Multiquip LT12DAB User Manual

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OPERATION MANUAL

NIGHTHAWK SERIES

MODEL LT12DAB

DEDICATED LIGHT TOWER

(LOMBARDINI LDW 1003 DIESEL ENGINE)

Revision #0 (06/03/11)

To ﬁnd the latest revision of this

publication, visit our website at:

www.multiquip.com

THIS MANUAL MUST ACCOMPANY THE EQUIPMENT AT ALL TIMES.

PN 49498

LT12DAB Light Tower

Table Of Contents .................................................... 2

Safety Information ..............................................3-10

Lamp Footcandle Plot ............................................ 11

Speciﬁcations ...................................................12-13

Dimensions ............................................................ 14

General Information ............................................... 15

Components ..................................................... 16-17

Control Panel .................................................... 18-19

Inspection ......................................................... 20-21

Inspection ......................................................... 22-23

Operation .......................................................... 24-28

Maintenance ..................................................... 29-33

Maintenance — Trailers .................................... 34-35

Troubleshooting ................................................ 36-41

Light Tower Wiring Diagram .............................. 42-43

Lombardini Engine Wiring Diagram ....................... 44

Trailer Guidelines .............................................. 45-59

TABLE OF CONTENTS

NOTICE

Speciﬁcations are subject to change without notice.

PAGE 2 — LT12DAB LIGHT TOWER • OPERATION MANUAL — REV. #0 (06/03/11)

SAFETY INFORMATION

Do not operate or service the equipment before reading the

SAFETY SYMBOLS

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.

SAFETY MESSAGES

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:

DANGER, WARNING, CAUTION or NOTICE.

SAFETY SYMBOLS

DANGER

Indicates a hazardous situation which, if not avoided,

WILL result in DEATH or SERIOUS INJURY.

WARNING

Indicates a hazardous situation which, if not avoided, COULD result in DEATH or SERIOUS 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.

CAUTION

Indicates a hazardous situation which, if not avoided, COULD result in MINOR or MODERATE INJURY.

NOTICE

Addresses practices not related to personal injury.

LT12DAB LIGHT TOWER • OPERATION MANUAL — REV. #0 (06/03/11) — PAGE 3

GENERAL SAFETY



NOTICE

This equipment should only be operated by trained and

Whenever necessary, replace nameplate, operation and

accident due to equipment modiﬁ cations. Unauthorized

recommended by Multiquip for this equipment. Damage

Also, know the phone

ﬁ re

SAFETY INFORMATION

CAUTION

 NEVER 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.

NEVER operate this equipment when not feeling well due to fatigue, illness or when under medication.

NEVER operate this equipment under the inﬂ uence of

drugs or alcohol.

ALWAYS check the equipment for loosened threads or bolts before starting.

DO NOT use the equipment for any purpose other than

its intended purposes or applications.



qualiﬁ ed personnel 18 years of age and older.



safety decals when they become difﬁ cult read.

 Manufacturer does not assume responsibility for any

equipment modiﬁ cation will void all warranties.

 NEVER use accessories or attachments that are not

to the equipment and/or injury to user may result.

 ALWAYS know the location of the nearest

ﬁ re extinguisher.

 ALWAYS know the location of the nearest

ﬁ rst aid kit.

 ALWAYS know the location of the nearest phone or

keep a phone on the job site. numbers of the nearest ambulance, doctor and department. This information will be invaluable in the

case of an emergency.

PAGE 4 — LT12DAB LIGHT TOWER • OPERATION MANUAL — REV. #0 (06/03/11)

LIGHT TOWER SAFETY

NOTICE

keep the immediate area surrounding the light

keep the machine in proper running condition.

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.

use

Always shut down the engine and turn off circuit breakers

allow a sufﬁ cient amount of time for the lamp to

before touching or changing. The possibility exists of

use force when installing the lamp. Excessive force

leave any grease or oil residue on lamp surface

install and remove

SAFETY INFORMATION

DANGER

 NEVER use light tower in rain, snow, or

areas of high humidity that could generate electrical storms.

 NEVER operate the equipment in an explosive

atmosphere or near combustible materials. An explosion or ﬁ re could result causing severe

bodily harm or even death.

WARNING

 NEVER disconnect any emergency or safety devices.

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.

CAUTION

 NEVER 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.

 NEVER remove safety pin or pull mast locking pin while

tower is in a raised position!

 CHECK 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.

 NEVER pivot or retract mast while unit is operating.

 ALWAYS

tower clean, neat, and free of debris.

 ALWAYS

 Fix damage to machine and replace any broken parts

immediately.

 ALWAYS

 To prevent the light tower from overturning, NEVER

in winds that exceed 65 mph (105 kph).

LAMP SAFETY

WARNING

 NEVER attempt to replace lamp with the power on.

when changing the lamp.

 ALWAYS

cool

severe burns.

CAUTION

 NEVER

could cause the lamp to break, causing bodily harm.

NOTICE

 NEVER

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

a ﬂ oodlight, or replace any damaged ﬁ xture wiring.

 NEVER use the light tower mast as a crane. DO NOT lift

anything with the mast.

 NEVER 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.

LT12DAB LIGHT TOWER • OPERATION MANUAL — REV. #0 (06/03/11) — PAGE 5

ENGINE SAFETY



DANGEROUS

GAS FUMES

NOTICE

run engine without an air ﬁ lter or with a dirty air

ﬁ lter. Severe engine damage may occur. Service air ﬁ lter

tip the engine to extreme angles during lifting as

it may cause oil to gravitate into the cylinder head, making

Wet stacking is a common problem with diesel engines

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

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

applied to relieve the condition. It can reduce the system

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

from the engine exhaust. Spark arresters are qualiﬁ ed

SAFETY INFORMATION

DANGER

 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. NEVER 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.

WARNING

 D O NOT pl ace h ands or fing ers i nside engi ne

compartment when engine is running.

 NEVER operate the engine with heat shields or

guards removed.

Keep ﬁ ngers, hands hair and clothing away

from all moving parts to prevent injury.

 NEVER

frequently to prevent engine malfunction.

 NEVER 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.

 NEVER

the engine start difﬁ cult.



which are operated for extended periods with light or

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.

 DO NOT 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.

DO NOT 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.

 DO NOT 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.

CAUTION

NEVER touch the hot exhaust manifold,

mufﬂ er or cylinder. Allow these parts to cool before servicing equipment.

to completely burn all of the fuel.

Wet stacking does not usually cause any permanent

damage and can be alleviated if additional load is

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

to prevent accidental discharge of sparks or ﬂ ames

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.

PAGE 6 — LT12DAB LIGHT TOWER • OPERATION MANUAL — REV. #0 (06/03/11)

FUEL SAFETY

 DO NOT start the engine near spilled fuel or combustible

 ALWAYS inspect the hitch and coupling for wear. NEVER

tow a trailer with defective hitches, couplings, chains, etc.

Trailer tires should be inﬂ ated to 50 psi cold.

safety

attach trailer’s safety chains to towing

make sure the vehicle and trailer directional,

unless

posted otherwise. Recommended off-road towing is not to

Avoid sudden stops and starts. This can cause skidding,

Trailer should be adjusted to a level position at all times

rolling

underneath the trailer’s bumper

Use the trailer’s swivel jack to adjust the trailer height to

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.

 DO NOT ﬁ ll the fuel tank while the engine is running

or hot.

 DO NOT overﬁ ll tank, since spilled fuel could ignite if it

comes into contact with hot engine parts or sparks from the ignition system.

DANGER

SAFETY INFORMATION

 Check the tire air pressure on both towing vehicle and

trailer. Also check the tire tread wear on both vehicles.

 ALWAYS make sure the trailer is equipped with a

chain.

 ALWAYS properly

vehicle.

 ALWAYS

backup, brake and trailer lights are connected and working properly.

 DOT Requirements include the following:

• Connect and test electric brake operation.

 Store fuel in appropriate containers, in well-ventilated

areas and away from sparks and ﬂ ames.

 NEVER use fuel as a cleaning agent.

 DO NOT smoke ar ound or near the

equipment. Fire or explosion could result from fuel vapors or if fuel is spilled on a hot engine.

TOWING SAFETY

CAUTION

 Check with your local county or state safety

towing regulations, in addition to meeting

Department of Transpor tation (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.”

• Secure portable power cables in cable tray with tie wraps.

 The maximum speed for highway towing is 55 MPH

exceed 15 MPH or less depending on type of terrain.



or jack-kniﬁ ng. Smooth, gradual starts and stops will improve towing.

 Avoid sharp turns to prevent rolling.



when towing.

 Raise and lock trailer wheel stand in up position when

towing.

 Place chock blocks underneath wheel to prevent

while parked.

 Place support blocks

to prevent tipping while parked.



a level position while parked.

LT12DAB LIGHT TOWER • OPERATION MANUAL — REV. #0 (06/03/11) — PAGE 7

TRANSPORTING SAFETY

CAUTION

STOWED

POSITION

REAR MAST

LOCK

 If lifting through pockets, make sure forks of forklift are

Never allow any person or animal to stand underneath the

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.

jackstand of light tower is retracted and in the horizontal position so that the foot does not make contact with the

Make sure that the two side (left and right) and two rear jackstands are in the vertical postion, slightly extended,

Straps and chains should be routed through the transport

secure the unit by running a strap or chain over

TRANSPORT

TIE-DOWN

POINT (4)

FRONT JACKSTAND

RETRACTED

TONGUE

SIDE JACK STAND (2)

REAR JACK STAND (2)

 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.

 NEVER lift the equipment while engine is running.

SAFETY INFORMATION

inserted in pockets as far as possible before lifting.



equipment while lifting.

 DO NOT lift equipment to unnecessary heights.

Loading and Tie-Down on Flatbed Truck

NOTICE

 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.



CABLE

TIE

CABLE

CONNECTORS

DISCONNECTED

 When loading onto ﬂ atbed truck, make sure that front

deck ﬂ oor.

FORKLIFT POCKETS

LIFTING BALE



LIGHT TOWER

so that each foot makes contact with the deck ﬂ oor.



tie-down points located beneath each corner of the cabinet to allow even application of forece to the front and rear of the machine.

 DO NOT

PAGE 8 — LT12DAB LIGHT TOWER • OPERATION MANUAL — REV. #0 (06/03/11)

the tongue of the light tower. This may cause severe damage to the unit.

ELECTRICAL SAFETY

DANGER



 Backfeed to a utility system can cause electrocution

connect the generator

to a building’s electrical system without a transfer switch

cables or cords when

make certain that proper power or extension

complete the grounding path

make sure that electrical circuits are properly

Severe injury or death by

can result from operating an ungrounded

 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.

NEVER insert any objects into the output receptacles during operation. This is extremely dangerous. The possibility exists of electrical shock, electrocution or

death.

NEVER 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 har m or even death.

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 w i t h overhead power lines or other obstructions could result in equipment damage, electrical shock,

electrocution and even death.

 Similar to boom equipment, light tower may become

energized with high voltage. DO NOT operate the light tower within a radial distance of 17 feet from high voltage power lines. If light tower becomes energized with high voltage, contact with the equipment could result in electrocution.

SAFETY INFORMATION

and/or property damage. NEVER

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

or even death.

Power Cord/Cable Safety

DANGER

 NEVER let power cords or cables lay in water.

 NEVER use damaged or worn

connecting equipment to generator. Inspect for cuts in the insulation.

 NEVER grab or touch a live power

cord or cable with wet hands. The possibility exists of electrical shock,

electrocution or death.

 Make sure power cables are securely connected.

Incorrect connections may cause electrical shock and damage to the light tower.

NOTICE

 ALWAYS

cord has been selected for the job.

Grounding Safety

DANGER

 The light tower is equipped with a ground terminal for

your protection. ALWAYS from the light tower to an extrnal grounding source.

 ALWAYS

grounded to a suitable earth ground (ground rod) per the National Electrical Code (NEC) and local codes before operating generator.

electrocution

generator.

 NEVER use gas piping as an electrical ground.

LT12DAB LIGHT TOWER • OPERATION MANUAL — REV. #0 (06/03/11) — PAGE 9

SAFETY INFORMATION

BATTERY SAFETY

ENVIRONMENTAL SAFETY

pour waste, oil or fuel directly onto the ground,

DANGER

 DO NOT drop the battery. There is a possibility that the

battery will explode.

 DO NOT 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.

WARNING

 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.

NOTICE

 Dispose of hazardous waste properly.

Examples of potentially hazardous waste are used motor oil, fuel and fuel ﬁ lters.

 DO NOT use food or plastic containers to dispose of

hazardous waste.

 DO NOT

down a drain or into any water source.

 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.

CAUTION

 ALWAYS disconnect the NEGATIVE battery terminal

before performing service on the generator.

 ALWAYS keep battery cables in good working condition.

Repair or replace all worn cables.

PAGE 10 — LT12DAB LIGHT TOWER • OPERATION MANUAL — REV. #0 (06/03/11)

LAMP FOOTCANDLE PLOT

Figure 1. Lamp Footcandle Plot

LT12DAB LIGHT TOWER • OPERATION MANUAL — REV. #0 (06/03/11) — PAGE 11

SPECIFICATIONS

Table 1. LT12DAB Speciﬁcations

Light Tower Model LT12DAB

Engine Model

Weight (Dry) 1690 lbs. (766 kg.)

Support Points 5

Wind Stability with Genset 65 mph (80.46 kph)

Lamps Four 1,000-Watt Metal Halide

Lumens 440,000

Light Coverage 20, 234 – 28,000 m

Light Termination 4 x 3-pin QD plug

Generator Speciﬁcations

Twist-Lock Circuit Breaker (Amps) 30 A

Continuous Output (Watts) 6,000 W

Noise Level @ 23 ft. (7 m) 73 dB

Trailer Speciﬁcations

Lombardini LDW 1003

Diesel Engine

Jackstand Capacity 2,000 lbs. (907 kg.)

Hitch Type 2-in. Ball (Optional Pintle Kit available)

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 3-Leaf

Electrical Tail-light Connector 4-Wire

Winch Capacity 1,500 lbs. (680 kg.)

Winch Rope Wire 3/16 in. (5 mm)

PAGE 12 — LT12DAB LIGHT TOWER • OPERATION MANUAL — REV. #0 (06/03/11)

Lombardini LDW 1003

Diesel Engine

SPECIFICATIONS

Table 2. Engine Speciﬁcations

Engine Type 3-cylinder, Diesel Engine

Displacement 62.73 cu. in. (1028 cc)

Max Output Standby 12 H.P. at 1,500 R.P.M.

Fuel Tank Capacity Approx. 30 U.S. Gallons (113 Liters)

Run Time With 4 Lights 64 Hours

Standard Idle Speed 1,500 R.P.M.

Fuel Type N0. 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.)

LT12DAB LIGHT TOWER • OPERATION MANUAL — REV. #0 (06/03/11) — PAGE 13

DIMENSIONS

DEPLOYED

POSITION

STOWED

POSITION

REAR

RIGHT SIDE

Figure 2. Dimensions

Table 3. Dimensions

Reference Letter Description Dimension

A Length (Mast Stowed Position) 170 in. (431 cm.)

B Length (Mast Deployed Position) 101 in. (256 cm.)

C Max. Height (Mast Deployed Position) 31.5 ft. (9.6 m)

D Height (Mast Stowed Position) 74 in. (187 cm.)

E Ground Clearance (From Axle) 8 in. (20 cm.)

F Width (Tow Ready) 51 in. (129 cm.)

G Width (Outriggers Deployed) 109 in. (276 cm.)

PAGE 14 — LT12DAB LIGHT TOWER • OPERATION MANUAL — REV. #0 (06/03/11)

GENERAL INFORMATION

The Multiquip LT12DAB 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.

METAL HALIDE LAMPS

The lighting system of the LT12DAB Light Tower is comprised of 4 metal halide, 1000-watt lamps. These lamps provide maximum illumination with typical lighting coverage of 5 to 7 acres. The lamps are controlled by individual circuit breakers for versatility.

ENGINE

The LT12 Light Tower is powered by a diesel engine that is equipped with automatic shutdowns for low oil pressure, high coolant temperature, and alternator charge failure.

STABILITY

The light tower can be raised vertically in excess of 31.5 feet (9.6 meters) 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.

PANEL LIGHT

A panel light automatically illuminates the control panel and all functions when the engine access door is opened. This feature is convenient for night deployment.

CONVENIENCE RECEPTACLE PLATES

As an added feature, the LT12DAB is equipped with two external plates with wiring ready to install auxiliary output receptacles. Receptacles can be installed for use with light power tools or other similar applications.

FUEL TANK

The 30-gallon fuel tank provides up to 64 hours of run time while running at 3/4 load.

TRAILER DESIGN

The trailer design of the LT12DAB light tower withstands the rigors of the jobsite in addition to providing smooth highway towing.

LT12DAB LIGHT TOWER • OPERATION MANUAL — REV. #0 (06/03/11) — PAGE 15

COMPONENTS

Figure 3. Major Components (Control Panel Side)

Figures 3 and 4 show the location of the controls and components for the LT12DAB light tower. The function of each control is described below.

1. Mast Rotation Locking Knob — Unscrew this knob to release mast for rotation. Tighten this knob to lock mast after it is set to the desired position.

2. Mast Extension Winch — Use this winch to extend the mast to the desired height. Maximum height is approximately 31.5 feet (9.6 meters).

3. Mast Rotation Handles — Grip these handles to rotate mast to desired position.

4. Lifting Bale — Light tower can be lifted using this lifting bale. The lifting bale is balanced for a fully conﬁgured light tower. Removal of any components will unbalance the lifting bale.

5. Forklift Pockets — Light tower can be lifted using these forklift pockets. Insert the forks of the forklift as far possible into the pockets.

6. Mast Cradle Support — 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. T-Bar — Allows the lamps to be mounted vertically or horizontally.

8. Lamps — Four 1000-watt metal-halide bulbs with a 110,000 lumens capacity each. Light coverage is typically between 5 to 7 acres.

9. Cradle Lock/Release Pin — Locks mast in cradle support and releases mast when removed.

10. Rear Jackstands — There are two jackstands located at the rear of the trailer. Use these jackstands to level and support the light tower.

11. Chock Blocks — Place these blocks (not included as part of the light tower package) under each trailer wheel to prevent rolling.

12. Outrigger Jacks — Use these 2 outrigger jacks to level and support the light tower. For more stability, the outriggers can be deployed.

13. Tongue Jackstand — Use this jackstand to support the tongue when attaching the light tower to a towing vehicle.

PAGE 16 — LT12DAB LIGHT TOWER • OPERATION MANUAL — REV. #0 (06/03/11)

COMPONENTS

14. Safety Chain — Always attach safety chain to the towing vehicle. Never tow the light tower with the safety chain unattached.

15. Ball Hitch Coupler — Attach this 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.

16. Vertical Mast Winch — Use this winch to raise the mast to the vertical position.

17. Mast Lock/Release Pin — Pull this pin to start placing the tower mast in the vertical position.When tower mast has reached full vertical position, insert pin to keep mast from falling.

REAR VIEW

Figure 4. Major Components (Front/Rear)

FRONT

VIEW

19. Engine Exhaust Pipe — Directs engine exhaust to the rear of the light tower. NEVER block this exhaust pipe with obstructions. ALWAYS place the generator in an area free of obstructions.

20. Tires — This light tower uses a ST175-13C size tire. Replace with only recommended tire size. Never tow light tower with bad or worn tires.

21. Docum entation Box — Contai ns informatio n regarding the light tower.

22. Auxiliary Output Receptacle — Wired ready to install an output receptacle.

23. Auxiliary Output Receptacle — Wired ready to install an output receptacle.

18. Tie-Down Points — Used to tie down light tower with strap or chains to allow even application of force to the front and rear of the equipment during transport.

LT12DAB LIGHT TOWER • OPERATION MANUAL — REV. #0 (06/03/11) — PAGE 17

CONTROL PANEL

240 VAC/30A

BREAKER

LIGHT CONTROL/BREAKER

MAIN

120 VAC/15A

BREAKER

LOMBARDINI

GFCI

= NOT USED

Figure 5. Controls and Indicators

PAGE 18 — LT12DAB LIGHT TOWER • OPERATION MANUAL — REV. #0 (06/03/11)

CONTROL PANEL

Figure 5 shows the location of the controls and indicators on the control panel for the different engines used with the LT12 light tower. Service the equipment as needed depending on the alarm indicated. Below is a brief explanation of each control or indicator.

1. Internal Cabinet Light Switch — This switch controls the internal cabinet light for the light tower control panel. 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.

2. Internal Cabinet Light — Provides illumination for the LT12DAB control panel during nighttime operation. The light is automatically activated when the cabinet door is raised.

3. Hour Meter — This digital hour meter indicates the number of hours machine has been in use.

4. Main Circuit Breaker — A double-pole 30 amp, ON/ OFF circuit breaker which allows voltage to be supplied to the 15 amp breakers.

10. PreHeat Indicator — Lights when the ignition key is turned to the ON position indicating that the glow plugs are warming up. When the light goes off, the engine is ready for starting..

11. Ignition Key Switch — Insert key into ignition switch and turn clockwise to the ON position to warm the glow plugs. When preheat indicator light goes OFF, turn the key to the START position. Release key when engine starts.

12. Normal Operatio n In di ca tor — This indicator (green lamp) lights when the engine is functioning normally.

13. Alternator Alarm Indicator — This indicator lights when the engine has shut down because the electrical charging system is not working properly.

5. Auxiliary Output Receptacle Circuit Breaker — A single-pole, 15 amp, ON/OFF circuit breaker which protects auxiliary output receptacle (if installed) from overload.

6. Lamp Circuit Breakers — A single-pole, 15 amp, ON/ OFF circuit breaker for each of the four lamps.

7. Air Filter Alarm Indicator — This indicator lights when a blockage or problem with the air ﬁlter is detected.

8. Water Temperature Alarm Indicator — This indic ator lights whe n t he wa ter temperature becomes to hot for normal engine operation. The unit will shut down and the light will remain on.

9. Oil Pressure Alarm Indicator — This alarm lights when the oil pressure has fallen too low for normal engine operation The unit will shut down and the light will remain on.

LT12DAB LIGHT TOWER • OPERATION MANUAL — REV. #0 (06/03/11) — PAGE 19

INSPECTION

BEFORE STARTING

1. Read all safety instructions at the beginning of manual.

2. Clean the light tower, removing dirt and dust, particularly the engine cooling air inlet and air cleaner.

3. Check the air ﬁlter for dirt and dust. If air ﬁlter is dirty, replace air ﬁlter with a new one as required.

4. Check all fastening nuts and bolts for tightness.

WARNING

Ens ure ad equ ate vent ila tio n wh en operating the light tower in enclosed areas. The engine exhaust contains noxious elements.

INDOOR INSTALLATION

Exhaust gases from diesel engine s 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.

ENGINE OIL CHECK

To check the engine oil level, make sure the light tower is placed on secure level ground with the engine stopped.

on the dipstick. Verify that the oil level is maintained between the two notches as shown in Figure 6. Always ﬁll with recommended type oil as listed in Table 4. See Table 2 for engine oil capacity.

Figure 6. Oil Dipstick

Table 4. Recommended Motor Oil

(Lombardini Engines)

-40 -35 -30 -25 -20 -15

°C

-40 -31 -22 -13 -4 51423 32 41 50 59 68 77 86 95 104 113 122

°F

-10

SAE 10W

-5 0 5 10 15 20 25 30 35 40 45 50

SAE 20W

SAE 30

SAE 40

SAE 10W-30

SAE 10W-40

SAE 10W-60

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

FUEL CHECK

1. Remove the ﬁller cap/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 NOT overﬁll. Fill to the normal operating level as shown

PAGE 20 — LT12DAB LIGHT TOWER • OPERATION MANUAL — REV. #0 (06/03/11)

CAUTION

Diesel fuel and its vapors are dangerous to your he al th and the surrounding environment. Avoid skin contact and/or inhaling fumes. DO NOT smoke while refueling. DO NOT attempt to refuel the

light tower if the engine is hot or running.

INSPECTION

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 7) opposite the

control panel. Set the door support latch in place to keep the door open (up).

Figure 7. Adding Fuel

3. Remove the fuel cap from the fuel tank.

CAUTION

ALWAYS ﬁll the fuel tank with clean, fresh #2 diesel fuel. DO NOT ﬁll the fuel tank beyond its capacity. DO NOT TOP-OFF.

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!

BATTERY CHECK

WARNING

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.

The 12-volt DC battery (Figure 8) is shipped dry and will require a proper electrolyte level for operation.

Figure 8. 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.

 DO NOT overﬁll the battery.

WARNING

Electroly te is a n acid and must be handled with caution. ALWAYS follow servicing instructions from the electrolyte

manufacturer to ensure safety. Serious injur y can resul t f rom care less handl ing 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).

WARNING

When connecting the positive (+) cable

to the battery's positive (+) terminal post,

DO NOT allow the wrench or any metallic

part to come in contact with the battery's negative (-) terminal post. This may result in an electrical short circuit or an explosion. Always connect positive (+) end ﬁrst then negative (-) end. Always disconnect (-) end ﬁrst then positve (+) end.

NOTICE

Use only distilled water in the battery. Tap water can reduce the operating life of the battery.

LT12DAB LIGHT TOWER • OPERATION MANUAL — REV. #0 (06/03/11) — PAGE 21

INSPECTION

COOLANT

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.

WARNING

If adding coolant/antifreeze mix to the radiator, DO NOT remove the radiator cap until the unit has completely cooled. The possibility of hot coolant exists which can

cause severe burns.

Day-to-day addition of coolant is done from the recovery tank. When adding coolant to the radiator, DO NOT 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.

Table 5. Coolant Capacity

CLEANING THE RADIATOR

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.

AIR CLEANER

Periodic cleaning/replacement of the air cleaner is necessary. Inspect it in accordance with the engine owner's manual.

FAN BELT TENSION

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 9.

Engine Type Coolant Capacity

Perkins 103-10 5 qt. (4.7 liters)

Lombardini LDW 1003 5.18 qt. (4.9 liters)

Deutz F3M1008F 5.18 qt. (4.9 liters)

OPERATION IN FREEZING WEATHER

When operating in freezing weather, make sure the proper amount of antifreeze (Table 6) has been added.

Table 6. Anti-Freeze Operating Temperatures

Vol (%)

Anti-Freeze

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%.

Freezing Point Boiling Point

°C °F °C °F

Figure 9. Fan Belt Tension

WARNING

Never place hands near the belts or fan while the engine is running.

WARNING

The engine's exhaust contains harmful emissions. ALWAYS ventilate the exhaust when operating inside tunnels, excavations or buildings. Direct exhaust away from nearby personnel.

Before starting the engine, make sure of the following:

 The electrical load is disconnected and the main circuit

breaker and all lamp (4) circuit breakers are switched to the OFF position.

PAGE 22 — LT12DAB LIGHT TOWER • OPERATION MANUAL — REV. #0 (06/03/11)

KEY-LOCK FEMALE CONNECTORS

INSPECTION

CAUTION

NEVER start the engine with any circuit breakers in

the ON position.

 Light tower is placed on secure level ground with chock

blocks underneath each wheel to prevent the light tower from rolling.

 Outriggers have been fully extended to prevent the trailer

from tipping.

 Light tower trailer support stands have been positioned

properly and the trailer is level.

 Lamps have been adjusted to desired position.

 Light tower trailer frame has been grounded correctly.

 Lamps do not interfere with any overhead obstructions.

DANGER

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 ft. (9 meters). Contact with overhead power lines or other obstructions could result in equipment damage, serious injury or death!

b. Locate the slot or key (A) on each female connector

as shown in Figure 11.

Figure 11. Female Connector

c. On the corresponding male connector, locate the

key tab (B) as shown in Figure 12.

Figure 12. Male Connector

d. Align the key tab (B) on the male connector with

the slot or key (A) on the female connector and press together until fully seated.

e. Secure the connector by screwing the knurled

locking nut of the male connector to the threaded po rtion of the female connector to ensure good contact between the two connectors. See Figure 13.

 Lamp power cables have been plugged into the

appropriate receptacles (J1-J4) on the T-Bar assembly. Follow instructions below to correctly install the power cable plugs.

a. Locate the 4 key-lock female 3-pin DIN connectors

on the T-bar. See Figure 10.

Figure 10. Location of Female Connectors

LT12DAB LIGHT TOWER • OPERATION MANUAL — REV. #0 (06/03/11) — PAGE 23

LOCKING

NUT

Figure 13. Cable Connectors

OPERATION

STARTING THE ENGINE

1. Open the access panel door on the right side of the light tower (opposite the fuel tank). Set the door latch in place to hold the door open (up).

2. Ensure all breakers are off.

3. Insert the ignition key into the ignition key switch (Figure 14). Turn the ignition key clockwise one click to the ON 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.

PREHEAT INDICATOR

LOMBARDINI

LAMP

IGNITION KEY SWITCH

MAST OPERATION

DANGER

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!

DANGER

DO NOT stand behind

the trai ler w hil e the mast is being raised or lowered. Serious injury could result if the mast falls down.

Outriggers and Support Stands

Figure 14. Ignition Key Switch (Lombardini/

Deutz Engine)

4. Continue turning the ignition key all the way clockwise When the engine has started, release the key.

5. 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 light tower and correct the problem.

See Figure 15 for location of components.

1. Make sure both outriggers are extended. To extend the outriggers, pull the locking pin on the outrigger and hold while sliding out the outrigger assembly.

TO RELEASE OUTRIGGER

PULL PIN

PULL

OUTRIGGER

TO EXTEND

OUTRIGGER

JACK STAND

ROTATE JACK

STAND TO PLACE

IN SUPPORT

POSITION

Figure 15. Deploying Outriggers

PAGE 24 — LT12DAB LIGHT TOWER • OPERATION MANUAL — REV. #0 (06/03/11)

OPERATION

2. 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.

3. After extending all outriggers, rotate all trailer jack stands into the foot down position, then turn the crank handle on the jackstands clockwise to lower it and level the light tower.

4. Check behind the light tower and make sure all personnel and objects are clear of the mast.

Deploying the Mast to Vertical Position

Refer to Figure 16 for the location of components:

1. To release the mast from the mast cradle support, pull the retaining pin out of the cradle lock/release pin. Pull the cradle lock/release pin. This will unlock the mast from the horizontal position.

2. Remove the mast lock/release pin before raising tower 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 at 90 degrees.

4. Once the mast is in the vertical position, insert the mast lock/release pin to prevent the mast from falling.

Lowering the Mast

1. Turn the mast extension winch counterclockwise, and observe that the mast begins to lower.

2. Continue turning the winch counterclockwise until the mast has been fully retracted (slack in the cable).

Stowing the Mast to Horizontal Position

Refer to Figure 16 for the location of components:

1. Remove the mast lock/release pin to allow the mast section to be lowered to the horizontal position. Pull out the mast lock handle to unlatch.

2. Turn the vertical mast winch counterclockwise and observe that mast begins to approach the horizontal position. The mast lock handle can now be released.

3. Continue turning the vertical mast winch in the counterclockwise direction. As the mast approaches the mast cradle support, pull the retaining pin and then the cradle lock/release pin to allow the mast to rest in the cradle.

4. Once the mast is resting in the mast cradle support, inser t the cradle lock/release pin and secure with retaining pin to keep mast in place.

Rotating the Mast

Raising the Mast

Once the tower mast has been locked into its vertical position, the mast can now be raised. The tower allows the lamps to be extended upwards in excess of 30 feet.

Refer to Figure 16 for location of components.

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. This winch is of the self-locking type. The tension on the cable will keep the mast in place.

LT12DAB LIGHT TOWER • OPERATION MANUAL — REV. #0 (06/03/11) — PAGE 25

To change the direction that the lamps are facing, the mast can be rotated.

Refer to Figure 16 for the location of components.

1. With the mast in the deployed position (vertical), unscrew the mast rotation locking knob to release the mast for rotation.

2. Grip the mast rotation handles and rotate the mast until the lamps are facing the desired direction.

3. When the lamps are facing the desired direction, tighten the mast rotation lock knob to lock the mast in place.

MAST

EXTENSION

WINCH

RETAINING

OPERATION

MAST

CRADLE

SUPPORT

CRADLE

LOCK/

RELEASE

VERTICAL

MAST

WINCH

MAST

LOCK/

RELEASE

MAST LOCK

HANDLE

MAST

ROTATION

HANDLES

MAST

ROTATION

LOCKING

KNOB

ROTATING THE MAST

Figure 16. Mast Operation

PAGE 26 — LT12DAB LIGHT TOWER • OPERATION MANUAL — REV. #0 (06/03/11)

OPERATION

TURNING ON THE LAMPS

The main circuit breaker (30 amps), and 4 lamp circuit breakers (15 amps each) are located on the upper control panel (Figure17).

1. Place the main circuit breaker (Figure 17) on the control panel to the ON position.

30A

15A

MAIN

BREAKER

MAIN

CIRCUIT

BREAKER

LAMP

CIRCUIT

BREAKERS

LIGHT CONTROL/BREAKER

Figure 17. Control Panel Circuit Breakers

2. Set lamp circuit breaker #1 on the control panel to the ON position.

3. Wait a few minutes for the ballast to activate. Observe that lamp #1 is ON.

AUX

BREAKER

AUXILIARY

RECEPTACLE

CIRCUIT

BREAKER

AUXILIARY OUTPUT RECEPTACLES

The light tower is equipped with auxiliary output receptacle wiring ready to install auxiliary receptacles (Figure 18).

AUXILIARY

15 AMPS

DOCUMENTATION

BOX

FRONT

VIEW

Figure 18. Auxiliary Output Receptacles

DANGER

NEVER grab or touch a live power cord

with wet hands. The possibility exists of electrical shock, electrocution, and even death!

OUTPUT

RECEPTACLES

4. Repeat steps 2 and 3 for lamps 2 through 4.

5. If all the lamp circuit breakers are in the ON position (up), then all of the lights should be on.

6. If any of the lamps are not on, refer to the troubleshooting section of this manual.

7. Close all cabinet doors.

NOTICE

NEVER 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.

LT12DAB LIGHT TOWER • OPERATION MANUAL — REV. #0 (06/03/11) — PAGE 27

NORMAL SHUTDOWN

1. If a load is attached to the generator of the light tower, remove the load.

2. Set the four lamp circuit breakers on the control panel to the OFF position.

3. Place the MAIN circuit breaker on the control panel to the OFF position.

NOTICE

Failure to turn the breakers off may damage the generator.

4. Wait a few seconds and observe that all four lamps are OFF.

5. Let the engine idle for a few minutes with no load.

6. Turn the ignition key to the OFF position. Store key in a safe location.

OPERATION

7. Lower light tower mast and place in stow position as outlined in this manual.

8. Place outriggers in tow position, and remove chock blocks.

9. Store light tower in a clean, dry location out of the reach of children and unauthorized personnel.

NOTICE

If servicing is required, allow lamps to cool for about 15 minutes before removing lamps.

EMERGENCY SHUTDOWN

1. Turn the ignition key to the OFF position and turn all circuit breakers to the OFF position.

PAGE 28 — LT12DAB LIGHT TOWER • OPERATION MANUAL — REV. #0 (06/03/11)

MAINTENANCE

BASIC INSPECTION AND MAINTENANCE

See Table 7 below for a general inspection and maintenance checklist. For more detailed maintenance, refer to the engine service manual.

Table 7. Inspection/Maintenance

Frequency

Engine

10 hrs

Daily

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

Service Battery X

Clean Unit, Inside and Outside X

Change Fuel Filter

Clean Radiator and Check Coolant Protection Level X

Replace Air Filter Element X

Test Thermostats X

200 hrs 500 hrs

1000

hrs

Generator

Check all Hoses and Clamps/Flush Radiator X

Clean Inside of Fuel Tank X

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.

LT12DAB LIGHT TOWER • OPERATION MANUAL — REV. #0 (06/03/11) — PAGE 29

MAINTENANCE

GENERAL INSPECTION

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.

Air Cleaner

Check dust indicators on control panel daily or every 10 hours of operation. If light is ON, clean the air cleaner element.

1. Unlatch the holding clips and take out the air cleaner element.

2. Clean the inside of the body and cover using a damp cloth.

3. Blow dry with compressed air (0.69Mpa {7kgf.cm2,

99.4 PSI} maximum) against the side of the element along the pleats. Then blow dry against outside along the pleats, then against inside again.

4. Remove evacuator valve and clean it with compressed air. Reinstall.

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.

Cleaning the Fuel Strainer

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 Oil Level

Check the 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 6.

FLUSHING OUT RADIATOR AND CHANGING COOLANT

Fuel Addition

Add diesel fuel (the grade may vary according to season and locations). Always pour through the mesh ﬁlter.

Removing Water from the Tank

After prolonged use, water and other impurities accumulate in the bottom of the 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.

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, operate the fuel primer lever to pump fuel into the engine. This unit is equipped with an automatic air bleeding system.

WARNING

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. Stop the engine and allow 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

PAGE 30 — LT12DAB LIGHT TOWER • OPERATION MANUAL — REV. #0 (06/03/11)

MAINTENANCE

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.

CHANGING OIL

1. Make sure the oil is cool before changing.

2. Set a container directly under the drain plug of the oil pan. Loosen the drain plug slowly.

3. Check the drained oil for excessive metal particles or foreign material. Contact the distributor if there is metal particles or foreign material.

4. Using a ﬁlter wrench, turn ﬁlter cartridge 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.

5. 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.

6. Add engine oil through oil ﬁller until the oil level is between the H and L marks on the dipstick.

7. Run the engine at idling for a short time, then stop the engine. Recheck the oil level and ﬁll as necessary.

REPLACING FUEL FILTER

1. Set the container under the ﬁlter cartridge to catch fuel.

2. Using a ﬁlter wrench, turn the ﬁlter cartridge to the left to remove it.

3. Clean the ﬁlter holder, ﬁll the new ﬁlter cartridge with fuel, coat the packing surface of the ﬁlter cartridge with engine oil, then install the cartridge to the ﬁlter holder.

4. When installing, tighten until the packing surface contacts the seal surface of the ﬁlter holder then tighten a further 2/3 of a turn. If the ﬁlter cartridge is tightened too much, the packing will be damaged and will cause fuel leakage. Fuel leakage will occur if the ﬁlter cartridge is not tightened enough. Always tighten to the correct angle.

5. Operate the fuel primer lever to pump fuel back into the engine.

6. Replace corrosion resistor cartridge (if equipped).

7. Screw in valves at the top of the corrosion resistor.

8. Using a ﬁlter wrench, turn the cartridge to the left to remove it.

9. Lightly coat the seal surface of the new cartridge with engine oil and install it to the ﬁlter holder.

10. Tighten until he packing surface contacts the seal surface of the ﬁlter holder, then tighten a further 2/3 of a turn.

11. Open valves.

LT12DAB LIGHT TOWER • OPERATION MANUAL — REV. #0 (06/03/11) — PAGE 31

MAINTENANCE

CHECK CABLE WEAR

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.

DANGER

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.

Do not use it if there is even the slightest cause for concern and replace any damaged cables or pulleys immediately.

SERVICING THE MAST RAISE/LOWER CABLE SYSTEM:

To replace any components in the mast raise/lower cable system, use the following steps (See Figure 19):

5. Rethread the cable through the pin and pulleys and reattach the cable to the winch.

6. Raise and lower the mast several times to verify correct operation.

SERVICING THE MAST EXTENSION CABLE SYSTEM:

To replace the cable in the mast extension cable system, use the following steps (See Figure 20):

CENTER

MAST

PULLEY

UPPER

MAST

Figure 20. Mast Extension Cable System

LOWER

MAST

PULLEY

CENTER

MAST

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.

LOWER

MAST

SHACKLE

ROUTE TO

HAND WINCH

LOWER

MAST

Figure 19. 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 winch 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.

3. Disassemble the mast by disconnecting the cables from the mast and sliding the sections apart. Plastic guides and lock bolt must be removed. The lower cable can be disconnected from the winch.

WARNING

The mast sections are heavy and awkward to handle. Use proper lifting devices and procedures when servicing the mast and its components.

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.

PAGE 32 — LT12DAB LIGHT TOWER • OPERATION MANUAL — REV. #0 (06/03/11)

MAINTENANCE

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.

REMOVAL FROM LONG TERM STORAGE

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 Lombardini distributor to have engine overhauled.

 If the ambient temperature is expected to drop below

0°C, add antifreeze to the radiator.

 Cover the light tower and store in a clean, dry place away

from children and unauthorized personnel.

LT12DAB LIGHT TOWER • OPERATION MANUAL — REV. #0 (06/03/11) — PAGE 33

MAINTENANCE — TRAILERS

The following trailer maintenance guidelines are intended to assist the operator in preventive maintenance.

ADJUSTABLE CHANNEL

Your trailer may be equipped with an adjustable channel (Figure 21) that allows the coupler to be raised or lowered to a desired height. Periodically check the channel bolts for damage or loosening.

Figure 21. Adjustable Channel

Follow the steps below to disassemble the wheel hub and service the wheel bearings. See Figure 22.

BEARING

OIL

SEAL

BEARING

CUP

Figure 22. Wheel Hub Components

LUG NUT

WHEEL

HUB

SPINDLE WASHER

BEARING

CUP

BEARING

COTTER

DUST

CAP

SPINDLE

NUT

 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.

Wheel Bearings

Wheel bearings (Figure 22) 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.

DANGER

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!

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.

 Replace seals that have nicks, tears or wear.

 Lubricat e the bearings with a high quality EP-2

automotive wheel bearing grease.

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).

PAGE 34 — LT12DAB LIGHT TOWER • OPERATION MANUAL — REV. #0 (06/03/11)

MAINTENANCE — TRAILERS

DANGER

NEVER 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!

DANGER

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.

DANGER

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.

LEAF SUSPENSION

The leaf suspension springs and associated components (Figure 23) 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.

AXLE

U-BOLT

HANGER SUPPORT

BRACKET IS WELDED

TO FRAME

LEAF

FRONT

HANGER NUT

FRONT

HANGER BOLT

U-BOLT

LOCKING

NUT

TIE PLATE

Figure 23. Leaf Suspension Components

DANGER

Worn or broken suspension parts can cause loss of control, damage to equipment and severe bodily injury, even death!

Check suspension regularly.

SUSPENSION

WARNING

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.

LT12DAB LIGHT TOWER • OPERATION MANUAL — REV. #0 (06/03/11) — PAGE 35

TROUBLESHOOTING

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.

Symptom Possible Problem Solution

No Voltage Output

Low Voltage Output

High Voltage Output Is wiring connections loose? Check wiring and repair.

Circuit Breaker Tripped

Engine fails to start and

starter does not rotate

Engine fails to start and

start rotates

Is wiring connection loose? Check wiring and repair.

Defective Rectiﬁer? Check and replace.

Is engine speed correct? Turn engine throttle lever to “High”.

Is wiring connection loose? Check wiring and repair.

Short Circuit in load? Check load and repair.

Over current? Conﬁrm load requirements and reduce.

Defective circuit breaker? Check and replace.

Dead battery? Replace battery.

Defective ignition switch? Replace ignition switch.

Defective starter? Replace starter

Burned fuse? Replace fuse.

Broken preheat circuit? Check preheat circuit.

No fuel? Add diesel fuel.

Defective wiring? Check wiring.

Table 8. Generator Troubleshooting

PAGE 36 — LT12DAB LIGHT TOWER • OPERATION MANUAL — REV. #0 (06/03/11)

TROUBLESHOOTING

Table 9. Engine Troubleshooting

Symptom Possible Cause Solution

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.

Engine does not start.

Excessively high viscosity of fuel or engine oil at low temperature?

Fuel with low cetane number? Use the speciﬁed fuel.

Fuel leak due to loose injection pipe retaining 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?

Compression leak from cylinder?

Improper valve timing? Correct or replace timing gear.

Piston ring and liner worn? Replace.

Excessive valve clearance? Adjust.

Battery discharged? Charge battery.

Use the speciﬁed fuel or engine oil.

Tighten nut.

Repair or replace.

Replace head gasket, tighten cylinder head bolt, glow plug and nozzle holder.

Starter does not run.

LT12DAB LIGHT TOWER • OPERATION MANUAL — REV. #0 (06/03/11) — PAGE 37

Starter malfunctioning? Repair or replace.

Key switch malfunctioning? Repair or replace.

Wiring disconnected? Connect wiring.

TROUBLESHOOTING

Table 9. Engine Troubleshooting (continued)

Symptom Possible Cause Solution

Fuel ﬁlter clogged or dirty? Clean or change.

Air cleaner clogged? Clean or change.

Engine revolution is not smooth.

Either white or blue exhaust gas is observed.

Either black or dark gray exhaust gas is observed.

Fuel leak due to loose injection pipe retaining 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.

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.

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.

Incorrect injection timing? Adjust.

Tighten nut.

Deﬁcient output.

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?

PAGE 38 — LT12DAB LIGHT TOWER • OPERATION MANUAL — REV. #0 (06/03/11)

Replace head gasket, tighten cylinder head bolt, glow plug and nozzle holder.

TROUBLESHOOTING

Table 10. Lamp Troubleshooting

Symptom Possible Cause Solution

Lamp will not start.

Lamp Burned Out?

Lamp Loose in Socket?

Floodling Plugs Not Tight? Check plug and receptacle. Tighten if loose.

Defective Ballast?

Low Voltage?

Improper Ballast?

Test the lamp in a ﬁxture which is operating properly. Replace if necessary.

Inspect lamp base to see if there is arcing at center contact button. Tighten lamp snugly. Check socket for damage. Replace if defective.

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.

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.

Proper HID lamps will 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 lamps of the same wattage will operate properly on Metal Halide ballasts.

Lamp ﬂickers and goes out intermittent or cycling.

Operating position should agree with the lamp tech.

A BU-HOR lamp can be operated base up vertical to Improper Lamp Operating Position (Metal Halide only)?

Lamp has been Operating: Cool Down Time Insufﬁcient?

Improper Ballast?

New Lamp?

Defective Lamp? Replace lamp.

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.

HID lamps (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.

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).

Under certain conditions new lamps may "cycle".

Usually after 3 tries to start at 30 to 60 second

intervals, lamps will stabilize and operate satisfactorily.

LT12DAB LIGHT TOWER • OPERATION MANUAL — REV. #0 (06/03/11) — PAGE 39

Symptom Possible Cause Solution

Lamp starts slowly (ARC does not strike when switch is ﬁrst turned on)

Table 10. Lamp Troubleshooting (continued)

Defective Lamp?

TROUBLESHOOTING

Lamp may glow for extended period of time. Replace after checking voltage and ballast.

Circuit breaker trips on lamp start-up

Lamp light output low

Lamp colors different.

Short Circuit or Ground? Check wiring against diagram. Check for shorts or ground.

Normal Lamp Depreciation?

Dirty Lamp or Fixture? Clean lamp and ﬁxture.

Defective Ballast?

Wrong Voltage?

Improper Ballast? Check ballast nameplate against lamp data.

Normal Lamp Depreciation?

Dirty Fixture?

Replace Lamp.

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.

Check voltage at ballast input. Voltage should be within 10% of nameplate rating. Check wiring connections for voltage loss. Check socket contact point.

Lamp output and brightness decreases and color changes slightly as lamps age. Spot replacement with new lamps may cause noticeable differences in lamp colors. Group replacement minimizes color differences.

Dirty ﬁxtures will cause lamps to appear different in color. Clean ﬁxture.

ARC tube discolored or swollen.

Short lamp life.

PAGE 40 — LT12DAB LIGHT TOWER • OPERATION MANUAL — REV. #0 (06/03/11)

Wrong Lamp?

Over Voltage from Power Supply?

Improper Ballast?

Lamp Damaged?

Improper Ballast?

Check data on lamps which appear different in color. Replace with correct color lamp.

Check voltage at ballast. Check for current or voltage surges. Check for shorted capacitors and replace if defective.

Lamp operated on ballast designed for higher wattage lamp. Check ballast nameplate against lamp data.

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.)

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

LAMP TROUBLESHOOTING GUIDE

Use the following procedure and wiring diagram on the next page to determine which of the four lamps is not functioning:

Connections

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.

5. 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.

6. Connect the positive lead of the voltmeter to the output side of CB1 and observe that 230 VAC is present. Make sure circuit breaker is ON.

7. Repeat step 1-6 for CB2 thru CB4.

8. If the correct output voltages are present for CB1 thru CB4 then it can be assumed that the generator is working correctly and the correct voltage (230 VAC) are being supplied to the ballast.

Starting

1. Start the generator and verify that there are no abnormal sounds.

2. Turn CB1 thru CB4 circuit breakers t o the ON position.

3. Wait a few minutes and determine which lamp is not igniting.

4. If one of the lamps is OFF, disconnect its power cable and plug it into a receptacle that is known to be working. DO NOT 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 (380-440 VAC present to ignite the arc tube), then it can be assumed that the ballast for that lamp is defective. Replace ballast.

Ballast Removal:

1. Remove the power cable from the generator, and make sure that no voltage is being supplied to the ballast compartment.

2. Remove the four screws securing the ballast cover, and remove cover.

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.

LT12DAB LIGHT TOWER • OPERATION MANUAL — REV. #0 (06/03/11) — PAGE 41

ROTOR

LIGHT TOWER WIRING DIAGRAM

ROTOR

WINDINGS

FIXED FLOW

CURRENT

DIODE

STATOR

WINDING

EXCITATION

WINDING

60 HZ

STATOR

BLACK 3

BLACK 2

50 HZ

BLACK 4

230 VAC

50 HZ

BLACK 1

WHT

GRN

4 3

BLK

RED

C1 35µF@425V EXCITATION CAPACITOR

RED

BLK

TB1

44444

33333

22222

111111

NOTES

USE ONLY 50 Hz GENERATOR, P/N 49126.

USE ONLY 35µF@425 EXCITATION

CAPACITOR P/N GECAP35MF.

RED

35µF@425V

EXCITATION

CAPACITOR

PAGE 42 — LT12DAB LIGHT TOWER • OPERATION MANUAL — REV. #0 (06/03/11)

4 3

WHT

GRN

BLK

CB6

15 AMP

AUX.

BREAKER

BLK

J1 J2

BLK

BLK 16AWG

BLUE 16 AWG

RED 16 AWG

YEL 16 AWG

BRN 14 AWG

WHT 14 AWG

GRN 16 AWG

WHT

BREAKER

(LAMP 4)

BRN

GRN

CB5

30 AMP

MAIN

BREAKER

BLK

CB4

15 AMP

BLK

NEUTRAL BUS

BLUE

BLK

WHT

BRN

T-BAR ASSEMBLY

P/N 19954

7-WIRE COIL CORD

P/N 29433

230 VAC

FROM GENSET

CB3

15 AMP

BREAKER

(LAMP 3)

BLK

230 VAC

GRN

AUX RECPT.

WHT

BRN

LIGHT TOWER WIRING DIAGRAM

NOTES:

WIRE SIZE IS 12 AWG UNLESS

OTHERWISE SPECIFIED.



NEU. 120V IN

BLK

NEU. 120V IN

BLK

NEU. 120V IN

BLK

NEU. 120V IN

BLK

RED

CB2

15 AMP

BREAKER

(LAMP 2)

BLK

TB2

BLK

WHT

BLK

BLUE

RED

YEL

BRN

WHT

GRN

CB1

15 AMP

BREAKER

(LAMP 1)

YEL

WHT

SOME UNITS MAY HAVE A 47K ½ WATT RESISTOR INSTALLED

ACROSS THE CAPACITOR

TERMINALS. OTHER UNITS MAY HAVE THIS RESISTOR INTERNALLY INSTALLED WITHIN THE CAPACITOR.

CONNECT AUX. POWER RECEPTACLE

TO THESE CONNECTION POINTS.

CONTROL PANEL/BALLAST

ASSEMBLY P/N 29614

30µF@440V CAPACITOR

OUTPUT

BLUE

BLK

RED

YEL

30µF@440V

CAPACITOR

30µF@440V

CAPACITOR

30µF@440V

CAPACITOR

RED

YEL

OUTPUT

RED

YEL

OUTPUT

RED

YEL

OUTPUT

RED

BALLAST #1

BALLAST #2

BALLAST #3

BALLAST #4

YEL

WHT

GRN

CHASSIS GROUND

LT12DAB LIGHT TOWER • OPERATION MANUAL — REV. #0 (06/03/11) — PAGE 43

LOMBARDINI ENGINE WIRING DIAGRAM

Operating voltage: 10 to 16 VDC (30VDC max 10 sec.)

PAGE 44 — LT12DAB LIGHT TOWER • OPERATION MANUAL — REV. #0 (06/03/11)

TRAILER GUIDELINES

The following guidelines are intended to assist the operator

 Shift your automatic transmission into a lower gear for

use lower gears for climbing and descending

ride the brakes while descending grades, they

Slow down for bumps in the road. Take your foot off the

curve and power through the curve. This way, the towing

swaying. Continued pulling of the trailer, and even slight

trucks and buses. Continued pulling of the trailer provides a stabilizing force to correct swaying. DO NOT apply the

Use lower gear when driving down steep or long grades.

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.

COMMON CAUSES FOR LOSS OF TRAILER

 Driving too fast for the conditions (obey local speed

laws).

 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.

TRAILER TOWING GUIDELINES

 Recheck the load tiedowns to make sure the load will

not shift during towing.

city driving.

 ALWAYS

grades.

 DO NOT

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.



brake when crossing the bump.

 DO NOT brake while in a curve unless absolutely

necessary. Instead, slow down before you enter the

vehicle remains in charge.

 DO NOT apply the brakes to correct extreme trailer

acceleration, will provide a stabilizing force.

 Anticipate the trailer “swaying.” Swaying is the trailer

reaction to the air pressure wave caused by passing

brakes to correct trailer swaying.

 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.

 DO NOT 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.



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.

LT12DAB LIGHT TOWER • OPERATION MANUAL — REV. #0 (06/03/11) — PAGE 45

DRIVING CONDITIONS

When towing a trailer, you will have decreased acceleration,

for the use of your trailer. Again, be sure your hitch and tow

Use of a hitch with a load rating less than the load rating

the load rating of the trailer can result in loss of control,

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.

 NEVER drive faster than what is safe.

WARNING

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.

WARNING

Do not transport people on the trailer. The transport of people puts their lives at risk and may be illegal.

COUPLING TO THE TOW VEHICLE

TRAILER GUIDELINES

vehicle are rated for the Gross Vehicle Weight Rating of your trailer.

WARNING

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.

WARNING

An improperly coupled trailer can result in death or serious injury.

DO NOT 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.

DO NOT tow the trailer on the road until:

• Tires and wheels are checked.

• The trailer brakes are checked.

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.

The trailer VIN tag contains the critical safetyinformation

PAGE 46 — LT12DAB LIGHT TOWER • OPERATION MANUAL — REV. #0 (06/03/11)

• The breakaway switch is connected to the tow vehicle.

• The load is secured to the trailer.

• The trailer lights are connected and checked.

WARNING

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

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.

INOPERABLE BRAKES, LIGHTS OR MIRRORS

Be sure that the brakes and all of the lights on your trailer

Drive slowly at ﬁ rst, 8 kph or so, and turn the wheel to get

Stop the rig a few times from speeds no greater than 16 kph.

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

with a trailer attached. Take it slow. Before backing up, get out of the tow vehicle and look behind the trailer to make

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

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

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

Number (VIN) Tag which is typically located on the left front

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.

WARNING

Improper electrical connection between the tow vehicle and the trailer will result in inoperable lights and can lead to collision.

TRAILER GUIDELINES

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.

If your trailer is equipped with brakes, try using different

come on just before the tow vehicle brakes.

It will take practice to learn how to back up a tow vehicle

sure that there are no obstacles.

Before each tow, check that the tail lights, brake lights and turn signals work.

TRAILER TOWING TIPS

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.

move to the right (counterclockwise, as you would do to

backing up.

the steering wheel in the opposite direction.

TRAILER VIN TAG

Figure A below is a sample of the Vehicle Identiﬁ cation

of the trailer. See Figure B for location.

Figure A. Vehicle VIN Tag

LT12DAB LIGHT TOWER • OPERATION MANUAL — REV. #0 (06/03/11) — PAGE 47

TRAILER GUIDELINES

To determine the “empty” or “net” weight of your trailer, weigh it on an axle scale. To ﬁ nd the weight of the trailer

trailer weight will be transferred from the trailer to the tow vehicle axles, and an axle scale weighs all axles, including

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

law regulations determine the size of the mirrors. However,

A Heavy Duty Flasher is an electrical component that may be required when your trailer turn signal lights are attached

EMERGENCY FLARES AND TRIANGLE REFLECTORS

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

using an axle scale, you must know the axle weights of your tow vehicle without the trailer coupled. Some of the

the tow vehicle axles.

VINTAG

VIN TAG

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.

GVWR: 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.

PSIC: The tire pressure (psi) measured when cold.

VIN: The Vehicle Identiﬁ cation Number.

EMPTY WEIGHT: 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.

TOW VEHICLE

and install the proper hitch on your tow vehicle.

SUSPENSION SYSTEM

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.

SIDE VIEW MIRRORS

The size of the trailer that is being towed and your state

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.

HEAVY DUTY FLASHER

to the tow vehicle ﬂ asher circuit.

ELECTRICAL CONNECTOR

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

vehicle lights.

PAGE 48 — LT12DAB LIGHT TOWER • OPERATION MANUAL — REV. #0 (06/03/11)

SAFETY CHAINS

If the coupler connection comes loose, the safety chains

Check the locking device that secures the coupler to the

the proper action to prevent possible failure of the ball and coupler system. All bent or broken coupler parts must be

The coupler handle lever must be able to rotate freely and

motor oil. Keep the ball socket and latch mechanism clean. Dirt or contamination can prevent proper operation of the

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

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

RATED TOWING CAPACITY EQUAL TO OR GREATER

. IT IS ESSENTIAL THAT THE HITCH BALL BE

The ball size and load rating (capacity) are marked on the

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.

TRAILER GUIDELINES

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

JACKSTAND

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”.

COUPLER TYPES

Two types of coupler used with the trailer are discussed below.

 Ball Hitch Coupler

 Pintel Eye Coupler

BALL HITCH COUPLER

A ball hitch coupler (Figure C) connects to a ball that is located on or under the rear bumper of tow vehicle. This system of coupling a trailer to a tow vehicle is sometimes referred to as “bumper pull.”

A ball hitch trailer may be ﬁ tted with a tongue jack 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.

replaced before towing the trailer.

automatically snap into the latched position. Oil the pivot points, sliding surfaces, and spring ends with SAE 30W

latching mechanism.

and ball is equal to or greater than that of your trailer.

and may cause death or serious injury.

THE TOW VEHICLE, HITCH AND BALL MUST HAVE A

THAN THE TRAILER Gross Vehicle Weight Rating

(GVWR)

OF THE SAME SIZE AS THE COUPLER.

ball. Hitch capacity is marked on the hitch.

WARNING

Figure C. Ball Hitch Coupler

Before each tow, coat the ball with a thin layer of automotive bearing grease to reduce wear and ensure proper operation.

LT12DAB LIGHT TOWER • OPERATION MANUAL — REV. #0 (06/03/11) — PAGE 49

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.

TRAILER GUIDELINES

 Lower the trailer (Figure D) until the coupler fully engages

Engage the coupler locking mechanism. In the engaged

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

Lower the trailer so that its entire tongue weight is held

Raise the jackstand to a height where it will not interfere

trailer so that its entire tongue weight is held by the hitch and

WARNING

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.

WARNING

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.

 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.

the hitch ball.

2-INCH

TRAILER

COUPLER

TOW

VEHICLE

2-INCH

BALL

Figure D. Ball Hitch Coupling Mechanism



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 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.

Coupling the Trailer to the Tow Vehicle (Ball Coupler)

 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.

the coupler is locked to the hitch.



by the hitch.



with the road.

NOTICE

Overloading can damage the tongue jack. DO NOT use the tongue jack to raise the tow vehicle more than one inch.

If the coupler cannot be secured to the hitch ball, do not tow the trailer. Call your dealer for assistance. Lower the

continue retracting the jack to its fully retracted position.

PAGE 50 — LT12DAB LIGHT TOWER • OPERATION MANUAL — REV. #0 (06/03/11)

TRAILER GUIDELINES

Attaching Safety Chain

 Backup Lights (place tow vehicle gear shift in reverse).

Block trailer tires to prevent the trailer from rolling, before

Disconnect the breakaway brake switch cable. Promptly

surface below the jackstand foot will support the tongue

Rotate the jackstand handle (or crank) clockwise. This will slowly extend the jack and transfer the weight of the

Improper electrical connection between the tow vehicle and the trailer will result in inoperable lights and electric

Check that the taillights, brake lights and turn signals

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.

TRAILER TONGUE

Figure E. Attaching Safety Chain (Ball Hitch)

• Loop around a frame member of the tow vehicle or holes provided in the hitch system (DO NOT 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

WARNING

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.

SAFETY CHAIN

MASTER LINK

TOW

VEHICLE

IMPORTANT!

CROSS BOTH

SAFETY CHAINS

 Turn Signals (activate tow vehicle directional signal

lever).

WARNING

brakes, and can lead to collision.

Before each tow:

• work.

• Check that the electric brakes work by operating the brake controller inside the tow vehicle.

Uncoupling the Ball Hitch

Follow these steps to uncouple ball hitch from tow vehicle:



jacking the trailer up.

 Disconnect the electrical connector.



replace the pullpin in the switchbox.

 Before extending jackstand, make certain the ground

load.



• Fasten chains to frame of tow vehicle. DO NOT 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.

Connecting Trailer Lights

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).

LT12DAB LIGHT TOWER • OPERATION MANUAL — REV. #0 (06/03/11) — PAGE 51

trailer tongue to the jack.

PINTLE HITCH COUPLER

A pintle eye coupler (Figure F) connects to a pintle-hook

If you see or feel evidence of wear, such as ﬂ at spots,

determine the proper action to prevent possible failure of the ball andcoupler system. All bent or broken coupler parts

COUPLER MUST HAVE A RATED TOWING CAPACITY

Gross

IT IS ESSENTIAL THAT THE PINTLE HITCH BE OF THE

The coupler size and load rating (capacity) are marked on

Wipe the inside and outside of the pintle coupler. Clean and inspect it visually for cracks and deformations. Feel

Be sure the coupler is secured tightly to the tongue of the trailer. All coupler fasteners must be visibly solid against

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.”

TRAILER GUIDELINES

deformations, pitting or corrosion, on the pintle hook or coupler, immediately have your dealer inspect them to

must be replaced before towing the trailer.

THE TOW VEHICLE, PINTLE HITCH AND PINTLE

Figure F. Pintle Hitch Coupler

A pintle hitch 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.

Pintle Coupler and Pintle Hook

EQUAL TO OR GREATER THAN THE TRAILER Vehicle Weight Rating (GVWR).

SAME SIZE AS THE PINTLE COUPLER.

the coupler. Hitch capacity is marked on the hitch.

WARNING

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.

WARNING

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.

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.

PAGE 52 — LT12DAB LIGHT TOWER • OPERATION MANUAL — REV. #0 (06/03/11)

 Rock the pintle eye coupler to make sure it is secured

tightly to the hitch.



the inside of the coupler for worn spots and pits.



the trailer frame.

TRAILER GUIDELINES

 Raise the bottom surface of the coupler to be above the

CHAIN

LINK

 Lower the trailer so that its entire tongue weight is held

Raise the jackstand to a height where it will not interfere

Trailer tires and wheels are more likely to fail than car tires and wheels because they carry a heavier load. Therefore,

If a tire has a bald spot, bulge, cuts, is showing any cords,

Uneven tread wear can be caused by tire imbalance, axle

Tires with too little tread will not provide adequate tracking on wet roadways and can result in loss of control, leading

can result in a tire blowout and loss of control. Therefore, before each tow you must also check the tire pressure. Tire

Allow 3 hours cool-down after driving as much as 1 kilometer at 64 kph before checking tire pressure. Trailer tires will be inﬂ ated to higher pressures than passenger vehicle tires.

wrench to tighten the lug nuts. If you do not have a torque

top of the pintle hitch hook. Use the tongue jackstand to support the trailer tongue. Wood or concrete blocks may also be used.

WARNING

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.

Coupling Trailer to Tow Vehicle (Pintle Coupler)

 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.

TRAILER TONGUE

TOW

VEHICLE

PINTLE

HOOK

by the hitch.



with the road.

TIRE SAFETY

Unsafe Tires, Lug Nuts or Wheels

it is essential to inspect the trailer tires before each tow.

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.

misalignment or incorrect inﬂ ation.

to death or serious injury.

Improper tire pressure causes an unstable trailer and

pressure must be checked when tires are cold.

SAFETY

MASTER

PINTLE

RING “EYE”

SAFETY

CHAIN

Figure G. Attaching Safety Chain (Pintle Hitch)

IMPORTANT!

CROSS BOTH

 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.

LT12DAB LIGHT TOWER • OPERATION MANUAL — REV. #0 (06/03/11) — PAGE 53

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

TRAILER GUIDELINES

wrench, use a lug wrench (from your tow vehicle) and

This certiﬁ cation/VIN label will indicate the trailer’s Gross

Gross Axle Weight Rating (GAWR). This is the most a the

There is a vehicle placard (Figure H) located in the same

placard provides tire and loading information. In addition,

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

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

Locate the statement, “The weight of cargo should never

Loading Information placard (Figure I). This value equals

tighten the nuts as much as you can. Then have a service garage or trailer dealer tighten the lug nuts to the proper torque.

WARNING

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 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.

WARNING

Lug nuts are prone to loosen after initial installation, which can lead to death or serious injury.

Vehicle Weight Rating (GVWR). This is the most weight the fully loaded trailer can weigh. It will also provide the

axle can weigh.

location as the certiﬁ cation label described above. This

this placard will show a statement regarding maximum cargo capacity.

The weight of cargo should never exceed XXX kg. Or XXX lbs

TIRE

FRONT

REAR

SPARE

TIRE AND LOADING INFORMATION

SIZE

COLD TIRE PRESSURE

Figure H. Trailer Tire Placard

SEE OWNER’S

MANUAL FOR

ADDITIONAL

INFORMATION

If additional work items (hoses, tools, clamps etc.) are

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.

WARNING

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.

WARNING

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.

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.

overload a tire.

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.

Step 1.

exceed XXX kg or XXX lbs.,” on your vehicle’s Tire and

the available amount of equipment load capacity.

PAGE 54 — LT12DAB LIGHT TOWER • OPERATION MANUAL — REV. #0 (06/03/11)

TRAILER GUIDELINES

Step 2.

along with other care and maintenance activities, can

Help protect you and others from avoidable breakdowns

Use the information contained in this section to make tire safety a regular part of your vehicle maintenance routine.

with the inconvenience and safety consequences of a ﬂ at

Federal law requires tire manufacturers to place standardized

identiﬁ cation number for safety standard certiﬁ cation and

millimeters of the tire from sidewall edge to sidewall edge.

: This two-digit number, known as the aspect

70 or lower indicate a short sidewall for improved steering

: The “R” stands for radial. Radial ply construction of tires

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).

Determining Load Limit of Tow Vehicle

Step 1.

Locate the statement, “The combined weight of occupants and cargo should never exceed XXX lbs.,” on your vehicle’s placard.

Step 2.

Determ ine the combined weight of the driver and passengers who will be riding in your vehicle.

Step 3.

Subtract the combined weight of the driver and passengers from XXX kilograms or XXX pounds.

also:

 Improve vehicle handling. 

and accidents.

 Improve fuel economy.  Increase the tire life.

Recognize that the time you spend is minimal compared

tire or other tire failure.

TIRE FUNDAMENTALS

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

in case of a recall.

Step 4.

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.).

Step 5.

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,

Figure I. Standard Tire Sidewall Information

P: The “P” indicates the tire is for passenger vehicles.

Next number: This three-digit number gives the width in

In general, the larger the number, the wider the tire.

Next number

ratio, gives the tire’s ratio of height to width. Numbers of

response and better overall handling on dry pavement.

has been the industry standard for the past 20 years.

LT12DAB LIGHT TOWER • OPERATION MANUAL — REV. #0 (06/03/11) — PAGE 55

TRAILER GUIDELINES

Next number: This two-digit number is the wheel or rim

in the tire. In general, the greater the number of plies, the

must indicate the materials in the tire, which include steel,

maximum load in kilograms and pounds that can be carried

: This number

is the greatest amount of air pressure that should ever be

Uniform Tire Quality Grading Standards (UTQGS)

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

This letter indicates a tire’s ability to stop

to stop your car on wet roads in a shorter distance than a tire with a lower grade. Traction is graded from highest to

resistance to heat. The temperature grade is for a tire that is inﬂ ated properly and not overloaded. Excessive speed,

in combination, can cause heat build-up and possible tire failure. From highest to lowest, a tire’s resistance to heat

diameter in inches. If you change your wheel size, you will have to purchase new tires to match the new wheel diameter.

Next number: 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.

M+S: 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.

Table A. 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

U.S. DOT Tire Identiﬁ cation Number: 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.

Tire Ply Composition and Materials Used: The number of plies indicates the number of layers of rubber-coated fabric

more weight a tire can support. Tire manufacturers also

nylon, polyester, and others.

Maximum Load Rating: This number indicates the

by the tire.

Maximum Permissible Inﬂ ation Pressure

put in the tire under normal driving conditions.

Treadwear Number: This number indicates the tire’s

200.

Traction Letter:

on wet pavement. A higher graded tire should allow you

lowest as “AA”,”A”, “B”, and “C”.

Tem pe rature Letter: Th is l et ter indicates a tire’s

underinﬂ ation or excessive loading, either separately or

is graded as “A”, “B”, or “C”.

Refer to Figure J for additional tire information for light trucks.

Figure J. UTQGS Tire Information

PAGE 56 — LT12DAB LIGHT TOWER • OPERATION MANUAL — REV. #0 (06/03/11)

Tires for light trucks have other markings besides those

found on the sidewalls of passenger tires.

sidewall should not be repaired. Tires must be removed from the rim to be properly inspected before being plugged

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

Table B below will help pinpoint the causes and solutions

pieces of the rim to explode (break off) with great force

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.

Max. Load Dual 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).

Max. Load Single 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 loadcarrying 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.

 DO NOT 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.

 DO NOT 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.

TRAILER GUIDELINES

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

a damaged tire before towing the trailer.

of tire wear problems.

Table B. Tire Wear Troubleshooting

Wear Pattern Cause Solution

Center Wear Over inﬂ ation.

Edge Wear Under inﬂ ation.

Side Wear

Toe Wear Incorrect toe-in. Align wheels.

Cupping Out-of-balance.

Flat Spots

Loss of camber or overloading.

Wheel lockup and tire skidding.

Adjust pressure to particular load per tire manufacturer.

Make sure load does not exceed axle rating. Align wheels.

Check bearing adjustment and balance tires.

Avoid sudden stops when possible and adjust brakes.

 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.

 DO NOT 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

LT12DAB LIGHT TOWER • OPERATION MANUAL — REV. #0 (06/03/11) — PAGE 57

WARNING

ALWAYS wear safety g la ss es when removing or installing force ﬁ tted parts. DO NOT attempt to repair or modify a wheel. DO NOT 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

and cause serious eye or bodily injury.

Wheel Rims

If the trailer has been struck, or impacted, on or near the

3. Check to see if the lug nuts are tight after the ﬁ rst 10,

Wheel Lug Nuts Tightening Sequence

Before each tow, check the trailer taillights, stoplights, turn

Check the wire harness for cuts, fraying or other damage.

Improper operating taillights, stoplights and turn signals

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.

Wheels, Bearings and Lug Nuts

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.

TRAILER GUIDELINES

25 and 50 miles of driving and before each tow thereafter

WARNING

Lug nuts are prone to loosen after initial installation, which can lead to death or serious injury. Check all wheel lug nuts periodically.

Lug Nut Torque Requirements

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.

NOTICE

NEVER 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.

Figure K.

Table C. Tire Torque Requirements

Wheel Size

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

First Pass

FT-LBS

Second Pass

FT-LBS

Third Pass

FT-LBS

Lights and Signals

signals and any clearance lights for proper operation.

Replace any broken or burned-out lamps as necessary.

If it needs replacing, contact your dealer.

WARNING

can cause collisions.

Check all lights before each tow.

PAGE 58 — LT12DAB LIGHT TOWER • OPERATION MANUAL — REV. #0 (06/03/11)

TRAILER GUIDELINES

Figure L. Trailer to Tow Vehicle Wiring Diagram

LT12DAB LIGHT TOWER • OPERATION MANUAL — REV. #0 (06/03/11) — PAGE 59

OperatiOn Manual

HERE’S HOW TO GET HELP

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

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.

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

Service Department Warranty Department

800-421-1244 310-537-3700

Technical Assistance

800-478-1244 Fax: 310-943-2238

Tel. (800) 421-1244 Fax (800) 537-3927

Fax: 310-537-4259 800-421-1244

800-427-1244 310-537-3700

310-537-3700

Fax: 800-672-7877 Fax: 310-637-3284

Fax: 310-943-2249

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

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

Tel: 0161 339 2223 Fax: 0161 339 3226

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.

and

Your Local Dealer is:

Multiquip LT12DAB User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual