Multiquip Portable Generator Lt6D Users Manual
LT6D to the manual 15da5ba2-b69f-486b-bfd9-2970d281c10d
2015-02-09
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Page Count: 70
OperatiOn Manual
THIS MANUAL MUST ACCOMPANY THE EQUIPMENT AT ALL TIMES.
To find the latest revision of this
publication, visit our website at:
www.multiquip.com
MODel lt6D
liGHt tOWer/GeneratOr
(KOHler KDW 1003 DieSel enGine)
Revision #0 (07/16/13)
pn 34639
proposition 65 warning
Diesel engine exhaust and some of
If you believe that your vehicle has a defect that could cause a crash or could cause
injury or death, you should immediately inform the National Highway Traffic Safety
Administration (NHTSA) in addition to notifying Multiquip at 1-800-421-1244.
If NHTSA receives similar complaints, it may open an investigation, and if it finds
that a safety defect exists in a group of vehicles, it may order a recall and remedy
campaign. However, NHTSA cannot become involved in individual problems
between you, your dealer, or Multiquip.
To contact NHTSA, you may either call the Vehicle Safety Hotline toll-free at 1-888-
327-4236 (TTY: 1-800-424-9153), go to http://www.nhtsa.dot.gov; or write to:
Administrator
NHTSA
1200 New Jersey Avenue S.E.
Washington, DC 20590
You can also obtain information about motor vehicle safety from
http://www.safecar.gov.
reporting safety Defects
page 4 — LT6D LIgHT TOWeR • OpeRaTIOn manuaL — Rev. #0 (07/16/13)
TABLE OF CONTENTS
LT6D Light Tower
Proposition 65 Warning ........................................... 2
Reporting Safety Defects ......................................... 3
Table Of Contents .................................................... 4
Safety Information .............................................. 5-13
Lamp Footcandle Plot ............................................ 14
Specifications ................................................... 15-16
Dimensions ............................................................ 17
General Information ............................................... 18
Components ..................................................... 20-22
Control Panel .................................................... 24-25
Engine Components .............................................. 26
Inspection ......................................................... 27-29
Setup ................................................................ 30-33
Operation .......................................................... 34-35
Maintenance ..................................................... 36-41
Maintenance (Trailers) ...................................... 42-43
Safety Guidelines (Trailers)............................... 44-57
Troubleshooting (Generator) .................................. 58
Troubleshooting (Engine) .................................. 59-60
Troubleshooting (Lamps) .................................. 60-63
Panel Light/Hour Meter Wiring Diagram ................ 64
Electronic Components Locator ............................ 65
Wiring Diagram (Generator/Lights) .................. 66-67
Lights Locator Diagram ......................................... 68
Lights Wiring Diagram ........................................... 69
safety information
Do not operate or service the equipment before reading the
entire manual. Safety precautions should be followed at all
times when operating this equipment. Failure to read and
understand the safety messages and operating instructions
could result in injury to yourself and others.
The four safety messages shown below will inform you
about potential hazards that could injure you or others. The
safety messages specifi cally address the level of exposure
to the operator and are preceded by one of four words:
or
Indicates a hazardous situation which, if not avoided,
WILL result in DEATH or
Indicates a hazardous situation which, if not avoided,
result in DEATH or
Indicates a hazardous situation which, if not avoided,
result in or
NOTICE
Addresses practices not related to personal injury.
Potential hazards associated with the operation of this
equipment will be referenced with hazard symbols which
may appear throughout this manual in conjunction with
safety messages.
safety information
operate this equipment without proper protective
clothing, shatterproof glasses, respiratory protection,
hearing protection, steel-toed boots and other protective
devices required by the job or city and state regulations.
operate this equipment when not
feeling well due to fatigue, illness or when
under medication.
operate this equipment under the infl uence of
drugs or alcohol.
ALWAYS check the equipment for loosened threads or
bolts before starting.
use the equipment for any purpose other than
its intended purposes or applications.
NOTICE
This equipment should only be operated by trained and
qualifi ed personnel 18 years of age and older.
Whenever necessary, replace nameplate, operation and
safety decals when they become diffi cult read.
Manufacturer does not assume responsibility for any
accident due to equipment modifi cations. Unauthorized
equipment modifi cation will void all warranties.
use accessories or attachments that are not
recommended by Multiquip for this equipment. Damage
to the equipment and/or injury to user may result.
ALWAYS know the location of the nearest
ALWAYS know the location of the nearest
ALWAYS
know the location of the nearest phone or
Also, know the phone
numbers of the nearest and
fi re
This information will be invaluable in the
case of an emergency.
safety information
LIGHT TOWER SAFETY
operate the equipment in an explosive atmosphere
or near combustible materials. An explosion or fi re could
result causing severe
disconnect any
These devices are intended for operator safety.
Disconnection of these devices can cause severe injury,
bodily harm or even death. Disconnection of any of these
devices will void all warranties.
lubricate components or attempt service on a
running machine.
ALWAYS ensure light tower is on level ground before use
so that it cannot slide or shift around, endangering workers.
Always keep immediate area free of bystanders.
ALWAYS make sure trailer is leveled with all outriggers
extended before raising tower. Outriggers must remain
extended while tower is up.
ALWAYS keep area behind trailer clear of people while
raising and lowering mast.
remove safety pin or pull mast locking pin while
tower is in a raised position!
the mast and winch cables for wear. If any
problem occurs when lowering or raising the tower, STOP
immediately! Contact a trained technician for assistance.
pivot or retract mast while unit is operating.
use the light tower mast as a crane.
lift anything with the mast.
attach anything to the light tower mast.
ALWAYS lower the light tower when not in use, or if high
winds or electrical storms are expected.
NOTICE
ALWAYS
keep the immediate area surrounding the light
tower clean, neat, and free of debris.
ALWAYS keep the machine in proper running condition.
Fix damage to machine and replace any broken parts
immediately.
ALWAYS
store equipment properly when it is not being
used. Equipment should be stored in a clean, dry location
out of the reach of children and unauthorized personnel.
To prevent the light tower from overturning,
use
in winds that exceed 65 mph (105 kph).
attempt to replace lamp with the power on.
Always shut down the engine and turn off circuit breakers
when changing the lamp.
ALWAYS
allow a suffi cient amount of time for the lamp to
cool
before touching or changing. The possibility exists of
severe burns.
use force when installing the lamp. Excessive force
could cause the lamp to break, causing bodily harm.
NOTICE
leave any grease or oil residue on lamp surface
when replacing or removing lamp. This can create hot
spots, reducing the service life of the lamp.
ALWAYS make sure lamp surface is clean and dry.
ALWAYS replace with MQ recommended type lamp.
ALWAYS have a trained technician
install and remove
a fl oodlight, or replace any damaged fi xture wiring.
safety information
The engine fuel exhaust gases contain poisonous carbon
monoxide. This gas is colorless and odorless, and can
cause death if inhaled.
The engine of this equipment
requires an adequate free
fl ow of cooling air.
operate this equipment in
any enclosed or narrow area
where free fl ow of the air is
restricted. If the air fl ow is
restricted it will cause injury to people and property and
serious damage to the equipment or engine.
place hands or fingers inside engine
compartment when engine is running.
operate the engine with heat shields or
guards removed.
Keep fi ngers, hands hair and clothing away
from all moving parts to prevent injury.
remove the radiator cap while the engine is hot.
High pressure boiling water will gush out of the radiator
and severely scald any persons in the general area of
the generator.
remove the coolant drain plug
while the engine is hot. Hot coolant will
gush out of the coolant tank and severely
scald any persons in the general area of
the generator.
remove the engine oil drain plug while the
engine is hot. Hot oil will gush out of the oil tank and
severely scald any persons in the general area of the
generator.
touch the hot exhaust manifold,
muffl er or cylinder. Allow these parts to cool
before servicing equipment.
DANGEROUS
GASFUMES
NOTICE
run engine without an air fi lter or with a dirty air
fi lter. Severe engine damage may occur. Service air fi lter
frequently to prevent engine malfunction.
tamper with the factory settings
of the engine or engine governor. Damage
to the engine or equipment can result
if operating in speed ranges above the
maximum allowable.
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.
Wet stacking is a common problem with diesel engines
which are operated for extended periods with light or
no load applied. When a diesel engine operates without
suffi cient load (less than 40% of the rated output), it will
not operate at its optimum temperature. This will allow
unburned fuel to accumulate in the exhaust system,
which can foul the fuel injectors, engine valves and
exhaust system, including turbochargers, and reduce
the operating performance.
In order for a diesel engine to operate at peak effi ciency,
it must be able to provide fuel and air in the proper ratio
and at a high enough engine temperature for the engine
to completely burn all of the fuel.
Wet stacking does not usually cause any permanent
damage and can be alleviated if additional load is
applied to relieve the condition. It can reduce the system
performance and increase maintenance. Applying an
increasing load over a period of time until the excess
fuel is burned off and the system capacity is reached
usually can repair the condition. This can take several
hours to burn off the accumulated unburned fuel.
State Health Safety Codes and Public Resources
Codes specify that in certain locations, spark arresters
must be used on internal combustion engines that use
hydrocarbon fuels. A spark arrester is a device designed
to prevent accidental discharge of sparks or fl ames
from the engine exhaust. Spark arresters are qualifi ed
and rated by the United States Forest Service for this
purpose. In order to comply with local laws regarding
spark arresters, consult the engine distributor or the
local Health and Safety Administrator.
safety information
start the engine near spilled fuel or combustible
fl uids. Diesel fuel is extremely fl ammable and its vapors
can cause an explosion if ignited.
ALWAYS refuel in a well-ventilated area, away from
sparks and open fl ames.
ALWAYS use extreme caution when working with
fl ammable liquids.
fi ll the fuel tank while the engine is running
or hot.
overfi ll tank, since spilled fuel could ignite if it
comes into contact with hot engine parts or sparks from
the ignition system.
Store fuel in appropriate containers, in well-ventilated
areas and away from sparks and fl ames.
use fuel as a cleaning agent.
smoke around or near the
equipment. Fire or explosion could result
from fuel vapors or if fuel is spilled on a
hot engine.
Check with your local county or state safety
towing regulations, in addition to meeting
Department of Transportation (DOT)
Safety Towing Regulations, before towing
your light tower.
In order to reduce the possibility of an accident while
transporting the light tower on public roads, ALWAYS
make sure the trailer that supports the light tower and
the towing vehicle are mechanically sound and in good
operating condition.
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.”
ALWAYS inspect the hitch and coupling for wear.
tow a trailer with defective hitches, couplings, chains, etc.
Check the tire air pressure on both towing vehicle and
trailer.
Trailer tires should be infl ated to 50 psi cold.
Also check the tire tread wear on both vehicles.
ALWAYS make sure the trailer is equipped with a
safety
ALWAYS properly
attach trailer’s safety chains to towing
vehicle.
ALWAYS
make sure the vehicle and trailer directional,
backup, brake and trailer lights are connected and
working properly.
DOT Requirements include the following:
• Connect and test electric brake operation.
• Secure portable power cables in cable tray with tie
wraps.
The maximum speed for highway towing is
unless
posted otherwise. Recommended off-road towing is not to
exceed or less depending on type of terrain.
Avoid sudden stops and starts. This can cause skidding,
or jack-knifi ng. Smooth, gradual starts and stops will
improve towing.
Avoid sharp turns to prevent rolling.
Trailer should be adjusted to a level position at all times
when towing.
Raise and lock trailer wheel stand in up position when
towing.
Place chock blocks underneath wheel to prevent
rolling
while parked.
Place support blocks
underneath the trailer’s bumper
to prevent tipping while parked.
Use the trailer’s swivel jack to adjust the trailer height to
a level position while parked.
safety information
Before lifting, make sure that light tower parts are not
damaged and screws are not loosened or lost.
ALWAYS make sure crane or lifting device has been
properly secured to lifting hook of the equipment.
lift the equipment while engine is running.
Make sure the tower is in the stowed position before
lifting.
ALWAYS Make sure rear mast lock is secure before
lifting.
Use adequate lifting cable (wire or rope) of suffi cient
strength.
Use one point suspension hook and lift straight upwards.
STOWED
POSITION
LIFTING BALE
LIGHT TOWER
FORKLIFT
POCKETS
(2)
If lifting through pockets, make sure forks of forklift are
inserted in pockets as far as possible before lifting.
allow any person or animal to stand underneath
the equipment while lifting.
lift equipment to unnecessary heights.
Loading and Tie-Down on Flatbed Truck
NOTICE
Before loading light tower to fl atbed truck, disconnect all
four fl oodlight connectors and tie-wrap the cables against
the T-bar to prevent damage to the cables and connectors.
When loading onto fl atbed truck, make sure that front
jackstand of light tower is retracted and in the horizontal
position so that the foot does not make contact with the
deck fl oor.
Make sure that the two side (left and right) and two rear
jackstands are in the vertical postion, slightly extended,
so that each foot makes contact with the deck fl oor.
Straps and chains should be routed through the transport
tie-down points located beneath each corner of the
cabinet to allow even application of forece to the front
and rear of the machine.
secure the unit by running a strap or chain over
the tongue of the light tower. This may cause severe
damage to the unit.
CABLE
TIE
CABLE (X4)
CONNECTORS
DISCONNECTED
TONGUE
FRONT
JACKSTAND
RETRACTED
TRANSPORT TIE-DOWN
POINT (4)
SIDE
JACK
STAND
(2)
REAR JACK
STAND (2)
safety information
The electrical voltage required to operate the generator
can cause severe injury or even death through physical
contact with live circuits. Turn generator and all circuit
breakers OFF before performing maintenance on the
generator.
insert any objects into the output
receptacles during operation. This is
extremely dangerous. The possibility exists
of
operate light tower
or handle any electrical
equipment while standing in
water, while barefoot, while
hands are wet or in the rain.
A dangerous electrical
shock could occur, causing
severe bodily harm or
ALWAYS make sure the
area above the light tower is
open and clear of overhead
power lines and other
obstructions. The tower
extends in excess of 30
feet (9 meters). Contact
with overhead power
lines or other obstructions
could result in equipment
damage,
electrocution and even
Similar to boom equipment light tower may become
energized with high voltage. operate the light
tower within a radial distance of 17 feet (5 meters)
from high voltage power lines. If light tower becomes
energized with high voltage, contact with the equipment
could result in equipment damage,
Backfeed to a utility system can cause electrocution
and/or property damage.
connect the generator
to a building’s electrical system without a transfer switch
or other approved device. All installations
should be performed by a licensed
electrician in accordance with all
applicable laws and electrical codes.
Failure to do so could result in electrical
shock or burn, causing serious injury
let power cords or cables
use damaged or worn
cables or cords when
connecting equipment to generator. Inspect for cuts in
the insulation.
grab or touch a live power
cord or cable with wet hands. The
possibility exists of
Make sure power cables are securely connected.
Incorrect connections may cause electrical shock and
damage to the light tower.
NOTICE
ALWAYS
make certain that proper power or extension
cord has been selected for the job.
Grounding Safety
The light tower is equipped with a ground terminal for
your protection. ALWAYS
complete the grounding path
from the light tower to an extrnal grounding source.
ALWAYS
make sure that electrical circuits are properly
grounded to a suitable earth ground (ground rod) per
the National Electrical Code (NEC) and local codes
before operating light tower.
Severe injury or death by
electrocution
can result from operating an ungrounded
generator.
use gas piping as an electrical ground.
safety information
drop the battery. There is a possibility that the
battery will explode.
expose the battery to open fl ames,
sparks, cigarettes, etc. The battery contains
combustible gases and liquids. If these
gases and liquids come into contact with a
fl ame or spark, an explosion could occur.
ALWAYS wear safety glasses when handling
the battery to avoid eye irritation. The battery
contains acids that can cause injury to the
eyes and skin.
Use well-insulated gloves when picking up the battery.
ALWAYS keep the battery charged. If the battery is not
charged, combustible gas will build up.
ALWAYS recharge the battery in a well-ventilated
environment to avoid the risk of a dangerous concentration
of combustible gasses.
If the battery liquid (dilute sulfuric acid) comes into
contact with clothing or skin, rinse skin or clothing
immediately with plenty of water.
If the battery liquid (dilute sulfuric acid) comes into
contact with eyes, rinse eyes immediately with plenty
of water and contact the nearest doctor or hospital to
seek medical attention.
ALWAYS disconnect the
before performing service on the generator.
ALWAYS keep battery cables in good working condition.
Repair or replace all worn cables.
NOTICE
Decommissioning is a controlled process used to safely
retire a piece of equipment that is no longer serviceable.
If the equipment poses an unacceptable and unrepairable
safety risk due to wear or damage or is no longer cost
effective to maintain (beyond life-cycle reliability) and is to
be decommissioned (demolition and dismantlement),be
sure to follow rules below:
pour waste or oil directly onto the ground, down
a drain or into any water source.
Contact your country's Department of
Public Works or recycling agency in your
area and arrange for proper disposal of
any electrical components, waste or oil
associated with this equipment.
When the life cycle of this equipment is over, remove
battery and bring to appropriate facility for lead
reclamation. Use safety precautions when handling
batteries that contain sulfuric acid.
When the life cycle of this equipment is over, it is
recommended that the trowel frame and all other metal
parts be sent to a recycling center.
Metal recycling involves the collection of metal from
discarded products and its transformation into raw
materials to use in manufacturing a new product.
Recyclers and manufacturers alike promote the process
of recycling metal. Using a metal recycling center
promotes energy cost savings.
safety information
NOTICE
The diesel engine used in this equipment has been
designed to reduce harmful levels of carbon monoxide
(CO), hydrocarbons (HC) and nitrogen oxides (NOx)
contained in diesel exhaust emissions.
This engine has been certifi ed to meet US EPA Evaporative
emissions requirements in the installed confi guration.
Attempting to modify or make adjustments to the engine
emission system by unauthorized personnel without proper
training could damage the equipment or create an unsafe
condition.
Additionally, modifying the fuel system may adversely affect
evaporative emissions, resulting in fi nes or other penalties.
The emission control label is an integral part of the emission
system and is strictly controlled by regulations.
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.
lamp footcanDle plot
Figure 1. Lamp Footcandle Plot
specifications
LT6D Specifications
Light Tower Model LT6D
Weight (Dry) 1,575 lbs. (714 kg.)
Support Points 5
Wind Stability 65 mph (80.46 kph)
Lights(4) 1,000-Watt Metal Halide
Lumens 440,000
Light Coverage 5 to 7 acres
Light Termination 4 x 3-pin QD plug
Winch Capacity (2) 1,500 lbs. (680 kg.)
Winch Rope Wire 3/16 in.
Generator Specifications
Twist-Lock Receptacle Output 240 VAC @ 25 Amps/125 VAC @ 25 Amps X2
GFCI Receptacle Output 120 VAC @ 15 Amps
Main Breaker (CB1, 2-Pole) 50 Amps
Light Circuit Breakers (CB2/CB3 Single Pole) 20 Amps
GFCI Circuit Breaker (CB4, Single Pole) 15 Amps
Continuous Output 6,000 Watts
Noise Level @ 23 ft. (7 m) 68 dB
Trailer Specifications
Jackstand Capacity 2,000 lbs. (907 kg.)
Coupler Types
Fixed 2 in. Ball Coupler (Standard)
Adjustable 2 in. Ball Coupler (Option)
Fixed Pintle Eye-Ring Coupler (Option)
Adjustable Pintle Eye-Ring Coupler (Option)
Tire Size 13 in. (330 mm.)
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
specifications
Engine Specifications
Kohler KDW 1003
Diesel Engine
Engine Type 3-Cylinder, Diesel Engine
Displacement 62.73 cu. in. (1028 cc)
Max Output Standby 12 H.P. at 1,800 R.P.M.
Fuel Tank Capacity Approx. 34 U.S. Gallons (103.6 Liters)
Run Time With 4 Lights 64 Hours
Standard Idle Speed 1,800 R.P.M.
Fuel Type No. 2 Diesel Fuel
Oil Sump Capacity 2.64 U.S. Quarts (2.5 Liters)
Cooling System Liquid-cooled
Coolant Capacity 5.18 U.S. Quarts (4.9 Liters)
Starting Method Electric Start
Battery Type Group 24
Total Weight (Dry) 187.3 lbs. (85 Kg.)
Dimensions
Figure 2. Dimensions
Dimensions
Reference Letter Description Dimension
A Length (Mast Stowed Position) 128.3 in. (326 cm.)
B Length (Hitch To Rear Ext. Outrigger) 106 in. (269 cm.)
C Max. Height (Mast Deployed Position) 31.5 ft. (960 cm)
D Height (Mast Stowed Position) 73.7 in. (187 cm.)
E Ground Clearance (From Axle) 18.6 in. (47.2 cm.)
F Width (Tow Ready) 42.4 in. (108 cm.)
G Width (Outriggers Deployed) 79 in. (201 cm.)
STOWED
POSITION
DEPLOYED
POSITION
A
B
E
C
D
F
G
general information
The Multiquip LT6D Series Light Tower is a dedicated
general purpose light tower engineered to provide
dependable lighting for a wide range of applications. This
includes lighting for construction sites, industrial locations,
special events, and emergency conditions.
The lighting system of the LT6D is comprised of 4 metal
halide, 1000-watt lamps. These lights provide maximum
illumination with typical lighting coverage of 5 to 7 acres.
The lights are controlled by two 20 amp circuit breakers.
Each breaker will turn on a pair of lights (top/bottom).
The LT6D is powered by a Kohler, 3-cylinder, water cooled,
direct injection, 12 HP diesel engine that is equipped with
automatic shutdowns for low oil pressure, high coolant
temperature, and alternator charge failure.
The light tower mast has a maximum vertical height of 31.5
feet (9.6 meters) and can be raised by means of a manual
winch. The tower tensioning system is designed to provide
the necessary tension to safely control the pivot of the tower.
The light tower has a wind stability of up to 65 mph with
outriggers and jackstands fully deployed.
A panel light automatically illuminates the control panel
when the engine access door is opened (fuel tank side).
This feature is convenient for night deployment.
The LT6D is equipped with two auxiliary output receptacles
located on the control panel. To gain access to these
receptacles, simply lift the side panel door on the fuel tank
side of the generator.
The uppermost receptacle (twist-lock) can provide 240
VAC @ 25 amps or 125 VAC @ 25 amps X2 . The bottom
receptacle is a GFCI receptacle which can supply 120 VAC
at 15 amps. These receptacles can be used for light power
tools or other similar applications.
The 34-gallon fuel tank provides up to 72.5 hours of run
time while running at 3/4 load.
The trailer design of the LT6D light tower withstands the
rigors of normal highway towing and jobsite environments.
The trailer is engineered to DOT and is in compliance to the
standards of the National Association of Trailers (NATM).
notes
components
Figure 3. Major Components 1 (Control Panel Side)
120/240 VAC ENGINE
HOURS
OFF OFF
OFF
OFF OFF
1/10
LIGHTING120 VAC
10
2
4
4
3
5
67
8
12
9
11
1
Figure 3, 4, and 5 show the location of the controls and
components for the LT6D light tower. The function of each
component is described below:
1. — Unscrew this knob to
release mast for rotation. Tighten this knob to lock mast
after it is set to the desired position.
2. — Use this winch to extend the
mast to the desired height. Maximum height is 31.5 feet
(9.60 meters).
3. D-Ring Lifting Point — Attach a suitable lifting device
to this lifting point capable of lifting 2000 lbs. (257
kg). The D-ring lifting point has been positioned for a
fully balanced/configured light tower. Removal of any
components will unbalance the light tower.
4. Forklift Pockets — The light tower can be lifted by
inserting the forks of a forklift as far possible into the
pockets.
5. — Locks mast in cradle
support and releases mast when removed.
6. — When towing of the light tower
is required, place the tower mast into the cradle support.
Make sure cradle lock/release pin has been inserted
and mast is locked.
7. Lights— Four 1000-watt metal-halide bulbs with a
110,000 lumens capacity each. Light coverage is
typically between 5 to 7 acres.
8. — Allows the lights to be mounted vertically or
horizontally.
9. — Use this winch to raise the mast
to the vertical position.
10. Side Reflectors — There are four reflectors located on
the side of the light tower. The front reflectors are amber
and the rear reflectors are red.
11. — When the mast is in the full
vertical position, this lever must be in the locked position
(down).To place the mast in the stow position, push the
lever upward to release the mast.
12. — Attach the trailer's 2-inch coupler
to the towing vehicle. Use only the specified ball diameter
as indicated on your coupler. Use of any other ball
diameter will create an extremely dangerous condition
which can result in separation of the coupler and ball
or ball failure.
components
Figure 4. Major Components 2 (Control Panel Side)
120/240 VAC ENGINE
HOURS
OFF OFF
OFF
OFF OFF
1/10
LIGHTING120 VAC
1514
13
17
16
18 22
20
23
16
21 19
13. — Use this jackstand to support the
tongue when attaching the light tower to a towing vehicle.
14. — Always attach safety chains to the
towing vehicle. tow the light tower with the safety
chain unattached. Make sure safety chains are crossed
when towing.
15. — Place blocks (not included as part
of the light tower package) under each trailer wheel to
prevent rolling.
16. Tie-Down Points — Used to tie down light tower with
straps or chains to allow even application of force to the
front and rear of the equipment during transport.
17. — Remove cap to add No. 2 diesel fuel.
Fuel tank capacity is 34 gallons (103.6 liters).
18. — Displays engine status via
LEDs, water temperature, air filter, fuel, alternator, oil
pressure, glow plugs. Insert ignition key, turn clockwise
to start engine.
19. — Contains the auxiliary output
receptacles, engine hour meter, excitation capacitor
and circuit breakers.
20. — Contains information regarding the
light tower.
21. Panel Light — When the cabinet door is raised, the
light will automatically turn on. When the cabinet door
is closed, the light will turn off
22. Engine — 3-cylinder, water cooled, direct injection,
12 HP diesel engine.
23. — The 12-volt DC battery (CA:550/
CCA:430) is shipped wet and is ready for use.
Battery is shown here for clarity.
components
Figure 5. Major Components (Front/ Rear)
REAR VIEW FRONT VIEW
25
29
30
24
28
3332
29 26
34
27
31 31
24. Rear Reflectors — There are two reflectors mounted
on the rear light tower panel. These reflectors provide
better visibility in dark conditions.
25. Engine Exhaust Pipe — Directs engine exhaust to the
rear of the light tower. block this exhaust pipe
with obstructions. ALWAYS place the light tower in an
area free of obstructions.
26. — Before towing the light tower, make
sure that this light is operational and is working correctly.
tow the light tower if this light is inoperative.
27. — Before towing the light tower, make
sure that this light is operational and is working correctly.
tow the light tower if this light is inoperative
28. License Light — This light illuminates the license plate.
Whenever towing of the light tower is required, make
sure this light is operational.
29. — There are two
jackstands located at the rear of the trailer. Use these
jackstands and outriggers to level and support the light
tower.
30. Tires — This light tower uses a ST175-80D size tire.
Replace with only recommended tire size. tow
light tower with bad or worn tires.
31. — There are two
jackstands located at the front of the trailer. Use these
jackstands and outriggers to level and support the light
tower.
32. — This area of the light tower
encloses the components for the ballast assembly
lights 1 and 3 (top).
33. — This area of the light tower
encloses the components for the ballast assembly
lights 2 and 4 (bottom).
34. Ground Point — Connect earth ground (ground rod) to
this connection point if required.
notes
control panel
Figure 6. Control Panel/Ignition Switch
120/240 VAC ENGINE
HOURS
OFF OFF
OFF
OFF OFF
1/10
LIGHTING120 VAC
= NOT USED
3
12
8
7 6
14
12
13
15
16
9
10
11
4
5
CB1
CB4 CB2 CB3
control panel
Figure 6 shows the location of the controls and indicators
on the LT6D control panel. Below is a breif description of
each component.
1. — A double-pole 50
amp circuit breaker which protects the 120/240 VAC
twist-lock receptacle from overload. In addition it allows
voltage to be supplied to the light circuit breakers (CB2/
CB3), and GFCI breaker (CB4).
2. — This dual
voltage twist-lock receptacle provides 240 VAC @ 25
amps or 120 VAC @ 25 amps X2.
3. Panel Light — When the cabinet door is raised, the
light will automatically come on. When the cabinet door
closes, the switch is depressed and the light turns off.
4. — This digital hour meter indicates the
number of hours machine has been in use.
5. — Single pole, 20 amp circuit
breaker, turns on bottom lights.
6. — Single pole, 20 amp circuit
breaker, turns on top lights.
7. — Provides 120 VAC @ 15 amps.
8. — Single-pole, 15 amp
circuit breaker, protects GFCI receptacle from overload.
9. — Displays engine status via
LEDs. Perform engine maintenance depending on alarm
status.
10. — This alarm
LED (green) lights when the engine is
functioning normal.
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.
OK
12. Water Temperature Alarm Indicator —
This alarm LED flashes when the water
temperature becomes too hot for normal
engine operation. This condition will shut
down the engine. The LED will stay on until
the problem is corrected.
13. Alternator Alarm Indicator — This LED
turns on when the engine has shut down
because the electrical charging system is
not working properly.
14. PreHeat Indicator — This LED turns on
when the ignition key is turned to the ON
position indicating that the glow plugs are
warming up. When the LED goes off, the
engine is ready for starting. If the LED is
flashing, a low battery charge is detected.
15. — Insert key into
ignition switch and turn clockwise to the
position to warm the glow plugs. When
pre-heat indicator light goes OFF, turn the
key to the START position. Release key
when engine starts.
16. Air Filter Alarm Indicator — This LED
flashes when a blockage or problem with
the air filter is detected.
Figure 7. Kohler Engine Components
1
2
3
1
5
4
7
6
19
18
11
12
10
9
8
14
16
17 15
13
1. — Displays engine status/
alarms for high water temperature, low oil pressure,
pre-heat, charging system, and air filter.
2. Starter — Starts engine when ignition key is rotated
to the "START" position.
3. Fuel Filter — Filters fuel for contaminants.
4. Engine — 3-cylinder, water cooled, direct injection, 12
HP diesel engine.
5. Air Filter — Prevents dirt and other debris from
entering the fuel system. Unsnap air filter cover to gain
access to filter element.
6. — Remove to add engine oil. Reference
Tables 4 and 6 when adding engine oil.
7. Emissions Tag — Provides emissions model
identification and information.
8. — Used in the starting of the engine.
In cold weather conditions, allow the glow plugs to be
warmed before starting the engine.
9. Oil Pressure Sensor — Monitors engine oil pressure.
In the event of low oil pressure will shut down the
engine.
10. — When lifting of the engine is required,
attach a strap or chain of adequate lifting capacity to
these lifting points.
11. Oil Dip Stick — Remove to check amount and
condition of oil in crankcase.
12. Oil Filter — Spin-on type, filters oil for contaminants.
13. Engine Tag — Provides engine model identification
and information.
14. — Used to reduce noise and emissions.
15. — Remove to drain crankcase
oil. Always dispose of used oil and oil filters in an
environmentally safe manner. allow used oil
to drain onto the ground or into a water runoff drain.
16. Alternator — Provides power to the electrical system.
Replace with only manufacturer's recommended type
alternator.
17. Fan Guard — Protects personnel from rotating fan
blades.
18. Radiator — Use only recocoolant/anti-freeze. Radiator
coolant capacity is 5.18 gallons (4.9 liters).
19. — ALWAYS make sure the V-belt is properly
tensioned. A loose or defective V-belt can adversely
affect the performance of the engine.
Engine components can generate extreme
heat. To prevent burns, touch
these areas while the engine is running or
immediately after operating. operate
the engine with the muffler removed.
engine components
inspection
The diesel engine (Figure 7) must be checked for proper
lubrication and filled with fuel prior to operation. Refer to the
manufacturer’s engine manual for instructions and details
of operation and servicing.
Check or do the following:
Clean the light tower, removing dirt and dust, particularly
the engine cooling air inlet and air cleaner.
Check the air filter for dirt and dust. If air filter is dirty,
replace air filter with a new one as required.
Check all fastening nuts and bolts for tightness.
Check winch cables, make sure they are not frayed or
defective. Replace any defective or worn winch cables.
To check the engine oil level, make sure the light tower is
placed on secure level ground with the engine stopped.
1. Remove the dipstick from its holder and wipe it clean.
2. Insert and remove the dipstick from its holder. Check
the oil level shown on the dipstick.
3. If the oil level is low, add oil through the oil filler hole. DO
overfill. Fill to the normal operating level as shown
on the dipstick. Verify that the oil level is maintained
between the two notches as shown in Figure 8. Always
fill with recommended type oil as listed in Table 4. See
Table 2 for engine oil capacity.
Figure 8. Oil Dipstick
use light tower if winch cables are worn or
defective. Replace defective cables immediately.
Other types of motor oils may be substituted if they meet
the following requirements:
API Service Classification CH-4
API Service Classification CG-4
API Service Classification CF-4
ACEA Specification E3
ACEA Specification E2
-40 -35 -30 -25 -20 -15 -10 -5 0510 15 20 25 30 35 40 45 50
-40 -31 -22 -13 -4 5 14 23 32 41 50 59 68 77 86 95 104 113 122
SAE 10W
SAE 20W
SAE 30
SAE 10W-30
SAE 10W-40
SAE 10W-60
SAE 40
°C
°F
1. To check the engine fuel level, make sure the light
tower is placed on secure level ground with the engine
stopped.
2. Lift the light tower access door (Figure 9), control panel
side. Set the door support latch in place to keep the
door open (up).
Figure 9. Adding Fuel
3. Remove the fuel cap from the fuel tank.
4. Pay attention to the fuel tank capacity when replenishing
fuel. The fuel tank cap must be closed tightly after filling.
Handle fuel in a safe container. If the container does
not have a spout, use a funnel.
5. Wipe up any spilled fuel immediately!
Diesel fuel and its vapors are dangerous
to your health and the surrounding
environment. Avoid skin contact and/or
inhaling fumes. smoke while
refueling. attempt to refuel the
light tower if the engine is hot or running.
FUEL
ALWAYS fill the fuel tank with clean, fresh #2 diesel
fuel. fill the fuel tank beyond its capacity. DO
.
inspection
The 12-volt DC battery (Figure 10) is shipped wet and is
ready for use.
Figure 10. Battery (
When servicing of the battery is required, perform the
following:
A face shield and rubber gloves should be worn while
handling and servicing the battery's electrolyte.
Disconnect battery terminal clamps, and remove the
battery from the generator cabinet when servicing is
required.
overfill the battery.
The operator must wear the appropriate
protective equipment and clothing while
handling the battery.
Failure to wear protective equipment or clothing could
result in serious injury.
Electrolyte is an acid and must be
handled with caution. ALWAYS follow
servicing instructions from the electrolyte
manufacturer to ensure safety. Serious
injury can result from careless handling and
noncompliance to safety handling instructions.
Overfilling the battery may cause the electrolyte to
overflow resulting in corrosion to nearby components.
Immediately wash off any spilled electrolyte (battery
acid).
inspection
It is recommended that antifreeze/summer coolant be used
with the engine. This can be purchased pre-diluted or in
concentrate and mixed with 50% demineralized water. See
engine owner's manual for more details.
Day-to-day addition of coolant is done from the recovery
tank. When adding coolant to the radiator, remove
the radiator cap until the unit has completely cooled.
See Table 5 for engine and radiator, coolant capacities.
Make sure the coolant level in the recovery tank is always
between the "H" and the "L" markings.
When operating in freezing weather, make sure the proper
amount of antifreeze (Table 6) has been added.
When connecting the positive (+) cable
to the battery's positive (+) terminal post,
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.
NOTICE
Use only distilled water in the battery. Tap water can
reduce the operating life of the battery.
If adding coolant/antifreeze mix to the
radiator, remove the radiator cap
until the unit has completely cooled. The
possibility of hot coolant exists which can
cause severe burns.
Engine Type
Kohler KDW 1003 5.18 qt. (4.9 liters)
The engine may overheat if the radiator fins become
overloaded with dust or debris. Periodically clean the
radiator fins with compressed air. Cleaning inside the
machine is dangerous, so clean only with the engine turned
off and the negative battery terminal disconnected.
Periodic cleaning/replacement of the air cleaner filter is
necessary. Inspect it in accordance with the engine owner's
manual.
A slack fan belt may contribute to overheating, or to
insufficient charging of the battery. Inspect the fan belt for
damage and wear and adjust it in accordance with the
engine owner's manual.
The fan belt tension is proper if the fan belt bends 10 to 15
mm when depressed with the thumb as shown in Figure 11.
Figure 11. Fan Belt Tension
Anti-Freeze Operating Temperatures
Vol (%)
Anti-Freeze
Freezing Point Boiling Point
°C °F °C °F
40 -24 -12 106 222
50 -37 -34 108 226
NOTICE
When the antifreeze is mixed with water, the antifreeze
mixing ratio must be less than 50%.
Exhaust gases from diesel engines are extremely
poisonous. Whenever an engine is installed indoors the
exhaust fumes must be vented to the outside. The engine
should be installed at least two feet from any outside wall.
Using an exhaust pipe which is too long or too small can
cause excessive back pressure which will cause the engine
to heat excessively and possibly burn the valves.
Eliminate the danger of deadly carbon monoxide gas.
Remember that exhaust fumes from any gasoline or diesel
engine are very poisonous if discharged in a closed area.
If the light tower is installed indoors, you must make
provisions for venting the engine exhaust to the outside
of the building.
1. Locate the 4 key-lock female 3-pin DIN connectors on
the T-bar as shown in Figure 12.
Figure 12. 3-Pin DIN Female Connector
2. Next, locate the slot or key (A) on each female
connector as shown in Figure 12.
3. On the corresponding male connector, locate the key
tab (B) as shown in Figure 13.
Figure 13. Male Connector
A
B
setup
4. Align the key tab (B) on the male connector with the slot
or key (A) on the female connector and press together
until seated. Connect the light power cables to the T-bar
as referenced in Table 7 and Figure 14.
Figure 14. Light Power Cable Connections
5. Secure all cable connectors by screwing the knurled
locking nut of the male connector to the threaded
portion of the female connector to ensure good contact
between the two connectors. See Figure 14.
Light 1 J1
Light 2 J2
Light 3 J3
Light 4 J4
LIGHT 1
LIGHT 3
LIGHT 2
LIGHT 4
J1
J3
J4
J2
REAR
FRONT
MAST RAISED
setup
If additional grounding (ground rod) of the light tower is
required, connect a suitable ground cable to the light tower
ground lug as shown in Figure 15.
Figure 15. Grounding
LIGHT TOWER
GROUND LUG
GROUND
ROD
FOR EARTH
GROUND
CONNECT
TO BLDG.
GROUND
8FT. MINIMUM
GROUND
CABLE
REFERENCE
NEC 250-83(C)
1. Place light tower on secure level ground with chock
blocks (Figure 16) underneath each wheel to prevent
the light tower from rolling.
2. Make sure both outriggers (Figure 16) are extended.
To extend the outriggers, pull the locking pin on the
outrigger and hold while sliding out the outrigger
assembly
Figure 16. Deploying Outriggers
3. As soon as the pin clears the travel position hole,
release it and continue sliding out the outrigger. The
pin must snap into the outrigger locking hole in the
extended position.
4. After extending all outriggers, rotate all trailer
jackstands into the foot down position, then turn the
crank handle on the jackstands clockwise to lower it
and level the light tower.
5. Check behind the light tower and make sure all
personnel and objects are clear of the mast.
PULL PIN TO
RELEASE
OUTRIGGER
OUTRIGGER
JACKSTAND
PULL OUTRIGGER
TO EXTEND
ROTATE
JACKSTAND
TO PLACE
IN SUPPORT
POSITION
CHOCK BLOCK
setup
Figure 22. Mast Operation
MAST
ROTATION
LOCKING
KNOB
MAST
EXTENSION
HANDLE
FORKLIFT
POCKET
USED
AS A
MAST
ROTATION
HANDLE
MAST CRADLE
SUPPORT
MAST
LOCK/RELEASE
PIN
MAST
VERTICAL MAST
WINCH
PULL
PIN
MAST LOCK/RELEASE
LEVER
MAST
ROTATION COTTER
PIN
setup
1. To release the mast from the mast cradle (stow
position), remove the cotter pin (Figure 22) from the
cradle lock/release pin.
2. Next, remove (pull) the mast lock/release pin. This will
allow the mast to be raised to the vertical position.
3. To place the mast in the vertical position, turn the
vertical mast winch hand lever clockwise until the mast
is pointing upwards, fully vertical.
4. Once the mast is in the fully vertical position, push
down the mast release lock lever to prevent the mast
from falling.
stand behind
the trailer while the
mast is being raised or
lowered. Serious injury
could result if the mast
falls down.
Once the tower mast has been locked into its fully vertical
position, the mast can now be extended. The tower allows
the mast to be extended upwards in excess of 30 feet.
1. Turn the mast extension winch clockwise and observe
that the mast begins to extend upwards.
2. Continue turning the winch in the clockwise direction
until the desired height has been reached.
3. Release the winch handle. This winch is of the self-
locking type. The tension on the cable will keep the
mast in place.
To change the direction that the lights are facing, the mast
can be rotated.
1. With the mast in the deployed position (fully vertical),
unscrew the mast rotation locking knob (Figure 22) to
release the mast for rotation.
2. Grab hold of the forklift pocket (Figure 22) near the mast
extension winch and rotate the mast until the lights are
facing in the desired direction.
3. When the lights are facing in the desired direction,
tighten the mast rotation lock knob to lock the mast
in place.
ALWAYS make sure the area above
light tower is open and clear of
overhead power lines and other
obstructions. The tower extends
in excess of 30 feet (9 meters).
Contact with overhead power lines
or other obstructions could result in
equipment damage, serious injury
or death!
operation
1. Place the main circuit breaker, CB1 (Figure 18) on the
control panel to the position.
Figure 18. Main Circuit Breaker (CB1)
2. Place circuit breaker, CB2 (Figure 19) on the control
panel to the position. This will turn on the top 2
lights.
3. Next, place circuit breaker, CB3 (Figure 19) on the
control panel to the position. This will turn on the
bottom 2 lights.
Figure 19. Lamp Circuit Breakers (CB2/CB3)
4. Wait a few minutes for the ballasts to activate. Observe
that all lights are .
5. If all the light circuit breakers (CB2 and CB3) are in the
position (up), then all of the lights should be on.
6. If any of the lights are not on, refer to the troubleshooting
section of this manual.
7. Close all cabinet doors.
OFF OFF
CB1
CB2 CB3
NOTICE
operate the light tower with the engine
compartment doors open. Operation with the doors
open may cause insufficient cooling to the unit, and
damage may result.
1. Open the access panel door on the fuel side of the
light tower. Set the door latch in place to hold the door
open (up).
2. Insert the ignition key into the ignition key switch
(Figure 17). Turn the ignition key clockwise one click
to the position. The preheat indicator lamp will
light. Wait for this indicator lamp to go OFF. When the
indicator lamp goes OFF, the glow plugs have been
preheated and the engine can now be started.
Figure 17. Ignition Switch
3. Continue turning the ignition key all the way clockwise
When the engine has started, release the key.
4. Before placing the light tower into actual operation, let
the engine run for 3-5 minutes. Check any abnormal
sounds or smells that would be associated with a
defective light tower. If any abnormal conditions occur,
shut down the engine and correct the problem.
start the engine with any circuit breakers in
the position. Disconnect all loads before starting.
place hands near the V-belt or fan
blades while the engine is running.
The engine's exhaust contains harmful
emissions. ALWAYS ventilate the exhaust
when operating inside tunnels, excavations
or buildings. Direct exhaust away from
nearby personnel.
IGNITION
SWITCH
PREHEAT
LED INDICATOR
operation
This light tower is equipped with two auxiliary output
receptacles which are located on the control panel. One is
a 120/240 VAC twist lock receptacle the other is a 120VAC
GFCI receptacle.
This receptacle (Figure 20) is a dual voltage receptacle that
can provide 240 VAC @25 amps or 120 VAC @25 amps X2.
Figure 20. 120/240 Twist-Lock Receptacle
This receptacle (Figure 21) can provide 120 VAC @15
amps. It is protected by a 15 amp breaker.
Pressing the reset button resets the GFCI receptacle after
being tripped. Pressing the test button (See Figure 21) in
the center of the receptacle will check the GFCI function.
This receptacle should be tested at least once a month.
Figure 21. GFCI Test Button
grab or touch a live power cord
with wet hands. The possibility exists
of electrical shock, electrocution, and
even death!
X
Y
WG240 VAC
@ 25
AMPS
120 VAC
@ 25 AMPS
LINE 2
LINE 1
NEUTRAL
120 VAC
@ 25 AMPS
1. If a load is connected to the light tower, remove the load.
2. Place CB2 and CB3, light circuit breakers on the
control panel in the OFF position.
3. Wait a few seconds and observe that all four lights
are OFF.
4. Place CB4, GFCI circuit breaker on the control panel
in the OFF position.
5. Place CB1, main circuit breaker on the control panel
in the OFF position.
6. Let the engine idle for a few minutes with no load.
7. Turn the ignition key to the OFF position. Store key in
a safe location.
8. Lower light tower mast and place in stow position as
outlined in this manual.
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.
1. Turn the ignition key to the OFF position and turn all
circuit breakers to the OFF position.
1. Turn the mast extension winch counterclockwise, and
observe that the extension of the mast begins to lower.
2. Continue turning the winch counterclockwise until the
extension section of the mast has been fully retracted
(slack in the cable).
1. 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.
2. Turn the vertical mast winch counterclockwise and
observe that mast begins to approach the horizontal
position.
3. Continue rotating the vertical mast winch in the
counterclockwise direction until the mast is seated in
the mast cradle.
4. 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.
Frequency 10 hrs
Daily 200 hrs 500 hrs 1000
hrs
Engine
Check Engine Fluid Levels X
Check Fuel Filter X
Check Air Cleaner Dust Indicator (if equipped) X
Check for Leaks/Visual Walk Around X
Check for Loosening of Parts X
Replace Engine Oil and Filter *X
Service Battery X
Clean Unit, Inside and Outside X
Change Fuel Filter ** X
Clean Radiator and Check Coolant Protection Level X
Replace Air Filter Element X
Test Thermostats X
Check all Hoses and Clamps/Flush Radiator X
Clean Inside of Fuel Tank X
Generator Measure Insulation Resistance Over 3M ohms X
*— Replace engine oil and filter at 100 hours, first time only.
** — Replace fuel filter at 250 hours, first time only.
See Table 9 below for a general inspection and maintenance checklist. For more detailed maintenance, refer to the engine
service manual.
maintenance
When performing any maintenance on the light tower
or engine, follow all safety messages and rules for safe
operation stated at the beginning of this manual.
Prior to each use, the light tower should be cleaned and
inspected for deficiencies. Check for loose, missing or
damaged nuts, bolts or other fasteners. Also check for
fuel or oil leaks.
Thoroughly remove dirt and oil from the engine and
Accidental starts can cause severe injury or
death.
ALWAYS place the ON/OFF switch in the
OFF position.
Disconnect and ground spark plug leads
and disconnect negative battery cable
from battery before servicing.
Some maintenance operations may
require the engine to be run. Ensure
that the maintenance area is well
ventilated. Exhaust contains poisonous
carbon monoxide gas that can cause
unconsciousness and may result in
DEATH
ALWAYS allow the engine to cool
before servicing. NEVER attempt any
maintenance work on a hot engine.
maintenance
sourounding area. Clean or replace the air cleaner
elements as necessary. Check and retighten all fasteners
as necessary.
1. Release the locking latch and remove the air filter paper
element as shown in (Figure 23).
Figure 23. Air Cleaner Components
2. Clean the inside of the cover using a damp cloth.
3. Blow dry with compressed air (0.69 Mpa {7 kgf.cm2,
99.4 PSI} maximum) against the side of the paper filter
element (Figure 24) along the pleats. Then blow dry
against outside along the pleats, then against inside
again.
Figure 24. Cleaning Inner Paper Filter
4. If the air filter alarm indicator lamp, Figure 6, item 8 is
ON, blow dry paper element . Replace paper
element with a new one.
5. Inspect air filter cover for cracks, heat damage or
warpage. Replace if necessary.
6. Reinstall air filter paper element and support. Attach
cover and secure cover with locking latch.
PAPER
FILTER
ELEMENT
Replacing Fuel Filter
1. Set a container under the fuel filter cartridge (Figure 25)
to catch spilled fuel.
Figure 25. Fuel Filter
2. Using a wrench, turn the fuel filter cartridge to the left
to remove fuel filter.
3. Clean the fuel filter holder.
4. Coat the seal surface of the fuel filter cartridge with
engine oil, then reinstall the fuel filter cartridge back
onto the fuel filter holder.
5. When installing, tighten the fuel filter cartridge until it
makes contact with the seal surface of the filter holder.
Then tighten a further 2/3 of a turn.
If the fuel filter cartridge is tightened too much, the
seal will be damaged and will cause fuel leakage. Fuel
leakage will occur if the filter cartridge is not tightened
enough.
Fuel Addition
When adding diesel fuel, always use low sulfur No. 2 diesel
fuel . Always pour fuel through a mesh filter.
Removing Water from the Fuel Tank
After prolonged use, water and other impurities accumulate
in the bottom of the fuel tank. Occasionally remove the
drain cock and drain the contents. During cold weather,
the greater the empty volume inside the tank, the easier it
is for water to condense. This can be reduced by always
keeping the tank as full as possible.
SEAL
FUEL
FILTER
maintenance
Air Removal
If air enters the fuel injection system of a diesel engine,
starting becomes impossible. After running out of fuel, or
after disassembling the fuel system, bleed the system.
To restart after running out of fuel, squeeze the fuel primer
bulb to pump fuel into the engine. This unit is equipped with
an automatic air bleeding system.
Service Daily
If engine is operating in very dusty and dry grass conditions,
a clogged air cleaner will result in high fuel consumption,
loss of power and excessive carbon buildup in the
combustion chamber.
Clean the fuel strainer if it contains dust or water. Remove
dust or water in the strainer cap and wash it in diesel.
Securely fasten the fuel strainer cap so that fuel will not
leak. Check the fuel strainer every 200 hours of operation
or once a month.
Check the engine crankcase oil level prior to each use,
or when the fuel tank is filled. Insufficient oil may cause
severe damage to the engine. Make sure the generator is
level. The oil level must be between the two notches on the
dipstick as shown in (Figure 8).
1. Drain the engine oil when the oil is warm.
2. Set a container directly under the drain plug (Figure 26)
of the oil pan. Loosen the drain plug slowly.
Figure 26. Draining Engine Oil
3. Check the drained oil for excessive metal particles or
foreign material. Contact the distributor if there is metal
particles or foreign material.
maintenance
Figure 28. V-Belt Inspection
Lamp Replacement
1. Place all circuit breakers in the OFF position.
2. Remove protective lens and rubber gasket from lamp
housing.
3. Remove defective lamp from housing.
4. Install new lamp, be careful not to touch lamp surface
with your hands.
5. Reinstall protective lens and rubber gasket.
GLAZED
OIL SOAKED
BROKEN
CORD FAILURE
CRACKS
MISSING RUBBER
SIDEWALL
WEAR
WORN BACK
COVER
NOTICE
If a light (lamp) replacement is required, allow light to
cool for about 30 minutes before removing lamp. DO
touch light with your hands.
The oil and perspiration from one fingerprint may cause
the lamp to fail prematurely. ALWAYS use a clean dry
cloth for cleaning or handling lamps
Allow engine to cool when flushing out
radiator. Flushing the radiator while hot will
damage radiator. In addition, the possibility
of hot coolant exists which can cause
severe burns.
1. Using a filter wrench, turn filter cartridge (Figure 27)
to the left to remove it. If the filter cartridge is filled
with a large amount of oil, wait 10 minutes or so
before removing. Make sure there is no old gasket
stuck on the filter holder.
Figure 27. Oil Filter
2. Tighten drain plug. Clean the filter holder, fill the new
filter cartridge with clean engine oil, coat the packing
and thread of the new filter cartridge with engine
oil, then install it to the filter holder. Tighten until the
gasket surface contacts the seal surface of the filter
holder, then tighten it a further 3/4 to 1 turn.
3. Add engine oil through oil filler until the oil level is
between the H and L marks on the dipstick.
4. Run the engine at idling for a short time, then stop
the engine. Recheck the oil level and fill as necessary.
Visually examine the V-belt (Figure 28) and determine if it
is full of tiny cracks, frayed, has pieces of rubber missing,
is peeling or otherwise damaged.
Also, examine the belt and determine if it is oil soaked
or "glazed " (hard shiny appearance on the sides of the
belt). Either of these two conditions can cause the belt
to run hot, which can weaken it and increase the danger
of it breaking.
If the V-belt exhibits any of the above wear conditions
replace the V-belt immediately.
SEAL
OIL
FILTER
maintenance
1. Stop the engine and allow it to cool. Tighten valve of
the corrosion resistor (if equipped).
2. Turn water filler cap slowly and remove it.
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.
4. After draining the coolant, close drain plugs and fill
with tap water.
5. When the water level is near the mouth of the water
filler, open drain plugs and start the engine, and run
at low idling. Keep the engine running at low idling and
flush the radiator for about 10 minutes.
6. Adjust the flow of the water flowing in and draining
out to ensure that the radiator is always full during the
flushing operation. While flushing water through the
system, make sure the water inlet hose does not come
out of the radiator filler port.
7. After flushing, stop the engine, open drain plug and
drain the water, then close drain plugs.
8. After draining the water, flush the system with a flushing
agent. See instructions on flushing agent label.
9. After flushing, open drain plugs and drain out all the
water, then close drain plugs and add tap water so the
water level is near the mouth of the water filler.
10. When the water level is near the mouth of the water
filler, open drain plugs and start the engine, run at low
idling and continue to flush the system until clean water
comes out. Adjust the flow of the water flowing in and
draining out to ensure the radiator is always full during
the flushing operation.
11. When clean water comes out, stop the engine, drain
all the water, then close drain plugs.
12. Remove the corrosion resistor (if equipped) and open
valve.
13. Supply water until it flows over the water filler.
14. Drain the water inside reserve tank, clean the inside of
the reserve tank, then fill with coolant/water mixture to
between the full and low lines.
15. Stop the engine, wait for 3 minutes, add tap water until
the water level reaches near the water filler port, then
tighten the radiator cap.
The wire rope (cable) that raises and extends the mast is
a very important part of the light tower. There is one cable/
hand winch system, located on the tongue of the trailer, that
raises and extends the light tower mast. There is a second
cable/hand winch system located on the mast that serves
to raise and lower the two extendable sections of the mast.
To replace any components in the mast raise/lower cable
system (Figure 29), use the following steps:
Figure 29. Mast Raise/Lower Cable System
1. Lower the mast to the horizontal resting position.
2. Inspect the cable clamps, pulleys, and other components
for worn or damaged parts.
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.
Wire rope (cable) will fail if it is worn, frayed, misused,
crushed, kinked or damaged in any way. ALWAYS
check the cables and pulleys for any abnormalities
before use.
use it if there is even the slightest cause for
concern and replace any damaged cables or pulleys
immediately.
VERTICAL
HAND WINCH
CABLE
CABLE
SHEAVE
maintenance
5. Rethread the cable through the pulley and reattach the
cable to the ball socket pin.
6. Raise and lower the mast several times to verify correct
operation.
To replace the cable in the mast extension cable system
(Figure 30), use the following steps:
Figure 30. Mast Extension Cable System
1. Lower the mast to the horizontal resting position.
2. Inspect the cable clamps, pulleys, and other components
for worn or damaged parts. If either of the cables on
the mast needs to be replaced, they should both be
replaced at the same time.
3. Disassemble the mast by disconnecting the cables
from the mast and sliding the sections apart. The lower
cable can be disconnected from the winch.
4. There are two pulleys in the mast raise/lower cable
system. They should be removed and replaced if worn
or damaged. Worn or damaged pulleys can cause
premature cable failure.
5. Reassemble the mast extension cable system by
connecting the cable to the bottom of the upper mast
and sliding the upper mast into the opening of the
center mast. 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.
CENTER
MAST
PULLEY
ROUTE TO
HAND WINCH
LOWER
MAST
PULLEY
UPPER
MAST
CENTER
MAST
LOWER
MAST
LOWER
MAST
SHACKLE
The mast sections are heavy and awkward to handle.
Use proper lifting devices and procedures when
servicing the mast and its components.
6. Route the upper mast cable through the center mast
pulley and connect the free end of the cable to the
lower mast ankle shackle. Route the center mast
cable through the lower mast pulley and connect the
free end of the cable to the hand winch at the bottom
of the lower mast.
7. Raise, extend, retract and lower the mast several times
to verify correct operation.
STORAGE
For storage for over 30 days, the following is required:
Fill the fuel tank completely. Treat with fuel stabilizer if
necessary.
Completely drain oil from the crankcase and refill if
necessary with fresh oil.
Clean the entire light tower.
Disconnect the negative terminals of the battery and
cover it, or remove and store it separately.
If the ambient temperature is expected to drop below
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.
If light tower is going to be used again after long term
storage, perform the following.
Apply oil to the engine valve and rocker arms, and
examine the operating condition of the valves.
Change the oil in engine oil pan.
Replace all the filters.
Flush the inside of the cooling system.
Drain the water from the fuel tank and bleed the air from
the fuel system.
If the engine has not been started for more than one
year, contact your Kohler distributor to have engine
overhauled.
maintenance — trailers
The following trailer maintenance guidelines are intended
to assist the operator in preventive maintenance.
Your LT6D trailer comes standard with a fixed 2" ball
coupler. The tow bar channel provides a fastening option to
place other couplers (height-adjustable 2" ball and height
adjustable pintle/eye - Figure 31) that can be raised/lowered
to a desired towing height. Periodically check the channel
bolts for damage or loosening. When ordering couplers
please reference Table 10.
Figure 31. 2-Inch Adjustable Ball/Pintle Couplers
NOTICE
When replacing channel mounting hardware (nuts,
bolts and washers), substitute substandard
hardware. Pay close attention to bolt length and grade.
ALWAYS use manufacturer's recommended parts
when replacing channel mounting hardware.
Type
Fixed 2-Inch Ball P/N 29546
Adjustable 2-Inch Ball P/N 29720
Fixed Pintle/Eye P/N 29791
Adjustable Pintle/Eye P/N 29721
ADJUSTABLE
CHANNEL
2” ADJUSTABLE
BALL COUPLER
PINTLE/EYE
COUPLER
5/8” NYLOC
NUT
5/8” X 11” X 5”
BOLT
5/8” FLAT
WASHER
Wheel Bearings
Wheel bearings (Figure 32) must be inspected and
lubricated once a year or 12,000 miles to insure safe
operation of your trailer.
If trailer wheel bearings are immersed in water, they must
be replaced.
If the trailer has not been used for an extended amount
of time, have the bearings inspected and packed more
frequently, at least every six months and prior to use.
Follow the steps below to disassemble the wheel hub and
service the wheel bearings. See Figure 32.
Figure 32. Wheel Hub Components
After removing the dust cap, cotter pin, spindle nut and
spindle washer, remove the hub to inspect the bearings
for wear and damage.
Replace bearings that have flat spots on rollers, broken
roller cages, rust or pitting. Always replace bearings
and cups in sets. The inner and outer bearings are to
be replaced at the same time.
Replace seals that have nicks, tears or wear.
Lubricate the bearings with a high quality EP-2
automotive wheel bearing grease.
If trailer wheels are under water for a long period of
time, wheel bearings may fail. If this is the case, service
wheel bearings immediately.
The possibility exists of the wheels falling off causing
equipment damage and severe bodily harm even death!
WHEEL
HUB
BEARING
CUP
BEARING
CUP
BEARING
BEARING
OIL
SEAL
SPINDLE
NUT
SPINDLE
WASHER
COTTER
PIN
DUST
CAP
LUG
NUT
maintenance — trailers
Wheel Hub Adjustment
Every time the wheel hub is removed and the bearings are
reassembled, follow the steps below to check the wheel
bearings for free running and adjust.
Turn the hub slowly, by hand, while tightening the spindle
nut until you can no longer turn the hub by hand.
Loosen the spindle nut just until you are able to turn it
(the spindle nut) by hand. Do not turn the hub while the
spindle nut is loose.
Install a new cotter pin through the spindle nut and axle.
Check the adjustments. Both the hub and the spindle nut
should be able to move freely (the spindle nut motion
will be limited by the cotter pin).
crawl under the trailer unless it is on firm
and level ground and resting on properly placed and
secured jackstands.
The possibility exists of the trailer falling thus causing
equipment damage and severe bodily harm even death!
When performing trailer inspection and maintenance
activities, you must jack up the trailer using jacks and
jackstands.
When jacking and using jackstands, place them so
as to clear wiring, brake lines, and suspension parts
(i.e., springs, torsion bars). Place jacks and jackstands
inside of the perimeter strip on the supporting structure
to which the axles are attached.
Leaf Suspension
The leaf suspension springs and associated components
(Figure 33) should be visually inspected every 6,000 miles
for signs of excessive wear, elongation of bolt holes, and
loosening of fasteners. Replace all damaged parts
(suspension) immediately.
Figure 33. Leaf Suspension Components
Improper weld repair will lead to early failure of the
trailer structure and can cause serious injury or death.
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.
If the trailer is involved in an accident, have it inspected
immediately by qualified personnel. In addition, the
trailer should be inspected annually for signs of wear
or deformations.
U-BOLT
LEAF
SUSPENSIO
N
TIE PLATE
AXLE
U-BOLT
LOCKING
NUT
FRONT
HANGER BOLT
FRONT
HANGER
NUT
HANGER SUPPORT
BRACKET IS WELDED
TO FRAME
Worn or broken suspension parts can cause loss of
control, damage to equipment and severe bodily injury,
even death!
Check suspension regularly.
The following guidelines are intended to assist the operator
in the operation and handling of a trailer.
Safety precautions should be followed at all times when
operating a trailer. Failure to read, understand and follow
the safety guidelines could result in injury to yourself and
others. Loss of control of the trailer or tow vehicle can result
in death or serious injury.
Driving too fast for the conditions (maximum speed when
towing a trailer is 55 mph).
Overloading the trailer or loading the trailer unevenly.
Trailer improperly coupled to the hitch.
No braking on trailer.
Not maintaining proper tire pressure.
Not keeping lug nuts tight.
Not properly maintaining the trailer structure.
Ensure machine is towed level to tow vehicle.
Recheck the load tiedowns to make sure the load will
not shift during towing.
Before towing, check coupling, safety chain, safety
brake, tires, wheels and lights.
Check the lug nuts or bolts for tightness.
Check coupler tightness after towing 50 miles.
Use your mirrors to verify that you have room to change
lanes or pull into traffi c.
Use your turn signals well in advance. Allow plenty of
stopping space for your trailer and tow vehicle.
Allow plenty of stopping space for your trailer and tow
vehicle.
drive so fast that the trailer begins to sway
due to speed.
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.
Shift your automatic transmission into a lower gear for
city driving.
ALWAYS
use lower gears for climbing and descending
grades.
ride the brakes while descending grades, they
may get so hot that they stop working. Then you will
potentially have a runaway tow vehicle and trailer.
To conserve fuel, don’t use full throttle to climb a hill.
Instead, build speed on the approach.
Slow down for bumps in the road. Take your foot off the
brake when crossing the bump.
brake while in a curve unless absolutely
necessary. Instead, slow down before you enter the
curve and power through the curve. This way, the towing
vehicle remains in charge.
apply the brakes to correct extreme trailer
swaying. Continued pulling of the trailer, and even slight
acceleration, will provide a stabilizing force.
Anticipate the trailer “swaying.” Swaying is the trailer
reaction to the air pressure wave caused by passing
trucks and buses. Continued pulling of the trailer provides
a stabilizing force to correct swaying. DO NOT apply the
brakes to correct trailer swaying.
Use lower gear when driving down steep or long grades.
Use the engine and transmission as a brake. Do not
ride the brakes, as they can overheat and become
ineffective.
Be aware of your trailer height, especially when
approaching roofed areas and around trees.
Make regular stops, about once each hour. Confi rm
that:
• Coupler is secure to the hitch and is locked.
• Electrical connectors are secure.
• There is appropriate slack in the safety chains.
•
There is appropriate slack in the breakaway switch
pullpin cable.
• Tires are not visibly low on pressure.
safety guiDelines — trailers
When towing a trailer, you will have decreased acceleration,
increased stopping distance, and increased turning radius
(which means you must make wider turns to keep from
hitting curbs, vehicles, and anything else that is on the
inside corner). In addition, you will need a longer distance
to pass, due to slower acceleration and increased length.
Be alert for slippery conditions. You are more likely to be
affected by slippery road surfaces when driving a tow
vehicle with a trailer, than driving a tow vehicle without
a trailer.
Check rearview mirrors frequently to observe the trailer
and traffi c.
drive faster than what is safe.
Follow all of the safety precautions and instructions in
this manual to ensure safety of persons, equipment, and
satisfactory life of the trailer. Always use an adequate tow
vehicle and hitch. If the vehicle or hitch is not properly
selected and matched to the Gross Vehicle Weight Rating
(GVWR) of your trailer, you can cause an accident that
could lead to death or serious injury.
If you already have a tow vehicle, know your vehicle tow
rating and make certain the trailer’s rated capacity is less
than or equal to the tow vehicle’s rated towing capacity. If
you already have (or plan to buy) a trailer, make certain
that the tow rating of the tow vehicle is equal to or greater
than that of the trailer.
Driving too fast for severe road conditions can result in
loss of control and cause death or serious injury.
Decrease your speed as road, weather, and lighting
conditions deteriorate.
Always check for local trailer tow speed limits in your
area.
transport people on the trailer. The transport
of people puts their lives at risk and may be illegal.
The trailer VIN tag contains the critical safetyinformation
for the use of your trailer. Again, be sure your hitch and tow
vehicle are rated for the Gross Vehicle Weight Rating of
your trailer.
Proper selection and condition of the coupler and hitch
are essential to safely towing your trailer. A loss of
coupling may result in death or serious injury.
• Be sure the hitch load rating is equal to or greater
than the load rating of the coupler.
• Be sure the hitch size matches the coupler size.
• Observe the hitch for wear, corrosion and cracks
before coupling. Replace worn, corroded or cracked
hitch components before coupling the trailer to the
tow vehicle.
• Be sure the hitch components are tight before
coupling the trailer to the tow vehicle.
An improperly coupled trailer can result in death or
serious injury.
move the trailer until:
• The coupler is secured and locked to hitch.
• The safety chains are secured to the tow vehicle.
• The trailer jack(s) are fully retracted.
tow the trailer on the road until:
• Tires and wheels are checked.
• The trailer brakes are checked.
• The breakaway switch is connected to the tow vehicle.
• The load is secured to the trailer.
• The trailer lights are connected and checked.
Use of a hitch with a load rating less than the load rating
of the trailer can result in loss of control and may lead
to death or serious injury.
Use of a tow vehicle with a towing capacity less than
the load rating of the trailer can result in loss of control,
and may lead to death or serious injury.
Be sure your hitch and tow vehicle are rated for the
Gross Vehicle Weight Rating of your trailer.
safety guiDelines — trailers
Be sure that the brakes and all of the lights on your trailer
are functioning properly before towing your trailer. Check
the trailer taillights by turning on your tow vehicle headlights.
Check the trailer brake lights by having someone step on
the tow vehicle brake pedal while you look at trailer lights.
Do the same thing to check the turn signal lights. See Trailer
Wiring Diagram section in this manual.
Standard mirrors usually do not provide adequate visibility
for viewing traffi c to the sides and rear of a towed trailer.
You must provide mirrors that allow you to safely observe
approaching traffi c.
Driving a vehicle with a trailer in tow is vastly different
from driving the same vehicle without a trailer in tow.
Acceleration, maneuverability and braking are all diminished
with a trailer in tow.
It takes longer to get up to speed, you need more room to
turn and pass, and more distance to stop when towing a
trailer. You will need to spend time adjusting to the different
feel and maneuverability of the tow vehicle with a loaded
trailer.
Because of the signifi cant differences in all aspects of
maneuverability when towing a trailer, the hazards and risks
of injury are also much greater than when driving without
a trailer. You are responsible for keeping your vehicle and
trailer in control, and for all the damage that is caused if
you lose control of your vehicle and trailer.
As you did when learning to drive an automobile, fi nd
an open area with little or no traffi c for your fi rst practice
trailering. Of course, before you start towing the trailer, you
must follow all of the instructions for inspection, testing,
loading and coupling. Also, before you start towing, adjust
the mirrors so you can see the trailer as well as the area
to the rear of it.
Improper electrical connection between the tow vehicle
and the trailer will result in inoperable lights and can
lead to collision.
Before each tow, check that the tail lights, brake lights
and turn signals work.
Drive slowly at fi rst, 5 mph or so, and turn the wheel to
get the feel of how the tow vehicle and trailer combination
responds. Next, make some right and left hand turns.
Watch in your side mirrors to see how the trailer follows
the tow vehicle. Turning with a trailer attached requires
more room.
Stop the rig a few times from speeds no greater than
10 mph. If your trailer is equipped with brakes, try using
different combinations of trailer brake and tow vehicle brake.
Note the effect that the trailer brakes have when they are
the only brakes used. When properly adjusted, the trailer
brakes will come on just before the tow vehicle brakes.
It will take practice to learn how to back up a tow vehicle
with a trailer attached. Take it slow. Before backing up, get
out of the tow vehicle and look behind the trailer to make
sure that there are no obstacles.
Some drivers place their hands at the bottom of the steering
wheel, and while the tow vehicle is in reverse, “think” of the
hands as being on the top of the wheel. When the hands
move to the right (counterclockwise, as you would do to
turn the tow vehicle to the left when moving forward), the
rear of the trailer moves to the right. Conversely, rotating
the steering wheel clockwise with your hands at the bottom
of the wheel will move the rear of the trailer to the left while
backing up.
If you are towing a bumper hitch rig, be careful not to allow
the trailer to turn too much because it will hit the rear of the
tow vehicle. To straighten the rig, either pull forward or turn
the steering wheel in the opposite direction.
Figure A below is a sample of the Vehicle Identifi cation
Number (VIN) Tag which is typically located on the left front
of the trailer. See Figure B for location.
Figure A. Vehicle VIN Tag
safety guiDelines — trailers
Figure B. VIN Tag Location
The trailer VIN Tag contains the following critical safety
information for the use of your trailer.
GAWR
: The maximum gross weight that an axle cansupport.
It is the lowest of axle, wheel, or tire rating.
Usually, the tire or wheel rating is lower than the axle rating,
and determines GAWR.
: The maximum allowable gross weight of the trailer
and its contents. The gross weight of the trailer includes
the weight of the trailer and all of the items within it. GVWR
is sometimes referred to as GTWR (Gross Trailer Weight
Rating), or MGTW (Maximum Gross Trailer Weight). GVWR,
GTWR and MGTW are all the same rating.
The sum total of the GAWR for all trailer axles may be less
than the GVWR for the trailer, because some of the trailer
load is to be carried by the tow vehicle, rather than by the
trailer axle(s). The total weight of the cargo and trailer must
not exceed the GVWR, and the load on an axle must not
exceed its GAWR.
: The tire pressure (psi) measured when cold.
: The Vehicle Identifi cation Number.
: Some information that comes with the
trailer (such as the Manufacturer’s Statement of Origin)
is not a reliable source for “empty” or “net” weight. The
shipping documents list average or standard weights and
your trailer may be equipped with options.
To determine the “empty” or “net” weight of your trailer,
weigh it on an axle scale. To fi nd the weight of the trailer
using an axle scale, you must know the axle weights of
your tow vehicle without the trailer coupled. Some of the
trailer weight will be transferred from the trailer to the tow
vehicle axles, and an axle scale weighs all axles, including
the tow vehicle axles.
The towing hitch attached to your tow vehicle must have a
capacity equal to or greater than the load rating of the trailer
you intend to tow. The hitch capacity must also be matched
to the tow vehicle capacity. Your vehicle dealer can provide
and install the proper hitch on your tow vehicle.
Sway bars, shock absorbers, heavy duty springs, heavy
duty tires and other suspension components may be
required to suffi ciently tow the trailer and pump.
The size of the trailer that is being towed and your state
law regulations determine the size of the mirrors. However,
some states prohibit extended mirrors on a tow vehicle,
except while a trailer is actually being towed. In this
situation, detachable extended mirrors are necessary.
Check with your dealer or the appropriate state agency
for mirror requirements.
A Heavy Duty Flasher is an electrical component that may
be required when your trailer turn signal lights are attached
to the tow vehicle fl asher circuit.
An Electrical Connector connects the lights on the trailer
to the lights on the towing vehicle.
It is wise to carry these warning devices even if you are
not towing a trailer. It is particularly important to have these
when towing a trailer because the hazard fl ashers of your
towing vehicle will not operate for as long a period of time
when the battery is running both the trailer lights and tow
vehicle lights.
safety guiDelines — trailers
If the coupler connection comes loose, the safety chains
can keep the trailer attached to the tow vehicle. With
properly rigged safety chains, it is possible to keep the
tongue of the trailer from digging into the road pavement,
even if the coupler-to-hitch connection comes apart.
A device on the trailer that is used to raise and lower the
coupler. The jack is sometimes called the “landing gear” or
the “tongue jack”.
The LT6D comes standard with a fi xed 2" ball coupler.
Optional couplers are available:
Fixed Pintle Eye-Ring Coupler
Adjustable 2" Ball Coupler
Adjustable Pintle Eye-Ring Coupler
A standard 2" ball coupler (Figure C) connects to a 2" ball
hitch normally located on the bumper of the tow vehicle. All
ball couplers come with a locking latch atop the coupler that
must be engaged to ensure that the hitch ball is securely
locked to the trailer coupler.
Figure C. Ball Coupler
Before each tow, coat the ball with a thin layer of automotive
bearing grease to reduce wear and ensure proper operation.
Check the locking device that secures the coupler to the
ball for proper operation.
If you see or feel evidence of wear, such as fl at spots,
deformations, pitting or corrosion, on the ball or coupler,
immediately have your dealer inspect them to determine
the proper action to prevent possible failure of the ball and
coupler system. All bent or broken coupler parts must be
replaced before towing the trailer.
The coupler handle lever must be able to rotate freely and
automatically snap into the latched position. Oil the pivot
points, sliding surfaces, and spring ends with SAE 30W
motor oil. Keep the ball socket and latch mechanism clean.
Dirt or contamination can prevent proper operation of the
latching mechanism.
The load rating of the coupler and the necessary ball size
are listed on the trailer tongue. You must provide a hitch and
ball for your tow vehicle where the load rating of the hitch
and ball is equal to or greater than that of your trailer.
Also, the ball size must be the same as the coupler size. If
the hitch ball is too small, too large, is underrated, is loose
or is worn, the trailer can come loose from the tow vehicle
and may cause death or serious injury.
THE TOW VEHICLE, HITCH AND BALL MUST HAVE A
RATED TOWING CAPACITY EQUAL TO OR GREATER
THAN THE TRAILER
. IT IS ESSENTIAL THAT THE HITCH BALL BE
OF THE SAME SIZE AS THE COUPLER.
The ball size and load rating (capacity) are marked on the
ball. Hitch capacity is marked on the hitch.
Coupler-to-hitch mismatch can result in uncoupling,
leading to death or serious injury.
Be sure the LOAD RATING of 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
the ball coupler.
safety guiDelines — trailers
Rock the ball to make sure it is tightened to the hitch,
and visually check that the hitch ball nut is solid against
the lock washer and hitch frame.
Wipe the inside and outside of the coupler. Clean and
visually inspect it for cracks and deformations. Feel the
inside of the coupler for worn spots and pits.
Be sure the coupler is secured tightly to the tongue of the
trailer. All coupler fasteners must be visibly solid against
the trailer frame.
The bottom surface of the coupler must be above the top
of the hitch ball. Use the tongue jackstand to support
the trailer tongue. Wood or concrete blocks may also
be used.
Lubricate the hitch ball and the inside of the coupler with
a thin layer of automotive bearing grease.
Slowly back up the tow vehicle so that the hitch ball is
near or aligned under the coupler.
Using the jackstand at the front of trailer (tongue), turn
the jackstand crank handle to raise the trailer. If the ball
coupler does not line up with the hitch ball, adjust the
position of the tow vehicle.
Open the coupler locking mechanism. Ball couplers have
a locking mechanism with an internal moving piece and
an outside handle. In the open position, the coupler is
able to drop fully onto the hitch ball.
A worn, cracked or corroded hitch ball can fail while
towing and may result in death or serious injury.
Before coupling trailer, inspect the hitch ball for wear,
corrosion and cracks.
Replace worn or damaged hitch ball.
A loose hitchball nut can result in uncoupling, leading
to death or serious injury.
Be sure the hitch ball is tight to the hitch before coupling
the trailer.
Lower the trailer (Figure D) until the coupler fully engages
the hitch ball.
Figure D. Ball Hitch Coupling Mechanism
Engage the coupler locking mechanism. In the engaged
position, the locking mechanism securely holds the
coupler to the hitch ball.
Insert a pin or lock through the hole in the locking
mechanism.
Be sure the coupler is all the way on the hitch ball and
the locking mechanism is engaged. A properly engaged
locking mechanism will allow the coupler to raise the rear
of the tow vehicle. Using the trailer jackstand, verify that
you can raise the rear of the tow vehicle by 1 inch after
the coupler is locked to the hitch.
Lower the trailer so that its entire tongue weight is held
by the hitch.
Raise the jackstand to a height where it will not interfere
with the road.
If the coupler cannot be secured to the hitch ball, do not
tow the trailer. Call your dealer for assistance. Lower the
trailer so that its entire tongue weight is held by the hitch
and continue retracting the jack to its fully retracted position.
2-INCH
TRAILER
COUPLER TOW
VEHICLE
2-INCH
BALL
NOTICE
Overloading can damage the tongue jack.
use the tongue jack to raise the tow vehicle more than
one inch.
safety guiDelines — trailers
Visually inspect the safety chains and hooks for wear or
damage. Replace worn or damaged safety chains and
hooks before towing.
Attach the safety chains so that they:
• Cross underneath the coupler. See Figure E.
Figure E. Attaching Safety Chain (Ball Hitch)
• Loop around a frame member of the tow vehicle or
holes provided in the hitch system ( attach
them to an interchangeable part of the hitch assembly).
• Have enough slack to permit tight turns, but not be
close to the road surface, so if the trailer uncouples, the
safety chains can hold the tongue up above the road
.
2-INCH
TRAILER
TONGUE
SAFETY CHAIN
MASTER LINK CROSS BOTH
SAFETY CHAINS
TOW
VEHICLE
IMPORTANT!
Improper rigging of the safety chains can result in
loss of control of the trailer and tow vehicle, leading
to death or serious injury, if the trailer uncouples from
the tow vehicle.
• Fasten chains to frame of tow vehicle. fasten
chains to any part of the hitch unless the hitch has
holes or loops specifi cally for that purpose.
• Cross chains underneath hitch and coupler with
enough slack to permit turning and to hold tongue
up, if the trailer comes loose.
Connect the trailer lights to the tow vehicle’s electrical
system using the electric connectors at the front of the
trailer (tongue). Refer to the wiring diagram shown in the
trailer wiring diagram section of this manual. Before towing
the trailer check for the following:
Running lights (turn on tow vehicle headlights).
Brake Lights (step on tow vehicle brake pedal).
Backup Lights (place tow vehicle gear shift in reverse).
Turn Signals (activate tow vehicle directional signal
lever).
Follow these steps to uncouple ball hitch from tow
vehicle:
Block trailer tires to prevent the trailer from rolling, before
jacking the trailer up.
Disconnect the electrical connector.
Disconnect the breakaway brake switch cable. Promptly
replace the pullpin in the switchbox.
Before extending jackstand, make certain the ground
surface below the jackstand foot will support the tongue
load.
Rotate the jackstand handle (or crank) clockwise. This
will slowly extend the jack and transfer the weight of the
trailer tongue to the jack.
Improper electrical connection between the tow vehicle
and the trailer will result in inoperable lights and electric
brakes, and can lead to collision.
Before each tow:
• Check that the taillights, brake lights and turn signals
work.
• Check that the electric brakes work by operating the
brake controller inside the tow vehicle.
safety guiDelines — trailers
A pintle eye coupler (Figure F) connects to a pintle-hook
hitch that is located on or under the rear bumper of the tow
vehicle. This system of coupling a trailer to a tow vehicle is
sometimes referred to as a “lunette eye, tow ring or G.I.
hitch.”
Figure F. Pintle Eye-Ring Coupler
A pintle coupler trailer may be fi tted with a tongue jackstand
that can raise and lower the coupler. The tongue jack is
mounted to the A-frame (front or tongue) part of the trailer.
By rotating the jack handle clockwise, the jack will extend
and raise the tongue of the trailer.
The load rating of the coupler and the necessary pintle
hitch size are listed on the trailer tongue. You must provide
a pintle hitch and pintle coupler for your tow vehicle, where
the load rating of the pintle hitch and pintle coupler is equal
to or greater than that of your trailer.
Also, the pintle hitch size must be the same as the pintle
coupler size. If the hitch is too small, too large, underrated,
loose or worn, the trailer can come loose from the tow
vehicle, and may cause death or serious injury.
Before each tow, check the locking device that secures the
coupler to the pintle hook assembly.
The pintle hook lever must be able to operate freely and
automatically snap into place into the latched position.
Lightly oil the pivot points and sliding surfaces with SAE30W
motor oil to prevent rust and help ensure proper operation
of the latching mechanism.
If you see or feel evidence of wear, such as fl at spots,
deformations, pitting or corrosion, on the pintle hook or
coupler, immediately have your dealer inspect them to
determine the proper action to prevent possible failure of
the ball andcoupler system. All bent or broken coupler parts
must be replaced before towing the trailer.
THE TOW VEHICLE, PINTLE HITCH AND PINTLE
COUPLER MUST HAVE A RATED TOWING CAPACITY
EQUAL TO OR GREATER THAN THE TRAILER
Gross
.
IT IS ESSENTIAL THAT THE PINTLE HITCH BE OF THE
SAME SIZE AS THE PINTLE COUPLER.
The coupler size and load rating (capacity) are marked on
the coupler. Hitch capacity is marked on the hitch.
Rock the pintle eye coupler to make sure it is secured
tightly to the hitch.
Wipe the inside and outside of the pintle coupler. Clean
and inspect it visually for cracks and deformations. Feel
the inside of the coupler for worn spots and pits.
Be sure the coupler is secured tightly to the tongue of the
trailer. All coupler fasteners must be visibly solid against
the trailer frame.
Coupler-to-hitch mismatch can result in uncoupling,
leading to death or serious injury.
Be sure the LOAD RATING of the pintle hitch hook is
equal or greater than the load rating of the pintle eye
coupler.
Be sure the SIZE of the pintle hitch hook matches the
size of the pintle eye coupler.
A worn, cracked or corroded pintle hitch hook can fail
while towing, and may result in death or serious injury.
Before coupling trailer, inspect the pintle hitch hook for
wear, corrosion and cracks.
Replace worn or damaged pintle hitch hook.
safety guiDelines — trailers
Raise the bottom surface of the coupler to be above the
top of the pintle hitch hook. Use the tongue jackstand
to support the trailer tongue. Wood or concrete blocks
may also be used.
Slowly back up the tow vehicle so that the pintle
hitch hook is near or aligned under the pintle eye ring
coupler.
Using the jackstand at the front of trailer (tongue), turn
the jackstand crank handle to raise the trailer. If the pintle
eye coupler does not line up with the pintle hitch hook,
adjust the position of the tow vehicle.
OPEN the pintle hook locking mechanism (Figure G).
Place the hook inside the eye coupler. CLOSE the pintle
hook mechanism.
Figure G. Attaching Safety Chain (Pintle Coupler)
Insert a pin or lock through the hole in the locking
mechanism.
Be sure the pintle hook is inserted completely through
the eye ring and the locking mechanism is engaged.
A properly engaged locking mechanism will allow the
coupler to raise the rear of the tow vehicle. 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.
A defective pintle hitch not properly fastened can result
in uncoupling, leading to death or serious injury.
Be sure the pintle hook is securly tighten to the tow
vehicle before coupling the trailer.
TRAILER
TONGUE
SAFETY CHAIN
MASTER LINK
TOW
VEHICLE
CROSS BOTH
SAFETY CHAINS
IMPORTANT!
PINTLE
HOOK
PINTLE
RING “EYE”
SAFETY
CHAIN
Lower the trailer so that its entire tongue weight is held
by the hitch.
Raise the jackstand to a height where it will not interfere
with the road.
TIRE SAFETY
Trailer tires and wheels are more likely to fail than car tires
and wheels because they carry a heavier load. Therefore,
it is essential to inspect the trailer tires before each tow.
If a tire has a bald spot, bulge, cuts, is showing any cords,
or is cracked, replace the tire before towing. If a tire has
uneven tread wear, take the trailer to a dealer service
center for diagnosis.
Uneven tread wear can be caused by tire imbalance, axle
misalignment or incorrect infl ation.
Tires with too little tread will not provide adequate tracking
on wet roadways and can result in loss of control, leading
to death or serious injury.
Improper tire pressure causes an unstable trailer and
can result in a tire blowout and loss of control. Therefore,
before each tow you must also check the tire pressure. Tire
pressure must be checked when tires are cold.
Allow 3 hours cool-down after driving as much as 1 mile at
40 mph before checking tire pressure. Trailer tires will be
infl ated to higher pressures than passenger vehicle tires.
Since trailer wheels and lug nuts (or bolts) are subjected
to greater side loads than automobile wheels, they are
more prone to loosen. Before each tow, check to make
sure they are tight.
The proper tightness (torque) for lug nuts is listed in the lug
nut tightening section of this manual. Use a torque wrench
to tighten the lug nuts. If you do not have a torque wrench,
use a lug wrench (from your tow vehicle) and tighten the
nuts as much as you can. Then have a service garage or
trailer dealer tighten the lug nuts to the proper torque.
safety guiDelines — trailers
Lug nuts are also prone to loosen after first being
assembled. When driving a new trailer (or after wheels
have been remounted), check to make sure they are tight
after the fi rst 10, 25 and 50 miles of driving and before
each tow thereafter.
Failure to perform this check can result in a wheel parting
from the trailer and a crash, leading to death or serious
injury.
Determining Load Limit of Trailer
Determining the load limits of a trailer includes more than
understanding the load limits of the tires alone. On all
trailers there is a Federal certifi cation/VIN label that is
located on the forward half of the left (road) side of the unit.
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
Metal creep between the wheel rim and lug nuts will
cause rim to loosen and could result in a wheel coming
off, leading to death or serious injury.
Tighten lug nuts before each tow.
Lug nuts are prone to loosen after initial installation,
which can lead to death or serious injury.
Check lug nuts for tightness on a new trailer or when
wheel(s) have been remounted after the fi rst 10, 25
and 50 miles of driving.
Improper lug nut torque can cause a wheel parting from
the trailer, leading to death or serious injury.
Be sure lug nuts are tight before each tow.
Improper tire pressure can result in a blowout and loss
of control, which can lead to death or serious injury.
Be sure tires are infl ated to pressure indicated on side
wall before towing trailer.
Gross Axle Weight Rating (GAWR). This is the most a the
axle can weigh.
There is a vehicle placard (Figure H) located in the same
location as the certifi cation label described above. This
placard provides tire and loading information. In addition,
this placard will show a statement regarding maximum
cargo capacity.
Figure H. Trailer Tire Placard
If additional work items (hoses, tools, clamps etc.) are
going to be added to the trailer, be sure they are distributed
evenly to prevent overloading front to back and side to side.
Heavy items should be placed low and as close to the axle
positions as reasonable. Too many items on one side may
overload a tire.
Excessive loads and/or underinfl ation cause tire overloading
and, as a result, abnormal tire fl exing occurs. This situation
can generate an excessive amount of heat within the tire.
Excessive heat may lead to tire failure. It is the air pressure
that enables a tire to support the load, so proper infl ation
is critical. The proper air pressure may be found on the
certifi cation/VIN label and/or on the Tire and Loading
Information placard. This value should never exceed the
maximum cold infl ation pressure stamped on the tire.
Perform the following steps to determine the load limit of
your trailer.
Locate the statement, “The weight of cargo should never
exceed XXX kg or XXX lbs.,” on your vehicle’s Tire and
Loading Information placard (Figure I). This value equals
the available amount of equipment load capacity.
The weight of cargo should never exceed XXX kg. Or XXX lbs.
TIRE
FRONT
REAR
SPARE
SIZE
COLD TIRE PRESSURE
TIRE AND LOADING INFORMATION
SEE OWNER’S
MANUAL FOR
ADDITIONAL
INFORMATION
safety guiDelines — trailers
Determine the weight of the equipment being loaded
on the tow vehicle. That weight may not safely exceed
the available equipment load capacity. The trailer’s Tire
Information Placard is attached adjacent to or near the
trailer’s VIN (Certifi cation) label at the left front of the trailer
(See Figure I).
Locate the statement, “The combined weight of occupants
and cargo should never exceed XXX lbs.,” on your vehicle’s
placard.
Determine the combined weight of the driver and
passengers who will be riding in your vehicle.
Subtract the combined weight of the driver and passengers
from XXX kilograms or XXX pounds.
The resulting fi gure equals the available amount of cargo
and luggage capacity. For example, if the “XXX” amount
equals 1400 lbs. and there will be fi ve 150 lb. passengers
in your vehicle, the amount of available cargo and luggage
capacity is 650 lbs. (1400-750 (5 x 150) = 650 lbs.).
Determine the combined weight of luggage and cargo
being loaded on the vehicle. That weight may not safely
exceed the available cargo and luggage capacity calculated
in Step 4.
If your vehicle will be towing a trailer, load from your trailer
will be transferred to your vehicle. Consult the tow vehicle’s
manual to determine how this weight transfer reduces the
available cargo and luggage capacity of your vehicle.
Studies of tire safety show that maintaining proper tire
pressure, observing tire and vehicle load limits (not carrying
more weight in your vehicle than your tires or vehicle can
safely handle), avoiding road hazards and inspecting tires
for cuts, slashes and other irregularities are the most
important things you can do to avoid tire failure, such as
tread separation or blowout and fl at tires. These actions,
along with other care and maintenance activities, can
also:
Improve vehicle handling.
Help protect you and others from avoidable breakdowns
and accidents.
Improve fuel economy.
Increase the tire life.
Use the information contained in this section to make tire
safety a regular part of your vehicle maintenance routine.
Recognize that the time you spend is minimal compared
with the inconvenience and safety consequences of a fl at
tire or other tire failure.
Federal law requires tire manufacturers to place standardized
information on the sidewall of all tires (Figure I). This
information identifies and describes the fundamental
characteristics of the tire and also provides a tire
identifi cation number for safety standard certifi cation and
in case of a recall.
Figure I. Standard Tire Sidewall Information
P: The “P” indicates the tire is for passenger vehicles.
: This three-digit number gives the width in
millimeters of the tire from sidewall edge to sidewall edge.
In general, the larger the number, the wider the tire.
: This two-digit number, known as the aspect
ratio, gives the tire’s ratio of height to width. Numbers of
70 or lower indicate a short sidewall for improved steering
response and better overall handling on dry pavement.
P
: The “R” stands for radial. Radial ply construction of tires
has been the industry standard for the past 20 years.
safety guiDelines — trailers
: This two-digit number is the wheel or rim
diameter in inches. If you change your wheel size, you
will have to purchase new tires to match the new wheel
diameter.
: This two- or three-digit number is the tire’s
load index. It is a measurement of how much weight each
tire can support. You may fi nd this information in your
owner’s manual. If not, contact a local tire dealer.
Note:
You may not fi nd this information on all tires because it is
not required by law.
: The “M+S” or “M/S” indicates that the tire has
some mud and snow capability. Most radial tires have
these markings; hence, they have some mud and snow
capability.
Speed Rating
: The speed rating denotes the speed at
which a tire is designed to be driven for extended periods
of time. The ratings range from 99 miles per hour (mph) to
186 mph. These ratings are listed in Table A. Note: You may
not fi nd this information on all tires because it is not required
by law.
: This begins with the
letters “DOT” and indicates that the tire meets all federal
standards. The next two numbers or letters are the plant
code where it was manufactured, and the last four numbers
represent the week and year the tire was built. For example,
the numbers 3197 means the 31st week of 1997. The other
numbers are marketing codes used at the manufacturer’s
discretion. This information is used to contact consumers
if a tire defect requires a recall.
: The number of
plies indicates the number of layers of rubber-coated fabric
Speed Rating
Letter Rating Speed Rating
Q 99 mph
R 106 mph
S 112 mph
T 118 mph
U 124 mph
H 130 mph
V 149 mph
W 168* mph
Y 186* mph
in the tire. In general, the greater the number of plies, the
more weight a tire can support. Tire manufacturers also
must indicate the materials in the tire, which include steel,
nylon, polyester, and others.
: This number indicates the
maximum load in kilograms and pounds that can be carried
by the tire.
: This number
is the greatest amount of air pressure that should ever be
put in the tire under normal driving conditions.
: This number indicates the tire’s
wear rate. The higher the treadwear number is, the longer
it should take for the tread to wear down. For example, a
tire graded 400 should last twice as long as a tire graded
200.
This letter indicates a tire’s ability to stop
on wet pavement. A higher graded tire should allow you
to stop your car on wet roads in a shorter distance than a
tire with a lower grade. Traction is graded from highest to
lowest as “AA”,”A”, “B”, and “C”.
This letter indicates a tire’s
resistance to heat. The temperature grade is for a tire that
is infl ated properly and not overloaded. Excessive speed,
underinfl ation or excessive loading, either separately or
in combination, can cause heat build-up and possible tire
failure. From highest to lowest, a tire’s resistance to heat
is graded as “A”, “B”, or “C”.
Refer to Figure J for additional tire information for light
trucks.
Figure J. UTQGS Tire Information
safety guiDelines — trailers
Tires for light trucks have other markings besides those
found on the sidewalls of passenger tires.
LT
: The “LT” indicates the tire is for light trucks or trailers.
ST
: An “ST” is an indication the tire is for trailer use only.
kg (lbs) at kPa (psi) Cold: This information
indicates the maximum load and tire pressure when the tire
is used as a dual, that is, when four tires are put on each
rear axle (a total of six or more tires on the vehicle).
kg (lbs) at kPa (psi) Cold: This information
indicates the maximum load and tire pressure when the tire
is used as a single.
Load Range
: This information identifi es the tire’s load-
carrying capabilities and its infl ation limits.
Tire Safety Tips
Slow down if you have to go over a pothole or other
object in the road.
run over curbs or other foreign objects in the
roadway, and try not to strike the curb when parking.
Check tire infl ation pressure weekly during use to insure
the maximum tire life and tread wear.
bleed air from tires when they are hot.
Inspect tires for uneven wear patterns on the tread,
cracks, foreign objects, or other signs of wear or
trauma.
Remove bits of glass and foreign objects wedged in
the tread.
Make sure your tire valves have valve caps.
ALWAYS check tire pressure on tow vehicle and trailer
before towing. Check tire pressure at least once a
month.
overload tow vehicle. Check the tire information
and loading placard for safe allowable tire loading
conditions.
Tire Repair
The proper repair of a punctured tire requires a plug for the
hole and a patch for the area inside the tire that surrounds
the puncture hole. Punctures through the tread can be
repaired if they are not too large, but punctures to the
sidewall should not be repaired. Tires must be removed
from the rim to be properly inspected before being plugged
and patched.
Replacing Worn or Damaged Tires
Replace the tire before towing the trailer if the tire treads
have less than 1/16 inch depth or the telltale bands are
visible. Check infl ation pressure weekly during use to insure
the maximum tire life and tread wear. A bubble, cut or bulge
in a side wall can result in a tire blowout. Inspect both side
walls of each tire for any bubble, cut or bulge; and replace
a damaged tire before towing the trailer.
Table B below will help pinpoint the causes and solutions
of tire wear problems.
Tire Wear Troubleshooting
Wear Pattern Solution
Center Wear Over infl ation. Adjust pressure to particular
load per tire manufacturer.
Edge Wear Under infl ation. Adjust pressure to particular
load per tire manufacturer.
Side Wear Loss of camber
or overloading.
Make sure load does not
exceed axle rating.
Align wheels.
Toe Wear Incorrect toe-in. Align wheels.
Cupping Out-of-balance. Check bearing adjustment
and balance tires.
Flat Spots Wheel lockup and
tire skidding.
Avoid sudden stops when
possible and adjust brakes.
ALWAYS wear safety glasses when
removing or installing force fi tted parts. DO
attempt to repair or modify a wheel.
install an inner-tube to correct a
leak through through the rim. If the rim is
cracked, the air pressure in the inner tube may cause
pieces of the rim to explode (break off) with great force
and cause serious eye or bodily injury.
safety guiDelines — trailers
Wheel Rims
If the trailer has been struck, or impacted, on or near the
wheels, or if the trailer has struck a curb, inspect the rims for
damage (i.e. being out of round); and replace any damaged
wheel. Inspect the wheels for damage every year, even if
no obvious impact has occurred.
A loose, worn or damaged wheel bearing is the most
common cause of brakes that grab.
To check wheel bearings, jack trailer and check wheels
for side-to-side looseness. If the wheels are loose, or spin
with a wobble, the bearings must be serviced or replaced.
Check infl ation pressure weekly during use to insure the
maximum tire life and tread wear. Most trailer axles are
built with sealed bearings that are not serviceable. Sealed
bearings must be replaced as complete units.
It is extremely important to apply and maintain proper wheel
mounting torque on the trailer. Be sure to use only the
fasteners matched to the cone angle of the wheel. Proper
procedure for attachment of the wheels is as follows:
1.
Start all wheel lug nuts by hand.
2.
Torque all lug nuts in sequence. See Figure K. DO
NOT torque the wheel lug nuts all the way down.
Tighten each lug nut in 3 separate passes as defi ned
by Table C.
Lug nuts are prone to loosen after initial installation,
which can lead to death or serious injury. Check all
wheel lug nuts periodically.
3. Check to see if the lug nuts are tight after the fi rst 10,
25 and 50 miles of driving and before each tow
thereafter
Figure K.
Wheel Lug Nuts Tightening Sequence
Lights and Signals
Before each tow, check the trailer taillights, stoplights, turn
signals and any clearance lights for proper operation.
Replace any broken or burned-out lamps as necessary.
Check the wire harness for cuts, fraying or other damage.
If it needs replacing, contact your dealer.
Tire Torque Requirements
Wheel Size First Pass
Second Pass
Third Pass
12" 20-25 35-40 50-65
13" 20-25 35-40 50-65
14" 20-25 50-60 90-120
15" 20-25 50-60 90-120
16" 20-25 50-60 90-120
Improper operating taillights, stoplights and turn signals
can cause collisions.
Check all lights before each tow.
NOTICE
use an pneumatic air gun to tighten wheel
lug nuts.
Over-tightening lug nuts will result in breaking the studs
or permanently deforming the mounting stud holes in
the wheels.
safety guiDelines — trailers
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.
Generator Troubleshooting
Symptom - Solution
No Voltage Output Is wiring connection loose? Check wiring and repair.
Defective Rectifier? Check and replace.
Low Voltage Output Is engine speed correct? Turn engine throttle lever to “High”.
Is wiring connection loose? Check wiring and repair.
High Voltage Output Are wiring connections loose? Check wiring and repair.
Circuit Breaker Tripped
Short Circuit in load? Check load and repair.
Over current? Confirm load requirements and reduce.
Defective circuit breaker? Check and replace.
troublesHooting (engine)
Engine Troubleshooting
Symptom Solution
Engine does not start.
No fuel? Replenish fuel.
Air in the fuel system? Bleed system.
Water in the fuel system? Remove water from fuel tank.
Fuel pipe clogged? Clean fuel pipe.
Fuel filter clogged? Clean or change fuel filter.
Excessively high viscosity of fuel or engine
oil at low temperature? Use the specified fuel or engine oil.
Fuel with low cetane number? Use the specified fuel.
Fuel leak due to loose injection pipe
retaining nut? Tighten nut.
Incorrect injection timing? Adjust.
Fuel cam shaft worn? Replace.
Injection nozzle clogged? Clean injection nozzle.
Injection pump malfunctioning? Repair or replace.
Seizure of crankshaft, camshaft, piston,
cylinder liner or bearing? Repair or replace.
Compression leak from cylinder? Replace head gasket, tighten cylinder head
bolt, glow plug and nozzle holder.
Improper valve timing? Correct or replace timing gear.
Piston ring and liner worn? Replace.
Excessive valve clearance? Adjust.
Starter does not run.
Battery discharged? Charge battery.
Starter malfunctioning? Repair or replace.
Key switch malfunctioning? Repair or replace.
Engine fails to start and
starter does not engage
Dead battery? Replace battery.
Defective ignition switch? Replace ignition switch.
Defective starter? Replace starter
Burned fuse? Replace fuse.
Engine fails to start and
starter engages
Broken preheat circuit? Check preheat circuit.
No fuel? Add diesel fuel.
Defective wiring? Check wiring.
troublesHooting (engine)
Symptom Solution
Engine revolution is not
smooth.
Fuel filter clogged or dirty? Clean or change.
Air cleaner clogged? Clean or change.
Fuel leak due to loose injection pipe
retaining nut? Tighten nut.
Injection pump malfunctioning? Repair or replace.
Incorrect nozzle opening pressure? Adjust.
Injection nozzle stuck or clogged? Repair or replace.
Fuel over flow pipe clogged? Clean.
Governor malfunctioning? Repair.
Either white or
blue exhaust gas is
observed.
Excessive engine oil? Reduce to the specified level.
Piston ring and liner worn or stuck? Repair or replace.
Incorrect injection timing? Adjust.
Deficient compression? Adjust top clearance.
Either black or dark
gray exhaust gas is
observed.
Overload? Lessen the load.
Low grade fuel used? Use the specified fuel.
Fuel filter clogged? Clean or change.
Air cleaner clogged? Clean or change.
Deficient nozzle injection? Repair or replace the nozzle.
Deficient output.
Incorrect injection timing? Adjust.
Engine's moving parts seem to be seizing? Repair or replace.
Uneven fuel injection? Repair or replace the injection pump.
Deficient nozzle injection? Repair or replace the nozzle.
Compression leak? Replace head gasket, tighten cylinder head
bolt, glow plug and nozzle holder.
troublesHooting (lamps)
Lamp Troubleshooting
Symptom Solution
Lamp will not start.
Lamp Burned Out? Test the lamp in a fixture which is operating properly.
Replace if necessary.
Lamp Loose in Socket?
Inspect lamp base to see if there is arcing at center
contact button. Tighten lamp snugly. Check socket for
damage. Replace if defective.
Lamp Plugs Not Tight? Check plug and receptacle. Tighten if loose.
Defective Ballast?
Interchange ballast plugs in generator enclosure.
If lamp starts, replace ballast. Check ballast wiring
against diagram. Check for swollen capacitor, charred
wiring, core and coil or other signs of excessive heat.
Low Voltage?
Check line voltage at ballast input. Voltage should
be within 10% of nameplate rating when operating
at normal load. Increase supply voltage or remove
external load.
Improper Ballast?
Proper HID lightswill perform erratically or fail to start
on an improper ballast. The ballast nameplate data
must agree with the line voltage and lamp used.
Improper ballast causes lamp failure. Note: Mercury
lightsof the same wattage will operate properly on
Metal Halide ballasts.
Improper Lamp Operating
Position (Metal Halide only)?
Operating position should agree with the lamp tech.
A BU-HOR lamp can be operated base up vertical to
and including the horizontal and a BD can be operated
base down vertical to, approaching, but not including
the horizontal. A lamp operated beyond the specified
position may not start.
Lamp has been Operating: Cool
Down Time Insufficient?
HID lights(High Pressure Sodium, Metal Halide,
Mercury Vapor) require from 4 to 8 minutes cool-down
time before restarting. Switch off breaker and allow
lamp to cool.
Lamp flickers and goes
out intermittent or
cycling.
Improper Ballast?
Improper ballasting can cause flickering or erratic
operation. In the start-up period the lamp may ignite,
start to warm up and then extinguish (cycle).
New Lamp?
Under certain conditions new lightsmay "cycle".
Usually after 3 tries to start at 30 to 60 second
intervals, lightswill stabilize and operate satisfactorily.
Defective Lamp? Replace lamp.
troublesHooting (lamps)
Symptom Solution
Lamp starts slowly
(ARC does not strike
when switch is first
turned on)
Defective Lamp? Lamp may glow for extended period of time. Replace after
checking voltage and ballast.
Circuit breaker trips on
lamp start-up Short Circuit or Ground? Check wiring against diagram. Check for shorts or ground.
Lamp light output low
Normal Lamp
Depreciation? Replace Lamp.
Dirty Lamp or Fixture? Clean lamp and fixture.
Defective Ballast?
Interchange ballast plugs in generator enclosure. If lamp
returns to normal light output, replace ballast. Check for
swollen capacitor, charred wiring, core and coil, or other signs
of excessive heat.
Wrong Voltage?
Check voltage at ballast input. Voltage should be within 10%
of nameplate rating. Check wiring connections for voltage
loss. Check socket contact point.
Improper Ballast? Check ballast nameplate against lamp data.
Lamp colors different.
Normal Lamp
Depreciation?
Lamp output and brightness decreases and color changes
slightly as lightsage. Spot replacement with new lightsmay
cause noticeable differences in lamp colors. Group
replacement minimizes color differences.
Dirty Fixture? Dirty fixtures will cause lightsto appear different in color.
Clean fixture.
Wrong Lamp? Check data on lightswhich appear different in color. Replace
with correct color lamp.
ARC tube discolored or
swollen.
Over Voltage from Power
Supply?
Check voltage at ballast. Check for current or voltage surges.
Check for shorted capacitors and replace if defective.
Improper Ballast? Lamp operated on ballast designed for higher wattage lamp.
Check ballast nameplate against lamp data.
Short lamp life.
Lamp Damaged?
Check for outer bulb cracks. If air enters outer bulb, arc tube
may continue to burn for 100 hours before failure. Check for
bulb cracks where glass meets the base due to tightening
Lamp too firmly in socket or scoring of glass where socket
inadvertently touches the lamp bulb. Look for broken arc tube
or loose metal parts. Replace lamp. (Bulb leads will cause
oxidation of metal parts.)
Improper Ballast?
Ballast nameplate data should agree with lamp line voltage
and lamp use. If improper ballast is used, the lamp life will be
shortened. A mismatch may also cause the ballast to fail.
troublesHooting
Use the following procedure and wiring diagrams on the
next pages to determine which of the four lights is not
functioning:
1. Make sure that lamp #1 power cable is plugged into
the J1 connector on the T-Bar assembly.
2. Make sure that lamp #2 power cable is plugged into
the J2 connector on the T-Bar assembly.
3. Make sure that lamp #3 power cable is plugged into
the J3 connector on the T-Bar assembly.
4. Make sure that lamp #4 power cable is plugged into
the J4 connector on the T-Bar assembly.
Starting
1. Start the generator and verify that there are no
abnormal sounds.
2. Turn lamp circuit breakers (CB2 and CB3) to the
position.
3. Wait a few minutes and determine which lamp is not
igniting.
4. If one of the lights is OFF, disconnect its power cable
and plug it into a receptacle that is known to be working.
unplug a power cable from the T-Bar while
power is being supplied by the generator. Always turn
the circuit breaker OFF before unplugging a power
cable.
5. If the lamp still does not ignite after plugging it into a
working receptacle (120 VAC present), then the lamp
is defective and has to be replaced.
6. If the lamp ignites after plugging it into a working
receptacle, continue with step 7.
7. With the voltmeter set to the AC position, connect the
negative lead of the AC voltmeter to any (neutral) white
wire on the junction terminal block. This block connects
all the neutral wires (white) in the system.
8. Connect the positive lead of the voltmeter to the output
side of the circuit breaker where the lamp was originally
OFF and observe that 120 VAC is present. Make sure
circuit breaker is .
9. If no output voltage is present, the circuit breaker is
defective and needs to be replaced.
10. If the correct output voltage is present then it can be
assumed that the generator is working correctly and
the correct voltage (120 VAC) is being supplied to the
ballast. Then it can be assumed that the ballast for that
lamp is defective. Replace ballast.
1. Place the main (CB1) and lamp circuit breakers (CB2
and CB3) in the OFF position. Make sure that no
voltage is being supplied to the ballast compartment.
2. Remove the panel from the generator frame that
encloses the ballasts. There are two such panels
located at the front of the generator just to the left and
right of the mast.
3. Make sure to discharge the ballast capacitor.
4. Remove the defective ballast, taking care to guard
against electrical shock when coming in contact with
the ballast and capacitor. The capacitor is known to
store an electrical charge, that when discharged could
result in a harmful shock. Make sure to discharge
capacitor.
panel ligHt/Hour meter wiring Diagram
120/240 VAC ENGINE
HOURS
OFF OFF
OFF
OFF OFF
1/10
LIGHTING120 VAC
REAR VIEW
HOUR METER
HOUR METER
FRONT VIEW
INSIDE OUTSIDE
REDRED WHITE
BLACK BLACK
SPLICE
GROUND
TO IGNITION SWITCH
+12V DC
CONTROL PANEL
CONTROL PANEL
B
BA
PANEL LIGHT
TO IGNITION SWITCH
+ 12V DC
DOOR SWITCH
CD
D
A
120/240 VAC ENGINE
HOURS
OFF OFF
OFF
OFF OFF
1/10
LIGHTING120 VAC
CONTROL PANEL
PANEL LIGHT
C
electronic components locator
120/240 VAC ENGINE
HOURS
OFF OFF
OFF
OFF OFF
1/10
LIGHTING120 VAC
120/240 VAC ENGINE
HOURS
OFF OFF
OFF
OFF OFF
1/10
LIGHTING120 VAC
LEFT
RIGHT
V
W
A1
Z
L
T
U
X
Y
M
N
F
H I
JK G
D
C
E
B
S
A
B1
J1
J3
J4 J2
O
P
C1
Q
R
FEMALE
CONNECTORS
wiring Diagram (generator/ligHts)
AB
D
H
J
TB1 L
TB2 M
LINE (L1)
X
Y
240/120 VAC
AUX RECPT.
WG
BLK (LINE 1)
RED
RED
C5
25µF@425V
EXCITATION
CAPACITOR
120 VAC
60 HZ
240 VAC
60 HZ
60 HZ 50 HZ
120 VAC
60 HZ
ROTOR
STATOR
EXCITATION
WINDING
C5
25µF@425V
EXCITATION
CAPACITOR
STATOR
WINDING
ROTOR
WINDINGS
FIXED FLOW
CURRENT
DIODE
BLACK
WHITE
WHITE
BLACK
RED
TB4 D
2-POLE, 50 AMP
MAIN
CIRCUIT BREAKER
H
CB1
LINE (L2)
CB2
20 AMP
CB3
20 AMP
G
120 VAC
GFCI
RECEPT.
LINE
GND
NEU.
LOAD
BLK (LINE 2)
WHT (NEU.)
12
11
10
9
8
7
WHT (GND.)
CHASSIS
(GND.)
NEUTRAL
CB4
15 AMP K
TO TB4-12
TO TB4-11
TO TB4-8
TO TB4-7
MAST GND.
POINT
C
IJ
B
F
P2
CONTROL BOX
SIDE
BALLAST SIDE
E
P1
2
4
5
3
1
2
4
5
3
1
4444
3333
1111
2222
1
2
3
4
1
3
4
2
BLK 12 AWG
WHT12AWG
WHT12AWG
WHT12AWG
BLK 12 AWG
RED 12 AWG
RED 12 AWG
GRN/YEL12 AWG
GRN/YEL12 AWG
BLUE12 AWG
BLK12 AWG
WHT12 AWG
WHT12 AWG
BLUE12 AWG
GRN
RED
BLK 12 AWG
NEUTRAL
A
5
6
7
8
5
6
7
8
6
5
3
2
1
4
TO TB4-9
GND.
GRN
STATOR
WINDING
S
BRN 12 AWG
WHT 12 AWG
GRN 12 AWG
K
BLK/YEL 12 AWG
YEL 12 AWG
I
BLK/YEL 12 AWG
YEL 12 AWG
BLK/YEL 12 AWG
C
YEL 12 AWG
E
BLK/YEL 12 AWG
YEL 12 AWG
F
G
NEUTRAL
AA
NEU.
BALLAST #1
(LAMP 1)
4 LAMP BALLAST ASSEMBLY
P/N 34050
24µF@480V
CAPACITOR
OUTPUT
120V IN
NEU.
BALLAST #2 24µF@480V
CAPACITOR
OUTPUT
120V IN
NEU.
BALLAST #3
YEL 24µF@480V
CAPACITOR
OUTPUT
120V IN
RED
12 AWG
NEU.
BALLAST #4
OUTPUT
120V IN
R1
24µF@480V
CAPACITOR
C1
TB3
T
U
V
W
A1
Z
C2
C3
Y
C4
X
N
RED 12 AWG
YEL 12 AWG
RED 12 AWG
RED 12 AWG
RED 12 AWG
BLUE
12 AWG
BLK
12 AWG
B1
1
2
3
4
5
6
47K ½ WATT RESISTOR.
R1 THROUGH R4
R2
R3
R4
7
8
9
10
11
12
GRN 12 AWG
K
AA
J
I
H
B
C
E
D
F
G
T-BAR ASSEMBLY
P/N 34195
LAMP1
O
P1
J1
LAMP1
O
P1
J1
LAMP2
P
P2
J2
LAMP3
Q
P3
J3
LAMP4
R
P4
J4
BRN 12 AWG (NEUTRAL)
T-BAR GND.
POINT
BLK 12 AWG
WHT 12 AWG
GRN 12 AWG
TYPICAL 4
PLACES
GRN 12 AWG
GP1
SPLICE
C1
7-WIRE COIL CORD
P/N 29433
GRN 12 AWG
BLUE 12 AWG
BLK 12 AWG
RED 12 AWG
YEL 12 AWG
WHT 12 AWG (NEUTRAL)
wiring Diagram (generator/ligHts)
REAR VIEW
LEFT SIDE VIEW
RIGHT SIDE VIEW
C
E
H
D
F
A
B
G
ligHts locator Diagram
ligHts wiring Diagram
P2
BK W
J2
BK W
P3
BK W
P4
BK W
P5
J5
BK W R
BK W R
P6
J6
BK
LICENSE PLATE
LAMP
RIGHT SIDE
AMBER REFLECTOR
SPLICE:TYPICAL
17 PLACES
CONNECT TO
TOWING
VEHICLE
W
P7
BK WR
BK W R
J3
BK W
J4
BK W
J7
BK W
B
AC
D E
F
H
RIGHT SIDE
RED REFLECTOR
LEFT SIDE
AMBER REFLECTOR
LEFT STOP
&
TURN SIGNAL
TAIL LIGHT
RIGHT STOP
&
TURN SIGNAL
TAIL LIGHT
LEFT SIDE
RED REFLECTOR
G
W Y GBR
P1
STOP
TURN
STOP
TURN
OperatiOn and parts Manual
Your Local Dealer is:
HERE’S HOW TO GET HELP
PLEASE HAVE THE MODEL AND SERIAL
NUMBER ON-HAND WHEN CALLING
United StateS
Multiquip Corporate Office MQ Parts Department
18910 Wilmington Ave.
Carson, CA 90746
Contact: mq@multiquip.com
Tel. (800) 421-1244
Fax (310) 537-3927
800-427-1244
310-537-3700
Fax: 800-672-7877
Fax: 310-637-3284
Service Department Warranty Department
800-421-1244
310-537-3700
Fax: 310-537-4259 800-421-1244
310-537-3700
Fax: 310-943-2249
Technical Assistance
800-478-1244 Fax: 310-943-2238
mexico United Kingdom
MQ Cipsa Multiquip (UK) Limited Head Office
Carr. Fed. Mexico-Puebla KM 126.5
Momoxpan, Cholula, Puebla 72760 Mexico
Contact: pmastretta@cipsa.com.mx
Tel: (52) 222-225-9900
Fax: (52) 222-285-0420
Unit 2, Northpoint Industrial Estate,
Globe Lane,
Dukinfield, Cheshire SK16 4UJ
Contact: sales@multiquip.co.uk
Tel: 0161 339 2223
Fax: 0161 339 3226
Canada
Multiquip
4110 Industriel Boul.
Laval, Quebec, Canada H7L 6V3
Contact: jmartin@multiquip.com
Tel: (450) 625-2244
Tel: (877) 963-4411
Fax: (450) 625-8664
© COPYRIGHT 2013, 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.
This manual
MUST accompany the equipment at all times. This manual is considered a permanent part of the equipment and should remain with the unit if resold.
The information and specifications included in this publication were in effect at the time of approval for printing. Illustrations, descriptions, references and technical data contained in
this manual are for guidance only and may not be considered as binding. Multiquip Inc. reserves the right to discontinue or change specifications, design or the information published
in this publication at any time without notice and without incurring any obligations.
pn 34639
