 16 — LT6K LIgHT TOWeR • OpeRaTIOn manuaL — Rev. #2 (09/11/14)

  • Page 17: Dimensions

    Height (Mast Stowed Position) 73.7 in. (187 cm.) Ground Clearance (From Axle) 18.6 in. (47.2 cm.) Width (Tow Ready) 42.4 in. (108 cm.) Width (Outriggers Deployed) 79 in. (201 cm.) LT6K LIgHT TOWeR • OpeRaTIOn manuaL — Rev. 2 (09/11/14) — page 17...

  • Page 18: General Information

    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. page 18 — LT6K LIgHT TOWeR • OpeRaTIOn manuaL — Rev. #2 (09/11/14)
  • Page 19 LT6K LIgHT TOWeR • OpeRaTIOn manuaL — Rev. 2 (09/11/14) — 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. page 20 — LT6K LIgHT TOWeR • OpeRaTIOn manuaL — Rev. #2 (09/11/14)
  • Page 21 CCA:430) is shipped wet and is ready for use. mast to the desired height. Maximum height is 31.5 feet Battery is shown here for clarity. (9.60 meters). LT6K LIgHT TOWeR • OpeRaTIOn manuaL — Rev. 2 (09/11/14) — page 21...
  • Page 22 29. Rear Jackstands/Outriggers — There is one jackstand located at the rear of the trailer. Use this jackstand and outrigger to level and support the light tower. page 22 — LT6K LIgHT TOWeR • OpeRaTIOn manuaL — Rev. #2 (09/11/14)
  • Page 23 LT6K LIgHT TOWeR • OpeRaTIOn manuaL — Rev. 2 (09/11/14) — page 23...

  • Page 24: Control Panel

    120/240 VAC ENGINE HOURS 1/10 120 VAC LIGHTING = NOT USED Figure 6. Control Panel/Ignition Switch page 24 — LT6K LIgHT TOWeR • OpeRaTIOn manuaL — Rev. #2 (09/11/14)
  • Page 25 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. LT6K LIgHT TOWeR • OpeRaTIOn manuaL — Rev. 2 (09/11/14) — page 25...

  • Page 26: 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. page 26 — LT6K LIgHT TOWeR • OpeRaTIOn manuaL — Rev. #2 (09/11/14)

  • Page 27: Inspection

    Figure 8. Always fill with recommended type oil as listed in Table 4. See Table 2 for engine oil capacity. Figure 8. Oil Dipstick LT6K LIgHT TOWeR • OpeRaTIOn manuaL — Rev. 2 (09/11/14) — page 27...
  • Page 28 Handle fuel in a safe container. If the container does Immediately wash off any spilled electrolyte (battery not have a spout, use a funnel. acid). 5. Wipe up any spilled fuel immediately! page 28 — LT6K LIgHT TOWeR • OpeRaTIOn manuaL — Rev. #2 (09/11/14)
  • Page 29 5.18 qt. (4.9 liters) OpeRaTIOn In FReezIng WeaTHeR When operating in freezing weather, make sure the proper amount of antifreeze (Table 6) has been added. Figure 11. Fan Belt Tension LT6K LIgHT TOWeR • OpeRaTIOn manuaL — Rev. 2 (09/11/14) — page 29...

  • Page 30: Setup

    3. On the corresponding male connector, locate the key between the two connectors. See Figure 14. tab (B) as shown in Figure 13. Figure 13. Male Connector page 30 — LT6K LIgHT TOWeR • OpeRaTIOn manuaL — Rev. #2 (09/11/14)
  • Page 31 5. Check behind the light tower and make sure all personnel and objects are clear of the mast. LT6K LIgHT TOWeR • OpeRaTIOn manuaL — Rev. 2 (09/11/14) — page 31...
  • Page 32 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 22. Mast Operation page 32 — LT6K LIgHT TOWeR • OpeRaTIOn manuaL — Rev. #2 (09/11/14)
  • Page 33 3. When the lights are facing in the desired direction, tighten the mast rotation lock knob to lock the mast in place. LT6K LIgHT TOWeR • OpeRaTIOn manuaL — Rev. 2 (09/11/14) — page 33...

  • Page 34: Operation

    If any abnormal conditions occur, shut down the engine and correct the problem. page 34 — LT6K LIgHT TOWeR • OpeRaTIOn manuaL — Rev. #2 (09/11/14)
  • Page 35 Figure 21. GFCI Test Button 5. Once the mast is fully seated in the mast cradle, insert the cradle lock/release pin and secure with cotter pin to keep in place. LT6K LIgHT TOWeR • OpeRaTIOn manuaL — Rev. 2 (09/11/14) — page 35...

  • Page 36: Maintenance

    Measure Insulation Resistance Over 3M ohms — Replace engine oil and filter at 100 hours, first time only. — Replace fuel filter at 250 hours, first time only. page 36 — LT6K LIgHT TOWeR • OpeRaTIOn manuaL — Rev. #2 (09/11/14)
  • Page 37 CauTIOn PAPER FILTER ALWAYS allow the engine to cool ELEMENT before servicing. NEVER attempt any maintenance work on a hot engine. Figure 24. Cleaning Inner Paper Filter LT6K LIgHT TOWeR • OpeRaTIOn manuaL — Rev. 2 (09/11/14) — page 37...
  • Page 38 Figure 26. Tub Access Cover Removal 3. Remove the retaining bolt and seal washer that secures the access cover to the tub bracket. Set cover and gasket aside. page 38 — LT6K LIgHT TOWeR • OpeRaTIOn manuaL — Rev. #2 (09/11/14)
  • 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 29. V-Belt Inspection LT6K LIgHT TOWeR • OpeRaTIOn manuaL — Rev. 2 (09/11/14) — page 39...
  • 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. page 40 — LT6K LIgHT TOWeR • OpeRaTIOn manuaL — Rev. #2 (09/11/14)
  • Page 41 3. Disconnect the cable from the ball socket pin and remove from the mast pulley and cable sheave. Detach the cable from the hand winch as necessary. 4. Replace the pulley and the cable as needed. LT6K LIgHT TOWeR • OpeRaTIOn manuaL — Rev. 2 (09/11/14) — page 41...
  • 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. page 42 — LT6K LIgHT TOWeR • OpeRaTIOn manuaL — Rev. #2 (09/11/14)

  • Page 43: Maintenance (Trailers)

    „ Replace seals that have nicks, tears or wear. „ Lubricate the bearings with a high quality EP-2 automotive wheel bearing grease. LT6K LIgHT TOWeR • OpeRaTIOn manuaL — Rev. 2 (09/11/14) — page 43...
  • Page 44 Figure 36. Leaf Suspension Components dangeR Worn or broken suspension parts can cause loss of control, damage to equipment and severe bodily injury, even death! Check suspension regularly. page 44 — LT6K LIgHT TOWeR • OpeRaTIOn manuaL — Rev. #2 (09/11/14)

  • Page 45: 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. LT6K LIgHT TOWeR • OpeRaTIOn manuaL — Rev. 2 (09/11/14) — page 45...
  • Page 46 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. page 46 — LT6K LIgHT TOWeR • OpeRaTIOn manuaL — Rev. #2 (09/11/14)
  • 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. LT6K LIgHT TOWeR • OpeRaTIOn manuaL — Rev. 2 (09/11/14) — page 47...
  • Page 48 To fi nd the weight of the trailer when the battery is running both the trailer lights and tow vehicle lights. page 48 — LT6K LIgHT TOWeR • OpeRaTIOn manuaL — Rev. #2 (09/11/14)
  • Page 49 Be sure the SIZE of the hitch ball matches the size of Figure C. Ball Coupler the ball coupler. LT6K LIgHT TOWeR • OpeRaTIOn manuaL — Rev. 2 (09/11/14) — page 49...
  • Page 50 In the open position, the coupler is able to drop fully onto the hitch ball. page 50 — LT6K LIgHT TOWeR • OpeRaTIOn manuaL — Rev. #2 (09/11/14)
  • Page 51 • Cross chains underneath hitch and coupler with enough slack to permit turning and to hold tongue up, if the trailer comes loose. LT6K LIgHT TOWeR • OpeRaTIOn manuaL — Rev. 2 (09/11/14) — page 51...
  • Page 52 „ 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 52 — LT6K LIgHT TOWeR • OpeRaTIOn manuaL — Rev. #2 (09/11/14)
  • 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. LT6K LIgHT TOWeR • OpeRaTIOn manuaL — Rev. 2 (09/11/14) — page 53...
  • Page 54 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 54 — LT6K LIgHT TOWeR • OpeRaTIOn manuaL — Rev. #2 (09/11/14)
  • Page 55 These actions, along with other care and maintenance activities, can also: LT6K LIgHT TOWeR • OpeRaTIOn manuaL — Rev. 2 (09/11/14) — page 55...
  • Page 56 Figure J. UTQGS Tire Information Tire ply Composition and materials used: The number of plies indicates the number of layers of rubber-coated fabric page 56 — LT6K LIgHT TOWeR • OpeRaTIOn manuaL — Rev. #2 (09/11/14)
  • Page 57 (break off) with great force and cause serious eye or bodily injury. LT6K LIgHT TOWeR • OpeRaTIOn manuaL — Rev. 2 (09/11/14) — page 57...
  • Page 58 Over-tightening lug nuts will result in breaking the studs Improper operating taillights, stoplights and turn signals or permanently deforming the mounting stud holes in can cause collisions. the wheels. Check all lights before each tow. page 58 — LT6K LIgHT TOWeR • OpeRaTIOn manuaL — Rev. #2 (09/11/14)

  • Page 59: 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 10. Generator Troubleshooting...

  • Page 60: 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 60 — LT6K LIgHT TOWeR • OpeRaTIOn manuaL — Rev. #2 (09/11/14)
  • Page 61 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. LT6K LIgHT TOWeR • OpeRaTIOn manuaL — Rev. 2 (09/11/14) — page 61...

  • 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. page 62 — LT6K LIgHT TOWeR • OpeRaTIOn manuaL — Rev. #2 (09/11/14)
  • 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. LT6K LIgHT TOWeR • OpeRaTIOn manuaL — Rev. 2 (09/11/14) — page 63...
  • Page 64 The capacitor is known to store an electrical charge, that when discharged could result in a harmful shock. Make sure to discharge capacitor. page 64 — LT6K LIgHT TOWeR • OpeRaTIOn manuaL — Rev. #2 (09/11/14)
  • Page 65 LT6K LIgHT TOWeR • OpeRaTIOn manuaL — Rev. 2 (09/11/14) — page 65...

  • Page 66: Panel Light/Hour Meter Wiring Diagram

    OIL SENDER BLACK BLACK GROUND CONTROL PANEL PANEL LIGHT 120/240 VAC ENGINE HOURS 1/10 120 VAC LIGHTING PANEL LIGHT TO IGNITION SWITCH DOOR SWITCH + 12V DC page 66 — LT6K LIgHT TOWeR • OpeRaTIOn manuaL — Rev. #2 (09/11/14)

  • Page 67: Electronic Components Locator

    RIGHT 120/240 VAC ENGINE HOURS 1/10 120 VAC LIGHTING LEFT LT6K LIgHT TOWeR • OpeRaTIOn manuaL — Rev. 2 (09/11/14) — page 67...

  • Page 68: 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 68 — LT6K LIgHT TOWeR • OpeRaTIOn manuaL — Rev. #2 (09/11/14)
  • Page 69 BALLAST #2 120V IN 24µF@480V CAPACITOR OUTPUT NEU. 12 AWG RED 12 AWG BALLAST #1 24µF@480V 120V IN CAPACITOR NEU. OUTPUT RED 12 AWG YEL 12 AWG LT6K LIgHT TOWeR • OpeRaTIOn manuaL — Rev. 2 (09/11/14) — page 69...

  • Page 70: Lights Locator Diagram

    Diagram REAR VIEW LEFT SIDE VIEW RIGHT SIDE VIEW page 70 — LT6K LIgHT TOWeR • OpeRaTIOn manuaL — Rev. #2 (09/11/14)

  • Page 71: 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 LT6K LIgHT TOWeR • OpeRaTIOn manuaL — Rev. 2 (09/11/14) — page 71...
  • Page 72 © COPYRIGHT 2014, MULTIQUIP INC. Multiquip Inc , the MQ 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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