Magnum MLT 5150 User manual

LIGHT TOWER
MLT 5150 • 5200
OPERATING/PARTSMANUAL
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INTRODUCTION
Thismanualprovides information andproceduresto safely operateandmaintainthelight tower and generator. For
yourown safety andprotection from physicalinjury, carefully read,understand,and observe the safety instructions
described in this manual. The information contained in this manual was based on machines in production at the
time of publication. Magnum Products LLC reserves the right to change any portion of this information without
notice.
DO NOT MODIFY or use this equipment for any application other than which it was designed for.
MagnumProducts LLCrecommendsthatatrainedandlicensedprofessionalperformallelectrical wiringandtesting
functions. Any wiring should be in compliance with the United States National Electric Code (NEC), state and local
codesand OccupationalSafetyandHealthAssociation(OSHA) guidelines.
Keep a copy of this manual with the unit at all times. An engine operators manual was also supplied with the unit at
the time of shipmentfromthe factory. The manual providesdetailedoperation and maintenanceproceduresfor the
engine.
CALIFORNIAPROPOSITION 65 WARNING:
Diesel engine exhaust and some of its constituents are known to the state
of California to cause cancer, birth defects and other reproductive harm.
WARNING
EngineMake:
EngineSerial Number:
EngineModel Number:
GeneratorMake:
GeneratorModelNumber:
GeneratorSerial Number:
UnitModelNumber:
UnitSerial Number:
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TABLE OF CONTENTS
Page
INTRODUCTION ..............................................................................................................................2
TABLEOFCONTENTS ...................................................................................................................3
SAFETYNOTES.............................................................................................................................4
OPERATINGSAFETY.....................................................................................................................4
ENGINESAFETY ...........................................................................................................................5
SERVICESAFETY .........................................................................................................................5
TOWINGSAFETY ..........................................................................................................................6
REPORTINGTRAILER SAFETYDEFECTS ....................................................................................6
UNITSERIALNUMBERLOCATIONS..............................................................................................6
SAFETYSYMBOL SUMMARY.......................................................................................................7
SPECIFICATIONS ..................................................................................................................... 8 - 9
LIGHTTOWERSETUP ................................................................................................................10
RAISINGTHE TOWER................................................................................................................. 11
RAISINGTHE TOWERWITHOPTIONALELECTRICWINCH ...................................................... 12
MAINCONTROLPANELCOMPONENTS .....................................................................................13
ENGINESTARTINGANDOPERATION .........................................................................................14
AUTOMATICSHUTDOWN ............................................................................................................14
LIGHTOPERATION.......................................................................................................................15
AUXILIARYOUTLETS ...................................................................................................................15
VOLTAGEREGULATION...............................................................................................................16
DERATINGFORALTITUDE ...........................................................................................................16
SHUTTINGDOWN ........................................................................................................................16
LOWERINGTHETOWER.............................................................................................................16
LOWERINGTHETOWERWITHTHEOPTIONALELECTRICWINCH .......................................... 17
TOWINGTHETRAILER ................................................................................................................17
LIFTINGTHETRAILER..................................................................................................................18
OPTIONALLOWER RADIATORHOSEHEATERUSEAND MAINTENANCE ................................18
TROUBLESHOOTINGTHELIGHTS .......................................................................................18 - 19
MASTLIGHT CONNECTIONS .......................................................................................................19
DAILYINSPECTION......................................................................................................................20
TRAILERWHEELBEARINGS ......................................................................................................20
ENGINEMAINTENANCE ..............................................................................................................21
UNITDECALS........................................................................................................................22 - 25
MANUALWINCH MASTASSEMBLY.....................................................................................26 - 27
ELECTRICWINCHMASTASSEMBLY ..................................................................................28 - 29
AUXILIARYOUTLETPANELASSEMBLY ..............................................................................30 - 31
AUXILIARYOUTLETPANELOPTIONS ..................................................................................32 - 33
ENCLOSUREASSEMBLY .....................................................................................................34 - 35
FRAMEASSEMBLY ..............................................................................................................36 - 37
COOLINGSYSTEMASSEMBLY ...........................................................................................38 - 39
ENGINEASSEMBLY- MLT5150, MITSUBISHI......................................................................40 - 41
ENGINEASSEMBLY-MLT5200, ISUZU ...............................................................................42 - 43
CONTROLBOXAND PANELASSEMBLY..............................................................................44 - 45
LIGHTASSEMBLY.................................................................................................................46 - 47
METALHALIDEBALLASTBOXASSEMBLY ................................................................................48
HIGHPRESSURESODIUMBALLASTBOXASSEMBLY-OPTIONAL .........................................49
MASTJUNCTIONBOXASSEMBLY- 4 LIGHT,QUICKDISCONNECT ..........................................50
MASTJUNCTIONBOXASSEMBLY- 6 LIGHT,QUICKDISCONNECT ..........................................51
GENERATORASSEMBLY-MLT5150..........................................................................................52
GENERATORASSEMBLY-MLT5200..........................................................................................53
WIRINGDIAGRAMS ..............................................................................................................54 - 63
3
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This is the safety alert symbol. It is used to alert you to potential personal injury hazards.
Obey all safety messages that follow this symbol to avoid possible injury or death.
ThismanualcontainsDANGERS,WARNINGS,CAUTIONS,NOTICESandNOTESwhichmustbe
followedtopreventthepossibilityofimproperservice,damagetotheequipment, personalinjuryordeath.
Thefollowingformattingoptionswillapplywhencallingthereaders attention to the DANGERS, WARN-
INGS,CAUTIONS,NOTICESandNOTES.
SAFETY NOTES
NOTICE
Indicatesahazardous situationwhich,ifnotavoided,
mayresultinpropertyorequipmentdamage.
Note: Notescontainadditionalinformationimportanttoaprocedureandwillbefoundwithintheregular
text body of this manual.
DANGER
INDICATESAHAZARDOUSSITUATIONWHICH,IFNOTAVOIDED,
WILLRESULTINDEATHORSERIOUSINJURY.
WARNING
Indicates a hazardous situation which, if not avoided,
could result in death or serious injury.
CAUTION
Indicates a hazardous situation which, if not avoided, may result in minor or moderate injury.
OPERATING SAFETY
Before using the light tower be sure you read and understand all of the instructions! This equipment was
designedforspecific applications; DONOTmodify or usethisequipment for anyapplicationother than
whichitwasdesignedfor. Equipmentoperatedimproperlyorbyuntrainedpersonnel canbedangerous!
Readtheoperating instructions andfamiliarizeyourself with thelocationand proper useofall instruments
andcontrols. Inexperiencedoperatorsshouldreceiveinstructionfromsomeonefamiliarwiththeequipment
before being allowed to operate or set up the light tower. The following points should be practiced at all
times:
•Theareaimmediatelysurroundingthelighttowershouldbedry,clean,andfreeofdebris.
•Positionand operate the lighttower on afirm, level surface.
• NEVER starta unit inneed of repair.
•Lower tower when not in use, or if high winds or electrical storms are expected in the area.
•Makecertainlight tower is well groundedandsecurely fastened to agoodearthenground.
•Thetower extends up to 30ft. (9 m). Make sure areaabove trailer isopen and clear of overheadwires
andobstructions.
•Bulbs become extremely hot in use! Allow bulb and light fixture to cool 10-15 minutes before handling.
•Keepareabehindtrailerclearofpeoplewhileraisingandloweringmast!
• NEVER raise,lowerorturn mast while unit isoperating!
•Trailermustbeleveledandoutriggersextendedbeforeraisingtower. Outriggersmustremainextended
while tower is up.
•Iffor anyreason any part of mast hangs up or winchcable developsslack while raising or lowering
tower,STOPimmediately! Contactanauthorizedservicerepresentative.
• NEVER removesafety pin or pull mastlocking pin while tower is up!
• NEVER use tower if insulation on electrical cord is cut or worn through.
• NEVER operatelights without protective lens cover in place or with a lens cover that is cracked or
damaged!
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Internalcombustionenginespresentspecialhazardsduringoperationandfueling! Failuretofollowthe
safety guidelines described below could result in severe injury or death. Also read and follow all safety
warnings described in the engine operator’s manual. A copy of this manual was supplied with unit when it
wasshippedfromthefactory.
• DO NOT run engine indoors or in an area with poor ventilation unless exhaust hoses are used. Diesel
engine exhaust contains carbon monoxide, a deadly, odorless and colorless gas which, if inhaled,
can cause nausea, fainting or death. Make sure engine exhaust cannot seep into closed rooms or
ventilationequipment.
• DO NOT fill fuel tank near an open flame, while smoking, or while engine is running. DO NOT fill tank
inanenclosedareawithpoorventilation.
• DO NOT operate with the fuel tank cap loose or missing.
• DO NOT touch or lean against hot exhaust pipes or engine cylinders.
• DO NOT clean air filter with gasoline or other types of low flash point solvents.
• DONOTremoveenginecoolantcapwhileengineishot.
• DO NOT operate the unit without a functional exhaust system. Prolonged exposure to sound
levels in excess of 85 DBA can cause permanent hearing loss. Wear hearing protection when
workingaroundarunningengine.
•Keep area around exhaust pipes and air ducts free of debris to reduce the chance of an accidental
fire.
•Batteries contain sulfuric acid which can cause severe injury or death. Sulfuric acid can cause eye
damage,burn flesh oreat holes inclothing. Protective eye wear and clothing arenecessary when
working on or around the battery. Always disconnect the NEGATIVE (-) battery cable from the
correspondingterminalbeforeperforminganyserviceontheengineorothercomponents.
• Shutthe engine down ifany of thefollowing conditions exist duringoperation:
1. Noticeablechangeinenginespeed.
2. Loss of electrical output.
3. Equipmentconnectedtothegeneratoroverheats.
4. Sparkingoccurs.
5. Enginemisfiresorthereis excessive engine/generator vibration.
6. Operatingonacombustible surface.
7. Protectivecoversareloose or missing.
8. Iftheambient air temperature isabove 110° F.
ENGINE SAFETY
SERVICE SAFETY
This unit uses high voltage circuits capable of causing serious injury or death. Only a qualified electrician
shouldtroubleshootor repairelectricalproblemsoccurringinthis equipment.
•Before servicing light tower, make sure the engine start switch is turned to OFF, circuit breakers are
open(off)andthenegativeterminalonthebatteryisdisconnected.NEVER performevenroutine
service (oil/filter changes, cleaning, etc.) unless all electrical components are shut down.
• NEVER allow water to accumulate around the base of the light tower. If water is present, DO NOT
service!
• NEVER service electrical components if clothing or skin is wet. If the unit is stored outside, check
theengineandgeneratorforany moisture and dry the unitbeforeuse.
• NEVER washtheunitwithapowerwasherorhighpressurehose.
•Openmaincircuit breaker before disconnectingbatterycables.
•Keephands,feet,andlooseclothingawayfrommovingpartsongeneratorandengine.
•Replaceallguardsandsafetydevicesimmediatelyafterservicing.
•Make sure slings, chains, hooks, ramps, jacks, and other types of lifting devices are attached
securelyand have enough weight-bearingcapacity to liftor hold theequipment safely. Always
remainawareofthepositionofotherpeoplearoundyouwhenliftingtheequipment.
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MANUFACTURED BY/FABRIQUE PAR:
GVWR/PNBV:
DATE OF MFG:
COLD INFL. PRESS./PRESS.
DE GONF A FROID
GAWR/PNBE TIRE/PNEU RIM/JANTE KPA(PSI/LPC) SGL/DUAL
THIS VIEHICLE CONFORS TO ALL APPLICABLE STANDARDS PRESCRIBED UNDER THE CANADIAN MOTOR VIEHICLE SAFETY REGULATIONS
IN ECCEFT ON THE DATE OF MANUFACTURE. / CE VEHICULE EST CONFORME A TOUTES LES NORMES QUI LUI SONT APPLICABLES EN
VERTU DU REGLEMENT SUR LA VEHICULES DES AUTOMOBILES DU CANADA EN VIGUEUR A LA DATE SA FABRICATION.
THIS VIEHICLE CONFORMS TO ALL APPLICABLE U.S. FEDERAL MOTOR VEHICLE SAFETY STANDARDS (FMVSS) IN EFFECT ON THE DATE OF
MANUFACTURE SHOWN ABOVE.
V.I.N./N.I.V.: TYPE/TYPE DE VEHICULE:
MANUFACTUREDBY/FABRIQUEPAR:
GVWR/PNBV:
DATEOFMFG:
COLDINFL.PRESS./PRESS.
DEGONFAFROID
GAWR/PNBE TIRE/PNEU RIM/JANTE KPA(PSI/LPC) SGL/DUAL
THISVIEHICLECONFORSTOALLAPPLICABLE STANDARDS PRESCRIBED UNDER THE CANADIAN MOTOR VIEHICLE SAFETY REGULATIONS
INECCEFTONTHEDATEOF MANUFACTURE. /CEVEHICULEESTCONFORMEA TOUTES LES NORMES QUI LUI SONT APPLICABLES EN
VERTUDUREGLEMENTSURLAVEHICULES DES AUTOMOBILES DU CANADA EN VIGUEUR A LA DATE SA FABRICATION.
THISVIEHICLECONFORMSTOALLAPPLICABLE U.S. FEDERAL MOTOR VEHICLE SAFETY STANDARDS (FMVSS) IN EFFECT ON THE DATE OF
MANUFACTURESHOWNABOVE.
V.I.N./N.I.V.: TYPE/TYPEDEVEHICULE:
Serial Number
kg lbs
rpm hz amb. temp.
V
A
Model
RATING: CONT. STAND BY
3 Phase 1 Phase
KVA
LR 114630-1
FOR ELECTRICAL
EQUIPMENT ONLY.
POUR MATERIAL
ELECTRIQUE SEULEMENT.
MADE IN USA
PRODUCTS LLC
215 Power Drive
Berlin, WI 54923
1-800-926-9768
TM
Mfg. Code
V
A
KW
®
SerialNumber
kg lbs
rpm hz amb.temp.
V
A
Model
RATING: CONT. STANDBY
3Phase 1Phase
KVA
LR114630-1
FORELECTRICAL
EQUIPMENTONLY.
POURMATERIAL
ELECTRIQUESEULEMENT.
MADEINUSA
PRODUCTSLLC
215PowerDrive
Berlin,WI54923
1-800-926-9768
TM
Mfg.Code
V
A
KW
®
Unit ID TagV.I.N. Tag
Towinga trailer requires care! Both thetrailer andvehicle must be in goodcondition and securely fas-
tened to each other to reduce the possibility of an accident. Also, some states require that large trailers
beregistered and licensed. Contact your localDepartment ofTransportation office to check onlicense
requirementsforyourparticularunit.
•Check that the hitch and coupling on the towing vehicle are rated equal to, or greater than, the trailer's
"grossvehicleweightrating"(GVWR).
• Checktiresontrailer for tread wear,inflation,and condition.
•Inspectthehitchandcouplingfor wear or damage. DONOTtowtrailerusingdefective parts!
•Make sure the trailer hitch and the coupling are compatible. Make sure the coupling is securely
fastenedtothevehicle.
•Connect safety chains in a crossing pattern under the tongue and attach the breakaway cable TO
THE REAR BUMPER OF THE TOWING VEHICLE. Do not attach the cable to the trailer hitch.
•Makesuredirectional and brakelights on the trailerare connected and workingproperly.
•Check that all lug nuts holding wheels on are tight and that none are missing.
•Maximumrecommendedspeedforhighwaytowingis45mph. Recommendedoff-roadtowingspeed
is not to exceed 10 mph or less depending on terrain.
Whentowing, maintain extra spacebetween vehicles andavoid soft shoulders, curbsand sudden lane
changes. Ifyou havenot pulled a trailer before, practice turning, stopping, and backing upin anarea
awayfromheavytraffic.
A film of grease on the coupler will extend coupler life and eliminate squeaking. Wipe the coupler clean
and apply fresh grease each time the trailer is towed.
TOWINGSAFETY
REPORTING TRAILER SAFETY DEFECTS
If you believe your trailer has a defect which could cause a crash or could cause injury or death, you should immedi-
atelyinform the National HighwayTrafficSafetyAdministration(NHTSA) in addition tonotifying Magnum Products
LLC. If NHTSA receives similar complaints, it may open an investigation; and if it finds that a safety defect exists in
agroupof vehicles, itmayorder a recall andremedy campaign. However,NHTSAcannotbecome involved in
individualproblembetween you, your dealer, orMagnumProductsLLC.
TocontactNHTSA, you may either call theAuto Safety Hotlinetoll-free at 1-888-327-4236or by fax at: (202)-366-
7882. Additionalcontactinformationcan be found at:www.nhtsa.dot.gov.
UNIT SERIAL NUMBER LOCATIONS
Refer to the locations illustrated at right to find the unit ID
tag, and V.I.N. Tag on your unit. Important information,
such as the unit serial number, model number and Vehicle
IdentificationNumber(V.I.N.)foryourtrailer are found on
these tags. Record the information from these tags, so it
is available if the tags are lost or damaged. When
orderingpartsorrequesting technical service information,
you may be asked to specify this information.
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UV
Hot surface(s) nearby.
Fire/explosion hazard; Keep
open flames away from unit.
Read and understand the
supplied operator’s manual
before operating unit.
Ultraviolet radiation hazard;
Operate only with lens intact.
Use clean diesel fuel only.
Unit electrical ground.
Anchor/tie down point.
Lift here only.
Asphyxiation hazard; Operate
in well ventilated area.
Dangerous voltage may be
present.
Crush hazard; Keep body parts
clear of this area.
Burn/scald hazard;
pressurized steam.
Fan hazard; Keep body parts
clear of this area. Forklift here only.
Belt/entanglement hazard; Keep
body parts clear of this area.
Safety alert symbol; Used to
alert you to potential personal
injury hazards.
Stop engine before fueling.
SAFETY SYMBOL SUMMARY
Thisequipmenthasbeensuppliedwithnumeroussafetyandoperatingdecals. Thesedecalsprovideimportant
operatinginstructionsandwarnofdangersandhazards. Replaceany missing or hard-to-read decals and use care
when washing or cleaning the unit. Decal placement and part numbers can be found in the beginning of the parts
section of this manual. Below is a summary of the intended meanings for the symbols used on the decals.
7
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SPECIFICATIONSARESUBJECTTO CHANGEWITHOUTNOTICE.
SPECIFICATIONS
Readthis manual carefullybefore attempting touse this lighttower The potential forproperty damage, personal
injury or death exists if this equipment is misused or installed incorrectly. Read all of the manuals included with this
unit. Each manual details specific information regarding items such as set up, use and service requirements.
Specifications are subject to change without notice.
MAGNUMMODEL MLT 5150 MLT 5200
Engine
Make/Brand ........................................................ Mitsubishi ..................................Isuzu
Model.................................................................. S4L2-W461ML...........................4LE1-PV05
Type .................................................................... Diesel, liquid cooled, 4-stroke....Diesel, liquid cooled, 4-stroke
Horsepower- prime hp (kW) ............................... 23.5 (17.5) .................................31.5 (23.5)
Horsepower- standby hp (kW) ........................... 24.7 (18.4) .................................34.5(25.7)
OperatingSpeedrpm ......................................... 1800 ..........................................1800
Displacement in3(L) ........................................... 107.40(1.76) .............................134.25 (2.20)
Cylinders - qty .................................................... 4 ................................................4
Fuel Consumption - 100% prime gph (Lph) ....... 1.30 (4.92) .................................1.80(6.81)
BatteryType - GroupNumber ............................. 24 ..............................................24
BatteryVoltage(Quantity per Unit) ..................... 12V(1).......................................12V(1)
BatteryRating..................................................... 440CCA ....................................720 CCA
Generator
Make/Brand ........................................................ MarathonElectric ......................Marathon Electric
Model.................................................................. 333CSA3024 .............................333CSA3028
Type,Insulation................................................... Brushless, F ..............................Brushless, F
Generator Set (Engine/Generator)
OutputkW (kVA)................................................. 15.0 (15.0) .................................20.0(20.0)
Output Voltage V................................................ 120/240,single phase................120/240, single phase
OutputAmperes 120V (240V) A .......................... 125(63) .....................................167(83)
FrequencyHz ..................................................... 60 ..............................................60
PowerFactor ...................................................... 1(1Ø) ........................................1(1Ø)
Weights
DryWeight lbs (kg)............................................. 2153(977) .................................2202 (999)
OperatingWeightlbs (kg) ................................... 2551(1157) ................................2600(1179)
Capacities
Fuel Tank Volume gal (L) ................................... 56(212) .....................................56(212)
Usable Fuel Volume gal (L) ................................ 56(212) .....................................56(212)
Coolant (incl. engine) qt (L)................................. 11.6(11.0)..................................11.6(11.0)
Oil (incl. filter) qt (L)............................................ 5.7 (5.4) .....................................8.6 (8.1)
Maximum Run Time hrs...................................... 43 ..............................................31
ACDistribution
Circuit Breaker Size............................................ 70 ..............................................100
VoltageRegulation .............................................. +/-1%.........................................+/-1%
VoltagesAvailable1Ø ......................................... 120,240.....................................120, 240
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SPECIFICATIONSARESUBJECTTO CHANGEWITHOUTNOTICE.
SPECIFICATIONS
Readthis manual carefullybefore attempting touse this lighttower The potential forproperty damage, personal
injury or death exists if this equipment is misused or installed incorrectly. Read all of the manuals included with this
unit. Each manual details specific information regarding items such as set up, use and service requirements.
Specifications are subject to change without notice.
MAGNUMMODEL MLT5150/5200
Lighting
LightingType....................................................... Metal Halide
BallastType ........................................................ Coil & Core
Lumens ............................................................... 440,000
Coverageacres(m2)........................................... 5 - 7 (20,234 - 28,328)
Dimensions
Length w/ mast stowed in (m) ............................ 170 (4.32)
Width in (m) ....................................................... 80(2.03)
Width w/ outriggers extended in (m) ................... 151(3.84)
Height w/ mast stowed in (m)............................. 70(1.78)
Maximumheight of tower ft (m) .......................... 30(9.14)
Trailer
NumberofAxles ................................................. 1
Capacity -Axle Rating lbs (kg) ........................... 3500(1588)
Tire Size in ......................................................... 15
Hitch -Standard .................................................. 2" Ball
MaximumTire Pressure psi ................................ 50
SPECIFICATIONSARESUBJECTTOCHANGE WITHOUTNOTICE.
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10
LIGHT TOWER SET UP
1. Formaximumlight coverage locate towerat ground levelor in aspot higher thanthe area beingilluminated by
the lamps.
2. Place the trailer on firm ground that is relatively flat. This will make it easier to level the tower. Block the wheels
on the trailer to keep it from moving (A).
3. Pull the locking pin on the tongue jack and rotate it 90º until the spring loaded pin snaps back into place (B).
Turnthe jackhandle clockwise to raise the trailer tongue off of the towing vehicle.
4. Connecta good earthen ground to the grounding stud on the frame of thetrailernearthetrailertongue(C).
5. Pull the locking pins (D) on the outriggers (E) and pull the outriggers out until the spring loaded locking pin
snaps back into place. Pull the locking pin on the outrigger jacks and rotate them 90º until the spring loaded
pin snaps back into place.
6. Pull the locking pin on the rear jack (F) and rotate it 90º until the spring loaded pin snaps back into place. Turn
the jack handle clockwise to start leveling the trailer. Adjust all four jacks by turning their handles clockwise
until they are firmly in contact with the ground and the trailer is as level as possible (G).
7. Before raising the tower it may be necessary to adjust the lamps. The lamps may be adjusted up, down, left or
right by loosening the wing bolts on the lamp fixture (H) and aiming them in the desired direction. Tighten the
hardware completely and make sure the lamps are connected to the junction box.
The tower extends up to 30 ft (9.14 m). Make sure area above
the trailer is open and clear of overhead wires and obstructions.
WARNING
DETAIL D
DETAIL G
DETAIL C
DETAIL H
F
A
C
E
B
E
D
H
D
G
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1. Remove the mast cradle locking pin from the mast cradle (I).
2. Check both sets of mast cables for excessive wear or damage. Make sure the cables are properly centered in
each pulley (J). Check the electrical cord for damage.
3. Make sure the area behind the unit is clear before
raising the mast to the vertical position.
4. Remove the safety pin (K) from the mast lock bar
(L). Using the handle for the lower mast winch (M),
raise the mast until it is vertical and the tab on the
mast is positioned into the mast lock. The mast lock
bar should snap into place automatically. Secure
the lock with the safety pin (N).
5. After the mast is up and locked into place, use
the upper mast winch (O) to telescope the
tower to the desired height. Extend the mast slowly,
making sure that the electrical cord is extending
at the top sections of the mast. If, for any reason,
the winch cable begins to develop slack or any of
the tower sections get stuck, STOP IMMEDIATELY
andcontact anauthorizedservicecenter.
6. The mast can be rotated by loosening the locking
knob at the bottom of the mast (Q). Turn the mast
until the lights face in the desired direction and
then tighten the knob.
M
J
O
J
K,L,N
Q
DETAIL I
DETAIL P
DETAIL K DETAIL N
I
11
The trailer must be leveled with the outriggers extended before raising the tower. The outriggers
must remain extended while the tower is up. Failure to level the trailer or extend the outriggers
will severely reduce the stability of the unit and could allow the tower to tip and fall.
WARNING
Do not start the unit if the insulation on the electrical cord is cut or worn through.
Bare wires in contact with the mast or frame may energize the trailer and cause electrocution.
Repair or replace cord.
WARNING
RAISING THE TOWER
CAUTION
Do not extend the mast beyond the colored mark
on the middle mast tube (P).
Never raise or lower the mast while the unit is
operating! Never remove the safety pin or mast
lock while the tower is up. Releasing the lock
will cause the mast to fall.
WARNING
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12
STOP
1. Set up and level the trailer as described on page 10, and follow steps 1-3 on page 11.
2. Remove the safety pin from the mast lock bar (R).
3. Press the lower winch control toggle switch upward to
raise mast into the vertical position (S). Hold switch until
the mast lock is engaged. The mast lock bar should snap
intoplace automatically. Note: Onlight towers equipped
with the electric winch option, a limit switch on the mast
tubewill disconnect powerto the lowerelectric winch to
preventdeadheadingthe winch.
4. Secure the lock with the safety pin (T).
5. Press and hold the upper winch control toggle switch
upward to telescope the mast to desired height (U).
Extend the mast slowly, making sure that the coiled
electrical cord is extending at the top sections of the
mast. If, for any reason, the winch cable begins to
develop slack or any of the tower sections get stuck,
STOPIMMEDIATELYand contactanauthorizedservice
center.
6. The mast can be rotated by loosening the locking
knob at the bottom of the mast (W). Turn the mast
until the lights face in the desired direction and
then tighten the knob.
W
R,T
V
S
DETAIL W
DETAIL V
DETAIL T
DETAIL R
DETAIL S
DETAIL U
U
WARNING
Never raise or lower the mast while the
unit is operating! Never remove the safety
pin or mast lock while the tower is up.
Releasing the lock will cause the mast to fall.
RAISING THE TOWER WITH THE OPTIONAL ELECTRIC WINCH
CAUTION
Do not extend the mast beyond the colored mark
on top of the lower mast section (V). On light
towers equipped with the electric winch option, a
limit switch on the main mast section will discon-
nect power to the upper electric winch to prevent
over extending the mast.
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MAIN CONTROL PANEL COMPONENTS
1. MAIN CIRCUIT BREAKER (70A or 100A): Thisbreakerwill disconnect powerto the lights andauxiliary outlets.
2. BALLAST INDICATOR LIGHTS: Indicatespower fromthe ballast toeach light.
3. INDIVIDUAL CIRCUIT BREAKERS: One breaker is supplied foreachlight.
4. ENGINE STARTING SWITCH: Keyed switch operates glow plugs, starts and stops engine.
5. ENGINE GLOW PLUG INDICATOR: Indicatesoperation oftheengineglow plugs.
6. ENGINE HOUR METER: Keepstrackofenginehoursforservice.
7. CIRCUIT BREAKER INDICATOR LIGHT:This light indicatesthat the main circuitbreaker must beopened
(switchedoff)beforestarting the engine.
13
PRODUCTS LLC
BERLIN, WI. USA
1-800-926-9768
7
6
4
5
132
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ENGINE STARTING AND OPERATION
1. Check engine oil, fuel and coolant levels. Note: If the engine was run out of fuel or the fuel tank was drained, it
may be necessary to bleed the fuel lines. Refer to the engine operators manual supplied with the unit.
2. Check the condition of the electrical cord on the inside of the unit.
3. Check that the main circuit breaker and individual circuit breakers for each of the lights are in the off ”O” position.
Note: If the red light on the control panel “TURN MAIN BREAKER OFF” is illuminated when the key is turned to
the “START” position, the breaker is closed (switched on).
4. Turn the key on the engine start switch to the left “GLOW PLUG” position and hold the key in place until the
glow plug indicator turns red. As soon as it’s glowing turn the key to the right to the “START” position and hold it
until the engine cranks and starts running. Release the key, it will move to the “RUN” position.
NOTICE
Do not crank the engine longer than 10 seconds at a time. If the engine will not start, wait 30 seconds to
allow the starter motor to cool and then repeat the starting procedure. Excessive cranking will cause
damage to the starter.
5. Note: If oil pressure is not obtained within 30 seconds after the key is switched to the “RUN” position, the low-oil
automatic shutdown will turn off the fuel supply, stopping the engine. Check the oil level and turn the key to the
“OFF” position to reset the oil pressure timer before attempting to restart the engine.
6. Oncetheengine is running,allow it toreach normal operatingtemperature before switchingon any loads.
AUTOMATIC SHUTDOWN
This unit is equipped with a low oil pressure and high coolant temperature auto-shutdown system. This system will
automatically shut off the fuel supply to stop the engine if oil pressure drops too low or the engine exceeds normal
operating temperature. Return the switch to the “OFF” position to reset the unit after you have determined the cause
oftheshutdown.
RELEASE KEYACTIVATE GLOW PLUGS CRANK ENGINE TO START
14
Do not start the unit if the insulation on the electrical cord is cut or worn through.
Bare wires in contact with the mast or frame may energize the trailer and cause electrocution.
Repair or replace cord.
WARNING
NEVER START THE ENGINE WITH ANYOF THE
CIRCUIT BREAKERS SWITCHED ON! Any load on
the generator during start up will cause severe
damage or destroy the generator!
WARNING
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LIGHT OPERATION
1. Oncetheengine is upto temperature and running
smoothly, switch main circuit breaker (1) to the ON
“I”position.
2. With main circuit breaker on, switch each individual
circuit breaker for the lights (2) to ON “I”, one at a time.
3. The ballast indicator lights (3) will come on
momentarily as the lights strike. As the lights warm
up, the ballast indicator lights will continue to get brighter
and then remain on. This confirms that power is coming
from the ballasts to the lights.
4. If an indicator light does not come on, the ballast may need to
be serviced. If the indicator light comes on and stays lit, but
the related light is not illuminated, check the bulb or the mast
wiring.
5. Thelightsrequirea warm upperiodof 5-15 minutesbefore they
reach full output. If the lights are shut down, they require a
cool-downperiod of approximately 10minutes before theycan be switchedon again.
6. The light tower uses four 1000W bulbs. When checking or replacing the bulbs, wipe them with a clean cloth to
avoid leaving any grease, oil residue or fingerprints on the glass. Any residue can create a hot spot on the bulb
causingprematurebulbfailure.
AUXILIARY OUTLETS
The control panel is equipped with six outlets for running accessories or tools from the generator. Power is supplied
to the outlets any time the engine is running and the main circuit breaker is switched ON “I”. Each outlet has its
ownindividual circuit breaker,located inside thecabinet under a flip-upcover. Thecircuitbreakers correspond with
each outlet located below on the outlet panel.
Shouldthe main breakertrip, or ifany of the individual
circuit breakers trip, remove some of the load to the
outlets before turning them back on. With all of the
lights off, the full generator output may be used with
the outlets.
Note:To ensure proper grounding, anytime the
generatorisprovidingpowertoany equipment or load
panelsthat do nothave a grounded plug, a ground
wiremust be added betweenthe equipment andthe
grounding stud on the outlet panel per any local, state
orNEC codes andguidelines.
AUXILIARYOUTLET
GROUNDINGSTUD
PRODUCTS LLC
BERLIN, WI. USA
1-800-926-9768
213
15
Bulbs become extremely hot in use! Allow bulb fixture to cool 10-15 minutes before handling.
WARNING
NEVER OPERATE THE LIGHTS WITHOUT THE PROTECTIVE LENS COVER OR WITHALENS
COVER THAT IS CRACKED OR DAMAGED! The bulbs in the light fixtures produce high
temperatures and operate under pressure. A broken or missing lens cover could cause the
bulbs to shatter, causing injury.
WARNING
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VOLTAGE REGULATION
Theelectronic voltage regulatorcontrols the outputof the generatorby regulating thecurrent into theexciter field.
Theregulatorhas three screwdriveradjustablepotentiometers that may beadjusted for voltage, stabilityandunder
frequency(U/F). The voltageregulator on yourunit is adjustedbefore shipment fromthe factory. ContactMagnum
ProductsLLC foradditionalinformation before attempting toadjustthe voltageregulator.
DERATING FOR ALTITUDE
Alllight towers aresubject to derating for altitudeand temperature. Although deratingshould not affecttheoperation
of the lights, it will reduce the available power for operating tools and accessories connected to the auxiliary outlets.
Typical reductionsin performance are 2-4%for every 1000ft.(305meters)of elevation and1% per 10º F(3-5º C)
increasein ambient air temperatureover 72º F(22.2º C).
SHUTTING DOWN
Whenyou have finishedusing the light tower proceedwith shut downas follows:
1. Removeanyloads from theauxiliary outlets.
2. Switch the individual circuit breakers for each light to the OFF “O” position.
3. Switch the main circuit breaker to the OFF “O” position.
4. TurntheENGINESTARTSWITCHto the “OFF”position.
LOWERING THE TOWER
1. Shut down the lights and engine. Allow the lights to cool 10-15 minutes before lowering the tower.
2. Turn the upper mast winch handle to collapse the tower to it’s lowest position. Make sure the coiled electrical
cordreturns to thestorage tube properly.
3. Loosen the mast rotation knob and rotate the tower so the mast mounted winches face the front of the unit. The
white alignment arrow points should line up on the mast sections and the metal stop tabs should be touching.
Tightenthe mast rotationknob.
4. Release the mast lock by pulling the safety pin on the mast lock and pulling the lock free. Turn the handle of
the lower mast winch until the mast spring begins to pivot the tower down. Release the mast lock and continue
to lower the tower until it rests in the cradle. Note: If the mast lock does not pull free, operate lower winch
slightly to relieve pressure on the mast lock.
5. After the mast is completely down, insert the cradle lock pin and secure it with the safety pin.
6. Position lights to aim at the ground. If the trailer is going to be moved, Magnum Products LLC strongly recom-
mends that the lights be removed from the mast and stowed for transportation. On units equipped with quick
disconnect fittings for the lights, disconnect the power cords from the junction box at the top of the mast.
Replace the dust caps on the junction box. On other units, remove the junction box cover on the top of the mast
and disconnect the wires from the terminal blocks by clipping the wires as close as possible to the terminal
blocks. Note: Pull any excess wire strands from the terminal blocks. When reconnecting the lights the next
time the light tower is used, strip 1/2” of the insulation from each wire and insert the bare wires into the correct
terminal block until locked.
7. Remove the lights by removing the wing nut that holds the light fixture bracket to the cross tube. Insert the
lights into the storage brackets inside the unit, placing two lights into the roof mounted brackets first (see
illustration on page 17). Then, place a light into the vertical bracket next to the engine with the last light going
into the angled bracket.
16
CAUTION
Always switch all circuit breakers to the OFF “O” position to prevent starting the generator under load.
WARNING
If the mast hangs up or the winch cable begins to develop slack, STOP IMMEDIATELY! Excess
slack in the cable could cause the mast to collapse should it free up without warning. Contact an
authorized service center.
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LOWERING THE TOWER EQUIPPED WITH THE OPTIONAL ELECTRIC WINCH
1. Shut down the lights and engine. Allow the lights to cool 10-15 minutes before lowering the tower.
2. Loosen the mast rotation knob and rotate the tower so the mast mounted winches face the front of the unit. The
white alignment arrow points should line up on the mast sections and the metal stop tabs should be touching.
Tightenthe mast rotationknob.
3. Press and hold the upper winch control toggle switch downward to collapse the mast to its lowest level. Make
sure the coiled electrical cord on the top sections of the mast does not get tangled on the mast sections. Note:
Some electric winch models are equipped with an anti-backlash safety limit switch. This switch will disconnect
power to the winch if excess cable slack is detected, preventing accidental lowering of the tower. If, for any
reason, the cable begins to develop slack or any of the tower sections get stuck, STOP IMMEDIATELY and
contactan authorized servicecenter.
4. Release the mast lock bar by pulling the safety pin on the mast lock and pulling the lock bar free. Lower the
mast by holding the lower winch control toggle switch to the right until the mast is resting in the transport cradle.
Note: If the lock bar does not pull free, activate lower winch slightly to relieve pressure on the mast lock bar.
5. After the mast is completely down, insert the cradle lock pin and secure it with the safety pin.
6. Position lights to aim at the ground. If the trailer is going to be moved, Magnum Products LLC strongly recom-
mends that the lights be removed from the mast and stowed for transportation. On units equipped with quick
disconnect fittings for the lights, disconnect the power cords from the junction box at the top of the mast.
Replace the dust caps on the junction box. On other units, remove the junction box cover on the top of the mast
and disconnect the wires from the terminal blocks by clipping the wires as close as possible to the terminal
blocks. Note: Pull any excess wire strands from the terminal blocks. When reconnecting the lights the next
time the light tower is used, strip 1/2” of the insulation from each wire and insert the bare wires into the correct
terminal block until locked.
7. Remove the lights by removing the wing nut that holds the light fixture
bracket to the cross tube. Insert the lights into the storage brackets inside
the unit, placing two lights into the roof mounted brackets first. Then, place
a light into the vertical bracket next to the engine with the last light going
into the angled bracket.
TOWING THE TRAILER
Once the engine is shut down and the mast and lights are properly stowed, the trailer can be made ready for
transport.
1. Raise the rear jack completely and release the locking pin to rotate it up into the travel position. Make sure the
locking pin snaps into place.
2. Raise the outrigger jacks completely and release the jack locking pin to swing the jacks up into the travel
position. Make sure the locking pins snap into place. Release the outrigger locking pins and slide the
outriggers into the trailer frame until the locking pins snap into place.
3. Use the tongue jack to raise or lower the trailer onto the hitch of the towing vehicle. Lock the hitch coupling and
attach the safety chains or cables to the vehicle. Release the jack locking pin and rotate the jack into the travel
position. Make sure the locking pin snaps into place.
4. To ensure proper operation of the jacks, lube the grease fittings located on the leveling jacks.
5. Connect any trailer wiring to the tow vehicle. Check for proper operation of the stop and signal lights.
6. Make sure the cradle locking pin is in place.
7. Makesurethe doors areproperly latched.
8. Ifthetraileris going tobe driven over roughground, remove thebulbs from the lightfixtures.
9. Check for proper inflation of the trailer tires. The maximum tire inflation is 50 psi.
10. Attach a red flag to the end of the mast before towing.
11. Maximumrecommendedspeed for highwaytowing is 45mph. Recommended off-road towingspeed is not to
exceed10 mph orless depending onterrain.
17
INSERT
VERTICAL
LAMPFIRST
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LIFTING THE TRAILER
When lifting the light tower and trailer, attach any slings, chains or hooks directly to the central lifting eye. The lifting
eye is located on the mast between the two upper forklift pockets.
1. Make sure the equipment being used to lift the light tower
has sufficient capacity. Note: See the unit specifications on
pages8and 9 forapproximateweights.
2. Make sure the cradle locking pin is in place.
3. Alwaysremainaware of the positionof other peopleand
objects around you as you move the unit.
4. Use the upper or lower forklift pockets with care. Approach
the unit as perpendicular as possible to avoid any damage to
the unit. Make sure the mast winch handles or any other
obstructionsare clear ofthe forklift tines before lifting.
OPTIONAL LOWER RADIATOR HOSE HEATER USE AND MAINTENANCE
Thefollowingpointsshouldbe followed when operatingaunitequipped with alowerradiatorhose heater.
•Ensurecooling system is full ofproper mixture of water andengine coolant before each heateruse.
•Heaterisdesignedforall-nightoperation;however,2-5 hours of heatingjustpriortostartingisusually sufficient
forproperenginestarting.
•When heater is in operation, unit must be parked in a level position to maintain the proper orientation of the
heater.
•Useonlyan undamaged extension cord,outdoorsrated,three-pronggrounded 120VACcord withaminimum
amperagerating of 10A. Connect toproperly grounded 120VAC,GFCI outlet only.
•Unplugextension cord from powerfirst; then unplugheater cordset from extensioncord before startingthe
engine.
TROUBLESHOOTING THE LIGHTS
MASTLIGHTSOFF BUTBALLASTINDICATORSONCONTROLPANELAREON:
1. Mast light is too hot. Allow light to cool 10-15 minutes before restarting.
2. Faulty bulb connection. Check that the bulb is tight in the socket.
3. Bulbbroken. Check forbroken arc tube or outer bulb jacket,broken orloose components in bulb envelope
orblackening/deposits inside tube.
4. Check the connections inside the mast junction box and each mast light housing/socket.
5. Check the mast electrical cord for damage and check the cord connections inside the control box.
MASTLIGHTS OFFANDBALLASTINDICATORSONCONTROLPANELARE OFF:
1. Check the connections inside the control box and inside each ballast box.
2. Generatoroutput incorrect. Check theincoming voltage tothe ballast by checking the available voltage on
the duplex receptacle. Incoming voltage should be 120V +/- 5V. If voltage is incorrect engine speed may
needto be adjusted orgenerator may requireservice. ContactMagnumProductsTechnical Service Depart-
mentformoreinformation.
18
DANGER
HIGHVOLTAGE! THISUNITUSESHIGHVOLTAGECIRCUITSCAPABLEOFCAUSINGSERIOUS
INJURYORDEATH. ONLYAQUALIFIEDELECTRICIANSHOULDTROUBLESHOOTORREPAIR
ELECTRICALPROBLEMSOCCURRINGINTHISEQUIPMENT.
CENTRAL
LIFTING EYE
FORKLIFT
POCKETS
FORKLIFT
POCKETS
Improper use of the lower radiator hose heater could result in serious personal injury.
WARNING
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19
3. Lowtransformer output. The voltagefrom thetransformer should readapproximately 400 VAC asthe light
“strikes” (induces an arc), then drop and slowly rise back up to stabilize at 240-260 VAC. On quick discon-
nect models, measure across the junction box terminals when the light is unplugged. On hard wired
models, remove the mast junction box cover and insert the wire probes into the connector blocks for the
lightsand ground. If propervoltage is notachieved, perform capacitorcheck to determineif the capacitor or
coil needs to be replaced.
MASTLIGHTSONBUTTHELIGHT OUTPUT IS LOW:
1. Fixture or lens dirty. Clean reflective surface inside fixture and both inside and outside surface of glass lens.
2. Bulbworn.Replace bulb dueto normal use.
3. Check the mast coil cord, mast junction box and mast light connections.
4. Generatoroutputincorrect. Check theincoming voltage tothe ballast. Incomingvoltage should be120V +/-
5V. Ifvoltageis incorrect enginespeed may needto be adjustedor generator mayrequire service.
5. Low transformer output. Perform transformercheckasdescribed above.
MAST LIGHT CONNECTIONS
4
43
3
2
12
1
4
6
5
3
21
21
43
65
RED
GN/BK
OR/BK
BLU
BLK
ORG
WHT
GRN
WT/BK
RD/BK
GRN
WHT
BLK
GRN
WHT
BLK
GRN
WHT
BLK
GRN
WHT
BLK
GRN
WHT
BLK
GRN
WHT
BLK
21
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